HSF TIG-MAX XT 2500 User manual
XT 2500 I XT 4000 I XT 6000
XT 7000 I XT 9000
XT 2500 I XT 4000 I XT 6000
XT 7000 I XT 9000
operating instructions
Page 2 Page 3
P +49 2776 92278-0 |F +49 2776 92129-5 |www.hsf-group.de |info@hsf-group.de
1. forewordcontent
1. foreword
These operating instructions are an important aid. Keep them with the device. The
instruction manual provides information on the operating procedures and precautions
necessary for the safe and proper operation of TIG-MAX®XT that are required.
1.1. Product description
The TIG-MAX®XT Stainless Steel Weld Cleaners (strippers) are metal cleaning, polis-
hing, electropolishing and etch plating machines that are ideal for processing materials
such as stainless steel, copper and brass. The cleaning system consists of a control unit,
a wand with a conductive brush on the end and a cable set. The weld can be treated wi-
thin seconds by using the brush. This unique cleaning system is fast and delivers a safe
and high quality - without any pickling paste.
The fastest, safest and most efcient
cleaning method for stainless steel welds
1. foreword Page 3
1.1. Product description Page 3
2. safetY precautions Page 4
2.1. Safety information Page 4
2.2. Environmental conditions Page 5
3. tips - care - Maintenance Page 6
3.1. Cleaning and maintenance after work Page 6
3.2. Care of the ground clamp Page 7
4. coMMisioning Page 7
4.1. Mains connection Page 7
4.2. Connecting the cable Page 7
4.3. TIG-MAX®XT 2500 Page 8
4.3.1. Cleaning Page 8
4.3.2. Polishing Page 9
4.4. TIG-MAX®XT 4000 Page 10
3.4.1. Cleaning Page 10
3.4.2. Polishing Page 11
4.5. TIG-MAX®XT 6000 Page 13
4.5.1. Cleaning Page 13
4.5.2. Polishing Page 14
4.5.3. Marking/Etching Page 15
4.6. TIG-MAX®XT 7000 Page 16
4.6.1. The front panel Page 16
4.6.2. Description of buttons Page 16
4.6.3. Cleaning Page 17
4.6.4.. Polishing Page 18
4.6.5. Marking/Etching Page 19
4.7. TIG - MA X®XT 9000 Page 20
4.7.1. The front panel Page 20
4.7.2. Description of buttons Page 20
4.7.3. Cleaning Page 21
4.7.4. Polishing Page 22
4.7.5. Marking/Etching Page 23
5. setting tips Xt 7000/Xt 9000 Page 24
5.1. Cleaning with XT 7000 / XT 9000 Page 24
5.2. Polishing with XT 7000 / XT 9000 Page 25
6. trouBLesHooting Page 22
7. care and Maintenance Page 22
7.1. Device disposal Page 22
8. tecHnicaL data Page 23
Page 4 Page 5
• Alwaysswitchothedevicebeforechangingthecarbonbrushes.
• Warning! Over extended treatment periods, the temperature of the carbon brush can
reach as high as 200°C (400°F).
• You must wear suitable protective clothing when using the device (acid-resistant
gloves, apron and goggles).
• If the electrolyte comes into contact with your skin or face, you should rinse the
aectedareasofskinwithplentyofwaterimmediatley.Ifyoucontinuetoexperience
any discomfort, visit a doctor: do not forget to take the label with you.
• Do not eat or drink at the workplace. After working with electrolytes, always wash
your hands thoroughly with soap and plenty of water.
2.2. Environmental conditions
Ambient air temperature range:
• -10°C to +40°C,
• during transport and storage -25°C to +55°C
relative humidity:
• up to 50% at 40°C
• up to 90% at 20°C
Ambient air must be free from abnormal amounts of dust, acids, corrosive gases or sub-
stances, etc., other than those generated by welding.
Examples of unusual operating conditions:
• unusual corrosive smoke,
• Steam,
• excessive oil haze,
• unusual vibrations or shocks,
• Excessive dust such as grinding dust, etc.,
• harsh weather conditions,
• unusual seacoast or shipboard conditions.
Ensure free supply and exhaust air when setting up the device.
The device has been tested according to protection class IP23, which means:
• Protection against ingress of solid foreign bodies Ø> 12mm,
• Protection against spray water up to an angle of 60° from the vertical.
2. safetY precautions
2. safetY Measures
Protect yourself and others by following all safety information, warnings, and precau-
tions. Failure to follow instructions can result in personal injury and/or damage to the
product or property. Please be sure to observe the detailed information on our EC safety
data sheet for the electrolytes.
Before using the TIG-MAX®XT, make sure the work area is well ventilated and there are
noammablesubstancesnearby.
