MagicCleaner 150 Operating instructions

1. Safety Instructions

1. Safety Instructions

• Serious or fatal injury to the operator or third parties
• Damage to the device and other material assets belonging to the operating company
• Inefficient operation of the device

• Be suitably qualified
• Have fully read and precisely followed these Operating Instructions

The Operating Instructions must always be kept to hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.

• Must be kept in a legible state
• Must not be damaged/marked
• Must not be removed
• Must not be covered, pasted, or painted over

Before starting up the device, remedy any faults that could compromise safety.
Your personal safety is at stake!

1. Safety Instructions

The device is to be used exclusively for its intended purpose.

The manufacturer shall not be liable for any damage resulting from any other use or use beyond the scope of this manual.

• Carefully reading and adhering to these Operating Instructions
• Following all instructions, safety and hazard warnings
• Carrying out all the specified inspection and maintenance work.

The device is designed for operation in industry and business. The manufacturer shall not be liable for any damage resulting from use in a living area.

The manufacturer shall also not be liable for faulty or incorrect work results.

1. Safety Instructions

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.

• During operation: 0 °C to +40 °C (32 °F to 104 °F)
• During transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

• up to 50% at 40 °C (104 °F)
• up to 90% at 20 °C (68 °F)

Ambient air: free of dust, acids, corrosive gases or substances.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

1. Safety Instructions

• Are familiar with the basic occupational safety and accident prevention regulations and are trained in handling the device
• Have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
• Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

1. Safety Instructions

• Follow the basic regulations for occupational safety and accident prevention
• Read these Operating Instructions, especially the section "Safety Rules," and confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can occur in one's absence.

1. Safety Instructions

You are exposed to numerous hazards while working with the device, for example:

• Irritation or burning of the skin due to contact with cleaning electrolyte or Print electrolyte
• Danger of serious eye damage due to contact with cleaning electrolyte or Print electrolyte
• General hazards when handling chemicals
  
  Observe the safety data sheets of the cleaning and Print electrolytes!

• Electrical risks from grid current and cleaning current
• Harmful vapors

• Resistant against acids and chemicals
• Insulating and dry
• Covering the entire body and in good condition with no damage

Work clothing includes the following:

• Tightly fitting safety goggles (eye protection)
• Rigid, wet-insulating footwear
• Protective gloves (hand protection): impermeable, resistant to acids and chemicals
• Breathing protection

The required condition of work clothing and protective measures are indicated on the safety data sheet of the cleaning and Print electrolytes.

Immediately remove work clothing contaminated with cleaning agent!

• Do not eat or drink when working with the device
• Keep cleaning and Print electrolytes away from food, beverages, and feedstuffs

• Wash hands before breaks and at the end of work

• Inform them of all risks
• Provide suitable protective equipment
  or
• Construct suitable protective walls or curtains.

1. Safety Instructions

The following points must be observed when handling the cleaning and Print electrolytes. For exact data, please refer to the respective safety data sheets. For current safety data sheets, use the following link:

www.fronius.com/magiccleaner

First aid measures

• After inhalation provide fresh air. Consult a physician if complaints persist.
• After skin contact, wash immediately with soap and water, and rinse thoroughly. Consult a physician if skin irritation persists.
• If swallowed, do not induce vomiting, rinse mouth and drink plenty of water, seek medical advice immediately.
• After eye contact, rinse opened eye for several minutes under running water (eye wash) and seek medical advice.
  If present, remove contact lenses and continue rinsing.

Storage

• Only use containers specifically approved for the cleaning agents
• Keep container tightly closed
• Do not store together with alkalis (lyes) and metals
• Store in a cool and dry place
• Provide acid resistant floor

• Keep under lock and key and out of reach of children

Other notes

• To avoid thermal decomposition, do not heat (danger of toxic gases being produced)
• Provide emergency cooling in the event of a fire in the environment
• Avoid contact with skin, eyes, and mucous membranes
• Use only in well ventilated areas, use respiratory protection or adequate exhaust ventilation.
• When diluting, always add acid to water - not vice versa!
• Dispose of cleaning agents or uncleaned packaging in accordance with national regulations. Do not dispose of with household waste!

