Walter SURFOX 204 User manual

SURFOX 204
User’s guide
Manuel de l’utilisateur
Manual de usuario
Manual do Usuário
SURFOX website
(Link to surfox.com)

SURFOX 204 User’s Guide 1
Table of contents
Table of contents
1 Introduction 2
2 Safety instructions 3
3 Equipment controls 4
A) Control panel pictograms 4
B) Front and back view of the machine 5
C) Wand control buttons 6
D) Fume elimination system 6
E) Tip repositioning (comfort for operator) 6
4 Control panel 7
A) Main power switch 7
B) Wand selector switch 7
C) Amperage regulating switch 7
D) Solution pump switch 7
E) Indicator lights 7
F) Accessory outlet 7
5 Start-up procedure 8
A) What is included in the box 8
B) Filling the reservoir 8
C) Connecting the air supply 8
D) Plugging in the power cord 8
E) Plugging in the ground clamp 8
6 Using the hand wand to electrochemically
clean, polish and passivate 9
A) Selecting the proper mode 9
B) Selecting the proper amperage type, AC or DC 9
C) Selecting the proper amperage setting 9
D) Selecting the proper pumping mode 9
E) Cleaning and passivating 9
F) Neutralizing 9
7 Using the mini wand (optional) to clean
and passivate 10
A) Selecting the proper mode 10
B) Selecting the amperage type, AC or DC 10
C) Selecting the proper amperage setting 10
D) Manual pumping mode 10
E) Cleaning and passivating 10
F) Neutralizing 10
G) List of supplies and part numbers 11
8 Using the marking/etching wand (optional) 12
A) Marking kits 12
B) Selecting the proper mode 12
C) SURFOX testing devices 12
9 Neutralizing 13
A) Directions for neutralizing SURFOX
electrolyte cleaning solutions 13
B) SURFOX WELD cleaning and neutralization
procedure 13
10 Accessories 14
A) Selection and mounting of the cleaning
pads and tips 14
B) PTFE clamp rings 16
C) SURFOX electrolyte solutions 16
D) Mounting a cleaning pad
11 Safety features 17
A) Sparks on the tip/work piece 17
B) Internal temperature 17
C) AC/DC current basics 17
D) AC/DC settings on the SURFOX machine 18
E) Welds that cannot be cleaned 18
12 Technical data 19
13 Warranty and service 19
A) Warranty policy 19
B) Repair and service 19
Version française 21
Versión española 41
Versão Portuguaise 61

2
1
Congratulations on purchasing the nest electrochemical
weld cleaning and passivation equipment available today.
WALTER’s SURFOXTM weld cleaning equipment quickly,
easily and cost effectively removes the heat tint from heat
affected zones while completely passivating the stainless
steel surface.
Our new generation of SURFOX machines are equipped
with self-regulating inverter boards, automatically monitoring
and adjusting the current so as to ensure maximum clean-
ing effectiveness without loss of productivity.
Before starting, please read the SURFOX owner’s manual
completely as we take you step-by-step through the start-
up, operating and maintenance procedures of your new
SURFOX equipment. Your new SURFOX machine has been
built with extra durability to stand up to the heavy demands
of industrial use. However, like any piece of electrical equip-
ment, care and safety should always be taken when using
and maintaining this valuable investment. With proper care
and maintenance your SURFOX equipment will provide
years of dependable service.
To learn more about the other WALTER products, visit our
website: www.walter.com
Operation
The SURFOX machine works by an electrochemical process
to clean and passivate welds on stainless steel. SURFOX
electrolyte solutions are phosphoric acid based, approved
for food industry, and are activated by an electrical cur-
rent to clean welds. The process takes only a few seconds
without damaging or scratching the surface of the parts to
be cleaned.
Your SURFOX machine can clean:
uTIG welds
uPlasma welds
uLaser welds
uSpot welds
uMIG welds (with Pulse technology)
Basics of passivation:
uThe cleaning of the welds is not only for aesthetic
purposes but most importantly for passivation.
uPassivation is the treatment of stainless steel surfaces
to remove contaminants and promote the formation of
a thick and durable protective chromium oxyde layer.
uThis passive layer will insure the corrosion resistance of
stainless steel.
uIf passivation is not done properly, stainless steel and
heat affected zones may start to rust.
Introduction
Introduction

SURFOX 204 User’s Guide 3
2
14. Make sure the switch is in its OFF position before
plugging in or when moving the unit to avoid uninten-
tional starting.
15. Hold the wand rmly. Do not overreach, maintain good
footing and balance at all times.
16. Before use, all parts should be carefully examined to
determine that the unit will operate properly and
perform its intended function.
17. Parts that are damaged or defective should be properly
repaired or replaced by a WALTER Factory Service
Center or a WALTER Authorized Service Center.
18. Do not use the unit if the switch does not turn ON
and OFF.
19. Use only the accessories recommended for this
system. Always check accessories before starting to
work and do not use if damaged.
20. CAUTION: WALTER SURFOX electrolyte weld cleaning
solutions contain phosphoric acid and may cause burns
when not handled properly. Avoid skin contact.
First aid Wash affected area with water.
Eye contact Flush with water for 15 minutes lifting
eyelids occasionally. Contact physician if necessary.
Ingestion DO NOT induce vomiting. Rinse mouth,
drink plenty of water and get medical attention.
Refer to WALTER product MSDS for complete
safety data information.
21. Use only WALTER SURFOX electrolyte weld cleaning
solutions with this unit and NEVER mix it with any other
products.
22. Store solution in its original container and in a safe
place, out of the reach of children and other unquali-
ed persons. Keep container contents clean. Do not
reuse SURFOX electrolyte cleaning solutions.
23. Do not touch the wand tip or work piece while working
or immediately after use, they may be extremely hot
and could cause serious burns.
24. Do not abuse the power cord. Never pull or lift this unit
by its cord or yank to disconnect it from the receptacle.
Keep the cord away from heat, oil and sharp edges.
Inspect the cord periodically, if damaged, have it re-
placed by a WALTER Factory Service Center or a
WALTER Authorized Service Center.
25. When not in use, switch OFF and unplug the electrical
cord and air hose (if connected). It must also remain
unplugged when replacing cleaning pads and other
accessories, while performing maintenance and before
servicing.
26. Store the unit in a dry safe place, out of the reach of
children and other unqualied persons.
WALTER weld cleaning machines are produced in accor-
dance with applicable standards governing the manufac-
ture, performance and safety of industrial products.
WARNING: When using these machines, basic safety
precautions should always be observed to reduce the risk
of re, electrical shocks and personal injuries.
Before using this machine, read all Safety and
Operating Instructions carefully and save this owner’s
manual for future reference.
1. Read this owner’s manual to familiarize yourself with
this unit’s operation, its particular features, applications
and limitations.
2. This unit is equipped with a 3-conductor power cord
and 3-prong electrical plug, it must be connected to
a correspondingly grounded receptacle.
3. Allow a minimum of 8” clearance around the unit to
keep all air openings clear of any obstruction. Free
airow through the vent openings is required to
prevent the unit from overheating.
4.
Keep work area clean and well lit. A cluttered environ-
ment invites accidents. Remove any material that
may be ignited by sparks. Do not use this tool when
ammable liquids or gases are present. Keep handles
clean, dry and free from cleaning solution, oil and
grease. Do not use in rain, damp or wet locations.
5. Keep children and other persons at a safe distance
from the work. Make sure no one is under you when
working in high places. Do not let unqualied persons
handle this machine.
6. When working, always wear appropriate clothing
and safety gear, such as suitable and safety approved
chemical resistant gloves, overalls, safety shoes, etc.
7. Always wear approved safety goggles.
8. During the cleaning process, the wand tip and work
piece can reach very high temperatures, allow to cool
before coming in contact with exposed skin.
9. Avoid inhalation of fumes, use only in well ventilated
areas. Use a respirator, if necessary.
10. All electric shocks can be potentially dangerous.
11. Should you encounter an electrical problem, do not
use the unit until qualied personnel have inspected
the equipment.
12. Never operate the unit with its protective cover
removed.
13. Stay alert at all times when handling this unit. Watch
what you are doing. Use common sense. Do not
operate the tool when you are tired. Never leave it
running unattended.
Safety instructions
Safety instructions

