Fronius CU 800i, CU 1100i, CU 1200i, CU 1400 Operating Instruction [EN]

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Operating Instructions

CU 800i CU 1100i CU 1200i CU 1400i

Operating instructions

42,0426,0115,EN 038-19102022

Contents

Safety rules 5

Explanation of safety notices 5 General 5 Proper use 6 Environmental conditions 6 Obligations of the operator 6 Obligations of personnel 6 Mains connection 7 Protecting yourself and others 7 Noise emission values 8 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 14 Commissioning, maintenance and repair 14 Safety inspection 15 Safety symbols 15 Data protection 15 Copyright 15

General information 17

General 19

Device concept 19 Device versions 19 Scope of supply 21 Validity of 'General Delivery and Payment Conditions' 21 Firmware updates 21 Information on leaks 21 Information about the coolant 22

Options 23

OPT/i CU ﬂow temperature sensor 23 OPT/i CU level sensor 24 OPT CU front coolant connections 24 OPT/i CU Torch deﬂate 24

Service life of the coolant pumps 25

Coolant pump service life in cooling units for single-shift operation 25 Coolant pump service life in cooling units for multi-shift operation 25

Warning notices on the device 26

Overview 26

Connections and mechanical components 27

Connections and mechanical components 29

Connections and mechanical components: CU 1100i, CU 1200i, CU 1400i 29 Connections and mechanical components: CU 800i 30

Installation and commissioning 31

Before installation and commissioning 33

Safety 33 Setup regulations 33

Guarantee provisions regarding the coolant pump 34 Intended use 34

Fitting the cooling unit to the trolley 35

General 35 Screwing the cooling unit to the trolley 35

Connecting the cooling unit to the power source 36

Safety 36 Connecting the cooling unit to the power source 36

Connecting the coolant return filter and coolant hoses 38

Safety 38 Connecting the coolant return filter and coolant hoses 38

Filling and starting up the cooling unit 39

Filling the cooling unit 39 Starting up the cooling unit 40 OPT/i CU Torch deﬂate: Emptying/filling the torch hosepack 41

Operating modes 43

Available operating modes 43 Recommended application of the operating modes 44

Disconnect the cooling unit from the power source 45

Safety 45 Disconnecting the cooling unit from the power source 45

Troubleshooting 47

Troubleshooting 49

Safety 49 Troubleshooting 49

Turning the coolant pump shaft on the CU 800i, CU 1100i, CU 1100i /MV 52

Safety 52 Turning the coolant pump shaft 52

Care, maintenance and disposal 53

Care, maintenance and disposal 55

Safety 55 Symbols for care and maintenance of the cooling unit 56 Maintenance intervals, maintenance work 56 Cleaning the coolant return filter on the outside of the unit 57 Cleaning the coolant pre-filter inside the unit (CU 1200i Pro /MC only) 59 Gas purging the cooler 60 Changing coolant (CU 800i, 1100i, and 1400i) 62 Changing coolant (CU 1200i) 65 Disposal 69

Technical data 71

Technical data 73

General 73 CU 800i, CU 800i /460 V 73 CU 800i Pro 75 CU 1100i, CU 1100i /460 V 76 CU 1100i /MV, CU 1100i /MV RVP 78 CU 1200i Pro /MC 80 CU 1400i Pro /MC 81

Safety rules

Explanation of safety notices

DANGER!

Indicates immediate danger.

If not avoided, death or serious injury will result.

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WARNING!

Indicates a potentially hazardous situation.

If not avoided, death or serious injury may result.

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CAUTION!

Indicates a situation where damage or injury could occur.

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

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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

recognised 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.

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 in-

structions 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 sec-

tion "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

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

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

vention 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.

Mains connection

Protecting yourself and others

Devices with a higher rating may affect the energy quality of the mains due to their current 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

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 us-

ing 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 protect-

ive 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 in-

jury

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.

Noise emission values

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.

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.

Risks from mains current and welding current

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.

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.

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.

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

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, such as insulation against conductive ﬂoor or insulation to conductive racks.

If power 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

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 lowvoltage mains.

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

emissions, 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

Network, signal and data transfer lines

IT and telecommunications devices

Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

Mains supply

1. If electromagnetic interference arises despite the correct mains connec-

tion, additional measures are necessary (e.g. use of a suitable line filter)

Welding power-leads

2. must be kept as short as possible

must be laid close together (to avoid EMF problems)

must be kept well apart from other leads

Equipotential bonding

Earthing of the workpiece

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

Shield, if necessary

5. Shield other devices nearby

Shield the entire welding installation

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

Effects on the health of persons in the vicinity, e.g. those with pacemakers

and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-

proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the

welding power-leads and the head/torso of the welder Do not carry welding power-leads 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

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 wirefeeder) 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.

Hook chains or ropes onto all suspension points provided on the load-carry-

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

Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

Requirement for the shielding gas

If the wirefeeder 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 tackle (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.

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

Danger from shielding gas cylinders

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.

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.

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 tak-

ing 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.

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.

Safety measures in normal operation

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.

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.

Commissioning, maintenance and repair

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.

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.

Safety inspection

Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage

The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.

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

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.

and electromagnetic 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.

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.

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.

General information

General

Device concept 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.

Device versions

Cooling unit description Cooling unit compatible with

CU 800i (standard version)

For single-shift operation

The coolant pump and fan are switched

on and off automatically as standard. The operating status of the cooling unit can be manually changed by selecting different operating modes

CU 800i /460 V (standard version for 460 V operation)

For single-shift operation

The coolant pump and fan are switched

on and off automatically as standard. The operating status of the cooling unit can be manually changed by selecting different operating modes

CU 800i Pro (professional version)

For multi-shift operation, multivoltage

operation, 600 V operation The coolant pump and fan are

switched on and off automatically as standard (if the OPT/i CU ﬂow temperature sensor option has been selected, the coolant pump and fan are controlled electronically). The operating status of the cooling unit can be manually changed by selecting different operating modes

TPS 270i C power sources

Cooling unit description Cooling unit compatible with

CU 1100i (standard version)

For single-shift operation

The coolant pump and fan are switched

on and off automatically as standard. The operating status of the cooling unit can be manually changed by selecting different operating modes

CU 1100i /460 V (standard version for 460 V operation)

For single-shift operation

The coolant pump and fan are switched

on and off automatically as standard. The operating status of the cooling unit can be manually changed by selecting different operating modes

CU 1100i /MV, CU 1100i /MV RVP (multivoltage version)

For single-shift and multivoltage opera-

tion The coolant pump and fan are switched

on and off automatically as standard. The operating status of the cooling unit can be manually changed by selecting different operating modes

TPS 320i - 600i power

sources iWave 300i - 500i power

sources (not compatible with Mulitvoltage power sources of the iWave series)

TPS 320i - 600i power

sources

TPS 320i - 600i power

sources

CU 1200i Pro /MC (professional version)

For single- and multi-shift operation,

multivoltage operation, 600 V operation Coolant pump is electronically con-

trolled as standard. The fan is switched on and off automatically. The operating 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 be installed in the power sources.

TPS 320i - 600i power

sources iWave 300i - 500i power

sources

Cooling unit description Cooling unit compatible with

CU 1400i Pro /MC (professional version)

For multi-shift operation, multivoltage

operation, 600 V operation The coolant pump and fan are con-

trolled electronically as standard. The operating status of the cooling unit can be manually changed by selecting different operating modes.

To operate the cooling unit with the TPS 320i - 600i power sources, the "OPT/i TPS

2. NT241 CU 1400i" option must be installed in the power sources.

To operate the cooling unit with the iWave 300i - 500i power sources, the "OPT/i TIG 2nd NT242" option must be installed in the power sources.

Scope of supply The scope of supply comprises:

Cooling unit

5 l coolant in a canister

Four 5x25 mm self-tapping screws

Coolant return filter

Operating Instructions

TPS 320i - 600i power

sources iWave 300i - 500i power

sources

Validity of 'General Delivery and Payment Conditions'

Firmware updates

Information on leaks

With respect to cooling units, the "General Delivery and Payment Conditions" as stated in the price list only apply under the conditions listed below.

CU 800i, CU 800i /460 V, CU 1100i, CU 1100i /460 V, CU 1100i /MV, CU 1100i /MV RVP:

max. 8 hrs operation per day (single-shift operation)

only original Fronius coolant is used

with regular maintenance and regular coolant change

CU 800i Pro, CU 1200i Pro /MC, CU 1400i Pro /MC:

for multi-shift operation

only original Fronius coolant is used

with regular maintenance and regular coolant change

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

The following information on leaks does not 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, meaning that a certain leakage ﬂow should always be expected. A low leakage ﬂow is permitted.

