Manual - Ew-Combi Mk2

Finishing Solutions Ltd.
Electro-Wand
EW-Combi Kit
(MK 2)
Operators manual
EW-Combi(MK2)-240-K
EW-Combi(MK2)-110-K
1.0 INTRODUCTION
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.
2.0 CONTROLS
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.
3.0 PREPARATION
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.
4.0 OPERATING
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-500
EW-500-L200
EW-500-L350
EW-500-L500
Electro-Wand
Electro-Wand
Electro-Wand
Electro-Wand
Pads - pack of 20
Pads - pack of 200
Pads- pack of 350
Pads - box of 500
EW-400-5A Electro-Wand Long life Brush - pack of 5

EW-400-10A Electro-Wand Long life Brush - pack of 10
EW-400-30A
Electro-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
ElectroSolution
ElectroNeutralising
Agent
Wand
and
Wand
The Electro-Wand Solution and the Electro-Wand Neutralising Agent

are the only two consumables required with the Electro-Wand cleaning
process.
EW-655
EW-600
0.5 litres Electro-Wand Solution

5.0 litres Electro-Wand Solution
EW-685
EW-680
0.5 litres Electro-Wand Neutralising Agent

1.0 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 EW680 has a spray nozzle. The reusable trigger spray can be fitted to the EW680
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 no HazChem
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
5.0 TECHNICAL SPECIFICATION

EW-Combi(MK2)-240-K
EW-
Combi(MK2)-110-K
Input voltage
230V AC
110 V AC
Frequency
50/60 Hz
50/60 Hz
Input current
1.3 Amps
2.7Amps
Quiescent current
0.2 Amps
O.3 Amps
Max designed output
300Watts
Thermal trip setting
2 Amps
Fuse rating
Weight
4 Amp
300 Watts
3 Amps
6.3Amp
9Kg
9Kg
Dimensions
x 145mm
242 x 142 x 145mm
242 x 142
(Length, height, width)
6.0 SAFETY 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: [email protected]

www.finishingsolutions.co.uk
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Finishing Solutions Ltd.

The Electro-Wand Combi (EW-Combi) enables quick removal of weld burn /

Electro-Wand pads and brushes

The Electro-Wand Pad and Electro-Wand Brush are expendable items

EW-400-5A Electro-Wand Long life Brush - pack of 5

Electro-Wand Long life Brush - pack of 30

Retractable Device for Brush

The Electro-Wand Solution and the Electro-Wand Neutralising Agent

0.5 litres Electro-Wand Solution

0.5 litres Electro-Wand Neutralising Agent

Every Electro-Wand Combi kit is supplied with 0.5 litres of Electro-Wand

The cleaning solution used by electrolytic weld cleaners contains an acid

5.0 TECHNICAL SPECIFICATION

Max designed output

Thermal trip setting

242 x 142 x 145mm

(Length, height, width)

6.0 SAFETY PRECAUTIONS

The Electro-Wand Combi is only to be used by competent, trained

The ELECTRO-WAND COMBI

FINISHING SOLUTIONS LTD in the UK.

FINISHING SOLUTIONS Ltd.

UK Tel: +44(0) 1252 819442

UK Fax: +44(0) 1252 819443

Email address: [email protected]

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