• Do not allow to enter drains, watercourses or groundwater (e.g., via the soil)

1. Safety Instructions

An electric shock can be fatal. Every electric shock poses a risk of death.

Do not touch voltage-carrying parts inside or outside the device.

Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential.

All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.

Do not wrap cables or leads around your body or parts of the body.

Have the mains and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.

Only operate the device on a grid with a ground conductor and a socket with a ground conductor contact.

Operating the device on a grid without a ground conductor and on a socket without a ground conductor contact is considered gross negligence. The manufacturer accepts no liability for any damage resulting from improper use.

Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.

Switch off unused devices.

Before working on the device, switch off the device and unplug the mains plug.

Secure the device to prevent the mains plug from being connected and switched on again by applying a clearly legible and understandable warning sign.

The device may only be opened by professionally trained service technicians.

1. Safety Instructions

It is the responsibility of the operator to take care to ensure that there is no electromagnetic interference with electrical and electronic equipment.

If electromagnetic interference is identified, then the operator is obliged to take action to rectify the situation

• Safety devices
• Mains power lines, signal lines, and data transfer lines
• IT and telecommunications equipment
• Devices for measuring and calibrating
• The health of persons close by, e.g., those with pacemakers and hearing aids
• Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the cleaning process

Electromagnetic fields may cause health problems that are not yet known.

1. Mains power supply
   • If electromagnetic interference occurs despite a mains connection that complies with regulations, take additional measures (e.g., use a suitable mains filter).
2. Equipotential bonding
3. Workpiece grounding
   • If necessary, establish grounding using suitable capacitors.
4. Shield, if necessary
   • Shield other devices in the vicinity
   • Shield entire system

1. Safety Instructions

Special regulations apply in areas at risk of fire or explosion

• Follow the appropriate national and international regulations.

Devices for work in areas with increased electrical hazard (such as boilers) must be labeled with the symbol [S] (Safety).

Measurements of toxic emissions when working with the device showed values below permissible "average workplace concentrations" (MAK).
Nevertheless:

• Ensure there is a sufficient supply of fresh air.
• Keep your face away from any vapors that arise.
• Do not inhale vapors, or extract vapors from the work area by suitable means.

• Ensure that all covers are closed, and all side parts have been mounted properly.
• Keep all covers and side parts closed.

If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand. The carrier belt is not suitable for transport by crane, counterbalanced lift truck or other mechanical lifting tools.

1. Safety Instructions

• The maximum permitted tilt angle is 10°.

• Follow the appropriate national and international regulations.

Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.

Only set up and operate the device in accordance with the protection class shown on the rating plate.

When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to allow cooling air to circulate unhindered.

Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.

Before transporting the device, always completely drain the cleaning electrolyte.

It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage repaired by trained service technicians before commissioning the device.

1. Safety Instructions

• Serious or fatal injury to the operator or third parties
• Damage to the device and other material assets belonging to the operating company
• Inefficient operation of the device

Safety devices that are not fully functional must be repaired before the device is switched on.

Never bypass or disable protection devices.

Before switching on the device, ensure that no one can be put in danger.

The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.

Only Fronius cleaning and Print electrolytes are suitable for use in our devices.

Do not mix Fronius cleaning and Print electrolytes with other cleaning agents.

If damage occurs due to the use of other cleaning agents, the manufacture is not liable for this and all warranty claims are forfeited.

Transport the cleaning and Print electrolytes in closed original containers exclusively.

1. Safety Instructions

It is impossible to guarantee that externally procured parts are designed and manufactured to meet the demands made on them, or that they satisfy safety requirements.

