Fronius CU 2000i Pro /MC Operating Instruction [EN]

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CU 2000i Pro /MC

Operating instructions

EN

Cooling unit

42,0426,0228,EN 006-16062021

Contents

Safety rules 5

Explanation of safety notices 5
General 5
Proper use 5
Environmental conditions 6
Obligations of the operator 6
Obligations of personnel 6
Mains connection 6
Protecting yourself and others 7
Noise emission values 7
Danger from toxic gases and vapours 8
Danger from flying sparks 8
Risks from mains current and welding current 9
Meandering welding currents 10
EMC Device Classifications 10
EMC measures 10
EMF measures 11
Specific hazards 11
Requirement for the shielding gas 12
Danger from shielding gas cylinders 12
Danger from escaping shielding gas 13
Safety measures at the installation location and during transport 13
Safety measures in normal operation 13
Commissioning, maintenance and repair 14
Safety inspection 14
Disposal 15
Safety symbols 15
Data protection 15
Copyright 15

EN

General information 17

General 19

Device concept 19
Validity of "General Delivery and Payment Conditions" 19
Coolant pump service life in cooling units for multi-shift operation 19
General 19
Information about the coolant 19
Warning notices on the device 20

Scope of supply and options 21

Scope of supply 21
OPT CU coolant filter 21

Function of the installed sensors 22

Function of the CU Flow-Thermo-Sensor 22
Function of the CU Level-Sensor 22

Connections and mechanical components 23

Connections and mechanical components 25

Connections and mechanical components: CU 2000i Pro /MC main part 25
Connections and mechanical components: CU 2000i Pro /MC cooling part 26

Installation and commissioning 27

Before installation and commissioning 29

Safety 29
Setup regulations 29
Information about the coolant 30
Guarantee provisions regarding the coolant pump 30
Proper use 30

Securing the cooling unit and power source to the trolley/upright console 31

3

Safety 31
Securing the cooling unit and power source to the trolley 31
Securing the cooling unit and power source to an upright console 32
Securing the cooling unit and power source to two upright consoles 33

Connect the coolant hoses to the cooling unit 34

Safety 34
Connecting the coolant hoses to the cooling unit 34

Filling and starting up the cooling unit 37

Filling the cooling unit 37
Starting up the cooling unit 38
Operating modes 38
Recommended application of the operating modes 39

Disconnecting the system components 41

Disconnecting the system components 43

Safety 43
Disconnecting the system components 43

Troubleshooting 45

Troubleshooting 47

Safety 47
Troubleshooting 47

Care, maintenance and disposal 49

Care, maintenance and disposal 51

Safety 51
General 51
Symbols for care and maintenance of the cooling unit 52
Maintenance intervals, maintenance work 52
Gas purging the cooler 53
Changing the coolant 53
Disposal 56

Technical data 57

Technical data 59

General 59
CU 2000i Pro /MC 59

4

Safety rules

EN

Explanation of
safety notices

DANGER!

Indicates immediate danger.

If not avoided, death or serious injury will result.

▶

WARNING!

Indicates a potentially hazardous situation.

If not avoided, death or serious injury may result.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

If not avoided, minor injury and/or damage to property may result.

▶

NOTE!

Indicates a risk of flawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to recog-

nised safety standards. If used incorrectly or misused, however, it can cause:

- injury or death to the operator or a third party,

- damage to the device and other material assets belonging to the operating com­pany,

- inefficient operation of the device.

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 instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applic­able and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

- must be in a legible state,

- must not be damaged,

- must not be removed,

- must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section
headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

5

The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.

Proper use includes:

- carefully reading and following all the instructions given in the operating instructions

- studying and obeying all safety and danger notices carefully

- performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

- Thawing out pipes

- Charging batteries

- Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental
conditions

Obligations of the
operator

Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer shall not be held liable for any
damage arising from such usage.

Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)

- during transport and 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 altitudes of up to 2000 m (6561 ft. 8.16 in.)

The operator must only allow persons to work with the device who:

- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device

- have read and understood these operating instructions, especially the section
"safety rules", and have confirmed as much with their signatures

- are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.

Obligations of
personnel

Mains connection Devices with a higher rating may affect the energy quality of the mains due to their cur-

6

Before using the device, all persons instructed to do so undertake:

- to observe the basic instructions regarding safety at work and accident prevention

- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm
in your absence.

rent consumption.

This may affect a number device types in terms of:

- Connection restrictions

-

Criteria with regard to the maximum permissible mains impedance

-

Criteria with regard to the minimum short-circuit power requirement

*)

at the interface with the public grid

*)

*)

see "Technical data"

In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power
supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

EN

Protecting your­self and others

Anyone working with the device exposes themselves to numerous risks, e.g.

- flying sparks and hot pieces of metal

- Arc radiation, which can damage eyes and skin

- Hazardous electromagnetic fields, which can endanger the lives of those using car­diac pacemakers

- Risk of electrocution from mains current and welding current

- Greater noise pollution

- Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:

- Flame-resistant

- Insulating and dry

- Covers the whole body, is undamaged and in good condition

- Safety helmet

- Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

- Protect eyes and face from UV rays, heat and 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 conditions

- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)

- Wear ear protection to reduce the harmful effects of noise and to prevent injury

Noise emission
values

Keep all persons, especially children, out of the working area while any devices are in
operation or welding is in progress. If, however, there are people in the vicinity:

- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)

- Provide suitable protective equipment

- Alternatively, erect suitable safety screens/curtains.

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation at the maximum permissible operating point
under maximum rated load conditions according to EN 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cut­ting) as this is influenced by both the process and the environment. All manner of differ­ent welding parameters come into play, including the welding process (MIG/MAG, TIG
welding), the type of power selected (DC or AC), the power range, the type of weld
metal, the resonance characteristics of the workpiece, the workplace environment, etc.

7

Danger from
toxic gases and
vapours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

- must not be breathed in

- must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured
toxic emission values should be compared with the permissible limit values.

The following components are responsible, amongst other things, for the degree of tox­icity of welding fumes:

- Metals used for the workpiece

- Electrodes

- Coatings

- Cleaners, degreasers, etc.

- Welding process used

Danger from fly­ing sparks

The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identify­ing working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation
area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or
alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near
sealed tanks, vessels or pipes unless these have been prepared in accordance with the
relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.

8

Risks from mains
current and weld­ing current

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed
rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insu­lated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or
cover for the earth or ground potential. This base or cover must extend over the entire
area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimen­sioned. Replace loose connections and scorched, damaged, or inadequately dimen­sioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must

- never be immersed in liquid for cooling

- Never touch the electrode when the power source is switched on.

EN

Double the open circuit voltage of a power source can occur between the welding elec­trodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician to ensure
the ground conductor is functioning properly.

Protection class I devices require a mains supply with ground conductor and a connector
system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket
without ground conductor contact is only permitted if all national regulations for protective
separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable
for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent
anyone from plugging the mains plug back in and switching it on again.

After opening the device:

- Discharge all live components

- Ensure that all components in the device are de-energised.

If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.

9

Meandering weld­ing currents

If the following instructions are ignored, meandering welding currents can develop with
the following consequences:

- Fire hazard

- Overheating of parts connected to the workpiece

- Irreparable damage to ground conductors

- Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments,
e.g. Insulation against conductive floor or insulation to conductive racks.

If distribution boards, twin-head mounts, etc., are being used, note the following: The
electrode of the welding torch / electrode holder that is not used is also live. Make sure
that the welding torch / electrode holder that is not used is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire elec­trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the
wirefeeder.

EMC Device Clas­sifications

EMC measures In certain cases, even though a device complies with the standard limit values for emis-

Devices in emission class A:

- Are only designed for use in industrial settings

- Can cause line-bound and radiated interference in other areas

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 mains.

EMC device classification as per the rating plate or technical data.

sions, it may affect the application area for which it was designed (e.g. when there is
sensitive equipment at the same location, or if the site where the device is installed is
close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the
situation.

Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interfer­ence from the device include:

- Safety devices

- Power, signal and data transfer lines

- IT and telecommunications devices

- Measuring and calibrating devices

10

Supporting measures for avoidance of EMC problems:

1. Mains supply

- If electromagnetic interference arises despite correct mains connection, addi-

tional measures are necessary (e.g. use a suitable line filter).

2. Welding power leads

- must be kept as short as possible

- must run close together (to avoid EMF problems)

- must be kept well apart from other leads

3. Equipotential bonding

4. Earthing of the workpiece

- If necessary, establish an earth connection using suitable capacitors.

5. Shielding, if necessary

- Shield off other nearby devices

- Shield off entire welding installation

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hear­ing aids

- wearers of pacemakers must seek advice from their doctor before approaching the
device or any welding that is in progress

- for safety reasons, keep distances between the welding cables and the welder's
head/torso as large as possible

- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body

Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:

- Fans

- Cogs

- Rollers

- Shafts

- Wirespools and welding wires

EN

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened/removed while maintenance or repair work
is being carried out.

During operation

- Ensure that all covers are closed and all 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, etc.).

