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Related Manuals for Fronius MagicCleaner 300 /EF
Summary of Contents for Fronius MagicCleaner 300 /EF
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions MagicCleaner 300 42,0426,0396,EA 002-20012022 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Table of contents Safety Instructions Explanation of Safety Instructions General Intended use Environmental conditions Obligations of the Operating Company Obligations of Personnel Personal protection and protection of others Notes on the correct handling of the cleaning and Print electrolytes Risks from grid current and cleaning current EMC measures Particular hazard areas Safety measures at the setup location and during transport... - Page 4 Preparing the workstation for Printing Printing After the Print process Service, maintenance and disposal Care, maintenance General At every start-up At the end of each shift Disposal Disposal Technical data Technical data MagicCleaner 300 /EF 300 /CN 300 /np MagicCleaner 300 MV/B 300 MV/np...
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Page 5: Safety Instructions
Safety Instructions Explanation of DANGER! Safety Instruc- tions 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. -
Page 6: Environmental Conditions
Intended use also means Reading and adhering to all instructions in the Operating Instructions Carefully reading and obeying all safety instructions and danger notices 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. - Page 7 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...
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Page 8: Notes On The Correct Handling Of The Cleaning And Print Electrolytes
For exact data, please refer to the respective safety data sheets. For current safety data the cleaning and sheets, use the following link: Print electrolytes 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. -
Page 9: Risks From Grid Current And Cleaning Current
Risks from grid An electric shock can be fatal. Every electric shock poses a risk of death. current and Do not touch voltage-carrying parts inside or outside the device. cleaning current Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. -
Page 10: Particular Hazard Areas
Supporting measures to avoid EMC problems: 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). Equipotential bonding Workpiece grounding If necessary, establish grounding using suitable capacitors. Shield, if necessary Shield other devices in the vicinity Shield entire system... -
Page 11: Safety Measures In Normal Operation
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. -
Page 12: Copyright
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. -
Page 13: General Information
General information... -
Page 15: General Information
General information Device concept The MagicCleaner 300 is a device for the electrochemical surface treatment of stain- less steel. The following surface treatments can be carried out: Cleaning of temper coloration and res- toration of the oxide layer after weld- ing and cutting Polishing of welds Printing - electrochemical surface... -
Page 16: Setup Regulations
L2 = 0 to 30A IP23 P1max = 900W Duty (%) = 0 to 80% FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Phone: +43 (0)7242 241-0 Rating plate and warnings on the device Wear tightly sealed eye protection / tightly sealed safety goggles... -
Page 17: Scope Of Supply And Options
Scope of Supply and Options Scope of supply (11) (13) (12) (14) (18) (19) (15) (17) (20) (10) (16) MagicCleaner 300 with blow-off torch and torch holder Adapter for the large cleaning brush Large cleaning brush Grounding cable with bayonet connector, 10 mm², 3 m / 9 feet 10.11 inch Tungsten cleaning electrode, 22 mm / 0.87 inch Mounting ring 19 x 23 x 10 mm / 0.75 x 0.91 x 0.39 inch Cleaning felt 22 mm / 0.87 inch (2 pcs.) - Page 18 (19) Small cleaning brush (20) Brush insert (for the small cleaning brush) Not shown: 2.5 mm / 0.10 inch Allen key These Operating Instructions Small parts boxes The cleaning electrolytes are not included in the scope of supply.
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Page 19: Options For The Blow-Off Torch
Options for the (10) (11) (13) (14) (15) blow-off torch (12) (16) (17) 10 x cleaning felt (10) 10 x cleaning felt 22 mm / 0.87 inch 45 mm / 1.77 inch 42,0510,0501 42,0510,0525 Tungsten cleaning electrode (11) Graphite cleaning electrode 22 mm / 0.87 inch 45 mm / 1.77inch 42,0510,0520... -
Page 20: Options For The Small Cleaning Torch
Options for the (10) (13) (14) (15) small cleaning torch (11) (12) (16) Adapter for the small cleaning 10 x cleaning felt brush 22 mm / 0.87 inch / 70° 42,0510,0511 42,0510,0503 5 x small cleaning brushes Graphite cleaning electrode 42,0510,0510 10 mm / 0.39 inch / 70°... - Page 21 (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 (16) Neutralizer 5 l canister ... 42,0510,0386...