4
2
Amperage
Before connecting this unit, check that the amperage
shown on the rating plate is the same as the power supply.
Operating this unit on an amperage other than specied on
its rating plate may result in personal injury to the user and
damage the unit.
Preventive maintenance
After use, allow the tip to cool and remove the cleaning pad .
Neutralize with SURFOX-N and rinse the cleaning pad and
wand tip with water and dry. Clean dust and dirt deposits
from the exterior of the unit. Keep all airow vent openings
free of any obstructions. Clean the power cord to prevent
deterioration and check for possible damage to cord and
plug.
Note: Damaged cords must be replaced immediately by
qualied personnel only. Refer to Spare Parts List for the
ordering number.
Transportation
Before transporting the machine, make sure the cleaning
solution reservoir and supply line are completely empty
and all connecting lines disconnected. The machine must
be carefully packed in a suitable container and properly
protected. WALTER will not be held responsible for any
damages resulting from leaked cleaning solution or rough
handling.
Storage
If the machine is to be stored for any length of time, the
cleaning solution reservoir and supply line must be emptied,
cleaning pad removed (neutralized, rinsed and left off) and
the tip neutralized, rinsed and dried. Store in a dry
safe place to avoid damage, especially to the electronic
components.
Waste disposal
Dispose of residual waste in compliance with Federal,
Provincial, State and local environmental regulations. Refer
to WALTER Material Safety Data Sheet of the SURFOX
electrolyte cleaning solutions.
Extension cord
When an extension cord is needed, use wire size 14 (AWG)
for up to 50 feet (15 meters) and size 12 (AWG) for 50 to
100 feet (15 to 30 meters).
Safety instructions
Equipment controls
3
Equipment controls
A) Control panel pictograms
Outlet for mini wand
or marking wand
Indicator for unit
power ON
Indicator for wand tip
power ON
Indicator for LOW
solution level
Manual pumping mode Automatic pumping mode
Marking wand selector Mini wand selector Cleaning or polishing
wand selector
Mode selector
Large insert selector

SURFOX 204 User’s Guide 5
3
Equipment controls
B) Front and back view of the machine
ON/OFF button
Accessory outlet
Ground connector
Hand wand hose
(electrical and solution
supply lines)
Control panel
Cleaning pad mounting unit
SURFOX electrolyte solutions
lling and reservoir
Wand holder
Compressed air
connector (for fume
elimination system)
Power cord

6
3
The ON button is used to give power to the tungsten tip.
When the pumping mode is set to manual, press the ON
button to activate the pump. Press and keep the button
pressed to get continuous ow of liquid.
However, if the pumping mode is set to automatic, press
the ON button once to activate the pump. To stop the
pump, press the OFF button. When nished working
with the machine (in either mode) make sure to press
the OFF button.
Once the ON button is pressed, there will be continuous
power at the tip until the OFF button is pressed.
The SURFOX 204 machine comes with the integrated fume
elimination system. This system provides for better work-
ing conditions. Although the fumes are non-toxic and non
hazardous, they can be uncomfortable when working in
conned areas.
To activate this feature simply connect a compressed air line
(150 PSI max., 80 PSI min.) to the tting at the back of the
machine. The fume elimination system is automatically ac-
tivated when the ON button is pressed on the Hand Wand.
The fume elimination system is turned OFF when the OFF
button on the Hand Wand is pressed. If the fume elimination
system is not wanted, simply disconnect the compressed
air line.
The working principle is quite simple and highly effective;
the air comes out through the small openings behind the
tungsten tip. This preset regulated air pressure condenses
the vapors out of the air.
The tungsten tip may be rotated from the standard horizon-
tal position to a vertical position or anywhere in between to
make your cleaning as comfortable as possible. To loosen
the right hand threaded fume elimination sleeve, turn tip to
desired position and retighten sleeve.
Important: Always retighten fume elimination sleeve to
ensure a good electrical connection and avoid damaging
the contact points.
Equipment controls
C) Wand control buttons
Tungsten tip
ON OFF
D) Fume elimination system (patented)
E) Tip repositioning (comfort for operator)
Compressed
air line tting
Small openings
Tungsten tip close up

