Walter SURFOX 305 User manual

SURFOX 305
User’s Guide

SURFOX 305 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 ofthe machine 5
C) Wand control buttons 6
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
pads and tips
E) Plugging in the power cord 8
6 Using the hand wand to electrochemically
clean, polish and passivate 9
A) Selecting theproper mode 9
C) AC/DC current basics 17
D) AC/DC settings on theSURFOX machine 18
E) Welds that cannot be cleaned 18
12 Technical data 19
B)Selectingthepropercurrenttype,
AC or DC on stainlesssteel 9 13 Warranty and service 19
A) Warranty policy 19
B) Repair and service 19
10
10
11
C) Selecting the proper current type,
9
AC or DC on stainless steel
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
10
10
10
A) Selecting the proper mode
B) Selectingthepropercurrenttype,
AC or DC on stainlesssteel
C) Selecting the proper current type,
AC or DC on stainless steel
D) Selecting the proper pumping mode
E) Cleaningandpassivating
F) Neutralizing
G) List of supplies and part numbers
10
D) Fume elimination system
6 electrolyte cleaning solutions 13
E) Fastening inserts on the large wand
6 B) SURFOX WELD cleaning and neutralization
4
Control panel
procedure
13
A) Main power switch
7 10 Accessories 14
B) Application Selector
7 A) Selection and mounting of thecleaning
C) Power selector
7 B) High conductivity cleaning pads 15
D) Electrolyte flow
7 C) PTFE clamp rings 16
5
Start-up procedure
8 D) SURFOX electrolyte solutions 16
A) Attaching the wand to the quick-connect
8E) Mounting a cleaning pad 16
adaptor on the machine
B) Filling the tank and purging the line
8
11
Safety features
17
C) Connecting the air supply 8
A) Sparks on the tip/work piece
17
D) Plugging in the ground clamp 8
B) Internal temperature
17
15
7

2
1
Introduction
Introduction
Congratulationsonpurchasingthefinestelectrochemical weld
cleaningandpassivationequipmentavailabletoday.
WALTER’sSURFOXTMweldcleaningequipmentquickly,
easilyandcosteffectivelyremovestheheattintfromheat
affected zones on stainless steel and aluminum while
completely passivating the stainless steel surface.
SURFOX machines are equipped with self-regulating
inverterboards,automaticallymonitoringandadjusting
thecurrentsoastoensure maximumcleaningeffective-
ness without loss of productivity.
Beforestarting,pleasereadtheSURFOXowner’s manual
completely as we take you step-by-step throughthe
start-up, operating and maintenance procedures of your
newSURFOXequipment.YournewSURFOXmachinehas
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 invest-
ment. With proper care and maintenance your SURFOX
equipment will provide years of dependable service.
Tolearn moreabout theotherWALTERproducts,
visit our website: walter.com
Operation
The SURFOX machine works by an electrochemical
process to clean and passivate welds on stainless steel.
SURFOXelectrolytesolutionsarephosphoricacidbased,
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 thesurface
of the parts to be cleaned.
Your SURFOX machine can clean:
• TIG welds
• Plasma welds
• Laser welds
• Spot welds
• MIG welds (with Pulse technology)
Basics of passivation:
• Thecleaning of the welds is not only foraesthetic
purposes but most importantly for passivation.
• Passivationisthetreatmentofstainlesssteelsurfaces
to remove contaminants and promote the formation of
athick and durableprotective chromium oxidelayer.
• Thispassivelayerwillinsurethecorrosionresistance
of stainless steel.
• Ifpassivationisnotdoneproperly,stainlesssteeland
heat affected zones may start torust.

SURFOX 305 User’s Guide 3
2
Safety Instructions
Safety Instructions
WALTERweldcleaningmachinesareproducedinaccordance
with applicable standards governing the manufacture,
performance and safety of industrial products.
Before using this machine, read all Safety and Operating
Instructions carefully and save this owner’s manual for
future reference.
1. Readthisowner’s manualtofamiliarizeyourselfwith
thisunit’soperation,itsparticularfeatures,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
keepallairopeningsclear of anyobstruction.Free
airflow through the vent openings is required to
prevent the unit from overheating.
4. Keepworkareacleanandwelllit.Aclutteredenvironment
invites accidents. Remove any material that may be
ignited by sparks. Do not use this tool when flammable
liquidsorgasesarepresent. Keephandlesclean,dry
andfreefromcleaningsolution,oilandgrease.Donot
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 unqualified persons
handle this machine.
6. Whenworking,alwayswearappropriateclothingand
safety gear, such as suitable and safety approved
chemicalresistantgloves,overalls,safetyshoes,etc.
7. Always wear approved safetygoggles.
8. During the cleaning process, the wand tip and work
piececanreachveryhigh temperatures,allowtocool
before coming in contact with exposedskin.
9. Avoidinhalationoffumes,useonlyinwellventilated
areas. Use a respirator, ifnecessary.
10. All electric shocks can be potentially dangerous.
11. Should you encounter an electrical problem, do not
use the unit until qualified personnel have inspected the
equipment.
12. Neveroperatetheunitwithitsprotectivecoverremoved.
13. Stayalertatalltimeswhenhandlingthisunit.Watch
what you are doing. Use common sense. Do not
operate the tool when you are tired. Never leave it
running unattended.
14. Makesurethe switchisinitsOFFpositionbefore
plugging in or when moving the unit to avoid
unintentional starting.
15. Hold the wand firmly. Do not overreach, maintain
good footing and balance at all times.
16. Beforeuse,allpartsshouldbecarefullyexaminedto
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
ServiceCenteroraWALTERAuthorizedServiceCenter.
18. DonotusetheunitiftheswitchdoesnotturnONandOFF.
19. Use only the accessories recommended for this
system.Alwayscheckaccessoriesbeforestartingto
work and do not use if damaged.
20. CAUTION: WALTER SURFOX electrolyte weld
cleaning solutions contain phosphoric acid and may
causeburnswhennothandledproperly.Avoidskincontact.
First aid Wash affected area with water.
Eye contact Flush with water for 15 minutes lifting
eyelidsoccasionally.Contactphysicianifnecessary.
Ingestion DO NOT induce vomiting. Rinse mouth,
drink plenty of water and get medical attention.
RefertoWALTER product SDS for completesafety
data information.
21. UseonlyWALTERSURFOXelectrolyteweldcleaning
solutions with this unit and NEVER mix it with any
other products.
22. Store solution in its original container and in a safe
place,outofthereachofchildrenandotherunqualified
persons.Keepcontainercontentsclean.Donotreuse
SURFOX electrolyte cleaningsolutions.
23. Do not touch the wand tip or work piece while
working orimmediatelyafter use,theymaybe
extremelyhotand could causeseriousburns.
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
sharpedges.Inspectthecordperiodically,ifdamaged,
have it replaced by a WALTER Factory Service
Centeror a WALTER Authorized Service Center.
25. Whennotinuse,switchOFFandunplugtheelectrical
cordandairhose(ifconnected).Itmustalsoremain
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 unqualifiedpersons.
WARNING! When using these machines, basic
safety precautions should always be observed to
reducetheriskoffire, electricalshocksand personal
injuries.

4
2
3
Safetyinstructions Equipment controls
Equipment controls
Voltage/Amperage
Beforeconnectingthisunit,checkthatthevoltageandamper-
ageshownontheratingplateisthesameasthepowersupply.
Operatingthisunitotherthanspecified onitsratingplatemay
result in personal injury to the user and damage the unit.
A) Control panel pictograms
Preventive maintenance
Afteruse,allowthecleaningaccessorytocool.Removethe
cleaning padandtungstenorthebrushandtheadaptor.
Neutralize with SURFOX-N and rinse with water and dry.
Clean dust and dirt deposits on the outside of the unit.
Keepairventscleanandfreeofanyobstructions.Cleanthe
powercordtopreventdeteriorationandcheckforpossible
damage to cord andplug.
Note:Damagedcordsmustbereplacedimmediatelyby
qualified personnel only. Refer to Spare Parts List for the
ordering number.
Transportation
Beforetransportingthemachine,makesurethecleaning
solutionreservoirandsupplylinearecompletelyemptyand
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
damagesresultingfromleakedcleaningsolutionorrough
handling.
Storage
If the machine is to be stored for any length of time, the
cleaningsolutionreservoirandsupplylinemustbeemptied,
cleaning accessories removed, neutralized, rinsed and
dried.Storeinadrysafeplacetoavoiddamage,especially
to the electronic components.
Waste disposal
Outlet for mini wand
or marking wand
Indicator for
internal temperature
Manual
pumping mode
INOX / STAINLESS
Indicator for
power output
(Marking/Mini/Large)
Indicator for LOW
solution level
Automatic
pumping mode
AC DC
Dispose of residual waste in compliance with Federal,
Provincial, State and local environmental regulations. Refer
toWALTERSafetyDataSheetoftheSURFOXelectrolyte
cleaning solutions.
Cleaning
Marking
Polishing
Etching
Extension cord
Whenanextensioncordisneeded,usewiresize14(AWG)
for up to 50 feet (15 meters) and size 12 (AWG) for 50 to
100 feet (15 to 30meters). ApplicationSelector Power Selector
ALU

SURFOX 305 User’s Guide 5
3
Equipment controls
B) Front and back view of the machine
ON/OFF button Control panel
Large wand hose
quick connect
(electrical, air and
solution supply lines)
Connect the hose to
the adaptor by rotating
the quick-connect part
of the hose clockwise
and making sure the
white dot ends in
the locked position
A ccessory Outlet
(Marking and
Mini-Wand port)
Ground Connector
SURFOX electrolyte
solutions
filling and tank
Cleaning pad
mounting unit
Wand holder
Compressed air
connector
Power cord

