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

SURFOX 305 User’s Guide 9
6
Using the hand wand to electro chemically clean, polish and passivate
Usingthehandwandtoelectrochemicallyclean,polish
and passivate stainless steel or cleaning aluminum
A) Selecting the proper mode D) Selecting the proper pumping mode
INOX / STAINLESS AC
Cleaning
Marking
DC
Polishing
Etching
Manual
pumping mode Automatic
pumping mode
Large wand selector. Select this icon when
usingthehandwandattachedtotheSURFOX
unit.
B) Selecting the proper current type,
AC or DC on stainless steel
SelectACforcleaningandDCforpolishing.Level1has
the lowest amperage setting. Level 3 has the highest
amperage setting.
C) Selecting the proper current type,
AC or DC on aluminum
Onaluminum,selectACforcleaning.DCmodewillnot
polish aluminum.
TIP. When using the polishing mode (DC), use
plenty of SURFOX electrolyte solution.
Note:WhenusingDCsetting,theSURFOXelectrolytesolutionwill
become slightly yellow or willdarken.
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
accessory wet.
Automatic pumping mode. To start the automatic
pumpingmode,press the ON buttononthewand. Once
it is activated, it will automatically pump the liquid. The
quantity of liquid can beselected from less to more.
E) Cleaning and passivating
Tocleanandpassivate,pressthehandwandONbutton.
Make sure the cleaning pad is saturated with SURFOX
electrolytecleaningsolutionbeforestartingtowork.Ifthe
cleaning accessoryistoo dry,itwillwearprematurely.
Start working when solution drips from the cleaning pad.
Donotpresshard,lettheelectrochemicalprocessdothe
work.Donotusethecleaningaccessorylikeanabrasive
pad or a brush.
F) Neutralizing
1. Remove any excess of SURFOX electrolyte cleaning
solution using a soft clean cloth orby rinsing with water.
2. Spray SURFOX-N or FT-100 on the surface.
3. Wipe dry with another soft clean cloth to avoid cross
contamination or by rinsing with water.
Refertoneutralizationprocedureinneutralizationsection
for instructions on how to properlyneutralize.
WARNING! When using the machine for the first 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 pumping speed.
WARNING! DC mode is used to polish the weld
bead to match the mirror finish of the material.
ALU

10
7
Using the mini wand (optional) to clean and passivate
Using the mini wand (optional) to clean and passivate
stainless steel or cleaning aluminum
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
D) Manual pumping mode
Theminiwandusesamanualpumpingmodeonly.One(1)
press equals one (1) pump. To pump more liquid, press
repeatedly.Seeminiwandinstructionsformoreinformation.
INOX / STAINLESS AC
Cleaning
Marking
DC
Polishing
Etching
E) Cleaning and passivating
ScrewinSURFOXelectrolytesolution100mltubeontothe
miniwand.Makesurethecleaningpadorbrushissaturated
with solution before startingto
work.Iftheaccessory is too
dry,itwillwearprematurely.
Startworkingwhensolution
dripsfromthecleaningpad.
Do not press hard, let the
electrochemical process do
thework.Theaccessoryisa
bridgebetweenthemachine
When this mode is selected, it automatically cuts
the power to the hand wand, stops the solution
pumpandthefumeeliminationsystem(ifconnected)
fromoperating.Onlypowerisprovidedtothemini
wand/markingwandoutlet.Besureworkpieceis
grounded.
B) Selecting the proper current type,
AC or DC on stainless steel
SelectACforCleaningandDCforPolishing.Level1has
the lowest amperage setting. Level 3 has the highest
amperage setting.
C) Selecting the proper current type,
AC or DC on aluminum
Onaluminum,selectACforcleaning.DCmodewillnot
polish aluminum.
and the weld. Do not use the
accessorylikeanabrasivepad.
F) Neutralizing
1. Remove any excess of SURFOX electrolyte cleaning
solution using a soft clean cloth orby rinsing with water.
2. Spray SURFOX-N or FT-100 on the surface.
3. Wipe dry with another soft clean cloth to avoid cross
contamination or by rinsing with water.
Refertoneutralizationprocedureinneutralizationsection
for instructions on how to properlyneutralize.
TIP. When using the polishing mode (DC), use
plenty of SURFOX electrolyte solution.
Note:WhenusingDCsetting,theSURFOXelectrolytesolutionwill
become slightly yellow or willdarken.
WARNING! DC mode is used to polish the weld
bead to match the mirror finish of the material.
ALU

