REUTER Cleanox 3.0 User manual

Operating instructions Cleanox 3.0
Side 1 from 37
Operating instructions
Cleanox 3.0
Electrochemical cleaning
11.11.2022
Rev.4
RE TER GmbH & Co. KG
Schimmelbuschstr. 9E
D-40699 Erkrath, Germany
Phone: [phone]
Fax: [phone]
[email protected]orks
www. reuter.works

Operating instructions Cleanox 3.0
Side 2 from 37
Content
1 Preface .................................................................................................... 4
1.1 Validity of these instructions .................................................................... 4
1.2 Target group of this instruction manual ................................................... 4
1.3 Intended use ............................................................................................ 4
1.4 Observance of the operating instructions ................................................ 4
1.5 EC and VDE Directives ........................................................................... 5
1.6 Accident prevention ( VV) ...................................................................... 5
2 For your safety ........................................................................................ 7
2.1 Convention .............................................................................................. 7
2.1.1 Pictograms .............................................................................................. 7
2.1.2 Presentation ............................................................................................ 7
2.1.3 Warning signs .......................................................................................... 7
2.1.4 Prohibition signs ...................................................................................... 8
2.1.5 Mandatory signs ...................................................................................... 8
2.1.6 Information signs ..................................................................................... 8
2.2 Safety measures in the event of a malfunction ....................................... 8
2.2.1 Safety-relevant environmental conditions ............................................... 9
2.3 Possible sources of danger and protective measures ............................ 9
2.3.1 Possible sources of danger ..................................................................... 9
2.3.2 Safeguard measures ............................................................................. 11
2.3.3 Check before each start of work ........................................................... 12
2.4 Possible misuse .................................................................................... 12
2.5 Residual risks ........................................................................................ 12
3 Requirements for staff and operators .................................................... 13
3.1 Operators .............................................................................................. 13
3.2 Operators .............................................................................................. 13
4 Warranty and liability ............................................................................. 13
4.1 Material defects ..................................................................................... 14
5 Technical terms ..................................................................................... 14
6 Delivery, internal transport, unpacking .................................................. 15
6.1 Delivery.................................................................................................. 15
6.2 npacking ............................................................................................. 15
6.2.1 Opening the Europlastic Box ................................................................. 15
7 Scope of delivery Cleanox 3.0 device set ............................................. 15
7.1 Delivery list cleaning set Cleanox 3.0 ................................................... 16
8 Storage conditions ................................................................................. 17
9 Installation conditions ............................................................................ 18
9.1 Security.................................................................................................. 18
10 Decommissioning / Storage .................................................................. 18
11 Storage .................................................................................................. 18
12 Equipment technology ........................................................................... 18
13 Controls 19 ............................................................................................ 19
13.1 Elements on the front panel .................................................................. 19
13.2 Sicherungsautomat (Overload F SE) ................................................... 19
13.3 Elements on the rear wall ...................................................................... 20
14 Accessories ........................................................................................... 20
14.1 Handle with cable .................................................................................. 20
14.2 Ground terminal with cable.................................................................... 21
14.3 Cleaning Accessories ............................................................................ 21
14.4 Assembly Carbon Fiber Brush / Handle ................................................ 22
14.4.1 Adjusting the Teflon Sleeve .................................................................. 23
14.5 Electrolyte .............................................................................................. 23
14.5.1 sing the electrolyte .............................................................................. 23
14.5.2 Information on non-toxicity .................................................................... 23
14.5.3 Scope of delivery information ................................................................ 23
15 Commissioning ...................................................................................... 24
15.1 Power connector ................................................................................... 24
15.2 Connection handle with carbon fiber brush ........................................... 24
15.3 Connection ground terminal .................................................................. 24
15.4 Lock/unlock high current plug ............................................................... 25
15.4.1 Locking High Current Plugs................................................................... 25