2.1. Safety information
• The stainless steel cleaning device (pickling device) may only be used for the elec-
trolytic processing methods described in these instructions. Inappropriate uses are
not permitted.
• Before each start-up, the mains cable, the mains plug, the electrode cable, the
cleaning electrode, the handle, the ground cable and the workpiece clamp must be
checked for external damage.
• Place the device in a dry place or make sure that it cannot fall down.
• Route cables so that people cannot trip over them.
• Never place the cleaning brush or the handle on the workpiece or work surface in
suchawaythattheelectrodeorthecarbonbercleaningbrushcancomeintocont-
actwiththemetalsurface.Otherwisecurrentwillcontinuetoow,whichcanleadto
damage or even danger.
2. safetY precautions
Page 6 Page 7
After completing work with the TIG-MAX® XT observe the following simple care and
maintenance instructions!
Dirt,corrosionordepositsontheearthclampcanaecttheelectricalcontinuity,which
reduces the cleaning performance!
3. tips -care -Maintenance3. tips -care -Maintenance
4.1. Mains connection
Ensurethatthevoltagespeciedontheratingplateiscompatiblewiththeratedvoltage
of your AC voltage supply.
4.2. Connecting the cable
4. coMMisioning
Moulded grip cable
Earth clamp
cable
1. Turn o the device and
disconnect the earth cable
from the TIG-MAX®XT de-
vice. Lock the clamp in a
vice with soft jaws.
2. Clean the clamp and
especially the prongs with a
newirebrush.
3. The earth clamp now has
the full electrical continuity
again.
1. Thoroughly rinse the brushes with warm
water after each weld cleaning and allow
them to dry thoroughly, taking care to keep
thebersstraight.
2. If the copper socket on the brush starts
to run or becomes dirty, clean it with a small
stainless steel wire brush to ensure good
electrical contact.
3. If hard deposits pads form on or in the threads of the brush, wand or handle, clean them
with a miniature wire brush. The threads could otherwise seize and the cleaning perfor-
mance could be reduced or completely lost.
1.Turnothedeviceandunplug
the blue cable.
2. Unscrew the brush from the wand.
3. Remove the sliding shroud.
4. Unscrew the wand from the handle.
5. Wash all parts thoroughly under
running water.
6. Allow the parts to dry overnight before
packing them away.
3.1. Cleaning and maintenance after using the TIG-MAX®XT 3.2. Care of the earth clamp
Page 8 Page 9
4. tig-MaX®Xt 2500
4.3.2. Marking/etching
• Placethetemplateinthedesiredpositionandxitwithsomeadhesivetapeatthe
corners to prevent it from slipping.
• Slightly wet the stencil with the TM-90 marking liquid.
• MoistenthefeltonthemarkingelectrodewithTM-90markinguid.
• Now stroke the stencil with only light pressure and a slow movement.
• The felt and the area to be marked must be kept wet with the marking liquid during
the marking process.
• At the end, removethetemplatefromtheworkpieceandrinseotheelectrolyte
residues well with water.
4.3.1. Cleaning
• Only use the brush tip to clean.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be cleaned must be kept moist with the TC-225 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
4.3. tig-MaX® Xt 2500
4. tig-MaX® Xt 2500
Page 10 Page 11
4. tig-MaX®Xt 4000
4.4.2. Polishing
• Only use the brush tip for polishing.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be polished must be kept wet with the TC-275 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
4.4.1. Cleaning
• Only use the brush tip to clean.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be cleaned must be kept moist with the TC-225 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
4.4. tig-MaX®Xt 4000
4. tig-MaX®Xt 4000
TIP:
Excessive smoke is
an indication of too high a power setting.
The result is a high brush and electrolyte consumption!
TIP:
Excessive smoke is
an indication of too high a power setting.
The result is a high brush and electrolyte consumption!
Page 12 Page 13
4.5.1. Cleaning
• Only use the brush tip to clean.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be cleaned must be kept moist with the TC-225 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
4.5. tig-MaX®Xt 6000
4. tig-MaX®Xt 6000tig-MaX®Xt accessories
TIP:
Excessive smoke is
an indication of too high a power setting.
The result is a high brush and electrolyte consumption!
Page 14 Page 15
4. tig-MaX®Xt 6000
4.5.2. Polishing
• Only use the brush tip for polishing.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be polished must be kept wet with the TC-275 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
4. tig-MaX®Xt 6000
4.5.3. Marking/etching
• Placethetemplateinthedesiredpositionandxitwithsomeadhesivetapeatthe
corners to prevent it from slipping.
• Slightly wet the stencil with the TM-90 marking liquid.
• MoistenthefeltonthemarkingelectrodewithTM-90markinguid.
• Now stroke the stencil with only light pressure and a slow movement.