• Use only original spare and wearing parts (also applies to standard parts).
• Do not carry out any alterations, installations, or modifications to the device without first obtaining the manufacturer's permission.
• Components that are not in perfect condition must be changed immediately.
• When ordering, specify the exact name and part number according to the Spare Parts List, as well as the serial number of your device.

In addition to a cable connection, the housing screws provide the protective conductor connection for grounding the housing parts.
Always use original housing screws in the appropriate number with the specified torque.

1. Safety Instructions

The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.

• After changes
• After alterations
• After repair, service and maintenance
• At least every twelve months.

For the safety inspection, follow the appropriate national and international standards and guidelines.

You can obtain more information about the safety inspection from your service center. The service center will provide the necessary documents upon request.

1. Safety Instructions

Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives (e.g., relevant product standards of the EN 60974 series).

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

1. Safety Instructions

Copyright of these Operating Instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the Operating Instructions, we will be most grateful for your comments.

1. General information

MagicCleaner 150

The MagicCleaner 150 is a device for the electrochemical surface treatment of stainless steel.

The following surface treatments can be carried out:

• Elimination of oxides and burns after welding and cutting.
• Polishing of welds
• Printing - electrochemical surface printing
  (optional)

1. General information

The MagicCleaner 150 is intended exclusively for the electrochemical cleaning of stainless steel. Any other use is deemed to be "not in accordance with the intended purpose." The manufacturer shall not be liable for any damage resulting from such improper use.

Intended use also means

• Reading and understanding these Operating Instructions,
• Reading and understanding all safety data sheets of the cleaning and Print electrolytes,
• Carrying out all the specified inspection and maintenance work.

1. General information

Not shown:

• 2.5 mm / 0.10 inch Allen key
• These Operating Instructions
• Small parts box

1. General information

(13)	6 x cleaning electrolyte blue 0.1 l 42,0510,0381
(14)	6 x cleaning electrolyte red 0.1 l 42,0510,0380
(15)	Neutralizer 1 l spray bottle ...42,0510,0385 5 l canister ... 42,0510,0386

Print set 42,0510,0540

(16)	Print film with Fronius logo (for testing)
(17)	Print electrolyte black 0.1 l 42,0510,0390
(18)	Print electrolyte white 0.1 l 42,0510,0391
(19)	Print torch holder
(20)	Print torch
(21)	Allen key WAF 2.5 mm
(22)	Print torch cable
(23)	Print electrode
(24)	5 x O-ring (for attaching the Print felt to the Print electrode)
(25)	20 x Print felt
(26)	Print film (option, to be ordered separately from Fronius)

1. General information

 IMPORTANT! Before transport:

• Unscrew the cleaning electrolyte
• Empty hand pump
• Empty cleaning torch
• Remove used cleaning or Print felt
• Clean the cleaning and Print electrodes

1. General information

Operation outdoors
The device can be installed and operated outdoors in accordance with its degree of protection IP 23. However, the installed electrical parts must be protected from direct exposure to moisture, e.g. external wet cleaning.

• without cleaning electrolyte: -25 °C / -13 °F
• with cleaning electrolyte: 0 °C / 32 °F

Install the device in such a way that it is not additionally heated by heat sources such as radiators, heaters or annealing furnaces, direct sunlight, etc.

1. General information

The device is equipped with warning notices and a rating plate.
The warning notices and rating plate must not be removed or painted over.

Rating plate and warnings on the device

	Use eye protection / safety goggles
	Use respiratory protection
	Use gloves
	Use protective equipment according to the safety data sheet of the cleaning electrolyte used!
	Caution! Corrosive liquids

1. Operating controls, connections and mechanical components

1. Operating controls, connections and mechanical components

Control panel

Front/back

Cleaning torch + cleaning torch holder

(9)	Cleaning electrolyte 0.1 l For screwing onto the cleaning torch
(10)	Cleaning torch or Print torch
(11)	Cleaning torch holder or Print torch holder
(12)	Hand pump For conveying the cleaning electrolyte (only at the cleaning torch)
(13)	Fixing screw
(14)	Cleaning electrode or Cleaning brush with adapter Print electrode
(15)	Cleaning felt or Print felt

The following Safety Instructions provide information about dangers that occur when working with and on the device.

