Masterweld MW 1900 Instruction manual

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MW 1900
WELDING FUME EXTRACTOR
INSTRUCTION MANUAL FOR USE
AND MAINTENANCE
Masterweld | 2018 all rights reserved

Rev 00.00 Page 2 of 32
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CONTENTS
Par Description
0Analytical index of the operating and maintenance manual
CONTENTS.........................................................................................................................2
Analytical index of the operating and maintenance manual .................................................. 2
INTRO DUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Scope of the operating and maintenance manual................................................................... 4
Storage of the instruction manual............................................................................................ 5
Updating of the Instruction Manual.......................................................................................... 5
Glossary and pictograms.......................................................................................................... 6
GENERA L INFORMA TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Manufacturer’s identication data ......................................................................................... 10
Machine identification and data plates (if they are present) ................................................ 11
Declarations............................................................................................................................. 11
Guarantee activation form (with repairs by authorised centres) ......................................... 13
GENERA L INFORMA TION ON THE MA CHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General description of the machine....................................................................................... 14
Technical data of the MW 1900 Unit ...................................................................................... 16
Description of machine components..................................................................................... 17
INITIA L STA RT- UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical connections ............................................................................................................ 18
Control panel and electrical panel on the machine............................................................... 19
Use of the suction arm............................................................................................................ 20
MA CHINE MA INTENA NCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacing the filters ................................................................................................................ 21
Detail of the filters in the air cleaner with rigid pocket bag HEPA filtration system........... 22
Detail of carbon filter, for MW 19000 ..................................................................................... 23
Malfunctions ............................................................................................................................ 24
Maintenance programme ........................................................................................................ 25
Wiring diagram for single-phase power supply .................................................................... 26
OPERA TOR S NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Details of maintenance operations ........................................................................................ 27
MW 1900 WELDING FUME EXTRACTOR
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SPA RE FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Filter’s codes ........................................................................................................................... 28
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INTRODUCTION
Par Description
1Scope 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 sta󰀨 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
Par Description
2Storage of the instruction manual
The instruction manual must be kept safely and must be handed over to 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
3Updating 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
4Glossary 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 D EFINITIONS
MAN-MACHINERY INTERACTION
Any situation in which the operator interacts with machinery in any of the operating phases during the
lifecycle of the machinery.
OPERATOR QUALIFICATIONS
Minimum level of skill that an operator must have to carry out the described operation.
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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 running mode, jog command,
stop, etc., the condition of the safety devices on the machines such as protection 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 qualied 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.
Tab l e 0 - 4. 1
MW 1900 WELDING FUME EXTRACTORMW 1900 WELDING FUME EXTRACTOR
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PICTOGRAMS CONCERNING THE STATE OF THE MACHINE
Pictograms inside a square/rectangle provide INFORMATION.
Symbol Description
Machine o󰀨: 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 waiting for functional consent to start (e.g. presence of product),
mobile protection devices closed with safety device closed, and fixed protection devices
closed.
Tab l e 0 - 4. 2
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SAFETY SIGNS
•The pictograms inside a triangle indicate DANGER;
•The pictograms inside a circle mean PROHIBITION/OBLIGATION.
Symbol Description
Dangerous electrical voltage
Danger of crushing of upper limbs
Danger of entanglement
Danger of being dragged by machine parts
General hazard
Danger of entanglement in transmission belt
Hot surfaces; danger of burning
Danger of being dragged by impellers or rotating parts
No access to unauthorised people
Do not remove safety devices
Do not manually clean, oil, grease, repair of adjust moving parts
Do not carry out any work without disconnecting the power
Protective gloves must be worn
Safety footwear must be worn
Safety helmets must be worn
Tab l e 0 - 4. 3
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Rev 00.00 Page 10 of 32
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GENERAL INFORMATION
Par Description
1Manufacturer’s identication data
MANUFACTURER
AES INDUSTRIAL SUPPLIES LTD
REGISTERED OFFICE – ADMINISTRATIVE OFFICE
Olympic House, Collett, Southmead Industrial Park, Didcot, OX11 7WB
AFTER SALES/SPARE PARTS SERVICE
Tel . + 44 1235 510 717
E- m ai l : [e-mail]
CONTACTS
Tel : + 44 1235 510 717
E- m ai l : :[e-mail]
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Rev 00.00 Page 11 of 32
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GENERAL INFORMATION
Par Description
2Machine identication and data plates (if they are present)
Each machine is fitted with a CE plate with indelible identification data. All communications with the
manufacturer or technical assistance centres must refer to the said data.