• The felt and the area to be marked must be kept wet with the marking liquid during
the marking process.
• At the end, remove the templatefromtheworkpieceandrinseotheelectrolyte
residues well with water.
TIP:
Excessive smoke is
an indication of too high a power setting.
The result is a high brush and electrolyte consumption!
Page 16 Page 17
4. tig-MaX®Xt 7000
4.6.1. The front panel
voltage value
voltage setting
4.6.2. Description of buttons
Operating menu:
• – WIG cleaning
• – MIG cleaning
• – Polishing with brush
• – Dark marking
Operating button to control voltage output:
• 100 % – Cleans at 100% of the maximum current
• 60 % – Cleans at 60% of the maximum current
• 30 % – Cleans at 30% of the maximum current
4.6. tig-MaX®Xt 7000
XT 7000
4. tig-MaX®Xt 7000
4.6.3. Cleaning
Setting:
or
Setting tips on page 24
Electrolyte:
• Only use the brush tip to clean.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be cleaned must be kept moist with the TC-225 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
XT 7000
XT 7000
Page 18 Page 19
4. tig-MaX®Xt 7000
4.6.4. Polishing
Setting:
Setting tips on page 25
Electrolyte:
• Only use the brush tip for polishing.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be polished must be kept wet with the TC-275 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
XT 7000
4. tig-MaX®Xt 7000
4.6.5. Marking/etching
Setting:
Electrolyte:
• Placethetemplateinthedesiredpositionandxitwithsomeadhesivetapeatthe
corners to prevent it from slipping.
• Slightly wet the stencil with the TM-90 marking liquid.
• MoistenthefeltonthemarkingelectrodewithTM-90markinguid.
• Now stroke the stencil with only light pressure and a slow movement.
• The felt and the area to be marked must be kept wet with the marking liquid during
the marking process.
• At the end, remove the templatefromtheworkpieceandrinseotheelectrolyte
residues well with water.
XT 7000
Page 20 Page 21
4. tig-MaX®Xt 9000
4.7.1. The front panel
voltage value
voltage setting
4.7.2. Description of buttons
Operating menu:
• – WIG cleaning
• – MIG cleaning
• – Polishing with brush
• – Dark marking
Operating button to control voltage output:
• 100 % – Cleans at 100% of the maximum current
• 60 % – Cleans at 60% of the maximum current
• 30 % – Cleans at 30% of the maximum current
4 .7. t i g -MaX®Xt 9000
XT 9000
4. tig-MaX®Xt 9000
4.7.3. Cleaning
Setting:
or
Setting tips on page 24
Electrolyte:
• Only use the brush tip to clean.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be cleaned must be kept moist with the TC-225 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
XT 7000
XT 7000
Page 22 Page 23
4. tig-MaX®Xt 9000
4.7.4. Polishing
Setting:
Setting tips on page 25
Electrolyte:
• Only use the brush tip for polishing.
• The container must be close to the workplace, since the brush must be regularly
dipped in the liquid.
• The brush and the surface to be polished must be kept wet with the TC-275 clea-
ning electrolyte during the cleaning process.
• At the end spray with the TC-510 neutralizer. Then rinse well with clear water to
remove all the cleaning electrolyte.
• Clean contacts and threads well. The brush must be removed from the wand and
carefully cleaned. To maintain full performance, we recommend placing the brush in
warm water to remove any remaining liquid.
XT 7000
4. tig-MaX®Xt 9000
4.7.5. Marking/etching
Setting:
Electrolyte:
• Placethetemplateinthedesiredpositionandxitwithsomeadhesivetapeatthe
corners to prevent it from slipping.
• Slightly wet the stencil with the TM-90 marking liquid.
• MoistenthefeltonthemarkingelectrodewithTM-90markinguid.
• Now stroke the stencil with only light pressure and a slow movement.
• The felt and the area to be marked must be kept wet with the marking liquid during
the marking process.
• At the end, remove the templatefromtheworkpieceandrinseotheelectrolyte
residues well with water.
XT 7000
Page 24 Page 25
Feel your way towards the optimal setting.
Start with the 1st setting:
1
2
3
4
5
6
5. setting tips
XT 7000
XT 7000
XT 7000
XT 7000
XT 7000
XT 7000
5.1. Cleaning with tig-MaX®Xt 7000 / Xt 9000
Not enough
power?
Continue with
the 2nd setting!
Not enough
power?
Continue with
the 3rd setting!
Not enough
power?
Continue with
the 4th setting!
Not enough
power?
Continue with
the 5th setting!
Not enough
power?
Continue with
the 6th setting!
Feel your way towards the optimal setting.
Start with the 1st setting:
1
2
3
XT 7000
XT 7000
XT 7000
5. setting tips
5.2. Polishing with tig-MaX®Xt 7000 / Xt 9000
Not enough
power?
