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MagicCleaner 150

Fronius MagicCleaner 150 Operating Instruction [EN]

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MagicCleaner 150
Operating instructions
EN-US
42,0426,0395,EA 002-17012022
Table of contents
Safety Instructions 5
General information 12
Device concept 12 Intended use 12 Scope of supply 13 Options 14 Transport information 16 Setup regulations 17 Warning notices on the device 17
Operating controls, connections and mechanical components 18
Safety Instructions for commissioning, operation, and maintenance 20
Read and follow the Safety Instructions! 20 Safety Instructions for commissioning, operation, and maintenance 20
Mounting the cleaning electrode 23
Overview 23 Mounting the cleaning electrode 24 Attaching the supplied cleaning felt to the cleaning electrode 25
Mounting the optionally available cleaning felt 26
Mounting the cleaning brush 29
Preparing the workstation 31
Connecting the grounding cable and cleaning torch cable 31 Preparing the workstation 31 Before using the cleaning torch for the first time 32
Cleaning 33
Screwing the cleaning electrolyte onto the cleaning torch 33 Placing the cleaning torch in the cleaning torch holder 34 Cleaning 34 After cleaning 36
Polishing 38
Printing 42
EN-US
3
Service, maintenance and disposal 49
Technical data 51
MagicCleaner 150 /EF 150 /CN 150 /np 51 MagicCleaner 150 MV/B 150 MV/np 52
4
Safety Instructions
EN-US
Explanation of Safety Instruc­tions
DANGER!
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
▶
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are not
▶
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured in line with the state of the art and according to re-
cognized safety standards. If used incorrectly or misused, however, it can cause:
- 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
All persons involved in the commissioning, operation, maintenance, and servicing of the device must
- 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.
All safety and danger notices on the device:
- 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!
Intended use 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.
5
Intended use also means
- 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.
Environmental conditions
Obligations of the Operating Com­pany
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.
Temperature range of ambient air:
- 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)
NOTE!
The minus temperature range for transport and storage refers only to the device and accessories, not to the cleaning and Print electrolytes.
Relative humidity:
- 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.)
The operating company must only allow persons to work with the device if they
- 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
Obligations of Personnel
Personal protec­tion and protec­tion of others
6
The safety-conscious work of the personnel must be checked regularly.
All persons who are assigned to work with the device must do the following before begin­ning the work:
- 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.
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
Individuals working on the workpiece during the cleaning process must wear suitable work clothing with the following properties:
- 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
EN-US
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
Keep persons, especially children, and those who are pregnant or unwell, away during the operation of the devices and during the working process. However, if persons are in the vicinity:
- Inform them of all risks
- Provide suitable protective equipment or
- Construct suitable protective walls or curtains.
Notes on the cor­rect handling of the cleaning and Print electrolytes
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:
7
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
Risks from grid current and cleaning current
- 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)
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.
8
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.
EN-US
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.
EMC measures It is the responsibility of the operator to take care to ensure that there is no electromag-
netic interference with electrical and electronic equipment.
If electromagnetic interference is identified, then the operator is obliged to take action to rectify the situation
Check and evaluate possible problems and the interference immunity of equipment in the vicinity according to national and international regulations:
- 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.
Supporting measures to avoid EMC problems:
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
9
Particular hazard areas
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.
During operation
- 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.
Safety measures at the setup loca­tion and during transport
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- 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 agent.
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.
Safety measures in normal opera­tion
10
Only operate the device when all safety devices are fully functional. If the protection devices are not fully functional, there is a danger of:
- 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.
Commissioning, maintenance and repair
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.
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.
EN-US
Safety inspection The manufacturer recommends that a safety inspection of the device be performed at
least every 12 months.
A safety inspection by a certified electrician is recommended:
- 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.
Safety Symbols
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.
Copyright 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.
11
General information
Device concept
MagicCleaner 150
Intended use The MagicCleaner 150 is intended exclusively for the electrochemical cleaning of stain-
less 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.
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)
12
Scope of supply
*
(1)
(2)
(3)
(4) (5)
(6) (7) (10)(8)
(9)
(11) (12)
EN-US
(1) Brush insert
(2) Cleaning torch
(3) Cleaning torch holder
(4) Cleaning torch cable
(5) MagicCleaner 150
(6) Grounding cable with bayonet connector
(7) Cleaning electrode
(8) 3 x cleaning felt
(9) Cleaning electrode
(10) 3 x cleaning felt
(11) Adapter for cleaning brush
(12) Cleaning brush
* The cleaning electrolyte is not included in the scope of supply.
Not shown:
- 2.5 mm / 0.10 inch Allen key
- These Operating Instructions
- Small parts box
10 mm / 0.39 inch
10 mm / 0.39 inch
22 mm / 0.87 inch
22 mm / 0.87 inch
13
Options
(1) (2)
(3) (4)
(5)
(7) (8)
(9)
(6) (13)
(12)
(11)
(10) (14)
(15)
+
red
b
lue
(1) Adapter for cleaning brush
42,0510,0531
(2) 5 x cleaning brush
42,0510,0510
(3) Cleaning electrode
22 mm / 0.87 inch 42,0510,0500
(4) 10 x cleaning felt
22 mm / 0.87 inch 42,0510,0501
(5) Cleaning electrode
10 mm / 0.39 inch 42,0510,0506
(6) 10 x cleaning felt
10 mm / 0.39 inch 42,0510,0507
(7) Cleaning electrode
22 mm / 0.87 inch / 70° 42,0510,0502
(8) 10 x cleaning felt
22 mm / 0.87 inch / 70° 42,0510,0503
(9) Cleaning electrode
10 mm / 0.39 inch / 70° 42,0510,0508
(10) 10 x cleaning felt
10 mm / 0.39 inch / 70° 42,0510,0509
(11) Cleaning electrode
35 mm / 1.38 inch 42,0510,0504
(12) 10 x cleaning felt
35 mm / 1.38 inch 42,0510,0505 +
1 x O-ring
D=27.08 x d=23.52 mm / D=1.07 x d=0.93 inch
14
(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
EN-US
15
(16)
(17) (18) (19)
(20) (21) (22)
(24)
(23)
(25)
ABC- 123
(26)
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
Transport inform­ation
16
(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)
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
Setup regulations Operation outdoors
Model No.
Part No.
Ser. No.
FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria Phone: +43 (0)7242 241-0
MAGIC CLEANER MC 150
.........................
.........................
CAN/CSA-E60974-1: 2012
ANSI/IEC 60974-1:2008
1~
50/60Hz
IP23
U0 = 30V AC Rms - 30V DC peak
U1 = 85-260V
U2 = 0 to 30V AC/DC
P1max = 450W
L1 max = 5A
L2 = 0 to 15A
Duty (%) = 0 to 80%
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.
Ambient temperature IMPORTANT! The operating and storage temperature must not fall below the following
temperatures:
- 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.
EN-US
Warning notices on the device
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
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