GENERAL INFORMATION
Par Description
3Declarations
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
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Rev 00.00 Page 12 of 32
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EC DECLARATION OF CONFORMITY
(Annex IIA DIR. 2006/42/CE)
THE MANUFACTURER
Company
AES INDUSTRIAL SUPPLIES
LTD
Address
DECLARES THAT THE MACHINE
Trolley-mounted air cleaner for the extraction of welding fumes MW 1900
Description Model
_ _-_ _ _ _ _ _-_ _ _ _ _ _ _ _
Serial number Year of manufacture
MW 1900 Welding Fume Extractor
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:
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
AND DECLARES THAT THE TECHNICAL FILE
Has been compiled by the manufacturer and is kept at:
Place and date of document The manufacturer
Date, _ _ / _ _ / _ _ _ _
Legal representative
D.C.: DC N-001/00001
MW 1900 WELDING FUME EXTRACTOR
Olympic House, Collett, Southmead Industrial Park, Didcot, Oxfordshire, United Kingdom, OX11 7WB
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Rev 00.00 Page 13 of 32
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GENERAL INFORMATION
Par Description
4Guarantee 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 purchased▼
_________
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 AES and by specialised companies
operating in the UK and abroad on behalf of AES 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 for the attention of the Data
Controller.
Check this box if 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 AES 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 the outer enclosures or faults caused by natural events (lightening, flooding, etc), intent, improper use or use of incompatible
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, Collett, Southmead Park, Didcot, OXON, United Kingdom, OX11 7WB
Please attach a copy of the purchase document.
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, Southmead Park
Didcot, Oxon, United Kingdom
OX11 7WB
Please enclose also a copy of the purchase
document (delivery note, invoice, receipt)
showing the date of purchase.
.
By providing AES Industrial Supplies with personal data you have
the right to a further six months GUARANTEE following
on from the twelve month normally guaranteed
By providing AES Industrial Supplies with personal data
you have the right to a further six months
GUARANTEE following on from the twelve
month normally guaranteed
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Rev 00.00 Page 14 of 32
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GENERAL INFORMATION ON THE MACHINE
Par Description
1General description of the machine
The portable unit is the ideal solution for the extraction and ltration of welding fumes from variable position
work stations with discontinuous welding operations. The gases and fumes given off during welding are
captured to prevent them from spreading throughout the workplace; the air containing the contaminants is
thoroughly filtered and recycled back to the workplace. This unit is designed for the suction and treatment of
dry fumes produced by work processes such as spot or discontinuous welding wire or electrode welding,
hence involving the emission of low concentrations of pollutants containing gas or suspended welding slag.
National and international regulations allow the use of these devices in replacement of conventional air
cleaners with an articulated arm in special conditions such as occasional or discontinuous use (e.g. 20 hours
out of a 40 hour working week) or in conditions in which the work processes are dynamic to the point at
which a fixed capture system is ineffective. In addition, the filtration unit also purifies the air in the
surrounding environment, thus not only treating the area contaminated by the work process but
simultaneously creating air exchange in the workplace and further decreasing the level of pollutants present.
To comply with regulations and to obtain high quality filtration with consequent safety for the operator, it is
essential to perform correct maintenance/ periodic replacement of the filters, which, in our units, provide high
capacity for accumulation of contaminants and very low costs for the ltration sections.
MACHINE CHARACTERISTICS
The portable unit is fitted with a high efficiency suction fan in a negative pressure sound-insulated
compartment which acts as flow calming plenum to reduce the turbulent flow of the treated air before it goes
out through the special output grilles.
The excellent manoeuvrability and highly ergonomic use of this unit ensure it can be utilised in several
different work stations, while the flexible arm is able to operate over a working radius of 3 m.
The machine is supplied as standard with an electrical control panel, IP65 protection, made up of:
-ON/OFF switch;
-magneto-thermal protection (for electric motor);
-differential pressure switch with simultaneous temperature control;
-machine power supply signal (white light);
-machine on signal (green light);
-clogged filter signal (red light).
According to the version, the filtration section is made up as follows:
FILTRATION LEVEL MW 1900 UNIT
1
2
3 H12 HEPA FILTER
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ALUMINIUM MESH FILTER
PLEATED PANEL FILTER

Rev 00.00 Page 15 of 32
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Masterweld MW 1900 supports 3 or 4 m length arms; these can be of the following types:
MASTERFLEX SELF-SUPPORT ARM ( Available in 3 / 4 mtr )
The internal supporting structure is realized with reinforced steel billet pipes and 6061 aluminum alloy
components after CNC worked for T6 in physical state, then anodized to ensure durability despite continuous
exposure to fumes.
The flexible covering pipe is an multilayered PVC to guarantee the protection from eventual sparks and a
high temperature resistance (max 40°C).
The extraction hood has a square profile for a maximum efficiency of extraction, complete of manual damper
for the airflow calibration, anti-intrusion grille and bridge handle.
MASTERTECH HD SELF-SUPPORT ARM ( Available in 3 mtr only )
The internal supporting structure is realized with reinforced steel billet pipes and 6061 aluminum alloy
components after CNC worked for T6 in physical state, then anodized to ensure durability despite continuous
exposure to fumes.
The rigid pipe in aluminum allows a high lightness.
The suction hood has a square profile to provide a maximum efficiency of extraction, complete of a manual
damper for an airflow calibration, safety anti-intrusion grate and handle.
The wall mounted version are provided with a steel painted bracket for fixing and connection pipe for fume
expulsion.
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GENERAL INFORMATION ON THE MACHINE
Par Description
2Technical data of the Masterweld MW 1900 unit
Unit data MW 1900
Suction arm N° 1
Supply voltage V 230
Mains frequency Hz 50
Installed power kW 1.1
Absorbed current A 4.85
Maximum extractor fan flow rate m
3
/h 2500
Extractor fan negative pressure Pa 1400
IP Protection class 55
ISO insulation class F
Machine air flow rate m
3
/h 1500
Machine negative pressure Pa 630
Filtration efficiency
According to EN 779
%G2 25%
%G4 70%
%
H12 99,5%
Optional carbon filter Kg 10
Sound pressure level db(A) 73
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Rev 00.00 Page 17 of 32
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GENERAL INFORMATION ON THE MACHINE
Par Description
3Description of machine components
Air expulsion slots,
access to the fan
and substitution of
Active carbon filter
Aluminium handle
Swivel wheel with
brake
Electrical panel
Inspection door for
the replacement of
the filters
Suction arm
Housing plate for
suction arm
1200 mm
Ph o to 2 - 3. 2
Ph o to 2 - 3. 1
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INITIAL START-UP
Par Description
1Electrical connections
All versions of the portable air cleaner come with a 5 m power supply cable.
The cable comes with a wired plug (Photo 3 - 1.1).
Ph o to 3 - 1. 1
250 V Plug~ French and German standard*
MW 1900 WELDING FUME EXTRACTOR
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* Adaptor supplied for UK market

Rev 00.00 Page 19 of 32
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INITIAL START-UP
Par Description
2Control panel and electrical panel on the machine
The machine is equipped with an electrical panel which acts as control panel and as container for the
protection devices of the electric motor.
The control panel is on the front of the machine near the handle. The control panel is covered by a painted
plate with the adhesive strip as shown below.
The position of the panel makes it easy to switch the machine on and off and to keep all the machine
functions under control by means of the indicator lights on the panel.
The handle protects the panel against accidental knocks which could damage the equipment thus making it
impossible to control the machine.
The label above the panel helps the operator use the equipment and check its correct operation.
Indicator for fan on/off
Filters clogging
indicator
On/off switch
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Rev 00.00 Page 20 of 32
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INITIAL START-UP
Par Description
3Use of the suction arm
The machine is fitted with one suction arm which must be assembled separately using the screws supplied in
the package. The arm's flange must be fixed to the plate, with pre-drilled holes, on the air cleaner.
The suction arm can rotate 360° about the central axis during the rotation phase.
Arm closing and/or opening operations must be carried out only from the front of the machine with the
operator facing the control panel.
The use of the suction arm outside the recommended range may cause the machine to tip over. In fact,
when movements are carried out along the longest side of the machine the force exercised is such as to
move the barycentre and act as a lever lifting and/or tipping over the air cleaner in the direction of the
operator moving the arm.
Max 30
°
Max 30
°
MW 1900 WELDING FUME EXTRACTOR
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