Continue with
the 2nd setting!
Not enough
power?
Continue with
the 3rd setting!
TIP:
Excessive smoke is
an indication of too high a power setting.
The result is a high brush and electrolyte consumption!
Page 26 Page 27
6. trouBLesHooting
7. care and Maintenance
Before carrying out any maintenance or troubleshooting activities, always disconnect
the device from the mains. After using the brush, rinse it ideally in warm/hot water to re-
move all traces of cleaning electrode. Any cleaning solution that comes into contact with
the TIG-MAX® XT itself, the cables or other components should be wiped of immediately
with a damp cloth.
6.1. Device disposal
TIG-MAX® XT must not be disposed of with ordinary household
waste! EU Directive 2002/96/EC states the following on the
disposal of waste electrical and electronic equipment:
„Equipment must be disposed of in an environmentally
compatible manner and separated according to recyclable
materials.“
X
Potential faults and their rectication
The device is switched on, but there is no light on:
- Check the connection cable to the plug.
The device shuts down and the red LED lights up:
- The output current is too high: Make sure that the brush has been moistened with
the cleaning solution.
- Switch-on duration exceeded: Allow the device to cool down.
The device is switched on, but its cleaning performance is poor:
- Poor electrical contact: Make sure that none of the cables is damaged and that they
are all properly connected. To ensure good contact, you may have to carefully adjust
the earth clamp.
Dirtontheearthclampcanaectcontactquality,somakesurethattheearthclampis
clean. Ensure that the brush is tightly screwed in the wand. Take care when checking
this - a loose connection can be extremely hot.
If you encounter any problems not mentioned here,
please contact HSF on +49 (0) 2776-922780.
We will be happy to help!
8. tecHnicaL data
8.2. TIG-MAX® XT 4000
Supply voltage 1~ 230V +10%/-20%
Fuse 16Amp
Power cable 3x1.5qmm
No-load output voltage 5 - 36V
Output load 1440W
Eciency87%
Power factor 0.75 @ 70Amp/35V
Temperature range +5 ..+40°C - in use
-40 ..+ 80°C - storage
Housing LxWxH 350x133x213mm
We i gh t 7. 0 Kg
Protection class IP23
EMC class A
8.3. TIG-MAX® XT 6000
Supply voltage 1~ 230V +10%/-20%
Fuse 16Amp
Power cable 3x1.5qmm
No-load output voltage 5 - 36V
Output load 2880W
Eciency87%
Power factor 0.75 @ 70Amp/35V
Temperature range +5 ..+40°C - in use
-40 ..+ 80°C - storage
Housing LxWxH 350x133x213mm
Weight 7.5 Kg
Protection class IP23
EMC class A
8.4. TIG-MAX® XT 7000
Supply voltage 1~ 230V +10%/-20%
Fuse 16Amp
Power cable 3x2.5qmm
No-load output voltage
10-37V AC/9.5-36V DC
Output load 2500W
Output current 70A
Eciency87%
Power factor 0.75 @ 50Amp/30V
Temperature range +5 ..+40°C - in use
-40 ..+ 80°C - storage
Housing LxWxH 385x170x315mm
We i gh t 17. 0 Kg
Protection class IP23
EMC class A
8.5. TIG-MAX® XT 9000
Supply voltage 1~ 230V +10%/-20%
Fuse 16Amp
Power cable 3x2.5qmm
No-load output voltage
10-37V AC/9.5-36V DC
Output load 4000W
Output current 110A
Eciency87%
Power factor 0.75 @ 50Amp/30V
Temperature range +5 ..+40°C - in use
-40 ..+ 80°C - storage
Housing LxWxH 385x170x315mm
We i gh t 17. 0 Kg
Protection class IP23
EMC class A
ThemachinesfulltherequirementsforCEandSclassication.
Supply voltage 1~ 230V +10%/-20%
Fuse 10Amp
Power cable 3x0.75qmm
No-load output voltage 12V AC
Output load 456W
Eciency75%
Power factor 0.85
Temperature range +5 ..+40°C - in use
-40 ..+ 80°C -
storage
Housing LxWxH 240x130x160mm
Weight 6.0Kg
Protection class IP23
EMC class A
8.1. TIG-MAX® XT 2500
© copyright 2022 - HSF GROUP GmbH
No part of this publication may be reproduced in whole or in part, copied, scanned or stored in electronic databases.
HSF GROUP GmbH is prosecuting violations of its rights by using available legal means.
Technical changes, further developments and errors excepted. Dated: 09/2022
Wissenbacher Weg 3 · 35684 Dillenburg · Germany
T +49 2776 92278-0 · F +49 2776 921295
info@hsf-group.de · www.hsf-group.de
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