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Page 22: Print Set
Graphite Print electrode, 35 x 10 mm / 1.38 x 0.39 inch 5 x mounting ring (for attaching the Print felt to the Print electrode) (10) 20 x Print felt 40 x 60 mm / 1.57 x 2.36 inch (11) Print film (option, to be ordered separately from Fronius) -
Page 23: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components... -
Page 25: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. -
Page 26: Controls, Connections, And Mechanical Components - Small Cleaning Torch
(10) Stop key to switch off the pump and deactivate the cleaning current (11) Allen screws (12) Power switch (13) Compressed air connection (14) Mains cable (12) (15) Cleaning electrolyte tank (13) (15) (14) Controls, connec- Cleaning electrolyte 0.1 l tions, and mech- for screwing onto the small clean- anical compon-... -
Page 27: Control Panel
Control Panel Control panel Blow-off torch LED lights up when blow-off torch is active Small torch LED lights up when the small torch is activated Cleaning power control knob 1 ... low cleaning power 4 ... high cleaning power The cleaning power cannot be set in Print mode. - Page 28 Operating mode control knob to set the following operating modes: Blow-off torch AC - CLEAN ... for cleaning welds DC - POLISH ... for polishing welds Small torch AC - CLEAN ... for cleaning welds DC - POLISH ... for polishing welds Printing •...
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Page 29: Before Commissioning
Before commissioning... -
Page 31: Safety Instructions For Commissioning, Operation, And Maintenance
Safety Instructions for commissioning, operation, and maintenance Read and follow The following Safety Instructions provide information about dangers that occur when the Safety In- working with and on the device. structions! 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! - Page 32 CAUTION! Danger from escaping cleaning or Print electrolyte! Personal injury and damage to property may result. ▶ Observe the safety data sheets of the cleaning and Print electrolytes ▶ Always screw the cleaning electrolyte onto the small cleaning torch with the opening facing upwards ▶...
- Page 33 NOTE! A short circuit between the bare cleaning or print electrode and the workpiece can impair the cleaning result, the print result, and/or the surface of the workpiece! ▶ Make sure that the cleaning or Print felt does not have any holes or chafed areas ▶...
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Page 34: Preparing The Workstation
Preparing the workstation Preparing the NOTE! workstation Prepare the workstation in such a way that the cleaning, polishing or Print process and the final operations do not have to be interrupted. ▶ Prepare an acid-resistant collection tray for excess or dripping cleaning or Print elec- trolyte ▶... - Page 35 NOTE! The small cleaning torches are tested and filled with glycol before delivery. ▶ Before using for the first time, pump out the small cleaning torch well with the hand pump to remove any glycol residues.
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Page 37: Cleaning
Cleaning... -
Page 39: Cleaning With The Blow-Off Torch - Preparation
Cleaning with the blow-off torch - preparation Overview The following cleaning electrodes are available for cleaning and polishing with the blow- off torch: 22 mm / 0.87 inch 22 mm / 0.87 inch / 70° 10 mm / 0.39 inch 10 mm / 0.39 inch / 70°... -
Page 40: Aligning The Cleaning Electrode
Aligning the cleaning elec- trode Mounting clean- ing felt by means of O-ring on 45 mm / 1.77 inch cleaning elec- trode... -
Page 41: Attaching Supplied Cleaning Felt To Cleaning Electrode 22 Mm / 0.87 Inch
Attaching sup- The MagicCleaner 300 is supplied with 2 cleaning felts for the cleaning electrode in size plied cleaning felt 22 mm / 0.87 inch. to cleaning elec- These cleaning felts are manufactured in the form of a pocket and are slid over the trode 22 mm / cleaning electrode. -
Page 42: Fitting The Optionally Available Cleaning Felts To The Blow-Off Torch
- 22 mm / 0.87 inch clean- ing electrode Other cleaning felt and mounting rings are optionally available from Fronius. NOTE! The alternative mounting of the clean- ing felt on the 10 mm / 0.39 inch clean- ing electrode is done in the same way. -
Page 43: Fitting The Large Cleaning Brush To The Blow-Off Torch
Fitting the large cleaning brush to the blow-off torch Fitting the large cleaning brush to the blow-off torch IMPORTANT! The fibers of the cleaning brush must not protrude more than 15 mm / 0.59 inch from the brush housing. -
Page 44: Re-Adjusting The Large Cleaning Brush
Re-adjusting the NOTE! large cleaning brush If the fibers are worn or short, push the brush housing towards the cleaning torch. ▶ Only push the brush housing back when the cleaning brush is mounted on the cleaning torch. ▶ The first few times you push the brush housing back this may require more force. -
Page 45: Cleaning With The Blow-Off Torch
Cleaning with the blow-off torch Filling with clean- WARNING! ing electrolyte Danger due to improper use! This can result in serious personal injury, damage to property and the environment. ▶ Observe the safety data sheets of the cleaning electrolytes! ▶ Observe Safety Instructions from page 31! The following cleaning electrolytes are available for cleaning with the blow-off torch: Cleaning electrolyte blue 5 l... - Page 46 IMPORTANT! Do not mix cleaning electrolytes! Cleaning electrolyte max. Level...
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Page 47: Connecting To The Compressed Air
Connecting to the For cleaning and polishing with the blow-off torch, a compressed air supply with the fol- compressed air lowing specifications is required: 6 bar compressed air supply with pressure relief valve and compressed air filter Compressed air quality according to ISO 8573-1:2001, class 7 4 3, instrument air Solid particle concentration ≤... - Page 48 Cleaning power standard values (POWER): Cleaning electrode 10 mm / 0.39 inch: 1 - 2 Cleaning electrode 22 mm / 0.87 inch: 1 - 3 Cleaning electrode 45 mm / 1.77 inch: 3 - 4 Large cleaning brush: 1 - 3 As the cleaning power increases, higher cleaning speeds are possible.
- Page 49 Cleaning electrode Large cleaning brush NOTE! Observe the following points for smooth cleaning operation: ▶ With higher cleaning performance, more cleaning electrolyte is required because the cleaning electrode and workpiece become hotter and the cleaning electrolyte evap- orates more quickly. ▶...
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Page 50: After Cleaning
After cleaning... - Page 51 IMPORTANT! For an optimal cleaning result, remove the excess cleaning electrolyte to avoid white spots due to cleaning electrolyte residues. Subsequently clean the surface with the neutralizer. * Excess cleaning electrolyte ** New microfiber cloth IMPORTANT! Do not dispose of cloths wetted with cleaning electrolyte in household waste! Dispose of cloths wetted with cleaning electrolyte in accordance with regional regu- lations! Observe the safety data sheets of the cleaning electrolytes!
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Page 52: Cleaning With The Small Cleaning Torch
Cleaning with the small cleaning torch Overview The following cleaning electrodes are available for cleaning and polishing: 10 mm / 0.39 inch / 70° 10 mm / 0.39 inch 22 mm / 0.87 inch 22 mm / 0.87 inch / 70° 35 mm / 1.38 inch Mounting the cleaning elec-... - Page 53 2,5 Nm 1.84 lb-ft...
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Page 54: Attaching The Supplied Cleaning Felt To The Cleaning Electrode
Attaching the The MagicCleaner 150 is supplied with 3 cleaning felts each for the two cleaning elec- supplied cleaning trodes in sizes 10 mm / 0.39 inch and 22 mm / 0.87 inch. felt to the clean- These cleaning felts are manufactured in the form of a pocket and are slid over the ing electrode cleaning electrodes. -
Page 55: Mounting The Cleaning Brush
Other cleaning felt and mounting rings are optionally available from Fronius. Mounting the cleaning brush IMPORTANT! When inserting the cleaning brush, make sure that the plastic tube (*) is inserted into the hole (**) on the cleaning torch. -
Page 56: Readjusting The Cleaning Brush
IMPORTANT! The fibers of the cleaning brush must not protrude more than 15 mm / 0.59 inch from the brush housing. 2,5 Nm 1.84 lb-ft Readjusting the NOTE! cleaning brush If the fibers are worn or short, push the brush housing towards the cleaning torch. -
Page 57: Placing The Cleaning Torch In The Cleaning Torch Holder
Placing the clean- Place the cleaning torch with mounted cleaning electrode in the cleaning torch holder ing torch in the cleaning torch holder Place cleaning torch with mounted cleaning brush in cleaning torch holder Connecting the small cleaning torch... -
Page 58: Screwing The Cleaning Electrolyte Onto The Cleaning Torch
Screwing the WARNING! cleaning electro- lyte onto the Danger due to improper use! cleaning torch This can result in serious personal injury, damage to property and the environment. ▶ Observe the safety data sheets of the cleaning electrolytes! ▶ Observe Safety Instructions from page 31! The following cleaning electrolytes are available for cleaning purposes: Cleaning electrolyte blue 0.1 l for cleaning welds... -
Page 59: Cleaning With The Small Cleaning Torch
Cleaning with the small cleaning torch NOTE! To avoid possible electrical interference: ▶ Connect the device only to power lines to which no other devices such as welding systems, electric motors, or similar are connected, ▶ Ground the device. - Page 60 If the operating mode (MODE) is set to 'No cleaning torch', the blow-off function of the blow-off torch and the pump are deactivated. Cleaning power standard values (POWER): Cleaning electrode 10 mm / 0.39 inch: 1 - 2 Cleaning electrode 22 mm / 0.87 inch: 1 - 3 Cleaning electrode 35 mm / 1.38 inch: 3 - 4 Small cleaning brush: 1 - 3 As the cleaning power increases, higher cleaning speeds are possible.
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Page 61: After Cleaning
NOTE! Observe the following points for smooth cleaning operation: ▶ Press the hand pump every 2 to 3 seconds to deliver cleaning electrolyte. More cleaning electrolyte is required with a higher cleaning power, because the cleaning electrode and workpiece become hotter and the cleaning electrolyte evap- orates more quickly. - Page 62 IMPORTANT! For an optimal cleaning result, remove the excess cleaning electrolyte to avoid white spots due to cleaning electrolyte residues. Subsequently clean the surface with the neutralizer. * Excess cleaning electrolyte ** New microfiber cloth IMPORTANT! Do not dispose of cloths wetted with cleaning electrolyte in household waste! Dispose of cloths wetted with cleaning electrolyte in accordance with regional regu- lations! Observe the safety data sheets of the cleaning electrolytes!
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Page 63: Polishing
Polishing... -
Page 65: Polishing With The Blow-Off Torch
Polishing with the blow-off torch General WARNING! Danger due to improper use! This can result in serious personal injury, damage to property and the environment. ▶ Observe the safety data sheets of the cleaning electrolytes! ▶ Observe Safety Instructions from page 31! Electrochemical polishing of welds is carried out with: Cleaning electrolyte red 5 l 42,0510,0384... -
Page 66: Polishing With The Blow-Off Torch
For polishing, place a fresh cleaning felt on the cleaning electrode (see page 41) Polishing with Requirement: the blow-off torch Cleaning electrode and cleaning felt mounted on the blow-off torch (see from page 39) Tank filled with cleaning electrolyte red (see from page 45) NOTE! To avoid possible electrical interference:... - Page 67 Cleaning power standard values (POWER): Cleaning electrode 10 mm / 0.39 inch: 1 - 2 Cleaning electrode 22 mm / 0.87 inch: 1 - 3 IMPORTANT! The cleaning electrode 45 mm / 1.77 inch is not suitable for polishing. In manual mode, press and hold the Start key to start the cleaning electrolyte supply.
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Page 68: After Polishing
NOTE! ▶ When polishing with the cleaning electrode, apply slight pressure to the weld. After polishing IMPORTANT! For an optimal cleaning result, remove the excess cleaning electrolyte to avoid white spots due to cleaning electrolyte residues. Subsequently clean the surface with the neutralizer. - Page 69 * Excess cleaning electrolyte ** New microfiber cloth IMPORTANT! Do not dispose of cloths wetted with cleaning electrolyte in household waste! Dispose of cloths wetted with cleaning electrolyte in accordance with regional regu- lations! Observe the safety data sheets of the cleaning electrolytes! After finishing work, remove the cleaning felt used for polishing from the cleaning electrode.
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Page 70: Polishing With The Small Cleaning Torch
Polishing with the small cleaning torch General WARNING! Danger due to improper use! This can result in serious personal injury, damage to property and the environment. ▶ Observe the safety data sheets of the cleaning electrolytes! ▶ Observe Safety Instructions from page 31! Electrochemical polishing of welds is carried out with: Cleaning electrolyte red 0.1 l 42,0510,0380... -
Page 71: Polishing
For polishing, place a fresh cleaning felt on the cleaning electrode (see page 54) Polishing Requirement: Small cleaning torch connected to the MagicCleaner 300 (see from page 57) Cleaning electrode and cleaning felt mounted on the cleaning torch (see from page 52) Cleaning electrolyte red 0.1 l screwed onto the cleaning torch (see from page 58) NOTE! - Page 72 If the operating mode (MODE) is set to 'No cleaning torch', the blow-off function of the blow-off torch and the pump are deactivated. Cleaning power standard values (POWER): Cleaning electrode 10 mm / 0.39 inch: 1 - 2 Cleaning electrode 22 mm / 0.87 inch: 1 - 3 Cleaning electrode 35 mm / 1.38 inch: 3 - 4 2 - 3 sec.
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Page 73: After Polishing
NOTE! ▶ When polishing with the cleaning electrode, apply slight pressure to the weld. After polishing Switching off the device IMPORTANT! For an optimal cleaning result, subsequently remove the excess cleaning electrolyte to avoid white spots due to cleaning electrolyte residues. Finally, clean the surface with the neutralizer. -
Page 75: Printing
Printing... -
Page 77: Printing
The print on stainless steel can be either light or dark. For printing on stainless steel, the Print set is required: (11) ABC- 123 (10) Print set 42,0510,0540 Print film with Fronius logo (for testing) Print electrolyte black 0.1 l 42,0510,0390 Print electrolyte white 0.1 l 42,0510,0391... -
Page 78: Mounting The Print Electrode And Print Felt
O-ring (10) 20 x Print felt (11) Print film (option, to be ordered separately from Fronius) Mounting the Print electrode and Print felt... -
Page 79: Preparing The Workstation For Printing
Preparing the For further preparation steps, see "Preparing the workstation" from page 34. workstation for Printing... -
Page 80: Printing
Printing NOTE! To avoid possible electrical interference: ▶ Connect the device only to power lines to which no other devices such as welding systems, electric motors, or similar are connected, ▶ Ground the device. Print - dark print Print - light print The power for the Print process is automatically preset by the device, the settings on the cleaning power control knob have no influence on the Print process. - Page 81 Print electrolyte black 0.1 l ... for dark printing Print electrolyte white 0.1 l ... for light printing Do not mix Print electrolytes Wetting the Print felt once is sufficient for a maximum of 15 Print operations in succes- sion. Printing electrolyte NOTE!
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Page 82: After The Print Process
After the Print process... - Page 83 As an alternative to the neutralizer, a microfiber cloth moistened with clear water can be used. New, dry microfiber cloth New, dry microfiber cloth - clean both sides of the Print film; clear water can be used as an alternative to the neutralizer.
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Page 85: Service, Maintenance And Disposal
Service, maintenance and disposal... -
Page 87: Care, Maintenance
Care, maintenance General The MagicCleaner 300 requires minimal service and maintenance under normal operat- ing conditions. However, several points must be observed in order for the device to re- main operational for years to come. WARNING! Danger due to improper use! This can result in serious personal injury, damage to property and the environment. -
Page 88: Disposal
Disposal Disposal Used cleaning felts are considered hazardous waste. During cleaning and polishing, heavy metals are deposited in the cleaning electrolyte used. Used cleaning electrolytes are therefore considered hazardous waste. Materials should be disposed of according to valid local and national regulations. Waste electrical and electronic equipment must be collected separately and recycled in an environmentally sound manner in accordance with the European Directive and nation- al law. -
Page 89: Technical Data
Technical data... -
Page 91: Technical Data
Technical data MagicCleaner Mains voltage ~ 1 x 230 V 300 /EF Mains voltage tolerance -15 / +10 % 300 /CN 300 /np Mains frequency 50/60 Hz Mains fuse protection 10 A slow-blow Max. primary power 1000 VA Output current 0 - 30 A Output voltage 0 - 30 V... -
Page 92: Magiccleaner 300 Mv/B 300 Mv/Np
MagicCleaner Mains voltage ~ 1 x 100 - 110 V 300 MV/B Mains voltage tolerance -15 / +10 % 300 MV/np Mains frequency 50/60 Hz Mains fuse protection 6.3 A slow-blow Max. primary power 500 VA Output current max. 15 A Output voltage 10 V 30 V... - Page 96 SPAREPARTS ONLINE Fronius International GmbH Froniusstraße 1 4643 Pettenbach Austria contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the adresses of all Fronius Sales & Service Partners and locations.
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