SURFOX 305 User’s Guide 11
7
Using the mini wand (optional) to clean and passivate
G) List of supplies and part numbers
The mini wand kit
(part no.: 54-B 133)
SURFOX-T electrolyte
cleaning solution 100 ml
Part no: 54-A 001
6 per package
SURFOX-G electrolyte
cleaning solution 100 ml
Part no: 54-A 061
6 per package
Threaded
brush adaptor
Part no: 54-B 150
1 per package
Threaded carbon
fiberbrush
Part no: 54-B157
To be mounted on
the mini-wand
5 per package
Ideal for tight corners,
narrow surfaces and
intricate areas

12
8
Using the marking/etching wand (optional)
Using the marking/etching wand (optional)
A) Marking kits
Standard kit (54-B 080) includes:
• 1 marking/etching wandwith
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/etchingwand
with graphite insert
• 35 mm X 10 mm
and connecting cable
• 20 marking pads
• 5 O-Rings
• 1 SURFOX-M, 100 mlsolution
• SURFOX solution, 100 ml
• 1 Stencil printer and software
• 1Stencilpaperroll100mm(W)
X 20 m (L)
B) Selecting the proper mode
Turn the selector knob to the marking/etching wand icon.
Usethemarking/etchingwandtopermanentlymarkoretch
your company name, logo, part number or other desired
informationontothesurfaceusingpermanentordisposable
stencils.Plugthemarking/etchingwandintotheaccessory
outlet on the frontpanel.
Onstainlesssteel,useACandSURFOX-Mtodoamarking;
useDCandSURFOX-Etomakeanetching.Onaluminum,
useACandSURFOX-MALUtomakeablackmarkingand
DCandSURFOX-Etomakeanetching.Ontitanium,use
AC and SURFOX-M to do a blue marking.
INOX / STAINLESS AC
Cleaning
Marking
DC
Polishing
Etching
C) SURFOX testing devices
SURFOX Smart Passivation Tester
(54-T 011)
Tomonitorthestateofcorrosion
protectionandtoensureproper
passivation of theworkpiece.
Corrosion resistance of stainless
steel is significantly reduced near
welds as a result of the heating
cycle. Visually, this can be seen
as a darkened zone next to the
weld.Whenelectro-chemicalcleaningis
performedontheweld,corrosionriskis
reducedbutthetreatedzonestillhasto
be passivated for 24-48 hours before
thecorrosionprotectionisfullyrestored.
Stainless steel Grade
Identification Testing Device
(54-T 001)
Informs you on the type of
stainless steel you are really
working with.
Because it is visually impossible
to differentiate 200, 300 and 400
grade stainless steel, the testing
device instantly identifies the grade
of stainless steel.
TECHNICAL BULLETINS AVAILABLE ON OUR WEB SITE.
ALU

