Masterweld MW8002 Instruction manual

MW8002
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MW8002
1023Rr
rrR
INSTRUCTION MANUAL
FOR USE
AND MAINTENANCE

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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

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INTRODUCTION
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Description
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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
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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
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Description
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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
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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
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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:

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EN 349:1993+A1:2008, EN 614-1:2006+A1:2009, EN 614-2:2000+A1:2008, EN 626-1:1994+A1:2008, EN 626-2:1996+A1:2008, EN
842:1996+A1:2008, EN 894-1:1997+A1:2008, EN 894-2:1997+A1:2008, EN 894-3:2000+A1:2008, EN 953:1997+A1:2009, EN 1005-
2:2003+A1:2008,
EN 1037:1995+A1:2008, EN 1037:1995+A1:2008, EN 1093-1:2008, EN 1093-4:1996+A1:2008, EN 13478:2001+A1:2008, EN ISO
13849-1:2008,
EN ISO 13849-2:2008, EN ISO 13850:2008, EN ISO 13857:2008, EN ISO 14121-1:2007, EN ISO 14159:2008
GENERAL INFORMATION
Par
Description
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Guarantee activation form (with repairs by authorised centres)
BUYER’S DETAILS:
COMPANY NAME ▼
_______________________________
BUSINESS/PROFESSION/DEPARTMENT ▼
_______________________________
USER DATA (Surname and Name) ▼
_______________________________
PLACE OF INSTALLATION ADDRESS ▼
_______________________________
POSTCODE ▼CITY ▼
_________ _________
Telephone ▼ Fax ▼
_________ _________
e-mail ▼
_________
Data di acquisto ▼
_________
Model ▼
_________
Serial number ▼ accessory/ies ▼
_________ _________
In accordance with article 10 of Law 675/96 data provided in this form shall be recorded on protected electronic supports and shall be treated using computerised systems; data must
be provided in order to enter into and execute the contractual relationship established by the Guarantee. Data may be used by service and by specialised companies operating in Italy
and abroad on behalf of service S.r.l., for customer communications.
Pursuant to article 13 of Law 675/96, you may, at any time and free of charge, check the data held and obtain the rectification or erasure of the data; you also have the right to object
in full or in part to the use of the data for the purposes described above, by writing to AES Industrial Supplies Ltd , for the attention of the Data Controller.
Check this boxif you do not consent to the use of the data provided for purposes other than the management of the Guarantee 󱪾
Customer’s Signature_____________

12 MONTH GUARANTEE ACTIVATION REQUEST FORM
This GUARANTEE gives the right to telephone assistance and to interventions by qualified service personnel to restore the equipment following problems caused by manufacturing
faults; this guarantee is valid for 12 months from the date of purchase.
The guarantee does not cover any damage to theouter enclosures or faults caused by naturalevents (lightening, flooding, etc), intent, improper use or use ofincompatible consumables.
The Guarantee does not cover consumable parts such as filters, flexible hose, lamps, etc.
Any assistance carried out by unauthorised personnel shall invalidate the guarantee,
To benefit from the Guarantee please fill in the upper section of this card and send it in a sealed envelope, within 10 days from the date of purchase of the equipment, to the following
address: AES Industrial Supplies Ltd, Olympic House, Southmead Park, Didcot, OX11 7WB
Please attach a copy of the purchase document, or send all documents via fax to [phone] , or to the website www.service.it.
Keep this section of the card together with the original purchase document to certify your right to the Guarantee.
For telephone support or technical assistance please call: [phone]
Section to be filled in and returned in a sealed
envelope to:
AES Industrial Supplies Ltd
Olympic House, Collett,
Didcot, OX11 7WB
Please enclose also a copy of the purchase
document (delivery note, invoice, receipt)
showing the date of purchase.

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MW8002 Welding Fume Extractor
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Description
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Use and general characteristics
Use
The MW8002 welding fume extractor series are particularly suitable to be used in businesses where the
welding operation is occasional and still in the presence of low concentrations of fumes, i.e. for those who, for
reasons dictated by their activity, must perform welding at an address of third where the need to transport the
purifier is a primary requirement. With the latest regulations for this type of use exhaust fans located at the
auto repair shop to clean up the welding fumes.

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MW8002 Welding Fume Extractor
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Description
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Construction features
The portable welding fume extractor MW8002 is made by:
- external metal structure, painted steel of suitable thickness, in such a way as to make the purifier
resistant to accidental impacts due to the use and to the movement. The property is also equipped
with a convenient handle and wheels to facilitate transport;
- filter section comprising a prefilter in metal wool with spark proof function, by one or two paper filters
pretreated depending on the version and an active carbon filter;
- electric motor with single-phase;
- hose and suction nozzle with magnet and tube;
- electric control panel and plug CEE norm.
MW8002
1. Dust separator panel
2. Side locks
3. Grid
4. Lock knob
5. External prefilter
6. Internal microfilter
7. Double vacuum cleaner with brush
motor
8. Handle
9. ‘Manual-auto’switch
10. Protection fuse
11. Electrical panel
12. Activated carbons filter
13. Panel
14. Air outlet slits
15. Sound insulation
16. Electrical cable
17. Wheels
18. Flex hose L= mt 3
19. Aluminium hood with bracket
20. Support magnet
21. Activator amperage clamp
(optional)

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MW8002 Welding Fume Extractor
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Description
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Construction features
The portable cleaner adopts mechanical filtration system to purify the air. The air is sucked in through the
nozzle, positioned near the pollutant source and connected to the purifier by means of flexible tubing, through
the filtration section in which occurs the separation of the particulates (dust present in welding). After this first
stage of separation, the air passes through the fan first and then pass through a panel with activated carbon
for deodorization.
- MW8002, with filter section comprising a filter paper in high efficiency ø = 280 mm L = 390 mm, from
an absolute filter ø = 180 mm L = 375 mm and an active carbon filter 225x265 mm. The suction is
obtained by two motors in parallel, individually operated, only one or both simultaneously. is also used
as a scavenger to be applied to the welding torches low amperage provided apparatus for the
aspiration of fumes.
Carchteristics MW8002
ON OFF switch YES
Complete control panel YES
Automatic start device Optional
Activated carbons filter 210 x 210 mm -
Activated carbons filter 225 x 265 mm YES
Paper filter Ø=195 L=285 mm -
Paper filter Ø=280 L=390 mm YES
Absolute filter Ø=180 L=375 mm YES
Flexible hose Ø=50 mm L=3 m YES
Conical extraction nozzle YES
Magnet for the hood YES
Extracting torch -

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MW8002 WELDING FUME EXTRACTOR
Par
Description
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Technical features
Unit
MW8002
Suction arm
N°
1
Supply voltage
V
230
Frequency
Hz
50
Power
kW
2.2
Absorbed current
A
9.7
Max flow rate - arm
m3/h
500
Pressure drop - machine
Pa
4400
Protection class IP
55
Insulating class ISO
F
Flow rate - machine
m3/h
220
Filtration efficiency ref. EN 779
%
G2 25%
%
F5 85%
%
F6 90%
Active carbon
(if present)
Kg
2
Sound level
dB(A)
77
Weight - machine
Kg
37

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INSTALLATION COMMISSIONING AND START-UP
Installation
For installation you must provide the electrical connection that can be made for reasons of practicality with
plug and socket 2 x 16 + T to be installed by the user.
To make the connection of the vacuum cleaner by grafting the filler hose for the conveyance of the fumes and
which in turn is connected to the element sensor.
It is advisable to protect the unit from moisture.
WARNINGS
Before installation, check the mains voltage.
Commissioning
It is recommended to include the use of the device by the following environmental conditions:
-The ambient operating temperature of the machine is between -10 ° C and 60 ° C
-The humidity of the indoor environment in which the work is carried out must be between 0% and 90%
Recommendations / Instructions:
-The elimination/removal of any waste materials should be carried out according to the regulations
-For cleaning or replacing the filters using the mask and protective gloves.
Description of manual controls
The activation of the purifier MW8002 is obtained manually by moving the switch from position to position or
manual gear and automatically moving the switch to automatic operation. So it is prepared for operation in
automatic by inserting into the jack of the activator applied to the ground lead on the stroke of the welding arc
will close the circuit controlling the activation of the purifier. In the case that both purifiers are not activated to
check the efficiency of the respective fuses, checking any abnormalities of electrical character.
Before startup, check that the mains voltage is in accordance with what is set at installation time.
ATTENTION:
Both containers and metal structures connected to it should be thoroughly grounded as required by safety
regulations.
For this reason, it must be available near the equipment MW8002 an effective line of grounding.
The test is carried out at the manufacturer’s premises, prior to shipment.
Starting
After carrying out the above checks, turn on the mechanical purifier with the switch on the panel and connect
the collector element, connect the activator attacking him with a clamp to the ground wire from the generator
and engage into the jack located on the front door of the air cleaner tools.
FUNCTIONING

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Normal use
The welding fume extractor MW8002 has been designed and built for low to medium use.
The cleaner should be used exclusively for mechanical exhaust of smoke, fine dust, gas, gaseous pollutants
in low concentrations through the torch hood or hose, the end of which is connected with the appropriate filler
plug on the door instead of a treatment plant mechanic.
Remember that: the law allows recycling in environment only if it is occasional welding operations.
The manufacturer is not liable for any use other than as described.
Not to do
-Do not remove the air cleaner filter panels with mechanical function
-In general, do not dismantle or remove any part of the mechanical treatment plant when it is in use or
connected to
-Do not insert the power cord in the closures of the panels
-Do not tamper with the components of the electrical panel
-Do not run the vacuum cleaner along with the suction nozzle closed
-Do not pick up liquids
-Do not place hot objects (eg cigarette butts)
IMPORTANT NOTE
THE EQUIPMENT SHOULD NOT BE USED IN EXPLOSIVE ATMOSPHERE
FUNCTIONING
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Description
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Most frequent faults: causes and remedies
Given that most of the malfunctions occur for improper use of the system, are indicated in the table below
some possible faults that may occur, and the measures to be taken to remedy them.
FAULT TYPE
CAUSES
ACTION
The cleaner suddenly stops
Power outage
Restore the power supply
The fuse is burned
Change
Motor is burned
Repair or change
The yield of the mechanical
cleaner is decreased
Filters are dirty
Repair or change
Fumes are escaping
Wrong installation of the filters
Check the closures of the panels
and seals

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Bad smell
Activated carbons filter full
Change
FUNCTIONING
Par
Description
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Risks and emergencies
Risks
Description hazards and specific protections
The manufacturer has, however, taken steps to reduce the dangers that can arise due to incorrect use of the
machine by installing on the machine itself of the protection devices.
Description hazards cannot be eliminated by the security measures adopted
The dangers cannot be eliminated bythe securitymeasures taken bythe manufacturer arecaused byincorrect
use of the machine or by a failure on the part of the user of the safety instructions in this manual (refer to the
above concerning the things do not do).
As already mentioned above we recommend the use of gloves and mask during cleaning and filter change, in
order to avoid the possible consequences to the operator.
Emergency situations
In case of fire:
-Use powder comply with standards
-Pay attention to the combustion gases (polyester filters and plastic electrical plant)
The materials and substances used in the construction of the equipment does not pose a risk of explosion.
IMPORTANT NOTE
THE EQUIPMENT SHOULD NOT BE USED IN EXPLOSIVE ATMOSPHERE
MAINTENANCE
Par
Description
2
MW8002 - Cleaning and change of parts
For model MW8002 open the dust separating panel (1) from the entrance of fumes acting on the enclosure
(2), then after removing the grill (3) must be emptied of the parts that were deposited on the inside.
Then unscrew the locking knob (4) Cartridges (pre-filter (5) external microfilter (6) inside) and then take them
off outside taking care not to drop them. Pull out the fine filter and wash with a jet of air from inside to outside
the pre-filter and same goes also to the microfilter.
Then replace the cartridges one inside the other and reposition them in their seat blocking in the bottom panel
(4).
From the side air outlet remove the panel (7) acting on the side locks but not before having removed with a
tool safety screw.

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Remove from the place the carbon filter (8) and replace it with a new one, making sure to put it back properly
when you replace the blanking plate (7) in its place.
Example of the progression of the reduction process.
ATTENTION:
All these operations have to be done absolutely by the socket (9) disconnected form electricity.
MAINTENANCE
Par
Description
3
Inspections, inspections, repairs, interventions other than ordinary
The engine of the model MW8002 is equipped with brushes, with detachment that reached a certain degree
of wear they touch blocking the operation of sewage treatment plant. To replace them, follow the diagram
below.

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Please note that regular maintenance of the system in general durability.
Periodic maintenance of the filters
The maintenance intervals recommended periodic maintenance are listed below.
GROUP TO CHECK
FREQUENCY OF CONTROL
OPERATIONS TO DO
Sportello contenitore di
decantazione
When checking the filters
Drain off and blow with
compressed air
Prefilter cartridge
When the extraction is low
Blow with compressed air
Microfilter cartridge
About every 300-500 hour
Change
Carbons
When the expelled air has bad
smell
Change
The filters should be replaced after 2 or 3 cleanings.
The filters, when replacing, be disposed of according to regulations.
For the replacement of the filters follow as described previously.
Non-ordinary interventions
Involves repair and replacement of one or more system components that normally are necessary after years
of successful operation and does not alter the characteristics of the machine.
In case of substantial changes, the manufacturer cannot be held responsible for any dangers that might arise.
DECOMMISSIONING
Par
Description
1
Dismantling and demolition