Fronius CU 1100i Operating Instructions Manual Download

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Connections and mechanical components

Connections and
mechanical com-
ponents: CU
1100i,
CU 1200i,
CU 1400i

(1) (2)

(3)

(4)

(5)

Front of cooling unit

(8)

(7)

(6)

(9)

(10)

Rear of cooling unit

(1)

Coolant flow connection blanking cover (blue)

(2)

Coolant return connection blanking cover (red)

(3)

Screw cap for coolant tank

(4)

Important notes on maintenance and operation

(5)

Coolant viewing window

(6)

Coolant return connection (red)

(7)

Coolant flow connection (blue)

(8)

Rating plate

(9)

Power source connection

(10)

Gas connection
-

Maximum 20 l/min (5.28 gal./min [US]) gas flow at gas pressure regulator

Maximum 4 bar (58.02 psi)

Summary of Contents for CU 1100i

Page 1: ...elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy CU 800i CU 1100i CU 1200i CU 1400i EN Operating instructions 42 0426 011...

Page 2: ......

Page 3: ...ion 14 Disposal 15 Safety symbols 15 Data protection 15 Copyright 15 General information 17 General 19 Device concept 19 Device versions 19 Scope of supply 20 Validity of General Delivery and Payment...

Page 4: ...t the cooling unit from the power source 44 Safety 44 Disconnecting the cooling unit from the power source 44 Troubleshooting 47 Troubleshooting 49 Safety 49 Troubleshooting 49 Turning the coolant pum...

Page 5: ...evice All persons involved in commissioning operating maintaining and servicing the device must be suitably qualified have sufficient knowledge of welding and read and follow these operating instructi...

Page 6: ...storage 20 C to 55 C 4 F to 131 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F The surrounding air must be free from dust acids corrosive gases or substances etc Can be used at alti...

Page 7: ...d sparks using a protective visor and regulation filter Wear regulation protective goggles with side protection behind the protective visor Wear stout footwear that provides insulation even in wet con...

Page 8: ...s specifications for the listed components should therefore be studied carefully Recommendations for trade fair scenarios risk management measures and for identify ing working conditions can be found...

Page 9: ...ouch the electrode when the power source is switched on Double the open circuit voltage of a power source can occur between the welding elec trodes of two power sources Touching the potentials of both...

Page 10: ...reas Devices in emission class B Satisfy the emissions criteria for residential and industrial areas This is also true for residential areas in which the energy is supplied from the public low voltage...

Page 11: ...l side panels are fitted properly Keep all covers and side panels closed The welding wire emerging from the welding torch poses a high risk of injury piercing of the hand injuries to the face and eyes...

Page 12: ...tape Requirement for the shielding gas Especially with ring lines contaminated shielding gas can cause damage to equipment and reduce welding quality Meet the following requirements regarding shieldin...

Page 13: ...es and checks to ensure that the workplace environment is always clean and clearly laid out Only set up and operate the device in accordance with the degree of protection shown on the rating plate Whe...

Page 14: ...afety data sheet may be obtained from your ser vice centre or downloaded from the manufacturer s website Check the coolant level before starting to weld while the system is still cool Commissioning ma...

Page 15: ...irements of the low voltage and elec tromagnetic compatibility directives e g relevant product standards of the EN 60 974 series Fronius International GmbH hereby declares that the device is compliant...

Page 16: ...16...

Page 17: ...General information 17...

Page 18: ...18...

Page 19: ...cooling unit can be manually changed by selecting different op erating modes TPS 270i C power sources CU 800i Pro professional version For multi shift operation multivoltage op eration 600 V operatio...

Page 20: ...ating status of the cooling unit can be manually changed by selecting different operating modes To operate the cooling unit with the iWave 300i 500i power sources the OPT i TIG 2nd NT242 option must b...

Page 21: ...apply to the CU 800i Pro CU 1200i Pro MC or CU 1400i Pro MC The shaft sealing surfaces inside the coolant pump are lubricated by the coolant mean ing that a certain leakage flow should always be expe...

Page 22: ...g unit remains operational If the temperature of the coolant exceeds 70 C 158 F The power source outputs an error message The temperature sensor interrupts the welding current The cooling unit remains...

Page 23: ...the minimum level the power source outputs an error message the level sensor interrupts the welding current the cooling unit switches off OPT CU front coolant connec tions This option is available for...

Page 24: ...ife in cooling units for multi shift opera tion Cooling units Information on the service life of the coolant pump CU 800i Pro CU 1200i Pro MC If used properly the coolant pump will have a service life...

Page 25: ...art No pmax I1 Welding is dangerous The following basic requirements must be met to ensure the equipment is used properly Welders must be sufficiently qualified Suitable protective equipment must be u...

