Masterweld MW8002 Instruction manual

MW8002
Rev 00.00
Page 1 of 25
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MW8002
1023Rr
rrR
INSTRUCTION MANUAL
FOR USE
AND MAINTENANCE

MW8002
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INDEX
Par
Description
0
Analytical index of the operating and maintenance manual
INDEX..................................................................................................................................2
Analytical index of the operating and maintenance manual ..................................................2
Purpose of the operating and maintenance manual.......................................................4
Storage of the instruction manual....................................................................................5
Updating of the Instruction Manual..................................................................................5
Glossary and pictograms..................................................................................................6
Manufacturer’s identification data....................................................................................9
Machine identification and data plates (if they are present)............Error! Bookmark not
defined.
Declarations .....................................................................................................................10
Guarantee activation form (with repairs by authorised centres).................................11
MW8002 WELDING FUME EXTRACTOR ..............................Error! Bookmark not defined.
Use and general characteristics.............................................................................................12
MW8002 WELDING FUME EXTRACTOR ..............................Error! Bookmark not defined.
Construction features.............................................................................................................13
Technical features...................................................................................................................14
INSTALLATION COMMISSIONING AND START-UP......................................................16
FUNCTIONING..................................................................................................................16
Normal use...............................................................................................................................17
Most frequent faults: causes and remedies ..........................................................................17
Risks and emergencies...........................................................................................................18
MAINTENANCE ................................................................. 19Error! Bookmark not defined.
MW8002 - Cleaning and change of parts ...............................................................................18
Inspections, controls, repairs, interventions other than ordinary .......................................19
DECOMMISSIONING........................................................................................................20
Dismantling and demolition....................................................................................................20
WIRINGS...........................................................................................................................22
MW8002...........................................................................................Error! Bookmark not defined.

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OPERATOR’S NOTES......................................................................................................23
Details of maintenance operations ........................................................................................23

MW8002
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INTRODUCTION
Par
Description
1
Purpose of the operating and maintenance manual
This instruction manual is an integral part of the machine and has the purpose of providing all the necessary
information for the following purposes:
•Raise the awareness of operators as regards safety matters;
•Safe handling of the machine when packaged and unpackaged;
•Correct installation of the machine;
•Thorough knowledge of the machine’s operations and limits;
•Correct use in total safety;
•Correct and safe maintenance;
•Dismantling of the machine in total safety, in compliance with the regulations in force on the health
and safety of workers and the environment.
The people in charge of the company’s departments in which this machine will be installed must,
according to the regulations in force, carefully read the content of this Operating Manual and ensure
that operators and maintenance staff operating and working on the machine read the relevant parts.
The time dedicated to this will be fully rewarded by the correct and safe operation of the machine.
This document is based on the assumption that the systems in which the machine is to be installed are in
compliance with the health and safety at work regulations in force.
The instructions, drawings and documentation contained in this Manual are of a technical confidential nature
and are property of the manufacturer; they may not be reproduced in any way, in part of fully.
If this manual is amended by the manufacturer, the Customer has the responsibility of ensuring that only the
updated versions are available in the points of use.

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INTRODUCTION
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Description
2
Storage of the instruction manual
The instruction manualmust be kept safely and must be handed overto new owners in case of sale throughout
the lifecycle of the machine.
To help preserve the manual in good condition it must be handled with care and with clean hands, and it must
not be placed on dirty surfaces.
It is forbidden to remove, tear out or arbitrarily modify any parts of the manual.
The manual must be stored in an environment away from humidity and heat, in a position near the machines
to which it refers.
Upon the User’s request the Manufacturer shall supply other copies of the machine’s instruction manual.
INTRODUCTION
Par
Description
3
Updating of the Instruction Manual
The manufacturer reserves the right to modify the project and improve the machine without informing
customers and without updating the manual already delivered to the User.
If modifications are made to a machine installed at the customer’s premises, in agreement with the
manufacturer, and which entail the amendment of one or more chapters of the manual, the manufacturer shall
send the amended chapters to the holders of the Instruction Manual and its new overall revision.
According to the instructions that will accompany the updated documentation, the User shall replace the old
chapters in the copies held with the new ones, as well as the first page and table of contents with the new
revision level.

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INTRODUCTION
Par
Description
4
Glossary and pictograms
This paragraph lists some terms which are not commonly used or with a meaning different from the common
one. The meaning of the abbreviations and pictograms used is described below. The abbreviations and
pictograms are used to indicate operator qualifications and state of the machine; they provide, in a quick and
univocal manner, the information necessary for the correct and safe use of the machine.
GLOSSARY (Annex I point. 1.1.1 Dir. 2006/42/EC)
HAZARD
A potential source of injury or damage to health;
DANGER ZONE
Any zone within and/or around machinery in which a person is subject to a risk to his health or safety;
EXPOSED PERSON
Any person wholly or partially in a danger zone;
OPERATOR
The person or persons installing, operating, adjusting, maintaining, cleaning, repairing or moving machinery;
RISK
A combination of the probability and the degree of an injury or damage to health that can arise in a hazardous
situation;
GUARD
A part of the machinery used specifically to provide protection by means of a physical barrier;
PROTECTIVE DEVICE
A device (other than a guard) which reduces the risk, either alone or in conjunction with a guard;
INTENDED USE
The use of machinery in accordance with the information provided in the instructions for use;
REASONABLY FORESEEABLE MISUSE
The use of the machinery in a way not intended in the instructions for use, but which may result from readily
predictable human behaviour.
OTHER DEFINITIONS
MAN-MACHINERY INTERACTION
Any situation in which the operator interacts with machinery in any of the operating phases during the lifecycle
of the machinery.

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OPERATOR QUALIFICATIONS
Minimum level of skill that an operator must have to carry out the described operation.
NUMBER OF OPERATORS
The suitable number of operators, able to carry out the operation described in an optimal way, as
established by a careful manufacturer analysis, whereby a different number of operators might not make it
possible to obtain the expected result or might endanger the safety of the personnel involved.
STATE OF THE MACHINE
The state of the machine includes operating modes,for example automatic runningmode,jog command, stop,
etc., the condition of the safety deviceson the machinessuch asprotection devices provided (or not provided),
pressed emergency button, type of isolation from energy sources, etc.
RESIDUAL RISK
Risks that persist despite the adoption of the protective measures included in the design of the machine and
despite the additional protective devices and measures adopted.
SAFETY DEVICE
Device:
-That carries out a safety function;
-which, when faulty and/or broken, endangers the safety of people.
(e.g. lifting equipment; fixed, mobile, adjustable protective device, etc., electric, electronic, optical, pneumatic,
hydraulic device interlocking a protection device, etc.).
PICTOGRAMS
The descriptions that follow this pictogram contain:
Very important information/instructions, in particular as regards safety.
Failure to respect them may lead to:
•danger for the safety of the operators;
•loss of contractual guarantee;
•waiver of the manufacturer’s liabilities.
PICTOGRAMS CONCERNING OPERATOR QUALIFICATIONS
Symbol
Description
Unskilled worker: operator without specific skills that can only carry out simple tasks
following the instructions of qualified technicians.
Driver of lifting and handling means: operator qualified to use machines and material
handling and lifting equipment (strictly following the manufacturer’s instructions), according
to the laws in force in the country of use of the machine.
Mechanical service man: a qualified technician that can manage the machine in normal
conditions, operate in jog mode with the protection devices disabled and work on its
mechanical parts to make the necessary adjustments, repairs and maintenance. Usually
he is not qualified to work on live electrical systems.
Electrical service man: a qualified technician that can use the machine in normal
conditions, operate in jog mode with the protection devices disabled and work on electrical
parts to make the necessary adjustments, repairs and maintenance. He can work on live
cabinets and junction boxes.
Manufacturer’s technician: qualified technician provided by the manufacturer to carry out
complex operations in particular situations, or in any case as agreed with the user.
According to the situation the technician will have mechanical and/or electrical and/or
electronic and/or software skills.

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Table 0 - 4.1
PICTOGRAMS CONCERNING THE STATE OF THE MACHINE
Pictograms inside a square/rectangle provide INFORMATION.
Symbol
Description
Machine off: with hydraulic or electric power supply disconnected.
Machine on: with hydraulic or electric power supply connected and in safe stop condition with
open mobile protective devices (specifying which); JOG disabled; fixed protection devices
closed.
Machine on: with hydraulic or electric power supply connected and in safe stop condition with
emergency mushroom button pressed or other control with the same function activated,
positioned near the intervention area (specifying the mushroom button or the device to be
used).
Machine moving: in automatic mode, with mobile protection devices closed, the relevant
interlocking devices activated, and the fixed protection devices closed.
Machine moving: in JOG mode, with mobile protection devices closed, the relevant
interlocking devices activated, and the fixed protection devices closed.
Machine moving: in JOG mode, with one or more mobile protection devices, that can be
disabled, open (specifying which) with the relevant interlocking devices activated and fixed
protection devices closed.
Machine on: in stand-by and waitingfor functionalconsent to start (e.g. presence of product),
mobile protection devices closed with safety device closed, and fixed protection devices
closed.
Table 0 - 4.2

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GENERAL INFORMATION
Par
Description
1
Manufacturer’s identification data
Importer & UK Distributor
AES Industrial Supplies Ltd
REGISTERED OFFICE –ADMINISTRATIVE OFFICE
Olympic House, Collet, Southmead Park, Didcot, Oxon, OX11 7WB
AFTER SALES/SPARE PARTS SERVICE
Tel. [phone]
Fax. [phone]
E-mail: [e-mail]
CALL CENTER
Tel. [phone]

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GENERAL INFORMATION
Par
Description
3
Declarations
The machine is manufactured in conformity with relevant EC Directives, applicable when the machine is put
on the market.
ANNEX IV Directive 2006/42/EC
The machine does not belong to the category of machines mentioned in Annex IV to directive 2006/42/EC.
EC DECLARATION OF CONFORMITY
(Annex IIA DIR. 2006/42/CE)
The Importer & Sole Distributor
AES Industrial Supplies Ltd
Company
Olympic House, Southmead Park
OX11 7WB
Oxfordshire
Address
Postcode
Province
Didcot
United Kingdom
City
Country
DECLARES THAT THE MACHINE
Trolley-mounted air cleaner for the extraction of welding fumes
MW8002
Description
Model
_ _-_ _ _ _ _ _-_ _ _ _
_ _ _ _
Serial number
Year of manufacture
MW8002
Commercial name
Extraction and treatment of welding fumes for oil and fat-free light duty processes
Intended use
IS IN COMPLIANCE WITH THE FOLLOWING DIRECTIVES
Directive 2006/42/EC of the European Parliament and Council of 17 May 2006 on machinery and amending directive
95/16/EC.
Directive 2004/10/8/EC of the European Parliament and Council of 15 December 2004 on the approximation of the laws
of the member States relating to electromagnetic compatibility.
Directive 2006/95/EC of the European Parliament and Council of 12 December 2006 on the approximation of the laws of
Member States relating to electrical equipment designed for use within certain voltage limits.
Reference to harmonised standards: