Ensitech TIG Brush User manual

TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
Stainless Steel Weld Cleaning System
TIG Brush Instruction Manual

Ensitech is committed to providing the highest quality goods, services,
and solutions for all of our customers. To achieve this goal, we adhere to
the process of a QUALITY MANAGEMENT SYSTEM which complies with
the requirements of ISO 9001:2015 for the following scope: the design,
manufacture, supply and repair of TIG Brush weld cleaning systems.
QUALITY YOU CAN TRUST

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TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
STOP!
Register your Warranty
Online and Extend your 2-Year
Warranty at no extra Cost!
Ensitech offers an extended 6-month warranty* on any new TIG Brush Control Unit that has its
warranty information registered on the TIG Brush website www.tigbrush.com/warranty.
Registering your TIG Brush online and activating your warranty is easy and links your product
with proof of ownership and warranty service. Online warranty activation also simplifies proof
of purchase in the event of a warranty claim.
Your TIG Brush extended warranty is issued on the condition that you complete the online
warranty activation within 30 days of purchase and purchase verification is attached. The
extended warranty only applies to the TIG Brush Control Unit, and does not include cables,
the PROPEL Torch, consumables or any other TIG Brush accessory.
*For full Terms and Conditions of your TIG Brush warranty see (Ensitech Warranty Against Defects)
on page 28 of this Instruction Manual.
Registration is quick and easy. Go to www.tigbrush.com/warranty

4TIG Brush™ Instruction Manual
2022
This instruction manual is an important tool and designed to help you get
the most out of your Ensitech products. We recommend you keep it with your
TIG Brush at all times.
Please take the time to read this manual as it provides users with the necessary
operating procedures and safety precautions, essential for the safe and proper
operation of the TIG Brush.
With correct usage and maintenance, you can be assured your TIG Brush will
give you reliable service for many years to come.
Due to continuous improvements, Ensitech Pty Ltd, reserves the right to make
specification changes and update this Instruction Manual accordingly.
© 2022 Ensitech Pty Ltd
FOREWORD
FOREWORD

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TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT
YOU TO THE POTENTIAL PERSONAL INJURY HAZARDS. OBEY
ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO
AVOID POSSIBLE INJURY.
WARNING
SYMBOL FOR “VOID WARRANTY” OR “DAMAGED WORK”
V
INDICATES AN IMMEDIATELY HAZARDOUS SITUATION. IF NOT
AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT
MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
CAUTION
THIS SYMBOL INDICATES A HAZARDOUS SUBSTANCE WHICH
MAY CAUSE MINOR OR MODERATE INJURY. SOME TIGBRUSH
KITS MAY SHIP WITH HAZARDOUS FLUIDS. CHECK SAFETY
DATA SHEETS CAREFULLY.
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
FOREWORD

6TIG Brush™ Instruction Manual
2022
FOR:
• Product safety publications
• Current owner updates
• Questions regarding product safety
• Standards and regulations compliance information
•
• Questions regarding product modifications
• Accident reporting
www.tigbrush.com/contact
Questions regarding special product applications
CONTACT
Ensitech Pty Ltd
Unit 1/144 Old Bathurst Road
Emu Plains NSW 2750
Australia
Phone: [phone]
Email: [email protected]
Ensitech Inc
340 Marshall Ave, Bldg#104
Aurora IL 60506
United States
Phone: [phone]
Email: [email protected]
Your local TIG Brush distributor/dealer or Ensitech direct:
FOREWORD

7
TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
REVISIONS LOG
Original issue of Manual: August 2016
Revision 1: April 2018
Revision 2: February 2020
Revision 3: July 2022
REVISIONS LOG

8TIG Brush™ Instruction Manual
2022
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INTRODUCTION
SAFETY PRECAUTIONS AND INFORMATION
DESCRIPTION OF BASIC EQUIPMENT
S1
S2
S3
3.1 Classic Kit
3.2 Flexi Handle Kit
3.3 PROPEL Kit
4.1 Preparation
4.2 Assembly
4.2.1 Classic Kit
4.2.2 Flexi Handle Kit
4.2.3 PROPEL Torch
4.3 Cleaning Fluid
4.4 Operation
OPERATIONS4
POWER AND MODE SETTING
5.1
5.2
S5
Power Settings
Mode Settings
MAINTENANCES6
28
WARRANTYS9
CONSUMABLES
7.1
7.2
7.3
S7
Brushes
Insulating Shrouds
257.4 PROPEL Torch Collets
Fluids
• Pre-Weld Cleaning Fluids
• Weld Cleaning Fluids
• Neutralising Fluids
• Finishing Fluid
• Printing Fluids
• Engraving Fluids
TROUBLESHOOTING
8.1 The mains power button on the back of the Control Unit doesn’t
operate properly or illuminate.
The front panel LEDs are not illuminating.
8.2
26
The Control Unit is making a humming/buzzing noise.
8.3
27
The front Control Unit lights are illuminated but it will not clean or
it’s not performing as well as normal.
8.4
S8
CONTENTS