Operating instructions Cleanox 3.0
Side 3 from 37
15.4.2 nlocking High Current Plugs ............................................................... 25
16 Cleaning with the carbon fiber brush ..................................................... 26
16.1 Preparation ............................................................................................ 26
16.2 Carbon Fiber Brush Cleaning Workflow ................................................ 26
17 Polishing with the carbon fiber brush .................................................... 29
17.1 Preparation ............................................................................................ 29
17.2 Polishing with the Carbon Fiber Brush Workflow .................................. 29
18 Possible errors and their remedy .......................................................... 32
19 Specifications ........................................................................................ 33
20 Clean containers, handles and workstation .......................................... 33
21 Maintenance .......................................................................................... 34
21.1 Inspection and maintenance plan ......................................................... 34
22 Disposal ................................................................................................. 35
22.1 Disposing of contaminated electrolytes ................................................. 35
22.2 Disposing of e-waste ............................................................................. 35
23 EC – Declaration of conformity ............................................................. 36
24 spare parts lists and circuit diagram ...................................................... 37

Operating instructions Cleanox 3.0
Side 4 from 37
1 Foreword
This instruction manual is intended to teach you how to handle and
operate the Cleanox 3.0 safely as well as general instructions for
cleaning.
The user is taught the basic concepts, possible applications and
practical information in order to avoid operating errors.
Please read this instruction manual carefully before commissioning.
We wish you a lot of fun and successful work with our devices.
1.1 Validity of these instructions
These instructions refer to the following device:
 Cleanox 3.0
1.2 arget group of this manual
These operating instructions are intended for the operator and the
operating personnel of the cleaning device.
Before using the device, familiarize yourself with the contents of these
operating instructions. In this way, you achieve better work results and
work safely.
We reserve the right to make technical changes that contribute to the
improvement of our electrochemical cleaning equipment.
1.3 Intended use
The Cleanox 3.0 is a device for electrochemical cleaning / polishing of
stainless steel welds. In addition, it is possible to sign metals dark / light.
1.4 Observance of the operating instructions
The operating instructions are part of the device and can be
downloaded from our homepage under the "Download" menu.
The instructions must be available to the operating personnel at all
times.
The operating instructions must be read by the operator before
commissioning the equipment.
The operator must have understood the content of the instructions
before putting the equipment into service.
When passing on or reselling the device, all operating instructions and
documentation belonging to the device must be handed over to the
new owner.

Operating instructions Cleanox 3.0
Side 5 from 37
1.5 EC and VDE directives
The electrochemical processing equipment complies with the CE
certificate of conformity:
 2014/35/E Low Voltage Directive
 2014/30/E EMC Directive
 2011/65/E RoHS Directive
1.6 Accident prevention (UVV)
 Hazards can occur due to:
 Electricity
 Pollutants
 Gases
 Electrolytes
 Carelessness
 Read our safety data sheets on the electrolytes we use.
 Observe the hazard warnings.
 Please observe the following VV regulations and information:
 DG V 1 Principles of prevention
 DG V 3 Electrical installations and equipment
 DG V 4 Electrical installations and equipment
 DG V 6 Occupational health care
 DG V 9 Safety and health labelling in the workplace
 DGV 209-074 Industrial robots
 DGV 109-602 Electroplating industry
 DGV 209-009 electroplating
 DG V 209-073 Workplace ventilation-decision support for
operational practice
 DG V 204-007 First aid manual
 DG V 204-022 First aid at work
 DG V 251-003 p-to-date occupational safety and health
 SDB’s Safety Data Sheets
 ChemG Act on Protection against Hazardous Substances
(Chemicals Act)
 TRGS528 Technical rules for hazardous substances

Operating instructions Cleanox 3.0
Side 6 from 37
Hint
As of 1.05.2014, all VV regulations and regulations have been
renumbered and named.
Abbreviations such as: BGV/G V-V, BGR/G V-R, BGI/G V-
I/BGG/G V-G or G V-SI no longer exist.
The fonts are consistently divided into four categories.
 DG V regulations
 DG V Rules
 DG V Information
 DG V Principles
Detailed information can be found e.g. nder www.dguv.de

Operating instructions Cleanox 3.0
Side 7 from 37
2 For your safety
Read this instruction manual carefully.
The following chapter explains the pictograms used in this manual.
2.1 Convention
2.1.1 Pictograms
The pictograms used in these instructions shall have the following
meanings:
Warning signs
 Information on possible dangers when handling
the device and accessories.
 Warning signs are marked by a yellow triangle
with a black border or a white square with a red
border and a symbol in the middle, which
indicates a special dangerous situation.
Prohibitions signs
 References to prohibitions in the handling of the
device and accessories
 Warning signs are marked by a white circle with a
red border and a symbol in the middle, which
indicates a special pro
hibition.
Mandatory signs
 Indications for the use of protective equipment.
 Mandatory signs are characterized by a blue
circle with a thin black border and a symbol in the
middle, which indicates a special commandment,
e.g.: Wearing protective clothing
Information signs
 References to sections of these operating
instructions to be observed in particular.
2.1.2 Darstellungsarten
All normal descriptions in the owner's manual are displayed in the
default font size " Arial 10.5".
 Special safety instructions to be observed are shown as shown in
the following example:
Security
Here is the corresponding text...
 Tips that make it easier to work with or handle the device or
accessory are shown as shown in the following example:
ip
Here is the corresponding text...
2.1.3 Warning sign
Electromagnetic field warning
Hot surface warning
Warning of explosive substances

Operating instructions Cleanox 3.0
Side 8 from 37
Warning against harmful substances
Warning of dangerous electrical voltage
Warning of danger to life and limb
"Warning" warning about corrosive chemicals
2.1.4 Prohibition signs
Ban on people with pacemakers
2.1.5 Mandatory signs
se eye protection
se protective gloves
nplug before opening
se protective clothing
2.1.6 Notice
Indication of general sources of danger. Be sure to read
this section!
Reference to tips or important information about working
with the device and accessories. Be sure to read this
section!
Disposal of old electrical and electronic equipment (valid
in the European nion and other European countries with
separate collection system).
This symbol on the product or on the packaging means
that this product must not be treated as household waste.
This product must be disposed of properly.
2.2 Safety measures in the event of a malfunction
Turn off the device immediately and unplug it.
Secure and mark the device against turning it back on.
 Restore the device to full functionality after each repair.
 Inspect cables for damage.
 Check all safety devices for function.
!

Operating instructions Cleanox 3.0
Side 9 from 37
If electrolyte fluid gets into the eyes, rinse the eyes immediately
with plenty of water.
 Consult the ophthalmologist immediately.
Secure heated workpieces from unauthorized access.
2.2.1 Safety-relevant environmental conditions
 he use of the device is:
 limited to closed industrial and commercial areas.
 expressly prohibited in fire and explosion hazard
environments.

expressly prohibited in humid environments.
 Cover stone and concrete floors well.
 Acids react with alkaline soil coverings such as:
- Granite
- Marble
- Limestone sandstone
- Stoneware
- Tile
- Screed
-
…
 Wash electrolyte splashes or stains immediately with plenty of
Water and/or neutralyte.
 The device may:

can only be operated in well
-
ventilated rooms.
 Chlorine-containing solvents must be removed from the
workspace.
 When operating the device, chemical
Reactions harmful vapours are produced.
 For details, please refer to our SDS's of the respective
electrolytes.
Security
The operator is obliged to ensure sufficient ventilation of the work
area.
It is the responsibility of the operator to remove the corresponding
vapours from the work area with a suitable extraction system if
necessary. Suction is not mandatory!
2.3 Possible sources of danger and protective measures
2.3.1 Possible sources of danger
Improper handling of the device and its components.
 The handle lies on the workpiece or work surface in such
a way that the carbon fiber brush comes into contact with
the metal surface. In this case, electricity continues to
flow.
If the components are connected incorrectly, stray currents can
lead to the destruction of electrical protective conductors.
 Defective live cables.
 Damaged or defective switching elements.

Defective connectors.
!
!

Operating instructions Cleanox 3.0
Side 10 from 37
 Non-existent or damaged Teflon insulation.
 Wrong work environment.
Do not use protective clothing.
 Goggles
 Apron or overalls
 Gloves
The carbon fiber brush or the electrode and the workpiece can be
heated to approx. 200°C. Risk of burns!
Improper handling of chemicals.
 Electrolyte splashes can cause burns to the eyes.
 Electrolyte splashes can lead to skin burns.
 Spilled electrolyte liquid can be found on stone floors or
cause chemical burns to other materials.
Electromagnetic fields may affect pacemakers.
!

Operating instructions Cleanox 3.0
Side 11 from 37
2.3.2 Protective measures
Repairs to electrical parts of the equipment or to power lines may
only be carried out by qualified electricians.
 Have the device checked immediately by a qualified
electrician after a short circuit or malfunction.
 se the device and accessories only as intended.
 se the device only in the designated working
environment.
Avoid wandering currents.
 Connect the ground cable directly to the workpiece or to
the holder intended for the workpiece.
 Place the cleaning electrode or handle on the workpiece
or work surface so that the electrode does not come into
contact with the metal surface. Otherwise, electricity will
continue to flow, which can lead to damage or hazards.
In the event of an accident, disconnect the device immediately.
Always unplug during maintenance.
Only use appropriate personal, acid-resistant protective equipment
[protective gloves, apron and goggles].
Always turn off the device before changing the editing tools
(brushes).
Secure hot objects against accidental touching.
Never eat or drink at work! It is forbidden!
After working with electrolytes, always wash your hands
thoroughly with soap and plenty of water.
 Wipe away any spilled electrolyte fluid immediately with
plenty of water.
Please note the detailed instructions of our EC safety data sheet
for the electrolytes used.
 Store the device, accessories or chemicals in such a way
that neither accessories nor chemicals can get into
children's hands.
Wearers of pacemakers may:
 do not work with the device and do not be in the
immediate vicinity of the device!
!

Operating instructions Cleanox 3.0
Side 12 from 37
2.3.3 Check before each start of work
 All live cables and wires for damage to the insulation.
 All live cables and wires on breaks and kinks of the strands
within the insulation.
 All Plugs and connectors for damage.
 All switches for damage, e.g. chipped housing parts.
 The ground clamp for external damage.
 Whether all accessible insulation is present and undamaged.
 Make sure that you do not draw or lay electrical wiring over
sharp edges.
 Your workplace must be freely accessible
 Make sure that there are no tripping hazards.
2.4 Possible misuse
 Connecting to an incorrect mains voltage can lead to the
destruction of the device.
 The connection of foreign components that are not released
may be:
 the destruction of the device.
 to danger to persons.
 The use of chemicals that are not approved by Reuter GmbH &
Co. KG may:
 lead to damage to health,
 the work result
 Endangering persons
 Destruction of components by the wrong chemicals
2.5 Restrisiken
Possible risk Effect Remedy
Electrolytes get into the hands
of children or people who are
inexperienced in handling
chemicals.
Depending on the misuse
 Skin burns
 Burns of clothing
 Burns of other objects
 Severe internal injuries
when ingesting the
chemicals
Store electrolytes and other
chemicals in such a way that
the substances are only
accessible to authorized
persons.
Device is used by unauthorized
persons (curiosity, play instinct)
 Burns of the skin due to
excessive heat generation
of the electrode or
workpiece
 Inhalation of vapours with
corresponding health
damage
Make sure that the device can
only be used by authorized
persons.
Secure the device against
improper use after use.
Table 1 Residual risks
!
!

Operating instructions Cleanox 3.0
Side 13 from 37
3 Requirements for personnel and operators
3.1 Operator
 The following knowledge is required:
 Read and understand the user manual.
 Safety instruction about the dangers of handling electrical
equipment.
 Safety instruction on the dangers of handling chemicals.
 The following activities may be carried out:
 Operating the device.
 Selection and use of electrolytes for appropriate
applications. (Only electrolytes from Reuter GmbH & Co.
KG)
 Change of carbon fiber brush and wear parts.
 Turn the device on and off.
 Correction of slight disturbances after instruction.
This knowledge is imparted either by this operating manual, Reuter
GmbH & Co. KG or other authorized persons or institutions.
3.2 Operator
 The operator must regularly instruct the personnel in accordance
with the legal requirements.
 ntrained personnel or unauthorized persons may not use the
device.
4 Warranty and liability
Warranty and liability claims for personal injury and property
damage are excluded if the damage is due to one or more of the
following causes:
 Improper use
 of the device.
 the components belonging to the device.
 the chemicals belonging to the electrochemical processing
equipment.
 se of unsuitable chemicals.
 se of non-releasing accessories.
 Failure to comply with the
 Work and safety instructions in this manual.
 Operating instructions of the device or components.
 Improper
 Commissioning of the device.
 Putting the equipment into service in the event of
improperly fitted protective devices.
 Operation of the device
 Maintenance of the device.
 repairs carried out on the device.
 Repair by unqualified personnel.
 Use
 of the device in residential and office premises.
 of the equipment in a fire and explosion hazard
environment.
 of the device in a humid environment.
 nauthorized structural changes to the device
 Noncompliance
 the prescribed maintenance intervals

Operating instructions Cleanox 3.0
Side 14 from 37
Hint
For damages and disturbances caused by the operation of the
device with components and chemicals from other manufacturers,
no claims whatsoever can be made against Reuter GmbH & Co. KG.
nless it is clearly proven that the damage was clearly caused by
negligent design or production by Reuter GmbH & Co. KG and was
foreseeable at the time of construction.
4.1 Material defects
 The customer must notify the supplier of material defects
immediately within 14 days in writing.
 If no limitation periods for claims for material defects have been
agreed by the supplier and consumer, the statutory provisions
shall apply.
 In the case of a claim for material defects, submit a certificate
showing that the limitation period has not been exceeded.
5 erms
Distilled water
Distilled water contains no minerals and is therefore very "soft". It is
obtained by distillation.
Demineralized water
Demineralized water is obtained by filtration. It contains hardly any
minerals and is also very "soft".
Electrolyte
Electrolytes are electrically conductive chemicals used to clean
welds.
Carbon fiber brushes
Carbon fiber brushes consist of up to 1.5 million individual carbon
fibers. In the cleaning process, the current is distributed over the
individual fibers.
A small arc (~3 - 7μm in size) forms on each fiber that comes into
contact with the workpiece surface.
Passivation
Passivation is the inactivation of oxidation processes on the
workpiece surface by chemical treatment.
Water hardness
The mineral content in the water determines the degree of
hardness. The higher the concentration of certain minerals in the
water, the higher the degree of hardness. The degree of hardness is
given in "degree of German hardness" [°dH].

Operating instructions Cleanox 3.0
Side 15 from 37
6 Delivery, internal transport, unpacking
The complete device set is delivered in a sturdy Euro plastic box.
This box is closed with two plastic cable ties and a metal cable tie
before shipment in our factory.
The lid can only be opened by destroying and removing the cable
ties.
Security
In principle, all activities required for delivery, transport, unpacking
and storage must be carried out with the utmost care and all rules
and regulations required for safety must be complied with.
Failure to comply with safety rules and regulations can lead to
severe cuts, bruises and bone fractures.
6.1 Delivery
 The delivery of the device set takes place in a Euro plastic box.
6.2 Unwrap
 Cut the cable ties
 Make sure you don't cut yourself on the metal cable tie!
 Open the Euro box carefully.
6.2.1 Opening the Euro plastic box
 Remove the three cable ties.
 Open the transport box.
 Check the scope of delivery for completeness on the basis of the
delivery note.
 Complain about missing, damaged or undelivered goods
immediately.
7 Scope of delivery Cleanox 3.0 device set
 When unpacking the delivery, check the completeness of the
device set.
 Complain about missing or damaged parts immediately.

Operating instructions Cleanox 3.0
Side 16 from 37
7.1 Delivery list cleaning set Cleanox 3.0
Description Quantit
y
Order-No. Illustration
Cleaning
Cleanox 3.0 Set

1 EP-01-013
Single parts cleaning set Quantit
y
Order-No. Illustration
Solo Device
Cleanox 3.0 only  1 EP-01-113
eflon handles with 4m cable
10mm²  1 EP-07-600
Ground cable 4m, with 200A
pliers  1 EP-07-605
Performance-Brush Adapter
M10 auf M10  1 EP-02-930
Performance-Brush Carbon
Brush XL – 5er Set  1/5 EP-02-929
Performance-Brush -
eflonsleeve XL  1 EP-02-928
Cleaner 1l bottle  1 EP-04-130
Polisher 1l bottle  1 EP-04-132

Operating instructions Cleanox 3.0
Side 17 from 37
Wide neck container with blue
lid  1 EP-07-100
Spray
for water
 1 EP-07-002
Wrench SW 10  1 EP-B-02-932
Mountingpin 5x100  2 EP-07-223
Euro plastic box  1 EP-07-017
Table 2 Delivery list
8 Storage
For safe and gentle storage of the device and accessories,
observe the following measures:
 Leave the device set in the closed transport box.
 Protection against moisture and dust.
 Ambient temperature 5°C to 40°C.
 Do not store outdoors.
 Protect against the effects of acids and alkalis.
 Store only in a normal position.
 Do not expose to ionising or non-ionising radiation.
 The equipment set must not be subjected to
vibration, shock or continuous shock.
Security
Chemicals must not get into the hands of children!
Keep the chemicals under lock and key!

Operating instructions Cleanox 3.0
Side 18 from 37
9 Installation conditions
9.1 Safety
The device and accessories may only be installed and
operated in one place corresponding to the installation
conditions.
All electrical connections must comply with the applicable
safety regulations and standards.
10 Decommissioning / Storage
 Decommissioning
 Turn off the device.
 Wipe the cables with a damp cloth.
 Clean the device and accessories thoroughly. Have
maintenance work carried out by a specialist.
 Detailed instructions for cleaning the device and
accessories can be found below.
 Dry all items
 Close the electrolyte containers carefully so that no
electrolyte can leak. Store the device and accessories
in the transport box.
 Close the transport box and secure it with a cable tie
against accidental opening
11 Storage
 Store the sealed transport box dry and frost-free.
 Make sure that the locked transport box cannot get
into the hands of children or unauthorized persons.
12 Equipment technology
The device is a compact electrochemical weld cleaning
device. It was developed for commercial use in trade and
industry. The simple operation makes the device ideal for
construction site and installation in pipeline construction.
 It is suitable for cleaning/polishing TIG and MAG
welds.
 Toxic hydrofluoric, sulfuric or nitric acids as in
conventional pickling processes are not used here.
 The electrochemical processing equipment works with
low alternating voltages that are harmless to humans.
Hint
Our cleaning electrolytes are guaranteed to be non
toxic!

Operating instructions Cleanox 3.0
Side 19 from 37
13 Control and operating elements
13.1 Elements on the front panel
13.2 Overload FUSE
The device is equipped with a circuit breaker.
 In the event of overload or electrical short circuit, the circuit
breaker interrupts the circuit.
Security
Wait a moment for the fuse to cool down. Before activating the
safety button:
 the device should be turned off.
 The brush must not be in contact with the workpiece or
mass.
If the backup is triggered again, check your way of working!
 Dip and dig brushes more often and longer!
 Do not press brush too the workpiece!
Fuse triggered by overload.
The safety button pops out of the
case. Press the safety button back into
the chassis to activate
1 device main switch
ON/OFF
2 indicator light
(green->device ready for operation)
3 Overload Fuse
4 high-current socket for ground cables
5 high current socket for cleaning tool
6 main switches to select:
cleaning/polishing
1
3
2
5
4
6

Operating instructions Cleanox 3.0
Side 20 from 37
13.3 Elements on the back wall
 Mains voltage 230V/50Hz
 Type plate :
14 Accessories
14.1 Handle with cable
 The PTFE- Handle (1) is fixed with the
blacks 10mm
2
Cable (2) and the blacks
High current plug (3).
 Always plug the black high-current
plug (3) into the black high-current
socket.
 Tool connections are always black.
The Teflon handle consists of the following
components:
 PTFE handle body (1)
 Electrical insulation
 Thermal insulation
 Inner part (1.2)
 Electrical transmission
 Wärmeabführung
 Performance Adapter(1.3)
 Electrical transmission
 Connection handle↔brush
 Protection of the inner part
 Performance Brush (1.4)
 Electrical transmission
 Cleaning tool
 Performance Teflonsleeve (1.5)
 Wear compensation
1 Cable gland with power cord
2 Nameplate
1
2
1 Teflon-handle body
1.2 Inner part
1.3 Performance Adapter
1.4 Performance Brush
1.5 Performance Teflonsleeve
1.2
1.4
1.3
1
1.2
1
2
3
1 Teflongriff
2 Cables 10mm2" Black
3 Insulated high-current plug "black"