The coolant pump requires a certain warm-up time after being started for the first time or upon restarting after a long period of downtime. An increased leakage ﬂow can occur during this warm-up phase. After the run-in period, the leakage ﬂow normally drops again to a low level. If this is not the case, contact the after-sales service.

Information about the coolant

CAUTION!

Danger from using non-permitted coolant.

This can result in severe damage to property.

Only use coolant available from the manufacturer. Other coolants are not re-

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commended for electrical conductivity and material compatibility reasons. Do not mix different coolants.

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

▶

When switching from ethanol-based coolant to FCL 10/20 coolant, Change

▶

Kit FCL10 must be used and the instructions provided must be followed. Operate the CU1200i Pro /MC exclusively with Cooling Liquid FCL10/20.

▶

Options

OPT/i CU ﬂow temperature sensor

This option is available for the following devices:

CU 800i

CU 800i /460 V

CU 800i Pro

The OPT/i CU ﬂow temperature sensor option offers monitoring of the coolant temperature and ﬂow rate.

Coolant temperature monitoring and ﬂow monitoring are parts of an installation set and cannot be ordered separately.

The CU 1100i, CU 1100i /460V, CU 1100i /MV, CU 1100i / MV RVP, CU 1200i Pro /MC and CU 1400i Pro /MC cooling units have this option installed as standard.

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.

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 remains operational

If the coolant ﬂow drops below 0.4 l/min (0.11 gal./min [US])

The power source outputs an error message

Flow monitoring interrupts the welding current

The cooling unit is switched off

OPT/i CU level sensor

This option is available for the following devices:

CU 1100i

CU 1100i /460 V

CU 1100i /MV

CU 1100i /MV RVP

CU 1200i Pro /MC

The option is installed as standard on the CU 1400i Pro/MC cooling unit.

The level sensor monitors the level of coolant in the cooling unit.

If both the OPT/i CU ﬂow temperature sensor and the OPT/i CU level sensor options are installed in the cooling unit, the level sensor works as follows:

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

If just the OPT/i CU level sensor option is installed in the cooling unit, the level sensor works as follows:

If the coolant drops below 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 connections

OPT/i CU Torch

deﬂate

This option is available for the following devices:

CU 1100i

CU 1100i /460 V

CU 1100i /MV

CU 1100i /MV RVP

CU 1200i Pro /MC

CU 1400i Pro /MC

The option can be used in conjunction with the following power sources:

TPS 320i C

iWave 300i - 500i

This option is available for the following devices:

CU 1100i

CU 1100i /460 V

CU 1100i /MV

CU 1100i /MV RVP

CU 1200i Pro /MC

CU 1400i Pro /MC

Prerequisites for using the OPT/i CU Torch deﬂate option:

OPT/i CU ﬂow temperature sensor installed in the cooling unit

OPT CU coolant connections installed in the front of the cooling unit

The option facilitates emptying/filling the torch hosepack, e.g. when changing the torch body. The power source does not have to be switched off during this process.

Service life of the coolant pumps

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

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

Cooling units Information on the service life of the coolant

pump

CU 800i, 1100i

CU 800i /460 V,

1100i /460 V CU 1100i /MV

CU 1100i /MV RVP

Cooling units Information on the service life of the coolant

CU 800i Pro

CU 1200i Pro /MC

CU 1400i Pro /MC If used properly, the coolant pump will have a

If used properly, the coolant pump will have a service life of approx. 10,000 operating hours. After the end of its nominal service life, the coolant pump could develop a fault. To avoid a lengthy period of work disruption, the pump should be scheduled for replacement after approx. 10,000 operating hours.

pump

If used properly, the coolant pump will have a service life of approx. 20,000 operating hours. After the end of its nominal service life, the coolant pump could develop a fault. To avoid a lengthy period of work disruption, the pump should be scheduled for replacement after approx. 20,000 operating hours.

service life of approx. 30,000 operating hours. After the end of its nominal service life, the coolant pump could develop a fault. To avoid a lengthy period of work disruption, the pump should be scheduled for replacement after approx. 30,000 operating hours.

Warning notices on the device

5 bar (0.5 MPa) 1.1 kW

P1l/min

50 Hz

IEC 60 974-2/-10 Cl.A IP 23

0.35 A

460 V

pmax

www.fronius.com

Ser.No.:

Part No.:

pmax

Overview The cooling unit displays safety symbols and has 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 could result in serious injury or damage to property.

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 safety rules and user documentation for this device and

all system components

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

+ 58 hidden pages

Fronius CU 800i, CU 1100i, CU 1200i, CU 1400 Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual