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Fronius CU 2000i Pro/MC Operating Instructions Manual
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Fronius CU 2000i Pro/MC Operating Instructions Manual

Fronius CU 2000i Pro/MC Operating Instructions Manual

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Operating
Instructions
CU 2000i Pro /MC
EN
Operating Instructions
42,0426,0228,EN
008-18122024

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Summary of Contents for Fronius CU 2000i Pro/MC

  • Page 1 Operating Instructions CU 2000i Pro /MC Operating Instructions 42,0426,0228,EN 008-18122024...
  • Page 3 Contents Safety rules Explanation of safety notices General Proper use Environmental conditions Obligations of the operator Obligations of personnel Mains connection Protecting yourself and others Noise emission values Danger from toxic gases and vapours Danger from flying sparks Risks from mains current and welding current Meandering welding currents EMC Device Classifications EMC measures...
  • Page 4 Safety Securing the cooling unit and power source to the trolley Securing the cooling unit and power source to an upright console Securing the cooling unit and power source to two upright consoles Connect the coolant hoses to the cooling unit Safety Connecting the coolant hoses to the cooling unit Filling and starting up the cooling unit...
  • Page 5 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 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...
  • Page 7 Before leaving the workplace, ensure that people or property cannot come to any harm in your absence. Mains connec- Devices with a higher rating may affect the energy quality of the mains due to tion 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...
  • Page 8 Noise emission The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) values when idling and in the cooling phase following operation at the maximum per- missible operating point under maximum rated load conditions according to EN 60974-1.
  • Page 9 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.
  • Page 10 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.
  • Page 11 If this is the case, then the operator is obliged to take appropriate action to recti- fy the situation. Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be sus- ceptible to interference from the device include: Safety devices Network, signal and data transfer lines...
  • Page 12 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 al- lowed to cool down before handling.
  • Page 13 Danger from Shielding gas cylinders contain gas under pressure and can explode if damaged. shielding gas cyl- As the shielding gas cylinders are part of the welding equipment, they must be inders handled with the greatest of care. Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
  • Page 14 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.
  • Page 15 (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...
  • Page 16 Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA. Data security With regard to data security, the user is responsible for: backing up any changes made to the factory settings saving and retaining personal settings Copyright Copyright of these operating instructions remains with the manufacturer.
  • Page 17 General information...
  • Page 19 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 Connections Cooling part, see and mechanical components: CU 2000i Pro /MC cooling part page The cooling unit and the power source form a unit.
  • Page 20 The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. Part No.: www.fronius.com Ser.No.: Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:...
  • Page 21 Scope of supply and options Scope of supply OPT CU coolant The coolant filter is equipped with a CrNi screen; its function is to filter dirt filter particles above 100 micrometres in size from the coolant. This ensures that no coarse dirt particles can pass into the coolant circuit.
  • Page 22 Function of the installed sensors Function of the The Flow-Thermo-Sensor (coolant temperature monitoring and flow monitoring) CU Flow- is installed in the cooling unit at the factory. Thermo-Sensor 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...
  • Page 23 Connections and mechanical com- ponents...
  • Page 25 (1) (2) (6) (7) (9) (10) mechanical com- ponents: CU 2000i Pro /MC main part Part No.: www.fronius.com Ser.No.: Blanking cover Blanking cover Screw cap for coolant container Operating and maintenance instructions Coolant viewing window Coolant return connection (red) Coolant flow connection (blue)
  • Page 26 Connections and (1) (2) (3) (4) mechanical com- ponents: CU 2000i Pro /MC cooling part Blanking cover Blanking cover Coolant return connection (red) Coolant flow connection (blue) Connection cable to connect to the CU 2000i Pro /MC main part Power source connection to connect to a power source Cooling unit connection to connect to the CU 2000i Pro /MC main part...
  • Page 27 Installation and commissioning...
  • Page 29 Before installation and commissioning Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
  • Page 30 Proper use The device is intended solely for use in conjunction with Fronius system compon- ents. 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.
  • Page 31 Securing the cooling unit and power source to the trolley/upright console Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved and dis- connect them from the grid.
  • Page 32 Securing the NOTE! cooling unit and The screws for securing the cooling unit to the upright console are supplied with power source to an upright con- the upright console. sole The rest of the screws required are supplied with the cooling unit.
  • Page 33 Securing the NOTE! cooling unit and The screws for securing the cooling unit to the upright consoles are supplied power source to two upright con- with the upright consoles. The rest of the screws required are supplied with the soles cooling unit.
  • Page 34 Connect the coolant hoses to the cooling unit Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved and dis- connect them from the grid. ▶...
  • Page 35 * = Interconnecting hosepack Connecting the coolant hoses to the cooling unit/welding system mounted on two upright consoles:...
  • Page 36 * = Interconnecting hosepack...
  • Page 37 Filling and starting up the cooling unit Filling the cool- WARNING! ing unit 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 ▶...
  • Page 38 Starting up the NOTE! cooling unit 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 prop- erly.
  • Page 39 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. The coolant pump starts working when welding starts and is controlled elec- tronically depending on the coolant return temperature and the coolant flow.
  • Page 41 Disconnecting the system compon- ents...
  • Page 43 Disconnecting the system components Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved and dis- connect them from the grid. ▶ Secure all devices and components involved so they cannot be switched back WARNING! Danger from hot coolant.
  • Page 44 "click" "click"...
  • Page 45 Troubleshooting...
  • Page 47 Troubleshooting Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
  • Page 48 Insufficient or no coolant flow Cause: Coolant level too low Remedy: Top up coolant Cause: Constriction or foreign body in cooling circuit Remedy: Remove constriction or foreign body Cause: Coolant contaminated Changing the coolant on page 54. Remedy: change coolant, see Cause: Coolant filter displaced when connecting coolant return Remedy:...
  • Page 49 Care, maintenance and disposal...
  • Page 51 Care, maintenance and disposal Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
  • Page 52 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 ad- dition, no warranty claims will be entertained.
  • Page 53 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 54 NOTE! The coolant must not be disposed of in the public sewage system. Dispose of coolant in accordance with the applicable local and national regula- tions. NOTE! Use only original Fronius coolant when refilling the cooling unit.
  • Page 55 NOTE! Seal off the coolant hose as soon as it is pulled out of the coolant pump con- nection. This will ensure that as little coolant as possible enters the device. Immedi- ately remove any coolant that enters the device or spills onto its exterior.
  • Page 56 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 57 Technical data...
  • Page 59 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 intercon- necting hosepack and the diameter of the hose. CU 2000i Supply voltage 24 V DC...