ESAB CC-11 Plasma Coolant Circulator User manual

C C-11

0558007524 01/2013

Plasma Coolant Circulator

Installation and operation instructions for the CC-11 Plasma Coolant Circulator P/N 0558007515

Instrukciju Rokasgrāmata (LV)

Instrukcijų vadovas (LT)

Instruksjonshåndbok (NO)

Instrukcja obsługi (PL)

Manual de instruções (PT)

 (RU)

Návod na obsluhu (SK)

Navodila za uporabo (SL)

Manual de Instrucciones (ES)

Bruksanvisning (SV)

Manual de utilizare (RO)

Uživatelská příručka (CS)

Instruktionsbog (DA)

Instructiehandleiding (NL)

Instruction Manual (EN)

Kasutusjuhend (ET)

Käyttöohje (FI)

Manuel d'instruction (FR)

Bedienungsanleitung (DE)

Használati útmutató (HU)

Manuale di istruzioni (IT)

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TABLE OF CONTENTS

Maintenance ............................................................................................ 341

Replacement Parts.......................................................................................345

Language Page

Uživatelská příručka (CS) ....................................................................................5

Instruktionsbog (DA).......................................................................................21

Instructiehandleiding (NL) .................................................................................37

Instruction Manual (EN) ....................................................................................53

Kasutusjuhend (ET) ....................................................................................... 69

Käyttöohje (FI)............................................................................................ 85

Manuel d’instructions (FR) ............................................................................... 101

Bedienungsanleitung (DE) ................................................................................117

Használati útmutató (HU) ................................................................................ 133

Manuale delle istruzioni (IT) .............................................................................. 149

Lietotāja rokasgrāmata (LV) .............................................................................. 165

Instrukcijų vadovas (LT) .................................................................................. 181

Instruksjonshåndbok (NO) ............................................................................... 197

Instrukcja obsługi (PL).....................................................................................213

Manual de Instruções (PT)................................................................................229

   (RU)...................................................................... 245

Používateľská príručka (SK) ............................................................................... 261

Navodila za uporabo (SL).................................................................................277

Manual de instrucciones (ES) .............................................................................293

Instruktionshandbok (SV) ................................................................................309

Manual de utilizare (RO)..................................................................................325

TABLE OF CONTENTS

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C C-11

Instructiehandleiding (NL)

0558007524

Circulatiepomp voor plasmavloeistof

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C C-11

Instruction Manual (EN)

0558007524

Plasma Coolant Circulator

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

1.0 Safety Precautions .................................................................................. 57

2.0 Description ..........................................................................................59

2.1 Specications ..................................................................................59

3.0 Installation...........................................................................................61

3.1 Input Power Connections ...................................................................... 62

3.2 Control Connections........................................................................... 64

3.3 Coolant Connections .......................................................................... 65

3.4 Delivery Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.5 CC-11 Front Panel Controls / Functions...........................................................67

4.0 Maintenance.......................................................................................325

4.1 Troubleshooting..............................................................................325

4.2 Test Procedure ...............................................................................326

5.0 Replacement Parts ................................................................................. 329

5.1 General ......................................................................................329

5.2 Ordering .....................................................................................329

Section / Title Page

56

TABLE OF CONTENTS

57

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that

anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding or plasma cutting equipment. The following

recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma

cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in

injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ame proof

clothing, safety gloves.

- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualied electrician.

- Appropriate re extinquishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or

water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and

against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not in-

tended to be used outside during precipitation unless sheltered.

Enclosure Class

Maximum

Tilt Allowed

15°

CAUTION

If equipment is placed on a surface that

slopes more than 15°, toppling over may oc-

cur. Personal injury and / or signicant dam-

age to equipment is possible.

58

SECTION 1 SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON

MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

This product is solely intended for plasma cutting. Any other

use may result in personal injury and / or equipment damage.

CAUTION

To avoid personal injury and/or equipment

damage, lift using method and attachment

points shown here.

59

SECTION 2 DESCRIPTION

2.0 Description

2.1 Specications

These instructions provide installation, operation, service and parts information for the CC-11 Plasma Coolant

Circulator. This unit recirculates coolant to cool electric arc cutting and welding equipment.

Dimensions: 34.00” high (864 mm) x 21.75” wide (552 mm) x 28.00 deep (711 mm)

Weight: 215 lb. dry (97.5 kg) / 249 lb. wet (113 kg)

Pump Type: Positive displacement, rotary vane type with adjustable by-pass valve (200 psi / 13.8 bars max.),

CW rotation as viewed from nameplate.

Radiator Type: Copper tubing, aluminum nned air-to-water type with galvanized steel frame.

