Fronius MagicCleaner Stand Alone, MagicCleaner Stand Alone 110 V Operating Instructions/spare Parts List

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MagicCleaner "Stand Alone"

MagicCleaner "Stand Alone" 110 V

Operating Instructions
Spare Parts List

EN

TIG power source
(CrNi cleaning)

42,0426,0024,EN 008-15022017

Dear Reader

Introduction

Thank you for choosing Fronius - and congratulations on your new, technically high­grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.

EN

ud_fr_st_et_00493 01/2012

Safety rules

DANGER!

WARNING!

CAUTION!

NOTE!

“DANGER!” indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.

“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not avo­ided, may result in minor or moderate injury. It may also be used to alert
against unsafe practices that may cause property damage.

“NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.

EN

Important!

General remarks

“Important!” indicates practical hints and other useful special-information. It

is no signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay even
closer attention to the contents of the manual!

This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for

- the life and well-being of the operator or of third parties,

- the equipment and other tangible assets belonging to the owner/operator,

- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must

- be suitably qualified

- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must be
kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:

- must be kept in a legible condition

- must not be damaged

- must not be removed

- must not be covered, pasted or painted over

I

General remarks

(continued)

- must not be removed

- must not be covered, pasted or painted over

It’s your safety that’s at stake!

Utilisation for
intended purpose
only

Ambient
conditions

The machine may only be used for jobs as defined by the “Intended
purpose”.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall
not be liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual

- complete reading and following of all the safety instructions and danger
warnings

- performing all stipulated inspection and servicing work.

The machine is designed to be used in industrial and workshop
environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.

Likewise Fronius will accept no liability for defective or faulty work results.

Operation or storage of the machine outside the stipulated range is deemed
to be “not in accordance with the intended use”. The manufacturer shall not
be liable for any damage resulting herefrom.

Obligations of
owner/operator

Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)

- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric 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 etc.

Elevation above sea level: Up to 2000 m (6500 ft)

The owner/operator undertakes to ensure that the only persons allowed to
work with the machine are persons who

- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine

- have read and understood the sections on “safety rules” and the “war­nings“ contained in this manual, and have confirmed as much with their
signatures

- be trained in such a way that meets with the requirements of the work
results

Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.

II

Obligations of
personnel

Before starting work, all persons to be entrusted with carrying out work with
(or on) the machine shall undertake

- to observe the basic regulations on workplace safety and accident
prevention

- to read the sections on “safety rules” and the “warnings” contained in this
manual, and to sign to confirm that they have understood these and will
comply with them.

Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.

EN

Protection for
yourself and
other persons

When working with this machine, you are exposed to many different hazards
such as:

- irritation and/or cauterization of skin in case of contact with cleaning
agent (cleaning electrolyte, brightening electrolyte, electrolyte powder and
printing electrolyte)

- danger of serious eye injury in case of contact with cleaning agent

- general hazards when handling chemicals

- electrical hazards from mains and cleaning current

- harmful vapours

Anybody working on the workpiece during cleaning must wear suitable
protective clothing with the following characteristics:

- resistant against acids and chemicals

- isolating and dry

- must cover whole body, be undamaged and in good condition

“Protective clothing” also includes:

- wearing a pair of appropriate regulation goggles (with sideguards)

- wearing stout footwear that will also insulate even in wet conditions

- wearing protective gloves (hand protection), impermeable, resistant
against acids and chemicals

- wearing protective apron (e.g. when refilling chemicals)

Immediately remove any working garment contaminated with cleaning agent!

III

Protection for
yourself and
other persons

(continued)

- Don’t eat and drink during working

- Keep cleaning agent away from food, drink and fodder

- Wash your hands before breaks and at the end of a working day

Keep other people - especially children, pregnant women and sick persons ­well away from the equipment and the working operation while this is in
progress. If there are still any other persons nearby during workinging, you
must

- draw their attention to all the dangers

- provide them with suitable protective equipment and/or

- erect suitable protective partitions or curtains.

Instructions for
the correct
handling of
cleaning agents

The following aspects must be observed when handling cleaning agents
(cleaning electrolyte, brightening electrolyte, electrolyte powder and printing
electrolyte). For more detailed data please refer to the relevant safety data
sheets. You will find the current safety data sheets on the Fronius-Homepage
under http://www.fronius.com.

First-aid measures

- After inhaling of vapours provide for supply of fresh air. In case of comp­laint see a doctor.

- After contact with skin wash with water and soap and rinse carefully. In
case of continued irritation of skin see a doctor.

- After swallowing do not cause vomiting. Rinse mouth and drink a lot of
water, see a doctor immediately.

- After contact with eyes rinse eyes several minutes under running water
with eyelid open (eye shower) and see a doctor.

Storage / safekeeping

- Use only containers especially approved for cleaning agents

- Keep container closed tightly

- Don’t store together with alkali (lyes) and metals

- Store in a cool and dry place

- Provide for acid-proof floor

- Keep under lock and key and without the reach of children

Other instructions

- Don’t heat to avoid thermal decomposition (development of toxic gases)

- Provide for emergency cooling in case of fire close by

- Avoid contact with eyes, skin and mucous membranes

- Use only in well ventilated areas. In case of insufficient ventilation use
respiratory protection

- For diluting always put acid into water - not the other way round!

- Dispose of cleaning agents and/or uncleaned packagings as provided by
national regulations. Don’t dispose together with domestic waste!

- Don’t let agent get into drain system, into waters or the ground water
(e.g. via the ground).

IV

Hazards from
mains and clea­ning current

An electric shock can be fatal. Every electric shock is hazardous to life.

Do not touch any live parts, either inside or outside the machine.

Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/frame
potential. The base or cover must completely cover the entire area between
your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.

Do not loop any cables or other leads around your body or any part of your
body.

Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor and
plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.

EN

EMC precautions

Wherever necessary, use suitable measures to ensure that the workpiece is
sufficiently grounded (earthed).

Switch off any appliances that are not in use.

Before doing any work on the machine, switch it off and unplug it from the
mains.

Put up a clearly legible and easy-to-understand warning sign to stop anybody
inadvertently plugging the machine back into the mains and switching it back
on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge

- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second
person on hand to immediately switch off the machine at the main switch in
an emergency.

It is the responsibility of the owner/operator to ensure that no
electromagnetic interference is caused to electrical and electronic
equipment.

If electromagnetic interference is found to be occurring, the owner/operator is
obliged to take all necessary measures to prevent this interference.

Examine and evaluate any possible electromagnetic problems that may
occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:

- safety features

V

EMC precautions

(continued)

- mains, signal and data-transmission leads

- IT and telecoms equipment

- measurement and calibration devices

- the health of persons in the vicinity, e.g. users of heart pacemakers and hearing aids

- users of heart pacemakers must take medical advice before going anywhere near
welding equipment or welding workplaces

Electromagnetic fields may cause as yet unknown damage to health.

Ancillary measures for preventing EMC problems:

a) Mains supply

- If electromagnetic interference still occurs, despite the fact that the mains connection
is in accordance with the regulations, take additional measures (e.g. use a suitable
mains filter).

b) Power supply lines

- Keep these as short as possible

- Arrange them so that they run close together

- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable capacitors.

Particular danger
spots

e) Shielding, where necessary

- Shield other equipment in the vicinity

- Shield the entire welding installation.

Covers and sideguards may only be opened or removed for as long as is
absolutely necessary to carry out maintenance and repair work.

While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are
properly mounted ...

- ... and that all covers and sideguards are kept closed.

Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.

Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.

If a machine is fitted with a carrying strap or carrying handle, remember that
this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.

Measurement of pollutant emissions while working with the device revealed
values below the admissible mean toxic limit.
Nevertheless:

- Provide for sufficient supply of fresh air.

- Keep head away from generated vapours.

- Don’t inhale generated vapours and/or exhaust them from working area
by appropriate means.

VI

Safety precauti­ons at the instal­lation site and
when being
transported

A machine that topples over can easily kill someone! For this reason, always
place the machine on an even, firm floor in such a way that it stands firmly.

- An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion.
Observe all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m
(1.6 ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportation
and carriage.

Before transportation, completely drain any cleaning agent.

Before commissioning and after transportation, a visual check for damage
must be carried out. Any damage must be repaired by Fronius-trained ser­vice personnel before commissioning.

EN

Safety precau­tions in normal
operation

Only operate the machine if all of its protective features are fully functional. If
any of the protective features are not fully functional, this endangers:

- the life and well-being of the operator or other persons

- the equipment and other tangible assets belonging to the owner/operator

- efficient working with the equipment.

Any safety features that are not fully functional must be put right before you
switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by
your doing so.

- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.

- Only Fronius cleaning agent is suitable for use in our machines.

- Do not mix Fronius cleaning agent with other cleaning agents.

- If any damage occurs in cases where other cleaning agents have been
used, the manufacturer shall not be liable for any such damage, and all
warranty claims shall be null and void.

- Only transport the cleaning agent in closed original containers.

VII

Preventive and
corrective main­tenance

With parts sourced from other suppliers, there is no certainty that these parts
will have been designed and manufactured to cope with the stressing and
safety requirements that will be made of them. Use only original spares and
wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine
without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.

The device, the sideguards and the mechanical components may be earthed
only by means of „Extrude-Tite“ screws.

Safety inspection

Safety markings

The owner/operator is obliged to have a safety inspection performed on the
machine at least once every 12 months.

A safety inspection, by a trained and certified electrician, is prescribed:

- after any alterations

- after any modifications or installations of additional components

- following repairs, care and maintenance

- at least every twelve months.

Observe the relevant national and international standards and directives in
connection with the safety inspection.

More detailed information on safety inspections and calibration is available
from your regional or national Fronius service centre, who will be pleased to
provide you with copies of the necessary documents upon request.

Equipment with CE-markings fulfils the basic requirements of the Low­Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974).

Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.

Copyright

Copyright to this instruction manual remains the property of Fronius Interna­tional GmbH.

The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the
instruction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.

VIII

Table of contents

General Remarks .......................................................................................................................................... 2

Design concept ........................................................................................................................................ 2

Functional sequence................................................................................................................................ 2

Utilization for intended purpose only ....................................................................................................... 3

Setting-up instructions ............................................................................................................................. 3

Transport Requirements .......................................................................................................................... 3

Options..................................................................................................................................................... 3

Mains connection .......................................................................................................................................... 4

MagicCleaner ........................................................................................................................................... 4

MagicCleaner 110 V ................................................................................................................................ 4

Technical data ............................................................................................................................................... 5

MagicCleaner ........................................................................................................................................... 5

MagicCleaner 110 V ................................................................................................................................ 5

Controls, connections and mechanical components .................................................................................... 6

Controls.................................................................................................................................................... 6

Connections and mechanical components .............................................................................................. 7

Operating modes .......................................................................................................................................... 9

Manual cleaning ....................................................................................................................................... 9

Auto cleaning ........................................................................................................................................... 9

Polishing / burnishing............................................................................................................................... 9

Printing ..................................................................................................................................................... 9

EN

Cleaning , polishing / burnishing ................................................................................................................. 10

Preparation ............................................................................................................................................ 10

Fitting a new cleaning cloth on the cleaning electrode ..........................................................................10

Start-up .................................................................................................................................................. 10

Cleaning procedure ................................................................................................................................11

Removal of electrolyte and heavy metal residues ..................................................................................11

Printing, if MagicCleaner is exclusively used for printing............................................................................ 12

Imprinting film for short-term use ........................................................................................................... 12

Preparation ............................................................................................................................................ 12

Mount the printing felt on the cleaning electrode ................................................................................... 12

Start-up .................................................................................................................................................. 13

Printing procedure ................................................................................................................................. 13

Printing, if MagicCleaner is used for cleaning, polishing/burnishing and for printing ................................. 14

Imprinting film for short-term use ........................................................................................................... 14

Preparation ............................................................................................................................................ 14

Mount the printing felt on the cleaning electrode ................................................................................... 14

Start-up .................................................................................................................................................. 15

Printing procedure ................................................................................................................................. 15

Care, maintenance and disposal ................................................................................................................ 16

Every start-up......................................................................................................................................... 16

Weekly ................................................................................................................................................... 16

Every 6 months ...................................................................................................................................... 16

Disposal ................................................................................................................................................. 16

Replacing the cleaning electrode ............................................................................................................... 17

Safety ..................................................................................................................................................... 17

Preparations........................................................................................................................................... 17

Removing the cleaning electrode .......................................................................................................... 17

Fitting the cleaning electrode ................................................................................................................. 18

Spare parts list

Fronius Worldwide

1

General Remarks

General Remarks

Design concept

The MagicCleaner CrNi cleaning unit
opens up brand-new dimensions in weld
finishing. With the aid of processor­controlled current curves and a specially
formulated electrolyte, the unit achieves
cleaning results of unparalleled quality.
The unit’s automatic, exactly controllable
electrolyte-dispensing system guarantees
a high level of safety and ease of hand­ling. Thanks to its unique cleaning quali­ties, its area of use ranges from craft and
trade workshops all the way up to the
food-processing and chemical industries.

Fig.1 MagicCleaner „Stand alone“

The unit’s powder-coated sheet-steel housing, shielded controls (in a recess protected
by a plastic surround) and its bayonet-latching earth socket are all features designed to
prolong its service life. Its shoulder strap makes it easy to carry around, both indoors in
the workshop and outdoors on site-erection jobs.

Functional
sequence

MICROPROCESSOR

Process control - Fault monitoring

L1

N

Fig. 1 Block diagram of “Stand alone” MagicCleaner

Switched-mode

power supply

Controller for

cleaning current

Inverter

Controller for

electrolyte flow

Fault

indicator

Pump

The mains voltage is regulated to operating voltage via an isolated switched-mode
power supply and the adjusted operating current. via a A series-connected inverter
transforms the DC voltage into a 50 Hz square-wave voltage and supplies this to the
output. Electronic controllers adjust the cleaning current and electrolyte dispensing rate
to suit the intended utilisation. The cleaning process as a whole is controlled and
monitored by a microprocessor.

2

Utilization for
intended purpose
only

The MagicCleaner is exclusively designed for the electro-chemical cleaning of high­alloy steels.
Utilisation for any other purpose, or in any other manner, shall be deemed to be "not in
accordance with the intended purpose". The manufacturer shall not be liable for any
damage resulting from such improper use.

Setting-up in­structions

Transport Re­quirements

Utilisation in accordance with the “intended purpose” also comprises

- the instructions given in this manual

- performing all stipulated inspection and servicing work.

Open-air operation

In view of the unit’s IP 23 protection rating, it is suitable for outdoor placement and
operation. However, the built-in electrical components must be protected from direct
wetting such as that caused by external wet-cleaning.

Ambient temperature
Important! The temperatures for employment and storage must not fall below the

following values:

- without electrolyte -25°C

- with electrolyte -10°C

The cleaning unit must be positioned well away from such sour-ces of heat as radiators,
heating or annealing furnaces, direct hot sunshine etc., which would raise its tempera­ture still further.

NOTE! Before being transported the reservoir must be emptied completely!
Otherwise the MagicCleaner would have to be packed and marked as hazar­dous material.

EN

Options MagicCleaner suction device

Fully automatic, portable unit for exhausting the fumes generated by the electro-chemi­cal cleaning process.

Carbon electrode

The high-strength graphite composite cleaning electrode allows to speed up the clea­ning process by 20 - 30 %, depending on the type of metal used.

3

Mains connection

MagicCleaner

MagicCleaner
110 V

The “Stand alone” MagicCleaner may be operated as standard on a mains voltage of
230V. Yellow-green lead = protective earth conductor (PE). The other conductors L1 and
N are connected to the phase and neutral conductors of the mains plug.

Important! Electrical work, fitting or changing the power plug, may only be carried out
by a qualified electrician!

The “Stand alone” MagicCleaner 110 V may be operated as standard on a mains
voltage of 100 - 110 V. Yellow-green lead = protective earth conductor (PE). The other
conductors L1 and N are connected to the phase and neutral conductors of the mains
plug.

4

Technical data

MagicCleaner

MagicCleaner
110 V

Unit suitable for use in confined spaces

Mains voltage -15%/+10% ~230 V / 50-60 Hz

Mains fuse 10 A

Apparent power 490 VA

Output current 5 - 20 A

Output voltage 2 - 12 V

Output power 200 W

Open-circuit voltage 17 V

Dispensing rate 0.55 - 2.2 l/h

Cleaning agent capacity 1.5 l

Degree of protection IP 23

Dimension l/b/h 430/180/280 mm

Weight 5 kg

Pollutant emission during operation phosphoric acid (H3PO4) < 0.2 mg/m³
(measured acc. to VDI 2462, part 8) sulphuric acid (H2SO4) < 0.6 mg/m³

Unit suitable for use in confined spaces

Mains voltage -6%/+6% ~100-110 V / 50-60 Hz

Mains fuse 10 A

Apparent power 490 VA

Output current 5 - 20 A

Output voltage 2 - 12 V

Output power 200 W

Open-circuit voltage 17 V

Dispensing rate 0.55 - 2.2 l/h

Cleaning agent capacity 1.5 l

Degree of protection IP 23

Dimension l/b/h 430/180/280 mm

Weight 8,4 kg

Pollutant emission during operation phosphoric acid (H3PO4) < 0.2 mg/m³
(measured acc. to VDI 2462, part 8) sulphuric acid (H2SO4) < 0.6 mg/m³

EN

5

Controls, connections and mechanical components

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and
completely understood all of the following documents:

- these Operating Instructions

- all “Operating Instructions” for the system components, especially the
“Safety rules”

General remarks

Controls

(1)

(5)(4)(3)(2)

(10) (9) (8) (7) (6)

Fig.4 Controls

(1) Cleaning-current dial

- Continuous adjustment of cleaning current from 5-20 A

(2) Program switch

- for switching the MagicCleaner from stand-by to the desired operating mode.

(3) LED indicator “Auto-Cleaning“ mode

- lights up when the “Auto-Cleaning“ mode is selected

(4) LED indicator “Manual-Cleaning“ mode

- lights up when the “Manual-Cleaning“ mode is selected

6

Controls

(continued)

(5) Dial for electrolyte dispensing rate

- Continuous adjustment of electrolyte dispensing rate from 0.55 - 2.2 l/h

(6) “Elektrolyte dispensing” LED

- lights up when the pump is in operation

Connections and
mechanical
components

(7) LED “Fault” indicator

- lights up if the unit is overloaded (if the temperature of the power section rea­ches 65°C).

- flashes if short-circuiting occurs between the stylus and earth (e.g. cleaning
cloth is defective)

(8) “Stand-by” LED

- lights up when the MagicCleaner is connected to the mains

(9) LED indicator “Printing“ mode

- lights up when the “Printing“ mode is selected

(10) LED indicator “Polishing / Burnishing“ mode

- lights up when the “Polishing / Burnishing“ mode is selected

(11) Handle with cleaning electrode and

cleaning cloth

for creating the electrical and electro­lytic connection between the Magic­Cleaner and the workpiece

(12) Bayonet-latching earth socket

for connecting the earth cable

EN

(12)(11)

Fig. 5 View from front, with cleaning handle

7

Connections and
mechanical
components

(continued)

(13) Storage compartment

for storing the accessories supplied
with the unit.

These include:

- 1 pc. safety goggles

- 1 pair of protection gloves

- 10 pcs. spare cleaning cloths

- 1 case of Fronius electrolyte
powder

- 1 pc. mixing container 1 l

CAUTION! Danger of injury
because of acid and/or acid
residues. Don’t keep cleaning
liquids, contaminated gloves and
used cleaning rags in the storage
compartment.
Store mixing container in the
storage compartment only when
cleaned!

(13)

Fig. 6 Rear view, showing accessories

8

Operating modes

Manual cleaning “Manual Cleaning” mode serves for removing tarnish discoloration

The Electrolyte is dispensed when the button is pushed on the cleaning handle (polis­hing not possible)

Current curve: AC

EN

Auto cleaning

Polishing / bur­nishing

Printing

“Auto-Cleaning” mode serves for removing tarnish discoloration
The electrolyte is automatically dispensed during cleaning. Adjustement of the desired
dispensing rate with dial for electrolyte dispensing rate (5). No need to push the
button! (Polishing not possible)

Current curve: AC

“Polishing / Burnishing“ mode serves for polishing (burnishing) the workpiece after
cleaning
The electrolyte is dispensed when the button is pushed on the cleaning handle

Current curve: DC

“Printing” mode serves for electrochemical printing of CrNi parts (e.g. graphics or
company logos).

Current curve: AC

9

Cleaning , polishing / burnishing

WARNING! O perating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and
completely understood all of the following documents:

- these Operating Instructions

- all “Operating Instructions” for the system components, especially the
“Safety rules”

- the safey data sheet for the cleaning and brightening electrolyte as well as
for Fronius electrolyte powder

General remarks

Preparation

1. Take safety precautions: Put on safety goggles, gloves and protective clothing

2. Switch off the MagicCleaner and disconnect it from the mains supply

3. Undo the screw-cap of the reservoir

4. Only for use of Fronius electrolyte powder: prepare electrolyte powder as cleaning
electrolyte
a) Fill 1/2 l of clear water into the mixing container included in the scope of supply
b) Add complete contents of the case containing Fronius electrolyte powder slowly

to water
c) Close mixing container tightly.
d) Shake mixing container with water and Fronius electrolyte powder for approx. 1

min.
e) Open mixing container and pour in the remaining 1/2 l of water
f) Again close mixing container tightly
g) Shake mixing container for another 1 min (until Fronius electrolyte powder is

completely dissolved).

5. Fill the reservoir with cleaning or polishing electrolyte up to just under the filler
neck. Clean mixing container for preparation of Fronius electrolyte powder, if
necessary.

Important! Use only original Fronius cleaning or polishing electrolyte!

6. Replace the screw-cap of the reservoir tightly

7. Make an earth connection between the MagicCleaner and the workpiece

Fitting a new
cleaning cloth on
the cleaning
electrode

Start-up

1. Using your index finger and thumb, pull the clamping plate towards the cleaning
handle and turn it 90°

2. Using your thumb, lift the clamping plate on each side at a time and clamp the
cleaning cloth in place

3. Turn the clamping plate back 90°

CAUTION! Danger of damage to workpiece and cleaning electrode because of
current flow. As soon as the mains cable of the MagicCleaner is connected to
the mains, cleaning current may be flowing, if the program switch is positioned
accordingly.
Deposit handle on insulated surface!

1. Connect up the MagicCleaner to the mains

2. Select the desired operating mode with the program switch (2)

3. Select the cleaning current on dial (1) and the electrolyte dispensing rate on dial (5).

10

Cleaning proce­dure

Fig.7 Wet thecleaning cloth with electrolyte

Manual cleaning
Auto-cleaning

1. Push the button on the handle to wet
sufficiently the stretched cleaning
cloth with electrolyte

The first time after the reservoir has
been (re)filled, it takes the electrolyte
approx. 30 sec to be pumped from
the reservoir to the handle

2. Applying gentle pressure, move the
cleaning electrode back and forward
along the tarnished weld and conti­nuously moisten the cleaning cloth
with electrolyte

EN

Removal of
electrolyte and
heavy metal
residues

Fig.8 Cleaning procedure

NOTE: During the cleaning procedure do not dwell on the same spot for too
long, as due to the increasing thermal load wear of the cleaning cloth increa­ses significantly!
Also ensure that the cleaning cloth is always moistened with sufficient electro­lyte!

Electrochemical cleaning with the MagicCleaner leaves electrolyte and heavy metal
residues on the workpiece surface. Such residues may cause deposits on the workpi­ece and affect corrosion resistance!

1. Soak a clean sponge in clean water.

2. Wipe the electrochemically treated surfaces with the wet sponge.

3. Rinse the sponge.

4. Repeat several times.

NOTE! During electrochemical cleaning ensure that no cleaning electrolyte
enters into the workpiece cavities. In most cases complete removal of electro­lyte residue from cavities can only be achieved with great difficulty.

11

Printing, if MagicCleaner is exclusively used for prin-

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and
completely understood all of the following documents:

- these Operating Instructions

- all “Operating Instructions” for the system components, especially the
“Safety rules”

- the safety data sheet for the printing electrolyte.

ting

General remarks

For this application, we recommend using the “Printing set (4,100,212 - not included in
MagicCleaner scope of supply). This set consists of:

- Printing electrolyte 0.5l

- 1 x printing film for doing your own printing

- 10 x printing felts

- 1 x plastic canister

- 1 x plastic case

Imprinting film
for short-term
use

Preparation

Use a dot matrix printer or a mechanical typewriter for imprinting the film for short-term
use.

1. Fix the film to a paper sheet size A4 with adhesive tape

2. Insert paper into printer in a way that the colored film is printed

3. Print text or graphics on the film

4. Remove colored printing film

The printing film can be used for abt 10 printings.

1. Switch off the MagicCleaner disconnect it from the mains

2. Undo the screw-cap of the reservoir

Important! Before pouring the printing electrolyte into the reservoir, this must first be
emptied completely! Also, the hosepack and reservoir must be rinsed with clean water!

3. Fill the reservoir with printing electrolyte, up to just under the filler neck

4. Replace the screw-cap of the reservoir tightly

5. Make an earth connection between the MagicCleaner and the workpiece

Mount the prin­ting felt on the

cleaning electro­de

1. Using your index finger and thumb, pull the clamping plate towards the cleaning
handle and turn it 90°

2. Using your thumb, lift the clamping plate on each side at a time and clamp the
printing-felt in place

3. Turn the clamping plate back 90°

12

Start-up

CAUTION! Danger of damage to workpiece and cleaning electrode because of

current flow. As soon as the mains cable of the MagicCleaner is connected to
the mains, cleaning current may be flowing, if the program switch is positioned
accordingly.
Deposit handle on insulated surface!

Printing procedu­re

1. Connect up the MagicCleaner to the mains

2. Select the Printing mode with the program switch (2)

3. Select the cleaning current on dial (1) and set the electrolyte dispensing rate to
maximum on dial (5)

4. Fix the printing film to the workpiece with adhesive tape

1. Push the button on the handle to ensure that the printing felt is sufficiently wetted
with electrolyte.

The first time after the reservoir has been (re)filled, it takes the electrolyte approx.
30 sec to be pumped from the reservoir to the handle

2. Applying gentle pressure, slowly move the cleaning electrode across the film, 1 - 3
times

Important! When you have finished printing, rinse the printing film thoroughly in water
(if the printing electrolyte dries onto the film, this may lead to poor-quality printing
results)!

NOTE! If the cleaning electrode touches the workpiece off the edge of the film,
this causes black marks on the workpiece!

EN

13

Printing, if MagicCleaner is used for cleaning,

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and
completely understood all of the following documents:

- these Operating Instructions

- all “Operating Instructions” for the system components, especially the
“Safety rules”

- the safety data sheet for the cleaning and brightening electrolyte, Fronius
electrolyte powder and the printing electrolyte

polishing/burnishing and for printing

General remarks

For this application, we recommend using the “Printing set (4,100,212 - not included in
MagicCleaner scope of supply). This set consists of:

- Printing electrolyte 0.5l

- 1 x printing film for doing your own printing

- 10 x printing felts

- 1 x plasic canister

- 1 x plastic case

Imprinting film
for short-term
use

Preparation

Mount the prin­ting felt on the
cleaning electro­de

Use a dot matrix printer or a mechanical typewriter for imprinting the film for short-term
use.

1. Fix the film to a paper sheet size A4 with adhesive tape

2. Insert paper into printer in a way that the colored film is printed

3. Print text or graphics on the film

4. Remove colored printing film

The printing film can be used for abt 10 printings.

1. Switch off the MagicCleaner and disconnect it from the mains

2. Pour the printing electrolyte into a plastic canister

3. Remove the cleaning cloth from the cleaning electrode and rinse the electrode well
with water

4. Make an earth connection between the MagicCleaner and the workpiece

1. Using your index finger and thumb, pull the clamping plate towards the cleaning
handle and turn it 90°

2. Using your thumb, lift the clamping plate on each side at a time and clamp the
printing-felt in place

3. Turn the clamping plate back 90°

14

Start-up

CAUTION! Danger of damage to workpiece and cleaning electrode because of

current flow. As soon as the mains cable of the MagicCleaner is connected to
the mains, cleaning current may be flowing, if the program switch is positioned
accordingly.
Deposit handle on insulated surface!

Printing procedu­re

1. Connect up the MagicCleaner to the mains

2. Select the “Printing“ mode with the program switch (2)

3. Set the cleaning current to maximum on dial (1) and the electrolyte dispensing rate
to minimum on dial (5)

4. Fix the printing film to the workpiece with adhesive plastic tape

1. Dip the cleaning electrode, with the mounted printing felt, into the printing electroly­te until the felt is well wetted.

2. Applying gentle pressure, slowly move the cleaning electrode across the film, 1 - 3
times

Important! When you have finished printing, rinse the printing film thoroughly in water
(if the printing electrolyte dries onto the film, this may lead to poor-quality printing
results)!

NOTE! If the cleaning electrode touches the workpiece off the edge of the film,
this causes black marks on the workpiece!

EN

15

WARNING! An electric shock can be fatal. Before opening up the machine:

- shift the mains switch into the "O" position

- unplug the machine from the mains

- put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again

- using a suitable measuring instrument, check to make sure that electrical­ly charged components (e.g. capacitors) have been discharged

Care, maintenance and disposal

General remarks

Every start-up

Under normal operating conditions the MagicCleaner requires only a minimum of care
and maintenance. However, it is indispensable to follow some important points to
ensure the operationality of the machine for many years.

- Check mains cable and interconnecting cable for damage

- Check container and pump for leakage

- Check whether the allround distance of 0.5 m (1ft. 8in.) is kept to ensure that the
cooling air can easily flow and escape.

NOTE! Furthermore, air inlets and outlets must in no case be covered, not
even covered partly.

Weekly

Every 6 months

Disposal

Clean device by means of solvent-free products.

- Dismantle machine side panels and clean machine inside with dry reduced com­pressed air

NOTE! Risk of damage to electronic components. Clean electronic compon­ents from a certain distance only.

- If a lot of dust has accumulated, clean the cooling-air ducts.

Carry out disposal in accordance with the valid national and local regulations.

16

Replacing the cleaning electrode

Safety

CAUTION! Risk of damage to the handle and cleaning electrode due to impro-

per replacement of the cleaning electrode.
No tools are required when replacing the cleaning electrode.
Tighten the cleaning electrode by hand only when screwing it onto the handle!

Preparations 1. Switch off MagicCleaner and disconnect it from the mains

2. Remove cleaning cloth from the cleaning electrode

Removing the
cleaning electro­de

2

1. Undo the fixing nut (2)

2. Unscrew the fixing nut (2) and clea­ning electrode (3) from the handle (1)

(3)

1

(2)

EN

(1)

Fig. 8 Undoing the fixing nut

4

(3)

3

(2)

Fig. 9 Unscrewing the cleaning electrode

3. Unscrew the cleaning electrode (3)
from the fixing nut (2)

17

Fitting the clea­ning electrode

1

(1)

1

2

1

(2)

Fig. 10 Screwing the cleaning electrode into the

fixing nut

1. Screw the new cleaning electrode (1)
as far as it will go into the fixing nut
(2)

2. Now unscrew the cleaning electrode
(1) by about 1 turn

4

4

(1)

(2)

3

5

3

(3)

Fig. 11 Tightening the fixing nut (finger-tight)

Important! Do not tighten the fixing nut
yet when screwing it onto the handle, as
the cleaning electrode still needs to be
adjusted!

