Walter Surfox 203 User Manual
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Walter Surfox 203 User Manual

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User's Guide
60-C 783EFS

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Summary of Contents for Walter Surfox 203

  • Page 1 User's Guide 60-C 783EFS...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS Page I - Introduction................3 II - Safety instructions .
  • Page 3 TABLE OF CONTENTS Page VIII - Using the Marking Wand (optional) ............17,18 A) Selecting the proper mode.

  • Page 4: I - Introduction

    With proper care and maintenance your SURFOX equipment will provide years of dependable service. To learn more about the other Walter products, visit our websites: In Canada: www.jwalter.ca www.jwalter.ca...

  • Page 5: Safety Instructions

    Refer to WALTER MSDS #S-01E for complete safety data information. 21. Use only WALTER Surfox-T weld cleaning solution with this unit and NEVER mix it with any other products. WALTER Surfox-T weld cleaning solution with this unit and NEVER mix it with any other products.
  • Page 6 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 WALTER will not be held responsible for any damages resulting from leaked cleaning solution or WALTER rough handling.

  • Page 7: Equipment Controls

    III - EQUIPMENT CONTROLS III - EQUIPMENT CONTROLS III - 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...

  • Page 8: B) Front And Back View Of The Machine

    III - EQUIPMENT CONTROLS ON/OFF button Control panel Accessory outlet Ground connector Hand Wand hose (electrical and solution supply lines) Wand holder Cleaning pad mounting unit Surfox-T filling and reservoir Compressed air connector (for fume elimination system) Power cord...

  • Page 9: C) Wand Control Buttons

    Once the ON button is pressed, there will be continuous power at the tip until the OFF button is pressed. D) FUME ELIMINATION SYSTEM (PATENTED) The Surfox 203 machine comes with the integrated fume elimination system. This system provides for better working conditions. Although the fumes are non-toxic and non hazardous, they can be uncomfortable when working conditions.

  • Page 10: Control Panel

    IV - CONTROL PANEL IV - CONTROL PANEL A) MAIN POWER SWITCH Turns the main power to the unit ON and OFF. B) WAND SELECTOR SWITCH Marking Wand selector. Select this setting when using a Marking Wand which has been plugged into the accessory outlet.

  • Page 11: D) Solution Pump Switch

    IV - CONTROL PANEL D) SOLUTION PUMP SWITCH 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.

  • Page 12: Start-Up Procedure

    V- V- V START-UP PROCEDURE V - START-UP PROCEDURE A) WHAT IS INCLUDED IN THE BOX 1- Surfox ma 1- Surfox ma 1- Surf chine 2- Hand Wand and connecting hose 3- Ground clamp 4- Accessory kit containing: - 3 cleaning pads - 1 PTFE clamping ring - 1 cleaning boot - 1 x 2.5mm hexagonal key for changing Tungsten cleaning tips...

  • Page 13: D) Connecting The Air Supply

    V- V- V START-UP PROCEDURE START-UP PROCEDURE START-UP PROC D) 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. (1000KPa). If the air supply is not plugged into the machine, the machine will still work but there will not be any fume elimination.

  • Page 14: Using The Hand Wand To Clean And Passivate

    VI - USING THE HAND WAND TO CLEAN AND PASSIVATE VI - USING THE HAND WAND TO CLEAN AND PASSIVATE VI - USING THE HAND WAND TO CLEAN AND PASSIVATE A) SELECTING THE PROPER MODE Hand Wand Wand B) SELECTING THE PROPER VOLTAGE TYPE, AC or DC AC for cleaning and passivating the weld.

  • Page 15: D) Selecting The Proper Pumping Mode

    VI - USING THE HAND WAND TO CLEAN AND PASSIVATE D) SELECTING THE PROPER PUMPING MODE Automatic mode Manual 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.

  • Page 16: Using The Mini Wand (Optional) To Clean And Passivate

    VII- VII- VII USING THE MINI WAND (OPTIONAL) TO C USING THE MINI WAND (OPTIONAL) TO C USING THE MINI WAN D (OPTIONAL) TO CLEAN AND PASSIVATE D (OPTIONAL) TO C LEAN AND PASSIVATE VII - USING THE MINI WAND (OPTIONAL) TO CLEAN AND PASSIVATE Use the Mini Wand to get into tight places where the Hand Wand cannot go.

  • Page 17: C) Manual Pumping Mode

    VI USING THE MINI WAND (OPTIONAL) TO C USING THE MINI WAND (OPTIONAL) TO C USING THE MINI WAN D (OPTIONAL) TO CLEAN AND PASSIVATE D (OPTIONAL) TO C LEAN AND PASSIVATE C) MANUAL PUMPING MODE C) MANUAL PUMPING MODE The Mini Wand uses a manual pumping mode only.

  • Page 18: Using The Marking Wand (Optional)

    VIII- VIII- VIII USING THE MARKING WAND (OPTIONAL) USING THE MARKING WAND (OPTIONAL) USING THE MARKING WAN VIII - USING THE MARKING WAND (OPTIONAL) VIII - USING THE MARKING WAND (OPTIONAL) Use the Marking Wand to permanently etch your company name, logo, part number or other desired information onto Use the Marking Wand to permanently etch your company name, logo, part number or other desired information onto the surface of stainless steel, aluminum, brass, copper or ste the surface of stainless steel, aluminum, brass, copper or steel.

  • Page 19: E) Marking Wand Supplies And Part Numbers

    VIII- VIII- VIII USING THE MARKING WAND (OPTIONAL) USING THE MARKING WAND (OPTIONAL) USING THE MARKING WAN 5- Remove the stencil. TIP! For best results, always tape the stencil in place using masking tape before marking. 6- Neutralize the work piece with Surfox-N. 7- Neutralize the stencil with Surfox-N, rince well with water and dry.

  • Page 20: Neutralizing

    IX - NEUTRALIZING IX - NEUTRALIZING The Surfox-N liquid is a specially formulated neutralizer for the Surfox-T solution. It is a powerful ready-to-use formula which leaves no residue, is non-toxic, solvent free, water-based and biodegradable. Surfox-N; part no.: 54-A 023 (500ml sprayer) Directions for neutralizing Surfox-T cleaning solution: 1- Remove any excess Surfox-T solution using a soft clean cloth.

  • Page 21: Accessories

    X - ACCESSORIES X - ACCESSORIES A) CLEANING TIPS. They are made from high quality Tungsten alloy material. Other materials will not resist the harsh environment created by the electrochemical process. Cleaning tips are available in several different shapes and sizes: Tungsten Insert 90º: For large flat surfaces and external angles.

  • Page 22: B) Cleaning Pads

    X - ACCESSORIES B) CLEANING PADS. Cleaning pads are used on flat surfaces and external angles. They can also be used for internal corners or as a first step, as they clean much faster than cleaning boots. The cleaning pads are made from specially engineered polymer comprised of two (2) separate layers: one internal rigid layer which is in contact with the insert for increased heat and chemical resistance, and one soft external layer which is soft so that it will not damage or scratch the work piece during the cleaning operation.

  • Page 23: C) Cleaning Boots

    X - ACCESSORIES C) CLEANING BOOTS. Cleaning boots are made from a specially engineered polymer. They are composed of one rigid layer which is very thin and durable, but not very absorbent (does not hold liquid). This may require additional Surfox-T solution to keep the boot wet during cleaning. They are used for internal angles or tight corners because they are thinner and reduce the chance of arcing.

  • Page 24: D) Ptfe Clamp Rings

    To be used with tungsten insert 54-B 017 and cleaning pad 54-B 023. E) SURFOX-T SOLUTION. Surfox-T solution is a specially formulated phosphoric acid cleaning solution designed to be used only in Walter Surfox cleaning systems. Surfox-T Electrolyte cleaning solution (1.5L bottle) Part number 54-A 005 (4 x 1.5L bottles per case)

  • Page 25: Safety Features

    XI - SAFETY FEATURES XI - SAFETY FEATURES 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.

  • Page 26: C) Ac/Dc Current Basics

    XI - SAFETY FEATURES C) AC/DC CURRENT BASICS Alternating Current (AC). Alternating Current (AC) flows one way, then the other way, continually reversing direction. An AC voltage is continually changing between positive (+) and negative (-). Direct Current (DC). Direct Current (DC) always flows in the same direction, but it may increase and decrease.

  • Page 27: D) Ac/Dc Settings On The Surfox Machine

    XI - SAFETY FEATURES D) AC/DC SETTINGS ON THE SURFOX MACHINE Example of cleaning and passivation with Surfox in AC mode: Cleaning and passivation is perfect. Oxide layer to be removed. Cleans every crack in the material. After Before Microscopic view of the material.

  • Page 28: E) Welds That Cannot Be Cleaned

    XI - SAFETY FEATURES E) WELDS THAT CANNOT BE CLEANED If the area around the weld is black (not blue) from contamination, 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.

  • Page 29: Technical Data

    XII - TECHNICAL DATA XII - TECHNICAL DATA MODEL: SURFOX 203 PART NUMBER: 54-D 213 INPUT VOLTAGE: 120 V, 50/60 Hz OUTPUT VOLTAGE: 10-30 V, AC/DC INPUT CURRENT: 6 Amps OUTPUT CURRENT: 10 Amps, AC/DC MAX. OUTPUT VOLTAGE: 33 V, AC/DC...

  • Page 30: Warranty And Service

    No other warranty, written or verbal, is authorized. In no event shall WALTER be liable for any indirect, incidental or consequential damages from the sale of the WALTER be liable for any indirect, incidental or consequential damages from the sale of the WALTER product.

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