FRO­NIUS MagicCleaner 150 User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
MagicCleaner 150
EN-US
Operating instructions
42,0426,0395,EA 002-17012022

Table of contents
Safety Instructions 5
Explanation of Safety Instructions 5
General 5
Intended use 5
Environmental conditions 6
Obligations of the Operating Company 6
Obligations of Personnel 6
Personal protection and protection of others 6
Notes on the correct handling of the cleaning and Print electrolytes 7
Risks from grid current and cleaning current 8
EMC measures 9
Particular hazard areas 10
Safety measures at the setup location and during transport 10
Safety measures in normal operation 10
Commissioning, maintenance and repair 11
Safety inspection 11
Safety Symbols 11
Copyright 11
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 18
Operating controls and connections 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 cleaning felt by means of torch holder - 22 mm / 0.87 inch cleaning electrode 26
Mounting cleaning felt by means of torch holder - 10 mm / 0.39 inch cleaning electrode 27
Mounting cleaning felt by means of O-ring - 35 mm / 1.38 inch cleaning electrode 28
Mounting the cleaning brush 29
Mounting the cleaning brush 29
Readjusting the cleaning brush 30
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
General 38
Placing the cleaning torch in the cleaning torch holder 38
Polishing 39
After polishing 40
Printing 42
General 42
Mounting the Print electrode and Print felt 43
3
EN-US

Preparing the workstation for Printing 44
Printing 45
After the Print process 46
Service, maintenance and disposal 49
General 49
At every start-up 49
At the end of each shift 49
Disposal 49
Technical data 51
MagicCleaner 150 /EF 150 /CN 150 /np 51
MagicCleaner 150 MV/B 150 MV/np 52
4

Safety Instructions
Explanation of
Safety Instruc-
tions
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
EN-US

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
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.)
Obligations of the
Operating Com-
pany
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
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following before begin-
ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and con-
firm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can oc-
cur in one's absence.
Personal protec-
tion and protec-
tion of others
You are exposed to numerous hazards while working with the device, for example:
6

- Irritation or burning of the skin due to contact with cleaning electrolyte or Print elec-
trolyte
- Danger of serious eye damage due to contact with cleaning electrolyte or Print elec-
trolyte
- 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
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 cor-
rect 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
EN-US

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 reg-
ulations. Do not dispose of with household waste!
- Do not allow to enter drains, watercourses or groundwater (e.g., via the soil)
Risks from grid
current and
cleaning current
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 dimen-
sioned. Replace loose connections and scorched, damaged, or inadequately dimen-
sioned 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 neces-
sary.
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.
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
EN-US

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 loca-
tion 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 work-
place 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 ser-
vice technicians before commissioning the device.
Safety measures
in normal opera-
tion
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.
10

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.
Commissioning,
maintenance and
repair
It is impossible to guarantee that externally procured parts are designed and manufac-
tured 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.
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 elec-
tromagnetic 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 stand-
ards 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 im-
provement, or can point out any mistakes that you have found in the Operating Instruc-
tions, we will be most grateful for your comments.
11
EN-US

General information
Device concept
MagicCleaner 150
The MagicCleaner 150 is a device for the
electrochemical surface treatment of stain-
less 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)
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 electro-
lytes,
- Carrying out all the specified inspection and maintenance work.
12

Scope of supply
*
(1)
(2)
(3)
(4) (5)
(6) (7) (10)(8) (9)
(11) (12)
(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
10 mm / 0.39 inch
(8) 3 x cleaning felt
10 mm / 0.39 inch
(9) Cleaning electrode
22 mm / 0.87 inch
(10) 3 x cleaning felt
22 mm / 0.87 inch
(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
13
EN-US

Options
(1) (2)
(3) (4)
(5)
(7) (8)
(9)
(6) (13)
(12)
(11)
(10) (14)
(15)
+
red
blue
(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
15
EN-US

(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
(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)
Transport inform-
ation
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
16

Setup regulations Operation outdoors
The device can be installed and operated outdoors in accordance with its degree of pro-
tection IP 23. However, the installed electrical parts must be protected from direct expos-
ure 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.
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.
Model No.
Part No.
Ser. No.
FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Phone: [phone]
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%
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
17
EN-US

Operating controls, connections and mechanical
components
Safety WARNING!
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
▶Do not use the functions described here until you have fully read and understood the
Operating Instructions.
▶Do not use the functions described here until you have fully read and understood all
of the Operating Instructions of the system components, especially the safety rules.
Operating con-
trols and connec-
tions
(1) (2) (3) (4)
Control panel
(5) (6) (7) (8)
-+
Front/back
(1) Controller cleaning power
1 ... low cleaning power
2 ... medium cleaning power
3 ... high cleaning power
The cleaning power can only be set on the cleaning power controller if the oper-
ating mode controller is set to the AC or DC position.
(2) LED overtemperature
Lights up if the device overheats;
Operation is interrupted and can only be continued after the device has cooled
down
(3) Power LED
Lights up when the mains supply is on and when the device is switched on
18

(4) Controller operating mode
AC ... CLEAN - for cleaning welds
DC ... POLISH - for polishing welds
I ... BRUSH - to use the cleaning brush
(for example with narrow or difficult to access components)
• ... PRINT - dark print
o ... PRINT - light print
(5) (-) Current socket
for connecting the cleaning torch cable
(6) (+) Current socket
For connecting the grounding cable
(7) Mains cable with strain relief
Depending on the version of the device
(8) Power switch
(15)
(14)
(13)
(12)
(11)
(10)
(9)
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 electro-
lyte (only at the cleaning torch)
(13) Fixing screw
(14) Cleaning electrode
or
Cleaning brush with adapter
Print electrode
(15) Cleaning felt
or
Print felt
19
EN-US

Safety Instructions for commissioning, operation,
and maintenance
Read and follow
the Safety In-
structions!
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 docu-
ment!
Safety Instruc-
tions for commis-
sioning, opera-
tion, and main-
tenance
WARNING!
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
▶Do not use the functions described here until you have fully read and understood the
Operating Instructions.
▶Do not use the functions described here until you have fully read and understood all
of the Operating Instructions for the system components, especially the safety rules
and the safety data sheets for the cleaning electrolyte.
WARNING!
Danger from electrical current!
This can result in serious personal injury and damage to property.
▶Before starting the installation work, switch off the device and disconnect it from the
grid.
▶Secure the device to prevent it from being switched back on again.
WARNING!
Danger due to harmful vapors!
When working with the device, vapors are produced which are severely harmful to the
human body and can cause respiratory problems, respiratory diseases, and further per-
sonal injury.
▶Do not breathe in vapors produced.
▶While working with the device, keep your head away from the working area and the
vapors produced
▶Use extraction and respiratory protection
20