3. Screw the fixing nut (2) and cleaning
electrode (1) onto the handle (3)

4. Adjust the cleaning electrode (1)
according to the application

5. Tighten the fixing nut (2) on the
handle (3) (finger-tight only, do not
use a tool)

18

Ersatzteilliste

DEENFRITESPT-BRNLNOCSRUSKSVTR

Spare Parts List

Liste de pièces de rechange

Lista parti di ricambio

Lista de repuestos

Lista de peças sobresselentes

Onderdelenlijst

Reservdelsliste

Seznam náhradních dílů

Список запасных частей

Zoznam náhradných dielov

Reservdelslistan

ud_fr_st_tb_00150 012014

Parça Listesi

Wykaz czesci zamiennych

PL

MagicCleaner Stand Alone 4,075,092
MagicCleaner Stand Alone Japanese 4,075,092,360
MagicCleaner Stand Alone 100-115/230V 4,075,092,361

42,0406,0295

45,0200,0943

42,0411,8015 - RED 1L
42,0411,8052 - RED 3L
42,0411,8018 - BLUE 1L

33,0030,0054

43,0006,0161

42,0100,0416

32,0300,2243

42,0407,0445

40,0001,0009

32,0300,7004

42,0411,8041

42,0411,8045

42,0407,0357

BE2,0200,9111

12,0405,0184

42,0411,8014

44,0450,0901

44,0550,0117

43,0004,0519

43,0004,1750

42,0300,0648

BE2,0200,9176

43,0001,3233

42,0406,0252

42,0406,0322

42,0406,0217

41,0009,0060

43,0001,0947 - MC LT3

43,0004,0533

12,0405,0184

BE2,0200,9109

43,0003,0040

MagicCleaner

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

el_fr_st_cn_00073 012006

1/1

6

2-3

451

POS. BENENNUNG ARTICLE DENOMINATION

1 PRINTFILZ FÜR MAGIC CLEANER PRINT- FELT FOR MAGIC CLEANER IMPRIMER FEUTRE POUR MAGIC CL. 42.0300.7030
2 ELEKTROLYT PRINTEN 0,5 L ELECTROLYTE PRINT 0,5L ELECTROLYTE DE IMPRIMER 0,5L 42.0411.8021
3 ELEKTROLYT PRINTEN 1,0 L ELECTROLYTE PRINT 1,0L ELECTROLYTE DE IMPRIMER 1,0L 42.0411.8022
4 PRINTFOLIE EINWEG 65X195 MM PRINT FOIL 65X195 MM IMPRIMER FEUILLE MET. 65X195 M 42.0411.8023
5 KUNSTSTOFFDOSE F.MAGIC-CLEANER PLASTIC-BOX F.MAGIC CLEANER PLASTIQUE-BAC MAGIC GLEANER 42.0411.8012

6 ERSATZTEILBOX M.SCHAUMSTOFF SPARE PART BOX WITH INLET BOITE CONSOMMABLES 42.0409.2638

PRINT - SET 1 MAGIC CLEANER 4,100,212

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

el_fr_st_cn_00175 012000

1/1

Hose pack Magic Cleaner

4,045,818

43,0002,0360

42,0300,7102

42,0401,0879

34,0350,2095

44,0001,1313

42,0100,0420

42,0001,2886

42,0402,0094

42,0402,0157

40,0001,0412

- specify length

old version

44,0001,1176 44,0450,1922

42,0001,2886

42,0402,0094

42,0400,1002

40,0001,0034

40,0001,0314

42,0402,0134

- specify length

- specify length

44,0350,1834

42,0407,0457

42,0404,0308

42,0201,0007

42,0001,5602

42,0411,8040

44,0450,1923

44,0450,1924

42,0435,0212

42,0435,0192

42,0407,0457

42,0404,0308

42,0201,0007

44,0450,1019

32,0405,0203

42,0411,8007

42,0411,8014

42,0407,0457

42,0404,0308

42,0201,0007

40,0001,0072
specify length

43,0004,1753

43,0004,1704
specify length

43,0004,2522
specify length

Hose pack

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

el_fr_st_vp_00109 012017

1/1

FRONIUS INTERNATIONAL GMBH

Froniusplatz 1, A-4600 Wels, Austria

Tel: [phone], Fax: [phone]

E-Mail: [e-mail]

www.fronius.com

Under http://www.fronius.com/addresses you will find all addresses

www.fronius.com/addresses

of our Sales & service partners and Locations.

ud_fr_st_so_00082 012011