Capital Weld Cleaners CW110 User manual

Capital Weld Cleaners
www.capitalweldcleaners.com
[phone]
Models:
CW110
CW200
Operating instructions

Safety Notices
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
This does not indicate a potentially hazardous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is
required.

General The device is manufactured using state-of-the-art technology and
according to recognized safety standards. If used incorrectly or
misused, however, it can cause:
- injury to the operator or a third party,
- damage to the device and other material assets belonging to the
operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servi-
cing the device must:
- be suitably qualified,
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is
being used. In addition to the operating instructions, attention must also be
paid to any generally applicable and local regulations regarding accident
prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
Before switching on the device, rectify any faults that could compromise
safety.
This is for your personal safety!
Utilization for
intended purpose
only
The machine may only be used for jobs as defined by the “Intended pur-
pose”.
Utilization for any other purpose, or in any other manner, shall be deemed
to be "not in accordance with the intended purpose". The manufacturer
shall not be liable for any damage resulting from such improper use.
Utilization in accordance with the “intended purpose” also comprises
- complete reading and following of all the instructions given in this
manual
- complete reading and following of all the safety instructions and
danger warnings
- performing all stipulated inspection and servicing work.
The machine is designed to be used in industrial and workshop environ-
ments. The manufacturer shall not be liable for any damage resulting from
use of the machine in residential premises.
Likewise Capital Weld Cleaners will accept no liability for defective or faulty
work results.
Environmental
conditions Operation or storage of the device outside the stipulated area will be
deemed as not in accordance with the intended purpose. The manufacturer
shall not be held liable for any damage arising from such usage.
Ambient temperature range:
-during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or sub-
stances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operating com-
pany
The operating company undertakes to allow only such people to work with
the device who:
- are familiar with the fundamental instructions regarding safety and
accident prevention, and have been instructed how to use the device
- have read and understood the "Safety rules" section and warning
notices in these operating instructions, and then signed them to con-
firm this
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
personnel Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and acci-
dent prevention
- to read the "Safety rules" section and warning notices in these operat-
ing instructions, and sign them to confirm that they have understood
them and will follow them.
Before leaving the work area, ensure that people or property cannot come
to any harm in your absence.
Protection for
yourself and
other persons
When working with this machine, you are exposed to many different haz-
ards such as:
- irritation of skin in case of contact with cleaning agent (cleaning
solution,)
- danger of serious eye injury in case of contact with cleaning solution
- general hazards when handling chemicals
- electrical hazards from mains and cleaning current
- harmful vapours
EN

Anybody working on the workpiece during cleaning must wear suitable
protective clothing with the following characteristics:
- resistant against acids and chemicals
- isolating and dry
-
Protective clothing” also includes:
- wearing a pair of appropriate regulation goggles (with sideguards)
- wearing stout footwear that will also insulate even in wet conditions
- wearing protective gloves (hand protection), impermeable, resistant
against acids and chemicals
- wearing protective apron (e.g. when refilling chemicals)
Immediately remove any working garment contaminated with cleaning
agent!
-Don’t eat and drink during working
-Keep cleaning solution away from food and drink
- Wash your hands before breaks and at the end of a working day
Keep other people
- well away from the equipment and the working operation while this is in
progress. If there are still any other persons nearby during working, you
must
- draw their attention to all the dangers
- provide them with suitable protective equipment and/or
- erect suitable protective partitions or curtains.
Instructions for
the correct hand-
ling of cleaning
solutions
The following aspects must be observed when handling cleaning solutions (For
more detailed data please refer to the relevant safety data sheets. You will find
the current safety data sheets on http://www.capitalweldcleaners.com.
First-aid measures
- After inhaling of vapors provide for supply of fresh air. In case of com-
plaint see a doctor.
- After contact with skin wash with water and soap and rinse carefully. In!
case of continued irritation of skin see a doctor.
-If swallowed do not induce vomiting. Rinse mouth and drink a lot of
water, see a doctor immediately.