IMPORTANT! Read and follow these Safety Instructions carefully before and during all installation, cleaning, polishing, printing, and maintenance activities!

Follow the safety rules below when carrying out all tasks described in this document!

1. Safety Instructions for commissioning, operation, and maintenance

The following Safety Instructions provide information about dangers that occur when working with and on the device.

IMPORTANT! Read and follow these Safety Instructions carefully before and during all installation, cleaning, polishing, printing, and maintenance activities!

Follow the safety rules below when carrying out all tasks described in this document!

1. Safety Instructions for commissioning, operation, and maintenance

CAUTION!

Danger from spilled, leaked or uncollected chemicals!

Personal injury and damage to property or the environment may result.

For cleaning, polishing or Print work, provide an acid-resistant drip tray.

Make sure that cleaning or Print electrolytes cannot escape in an uncontrolled manner.

The following cleaning electrodes are available for cleaning and polishing:

1. Mounting the cleaning electrode

The following cleaning electrodes are available for cleaning and polishing:

1. Mounting the cleaning electrode

1

IMPORTANT! When inserting the cleaning electrode, make sure that the plastic tube (*) is inserted into the hole (**) on the cleaning torch.

2

3

1. Mounting the cleaning electrode

The MagicCleaner 150 is supplied with 3 cleaning felts each for the two cleaning electrodes in sizes 10 mm / 0.39 inch and 22 mm / 0.87 inch.
These cleaning felts are manufactured in the form of a pocket and are slid over the cleaning electrodes. Fixing by means of a mounting ring is not necessary.

1

Attaching cleaning felt to cleaning electrode 10 mm / 0.39 inch

The cleaning felt is attached to the 22 mm / 0.87 inch cleaning electrode in the same way.

Alternative mounting option if cleaning felt other than the felt supplied is used for the 22 mm / 0.87 inch cleaning electrode.

1

2

3

4

5

Other cleaning felt, O-rings, and wide rubber rings are optionally available from Fronius.

1. Mounting the optionally available cleaning felt

Alternative mounting option if cleaning felt other than the felt supplied is used for the 22 mm / 0.87 inch cleaning electrode.

1

2

3

4

5

Other cleaning felt, O-rings, and wide rubber rings are optionally available from Fronius.

1. Mounting the optionally available cleaning felt

Alternative mounting option if cleaning felt other than the felt supplied is used for the 10 mm / 0.39 inch cleaning electrode.

1

2

3

4

5

Other cleaning felt and mounting rings are optionally available from Fronius.

1. Mounting the optionally available cleaning felt

Mounting option of the cleaning felt for the 35 mm / 1.38 inch cleaning electrode.

1

2

Other cleaning felt, O-rings, and wide rubber rings are optionally available from Fronius.

1

2

IMPORTANT! When inserting the cleaning brush, make sure that the plastic tube (*) is inserted into the hole (**) on the cleaning torch.

3

4

IMPORTANT! The fibers of the cleaning brush must not protrude more than 15 mm / 0.59 inch from the brush housing.

1. Mounting the cleaning brush

1

2

IMPORTANT! When inserting the cleaning brush, make sure that the plastic tube (*) is inserted into the hole (**) on the cleaning torch.

3

4

IMPORTANT! The fibers of the cleaning brush must not protrude more than 15 mm / 0.59 inch from the brush housing.

1. Mounting the cleaning brush

5

NOTE!

If the fibers are worn or short, push the brush housing towards the cleaning torch.

Only push the brush housing back when the cleaning brush is mounted on the cleaning torch.