Therefore always keep the welding torch away from the body (devices with wire-feed
unit) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to
cool down before handling.

Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting
coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The
coolant safety data sheet may be obtained from your service centre or downloaded from
the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when transport­ing devices by crane.

11

- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.

- Chains and ropes must be at the smallest angle possible to the vertical.

- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).

If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand.
The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck
or other mechanical hoist.

All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or
changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for
the shielding gas connection. Prior to assembly, seal the device-side thread of the
adapter for the shielding gas connection using suitable Teflon tape.

Requirement for
the shielding gas

Danger from
shielding gas cyl­inders

Especially with ring lines, contaminated shielding gas can cause damage to equipment
and reduce welding quality.
Meet the following requirements regarding shielding gas quality:

- Solid particle size < 40 µm

- Pressure condensation point < -20 °C

- Max. oil content < 25 mg/m³

Use filters if necessary.

Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat, mech­anical impact, slag, naked flames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions to pre­vent them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

12

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the cor­rect and appropriate accessories (regulator, hoses and fittings). Only use shielding gas
cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylin­der.

The manufacturer's instructions must be observed as well as applicable national and
international regulations for shielding gas cylinders and accessories.

EN

Danger from
escaping shield­ing gas

Safety measures
at the installation
location and dur­ing transport

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the
oxygen in the ambient air.

- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.

- Observe safety and maintenance instructions on the shielding gas cylinder or the
main gas supply.

- Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.

- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage
before every start-up.

A device toppling over could easily kill someone. Place the device on a solid, level sur­face such that it remains stable

- The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.

Use internal directives 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.

Safety measures
in normal opera­tion

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69
in.) to ensure that cooling air can flow in and out freely.

When transporting the device, observe the relevant national and local guidelines and
accident prevention regulations. This applies especially to guidelines regarding the risks
arising during transport.

Do not lift or transport operational devices. Switch off devices before transport or lifting.

Before transporting the device, allow coolant to drain completely and detach the follow­ing components:

- Wirefeeder

- Wirespool

- Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before
commissioning the device.

Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a risk of

- injury or death to the operator or a third party

- damage to the device and other material assets belonging to the operator

- inefficient operation of the device

Any safety devices that are not functioning properly must be repaired before switching on
the device.

Never bypass or disable safety devices.

13

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper functioning of
safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its
properties (electrical conductibility, anti-freeze agent, material compatibility, flammability,
etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other system
components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under
certain conditions. Transport the coolant only in its original, sealed containers and keep
well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your ser­vice centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

Commissioning,
maintenance and
repair

Safety inspection The manufacturer recommends that a safety inspection of the device is performed at

It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.

- Use only original spare and wearing parts (also applies to standard parts).

- Do not carry out any modifications, alterations, etc. to the device without the manu­facturer's consent.

- Components that are not in perfect condition must be replaced immediately.

- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.

least once every 12 months.

The manufacturer recommends that the power source be calibrated during the same 12­month period.

14

A safety inspection should be carried out by a qualified electrician

- after any changes are made

- after any additional parts are installed, or after any conversions

- after repair, care and maintenance has been carried out

- at least every twelve months.

For safety inspections, follow the appropriate national and international standards and
directives.

Further details on safety inspection and calibration can be obtained from your service
centre. They will provide you on request with any documents you may require.

Disposal Do not dispose of this device with normal domestic waste! To comply with the European

Directive on Waste Electrical and Electronic Equipment and its implementation as
national law, electrical equipment that has reached the end of its life must be collected
separately and returned to an approved recycling facility. Any device that you no longer
require must either be returned to your dealer or given to one of the approved collection
and recycling facilities in your area. Ignoring this European Directive may have poten­tially adverse affects on the environment and your health!

Safety symbols Devices with the CE mark satisfy the essential requirements 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 with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the follow­ing address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant stand­ards for Canada and the USA.

EN

Data protection The user is responsible for the safekeeping of any changes made to the factory settings.

The manufacturer accepts no liability for any deleted personal settings.

Copyright Copyright of these operating instructions remains with the manufacturer.

The text and illustrations are all technically correct at the time of printing. We reserve 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 improvement, or can point out any mistakes that you have found in the instruc­tions, we will be most grateful for your comments.

15

16

General information

17

18

General

Device concept The cooling unit consists of two parts:

- Main part, see Connections and

mechanical components: CU 2000i
Pro /MC main part on page 25

- Cooling part, see Connections and

mechanical components: CU 2000i
Pro /MC cooling part on page 26

The cooling unit and the power source
form a unit. As with the standalone power
source, the power source/cooling unit
combination can be mounted on the trol­ley.

