REUTER MagicBox EP-01-160 Technical manual

Operation instruction MagicBox
Seite 1von 21
Operation instruction
MagicBox
EP-01-160
Automatic electrolyte supply
2022-01-25
Rev.4
REUTER GmbH & Co. KG
Schimmelbuschstr. 9e
40699 Erkrath
Tel.: [phone]
[email protected]s
www.reuter.works

Operation instruction MagicBox
Seite 2von 21
Contents
1 Introduction..............................................................................................3
2 Delivery....................................................................................................4
2.1 Opening the Euro plastic box..................................................................4
3 Getting ready to start...............................................................................4
3.1 Opening MagicBox..................................................................................4
4 Description of the control, operating and connection elements ..............5
4.1 Connection for hose package .................................................................5
4.1.1 Removing blind plug / electrolyte supply hose........................................5
4.1.2 Fasten the blind plug / electrolyte supply hose .......................................6
4.2 Monitoring electrolyte level......................................................................6
4.3 Manuel supply of electrolyte....................................................................6
4.4 Electrolyte pump......................................................................................7
5 Connect machine / accessories ..............................................................7
5.1 Cleaning machine....................................................................................7
5.2 AutoFeed.................................................................................................7
5.3 Electrolyte canister..................................................................................8
5.4 Autofeed hose package...........................................................................9
5.4.1 Change brush........................................................................................10
5.4.2 Adjusting the Teflon sleeve...................................................................11
5.4.3 Connection of earth clamp - workpiece.................................................11
5.4.4 Tip for setting up....................................................................................11
6 Working with the AutoFeed Brush.........................................................12
7 Service Work.........................................................................................13
7.1 Replace the electrolyte canister............................................................13
7.2 Fill the electrolyte canistern...................................................................14
7.3 Measures when the device is not used for a long period......................15
7.4 Change the connection hose with sieve and weight.............................16
8 Spar Parts .............................................................................................17
8.1 AutoFeed-Hose ...................................................................................17
8.1.1 Change/Renew the O-Rings .................................................................18
8.2 Pump housing .......................................................................................19
8.3 Pump housing lower part.......................................................................20
9 EC –Declaration of Conformity.............................................................21

Operation instruction MagicBox
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1 Introduction Thank you for choosing the "MagicBox" electrochemical high-current
brush weld cleaner made by REUTER GmbH & Co. KG.
The purpose of this manual is to provide you with information concerning
the safe handling and operation of the " MagicBox “ as well as general
information on cleaning and marking.
The user is given information concerning basic concepts and
applications, as well as practical advice and help in the selection of
settings, so that operating errors can be avoided.
Your specialist dealer will be happy to support and advise you with
regard to commissioning, applications or problems.
Our telephone hotline is always available with expert advice on +49 (0)
171-5450200.
Please read through these operating instructions carefully before
commissioning.
We hope you enjoy working with our appliances and wish you every
success.
Safety Notice
These operating instructions do not replace the detailed instructions for
the cleaning devices and only serve as a supplement..
Please refer to all safety instructions in the operating instructions of the
devices, e.g .:
•SuperCleanox
•Cleanox
•EasyCleanox
•AkkuCleanox

Operation instruction MagicBox
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2 Delivery
⚫The complete appliance set is delivered in a sturdy Euro
plastic box.
➢This box is secured with a lead seal in our factory
before shipment.
➢The lid can only be opened by destroying and
removing the lead seal.
➢In addition, the lid latches are secured on both
sides with cable ties to prevent accidental opening.
⚫Alternatively, the MagicBox can also be sent in a
cardboard box.
➢In this case, the box is not sealed.
2.1 Opening the Euro plastic box
⚫First cut through the lead seal with metal shears.
⚫Remove the lead seal carefully.
⚫Remove the cable ties on the right and left of the lid
latches.
⚫Unlock the lid latches
➢To do this, slide the lid latches to the left or the
right. Open the transport box.
⚫Check the delivery against the delivery note for
completeness.
⚫Report missing, damaged or undelivered goods
immediately.
Safety information
Cut the lead seal with the metal shears can cause sharp edges. Wear gloves
when removing the lead seal to avoid cuts!
3 Getting ready to start
3.1 Opening MagicBox
⚫Open the MagicBox
⚫Take the AutoFeed hose package out of the box
Hinweis The AutoFeed hose package and electrolyte
canister must be ordered separately.
These are not included in the delivery.

Operation instruction MagicBox
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⚫Flip the control housing outwards.
➢Pull the red and black cables until the control
housing is unfolded.
Hinweis Push the canister slightly backwards so that
the control housing can be flipped out within
enough space.
⚫The control case is flipped out.
4 Description of the control, operating and connection elements
4.1 Connection for hose package
Note
The straight plug connection locks the electrolyte supply hose automatically when
it is plugged in.
The hose coupling must be released before removing the electrolyte supply hose.
4.1.1 Removing blind plug / electrolyte supply hose
⚫To remove the blind plug / electrolyte supply hose, the
plug connection must be unlocked.
➢Press the release flange in the direction of the
coupling.
➢Press and hold the release flange.
➢Pull out the blind plug / electrolyte supply hose.
6
1
7
2
4
3
8
5
9
1 Button for manual supply of electrolyte
2 Warning indicator of electrolyte level
3 High current socket (red) for earth clamp
4 High current socket (black) for Autofeed
power cable
5 Connecting hub if electrolyte supply hose
(AutoFeed)
6 Ground connection of cleaning machine
7 Power connection of cleaning machine
8 Pump
9 On/off LED indicator

Operation instruction MagicBox
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4.1.2 Fasten the blind plug / electrolyte supply hose
⚫Insert the blind plug / electrolyte supply hose in the plug
connection to the bottom.
⚫Check whether it is firmly seated by pulling it lightly.
4.2 Monitoring electrolyte level
The sensor for monitoring the electrolyte level is attached to the base
plate.
⚫When the level is low:
➢the level indicator turns on with a warning tone
Note
Replace the empty canister with a full one and pour
the rest into the new one.
4.3 Manuel supply of electrolyte
⚫Hold down the push button
➢The pump runs and supplies electrolyte
⚫Release the push button
➢The pump stops supplying electrolyte
Note
This function is only required to empty or fill the hose manually.
Supply only enough electrolyte until the brush is moistened!
Level sensor
Electrolyte level
Level sensor

Operation instruction MagicBox
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4.4 Electrolyte pump
⚫The electrolyte pump is driven by a stepper motor and
the control ensures an optimal amount of electrolyte on
the brush during a normal operation.
➢This works with a load-dependent control of the
pump.
⚫The operation of the pump can occur noises and slightly
jerky movements.
➢This is normal and indicates that the
load-dependent control of the stepper motor is
working.
5 Connect machine / accessories
5.1 Cleaning machine
⚫Connect the red earth cable to the red
high-current socket of the cleaning
machine.
⚫Connect the black power cable to the
black high-current socket on your
cleaning device.
⚫
Note
The extension cable can be installed up to 100m between the cleaning device and
the MagicBox.
5.2 AutoFeed
⚫Remove the blind plug together with
the hose section from the IQSG184PP
hose coupling.
⚫Remove the blind plug from the
AutoFeed electrolyte supply hose.
Electrolyte pump

Operation instruction MagicBox
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⚫Insert the electrolyte supply hose into
the hose coupling to the bottom.
⚫Connect the black power cable of the
AutoFeed handle to the black
high-current socket on the control unit.
⚫Connect the red earth cable of the
earth clamp to the red high-current
socket on the control unit.
Note
The Hose packages must be ordered separately. The extension can be customized
up to 10m by request.
5.3 Electrolyte canister
Note
Open the lid of the electrolyte canister before starting work.
➢Turn the lid slighty to prevent the vacuum formation
Close the lid after usage.
Open (turn) the lid
slightly

Operation instruction MagicBox
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5.4 Autofeed hose package
The AutoFeed handle (3) is firmly connected
to the black 10mm2cable (5) and the black
high-current plug (7).
The AutoFeed handle (3) consists of the
following components:
⚫Connector with threaded part
➢Mounting of the brush
➢Power transmission
⚫PP handle in orange (3)
⚫Performance AutoFeed carbon fiber brush
➢XL or XXL
➢EP-02-960 or EP-02-961
⚫Teflon sleeve
➢XL or XXL
➢EP-02-928 or EP-02-948
⚫Hose and cable package (4,5,6,7)
➢2,5m 10mm2highly flexible cable with
Teflon supply hose and siliconized
glass fiber hose (4)
Hinweis
In the delivery, the adapter, brush and Teflon sleeve are already firmly attached.
4
7
8
6
5
3
1 - Carbon fiber brush
2 - Teflon sleeve
3 - Adapter
4 - Handle
5 - Cable and hose protection
6 - Power cable
7 - Electrolyte supply hose
8 - High current plug
1
2

Operation instruction MagicBox
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5.4.1 Change brush
⚫Unscrew the Teflon sleeve completely.
⚫Remove the Teflon sleeve.
⚫Loosen the brush with the help of the
spanner (SW10).
➢To do this, insert the open-end wrench
into the wrench surface of the brush
and the adapter.
⚫Unscrew the old brush.
⚫Screw on a new brush.
➢Clean the thread of electrolyte
residues with distilled water.
⚫Now slide the Teflon sleeve over the new
brush again.
➢Tip: moisten the brush with electrolyte
Note Make sure that the Teflon sleeve
is not screwed onto the thread at
an angle.
⚫Screw the Teflon sleeve onto the adapter
until the working dimension (a =
10-15mm) is reached.
➢Please refer to chapter 4.4.2.
Note
When replacing the brush, check the O-rings of the adapter and inner part for
damage.
⚫Only remove the adapter if the front
contact surface or the thread are charred.
⚫Replace the damaged O-rings if
necessary.
⚫In this case, the O-ring seals set
EP-B-0049 are needed.
O-ring seals
EP-B-0049
2x1, 6x1, 8,5x2 FKM
Adapter

Operation instruction MagicBox
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5.4.2 Adjusting the Teflon sleeve
⚫During the cleaning process, the
carbon fiber tips of the carbon fiber
brush wear off.
⚫Use the Teflon sleeve to compensate
for the wear and tear on the carbon
fibers.
➢Adjust the Teflon sleeve on the
carbon fiber brush so that the
carbon fiber tips protrude approx.
A = 10-15 mm
➢Turn the Teflon sleeve clockwise
to increase the distance [a]
➢Turn the Teflon sleeve
anti-clockwise to decrease the
distance [a]
This is the only way to create arcs between the carbon fiber and the workpiece! This guarantees
an optimal work result.
5.4.3 Connection of earth clamp - workpiece
⚫The earth clamp establishes the
electrical contact to the cleaning
device.
➢Make sure there is good
electrical contact between the
earth clamp and the workpiece.
➢Clean the contact point if
necessary.
Security notice
Very high currents flow during cleaning.
➢Connect the earth clamp directly to the workpiece.
➢In this way you avoid shunt shortages.
5.4.4 Tip for setting up
⚫After all preparations for working with
the MagicBox, we recommend the
following:
➢Close the lid of the euro box.
➢Place the cleaning device on the
euro box.
➢In this way,the internal parts are
protected from soiling or
unintentional damage.
Nutzlänge
60mm
a=10-15mm

Operation instruction MagicBox
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6 Working with the AutoFeed Brush
➢Have all the preparations been done correctly?
➢Are all parts connected correctly??
➢Is the electrolyte canister filled with electrolyte?
➢Is the distance a = 10-15mm between the carbon fibers on the
brush set correctly?
➢is the canister lid opened slightly?
⚫Switch on the cleaning machine.
⚫Set the cleaning machine on any level.
➢Cleaning or polishing
⚫MagicBox activates itself and signals through the following:
➢a beep
➢the green LED lights up
Note
If you have installed a new hose package, press the button on the control unit until
electrolyte emerges from the brush.
⚫Please work as advised in the operating instructions of the cleaning
machine. Please note that the brush doesn’t need to be immersed in
the electrolyte. This is supplied through the electrolyte pump.
➢The electrolyte begins to flow automatically as soon as the
carbon fiber tips touch the material surface.
➢As soon as you lift the brush off the workpiece, the electrolyte
supply stops automatically without any more electrolyte flowing
out of the supply hose.
➢The control unit automatically regulates the correct amount of
electrolyte.
(The harder (higher current) you press the brush, the more
electrolyte gets into the brush.)
➢The more current flows, the more electrolyte is pumped.
Note
The larger the workpieces, the contact area of the brush or the voltage of the device:
➢the more current flows
➢the more electrolyte is automatically pumped into the brush
The regulation depends on the process current!
The current can be limited with the Auto- and AkkuCleanox.
With the EasyCleanox, the current is limited to 90A.
With the model:
AutoCleanox,
AkkuCleanox and
EasyCleanox,
the voltage must be set to at least 10V to activate the MagicBox!!
After you have "woken up" the box, you can reduce the voltage again!

Operation instruction MagicBox
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Attention
The AutoFeed Performance brushes are equipped with pressed-in capillary tubes
and special sealing surfaces so that the electrolyte reaches the center of the carbon
fiber brush. Therefore, the general performance brushes are not compatible with this!
Non-Reuter brushes will damage the AutoFeed handle.
➢Cleaning performance is not given and the guarantee
is no longer valid!
⚫Original Reuter brushes can be identified through the
orange string
Safety Notice:
Since it is possible to work without interruption (100% ED), there is a risk of
overheating the material and burning the operator in case of skin contact.
➢Therefore rinse/cool regularly with plenty of water.
➢If possible, use distilled or deionized water.
7 Service Work
7.1 Replace the electrolyte canister
Security notice
The MagicBox is normally delivered with an empty electrolyte canister.
➢Make sure that you are using the correct electrolyte for your
application.
The following electrolytes can be ordered separately in a 5 liter canister:
•EP-04-041 Cleaner Elektrolyte
•EP-04-042 SuperCleaner Elektrolyte
•EP-04-043 Polisher Elektrolyte

Operation instruction MagicBox
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1. Unscrew the cover with the supply hose from the empty canister.
2. Remove the supply tube from the empty canister.
3. Remove the empty canister from the MagicBox.
4. Place the full electrolyte canister in the MagicBox.
5. Insert the supply hose into the full electrolyte canister and screw on the lid.
6. Remove the lid (without a hole) from the full canister and screw it onto the empty electrolyte
canister.
If you want to work immediately, leave the lid open with one turn.
7.2 Fill the electrolyte canistern
If you order the "MagicBox" with an empty electrolyte canister, the canister needs to be filled on
your own.
Security notice
Be aware of all safety regulations when handling chemicals.
Use your personal protective equipment
➢Safety glasses
➢Protective gloves
➢Protective clothing
1. Take the electrolyte canister out of the MagicBox.
2. Unscrew the cover with the supply hose.
3. Fill the canister with the appropriate electrolyte.
4. Screw the lid and the hose back onto the canister.
If you want to work immediately, leave the lid open with one turn.
1, 2, 3. 4, 5 6
full
empty
empty
lid
1 2 3 4

Operation instruction MagicBox
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7.3 Measures when the device is not used for a long period
In the event of long periods of non-use or transport, e.g. weekends, vacations etc., we recommend
the following measures:
1. Unscrew the lid from the electrolyte canister.
2. Remove the connecting hose with sieve and weight from the electrolyte canister.
3. Close the electrolyte canister with the lid (without a hole).
4. Lift the electrolyte canister out of the MagicBox.
5. Place a suitable container with water in the MagicBox.
6. Place the hose with the weight and sieve in the water.
7. Press the button on the control unit until at least 200 ml of water flushed through the hose
package and brush.
8. Remove the supply hose of the AutoFeed hose package from the pump housing.
9. Clean the hose package and the handle with a wet cloth.
10. Empty the MagicBox if necessary.
11. 11. Clean electrolyte residues under the base plate with water.
8 9 10, 11
5 6 7
1 2 3
4

Operation instruction MagicBox
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12. Place the blind plug on the end of the supply hose.
13. Insert the blind plug into the hose connector on the front of the pump housing.
14. Place the sealed electrolyte canister in the plastic box.
15. Fold in the pump housing.
16. If necessary, tie a plastic bag around the end of the hose with the weight and strainer.
7.4 Change the connection hose with sieve and weight
1. Unscrew the lid from the electrolyte canister.
2. Remove the connecting hose with sieve and weight from the electrolyte canister.
3. Lift the pump housing up slightly.
4. Loosen the cap of the feed-through.
5. Disconnect the electrolyte supply hose.
12 13 14, 15 16
1, 2 3 4 5

Operation instruction MagicBox
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8 Spar Parts
8.1 AutoFeed-Hose
Pos.
Qty.
Name
1
1
EP-02-953 AutoFeed Adapter + PTFE-Sleeve + O-Ring
2
1
EP-B-02-956 PG Nut M20x2
3
1
EP-02-951 AutoFeed Inner Part + PTFE-Sleeve +
O-Ring
4
1
EP-B-02-954 AutoFeed Handle Part A
5
1
EP-B-02-954 AutoFeed Handle Part B
6
1
EP-B-02-957 PG Nut M28x2
7
1
EP-B-1091 anti-kink sleeve AutoFeed Handle
8
1
EP-B-1117 Protection Sleeve 17mm or
EP-B-1118 Protection Sleeve 19mm
9
1
EP-07-144-Cable Black 10mm²
10
1
EP-07-106 High Current Plug Black
11
1
EP-B-2010 PTFE-Sleeve Di12mm
Note:
The O-Rings are available as Set EP-B-0049

Operation instruction MagicBox
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8.1.1 Change/Renew the O-Rings
O-Rings at AutoFeed Inner Part:
Remove and replace the old O-Rings with the
new.
14 EP-B-0046-O-Ring 8,5x1
15 EP-B-0044-O-Ring 6x1
O-Rings at AutoFeed Adapter:
Remove and replace the old O-Rings with the
new.
14 EP-B-0046-O-Ring 8,5x1
16 EP-B-0045-O-Ring 2x1
Be careful not to cut into the O-rings during
assembly!
When assembling, make sure that you tighten
the AutoFeed adapter again with a SW10
open-end wrench!

Operation instruction MagicBox
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8.2 Pump housing
Pos.
Qty.
Name
1
1
EP-B-4100 MagicBox - Pump housing upper part
2
1
EP-B-0047 warning light AutoFeed
3
2
EP-B-8024 cable gland PG11
4
2
EP-B-1008 Lock nut for cable entry PG11
5
1
EP-07-106-16 high current plug+EP-07-244 cabel black 16mm2
6
1
EP-07-107-16 high current plug+EP-07-255-cabel red 16mm2
7
1
EP-06-050 Elektrolyte pump AutoFeed housing
8
1
EP-06-050 Elektrolyte pump AutoFeed engine
9
1
EP-B-1021 LED Green
10
2
EP-B-0043 Angle bulkhead fitting 6x4mm PP
11
1
EP-B-0042 Reduction 6mm barb x 4mm hose IQS-PP
12
1
EP-B-2011 PTFE Pipe 4mm-180mm
13
1
EP-B-0048 push button AutoFeed
14
1
EP-07-216 Stainless steel high current socket black
15
1
EP-07-217 Stainless steel high current socket red
16
1
EP-B-0040 Bulkhead connector body 4mm IQS PP
17
2
EP-B-0040 Bulkhead connector nut M12
18
1
EP-B-06-004 Electrolyte pump hose

Operation instruction MagicBox
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8.3 Pump housing lower part
Pos.
Qty.
Name
1
1
EP-B-4100 Pump housing bottom part+SW bolt
2
1
EP-B-1086 AutoFeed PCB
3
1
EP-B-1086 AutoFeed Sensor
4
4
Standoff M3x10 F-M
5
4
DIN 127 M3 spring washer
6
4
DIN 934 8 M3 nut
7
1
EP-B-1090 Cable bushing ring-shaped ø6mm