AC Input Voltages

50Hz, 1 Phase Input Power 60Hz, 1 Phase Input Power

200 / 230 / 400 / 460 / 575 V., + / - 10%

AC Input Amperage 9 / 8 / 5 / 4 / 3 Amperes

Pump Capacity

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

Cooling Capacity @ 1.60 gpm (6.0 l/min) 16,830 BTU / hr. (4900 watts) 20,200 BTU / hr. (5900 watts)

at 45° F (7.2° C) temperature dierence between high coolant temperature and ambient air temperature using ESAB cool-

ant P/N 0558004297 (25% propylene glycol / 75% distilled water).

Max. Delivery Pressure 175 psig (12 bars)

Reservoir Capacity 4 gallons (15.2 liters)

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61

SECTION 3 INSTALLATION

3.0 Installation

Install the CC-11 in an appropriate location so as to maintain adequate and unrestricted airow into and out of

the cabinetry. For permanent mounting refer to Figure 3.1 for mounting hole dimensions in the base of this unit.

Figure 3.1 Mounting Dimensions

0.531” (13.5 mm) diameter hole, typical, 8 places

19.50”

(495 mm)

1.69”

(43 mm)

3.42”

(87 mm)

17.78”

(452 mm)

3.42”

(87 mm)

62

Figure 3.2 Voltage Links

SECTION 3 INSTALLATION

3.1 Input Power Connections

A 3-conductor power cable suitable to meet the required input power must be installed. The cable must have

0.25" (6.4 mm) ring lugs installed on the machine end. Connect the power leads to the L1 and L2 terminals on

TB1 Input Power Terminal Board and the ground lead to the ground lug on the back of the fan support panel. A

strain relief tting is provided to feed a power cable through the rear panel of the cabinet. Refer to Figure 3.2

for proper Input Voltage Link placement, Figure 3.2 shows link in place for 460 volt input. Electrical installation

must be in accordance with local electrical codes for this type of equipment.

63

SECTION 3 INSTALLATION

Figure 3.3 Input Connection Diagram

Typical Installation -

User-supplied single phase fused power disconnect box with

receptacle and plug

Input Power Cable

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT

CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT

PROCEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS

ARE TO BE MADE FROM A LINE DISCONNECT SWITCH, PLACE THE

SWITCH IN THE OFF POSITION AND PADLOCK IT TO PREVENT IN

ADVERTENT TRIPPING. IF THE CONNECTION IS MADE FROM A FUSE

BOX, REMOVE THE CORRESPONDING FUSES AND PADLOCK THE

BOX COVER. IF IT IS NOT POSSIBLE TO USE PADLOCKS, ATTACH A

RED TAG TO THE LINE DISCONNECT SWITCH OR FUSE BOX WARN

ING OTHERS THAT THE CIRCUIT IS BEING WORKED ON.

WARNING

64

Do not intermittently operate the pump motor as this will cause need-

less wear to the pump.

SECTION 3 INSTALLATION

8-Pin Female Plug

3.2 Control Connections

An 8-pin receptacle J1 is provided on the rear panel to supply the CC-11 with 115 Vac control voltage for pump

motor contactor control. The CC-11 is normally supplied with this control voltage in order for the pump and fan

to operate. J-1 also provides contact closure signals for a satised 1.00 gpm (3.8 l/min) ow switch (pins D and C)

and coolant level switch satised (pins E and H).

CAUTION

65

Do not connect hoses to a solenoid valve that can be closed when the

pump is operating as damage to pump can result.

SECTION 3 INSTALLATION

3.3 Coolant Connections

These connectors are located on the back of the unit. Connect the hoses to the CC-11 accordingly. The torch

hose ends should be tted with one 5/8"-18 male left-hand air / water hose and one 5/8"-18 female right-hand

air / water hose connector.

With the torch and the CC-11 connected, ll the reservoir with the specially formulated torch coolant. Do not use

regular anti-freeze solutions, such as for an automobile, as the additives will harm the pump and torch. ESAB P/N

0558004297 is recommended for service down to 12° F (-11° C). ESAB P/N 156F05 is recommended for service

below 12° F (-11° C) to -34° F (-36° C).

After lling the reservoir, run the pump with its cap removed in order to purge air from the radiator, hoses, and

torch. Re-check coolant level to ensure reservoir is lled. Replace reservoir cap after purging and checking cool-

ant level.

CAUTION

Coolant Connections

66

SECTION 3 INSTALLATION

Pressure Adjustment Screw

3.4 Delivery Pressure Adjustment

Delivery pressure is controlled by the relief valve mounted next to the pump in the tank compartment. Turn-

ing the pressure adjustment screw clockwise increases pressure on the spring and raises the delivery pressure.

Turning it counterclockwise reduces pressure on the spring and reduces the delivery pressure. The pressure is

adjusted at the factory to deliver about 175 psig (12 bar) at 1.5 gallons per minute (5.7 l/min). This is an appropri-

ate setting for the PT-36 on an M3 system. Ordinarily, this should not require further adjustment unless the CC-11

is used in a dierent application.

This relief valve sends bypassed coolant through the radiators and back into the tank. Consequently, a closed

discharge line should not damage the pump.

The pump also has a relief valve built in. This valve is set to be fully open at 250 psig (17.3 bar) by the pump

manufacturer. Its sole purpose is to protect the pump should the external relief valve fail closed. This relief

valve should not be adjusted in the eld. In the unlikely event that the external relief valve fails closed and the

discharge line is closed, a thermostat will stop the pump motor if the pump temperature goes over 131° F (55° C).

67

SECTION 3 INSTALLATION

3.5 CC-11 Front Panel Controls / Functions

A. Pump Pressure Gage:

This is the delivery pressure at the supply tting. The

delivery pressure is set at the factory in the range of

170 to 175 psig at 1.5 gpm (11.7 to 12.1 bar at 5.7 l/min.).

Lower ows will result in higher pressure readings;

higher ows will result in lower pressure readings.

The pressure is set with a back pressure regulator

located near the coolant reservoir. It should not be

necessary to readjust the pressure setting in the eld,

unless the back pressure regulator is replaced or un-

less the CC-11 is used in an application requiring low-

er delivery pressure.

The pump also has a factory preset relief valve for

pump protection only. This setting should not be

tampered with.

B. Main Power On Lamp:

This lamp indicates that the main input supply volt-

age is present.

A

F

E

D

C

B

C. Pump On Lamp:

This lamp indicates that power is being supplied to

the pump and fan motors.

ELECTRIC SHOCK CAN KILL. DO NOT RELY ON

THIS LAMP TO DETERMINE WHETHER LETHAL

VOLTAGES ARE PRESENT BEFORE REMOVING A

SIDE PANEL OR SERVICING THIS UNIT. DISCON-

NECT THE UNIT FROM ITS POWER SOURCE AND

DISCONNECT THE CABLE AT THE AMPHENOL

CONNECTOR. THIS CONNECTOR IS USED TO SUP-

PLY 115 VAC TO A RELAY IN THE CC-11.

WARNING

D. Auto/Test Switch:

When toggled to the auto position the CC-11 pump

and fan motors are energized when a 115 VAC signal

is received from the plasma process controller. The

plasma process controller should supply this signal

whenever input power is supplied to the plasma cut-

ting power source.

When placed in the test position the CC-11 pump and

fan motors are energized without receiving a signal

from the process controller.

68

SECTION 3 INSTALLATION

E. Pump Over Temperature Lamp:

If coolant ow through the CC-11 is substantially blocked, and the back pressure regulator fails to operate prop-

erly, the pump will temporarily be protected by its internal relief valve. After a few minutes of such operation,

however, the pump will reach temperatures which will cause it to fail. A thermal switch is mounted near the

pump which will sense an over temperature condition and shut the pump motor o before damage occurs. If

this thermal switch is activated, this lamp will also be lit.

F. F1 & F2:

Each of these fuses is on one leg of the 230 VAC supplied by the CC-11 to the fan and pump motors.

3.5 CC-11 Front Panel Controls / Functions (con’t.)

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159

SEZIONE 3 INSTALLAZIONE

Figura 3.3 Diagramma di connessione di ingresso

INSTALLAZIONE tipica -

Sezionatore fuso di fase singola fornito dall’utente con connettore

e spina

Cavo di alimentazione

di ingresso

LE SCOSSE ELETTRICHE POSSONO UCCIDERE! PRIMA DI EFFETTUARE

CONNESSIONI DI INGRESSO ELETTRICO ALLA FONTE DI ALIMENTA

ZIONE, È NECESSARIO ESEGUIRE LE “PROCEDURE DI BLOCCO DEL

MACCHINARIO”. SE LE CONNESSIONI DEVONO ESSERE EFFETTUATE

DA UN SEZIONATORE DELLA LINEA, COLLLOCARE L’INTERRUTTORE

SULLA POSIZIONE OFF SPENTO E SIGILLARLO PER PREVENIRE LO

SCATTO INTEMPESTIVO. SE IL COLLEGAMENTO VIENE EFFETTUATO

DA UNA SCATOLA DEI FUSIBILI, RIMUOVERE I FUSIBILI CORRISPON

DENTI E SIGILLARE IL COPERCHIO DELLA SCATOLA. QUALORA NON

SIA POSSIBILE UTILIZZARE I SIGILLI, ATTACCARE UNA TARGHETTA

ROSSA AL SEZIONATORE O ALLA SCATOLA DEI FUSIBILI, PER FARE

SAPERE AGLI OPERATORI CHE IL CIRCUITO È IN FASE DI LAVORAZIONE.

AVVERTIMENTO

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ESAB CC-11 Plasma Coolant Circulator User manual

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