SURFOX 204 User’s Guide 7
4
Control panel
Control panel
A) Main power switch
Turns the main power to the unit ON
and OFF.
B) Wand selector switch
Marking and etching wand selector.
Select this icon when using a marking/
etching wand which has been plugged into
the accessory outlet. Select AC for marking
and DC for etching. Preset at 6 amps.
Mini wand selector. Select this icon
when using the mini wand which has been
plugged into the accessory outlet. Select
AC for cleaning and DC for polishing. Preset
at 12 amps.
Hand wand selector. Select this icon
when using the hand wand attached to the
SURFOX unit. Select AC for cleaning and
DC for polishing.
Large insert selector. Select this icon
when using the large insert which has been
plugged into the accessory outlet. Preset at
15 amps.
The electrochemical cleaning AC mode
has 3 settings: Low (6 amps), Medium
(9 amps), High (12 amps)
C) Solution pump switch
Manual pumping mode. Choose the man-
ual pumping mode to control the amount of
solution pumping to the tip. Hold the hand
wand ON button down to pump solution to
the tip. Release the ON button to stop the
pumping cycle. Always use enough solution
to keep the cleaning pad wet. Too little solu-
tion will reduce the cleaning pad life.
Automatic pumping mode. To start the
automatic pumping mode, press the ON
button on the wand. Once it is activated,
it will automatically pump the liquid. The
quantity of liquid can be selected from less
to more. Pumping will continue in this mode
until the OFF button is pressed.
D) Indicator lights
Power ON indicator. Green light is on
when the unit is plugged in and the main
power switch is turned on.
Hand wand power ON indicator. The
yellow light goes ON when the hand wand
ON button is pressed and there is power
to the tip. Power to the tip is OFF when the
hand wand OFF button is pressed.
Low solution level indicator. When
solution level is low, the red indicator light
will go on.
E) Accessory outlet
Outlet for optional mini wand or
marking/etching wand. The marking/etch-
ing wand is used to permanently etch/mark
your company name, logo, part
number or other desired information onto
stainless steel surfaces. The mini wand
is used to access hard to reach areas for
cleaning and passivating, which are too
small for the hand wand.
AB
CD
E
F

8
5
A) What is included in the box
uSURFOX machine
u Hand wand and connecting hose
uGround clamp
uAccessory kit containing:
• 1 90° tungsten tip (already installed on the hand wand)
• 3 high conductivity standard cleaning pads
• 1 PTFE clamping ring
• 1 x 2.5 mm hexagonal key for changing tungsten
cleaning tips
B) Filling the reservoir
Fill the reservoir in the back of the machine with SURFOX
electrolyte solution. The reservoir holds 1.9 L of SURFOX
electrolyte solution.
C) Connecting air supply
Connect the air supply at the back of the machine. Note
that the maximum allowed pressure is 150 PSI max.,
80 PSI min. (1000 KPa). If the air supply is not plugged into
the machine, the machine will still work but there will not be
any fume elimination.
D) Plugging in the power cord
When an extension cord is needed, use wire size 14 (AWG)
for up to 50 feet (15 meters) and size 12 (AWG) for 50 to
100 feet (15 to 30 meters).
E) Plugging in the ground clamp
Plug the ground clamp at the front of the unit. Attach the
clamp to the work piece being cleaned. The cleaning and
passivating process will not work if the part is not properly
grounded.
Start-up procedure
Start-up procedure
Reservoir Air supply
connector
Ground
clamp