SURFOX 305 User’s Guide 13
9
Neutralizing
Neutralizing
TheSURFOX-Nliquidisaspeciallyformulatedneutralizer
for the SURFOX electrolyte solutions. It is a powerful
ready-to-useformulawhichleavesnoresidue,isnon-toxic,
solvent free, water-based andbiodegradable.
A) Directions for neutralizing SURFOX
electrolyte cleaning solutions
1. Remove any excess SURFOX electrolyte solution using
a soft cloth or rinsing withwater.
2. Spray SURFOX-N on thesurface.
3. Wipe dry with another soft clean water.
Formoreinformationaboutthisproduct,refertoproductSDS.
SURFOX-N neutralizer Part No.
500 ml 54-A 023
5 L 54-A 026
20 L 54-A 027
208 L 54-A 028
B) SURFOXWELDcleaning andneutralization
procedure
CleantheweldusingtheSURFOXmachineandSURFOX
electrolyte solutions. Work only 2 feet at a time.
Note: The cleaning accessory should be kept moist –not dripping.
1. Afterweldcleaning,useacleanclothorpapertoweland
wipetheaffectedareainasqueegeeactionfromleftto
right. Then discard the cloth or paper towel. You could
also rinse the surface withwater.
AftercleaningtheweldwiththeSURFOXweldcleaning
machine,theelectrolytesolutionmustbeneutralized.
1. Spray the affected area with SURFOX-N neutralizer.
Allow to sit for 15 seconds on the surface.
2. Useacleanclothorpapertowel andwipetheaffected
areainasqueegeeactionfromlefttoright.Thendiscard
the cloth or paper towel. You could also rinse the
surface with water.
Note:Failuretoneutralizeorneutralizeproperlywillresultinclouding,
hazing and dulling of the surface on top of slowing the passivation
process.
Permanent salt deposits due
to unproper neutralization
and rinsing.
WARNING!Be suretowipe off all excessSURFOX
electrolyte solution from the surface and neutralize
otherwise the inorganic salt from the phosphoric
acid will adhere to the surface and cause deposits.

14
10
Accessories
Accessories
A) Selection and mounting of the cleaning
pads and tips
Tungstentipsaremadefromhighqualitytungstenalloy
material.Othermaterialswillnotresisttheharshenviron-
ment created by the electrochemical process.
Threaded carbon fiber brushes
Part no: 54-B 155
Triangular shape
Part no:54-B 156
Round shape
5 per package
Idealfortightcorners,
narrow surfaces and
intricate areas
TIP. Resurface the insert using a bench grinding
wheel or angle grinder.
Note: Besureto install the O-Ring located at the back of the insert
whenever they are changed.
O-Ring Worn edges on insert.
Inserts
Tungsten insert 90°
No: 54-B 143
Use with cleaning pad 54-B 026
or 54-B 040 and clamp ring 54-B 002
or boot 54-B 005.
Large graphite insert
No: 54-B 009
Use with large cleaning pad 54-B 043
Idealforlargeweldedareas
andforsurfacerenovation.
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.
WARNING! When the insert is too worn, it can
cause damage to the cleaning pads.

SURFOX 305 User’s Guide 15
10
Accessories
Accessories
B) High conductivity cleaning pads
Cleaningpadsaremadeofacomplexblendofhighly
conductivesyntheticpolymerwhichisveryresistantto
wear and which offers excellent thermal stability. For
longerlife,removethecleaningpadandneutralizewith
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 54-B 143
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
Usewithlargegraphiteinsert
54-B 009
Features
• Flexible: Can be folded manyways
• Soft on surfaces
• Can be used bothsides
• Long lasting
• Highlyconductive(4xmoreconductivethan
previous generation)