6
3
Equipment controls
C) Wand control buttons
The ON button is used to give power to the cleaning
accessory. When the pumping mode is set to manual,
presstheONbuttontoactivatethepump.Pressandkeep
thebuttonpressedtogetcontinuousflowofliquid,
However,ifthepumpingmodeissettoautomatic,press
the ON button once to activate the pump. To stop the
pump, press the OFF button. When finished working with the
machine(ineithermode)makesuretopresstheOFF
button.
OncetheONbuttonispressed,therewillbecontinuous
power at the tip until the OFF button is pressed.
D) Fume elimination system (patented)
The SURFOX 205 machine comes with the integrated
fume elimination system. This system provides for better
workingconditions.Althoughthefumesarenon-toxicand
nonhazardous,theycanbeuncomfortablewhenworking
in confined areas.
Toactivatethisfeaturesimplyconnectacompressedair
line(150PSImax.,80PSImin.)tothefittingatthebackof
themachine.Thefumeeliminationsystemisautomatically
activated when the ON button is pressed on the Hand
Wand.ThefumeeliminationsystemisturnedOFFwhen
theOFFbuttonontheHandWandispressed.If thefume
elimination system is not wanted, simply disconnect the
compressed air line.
Theworkingprincipleisquitesimpleandhighlyeffective;
theaircomesoutthroughthe smallopeningsbehindthe
tungstentip.Thispresetregulatedairpressurecondenses
the vapors out of theair.
E) Fastening inserts on the large wand
This unit comes with a quick-release adaptor on for the
cleaningaccessories.Thebrushholderortungsteninsert
mayberotatedcounterclockwisetoreleaseit.Similarly,
youcanfastenthecleaningaccessoriesbyrotating them
clockwise.Youcanalsoaddthe2xsetscrewstofixthe
tungsten or the brush holderpermanently.
Compressed
on-line fitting
Small
openings
ON
OFF
Small

SURFOX 305 User’s Guide 7
4
Control panel
Control panel
A) Main power switch
Turns the main power to the unit ON and OFF.
.
B) Application Selector
INOX / STAINLESS
C) Power selector
AC
Cleaning
Marking
DC
Polishing
Etching
ALU
On Stainless Steel, Select AC for Cleaning and
DC for Polishing. Level 1 has the lowest amperage
setting. Level 3 has the highest amperage setting.
Level 1 is for TIG welds, Level 2 is for MIG welds,
Level 3 should be used with a lot of electrolyte
solution with the air system only.
For marking or etching, select AC for marking and
DC for etching. Level 1 has the lowest amperage
setting. Level 3 has the highest amperage setting.
On Aluminum, select AC for cleaning. DC mode
will not polish aluminum. For black marking, select
AC. Level 1 has the lowest amperage setting. Level
3 has the highest amperage setting. For white
etching, select DC.
On Titanium for marking, select AC for blue
marking. Level 1 has the lowest amperage setting.
Level 3 has the highest amperage setting.

8
5
Start-up procedure
Start-up procedure
A) Attaching the wand to the quick-connect
adaptor on the machine
Whenanextension cord is needed, usewiresize
14(AWG)forupto50feet(15meters)andsize12(AWG)
for 50 to 100 feet (15 to 30 meters).
Connectthehoseto thequick-connectadapteron the
machine by turning the part on the hose clock-wise and
makingsurethatthewhitedotendsinthelockedposition.
B) Filling the tank and purging the line
FillthereservoirinthebackofthemachinewithSURFOX
electrolyte solution. The tank holds 1.9 L of SURFOX
electrolyte solution. Then purge the unit of the testing
solution.Select the highest levelofautomatic flow and
makesuretoletliquidflowfor 2 minutes.Themachinewill
stopafter30secondswhennocurrentisflowingthrough.
This mean you will have to press the ON button on the
large wand 4 times to complete the purge.
C) Connecting the air supply
Connecttheairsupplyatthebackofthemachine.Note
thatthemaximumallowedpressureis150PSImax.,
80PSImin.(1000KPa).Iftheairsupplyisnotpluggedinto
themachine,themachinewillstillworkbuttherewillnotbe
any fume elimination.
D) Plugging in the ground clamp
Plug the ground clamp at the front of the unit.Attachthe
clamptotheworkpiecebeingcleaned.Thecleaningand
passivatingprocesswillnotworkifthepartisnotproperly
grounded.
E) Plugging in the power cord
Whenanextensioncordisneeded,usewiresize14(AWG)
for up to 50 feet (15 meters) and size 12 (AWG) for 50 to
100 feet (15 to 30meters).
Tank
Ground
clamp
Air supply