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TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
INTRODUCTION
Congratulations on the purchase of your TIG Brush!
Designed, developed, and manufactured in Australia by Ensitech, the TIG Brush
is an electrochemical surface finishing system. It uses the combined action of
electric current, heat, and chemistry to provide fast metal finishing. The system
is famous for its ability to remove heat tint from stainless steel TIG and MIG
welds. In addition, the TIG Brush can perform other functions such as polishing
metal surfaces, indelibly printing logos, text, and even engraving/etching.
To meet your specific needs several options are available. The 440, 550 and 700
models offer different power levels for light work on thin metal through to
removing deep heat tint from the largest metalwork. See section S5 for
more information.
Several proprietary fluids are available for different operations. There are
solvents for adhesive removal and weld preparation, acids for fast heat tint
removal with matching neutralisers, and neutral solutions for food safe work.
See section 7.3.
There are several tools available to enable the different operations. The Classic
Wand for general work, the PROPEL for the more sophisticated user and the
Flexi-Wand to get to more inaccessible work. See section 4.2
When used with the Branding Kit and custom-made or single use stencils,
the TIG Brush will also permanently brand your stainless steel with an indelible
printed mark or engraving. For more details on the Branding Kit visit
www.tigbrush.com/products/branding-kit.
As well as Stainless Steel, the TIG Brush can also be used with other metals
such as brass, copper and aluminium (aluminum). Contact your local TIG
Brush distributor/dealer team for more information, or visit our website
www.tigbrush.com
S1 INTRODUCTION

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2022
S2
Protect yourself and others by observing all safety
information, warnings and cautions. Failure to comply with
instructions could result in personal injury and/or damage
to the product or property.
Read this documentation carefully before operating the
equipment. Please retain these instructions for future
reference.
Before using the TIG Brush, make sure the work environment
is well ventilated and away from any combustible substances.
Ensure that all required equipment is available.
Do not use the TIG Brush for any purpose other than that
described in this manual. Failure to observe this warning
may result in permanent damage to the TIG Brush, cause
damage to the workpiece, cause injury to the operator
and void the warranty.
The TIG Brush is one of the safest appliances in its class. However
some precautions must be taken with the use of the TIG Brush,
as with any electrolytic/electrochemical weld cleaner.
• The TIG Brush uses mild acids; gloves should be used to
avoid prolonged contact with any of the fluids.
•Goggles or safety glasses should be worn to prevent fluid
being splashed in the eyes.
Where an inhalation risk exists, wear a type B (Inorganic
gases & vapours) respirator.
SAFETY PRECAUTIONS
SAFETY INFORMATION
WARNING
•
SAFETY PRECAUTIONS AND INFORMATION

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TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
CAUTION
• Fluid spilled on the skin should be washed off as soon as practical.
• Safety Data Sheets are available for all fluids and should be
read before use (to access Safety Data Sheets online go to
www.tigbrush.com/resource-information/safety-data-sheets)
• The brush gets extremely hot in use, in excess of 200°C (400°F) so make
sure you wear protective gloves when touching the brush when in use or
directly after use. Do not place the brush near any flammable materials.
•DO NOT connect the TIG Brush to any metal work, which has a welding
machine, or other (cleaning) equipment attached to it. Welders can output
an open-circuit voltage, which can exceed 120 volts. While the TIG Brush
has been designed to withstand up to 150 volts, under certain circumstances
a welder can generate a high enough voltage to damage the TIG Brush.
• The TIG Brush produces an electric current which may generate small
sparks between the brush and the metal being cleaned.
• Hydrogen gas may also be generated (which is an invisible but
explosive gas). Always use the apparatus in a well ventilated area.
Do not use near flammable substances, or in areas where dense
flammable gases (such as petrol vapour) may accumulate.
• If the power cord is damaged or if the TIG Brush has been dropped
from a height and damaged, do not use the unit. Contact your
TIG Brush supplier to have the TIG Brush inspected and repaired.
• Do not short out the terminals, or use the TIG Brush with a damaged
wand or cables. Doing so may permanently damage the TIG Brush
and cause damage to the workpiece being cleaned. The high
currents involved may also cause intense heating of the shorted
or damaged part, which could result in burns to the operator.
• Ensure that the TIG Brush is located where it cannot easily
fall and cause injury. Ensure that the cables do not present
a trip hazard.
S2 SAFETY PRECAUTIONS AND INFORMATION

2022
1
2
47
8
3
1
2
4
5
67
8
3
1
2
3
4
5
6
7
8
TIG Brush Control Unit
Black Ground Cable
Red Handle Cable
Handle
Classic Wand
Insulating Shrouds*
(short and long)
Standard single Brush**
Power Cord
* When the brush is new, use the long
shroud and change to the short shroud
as brush wears down.
CLASSIC KIT3.1
** Standard single brush may be replaced
by Dual or Quad brush Adaptors and Shrouds.
12 TIG Brush™ Instruction Manual
DESCRIPTION OF BASIC EQUIPMENTS3