EN

Validity of "Gen­eral Delivery and
Payment Condi­tions"

Coolant pump
service life in
cooling units for
multi-shift opera­tion

General As a result of firmware updates, you may find that your device has certain functions that

Information about
the coolant

With regard to cooling units, the "General Delivery and Payment Conditions" according to
the price list only apply under the conditions listed below:

- for multi-shift operation

- if only original coolant from the manufacturer is used

- with regular maintenance and regular change of coolant

Depending on the operating mode used, the coolant pump will have a service life of
approx. 30,000 operating hours assuming it is used properly. After the end of its nominal
service life, the coolant pump may develop a fault. To avoid a lengthy period of work dis­ruption, the pump should be scheduled for replacement after approx. 30,000 operating
hours.

are not described in these operating instructions, or vice versa. Certain illustrations may
also differ slightly from the actual controls on your device, but these controls function in
exactly the same way.

CAUTION!

Danger from using non-permitted coolant.

This can result in serious damage to property.

Only use coolant available from the manufacturer.

▶

Do not mix different coolants.

▶

When changing the coolant, make sure all the coolant is replaced.

▶

When switching from ethanol-based coolant to FCL 10 coolant, Change Kit FCL10

▶

must be used and the instructions provided must be followed.

19

Warning notices

www.fronius.com

Ser.No.:

Part No.:

on the device

The cooling unit is fitted with safety symbols and a rating plate. The rating plate and
safety symbols must not be removed or painted over. The symbols warn against operat­ing the equipment incorrectly, as this may result in serious injury and damage.

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 used

- All persons not involved must be kept at a safe distance from the cool­ing unit and the welding process

Do not use the functions described here until you have fully read and
understood the following documents:

- this document

- all documents relating to the system components, especially the safety
rules

Do not dispose of used devices with domestic waste. Dispose of them
according to the safety rules.

20

Scope of supply and options

Scope of supply

EN

OPT CU coolant
filter

The coolant filter is equipped with a CrNi screen; its function is to filter dirt particles
above 100 micrometres in size from the coolant. This ensures that no coarse dirt
particles can pass into the coolant circuit. The coolant filter is fitted to the coolant return
connection on the cooling unit.

The coolant filter is available as an option for the cooling unit.

21

Function of the installed sensors

Function of the
CU Flow-Thermo­Sensor

The Flow-Thermo-Sensor (coolant temperature monitoring and flow monitoring) is
installed in the cooling unit at the factory.

Coolant temperature monitoring

A temperature sensor monitors the coolant return temperature during welding.

How it works:

- If the temperature of the coolant reaches 68 °C (154.4 °F)

• the power source outputs a warning

• the welding current is not interrupted

• the cooling 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 operational

- The temperature sensor restores the welding current when the coolant temperature
falls to 65 °C (149 °F)

Flow monitoring

A flow sensor monitors the coolant flow during welding.

Function of the
CU Level-Sensor

How it works:

- If the coolant flow falls to between 1 and 0.7 l/min (0.26 - 0.18 gal./min [US])

• the power source outputs a warning

• the welding current is not interrupted

• the cooling unit remains operational

- If the coolant flow drops below 0.7 l/min (0.18 gal./min [US])

• the power source outputs an error message

• flow monitoring interrupts the welding current

• the cooling unit is switched off

The Level-Sensor is installed in the cooling unit at the factory and monitors the coolant
level in the cooling unit.

How it works:
If the coolant drops below the minimum level

- the power source outputs a warning

- the welding current is not interrupted

- the cooling unit remains operational

22

Connections and mechanical com-

ponents

23

24

Connections and mechanical components

www.fronius.com

Ser.No.:

Part No.:

(1)

(2)

(3)

(4)

(6)

(7)

(9) (10)

(5)

(8)

Connections and
mechanical com­ponents: CU
2000i Pro /MC
main part

(1) Blanking cover

(2) Blanking cover

EN

(3) Screw cap for coolant container

(4) Operating and maintenance instructions

(5) Coolant viewing window

(6) Coolant return connection (red)

(7) Coolant flow connection (blue)

(8) Rating plate

(9) Connection

to connect to the CU 2000i Pro /MC cooling part

(10) Cooling unit/power source connection

Depending on the design of the welding system, to connect to the CU 2000i
Pro /MC cooling part or a power source

25

Connections and

(1) (2) (3) (4) (6)

(7)

(5)

mechanical com­ponents: CU
2000i Pro /MC
cooling part

(1) Blanking cover

(2) Blanking cover

(3) Coolant return connection (red)

(4) Coolant flow connection (blue)

(5) Connection cable

to connect to the CU 2000i Pro /MC main part

(6) Power source connection

to connect to a power source

(7) Cooling unit connection

to connect to the CU 2000i Pro /MC main part

26

Installation and commissioning

27

28

Before installation and commissioning

EN

Safety

Setup regulations

WARNING!

Danger due to incorrect operation and incorrectly performed work.

This can result in severe personal injury and damage to property.

All the work and functions described in this document must only be carried out and

▶

used by trained and qualified personnel.
Fully read and understand this document.

▶

Fully read and understand all the Operating Instructions for the system components,

▶

especially the safety rules.

WARNING!

Danger from machines falling or toppling over.

This can result in serious injury and damage to property.

Place all system components on a solid, level surface in such a way that they

▶

remain stable.

WARNING!

Danger from electric current.

An electric shock can be fatal.

Ensure the cooling unit is properly insulated.

▶

Always ensure that there is no electrically conductive connection between the base

▶

plate of the cooling unit and the surface.
Before installing the cooling unit, remove all electrically conductive parts between

▶

the base plate of the cooling unit and the surface.

The device is tested to IP 23 protection, meaning:

- Protection against penetration by solid foreign bodies with diameters > 12.5 mm
(0.49 in.)

- Protection against spraywater at any angle up to 60° to the vertical

Cooling air

The system must be set up in such a way that the cooling air can flow unimpeded
through the slots in the side panels. Ensure that there is always an all-round clearance of

0.5 m (1 ft 7.69 in.) around the device.

CAUTION!

Risk from insufficient cooling air supply.

This can result in serious damage to property.

Air inlets and outlets must never be covered, not even partially.

▶

Dust

Ensure that any metallic dust, for example from grinding work, is not sucked into the sys­tem by the fan.

Outdoor operation

The device can be set up and operated outdoors in accordance with degree of protection
IP23. Avoid direct wetting (e.g. from rain).

29

Information about
the coolant

The cooling unit is delivered empty.

Use only original Fronius coolant (Cooling Liquid FCL 10/20 or torch coolant) when filling
the cooling unit. Other coolants are not recommended for electrical conductivity and
material compatibility reasons.

Guarantee provi­sions regarding
the coolant pump

Proper use The device is intended solely for use in conjunction with Fronius system components.

The coolant pump may only be used with original coolant supplied by the manufacturer.
Do not allow the coolant pump to 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.

The device is to be used exclusively for its intended purpose.

Any use above and beyond this purpose is deemed improper. The manufacturer is not
liable for any damage, or unexpected or incorrect results arising out of such misuse.

Proper use also includes:

- carefully reading these operating instructions

- following all the instructions and safety rules in these operating instructions

- performing all stipulated inspection and maintenance work

The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.

30

Securing the cooling unit and power source to the
trolley/upright console

Safety

Securing the
cooling unit and
power source to
the trolley

Danger from electric current.

An electric shock can be fatal.

▶
▶
▶

The screws for securing the cooling unit to the trolley are supplied with the trolley.

The rest of the screws required are supplied with the cooling unit.

1 2

WARNING!

Turn the power source mains switch to the "O" position.
Disconnect the power source from the mains.
Ensure that the power source remains disconnected from the mains until all work

has been completed.

NOTE!

EN

3

31

Securing the
cooling unit and
power source to
an upright con­sole

NOTE!

The screws for securing the cooling unit to the upright console are supplied with
the upright console.

The rest of the screws required are supplied with the cooling unit.

1 2

3

32

Securing the
cooling unit and
power source to
two upright con­soles

NOTE!

The screws for securing the cooling unit to the upright consoles are supplied with
the upright consoles.

The rest of the screws required are supplied with the cooling unit.

NOTE!

On the main part of the cooling unit, only screw the power source which has the
OPT/i TPS 2. NT241 CU 1400i.

1

EN

2

NOTE!

If two upright consoles are being used, always position the welding systems so
that the air outlet openings on the cooling units point outwards.

33

Connect the coolant hoses to the cooling unit

Safety

Connecting the
coolant hoses to
the cooling unit

WARNING!

Danger from electric current.

An electric shock can be fatal.

Turn the power source mains switch to the "O" position.

▶

Disconnect the power source from the mains.

▶

Ensure that the power source remains disconnected from the mains until all work

▶

has been completed.

NOTE!

Connect the coloured coolant hoses to the corresponding coolant flow and return
connections on the cooling unit.

NOTE!

The coolant filter pictured below is available as an option.

Connecting the coolant hoses to the cooling unit/welding system mounted on trol­ley or an upright console:

1

2

34

3

* = Interconnecting hosepack

Connecting the coolant hoses to the cooling unit/welding system mounted on two
upright consoles:

4

EN

5

35

6

* = Interconnecting hosepack

36

Filling and starting up the cooling unit

3

2

max.

1

EN

Filling the cool­ing unit

WARNING!

Danger from electric current.

An electric shock can be fatal.
Before starting the work described below:

turn the power source mains switch to the "O" position

▶

disconnect the power source from the mains

▶

ensure that the power source remains disconnected from the mains until all work

▶

has been completed

NOTE!

Make sure that no coolant enters the device.

If there is any coolant on the exterior of the cooling unit, remove it immediately.

1 2

3 4

37

5

Starting up the
cooling unit

NOTE!

Before starting up the cooling unit, first check that it contains an adequate amount
of coolant and that the coolant is clean and uncontaminated.

NOTE!

During welding, check at regular intervals that the coolant is circulating properly.

You should be able to see a steady return flow of coolant into the coolant container.

The cooling unit is powered and controlled by the power source. If the power source
mains switch is turned to position "I", the cooling unit will start to operate as described
below.

- The fans run for approx. 5 seconds.

- The coolant pump runs for approx. 3 minutes. The coolant pump and the fans switch
off again if welding does not start after roughly 3 minutes.

NOTE!

Long hosepacks may cause the Level-Sensor to issue an error message after
starting the device for the first time.

If this happens, top up the coolant.

Operating modes

38

NOTE!

The individual operating modes are selected on the power source.

on

- As soon as the power source is switched on the coolant pump starts working and is
controlled electronically depending on the coolant return temperature and the
coolant flow. The coolant pump pumps at least 1.1 l/min (0.29 gal./min [US]) of
coolant.

- The fans work at full load.

- The coolant pump and fans remain on until the power source is switched off.

off

- Inoperative, even when welding starts.

auto
(factory setting)

- The coolant pump and fans start working when welding starts.

- At the end of welding the coolant pump and fans continue to work for 2 minutes.

eco

- The coolant pump starts working when welding starts and is controlled electronically
depending on the coolant return temperature and the coolant flow. The coolant
pump pumps at least 1 l/min (0.26 gal./min [US]) of coolant.

- The fans in the main part start working from a coolant return temperature of 40 °C
(104 °F) and are controlled electronically depending on the coolant return temperat­ure.

- The fans in the cooling part start working from a coolant return temperature of 40 °C
(104 °F) at full load.

- At the end of welding the coolant pump and fans in the main part continue to work
for 2 minutes depending on the coolant return temperature. The fans in the cooling
part continue to work at full load. After these 2 minutes have passed, all the fans and
the coolant pump are switched off.

EN

Recommended
application of the
operating modes

on

for high performance welding (maximum cooling capacity)

eco

for energy-efficient cooling

- longer service life of the coolant pump

- less soiling of the cooler in the cooling unit

- lower noise emissions

- reduced power consumption

39

40

Disconnecting the system compon-

ents

41

42

Disconnecting the system components

EN

Safety

Disconnecting
the system com­ponents

WARNING!

Danger from electric current.

An electric shock can be fatal.

Turn the power source mains switch to the "O" position.

▶

Disconnect the power source from the mains.

▶

Ensure that the power source remains disconnected from the mains until all work

▶

has been completed.

CAUTION!

Danger from hot coolant.

This can result in severe scalds.

Wait until the coolant has cooled down before carrying out any of the activities

▶

described below.

NOTE!

The following information must be observed for all possible system designs (weld­ing system on trolley, welding system on two upright consoles, etc.

).

CAUTION!

Risk of injury and damage due to short circuits at the connection on the underside
of the power source/cooling unit.

Dirt and damage can cause short circuits at the connection. After dismantling the power
source/cooling unit, always close the flap on the cover (1).

Disconnecting the coolant hoses from the cooling unit

1

43

"click"

"click"

8

5

3

6

3

6

4

7

(1)

(1)

2

44

Troubleshooting

45

46

Troubleshooting

EN

Safety

WARNING!

Danger due to work that has been carried out incorrectly.

This can result in serious injury and damage to property.

All the work described below must only be carried out by trained and qualified per-

▶

sonnel.
Fully read and understand this document.

▶

Fully read and understand all the Operating Instructions for the system components,

▶

especially the safety rules.

WARNING!

Danger from electric current.

An electric shock can be fatal.

Turn the power source mains switch to the "O" position.

▶

Disconnect the power source from the mains.

▶

Ensure that the power source remains disconnected from the mains until all work

▶

has been completed.
After opening the device, use a suitable measuring instrument to check that electric-

▶

ally charged components (e.g. capacitors) have been discharged.

WARNING!

Danger from inadequate ground conductor connections.

This can result in serious injury and damage to property.

The housing screws provide a suitable ground conductor connection for earthing the

▶

housing and must NOT be replaced by any other screws that do not provide a reli­able ground conductor connection.

CAUTION!

Danger from hot coolant.

This can result in severe scalds.

Wait until the coolant has cooled down before carrying out any of the activities

▶

described below.

CAUTION!

Risk from coolant leakage.

This can result in serious damage to property.

Make sure that no coolant gets into the device.

▶

If there is any coolant on the exterior of the cooling unit, remove it immediately.

▶

Troubleshooting Make a note of the serial number and configuration of the device and contact our After-

Sales Service team with a detailed description of the error, if

- errors occur that are not listed below

- the troubleshooting measures listed are unsuccessful

47

Insufficient or no coolant flow

Cause:

Remedy:

Coolant level too low

Top up coolant

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Insufficient cooling power

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Constriction or foreign body in cooling circuit

Remove constriction or foreign body

Coolant contaminated

change coolant, see Changing the coolant on page 53.

Coolant filter displaced when connecting coolant return

Clean coolant filter using clean tap water or change filter element

Coolant pump defective

Contact After-Sales Service

Cooler contaminated

Gas purge cooler with dry compressed air

Faulty fan

Contact After-Sales Service

Coolant pump defective

Contact After-Sales Service

High operating noise level

Cause:

Remedy:

Cause:

Remedy:

Welding torch becomes very hot

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Coolant level too low

Top up coolant

Coolant pump defective

Contact After-Sales Service

The specification of the cooling unit is inadequate

Observe the duty cycle and loading limits

The specification of the welding torch is inadequate

Observe the duty cycle and loading limits

Inadequate coolant flow

Check coolant level. Top up with coolant if necessary.
Check coolant for contamination. Change coolant if necessary, see Chan-

ging the coolant on page 53.

Inadequate coolant flow - coolant pump jammed

Contact After-Sales Service

48

Care, maintenance and disposal

49

50

Care, maintenance and disposal

EN

Safety

WARNING!

Danger due to work that has been carried out incorrectly.

All the work described below must only be carried out by trained and qualified personnel.

Fully read and understand this document.

▶

Fully read and understand all the Operating Instructions for the system components,

▶

especially the safety rules.

WARNING!

Danger from electric current.

An electric shock can be fatal.

Turn the power source mains switch to the "O" position.

▶

Disconnect the power source from the mains.

▶

Ensure that the power source remains disconnected from the mains until all work

▶

has been completed.
After opening the device, use a suitable measuring instrument to check that electric-

▶

ally charged components (e.g. capacitors) have been discharged.

WARNING!

Danger from inadequate ground conductor connection.

This can result in serious injury and damage to property.

The housing screws provide a suitable ground conductor connection for earthing the

▶

housing and must NOT be replaced by any other screws that do not provide a reli­able ground conductor connection.

CAUTION!

Danger from hot coolant.

This can result in severe scalds.

Wait until the coolant has cooled down before carrying out any of the activities

▶

described below.

CAUTION!

Risk from coolant leakage.

This can result in serious damage to property.

Make sure that no coolant gets into the device.

▶

If there is any coolant on the exterior of the cooling unit, remove it immediately.

▶

General Under normal operating conditions, the device requires only a minimum of care and

maintenance. However, it is vital to observe some important points to ensure the welding
system remains in a usable condition for many years.

51

Symbols for care

(1)

(2)

(3)

and maintenance
of the cooling
unit

(1) Changing the coolant
(2) Gas purging the cooler
(3) Read operating instructions

The relevant maintenance intervals and
maintenance work are described in detail
over the following pages.

Maintenance
intervals, main­tenance work

At every start-up

CAUTION!

Risk due to start-up without coolant.

This can result in serious damage to property.

If water-cooled system components are operated without coolant, this will normally

▶

result in the failure of the system components.
Fronius shall not be liable for any damage resulting from such action. In addition, no
warranty claims will be entertained.

- Ensure that all the hosepacks, the welding torch and the ground earth connection
are undamaged

- Check that there is an all-round clearance of 0.5 m (1 ft 7.69 in.) to ensure that cool­ing air can flow in and out freely

- Check the screw connections between all system components for tightness

- Check all the coolant connections of the welding system for tightness

- Monitor the coolant return flow in the coolant container

- If no coolant is returning to the container, identify and remedy the cause

Once a week

- Check coolant level. If the coolant level is below the "min" mark, top up with coolant

- Check the purity of the coolant. Change the coolant if necessary

52

CAUTION!

Risk from non-permitted coolant.

This can result in serious damage to property.

Use only original Fronius coolant (Cooling Liquid FCL 10/20 or torch coolant) when

▶

filling the cooling unit.
Other coolants are not recommended for electrical conductivity and material compat-

▶

ibility reasons.

Every 2 months

- If present: Check the coolant filter for dirt and clean if necessary

Every 6 months

- Gas purge the cooler

Every 6 months in 3-shift operation with ethanol-based coolant

1

- Gas purge the cooler

- Change the coolant

Every 12 months in single-shift operation with ethanol-based coolant

- Change the ethanol-based coolant

Every 12 months in 3-shift operation with FCL 10/20 coolant

- Change the coolant

Every 24 months in single-shift operation with FCL 10/20 coolant

- Change the coolant

EN

Gas purging the
cooler

Gas purging the cooler

NOTE!

For the sake of clarity, the cooling unit is shown in the following figures without
the power source.

However, the power source can remain on the cooling unit when gas purging the cooler.
Always follow the instructions in the "Safety" section at the start of the "Care, mainten­ance and disposal" chapter.

CAUTION!

Danger of damage to electronic components.

Do not bring the air nozzle too close to electronic components.

▶

Remove the device side panels and clean the cooler

1

If a large amount of dust has accumulated: Remove device side panels and clean

2

inside of device with dry, reduced compressed air

Changing the
coolant

Main part Cooling part

To change the coolant:

53

CAUTION!

2

1

6

4

5

3

1

3

2

4

Risk of injury and damage from the welding current and accidental ignition of an
arc.

Before starting work:

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 the system, remove the wirespool or the basket-type spool from the

▶

power source or the wirefeeder

NOTE!

The coolant must not be disposed of in the public sewage system.

Dispose of coolant in accordance with the applicable local and national regulations.

NOTE!

Use only original Fronius coolant when refilling the cooling unit.

1

2

NOTE!

Seal off the coolant hose as soon as it
is pulled out of the coolant pump con­nection.

This will ensure that as little coolant as
possible enters the device. Immediately
remove any coolant that enters the device
or spills onto its exterior.

54

2

1

3

4

min.

3

1

2

4

3

max.

2

1

5 6

4

EN

7 8

55

9

1

2

3

Ensure that all hose connections are properly established and are not leaking

10

Ensure that there is no coolant inside the device or on its exterior

11

12

Disposal Dispose of in accordance with the applicable national and local regulations.

56

Technical data

57

58

Technical data

General The cooling capacity of a cooling unit depends on

- Ambient temperature

- Delivery head

- Flow rate Q (l/min) - The flow rate Q depends on the length of the interconnecting
hosepack and the diameter of the hose.

EN

CU 2000i Pro /MC

Supply voltage 24 V DC

Current consumption max. 6.5 A

Cooling power at
Q = 1 l/min + 25 °C (77 °F)
Q = 1 l/min + 40 °C (104 °F)
Q = max. + 25 °C (77 °F)
Q = max. + 40 °C (104 °F)

Max. delivery head, at 5 bar (72.52 psi)
pump pressure

Max. delivery rate 3 l/min

0.79 gal./min [US]

Max. pump pressure at 4750 rpm, auto
operating mode

Max. pump pressure at up to 6500 rpm,
eco and on operating mode

Pump centrifugal pump with no seal

Pump service life up to 30,000 hrs

Coolant capacity 6 l

2000 W
1500 W
3200 W
2400 W

up to 45 m

147 ft. 7.65 in.

4 bar

58.02 psi

5 bar

72.52 psi

1.59 gal. [US]

Degree of protection IP 23

Dimensions of main part l/w/h 710/300/230 mm

27.95/11.81/9.06 in.

Dimensions of cooling part l/w/h 660/300/230 mm

25.98/11.81/9.06 in.

Weight (without coolant) 23 kg

50.71 lb.

Flow monitoring
(sensor)

Coolant temperature monitoring Warning above 68 °C (154.4 °F),

Level-Sensor Warning or error message

Marks of conformity CE, CSA

Warning between 1 and 0.7 l/min

(0.26 - 0.18 gal./min [US]),

error message below 0.7 l/min

(0.18 gal./min [US])

error message above 70 °C (158 °F)

59

FRONIUS INTERNATIONAL GMBH

Froniusstraße 1

A-4643 Pettenbach

AUSTRIA

[e-mail]

www.fronius.com

Under www.fronius.com/contact you will find the addresses

of all Fronius Sales & Service Partners and locations