Finishing Solutions Ltd.
Electro-Wand
EW-Combi Kit
(MK 2)
Operators manual
EW-Combi(MK2)-240-K
EW-Combi(MK2)-110-K
1.0INTRODUCTION
The Electro-Wand Combi (EW-Combi) enables quick removal of weld burn / weld discolouration on stainless steel that has been TIG welded. When welding Stainless Steel there are residue weld burn/weld discolouration marks left behind from the welding process. This is not only unsightly, but leaves the material vulnerable to corrosion.
For many years the cleaning process of stainless steel welds has been by means of putting a chemical on the discoloured area and leaving it for some time to etch clean. Alternatively the stainless steel is dipped into an acid bath. The traditional methods of pickling paste or acid baths are hazardous to the operator and to the environment. The EW-Combi uses a mild chemical solution which is less hazardous and offers a comfortable and safe method of work for the operator.
The EW-Combi operates both a “pad” for fast, effective cleaning and a long life “brush” for awkward corners and confined spaces.
The design of the EW-Combi MK2 enables the weld to be cleaned almost instantly, saving the operator time. This is achieved by passing an electric current through the weld using a solution of phosphoric acid as an electrolyte. In order to maximize the cleaning efficiency, the EW-Combi MK2 has a power control that regulates the current flow therefore providing just the right amount of power to clean the weld without producing excessive acid vaporization.
A chemical neutralizing solution is available which reduces the chemical solution to a harmless salt solution. The cleaning process encourages passivation, so enabling the stainless steel to remain stainless.
2.0CONTROLS
The EW-Combi MK 2 has controls that make it very flexible and easy to use. On the front of the unit there are two lights, two sockets and a variable control. On the rear of the unit there is a mains input socket and a thermal trip.
2.1 Front
There are two standard Dinse Sockets. The right hand Dinse Socket is used for the crocodile clip. This is to be connected to either the work piece or the metal table that the work is being cleaned on.
The left hand Dinse Socket is used for connecting either the paddle or brush that will be used for cleaning the work piece.
The yellow light at the bottom of the front plate is the mains light and will always be on when the mains supply is plugged in and switched on.
The green light at the top of the unit is the power output light and will only come on when the output power is turned on.
The control knob on the top right hand side is the power control. This controls the output power which is variable depending on the cleaning operation required. The control knob also turns the output to the Dinse Connectors on and off.
2.2 Rear
There is a mains input socket incorporating a mains switch and a fuse.
On the top right hand side is a thermal cut-out that will be activated if the output power exceeds the design specification for any length of time.
3.0PREPARATION
Before using the weld cleaner it is advisable to try it out on some sample welds to get used to the controls.
First prepare your work place. Place the EW-Combi MK2 close to the item you are going to clean making sure that the cables will easily reach the work.
Plug the EW-Combi MK2 into the mains supply and turn on.
Connect the black lead with the crocodile clip into the Dinse Socket on the right hand side of the machine. This should be connected to the work piece to be cleaned or the metal bench that the work piece is sitting on.
Insert the red lead with either the paddle or brush into the Dinse Socket on the front left hand side of the machine.
4.0OPERATING
Fill the non-spill fluid container with the cleaning solution.
Dip the pad or brush into the cleaning solution taking care not to put excessive cleaning solution onto the pad. Excessive cleaning solution will not clean the weld better –it will waste the solution and wear out the pad or brush more quickly.
Gently stroke the pad or brush across the area to be cleaned, adjusting the power control on the front of the unit until the weld is cleaned with the minimum of power being used. This will also save cleaning fluid and help the pad and brush to last longer.
Once the item has been cleaned, wash the work piece using the neutralising solution (Neutralising Agent) to remove any residual cleaning acid. (See section below)
Should the pad or brush wear out and a short circuit be created or, the power control is turned up too high (making the unit draw excessive current beyond its design capability) after a short time the thermal trip will activate. This is a safety mechanism designed to ensure that no damage can occur to the equipment.
To reset the thermal trip leave the equipment for approximately 1 minute then replace the worn pad/brush and turn the power down. Press the reset button on the rear of the unit and continue using.
4.1 Electro-Wand pads and brushes
The “Electro-Wand Pad” and “Electro-Wand Brush” are expendable items and will wear out with usage and need to be replaced. They can be purchased in a variety of different quantities. The Electro-Wand pads may also be referred to as “socks”.
EW-500Electro-Wand Pads - pack of 20
EW-500-L200Electro-Wand Pads - pack of 200
EW-500-L350Electro-Wand Pads- pack of 350
EW-500-L500Electro-Wand Pads - box of 500
EW-400-5AElectro-Wand Long life Brush - pack of 5
EW-400-10AElectro-Wand Long life Brush - pack of 10
EW-400-30AElectro-Wand Long life Brush - pack of 30
Do not vigorously rub the pad or brush, which will shorten their lives and not result in any quicker cleaning of the area. A few light strokes of the pad or brush are all that is necessary to remove the weld discoloration.