DESCRIPTION OF BASIC EQUIPMENT
1
2
3
4
5
6
TIG Brush Control Unit
Black Ground Cable
Flexi Handle
Insulating Shrouds*
(short and long)
Standard Brush
Power Cord
*When the brush is new use the long
shroud and change to the short shroud
as brush wears down.
FLEXI HANDLE KIT3.2
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TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
1
2
8
3
1
2
2
4
2
5
6
3
S3

14
2022
DESCRIPTION OF BASIC EQUIPMENT
PROPEL KIT3.3
1
2
3
4
5
6
TIG Brush Control Unit
Black Ground Cable
PROPEL Torch
PROPEL Torch
Insulating Shroud
PROPEL Torch Brush
Power Cord
1
2
8
1
2
6
8
3
4
4
4
5
TIG Brush™ Instruction Manual
S3

15
TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
Power Control
Mode Control
Handle Cable,
Flexi Handle or
PROPEL Torch
Socket
Ground Cable
Socket
On/Off Switch
Power Socket
DESCRIPTION OF BASIC EQUIPMENT
S3

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2022
S4 OPERATION
PREPARATION
ASSEMBLY
4.1
4.2
CLASSIC KIT4.2.1
1. Inspect the TIG Brush Control Unit for any damage, and cables for exposed wire.
2. Ensure the Control Unit is dry.
3. Ensure the work environment is well ventilated and away from any
combustible substances.
4. Ensure the cables do not present a trip hazard.
5. Ensure there is ready access to clean water and a suitable area for washing.
6. After cleaning and/or polishing, to remove all acidic residue, wash down with
clean water, spray the cleaned area with the recommended Ensitech neutraliser,
and wash down again.
7. Wear suitable personal protective equipment as recommended in the SDS.
The minimum requirement is for gloves to protect hands from the fluid,
and goggles or safety glasses to prevent fluid splashing into the eyes.
Work piece
120V AC/230V AC*
Single phase
INSULATING SHROUD
MUST BE USED!
Wand
Shroud
Brush
*240V TBX models

17 TIG Brush™ Instruction Manual
2022
Refer to illustration on page 16.
1. Attach Handle Cable plug to the red socket of the TIG Brush Control Unit
2. Screw Classic Wand into handle of the Handle Cable
3. Place long Shroud on Standard brush and screw into the Classic Wand
FLEXI HANDLE KIT4.2.2
Refer to illustration above.
1. Attach Flexi Handle plug to the red socket of the TIG Brush Control Unit
2. Place long Shroud on Standard brush and screw into the Flexi Handle
3. Attach Ground Cable plug to black Ground Cable Socket of the
TIG Brush Control Unit
4. Attach Ground Cable plug to black Ground Cable Socket of the
TIG Brush Control Unit
5. Set POWER switch on the back of the machine to OFF
6. Attach Power Cord to the Power Socket on the back of the TIG Brush
Control Unit and plug into mains power
7. Attach the Ground Clamp to workpiece
120V AC/230V AC*
Single phase
INSULATING SHROUD
MUST BE USED!
Flexi
Handle
Shroud
Brush
*240V TBX models
S4 OPERATION

4. Set POWER switch on the back of the machine to OFF
6. Attach the Ground Clamp to workpiece
5. Attach Power Cord to the Power Socket on the back of the TIG Brush
Control Unit and plug into mains power
PROPEL KIT4.2.3
Refer to illustration above.
1. Attach PROPEL Torch plug to the red socket of the TIG Brush Control Unit
2. Rotate Drive Sleeve clockwise until it stops. Do NOT overwind the
Drive Sleeve!
3. Insert the brass end of the PROPEL Torch brush into the nose of the
Shroud until it is seated in the Collet. The brush should slide into the
Collet with minimal resistance
4. Once the brush is seated in the Collet, turn the Drive Sleeve anti-clockwise
half a turn, and lightly pull the brush to ensure it is securely seated
5. Retract the brush back into the Shroud by turning the Drive Sleeve
anti-clockwise, until it leaves approximately 12-15mm (3/8”- 5/8”)
of the brush exposed
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TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
PROPEL Torch insulating
shroud must be used when
operating the PROPEL Torch
Work piece
120V AC/230V AC*
Single phase
*240V TBX models
S4 OPERATION

4.3 CLEANING FLUID
Pour a small quantity of Weld Cleaning Fluid into the fluid jar. Place the fluid
jar close to the work because the tip of the brush will be dipped into the fluid
regularly during operation.
6. Attach Ground Cable plug to black Ground Cable Socket of the
TIG Brush Control Unit
7. Set POWER switch on the back of the machine to OFF
8. Attach Power Cord to the Power Socket on the back of the TIG Brush
Control Unit and plug into mains power
9. Attach the Ground Clamp to workpiece
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TIG Brush™ Instruction Manual
2022
Ensitech Pty Ltd
www.tigbrush.com
S4 OPERATION

Workpiece
For best performance
use tip of brush only
Wand
Brush
Shroud
Insulating shroud
must be used
20 TIG Brush™ Instruction Manual
2022
S4 OPERATION