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Filling and starting up the cooling unit

Filling the cool-
ing unit

WARNING!

Danger from electrical 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 components involved so they cannot be switched back on.

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.

▶

Make sure that no coolant gets into the interior of the cooling unit.

CAUTION!

Danger due to work that has been carried out incorrectly.

This can result in severe damage to property.

▶

If the coolant connections are on the front of the cooling unit, carry out the following
steps as shown – but at the front coolant flow connection (blue).

Push the sealing cone in the coolant flow connection
backwards

Содержание CU 1100i

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 16: ...16...

Страница 17: ...General information 17...

Страница 18: ...18...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 26: ...26...

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

Страница 28: ...28...

Страница 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...

Страница 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...

Страница 31: ...Installation and commissioning 31...

Страница 32: ...32...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 46: ...46...

Страница 47: ...Troubleshooting 47...

Страница 48: ...48...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 53: ...Care maintenance and disposal 53...

Страница 54: ...54...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 70: ...70...

Страница 71: ...Technical data 71...

Страница 72: ...72...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 82: ...82...

Страница 83: ...83 EN...

Страница 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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