FK 5000
FK 5000 MV
42,0426,0079,EN
012009
GB
Operating instructions
Cooling unit
Dear Reader
Introduction
Thank you for choosing Fronius - and congratulations on your new, technically highgrade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
ud_fr_st_et_00493
012004
Table of contents
General .........................................................................................................................................................
Device concept .........................................................................................................................................
Variants ....................................................................................................................................................
Scope of supply ........................................................................................................................................
Field of application ...................................................................................................................................
Warning notices affixed to the device ......................................................................................................
2
2
2
2
2
3
Options ..........................................................................................................................................................
General ....................................................................................................................................................
Return temperature and flow monitoring ..................................................................................................
Coolant filter .............................................................................................................................................
4
4
4
4
Control elements and connections ................................................................................................................ 5
Front ......................................................................................................................................................... 5
Rear ......................................................................................................................................................... 5
Fitting the cooling unit to the trolley ............................................................................................................... 6
General .................................................................................................................................................... 6
Fitting the cooling unit to the trolley .......................................................................................................... 6
Installation ..................................................................................................................................................... 7
Connecting the cooling unit and the power source .................................................................................. 7
Connecting the interconnecting hosepack to the cooling unit .................................................................. 8
Before commissioning ................................................................................................................................... 9
Safety ....................................................................................................................................................... 9
Setup regulations ..................................................................................................................................... 9
Information on the coolant ........................................................................................................................ 9
Guarantee provisions regarding the coolant pump .................................................................................. 9
Utilisation in accordance with „intended purpose“ .................................................................................. 10
Putting the cooling unit into service .............................................................................................................. 11
General ................................................................................................................................................... 11
Filling the cooling unit .............................................................................................................................. 11
Bleeding the cooling unit ......................................................................................................................... 11
Putting the cooling unit into service ........................................................................................................ 12
Care, maintenance and disposal .................................................................................................................
General ..................................................................................................................................................
Symbols for care and maintenance of the cooling unit ...........................................................................
At every start-up .....................................................................................................................................
Once a week ..........................................................................................................................................
Every 2 months ......................................................................................................................................
Every 6 months ......................................................................................................................................
Every 6 months - in 3-shift operation ......................................................................................................
Every 12 months ....................................................................................................................................
Service life of the coolant pump .............................................................................................................
Disposal .................................................................................................................................................
Validity of „General Delivery and Payment Conditions“ ..........................................................................
13
13
13
13
14
14
14
14
17
19
19
19
Troubleshooting ...........................................................................................................................................
Service codes displayed on the wire-feed unit .......................................................................................
FK 5000 / FK 5000 MV ...........................................................................................................................
Tightening the coolant pump shaft .........................................................................................................
20
20
20
21
Technical data ............................................................................................................................................. 23
General .................................................................................................................................................. 23
FK 5000, FK 5000 MV ............................................................................................................................ 23
1
General
Device concept
The cooling unit fits perfectly into the
modular product concept of the TransSteel
3500 / 5000 power sources.
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.
Variants
Two versions of the cooling unit are produced:
- FK 5000 (basic version)
- FK 5000 MV (Multivoltage version)
The FK 5000 MV adapts itself automatically to the mains voltage.
The Multivoltage version is available only from the factory.
Scope of supply
The scope of supply comprises:
Cooling unit
5 l coolant
Four 5x25mm self-tapping screws
Operating instructions
Field of application
The FK 5000 / FK 5000 MV cooling unit can be used for:
water-cooled MIG/MAG manual welding torches
water-cooled MIG/MAG machine welding torches
water-cooled MIG/MAG robot welding torches
2
Warning notices
affixed to the
device
A number of safety symbols can be seen on the cooling unit rating plate. The safety
symbols must NOT be removed or painted over. The symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
Do not dispose of used cooling units with domestic waste. Dispose of them
according to safety rules.
Do not use the functions until you have read all the operating
instructions.
3
Options
General
The options listed below are available for all cooling unit variants.
Return temperature and flow
monitoring
Return temperature monitoring:
A temperature sensor monitors the return temperature of the coolant.
If the coolant temperature exceeds 75 °C, the sensor interrupts the welding current.
The wire-feed unit outputs the error message „hot | H2O“.
The temperature sensor restores the welding current when the coolant temperature
falls to 65 °C again.
Flow monitoring:
A flow sensor monitors the coolant flow during welding. The cooling unit will switch off if
the coolant flow is disrupted. The wire-feed unit outputs the error message „No | H2O“.
These two components form part of an installation kit.