- After contact with eyes rinse eyes several minutes under running water
with eyelid open (eye shower) and see a doctor.
Storage / safekeeping
- Use only containers especially approved for cleaning solutions
- Keep container closed tightly
- Don’t store together with alkali (lyes) and metals
- Store in a cool and dry place
- Provide for acid-proof floor
-!Keep under lock and key and out the reach of children
Other instructions
- Don’t heat to avoid thermal decomposition (development of toxic gases)
- Provide for emergency cooling in case of fire close by
- Avoid contact with eyes, skin and mucous membranes
- Use only in well ventilated areas. In case of insufficient ventilation use
respiratory protection
- Dispose of cleaning solutions and/or uncleaned packagings as provided
by national regulations. Don’t dispose together with domestic waste.
- Don’t let agent get into drain system, into waters or the ground water
(e.g. via the ground).
Hazards from
mains and clean-
ing current
An electric shock can be fatal. Every electric shock is hazardous to life.
Do not touch any live parts, either inside or outside the machine.
Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/
frame potential. The base or cover must completely cover the entire area
between your body and the ground/frame potential.
All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose con-
nections, scorched, damaged or underdimensioned cables or other leads.
Do not loop any cables or other leads around your body or any part of your
body.
Have the mains and the machine supply leads checked regularly by a quali-
fied electrician to ensure that the PE (protective earth) conductor is func-
tioning correctly.
Only run the machine on a mains network with a PE conductor, and
plugged into a power outlet socket with a protective-conductor contact.
If the machine is run on a mains network without a PE conductor and
plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is
sufficiently grounded (earthed).
Switch off any appliances that are not in use.
Before doing any work on the machine, switch the machine off and unplug
it from the main.
Put up a clearly legible and easy-to-understand warning sign to stop any-
body inadvertently plugging the machine back into the mains and switching
it back on again.
After opening up the machine:
- ensure that all machine components are electrically dead.
If work needs to be performed on any live parts, there must be a second
person on hand to immediately switch off the machine at the main switch in
an emergency.
Particular danger
spots Cover may only be removed as long as is absolutely necessary to carry
out maintenance and repair work.
While the machine is in use:
- ensure that the cover is properly secured.
-
Special regulations apply to rooms at risk from fire and/or explosion.
Observe all relevant national and international regulations.
Power sources for use in spaces with increased electrical danger (e.g. boil-
ers) must be identified by the [S] (for “safety”) mark.
Measurement of pollutant emissions while working with the device revealed
values below the admissible mean toxic limit.
Nevertheless:
- Provide for sufficient supply of fresh air.
- Keep head away from generated vapours.
- Don’t inhale generated vapours and/or exhaust them from working area
by appropriate means.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international
standards and directives.
Further details on safety inspection and calibration can be obtained from
Capital Weld Cleaners. They will provide you on request with any
documents you may require.

Safety precau-
tions in normal
operation
Only operate the machine if all of its protective features are fully functional.
If any of the protective features are not fully functional, this endangers:
- the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/oper-
ator
- efficient working with the equipment.
Any safety features that are not fully functional must be put right before you
switch on the machine.
Never evade safety features and never put safety features out of order.
Before switching on the machine, ensure that nobody can be endangered
by your doing so.
At least once a week, check the machine for any damage that may be vis-
ible from the outside, and check that the safety features all function cor-
rectly.
Only Capital Weld Cleaning solution is suitable for use in our machines.
Do not mix Capital Weld Cleaning solution with other cleaning agents.
If any damage occurs in cases where other cleaning agents have been
used, the manufacturer shall not be liable for any such damage, and all
warranty claims shall be null and void.
Only transport the cleaning soluiton in closed original containers.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manu-
factured to meet the demands made of them, or that they satisfy safety
requirements.
- Use only original spare and wearing parts (also applies to standard
parts).
- Do not carry out any modifications, alterations, etc. to the device
without the manufacturer's consent.
- Components that are not in perfect condition must be replaced
immedi-ately.
The housing screws provide the ground conductor connection for earthing
the housing parts.
Only use original housing screws in the correct number and tightened
securely.
Safety inspection The manufacturer recommends that a safety inspection of the device is per-
formed at least once every 12 months.
Utilization for
intended purpose
only
The Capital Weld Cleaner is exclusively designed for the electro-chemical cleaning of
stainless steels. Utilization for any other purpose, or in any other manner, shall be
deemed to be "not in accordance with the intended purpose". The manufacturer shall
not be liable for any damage resulting from such improper use.
Utilization in accordance with the “intended purpose” also comprises
- the instructions given in this manual
- performing all stipulated inspection and servicing work.

Technical data
CW110 Unit suitable for use in confined spaces [S]
Mains voltage -15%/+10% ~110 V / 50-60 Hz
Main fuse 20 A slow
Output current 5 - 110A
Output voltage 2 - 12 V
Output power 1320 W
Open-circuit voltage 17 V
Dimension l / b / h 17" x 12.5" x 17"
Weight 70lbs
Pollutant emission during operation
(measured acc. to VDI 2462, part 8)
phosphoric acid
CW200 Unit suitable for use in confined spaces [S]
Mains voltage -6% / +6% ~110V / 50-60 Hz
Main fuse 20 A slow
Output current 5 - 200 A
Output voltage 12 V
Output power 2400 W
Open-circuit voltage 17 V
Dimension l / b / h 22" x 12.5" x 17"
Weight 80lbs
Pollutant emission during operation
(measured acc. to VDI 2462, part 8)
phosphoric acid

Controls, connections and mechanical components
Safety WARNING!
Danger from incorrect operation.
Possible serious injury and damage to property.
▶Do not use the functions described here until you have fully read and understood all
of the Operating Instructions for the system components, in particular the safety
rules!
Button Controls:
ON/OFF: Allows for switching power outputs to leads on or off.
Clean: Switches to Cleaning output for general weld cleaning. Use
this setting with the use of Marking wand and stencils.
Polish: Switches to Polish mode for electro-polishing. Use this
setting for chemical Etching with the use of a stencil and etching
fluids.
Up: Allows the increase of cleaning output in 10 amp increments
Down: Allows the decrease of cleaning output in 10 amp increments.

Operating Instructions
General Setup
Instructions WARNING!
Danger from incorrect operation.
Operating the equipment incorrectly can cause serious injury and damage.
▶Do not use the functions described here until you have read and completely under-
stood all of the following documents:
▶Operating Instructions
▶Follow all “Operating Instructions” for the system components, especially the
“Safety rules”
Preparation
· Prepare the workpiece to be cleaned. Make sure the area is
clean and the floor is dry.
· Clean off any grease, oils, dust off the surface of the welds
to be cleaned.
· Make sure the area is ventilated and there is air movement
in the area.
· Prepare the area with how you will wipe off excess
solution, and prepare for a manner to neutralize the area being
cleaned.
· Inspect the equipment and cables for any damage.
· Repair any damage before operation.
· Ensure cables don't become a trip hazard.

Cleaning - Polishing
Operation
Take safety precautions: Put on safety goggles, gloves and protective clothing. Ensure the
workpiece is grounded by securing the ground clamp onto the workpiece.
With the brush secure into the the end of the wand, dip the brush into the container with
weld cleaning solution.
Make contact with the brush to the welded area to be cleaned.
As the chemical reaction happens keep the brush moving back and forth over the weld until
desired results are achieved. Do not dwell in one spot more than a few seconds. If the
brush starts to burn or is leaving black marks on your part the machine settings are too
high. If this happens adjust to a lower amperage.
•As the solution in the brush dissapates, re-dip the brush into the solution to keep
the brush saturated in solution
Whether in Clean mode or Polish mode, the process is the same with the
brush and cleaning solution. The polish mode will generate more heat on your
part so be cautious as your parts can get hot.
EN
•Connect power cord to properly sized power source.
•Connect ground cable to the bottom port on the front of the
machine, twist the connector clockwise until secure.
•Connect wand cable to the upper port on the front of the
machine, twist the connector clockwise until secure.
•Turn main paddle ON/OFF switch to the On position.
•This will initiate the start up mode and will run the self-
diagnostics program as displayed on the lcd screen.
•Once start up is complete press the On/Off button. This will
turn on the power output.
•Depending on the application, press either the Clean or
Polish button.
•Adjust Amperage output by pressing Up or Down on the
control panel.
•Machine is ready for use.
Amperage settings: 1 brush 30-70 AMPS
2-4 brushes 70-200 AMPS

Removal of Weld cleaning solution and metal
residues
Electrochemical cleaning leaves electrolyte and metal residues on the
workpiece surface. Such residues may cause deposits on the workpiece
and affect corrosion resistance.
•After weld cleaning is complete, Rinse or wipe off excess
solution off the workpiece.
•Spray on neutralizer everywhere the solution contacted.
•Rinsing off with clean water is also acceptable.
•Wipe off neutralizer with a separate rag or rinse with clean water.
Neutralizer wipes can be used in place of the neutralizer spray.
•Ensure the surface is clean and dry and can verify that the surface
has been properly neutralized by using the color changing
neutralizer wipes. If there is no color change then the surface has
been properly neutralized.
IMPORTANT! During electrochemical cleaning ensure that no cleaning electrolyte enters into
any workpiece cavities or seams. In most cases complete removal of electrolyte residue from
cavities, overlaps or seams can be difficult.

Care, maintenance and disposal
General remarks Under normal operating conditions the Weld Cleaner requires only a minimum of care
and maintenance. However, it is important to follow some points to ensure the
operationality of the machine for many years.
WARNING!
Danger from electric current.
An electric shock can be fatal. Before removing machine cover
consult with the manufacturer.
▶Turn the main switch into the "OFF" position
▶unplug the machine from the main
▶put up an easy-to-understand warning sign to stop anybody inadvertently switching it
back on again
▶using a suitable measuring instrument, check to make sure that electrically charged
components (e.g. capacitors) have been discharged
Every start-up - Check main cable and interconnecting cable for damage
- Check whether the all round distance of (2ft) is kept to ensure that the cooling
air can easily flow and escape.
NOTE!
Furthermore, air inlets and outlets must in no case be covered, not even covered
partly.
Weekly Clean device by means of solvent-free products.
Every 6 months CAUTION!
Danger from pressed air.
Risk of damage to electronic components.
▶Clean electronic components from a certain distance only.
1
If a lot of dust has accumulated, clean the vents in the front and back of the machine .
Disposal Dispose of solutions in accordance with the applicable national and local regulations.