REUTER SuperCleanox IV+ User manual

SuperCleanox Operating instructions
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Operating instructions
SuperCleanox IV+ EP-01-021
SuperCleanox VI EP-01-017
SuperCleanox VI HD EP-01-017-HD
Electrochemical cleaning, polishing, marking
2017-01-16
Rev.0
REUTER GmbH & Co. KG
Schimmelbuschstr. 9e
40699 Erkrath, Germany
Tel.: [phone]
Fax: [phone]
[email protected]
www.oreuter.de

SuperCleanox Operating instructions
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Table of contents
1 Introduction............................................................................................................5
1.1 Validity of these operating instructions...............................................................5
1.2 Target group for these operating instructions....................................................5
1.3 Compliance with the operating instructions.......................................................5
1.4 EC and VDE (Verband Deutscher Elektrotechniker –
German ElectrotechnologyFederation) directives...........................................6
1.5 Accident prevention (UVV (Unfallverhütungsvorschriften -
accident prevention regulations))........................................................................6
2 For your safety......................................................................................................7
2.1 Convention............................................................................................................7
2.1.1 Pictograms............................................................................................................7
2.1.2 Presentation..........................................................................................................7
2.1.3 Warning signs.......................................................................................................8
2.1.4 Prohibition signs ...................................................................................................8
2.1.5 Mandatorysigns...................................................................................................8
2.1.6 Information signs..................................................................................................8
2.2 Safetymeasures in the event of failure..............................................................9
2.2.1 Safety-relevant environmental conditions..........................................................9
2.3 Potential sources of danger and protectivemeasures..................................10
2.3.1 Potential sources of danger..............................................................................10
2.3.2 Before starting work, check..............................................................................12
2.4 Potentialmisuses.............................................................................................. 12
2.5 Residual risks.....................................................................................................12
3 Demands on personnel and operators...........................................................13
3.1 Users...................................................................................................................13
3.2 Operator .............................................................................................................13
4 Warranty and liability.........................................................................................13
4.1 Material defects..................................................................................................14
5 Technical terms.................................................................................................14
6Delivery, in-house transport, unpacking..........................................................15
6.1 Delivery...............................................................................................................15
6.2 Unloading...........................................................................................................16
6.3 In-house transport.............................................................................................16
6.4 Unpacking..........................................................................................................16
6.4.1 Opening the Euro plastic box...........................................................................16
7 Scope of deliveryof the "SuperCleanox" appliance set................................17
7.1 Delivery list "SuperCleanox" appliance set.....................................................17
8 Storage requirements .......................................................................................20
9 Installation conditions........................................................................................ 20
9.1 Safety.................................................................................................................. 20
10 Decommissioning / storage..............................................................................20
11 Storage............................................................................................................... 20
12 Appliance technology........................................................................................21
12.1 SuperCleanox VI HD ........................................................................................21
12.2 SuperCleanox VI...............................................................................................21
12.3 SuperCleanox IV+.............................................................................................21
12.4 Applications........................................................................................................ 22
13 Controls and operating elements on the front panel.....................................23
13.1 Performance level selector switch...................................................................23
13.1.1 SuperCleanox VI HD.......................................................................................24
13.1.2 SuperCleanox VI.............................................................................................24
13.1.3 SuperCleanox IV+...........................................................................................24
13.2 Automatic circuit breaker (overload FUSE).................................................... 25
13.3 High-current combo jacks.................................................................................25
13.4 Elements on the back panel.............................................................................26

SuperCleanox Operating instructions
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14 Accessories........................................................................................................26
14.1 Teflon handle with cable and plug...................................................................26
14.2 Earth clip with cable and plug ..........................................................................27
14.3 Carbon fibre brush XL.......................................................................................27
14.4 Assembly carbon fibre brush XL / Teflon handle........................................... 28
14.4.1 Adjusting the Teflon sliding sheath................................................................28
14.5 Cables and plugs............................................................................................... 29
14.5.1 1.5mm² cables with 4mm safetyplugs..........................................................29
14.6 Marking stamp...................................................................................................29
14.7 Cleaningstamp.................................................................................................29
14.8 Carbon electrode...............................................................................................30
14.8.1 90° for marking/labelling ..................................................................................30
14.8.2 60° for cleaning and polishing........................................................................30
14.9 Surface cleaner (optional for SuperCleanox VI HD) .....................................30
14.10 Felts.....................................................................................................................31
14.10.1 White................................................................................................................31
14.10.2 Yellow..............................................................................................................31
14.11 Electrolyte.........................................................................................................32
14.11.1 Fillinto wide-mouth containers.....................................................................32
14.11.2 Information concerning non-toxicity..............................................................33
14.11.3 Information concerning the scope of delivery..............................................33
14.12 Templates............................................................................................ 33
15 Initial operation ..................................................................................... 34
15.1 Connection........................................................................................... 34
15.1.1 Mains connection................................................................................. 34
15.1.2 Connecting the Teflon handle with carbon fibre brush........................... 34
15.2 Connect and lock the high-current plugs ................................................ 35
15.3 Release high-current plug and remove .................................................. 35
15.4 Connecting the marking / cleaning stamp............................................... 35
15.4.1 Changing the marking felt.................................................................... 36
16 Working with the "SuperCleanox" ...................................................................37
16.1 Cleaning / polishing with the carbonfibre brush............................................37
16.1.1 Preparation.......................................................................................................37
16.2 Workflow, cleaning with carbon fibre brush....................................................38
16.2.1 Workflow, strong cleaning withcarbon fibre brush......................................40
16.3 Workflow, polishing with carbon fibre brush...................................................41
16.3.1Workflow, strong polishing with carbon fibre brush......................................42
16.4 Cleaning / polishing with carbon electrode..................................................... 44
16.4.1 Preparation........................................................................................................ 44
16.4.2 Workflow, cleaning with carbon electrode.................................................... 44
16.5 Workflow, polishing with carbon electrode.....................................................46
16.6 Tips for cleaning with carbon fibre brush /carbon electrode........................47
16.7 Tips for polishing with carbon fibre brush / carbon electrode.......................48
16.8 Marking/Labelling..............................................................................................49
16.8.1 Preparation.......................................................................................................49
16.8.2 Workflow dark marking...................................................................................50
16.8.3 Workflow, light marking...................................................................................52
16.9 Tips for optimal marking / labelling..................................................................53
17 Possible faults and their remedies...................................................... 54
18 Technical Data .................................................................................... 55
19 Clean container, handles and workplace............................................ 55
20 Maintenance ....................................................................................... 56
20.1 Inspection and maintenance schedule ............................................... 56
21 Disposal .............................................................................................. 57
21.1 Disposal of contaminated electrolytes................................................ 57
21.2 Disposal of electronic waste............................................................... 57

SuperCleanox Operating instructions
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22 Ordering spare and wear parts........................................................... 57
23 Optional accessories .......................................................................... 58
23.1 Teflon sliding sheath........................................................................... 58
23.2 Assembly ............................................................................................ 58
23.3 2 and 4-fold brush............................................................................... 58
23.4 Extension............................................................................................ 59
23.5 Knee piece.......................................................................................... 59
23.6 Adapter brush ..................................................................................... 60
23.7 Surface cleaner................................................................................... 60
23.8 Printer ................................................................................................. 61
24 EC - Declaration of Conformity........................................................... 62

SuperCleanox Operating instructions
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1 Introduction Thank you for choosing an electrochemical high-current brush weld cleaner from
the "SuperCleanox series" 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 "SuperCleanox" as well as general information for
cleaning, polishing 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 at [phone].
Please read through these operating instructions carefully before commissioning.
We hope you enjoy working with our appliances and wish you every success.
1.1 Validity of these operating instructions
These operating instructions apply to the following appliances:
SuperCleanox IV+ EP-01-021
SuperCleanox VI EP-01-017
SuperCleanox VI HD EP-01-017-HD
Type-specific differences are identified and described accordingly.
1.2 Target group for these operating instructions
These operating instructions are intended for those operating and using the
"SuperCleanox".
Familiarise yourself thoroughly with these instructions before using the
"SuperCleanox". You will achieve better results and work safely.
If you have any difficulties or questions please contact our Customer Service,
who will be happy to assist you.
We reserve the right to make technical changes that help to improve our
electrochemical processing appliances.
1.3 Compliance with the operating instructions
These operating instructions are a constituent of the "SuperCleanox" and can be
downloaded from our website under the "Download" menu. Alternatively, you can
scan the QR code on the Quick Start Guide with your smartphone and receive
the operating instructions as a PDF document.
Theseoperatinginstructions mustbeavailabletotheoperatingpersonnelatalltimes.
These operating instructions must be read by the operating personnel before
commissioning the "SuperCleanox VI”.
The operating personnel must have understood the content of the operating
instructions before commissioning the "SuperCleanox".
If the "SuperCleanox" is passed on or resold, all operating instructions belonging to
the applianceas wellasanyrelevantdocumentationmustbegiventothenewowner.

SuperCleanox Operating instructions
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1.4 EC and VDE (Verband Deutscher Elektrotechniker –German Electrotechnology
Federation) directives
Our electrochemical high current brush-weld cleaner, "SuperCleanox", has been
EMC-tested and certified at the accredited laboratory of the International
Approval Center of Mitsubishi Electric in Dusseldorf.
We would be happy to send you a copy of the EMC investigation reports.
This electrochemical processing appliance complies with the certificate of
conformity "CE":
EC directive 2004/108/EC (EMC directive)
EC Directive 2006/95/EC (Low Voltage Directive)
This electro chemical processing appliance was made in accordance with:
EN 61558-1 (VDE 0570)
1.5 Accident prevention (UVV (Unfallverhütungsvorschriften - accident prevention
regulations))
Dangers may be caused by:
Electrical currents,
Pollutants,
Gases,
Electrolytes,
Read our safety data sheets concerning the electrolytes used by us.
Observe the danger warnings.
Note the following UVV regulations and information:
DGUV 1 (Deutsche Gesetzliche Unfallversicherung - German Social
Accident Insurance) Principles of prevention
DGUV 3 Electrical systems and equipment
DGUV 4 Electrical systems and equipment
DGUV 6 Occupational health care
DGUV 9 Health and safety signs
at work
DGUV 209-073 Workplace ventilation decision support
for operational practice
DGUV 204-007 First aid handbook
DGUV 204-022 First aid at work
DGUV 251-003 Contemporary occupational safety
SDB's Safety data sheets
Note
As of 01/05/2014, all UVV rules and regulations have been renumbered and
renamed.
Abbreviations such as BGV / GUV-V, BGR / GUV-R, BGI / GUV-I / BGG /
GUV-G or GUV-SI are no longer used.
The publications are consistently divided into three categories:
DGUV Regulations
DGUV Rules
DGUV Information
For detailed information see www.dguv.de, for example.

SuperCleanox Operating instructions
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2 For your safety Read the operating instructions carefully. In the following chapter,
the pictograms used in these operating instructions are explained.
2.1 Convention
2.1.1 Pictograms The pictograms used in these operating instructions have the following
meanings:
Warning signs
Indicate possible hazards in the handling of the appliance and accessories.
Warning signs are identified by a yellow triangle with a black border,
or white square with a red border and a symbol at the centre, which
indicates a specific hazard situation.
Prohibition signs
Indicate possible prohibitions in the handling of the appliance and
accessories
Warning signs are identified by a white circular area with a red border and
a symbol at the centre, which indicates a specific prohibition.
Mandatory signs
Indicate mandatory use of protective equipment.
Mandatory signs are identified by a blue circular area with a thin black
border and a symbol at the centre, which indicates a specific requirement
e.g.: wearing protective clothing
Information signs
Indicate sections of these operating instructions which demand special
attention.
2.1.2 Presentation
All normal descriptions in these operating instructions are written in the standard
font size "Arial 10".
Safety precautions which must be particularly observed are presented as
shown in the following example:
Safety information
The relevant text is written here................
Tips that facilitate working with or handling the appliance or accessories
are presented as shown in the following example:
Tip
The relevant text is written here................
!

SuperCleanox Operating instructions
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2.1.3 Warning signs
Warning of electromagnetic field
Warning of hot surface
Warning of explosive substances
Warning of harmful substances
Warning of dangerous electrical voltage
Warning of danger to life and limb
"Caution" warning of caustic chemicals
2.1.4 Prohibition signs
Prohibition for persons with cardiac pacemakers
2.1.5 Mandatory signs
Use eye protection
Use protective gloves
Disconnect power supply before opening
Use protective clothing
2.1.6 Information signs Information concerning general sources of danger. Read this section
carefully!
Information concerning tips or important information about
working with the "SuperCleanox" and accessories. Read this
section carefully!
!

SuperCleanox Operating instructions
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Disposal of old electrical and electronic equipment (applicable in
the European Union and other European countries with separate collection
systems).
This symbol on the product or packaging indicates that this product may not
be treated as household waste.
This product must be disposed of properly.
2.2 Safety measures in the event of failure
Turn off the "SuperCleanox" immediately and pull out the mains plug.
Secure and mark the "SuperCleanox" to ensure that it is not switched
on again.
After any repairs, ensure that the "SuperCleanox" is fully functional.
Inspect cables for damage.
Check the functioning of all safety devices.
If you get electrolyte fluid in your eyes, rinse your eyes immediately
with plenty of water.
See an eye specialist immediately.
Secure hot workpieces against unauthorized access.
2.2.1 Safety-relevant environmental conditions
The use of the "SuperCleanox" is:
restricted to closed industrial and commercial areas.
expressly prohibited in fire endangered and potentially
explosive environments.
expressly prohibited in humid environments.
Cover stone and concrete floors well.
Acids react with alkaline floor coverings such as:
ogranite
omarble
olime sandstone
ostoneware
otiles
oscreed
Wash electrolyte splashes or stains off immediately with plenty of water
and / or Neutralyt.
The "SuperCleanox" may:
only be operated in well ventilated area.
Chlorinated solvents must be removed from the work area.
!
!

SuperCleanox Operating instructions
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When operating the "SuperCleanox", harmful vapours can be
caused through chemical reactions.
For details, please refer to our MSDS's (Material Safety Data Sheets)
for the respective electrolytes.
Safety information
The operator is obliged to ensure adequate ventilation of the work area.
The operator must ensure that the corresponding vapours are removed from
the work area with a suitable extraction system .
2.3 Potential sources of danger and protective measures
2.3.1 Potential sources of danger
Improper use of "SuperCleanox" and its components.
Placing the cleaning electrode or handle on the workpiece or work surface in
such a way that the electrode or the felt / carbon fibre brush is in contact with
the metal surface. In this case, current is still flowing.
Incorrect connection of the components can lead to stray currents
destroying the electrical protective conductor.
Defective live cables.
Damaged or defective switching elements.
Defective connectors.
Non-existent or damaged Teflon insulation.
Incorrect work environment.
Not using protective clothing.
The carbon fibre brush or the electrode as well as the workpiece can
reach a temperature of approx. 200°C.
Improper handling of chemicals
Electrolyte splashes may cause eye burns.
Spilled electrolyte fluid can cause stains on stone floors or other
surfaces.
Electromagnetic fields can affect cardiac pacemakers.
!