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Troubleshooting
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Summary of Contents for Fronius CU 1100i
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions CU 800i CU 1100i Cooling unit CU 1400i 42,0426,0115,EN 034-15042021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Connections and mechanical components Connections and mechanical components Connections and mechanical components: CU 1100i, CU 1100i /460V, CU 1100i /MV, CU 1100i /MV RVP, CU 1400i Pro, CU 1400i Pro /MC Connections and mechanical components: CU 800i, CU 800i /460 V, CU 800i Pro... - Page 4 Safety Fitting the coolant filter option Troubleshooting Troubleshooting Safety Troubleshooting Turning the coolant pump shaft on the CU 800i, CU 1100i, CU 1100i /MV Safety Turning the coolant pump shaft Care, maintenance and disposal Care, maintenance and disposal Safety General...
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Page 5: Safety Rules
Safety rules Explanation of DANGER! safety notices 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. ▶... -
Page 6: Environmental Conditions
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. -
Page 7: Protecting Yourself And Others
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. -
Page 8: Danger From Toxic Gases And Vapours
Danger from The fumes produced during welding contain harmful gases and vapours. toxic gases and Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the vapours 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. -
Page 9: Risks From Mains Current And Welding Current
Risks from mains An electric shock is potentially life threatening and can be fatal. current and weld- Do not touch live parts either inside or outside the device. ing current 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. -
Page 10: Meandering Welding Currents
Meandering weld- If the following instructions are ignored, meandering welding currents can develop with ing currents 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. -
Page 11: Emf Measures
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 hear- ing aids wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress... -
Page 12: Requirement For The Shielding Gas
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). -
Page 13: Danger From Escaping Shielding Gas
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories. Danger from Risk of suffocation from the uncontrolled escape of shielding gas escaping shield- Shielding gas is colourless and odourless and, in the event of a leak, can displace the ing gas oxygen in the ambient air. -
Page 14: Commissioning, Maintenance And Repair
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. -
Page 15: Disposal
(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 follow- ing address: http://www.fronius.com... -
Page 17: General Information
General information... -
Page 19: General
CU 1100i /460 V, 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... -
Page 20: Application Area
Payment Condi- tions" 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... -
Page 21: Coolant Pump Service Life In Cooling Units For Multi-Shift Operation
Coolant pump The following coolant pump service life figures apply to the CU 1400i Pro /MC cooling service life in unit. cooling units for multi-shift opera- If used properly, the coolant pump will have a service life of approx. 30,000 operating tion hours. -
Page 22: Information On Leaks
The symbols warn against operat- ing the equipment incorrectly, as this could result in serious injury or damage to property. Part No.: www.fronius.com Ser.No.: IEC 60 974-2/-10 Cl.A IP 23 460 V 0.35 A... - Page 23 Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.
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Page 24: Options
CU 800i /460 V, 1100i /460 V CU 1100i /MV CU 800i Pro, 1400i Pro The option is included as standard on the CU 1100i /MC RVP and CU 1400i Pro/MC cooling unit. Coolant temperature monitoring and flow monitoring are parts of an installation set and cannot be ordered separately. -
Page 25: Opt Cu Coolant Filter
The coolant filter is fitted to the coolant return connection on the cooling unit. The option is included as standard on the CU 1100i /MV RVP cooling unit. OPT/i CU level This option is available with the following devices:... - Page 26 CU 1100i CU 1100i /460 V CU 1100i /MV CU 1100i /MV RVP CU 1400i Pro CU 1400i Pro /MC To operate the OPT/i CU Torch deflate option, the OPT/i CU flow temperature sensor option must be fitted on the cooling unit.
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Page 27: Connections And Mechanical Components
Connections and mechanical com- ponents... -
Page 29: Connections And Mechanical Components
Connections and mechanical components Connections and (1) (2) (10) mechanical com- ponents: CU 1100i, CU 1100i /460V, CU 1100i /MV, CU 1100i /MV RVP, CU 1400i Pro, CU 1400i Pro /MC Front of cooling unit Rear of cooling unit Function... - Page 30 Connections and (1) (2) mechanical com- ponents: CU 800i, CU 800i /460 V, CU 800i Pro Front of cooling unit Rear of cooling unit Function Coolant flow connection (blue) Coolant return connection (red) Screw cap for coolant container Information on maintenance and operation Coolant viewing window Blanking cover Blanking cover...
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Page 31: Installation And Commissioning
Installation and commissioning... -
Page 33: Before Installation And Commissioning
Before installation and commissioning Safety 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. -
Page 34: Information About The Coolant
Information about The cooling unit is delivered empty. the coolant 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 provi- The coolant pump may only be used with original coolant supplied by the manufacturer. -
Page 35: Fitting The Cooling Unit To The Trolley
Fitting the cooling unit to the trolley General The welding system can be fitted to a trolley to make the system (incl. cooling unit) more mobile. CAUTION! Risk due to work that has been carried out incorrectly. This can result in serious damage to property ▶... -
Page 36: Connecting The Cooling Unit To The Power Source
Connecting the cooling unit to the power source Safety 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. - Page 37 Only with OPT/i CU Torch deflate option on the cooling unit: Gas hose in cooling unit scope of supply For gas supply Max. 20 l/min. gas flow rate on the pressure regulator/max. 4 bar...
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Page 38: Connect The Coolant Hoses To The Cooling Unit
Connect the coolant hoses to the cooling unit Safety 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. -
Page 39: Filling And Starting Up The Cooling Unit
Filling and starting up the cooling unit Filling the cool- WARNING! ing unit 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. ▶... -
Page 40: Starting Up The Cooling Unit
"I", the cooling unit will start to operate as described below. CU 800i, CU 800i /460 V, CU 800i Pro, CU 1100i, CU 1100i /460 V, CU 1100i /MV, CU 1100i /MV RVP, CU 1400i Pro, CU 1400i Pro /MC: the fans run for approx. -
Page 41: Opt/I Cu Torch Deflate: Emptying/Filling The Torch Hosepack
The operating status of the cooling unit can be manually changed by selecting different operating modes. CAUTION! Risk from insufficient coolant when using the cooling unit for the first time. This can result in serious damage to property. ▶ If the cooling unit is fitted with an OPT/i CU level sensor, the OPT/i CU level sensor may cause an error message to be output if long hosepacks are being used when starting for the first time. -
Page 42: Operating Modes
The individual operating modes can be selected on the power source. Available on: CU 800i, CU 800i /460 V, CU 800i Pro, CU 1100i, CU 1100i /460 V, CU 1100i /MV, CU 1100i /MV RVP, CU 1400i Pro, CU 1400i Pro /MC Operating status: Continuous. -
Page 43: Recommended Application Of The Operating Modes
Recommended application of the for high performance welding (maximum cooling capacity) operating modes 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... -
Page 44: Disconnect The Cooling Unit From The Power Source
Disconnect the cooling unit from the power source Safety 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. - Page 45 CAUTION! Danger from short circuits. This can result in serious injury and dam- age to property. ▶ Dirt and damage can cause short cir- cuits on the cooling unit connection. ▶ After dismantling the power source, always close the cooling unit connec- "click"...
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Page 46: Fitting The Coolant Filter Option
Fitting the coolant filter option Safety 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. -
Page 47: Troubleshooting
Troubleshooting... -
Page 49: Troubleshooting
Troubleshooting 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. ▶... - Page 50 Remedy: Wait until the end of the coolant pump's cooling phase (2 - 3 minutes) With CU 800i Pro, CU 1100i /460 V, CU 1100i /MV RVP, CU 1400i Pro, CU 1400i Pro /MC: Insufficient or no coolant flow Cause:...
- Page 51 CU 1100i /MV"). Contact After-Sales Service if the coolant pump shaft proves impossible to turn With CU 800i /460 V, CU 800i Pro, CU 1100i /460 V, CU 1100i /MV RVP, CU 1400i Pro, CU 1400i Pro /MC: The welding torch becomes very hot...
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Page 52: Turning The Coolant Pump Shaft On The Cu 800I, Cu 1100I, Cu 1100I /Mv
Turning the coolant pump shaft on the CU 800i, CU 1100i, CU 1100i /MV Safety WARNING! Danger due to work that has been carried out incorrectly. This can result in severe personal injury and damage to property ▶ All the work described below must only be carried out by trained and qualified per- sonnel. -
Page 53: Care, Maintenance And Disposal
Care, maintenance and disposal... -
Page 55: Care, Maintenance And Disposal
Care, maintenance and disposal 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. -
Page 56: Symbols For Care And Maintenance Of The Cooling Unit
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 cool-... -
Page 57: Gas Purging The Cooler
Every 6 months in 3-shift operation with ethanol-based coolant 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 Gas purging the... -
Page 58: Change The Coolant
Dispose of coolant in accordance with the applicable local and national regulations. CAUTION! Risk from using a 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 refilling the cooling unit. - Page 59 CAUTION! Risk from coolant leakage. This can result in serious damage to prop- erty. ▶ Seal off the coolant hose as soon as it is pulled out of the coolant pump con- nection. ▶ Immediately remove any coolant that does get into the device or spills onto the exterior of the device.
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Page 60: Disposal
Ensure that all hose connections are properly established and are not leaking Ensure that there is no coolant inside the device or on its exterior Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 61: Technical Data
Technical data... -
Page 63: Technical Data
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. CU 800i, CU 800i CU 800i /460 V Mains voltage... - Page 64 CU 800i /460 V Mains voltage 460 V AC Mains voltage tolerance -10% / +10% Grid frequency 50/60 Hz Current consumption 0.35 A Cooling capacity at Q = 1 l/min + 25 °C (77 °F) 800 W Q = 1l / min + 40 °C (104 °F) 500 W Q = max.
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Page 65: Cu 800I Pro
CU 800i Pro If a TPS 270i C power source is used with a CU 800i Pro cooling unit, the cooling unit will not benefit from the maximum pump power. Supply voltage 24 V DC Current consumption 4.4 A Cooling capacity at Q = 1 l/min + 25 °C (77 °F) 850 W Q = 1l / min + 40 °C (104 °F) -
Page 66: Cu 1100I, Cu 1100I /460 V
CU 1100i, CU 1100i CU 1100i /460 V Mains voltage 400 V AC Mains voltage tolerance -10% / +10% Grid frequency 50/60 Hz Current consumption 0.7 A Cooling capacity at Q = 1 l/min + 25 °C (77 °F) 1100 W Q = 1l / min + 40 °C (104 °F) - Page 67 CU 1100i /460 V Mains voltage 460 V AC Mains voltage tolerance -10% / +10% Grid frequency 50/60 Hz Current consumption 0.35 A Cooling capacity at Q = 1 l/min + 25 °C (77 °F) 1100 W Q = 1l / min + 40 °C (104 °F) 800 W Q = max.
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Page 68: Cu 1100I /Mv, Cu 1100I /Mv Rvp
CU 1100i /MV, CU 1100i /MV CU 1100i /MV Mains voltage 200 - 230 V AC / 400 - 460 V AC Mains voltage tolerance -10% / +10% Grid frequency 50/60 Hz Current consumption 1.4 A / 0.7 A Cooling capacity at Q = 1 l/min + 25 °C (77 °F) - Page 69 CU 1100i /MV RVP Mains voltage 200 - 230 V AC / 400 - 460 V AC Mains voltage tolerance -10% / +10% Grid frequency 50/60 Hz Current consumption 0.8 A / 0.35 A Cooling capacity at Q = 1 l/min + 25 °C (77 °F) 1100 W Q = 1l / min + 40 °C (104 °F)
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Page 70: Cu 1400I Pro, Cu 1400I Pro /Mc
CU 1400i Pro, If a TPS 320i C power source is used with a CU 1400i Pro or CU 1400i Pro /MC CU 1400i Pro /MC cooling unit, the cooling unit will not benefit from the maximum pump power. CU 1400i Pro Supply voltage 24 V DC Current consumption... - Page 71 CU 1400i Pro /MC Supply voltage 24 V DC Current consumption 4.4 A Cooling capacity at Q = 1 l/min + 25 °C (77 °F) 1400 W Q = 1l / min + 40 °C (104 °F) 900 W Q = max. + 25 °C (77 °F) 1700 W Q = max.
- Page 72 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...