SURFOX 204 User’s Guide 9
6
C) Selecting the proper pumping mode
Manual pumping mode. Choose the manual pumping
mode to control the amount of solution pumping to the tip.
Hold the hand wand ON button down to pump solution to
the tip. Release the ON button to stop the pumping cycle.
Always use enough solution to keep the cleaning pad wet.
Automatic pumping mode. To start the automatic pump-
ing mode, press the ON button on the wand. Once it is
activated, it will automatically pump the liquid. The quantity
of liquid can be selected from less to more.
D) Cleaning and passivating
To clean and passivate, press the hand wand ON button.
Make sure the cleaning pad is saturated with SURFOX
electrolyte cleaning solution before starting to work. If the
cleaning pad is too dry, it will wear prematurely. Start work-
ing when solution drips from the cleaning pad.
Do not press hard, let the electrochemical process do the
work. Do not use the cleaning pad like an abrasive pad.
WARNING! When using the machine for the rst time, there
could be water in the system from factory testing. Adjust the
liquid pump setting to automatic at maximum speed and let
the liquid drip into a disposal cup for 2 minutes (amount of
time required to empty the hose from the tank to the wand).
Then, adjust the liquid pump setting back to desired pump-
ing speed.
E) Neutralizing
1. Remove any excess of SURFOX electrolyte cleaning
solution using a soft clean cloth.
2. Spray SURFOX-N on the surface.
3. Wipe dry with another soft clean cloth to avoid cross
contamination.
Refer to neutralization procedure in neutralization section for
instructions on how to properly neutralize.
A) Selecting the proper mode
B) Selecting the proper current type, AC or DC
AC for cleaning and passivating the weld.
DC for cleaning, passivating and polishing the weld. The
cleaning and passivating process takes longer in DC mode
than AC mode and requires more electrolyte cleaning solu-
tion to prevent premature wear of the cleaning pads and
tips as well as preventing white haloes on the parent mate-
rial.
WARNING! DC mode is used to polish the weld bead to
match the mirror nish of the material.
Note: When using DC setting, the SURFOX electrolyte solu-
tion will become slightly yellow or will darken.
Using the hand wand to electro chemically clean, polish and passivate
Using the hand wand to electrochemically clean, polish
and passivate
Manual
mode
Automatic
mode
Hand
wand
TIP! When using the polishing mode (DC), use plenty
of SURFOX electrolyte solution.

10
Mini
wand
7
Use the mini wand to get into tight places where the hand
wand cannot go. Plug the mini wand into the accessory
outlet on the front panel.
A) Selecting the proper mode
When this mode is selected, it automatically cuts the power
to the hand wand, stops the solution pump and the fume
elimination system (if connected) from operating. Only
power is provided to the mini wand/marking wand outlet.
Be sure work piece is grounded.
B) Selecting the proper current type, AC or DC
AC for cleaning and passivating the weld.
DC for cleaning, passivating and polishing the weld:
The cleaning and passivating process takes longer in the
DC mode than in the AC mode and requires more elec-
trolyte cleaning solution to prevent premature wear of the
cleaning pads and tips as well as preventing white haloes
on the parent material.
WARNING! DC mode is used to polish the weld bead to
match the mirror nish of the material.
Note: When using DC setting, the SURFOX electrolyte solu-
tion will become slightly yellow or will darken.
Using the mini wand (optional) to clean and passivate
Using the mini wand (optional) to clean and passivate
C) Manual pumping mode
The mini wand uses a manual pumping mode only. One
(1) press equals one (1) pump. To pump more liquid, press
repeatedly. See mini wand instructions for more information.
D) Cleaning and passivating
Screw in SURFOX electrolyte solution 100 ml tube onto the
mini wand. Make sure the cleaning pad is saturated with
solution before starting to work.
If the cleaning pad is too dry,
it will wear prematurely. Start
working when solution drips
from the cleaning pad.
Do not press hard, let the
electrochemical process do
the work. The cleaning pad is
a bridge between the machine
and the weld. Do not use the
cleaning pad like an abrasive
pad.
E) Neutralizing
1. Remove any excess of SURFOX electrolyte cleaning
solution using a soft clean cloth.
2. Spray SURFOX-N on the surface.
3. Wipe dry with another soft clean cloth to avoid cross
contamination.
Refer to neutralization procedure in neutralization section for
instructions on how to properly neutralize.
TIP! When using the polishing mode (DC), use plenty
of SURFOX electrolyte solution.