Page 26: ...26...

Page 27: ...Connections and mechanical com ponents 27...

Page 28: ...28...

Page 29: ...on blanking cover blue 2 Coolant return connection blanking cover red 3 Screw cap for coolant tank 4 Important notes on maintenance and operation 5 Coolant viewing window 6 Coolant return connection r...

Page 30: ...nit 9 8 7 6 Rear of cooling unit 1 Coolant flow connection blue 2 Coolant return connection red 3 Screw cap for coolant tank 4 Important notes on maintenance and operation 5 Coolant viewing window 6 B...

Page 31: ...Installation and commissioning 31...

Page 32: ...32...

Page 33: ...ightly fastened after installation WARNING Danger from electric current This can result in serious personal injury and damage to property Ensure the cooling unit is properly insulated Always ensure th...

Page 34: ...run dry even for a very short time as this will destroy the coolant pump The manufacturer accepts no liability for damage caused in such cases Intended use The device is intended solely for use in con...

Page 35: ...ue to devices toppling over This can result in serious personal injury and damage to property If the welding system is not equipped with an auto transformer the cooling unit must be installed right at...

Page 36: ...to property Before starting work switch off all devices and components involved and disconnect them from the grid Secure all devices and components involved so they cannot be switched back on Connect...

Page 37: ...i CU Torch deflate option max 20 l min 5 28 gal min US max 4 bar 58 02 psi Gas hose from the scope of delivery of the cooling unit gas hose is only supplied if the OPT i CU Torch deflate option is in...

Page 38: ...possible if the welding torch hosepack has separate coolant hoses and in conjunction with power sources TPS 270i C TPS 320i C iWave 300i 500i Connecting the coolant return filter and coolant hoses fro...

Page 39: ...rom coolant leakage This can result in serious personal injury and damage to property If there is any coolant on the exterior of the cooling unit remove it immediately Make sure that no coolant gets i...

Page 40: ...unit This can result in severe damage to property Before starting up the cooling unit first check that it contains an adequate amount of coolant and that the coolant is clean and uncontaminated CAUTI...

Page 41: ...the auto and eco operating modes This function can be used to return the coolant in the torch hosepack to the coolant tank for example when changing the torch body The power source does not have to be...

Page 42: ...the pump speed and the coolant flow rate are automatically increased off Available on All cooling units Operating status Inoperative even when welding starts auto factory de fault Available on All coo...

Page 43: ...1400i Pro MC The coolant pump starts to run when welding starts and is electron ically controlled subject to the coolant return temperature The fans start up at a return temperature of 40 C 104 F and...

Page 44: ...ol to 25 C 77 F WARNING Danger from coolant leakage This can result in serious personal injury and damage to property If there is any coolant on the exterior of the cooling unit remove it immediately...

Page 45: ...Close the cover on the cooling unit connection 3 45 EN...

Page 46: ...46...

Page 47: ...Troubleshooting 47...

Page 48: ...48...

Page 49: ...conductor connection This can result in serious personal injury and damage to property The housing screws provide a suitable ground conductor connection for grounding the housing The housing screws mu...

Page 50: ...ervice if the coolant pump shaft proves im possible to turn Cause Remedy Coolant pump does not work after turning the coolant pump shaft with CU 800i CU 1100i CU 1100i MV Temperature switch on coolant...

Page 51: ...ge 52 Contact After Sales Service if the coolant pump shaft proves impossible to turn Cause Remedy Cause Remedy Cause Remedy Cause Remedy Welding torch becomes very hot with CU 800i 460 V CU 800i Pro...

Page 52: ...current This can result in serious personal injury and damage to property Before starting work switch off all devices and components involved and disconnect them from the grid Secure all devices and...

Page 53: ...Care maintenance and disposal 53...

Page 54: ...54...

Page 55: ...they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally charged components such as capacitors have been discharged WARNING Danger due...

Page 56: ...ided CAUTION Danger from non permitted coolant This can result in severe damage to property Use only original coolant from the manufacturer Cooling Liquid FCL 10 20 or ethan ol based coolant when fill...

Page 57: ...00i Pro MC only clean the coolant pre filter in the interior of the unit and re place the filter insert if necessary Every 24 months in single shift operation with FCL 10 20 coolant Change the coolant...

Page 58: ...here is any coolant on the exterior of the cooling unit remove it immedi ately Make sure that no coolant gets into the interior of the cooling unit 3 If the filter insert can no longer be cleaned with...

Page 59: ...connection between the welding system and the work piece Remove the wire electrode from the welding torch being used Depending on the system remove the wirespool or the basket type spool from the powe...

Page 60: ...ide the device or on its exterior 7 Tightening torque of housing screws 3 Nm 2 21 ft lb Gas purging the cooler CAUTION Danger due to compressed air This may result in damage to electronic components A...

Page 61: ...he power source However the power source can remain on the cooling unit when gas purging the cooler Remove device side panels and clean inside of cooler with dry reduced compressed air With heavy dust...

Page 62: ...et type spool from the power source or the wirefeeder NOTE To avoid environmental pollution due to improper coolant disposal The coolant must not be disposed of in the public sewage system Dispose of...

Page 63: ...Push back the Push in connection on the coolant pump and pull the coolant hose out of the coolant pump at the same time 2 Drain the coolant 3 Insert the coolant hose into the coolant pump 4 63 EN...

Page 64: ...m using non permitted coolants This can result in severe damage to property Use only original coolant from the manufacturer when refilling the cooling unit refer also to section Information about the...

Page 65: ...in serious injury and damage to property Disconnect the ground earth connection between the welding system and the work piece Remove the wire electrode from the welding torch being used Depending on...

Page 66: ...e coolant hose as soon as it is pulled out of the coolant pump connection Immediately remove any coolant that does get into the device or spills onto the ex terior of the device Push back the Push in...

Page 67: ...the coolant 3 Insert the coolant hose into the coolant pre filter 4 Disconnect the coolant hose from the coolant supply connection 5 Push the sealing cone in the coolant flow connection backwards 6 6...

Page 68: ...cooling unit refer also to section Information about the coolant on page 21 7 Push the locking ring backwards until the sealing cone returns to its original position and release the locking ring again...

Page 69: ...12 Tightening torque of housing screws 3 Nm 2 21 ft lb Disposal Dispose of in accordance with the applicable national and local regulations 69 EN...

Page 70: ...70...

Page 71: ...Technical data 71...

Page 72: ...72...

Page 73: ...x 25 C 77 F Q max 40 C 104 F 800 W 500 W 1160 W 730 W Max delivery head 35 m 114 ft 9 95 in Max delivery rate 3 5 l min 0 92 gal min US Max pump pressure 4 2 bar 60 92 psi Pump Centrifugal pump Pump s...

Page 74: ...min 0 53 gal min US Max pump pressure 5 bar 72 52 psi Pump Vane pump Pump service life approx 10 000 hrs Coolant capacity 4 5 l 1 19 gal US Degree of protection IP 23 Dimensions l w h 706 260 219 mm 2...

Page 75: ...114 ft 9 95 in Max delivery rate 3 5 l min 0 92 gal min US Max pump pressure 4 bar 58 02 psi Pump Centrifugal pump Pump service life up to 20 000 hrs Coolant capacity 4 5 l 1 19 gal US Degree of prote...

Page 76: ...bar 60 92 psi Pump Centrifugal pump Pump service life approx 10 000 hrs Coolant capacity 6 l 1 59 gal US Degree of protection IP 23 Dimensions l w h 710 300 230 mm 27 95 11 81 9 06 in Weight without c...

Page 77: ...mp Vane pump Pump service life approx 10 000 hrs Coolant capacity 6 l 1 59 gal US Degree of protection IP 23 Dimensions l w h 710 300 230 mm 27 95 11 81 9 06 in Weight without coolant 16 3 kg 35 94 lb...

Page 78: ...pressure 4 2 bar 60 92 psi Pump Centrifugal pump Pump service life approx 10 000 hrs Coolant capacity 6 l 1 59 gal US Degree of protection IP 23 Dimensions l w h 710 300 230 mm 27 95 11 81 9 06 in Wei...

Page 79: ...72 52 psi Pump Vane pump Pump service life approx 10 000 hrs Coolant capacity 6 l 1 59 gal US Degree of protection IP 23 Dimensions l w h 710 300 230 mm 27 95 11 81 9 06 in Weight without coolant 16 5...

Page 80: ...mp Pump service life up to 20 000 hrs Coolant capacity 6 l 1 59 gal US Degree of protection IP 23 Dimensions l w h 710 300 230 mm 27 95 11 81 9 06 in Weight without coolant 12 kg 26 46 Ib Flow monitor...

Page 81: ...n 0 79 gal min US Max pump pressure at 4750 rpm 4 bar 58 02 psi Pump Centrifugal pump Pump service life up to 30 000 hrs Coolant capacity 6 l 1 59 gal US Degree of protection IP 23 Dimensions l w h 71...

Page 82: ...82...

Page 83: ...83 EN...

Page 84: ...Froniusstra e 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 spareparts fro...

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