ESAB CC-11 Instruction manual

GB

CC-11

Instruction manual

Valid for serial no. 015-xxx-xxxx0558 007 524 GB 100910

DECLARATION OF CONFORMITY

According to

The Low Voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007

The EMC Directive 2004/108/EC of 15 December 2004, entering into force 20 January 2005

Type of equipment

Liquid cooling system

Brand name or trade mark

ESAB

Type designation etc.

CC−11, Valid from serial number 015 xxx xxxx (2010 w.15)

Manufacturer or his authorised representative established within the EEA

Name, address, telephone number, telefax number:

ESAB AB, Welding Equipment Esabvägen, SE−695 81 LAXÅ, Sweden Phone: +46 584 81 000, Fax: +46 584 411 924

The following harmonised standard in force within the EEA has been used in the design:

EN 60974−1, Arc welding equipment – Part 1: Welding power sources EN 60974−2, Arc welding equipment – Part 2: Liquid cooling systems EN 60974−10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements

Additional information: Restrictive use, Class A equipment, intended for use in locations other than residential

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised representative established within the EEA, that the equipment in question complies with the safety requirements stated above.

Date Laxå 2010−04−12

Signature Position Global Director Equipment and Automation Kent Eimbrodt Clarification

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1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Equipment 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Extra equipment, accessory 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Lifting instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Mains supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Connecting the control cable 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Coolant connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 Pressure setting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Control device and indicators 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection and cleaning 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Filling the coolant 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 FAULT-TRACING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 ORDERING SPARE PARTS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rights reserved to alter specifications without notice.

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be ob served in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equip ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation S location of emergency stops S its function S relevant safety precautions S welding and cutting

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves. Note! Do not use safety gloves when replacing wire.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely. S Work on high voltage equipment may only be carried out by a qualified electrician. S Appropriate fire extinquishing equipment must be clearly marked and close at hand. S Lubrication and maintenance must not be carried out on the equipment during operation.

CAUTION!

Read and understand the instruction manual before installing or operating.

CAUTION!

Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility of class A equipment in those locations, due to conducted as well as radiated disturbances.

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WARNING

Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard data.

ELECTRIC SHOCK - Can kill

S Install and earth the unit in accordance with applicable standards. S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. S Insulate yourself from earth and the workpiece. S Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

S Keep your head out of the fumes. S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection. S Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical and/or electronic equipment that has reached the end of its life must be disposed of at a recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain information on approved collection stations.

For further information contact the nearest ESAB dealer.

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

This instruction manual contains information about installation and operation of plasma cooling unit CC-11. The cooling unit circulates coolant for cooling arc cutting machines and welding equipment.

ESAB's accessories for the product can be found on page 20.

2.1 Equipment

The cooling unit is supplied with:

S Instruction manual

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3 TECHNICAL DATA

CC-11 Mains voltage 200 / 230 / 400 / 460 / 575 V, ±10 %, 1~ 50/60 Hz Primary current (A, alternating

current) Cooling capacity

at 50 Hz at 60 Hz

Coolant Ready mixed, see accessories on page 20 Coolant quantity 15.2 litres Max water pressure 1203 KPa (175 psi ) Operating temperature

Transportation temperature -20 to 55 °C Dimensions, l x w x h 711 x 552 x 864 mm Weight

liquid filled empty

Pump type Displacement pump (vane pump) with adjustable bypass

Pump capacity 6.0 l/min at 1203 KPa (175 psi) Radiator type Copper pipe with aluminium flanges, air-water, in

Enclosure class IP21

9 / 8 / 5 / 4 / 3 A

4,9 kW at 6.0 l/min 5,9 kW at 6.0 l/min

at 25 °C temperature difference between high coolant temperature and ambient air temperature, when using ESAB's coolant.

–10 to 40 °C

113 kg 97,5 kg

valve (max. 1375 KPa (200 psi)), clockwise rotation seen from the identification plate.

galvanised steel chassis.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid objects or water. Apparatus marked IP21 are intended for indoor use.

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3.1 Extra equipment, accessory

If the cooling unit is installed higher than the plasma torch, a non-return valve must be installed, see accessories on page 20. Connect the non-return valve to the “COOLANT SUPPLY TO TORCH” outlet on the reverse of the cooling unit. The non-return valve closes if the supply pressure drops below 1719 KPa (250 psi), which ensures that the coolant does not run out of the cooling unit when replacing consumables.

Fig 1. The rear panel on the cooling unit

4 INSTALLATION

The installation must be executed by a professional.

WARNING!

ELECTRIC SHOCKS CAN KILL Always switch off and lock the machine according to the instructions before making the electrical connections. If conductors are equipped with mains circuit breakers, the breaker must be set to off and locked with a padlock to prevent switching on unintentionally. If the included conductors come from a fuse box, the affected fuses must be removed and the fuse box cover locked with a padlock. If it is not possible to use a padlock, the mains circuit breaker or fuse box must have a red notice displayed indicating that the circuit is being worked on.

CAUTION!

Do not run the pump motor intermittently, it causes unnecessary pump wear.

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CAUTION!

Do not use solenoid valves that can close when the pump is operating, the pump can become damaged.

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Position the cooling unit so that the air flow through the cover's ventilation openings are not obstructed. Installation hole pattern for permanent installation indicated by fig. 2.

Hole diameter 13.5 mm, usually 8 pcs.

Fig. 2. Installation hole pattern

4.1 Lifting instructions

WARNING!

The product must be lifted using a fork lift truck.

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4.2 Mains supply

The cooling unit must be connected with a 3-core cable. Connect the phase conductors to terminals L1 and L2 on terminal board TB1 and protective earth to the main earth point on the reverse of the fan bracket.

Fig. 3. Connecting the power supply

Fig. 4. Mains power supply

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4.3 Connecting the control cable

On the reverse of the cooling unit there is a terminal J1 with 8 pins for connecting 115 VAC operating voltage for the pump motor contactor. The cooling unit is usually supplied with this operating voltage for pump and fan. J1 is also used for signals for sufficient flow, 3.8 l/min, pin D and E, and for signals for sufficient coolant level, pin E and H.

Fig 5. 8-pin female connection

4.4 Coolant connections

Connect the torch coolant connection on the reverse of the cooling unit.

ESAB's coolant is recommended for use. See accessories on page 20.

Fig 6. Coolant connections

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4.5 Pressure setting

The pressure is controlled by a relief valve next to the pump in the tank. Turn the pressure setting screw clockwise to increase the pressure and anticlockwise to reduce the pressure. The pressure is default set to around 1203 KPa (175 psi) at 5.7 l/min. This setting is suitable for plasma torch PT-36 in M3 systems. The setting does not usually need to be changed if the cooling unit is to be used in any other application.

Fig. 7. Pressure setting screw

The relief valve allows the coolant to pass through the radiators and back to the tank.

The pump also has an integrated safety valve, which is default set to be fully open at 1719 KPa (250 psi). It is designed to protect the pump if the external relief valve jams in the closed position. The relief valve must not be adjusted by the user. If the external relief valve jams in the closed position and the outlet line is closed, the pump motor is stopped by a thermostat if the pump temperature exceeds 55 °C.

5 OPERATION

General safety regulations for the handling of the equipment can be found on page 4. Read through before you start using the equipment!

WARNING!

ELECTRIC SHOCKS CAN KILL Do not rely on the indicator lamp, disconnect the cooling unit from the power supply and disconnect the cable at the connection before opening the cover or carrying out any work on the cooling unit.

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5.1 Control device and indicators

A. Pump manometer

Indicates the pressure at outgoing connection. The pressure is default set to around 1169 - 1203 KPa (170-175 psi) at

5.7 l/min. Lower flow gives greater read off pressure, greater flow gives lower read off pressure.

Adjust the pressure using a pressure regulator near to the coolant tank. The pressure does not usually need adjusting by the user, if the pressure regulator is not replaced or the cooling unit is used for an application that requires a lower pressure.

The pump is protected by a default set safety valve. The setting for this valve must not be changed.

B. Indicator lamp for mains voltage ON

Indicates that incoming power supply is on.

C. Indicator lamp for pump ON

Indicates that the pump and fan motor are powered.

D. Switch Auto/Test

In Auto mode, the pump and fan motors are powered via the power source's control unit.

In test mode, the pump and fan motors are powered directly.

E. Indicator lamp for overheating

If the coolant flow through the cooling unit is blocked and the pressure regulator does not work properly, the pump is protected by the integrated safety valve. After a few minutes operation under these conditions, however, the pump reaches temperatures so high that it can become damaged. Too high temperature trips the pump's thermal cutout.

F. Fuse F1 and F2

Fuses for 230 VAC supply for cooling unit to the fan respectively pump motors.

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6 MAINTENANCE

WARNING!

ELECTRIC SHOCKS CAN KILL Take precautionary measures against electric shocks. Ensure that the mains voltage supply to the machine has been disconnected externally. Switch off the switch at the wall socket before inspecting or working in the cooling unit. Install all protection after finishing work. Never use the cooling unit without all the protection installed.

If the equipment does not work correctly, stop work immediately and determine the fault of the problem.

CAUTION!

All guarantee undertakings from the supplier cease to apply if the customer himself attempts any work in the product during the guarantee period in order to rectify any faults.

Regular maintenance is important for safe, reliable operation.

Only those persons who have appropriate electrical knowledge (authorized personnel) may remove the safety plates.

6.1 Inspection and cleaning

1. The coolant tank must always be filled with coolant to at least half.

2. Regularly check the coolant pressure and the flow through the system.

3. Regularly check the radiators for dust and other contamination that can affect the cooling capacity of the cooling unit.

4. Check the filter regularly and clean if necessary. Apply silicone based O-ring lubricant to the filter's rubber gasket for an optimum seal.

6.2 Filling the coolant

WARNING!

The coolant pump can become damaged if the equipment is used without coolant in the system.

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CAUTION!

The coolant must be handled as chemical waste.

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S Fill with coolant with 7.5 litres of refrigerant

ESAB's ready mixed coolant is recommended for use. See accessories on page

20.

Note! Coolant must be topped up if connecting a plasma torch or connection cables that are 5 metres in length or longer. When adjusting the water level by topping up, the coolant hose does not need to be disconnected.

When the tank has been filled, run the pump with the cover removed to bleed the radiator, hoses and torch. Check the coolant level in the tank and top up, if necessary. Reinstall the tank cover.

7 FAULT-TRACING

Try these recommended checks and inspections before sending for an authorised service technician.

Fault Action

The control panel indicates a fault code for water flow.

Poor cooling effect S Clean the cooling element using compressed air.

S Check that the cooling unit is running. S If there is a flow, the water flow guard may be defective.

8 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman. Use only ESAB original spare and wear parts.

CC-11 is designed and tested in accordance with the international and European stan dards EN 60974-1, EN 60974-2 and EN 60974-10. It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of this publication.

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Diagram

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- 17 Edition 100910

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CC-11

Ordering number

Ordering no. Denomination

0558 007 515 Cooling unit CC-11

0463 146 086 Instruction manual RU

Instruction manuals are available on the Internet at www.esab.com

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CC-11

Accessories

Coolant (Ready mixed) 25% distilled water

and 75% propylene-glycol (10 l) . . . . . . . . . . 0558 004 297

Information on further accessories can be found in separate brochures.

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NOTES

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notes

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ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 745 11 28

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o. Vamberk Tel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB Herlev Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLAND

ESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCE

ESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd Waltham Cross Tel: +44 1992 76 85 15 Fax: +44 1992 71 58 03

ESAB Automation Ltd Andover Tel: +44 1264 33 22 33 Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A. Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81

THE NETHERLANDS

ESAB Nederland B.V. Amersfoort Tel: +31 33 422 35 55 Fax: +31 33 422 35 44

NORWAY

AS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o. Katowice Tel: +48 32 351 11 00 Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda Lisbon Tel: +351 8 310 960 Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A. Alcalá de Henares (MADRID) Tel: +34 91 878 3600 Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB Gothenburg Tel: +46 31 50 95 00 Fax: +46 31 50 92 22

ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

North and South America

ARGENTINA

CONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A. Contagem-MG Tel: +55 31 2191 4333 Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc. Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P Shanghai Tel: +86 21 2326 3000 Fax: +86 21 6566 6622

INDIA

ESAB India Ltd Calcutta Tel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama Jakarta Tel: +62 21 460 0188 Fax: +62 21 461 2929

JAPAN

ESAB Japan Tokyo Tel: +81 45 670 7073 Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd USJ Tel: +603 8023 7835 Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd Singapore Tel: +65 6861 43 22 Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation Kyungnam Tel: +82 55 269 8170 Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE Dubai Tel: +971 4 887 21 11 Fax: +971 4 887 22 63

Representative offices

BULGARIA

ESAB Representative Office Sofia Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt Dokki-Cairo Tel: +20 2 390 96 69 Fax: +20 2 393 32 13

ROMANIA

ESAB Representative Office Bucharest Tel/Fax: +40 1 322 36 74

RUSSIA

LLC ESAB Moscow Tel: +7 095 543 9281 Fax: +7 095 543 9280

LLC ESAB St Petersburg Tel: +7 812 336 7080 Fax: +7 812 336 7060

Distributors

For addresses and phone numbers to our distributors in other countries, please visit our home page

www.esab.com

ESAB AB SE-695 81 LAXÅ SWEDEN Phone +46 584 81 000

www.esab.com

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