16
10
Accessories
Accessories
C) PTFE clamp rings
PTFEclampringsaredesignedtoholdthecleaningpads
on the tungsten inserts.
They are available in two sizes:
Narrow clamp ring for
narrow pads No: 54-B 020
Use with narrow inserts.
10 per package.
Clamp ring for standard
cleaning pads No: 54-B 002
Use with standard inserts.
10 per package.
D) SURFOX electrolyte solutions
Surfox electrolyte solutions are specially formulated
phos-phoricacidcleaningsolutionsdesignedtobeused
onlyinWALTERSURFOXelectrocleaningsystems.
SURFOX-G
pH NEUTRAL Electrolyte
Cleaning Solution
Cleans up to 3-5 feet per minute.
1.5 L / 50.7 oz. 54-A 065
STD Pack: 1 STD Carton: 4
5 L / 1.3 gal. 54-A 066
STD Pack: 1 STD Carton: 1
20 L/5.2 gal. 54-A 067
STD Pack: 1 STD Carton: 1
208 L / 55 gal. 54-A 068
STD Pack: 1 STD Carton: 1
SURFOX-T
Heavy-Duty Electrolyte
Cleaning Solution
Cleans up to 3-5 feet per minute.
1.5 L / 50.7 oz. 54-A 005
STD Pack: 1 STD Carton: 4
5 L / 1.3 gal. 54-A 006
STD Pack: 1 STD Carton: 1
20 L/5.2 gal. 54-A 007
STD Pack: 1 STD Carton: 1
208 L / 55 gal. 54-A 008
STD Pack: 1 STD Carton: 1
E) Mounting a cleaning pad
1. Squeeze and insert clamp ring.
2. Insert cleaning pad.
3. Firmly press in tungsten tip.
4. Remove tip with installed pad and clampring.

SURFOX 305 User’s Guide 17
11
Safety features
Safety features
A) Sparks on the tip/work piece
Toavoidshortcircuits(arcing),themachineautomatically
stopswhenametaltometalcontacthappens.Thereisan
inverterboardthatmonitorsthevoltageeverymillisecond.
Ifthevoltagesharplyincreasescreatingashort,thesystem
will automatically cut the power to the tip to avoid any
damage to theequipment.
Torestartthemachine,simplypressthehandwand
ON button.
Example: Onaflat surface,theamperageisaround
12amps.Thecontactsurfaceareaisrelativelysmall.
Example: Aninternal angle, which if you touch 2 sides
simultaneously, the contact surface area is doubled,
amperage goes above 15 amps and the machinestops.
Note: Automatic shut off if groundis not detectedwithin20seconds.
B) Internal temperature
To protect the internal components of the machine, there
aretemperaturesensorsinsidethemachine.Iftheoperating
temperature is too high, the machine will shut down, the
correspondingLEDonthefrontpanelwithlightandtheunit
will restart by itself when the temperature reaches an
acceptablelevel.ThecorrespondingLEDwillthenturnoff.
lighton.Thereisaninternalfaninsidethemachinetokeep
all the components cool.
C) AC/DC current basics
Alternating Current (AC) flows one way, then the other
way, continually reversing direction. An AC voltage is
con-tinually changing between positive (+) and negative (-).
DirectCurrent(DC)alwaysflowsinthe samedirection,
butitmayincreaseanddecrease.ADCvoltageisalways
posi-tive, but may increase anddecrease.
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.
WARNING! The inside temperature can increase
for many reasons: high ambienttemperature, lack of
proper air circu-lation around the machine, fluctuations
in voltage, electrical set-up in the shop,etc.

18
11
Safety features
Safety features
D) AC/DC settings on the SURFOX machine
Example of cleaning and passivation with SURFOX in
AC mode:
Microscopic view of the material.
BEFORE AFTER
E) Welds that cannot be cleaned
Iftheareaaroundtheweldisblack(notblue)fromcontami-
nation,thisisaproblemofhighheatgeneratedduringthe
weldingprocess. Thecontaminated areasdonotconduct
electricity. If there is no conductivity in the material, the
SURFOX system cannot work.
If there are two welds on topof the other, thestructure of
thematerialhasbeenseriouslyaltered.Theseareasmay
not be cleaned.
Thequalityoftheweldiscritical.Thebettertheweld,the
easier it will be toclean.
Example of cleaning and passivation with SURFOX in
DC mode:
Microscopic view of the material.
BEFORE AFTER
Oxide
layer to be
removed
Cleaning and
passivation is perfect.
Cleans every crack in
thematerial.
Alteration of
thematerial
due to the
DC setting.
Oxide
layertobe
removed
Cleaning and
passivationisperfect.
Cleanseverycrackin
the material.