SURFOX 204 User’s Guide 11
7
Using the mini wand (optional) to clean and passivate
F) List of supplies and part numbers
SURFOX-T electrolyte
cleaning solution 100 ml
Part no: 54-A 001
6 per package
SURFOX-H electrolyte
cleaning solution 100 ml
Part no: 54-A 011
6 per package
The mini wand kit (part no.: 54-B 133) includes:
• 1 mini wand
• 2 carbon ber ow-through brushes
• 1 black power cord
• 1 x 2.5 mm hex key to change cleaning tips
Carbon fiber brush
Part no: 54-B 029
To be mounted on the mini-wand
54-B 133, use with SURFOX-H electrolyte
solution only in 100 ml cartridges
5 per package
Ideal for tight corners, narrow surfaces
and intricate areas

12
8
Use the marking/etching wand to permanently mark or etch
your company name, logo, part number or other desired
information onto the surface of stainless steel, using perma-
nent or disposable stencils. Plug the marking/etching wand
into the accessory outlet on the front panel.
Using the marking/etching wand (optional)
Using the marking/etching wand (optional)
Marking/etching
wand
B) Selecting the proper mode
Turn the selector knob to the marking/etching wand icon.
• 1 marking/etching wand with
graphite insert
• 35 mm X 10 mm
and connecting cable
• 20 marking pads
• 5 O-Rings
• 1 SURFOX-M, 100 ml
solution
• 1 SURFOX-E, 100 ml
solution
PRO kit (54-B 081) includes:
• 1 marking/etching wand with
graphite insert
• 35 mm X 10 mm
and connecting cable
• 20 marking pads
• 5 O-Rings
• 1 SURFOX-M, 100 ml solution
• SURFOX solution, 100 ml
• 1 Stencil printer and software
• 1 Stencil paper roll 100 mm (W) X 20 m (L)
Stainless steel Passivation Testing Device
(54-T 010)
To monitor the state of corro-
sion protection and to ensure
proper passivation of the
workpiece.
Corrosion resistance of
stainless steel is signicantly
reduced near welds as a result of the heating cycle. Visu-
ally, this can be seen as a darkened zone next to the weld.
When electro-chemical cleaning is performed on the weld,
corrosion risk is reduced but the treated zone still has to be
passivated for 24-48 hours before the corrosion protection
is fully restored.
Stainless steel Grade Identication Testing
Device (54-T 001)
Informs you on the type of stain-
less steel you are really working
with.
Because it is visually impossible
to differentiate 200, 300 and 400
grade stainless steel, the test-
ing device instantly identies the
grade of stainless steel.
C) SURFOX testing devices
TECHNICAL BULLETINS AVAILABLE ON OUR WEB SITE.
A) Marking kits
Standard kit (54-B 080) includes:

SURFOX 204 User’s Guide 13
9
Neutralizing
The SURFOX-N liquid is a specially formulated neutral-
izer for the SURFOX electrolyte solutions. It is a powerful
ready-to-use formula which leaves no residue, is non-toxic,
solvent free, water-based and biodegradable.
A) Directions for neutralizing SURFOX
electrolyte cleaning solutions
1. Remove any excess SURFOX electrolyte solution using a
soft clean cloth.
2. Spray SURFOX-N on the surface.
3. Wipe dry with another soft clean cloth.
For more information about this product, refer to product
MSDS.
WARNING! Be sure to wipe off all excess SURFOX electro-
lyte solution from the surface and neutralize otherwise the
inorganic salt from the phosphoric acid will adhere to the
surface and cause deposits.
B) SURFOX WELD cleaning and neutralization
procedure
Clean the weld using the SURFOX machine and SURFOX
electrolyte solutions. Work only 2 feet at a time.
Note: The cleaning pad should be kept moist – not
dripping.
1. After weld cleaning, use a clean cloth or paper towel
and wipe the affected area in a squeegee action from left
to right. Then discard the cloth or paper towel.
After cleaning the weld with the SURFOX weld cleaning
machine, the electrolyte solution must be neutralized.
1. Spray the affected area with SURFOX-N neutralizer.
Allow to sit for 15 seconds on the surface.
2. Use a clean cloth or paper towel and wipe the affected
area in a squeegee action from left to right. Then discard
the cloth or paper towel.
Note: Failure to neutralize or neutralize properly will result in
clouding, hazing and dulling of the surface.
Neutralizing
Salt deposits due to unproper
neutralization and rinsing.
SURFOX-N neutralizer Part No.
500 ml 54-A 023
20 L 54-A 027
208 L 54-A 028

14
10
Accessories
Accessories
A) Selection and mounting
of the cleaning pads and tips
Tungsten tips are made from high quality tungsten alloy
material. Other materials will not resist the harsh environ-
ment created by the electrochemical process.
WARNING! When the insert is too worn, it can
cause damage to the cleaning pads.
In this example of a worn insert, there are only two
contact points. All the current comes out of these
two points. Because of the lower available cross
section, the temperature will be higher at the two
points and the cleaning pads may become dam-
aged or wear out prematurely.
Note: Be sure to install the O-Ring located at the back of
the insert whenever they are changed.
O-Ring
TIP! Resurface the insert using a bench grinding wheel
or angle grinder.
Tungsten insert 90°
No: 48-R 133
Use with cleaning pad 54-B 026 or 54-B 040 and
clamp ring 54-B 002 or boot 54-B 005.
Tungsten insert 60°
No: 54-B 016
Use with cleaning pad 54-B 027 and clamp ring
54-B 002 or boot 54-B 006.
Narrow tungsten insert 90°
No: 54-B 017
Use with cleaning pad 54-B 028 or 54-B 041
and clamp ring 54-B 020 or boot 54-B 007.
Narrow tungsten insert 60°
No: 54-B 018
Use with cleaning pad 54-B 028 and clamp
ring 54-B 020 or boot 54-B 008.
Inserts
Large graphite insert
No: 54-B 009
Use with large cleaning pad 54-B 043
Ideal for large welded areas and for
surface renovation

SURFOX 204 User’s Guide 15
10
Accessories
Cleaning pads are made of a complex blend of highly
conductive synthetic polymer which is very resistant to wear
and which offers excellent thermal stability. For longer life,
remove the cleaning pad and neutralize with SURFOX-N at
the end of each working day.
Cleaning pads are available in three sizes:
Standard cleaning pad
No: 54-B 026
Use with insert 48-R 133
Inside corners cleaning pad
No: 54-B 027
Use with insert 54-B 016
Narrow cleaning pad
No: 54-B 028
Use with inserts 54-B 017
and 54-B 018
Large cleaning pad
No: 54-B 043
Use with large graphite insert
54-B 009
Features
• Flexible: Can be folded many ways
• Soft on surfaces
• Can be used both sides
• Long lasting
• Highly conductive (4x more conductive than previous
generation)
High conductivity cleaning pads

Note: When mounting classic pads, ensure the Ωsign
is facing up on step 2.
16
10
Accessories
D) Mounting a cleaning pad
1. Squeeze and insert clamp ring.
3. Firmly press in tungsten tip.
2. Insert cleaning pad.
4. Remove tip with installed pad and clamp ring.
B) PTFE clamp rings
PTFE clamp rings are designed to hold the cleaning pads
on the tungsten inserts.
They are available in two sizes:
C) SURFOX electrolyte solutions
Surfox electrolyte solutions are specially formulated phos-
phoric acid cleaning solutions designed to be used only in
Walter SURFOX electro cleaning systems.
Clamp ring for standard cleaning pads
No: 54-B 002
Use with standard inserts. 10 per package.
Narrow clamp ring for narrow pads
No: 54-B 020
Use with narrow inserts. 10 per package.
Cleans up to 3-5 feet per minute.
Cleans up to 3-5 feet per minute.
SURFOX-H
Electrolyte Cleaning Solution
SURFOX-T
Heavy-Duty Electrolyte Cleaning Solution
1.5 L/50.7 oz. No: 54-A 015
STD Pack: 1 STD Carton: 4
20 L/5.2 gal. No: 54-A 017
STD Pack: 1 STD Carton: 1
208 L/55 gal. No: 54-A 018
STD Pack: 1 STD Carton: 1
1.5 L/50.7 oz. No: 54-A 005
STD Pack: 1 STD Carton: 4
20 L/5.2 gal. No: 54-A 007
STD Pack: 1 STD Carton: 1
208 L/55 gal. No: 54-A 008
STD Pack: 1 STD Carton: 1

SURFOX 204 User’s Guide 17
A) Sparks on the tip/work piece
To avoid short circuits (arcing), the machine automatically
stops when the insert touches the work piece (metal to
metal contact). There is an inverter board that monitors the
voltage every millisecond. If the voltage sharply increases
creating a short, the system will automatically cut the power
to the tip to avoid any damage to the equipment.
To restart the machine, simply press the hand wand ON
button.
WARNING! To avoid drawing too much amperage and
automatically stopping the power to the tip, make sure that
you touch only one surface at a time. The machine is set
to work at a maximum of 15 amps. If the amperage goes
above 15 amps, the machine automatically shuts down. C) AC/DC current basics
Alternating Current (AC) ows one way, then the other
way, continually reversing direction. An AC voltage is con-
tinually changing between positive (+) and negative (-).
Direct Current (DC) always ows in the same direction, but
it may increase and decrease. A DC voltage is always posi-
tive, but may increase and decrease.
B) Internal temperature
To protect the internal components of the machine, there
are temperature sensors inside the machine. If the operating
temperature is too high, the machine will shut down and re-
start by itself when the temperature reaches an acceptable
level. There is an internal fan inside the machine to keep all
the components cool.
WARNING! The inside temperature can increase for many
reasons: high ambient temperature, lack of proper air circu-
lation around the machine, uctuations in voltage, electrical
set-up in the shop, etc.
Example: On a at surface, the amperage is around
12 amps. The contact surface area is relatively small.
Example: An internal angle, which if you touch 2 sides
simultaneously, the contact surface area is doubled, amper-
age goes above 15 amps and the machine stops.
Note: Automatic shut off if ground is not detected within
20 seconds.
Safety features 11
Safety features

18
11
Safety features
D) AC/DC settings on the SURFOX machine
Example of cleaning and passivation with SURFOX in AC
mode:
Example of cleaning and passivation with SURFOX in DC
mode:
E) Welds that cannot be cleaned
If the area around the weld is black (not blue) from contami-
nation, this is a problem of high heat generated during the
welding process. The contaminated areas do not conduct
electricity. If there is no conductivity in the material, the
SURFOX system cannot work.
If there are two welds on top of the other, the structure of
the material has been seriously altered. These areas may
not be cleaned.
The quality of the weld is critical. The better the weld, the
easier it will be to clean.
Oxide
layer to be
removed
Oxide
layer to be
removed Alteration of the
material due to
the DC setting
Cleaning and passivation is
perfect. Cleans every crack in
the material.
Cleaning and passivation is
perfect. Cleans every crack in
the material.
BEFORE
BEFORE
AFTER
AFTER
Microscopic view of the material
Microscopic view of the material