The operator should take care when removing a worn pad- as it will still have acid (chemical solution) on it. The insert (paddle), over which the pad is fitted, might be hot.
4.2 “Retractable Device for Brush”
The EW-Combi Kit is supplied with EW-450 “Retractable Device for Brush”. This is fitted to the wand assembly that operates the brush.
The purpose of the EW-450 is to control the brush and to ensure that the operator gets the most efficient use out of the life of the brush. Without the EW-450, the bristles on the brush can separate, therefore making it difficult to only clean the actual area of stainless steel that requires weld cleaning.
As the brush begins to wear and reduce in length, the operator needs to loosen the screw on the EW-450 to enable the device to be relocated further down the length of the brush towards the plastic wand handle.
4.3 “Electro-Wand Solution” and “Electro-Wand Neutralising Agent”
The “Electro-Wand Solution” and the “Electro-Wand Neutralising Agent” are the only two consumables required with the Electro-Wand cleaning process.
EW-6550.5 litres Electro-Wand Solution
EW-6005.0 litres Electro-Wand Solution
EW-6850.5 litres Electro-Wand Neutralising Agent
EW-6801.0 litres Electro-Wand Neutralising Agent
Every Electro-Wand Combi kit is supplied with 0.5 litres of “Electro-Wand Solution”(EW-655) and 0.5 litres of “Neutralising Agent”(EW-685). For further supplies, the “Electro-Wand Solution” is available in 5 litre containers (EW-600) and the “Electro-Wand Neutralising Agent” is available in 1 litre containers (EW-680).
The EW-685 0.5 is supplied with a reusable trigger spray, whilst the EW-680 has a spray nozzle. The reusable trigger spray can be fitted to the EW-680
The contents of the EW-655 and EW-600 (Electro-Wand Solution) are poured directly into the “non spill container”.
The “EW-685 / EW680 Electro-Wand Neutralising Agent” has noHazChem Directive and is harmless in use.
The “EW-655 / EW-600 Electro-Wand Solution” has a HazChem Directive. It is therefore essential that before using the Solution, the operator has read the “Hazardous Chemical Safety Data Sheet” produced by Finishing Solutions ltd. Version Data, 1(01:06:1968), MSDM REF: AN05051
4.4 Benefits of using Electro-Wand Neutralising Agent
The cleaning solution used by electrolytic weld cleaners contains an acid in aqueous solution. In our case this is Phosphoric Acid although others may contain harsher chemicals than this.
If any of this acid is allowed to remain on the fabrication after weld cleaning has taken place it is highly likely that some staining/etching of the surface will take place which can only be removed by abrasive action.
Traditionally, this acid residue is removed by flushing with clean water; however, as the container of water becomes more contaminated - the acid removal process becomes less effective and so more time consuming.
The Electro-Wand Neutralising Agent is an alkali neutralising solution which will react with any acid residue. The reaction is very visible as the neutralizing solution will fizz when in contact with acid. When no reaction is apparent, the contamination has been neutralised. The resultant liquid is a harmless salt solution which can be wiped away with a tissue and discarded.
This process is very quick and convenient and is much valued by the catering, medical and bio chemical industries as a means of ensuring that no harmful chemicals are present.
Directions for use of the Neutralising Agent
- Use sparingly
- Direct spray onto area which has been cleaned
- Continue to spray until fizzing stops
- Wipe dry
5.0TECHNICAL SPECIFICATION
EW-Combi(MK2)-240-K EW-Combi(MK2)-110-K
Input voltage230V AC110 V AC
Frequency50/60 Hz50/60 Hz
Input current1.3 Amps2.7Amps
Quiescent current0.2 AmpsO.3 Amps
Max designed output 300Watts300 Watts
Thermal trip setting2 Amps3 Amps
Fuse rating4 Amp6.3Amp
Weight9Kg9Kg
Dimensions 242 x 142 x 145mm242 x 142 x 145mm
(Length, height, width)
6.0SAFETY PRECAUTIONS
Important Safety Precautions for operating your EW-Combi
- The Electro-Wand Combi is only to be used by competent, trained personnel.
- Operating this machine requires the use of corrosive substances. COSHH registers and data sheets associated with chemicals used during operations must be read and understood by any person using the machine.
- PPE (personal protective equipment) designated by the COSHH data sheets must be used.
- Do not place magnetically sensitive items close to the machine.
- Do not remove the cover. There are no user serviceable parts inside
The ELECTRO-WAND COMBI
is designed and manufactured by
FINISHING SOLUTIONS LTD in the UK.
FINISHING SOLUTIONS Ltd.
32 Reading Road South,
Fleet, Hampshire. GU52 7QL
UK Tel: +44(0) 1252 819442 UK Fax: +44(0) 1252 819443
Email address: Website: