EasyManua.ls Logo

Fronius CU 800i User Manual

Fronius CU 800i
84 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
CU 800i
CU 1100i
CU 1200i
CU 1400i
EN
Operating instructions
42,0426,0115,EN 001-13012022

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Fronius CU 800i and is the answer not in the manual?

Fronius CU 800i Specifications

General IconGeneral
BrandFronius
ModelCU 800i
CategoryAccessories
LanguageEnglish

Summary

Safety Rules

Explanation of safety notices

Clarifies the meaning of safety symbols and warning messages used throughout the manual.

General safety information

Covers device safety standards, operator qualifications, and adherence to operating instructions.

Proper use

Defines the intended purpose of the device and lists prohibited uses to prevent damage or injury.

Environmental conditions

Specifies operational requirements for ambient temperature, humidity, and air quality for optimal performance.

Operator and personnel obligations

Outlines the responsibilities and training requirements for personnel operating the equipment.

Mains connection requirements

Addresses potential impact on mains quality and connection criteria for high-rated devices.

Protecting yourself and others

Details risks from sparks, radiation, EMF, electric shock, noise, fumes, and required protective gear.

Noise emission values

States the maximum sound power level of the device during idling and cooling phases.

Toxic gases and vapours

Warns about hazardous welding fumes and mandates proper ventilation and extraction systems.

Flying sparks and fire hazards

Covers dangers from flying sparks, flammable materials, and potential explosion risks during operation.

Mains and welding current risks

Highlights dangers of electric shock from electrical currents and essential safety measures.

Meandering welding currents

Addresses hazards and consequences of ignoring instructions related to welding currents.

EMC device classifications and measures

Explains EMC emission classes and steps to mitigate electromagnetic interference.

EMF measures

Discusses potential health risks from electromagnetic fields and necessary safety precautions.

Specific hazards

Warns about risks from moving parts, hot components, fire hazards, and coolant handling.

Shielding gas requirements

Specifies quality criteria for shielding gas to ensure optimal welding performance and equipment longevity.

Shielding gas cylinder safety

Provides safety guidelines for handling, securing, and using gas cylinders to prevent accidents.

Escaping shielding gas hazards

Alerts to suffocation risks from undetected shielding gas leaks and the need for adequate ventilation.

Installation and transport safety

Details safety measures for device placement, stability, environmental considerations, and transport.

Safety measures in normal operation

Stresses operating the device only with fully functional safety features and avoiding bypass.

Commissioning, maintenance, and repair

Covers safety protocols for initial setup, regular upkeep, and repairs, including parts usage.

Safety inspection guidelines

Recommends periodic safety checks and calibration by qualified electricians for system integrity.

Disposal instructions

Guides on compliant disposal of the equipment and its components respecting environmental regulations.

Safety symbols explained

Defines compliance marks like CE and CSA, indicating adherence to relevant product standards.

Data protection and copyright

Addresses user responsibility for device settings and acknowledges the manufacturer's copyright.

General Information

General device information

Provides a basic introduction to the cooling unit and its integration with the power source.

Device concept and mounting

Explains how the cooling unit and power source form an integrated system, mountable on trolleys.

Cooling unit versions

Lists available cooling unit models and their compatibility with different Fronius power sources.

Scope of supply

Details the components included with the cooling unit package.

Validity of delivery conditions

Outlines the specific conditions under which standard delivery terms apply to cooling units.

Firmware updates and illustrations

Notes that firmware updates may alter device functions or the appearance of controls.

Information on coolant leaks

Discusses expected coolant leakage from seals and during initial operation phases.

Coolant information and safety

Warns about using non-approved coolants and advises on correct coolant types and handling.

Available optional features

Introduces optional features available for enhanced functionality, such as sensors and specific connections.

OPT/i CU flow temperature sensor

Describes the function of the sensor for monitoring coolant temperature and flow rate.

OPT/i CU level sensor function

Explains how the level sensor monitors coolant and its impact on device operation and error reporting.

OPT CU front coolant connections

Identifies the availability of front-mounted coolant connections for specific models.

OPT/i CU Torch deflate functionality

Details the procedure for emptying and refilling torch hosepacks, useful for torch maintenance.

Coolant pump service life

Provides expected service life estimates for coolant pumps based on operating shifts.

Device warning notices and rating plate

Explains the purpose of warning labels and rating plates for safe and correct device usage.

Overview of device warnings

Summarizes essential prerequisites for safe welding and the importance of reading documentation.

Connections and Mechanical Components

Connections for CU 1100i, 1200i, 1400i

Identifies front and rear connectors, including coolant, gas, and power source interfaces.

Connections for CU 800i

Details the front and rear connection points for the CU 800i model.

Installation and Commissioning

Safety before installation and commissioning

Emphasizes safety protocols, requiring trained personnel and full instruction comprehension.

Setup regulations and cooling air

Covers secure device placement, electrical insulation, and ensuring adequate airflow for cooling.

Guarantee provisions for coolant pump

States warranty conditions related to coolant pump usage and original coolant.

Intended use and proper operation

Defines the device's purpose and guidelines for correct and safe usage with Fronius systems.

Fitting cooling unit to trolley

Describes how to securely mount the cooling unit onto a trolley for enhanced mobility.

Connecting cooling unit to power source

Provides instructions for safely connecting the cooling unit to its power source, stressing clean interfaces.

Connecting coolant hoses and filter

Details the process of attaching coolant hoses and the return filter to the cooling unit.

Filling the cooling unit with coolant

Step-by-step guide for filling the cooling unit with coolant, including safety warnings.

Starting up the cooling unit

Instructions for initial startup, checking coolant levels, and ensuring proper flow.

OPT/i CU Torch deflate procedure

Explains how to empty and refill torch hosepacks, with specific steps for longer hosepacks.

Operating modes overview

Lists and describes the available operating modes (on, off, auto, eco) for controlling the unit.

Recommended operating modes application

Suggests optimal applications for different operating modes based on performance and efficiency needs.

Disconnecting cooling unit from power source

Outlines the safe procedure for disconnecting the cooling unit from the power supply.

Troubleshooting

Safety during troubleshooting

Emphasizes critical safety steps, such as power disconnection, before starting any troubleshooting.

General troubleshooting advice

Advises on recording device details and contacting service for unlisted issues or failed solutions.

Coolant flow issues

Addresses common problems like insufficient or no coolant flow due to low levels, contamination, or pump defects.

Insufficient cooling power

Covers causes of reduced cooling, such as contaminated coolers, faulty fans, or defective pumps.

High operating noise level

Explains potential causes for increased noise, including low coolant levels or pump issues.

Welding torch overheating

Discusses reasons for welding torch overheating, such as inadequate cooling or insufficient coolant flow.

Turning coolant pump shaft (CU 800i/1100i)

Provides instructions for manually rotating the coolant pump shaft on specific models.

Care, Maintenance and Disposal

Safety for care and maintenance

Stresses safety precautions, including power disconnection and checking for charged components, before maintenance.

Symbols for maintenance tasks

Illustrates key symbols representing maintenance actions like coolant change and filter cleaning.

Maintenance intervals and work

Details recommended maintenance schedules and specific tasks for ensuring optimal device performance.

Cleaning coolant return filter

Provides a step-by-step guide for cleaning the external coolant return filter assembly.

Cleaning coolant pre-filter (CU 1200i Pro/MC)

Explains the procedure for cleaning the internal coolant pre-filter unique to CU 1200i Pro/MC models.

Gas purging the cooler

Instructs on purging the cooler using compressed air, with caution regarding electronic components.

Changing coolant (CU 800i, 1100i, 1400i)

Details the process for changing coolant in CU 800i, 1100i, and 1400i models, including disposal notes.

Changing coolant (CU 1200i)

Provides specific instructions for changing coolant in the CU 1200i model.

Disposal of used coolant and device

Guides on the proper and environmentally compliant disposal of coolant and the equipment.

Technical Data

General technical information

Explains factors affecting cooling capacity, such as ambient temperature and flow rate.

CU 800i and CU 800i/460 V specifications

Lists technical data for CU 800i and CU 800i/460 V, including electrical, performance, and dimensional details.

CU 800i Pro specifications

Details technical specifications for the CU 800i Pro, including supply voltage, cooling capacity, and pump service life.

CU 1100i and CU 1100i/460 V specs

Presents technical data for CU 1100i and CU 1100i/460 V, covering electrical, flow, and operational parameters.

CU 1100i/MV and CU 1100i/MV RVP specs

Lists technical specifications for the multivoltage CU 1100i models, including voltage range and cooling performance.

CU 1200i Pro /MC specifications

Provides technical data for the CU 1200i Pro /MC, including cooling capacity, pump type, and protection rating.

CU 1400i Pro /MC specifications

Details technical specifications for the CU 1400i Pro /MC, covering supply voltage, cooling power, and delivery head.

Related product manuals