The first few times you push the brush housing back this may require more force.

The fibers of the cleaning brush must not protrude more than 15 mm / 0.59 inch from the brush housing.

1. Preparing the workstation

1

2

1. Preparing the workstation

1. Preparing the workstation

The following cleaning electrolytes are available for cleaning purposes:

Cleaning electrolyte blue 0.1 l
for cleaning welds

Cleaning electrolyte red 0.1 l
for cleaning welds at higher cleaning speeds

1

2

1. Cleaning

The following cleaning electrolytes are available for cleaning purposes:

Cleaning electrolyte blue 0.1 l
for cleaning welds

Cleaning electrolyte red 0.1 l
for cleaning welds at higher cleaning speeds

1

2

1. Cleaning

Place the cleaning torch with mounted cleaning electrode in the cleaning torch holder

1

Place cleaning torch with mounted cleaning brush in cleaning torch holder

1

1. Cleaning

1

2

AC / CLEAN ... for cleaning by means of cleaning electrode
BRUSH ... for cleaning by means of a cleaning brush

3

With increasing cleaning power, higher cleaning speeds are possible.

4

5

Press the hand pump 4 to 5 times at intervals of 2 to 3 seconds each time it is used for the first time

6

Cleaning electrode | Cleaning brush

1. Cleaning

1

Place cleaning electrode | cleaning brush ...
in the cleaning torch holder

2

3Switching off the device

IMPORTANT! For an optimal cleaning result, remove the excess cleaning electrolyte to avoid white spots due to cleaning electrolyte residues.
Subsequently clean the surface with the neutralizer.

4

* Excess cleaning electrolyte

5

** New microfiber cloth

IMPORTANT!

• Do not dispose of cloths wetted with cleaning electrolyte in household waste!
• Dispose of cloths wetted with cleaning electrolyte in accordance with regional regulations!
  Observe the safety data sheets of the cleaning electrolytes!
• Do not refill empty cleaning electrolyte tubes!
• Unscrew the cleaning electrolyte tubes from the cleaning torch after use, close them such that they are airtight, and label the container.
• After finishing work, remove the cleaning felt from the cleaning electrode.

Electrochemical polishing of welds is carried out with:

Cleaning electrolyte red 0.1 l
42,0510,0380

Supply of the cleaning electrolyte via the cleaning torch and the hand pump.

1. Polishing

Electrochemical polishing of welds is carried out with:

Cleaning electrolyte red 0.1 l
42,0510,0380

Supply of the cleaning electrolyte via the cleaning torch and the hand pump.

1. Polishing

Place the cleaning torch with mounted cleaning electrode in the cleaning torch holder

1

1. Polishing

• Cleaning electrode and cleaning felt mounted on the cleaning torch
  (see from page (→))
• Cleaning electrolyte red 0.1 l screwed onto the cleaning torch
  (see from page (→))
  

1

2

DC / POLISH ... Polishing

3

Polishing with maximum power

4

5

6

NOTE!

When polishing with the cleaning electrode, apply slight pressure to the weld.

1. Polishing

1

2

3Switching off the device

IMPORTANT! For an optimal cleaning result, subsequently remove the excess cleaning electrolyte to avoid white spots due to cleaning electrolyte residues.
Finally, clean the surface with the neutralizer.

4

* Excess cleaning electrolyte

5

** New microfiber cloth

IMPORTANT!

• Do not dispose of cloths wetted with cleaning electrolyte in household waste!
• Dispose of cloths wetted with cleaning electrolyte in accordance with regional regulations!
  Observe the safety data sheets of the cleaning electrolytes!
• After finishing work, remove the cleaning felt used for polishing from the cleaning electrode.

It is also possible to apply electrochemical surface prints to stainless steel with this device. Logos, graphics, texts, numbers, etc., can be printed on the surface using a customizable Print film.
The print on stainless steel can be either light or dark.

For printing on stainless steel, the Print set is required:

Print set 42,0510,0540

(1)	Print film with Fronius logo (for testing)
(2)	Print electrolyte black 0.1 l 42,0510,0390
(3)	Print electrolyte white 0.1 l 42,0510,0391
(4)	Print torch holder
(5)	Print torch
(6)	Allen key WAF 2.5 mm
(7)	Print torch cable
(8)	Print electrode
(9)	O-ring
(10)	20 x Print felt
(11)	Print film (option, to be ordered separately from Fronius)

1. Printing

It is also possible to apply electrochemical surface prints to stainless steel with this device. Logos, graphics, texts, numbers, etc., can be printed on the surface using a customizable Print film.
The print on stainless steel can be either light or dark.

For printing on stainless steel, the Print set is required:

Print set 42,0510,0540

(1)	Print film with Fronius logo (for testing)
(2)	Print electrolyte black 0.1 l 42,0510,0390
(3)	Print electrolyte white 0.1 l 42,0510,0391
(4)	Print torch holder
(5)	Print torch
(6)	Allen key WAF 2.5 mm
(7)	Print torch cable
(8)	Print electrode
(9)	O-ring
(10)	20 x Print felt
(11)	Print film (option, to be ordered separately from Fronius)

1. Printing

1

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3

4

1. Printing

For further preparation steps, see "Preparing the workstation" from page (→).

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3

1. Printing

1

2

   Print - dark print

   Print - light print

The power for the Print process is automatically preset by the device; the settings on the cleaning power control have no influence on the Print process.

IMPORTANT! Use the correct Print electrolyte depending on the Print process:

• Print electrolyte black 0.1 l ... for dark printing
• Print electrolyte white 0.1 l ... for light printing
• Do not mix Print electrolytes
  

3

Wetting the Print felt once is sufficient for a maximum of 15 Print operations in succession.

4

Position and secure the Print film on the workpiece to be printed

Pass the Print electrode with Print felt several times over the Print film

1. Printing

1

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3

4

*	As an alternative to the neutralizer, a microfiber cloth moistened with clear water can be used.

5

**	New, dry microfiber cloth

6

**	New, dry microfiber cloth - clean both sides of the Print film; clear water can be used as an alternative to the neutralizer.

The MagicCleaner 150 requires minimal service and maintenance under normal operating conditions. However, several points must be observed in order for the device to remain operational for years to come.

1. Service, maintenance and disposal

The MagicCleaner 150 requires minimal service and maintenance under normal operating conditions. However, several points must be observed in order for the device to remain operational for years to come.

1. Service, maintenance and disposal

• Check mains cable, grounding cable, and torch cable for damage
• Check cleaning electrodes and cleaning felt, cleaning brushes as well as Print electrodes and Print felt for wear and burns and replace if necessary;
  only use original spare parts and accessories from the manufacturer.

1. Service, maintenance and disposal

• In case of residues of cleaning agent or Print electrolyte, clean the device with neutralizer and clean cloths
• Remove cleaning felt, cleaning brushes or Print felt and rinse with clean water;
  replace worn or burnt cleaning felt / cleaning brushes / Print felt
• After cooling down, rinse the cleaning and Print electrodes with clear water
• Unscrew the cleaning electrolyte from the cleaning torch and close it
• Pump the cleaning torch empty

1. Service, maintenance and disposal

Used cleaning felts are considered hazardous waste.

During cleaning and polishing, heavy metals are deposited in the cleaning electrolyte used. Used cleaning electrolytes are therefore considered hazardous waste.

Materials should be disposed of according to valid local and national regulations.

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally sound manner in accordance with the European Directive and national law. Used equipment must be returned to the distributor or through a local authorized collection and disposal system. Proper disposal of the used device promotes sustainable recycling of material resources. A failure to observe this may lead to potential health/environmental impacts

1. Technical data

1. Technical data