Coolant filter
The coolant filter is equipped with a CrNi screen, and its function is to filter dirt particles
above 100 micrometers in size from the coolant. This ensures that no coarse dirt particles can pass into the coolant circuit. The coolant filter is installed on the cooling unit
housing from the outside.
4
Control elements and connections
Front
(1) (2)
(3)
No. Function
(4)
(1)
Water flow connection blanking cover
(black)
(2)
Water return connection blanking
cover (red)
(3)
Screw cap for coolant container
(4)
Operation and maintenance instructions
(5)
Coolant inspection window
(5)
Rear
(1)
No. Function
(2)
(4) (3)
5
(1)
Power source connecting plug
(2)
Rating plate
(3)
Water flow connection (black)
(4)
Water return connection (red)
Fitting the cooling unit to the trolley
General
The welding system can be fitted to a PickUp 5000 trolley to make the system (incl.
cooling unit) more mobile.
Important! If the welding system is not equipped with an auto-transformer, the cooling
unit must be installed right at the bottom.
Fitting the cooling unit to the
trolley
CAUTION! Risk of damage to the cooling unit. To ensure that the cooling unit is
properly insulated there must be no electrical conductor connecting the base
plate of the cooling unit to the bottom of the trolley.
6
Installation
Connecting the
cooling unit and
the power source
WARNING! An electric shock can be fatal. If the power source is connected to
the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the device when
- the power source mains switch is in the - O - position,
- the power source is unplugged from the mains.
1
2
1
2
2
7
6
3
4
1
1
2
3
5
2
CAUTION! Risk of short circuit from kinked or damaged cables. When connecting the power source to the cooling unit, ensure that the cables are not kinked.
4
3
3
2
1
1
6
5
7
4
6
CAUTION!! Danger from machines falling or toppling over. Ensure that all
screw connections are secure.
7
Connecting the
interconnecting
hosepack to the
cooling unit
8
Before commissioning
Safety
Setup regulations
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
These operating instructions
All the operating instructions for the system components, especially the
safety rules
WARNING! If one of these machines topples over or falls it could cause
serious or even fatal injury. Place device on a solid, level surface in such a way
that it remains stable.
Cooling air
The system must be set up in such a way that the cooling air can flow unimpeded
through the slots in the side panels.
Dust
Ensure that any metallic dust, for example from grinding work, is not sucked into the
system by the fan.
Outdoor operation
The system can be set up and used outdoors. The built-in electrical parts must, however,
be protected from direct contact with fluids (e.g. external wet cleaning).
Information on
the coolant
The cooling unit is delivered empty. The coolant is supplied separately in a 5 l canister.
Fill the cooling unit with coolant before commissioning the unit.
Use only original Fronius coolant (item no. 40,0009,0046) when filling the cooling unit.
Other coolants are not recommended for electrical conductivity and compatibility reasons.
Guarantee provisions regarding
the coolant pump
The coolant pump may only be used with original coolant supplied by the manufacturer.
Do not allow the coolant pump to run dry (even for a very short time), as this will destroy
the coolant pump. Warranty claims will not be entertained in such cases.
9
Utilisation in
accordance with
„intended purpose“
The device is intended exclusively for cooling Fronius hosepacks and welding torches.
The cooling unit is to be used exclusively for its intendedpurpose.
Utilisation for any other purpose, or in any other manner, shall be deemed to be „not in
accordance with the intended purpose“. The manufacturer is not liable for any damage,
inadequate or incorrect results arising out of such misuse.
Utilisation in accordance with the „intended purpose“ also comprises
carefully reading and following the operating instructions and all safety and danger
notices
performing all stipulated inspection and servicing work.
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.
10
Putting the cooling unit into service
General
The cooling unit is powered from the power source. If the power source mains switch is
turned to position - I -, the cooling unit will also start to operate.
Filling the cooling unit
NOTE! If the cooling unit is being
filled with coolant for the first
time, it must be bled before it is
used.
3
1
2
5
max.
6
Bleeding the
cooling unit
CAUTION!! Danger of scalding by hot coolant. Never bleed the cooling unit until
it has been allowed to cool down.
Bleed the cooling unit:
when it has just been filled
if the coolant is not circulating, even though the coolant pump is working
1
3
1
2
2
2
1
ma
.23 x. 6
6 i mm
nc
h
4
3
4
11
5
Bleeding the
cooling unit
(continued)
3
4
1
1
1
2
Putting the
cooling unit into
service
NOTE! The coolant level and
cleanliness of the coolant must
always be checked before starting the cooling unit.
3
1
2
5
NOTE! During welding, check at
regular intervals that the coolant
is flowing through properly. You
should be able to see a steady
return flow of coolant into the
coolant container.
max.
6
12
Care, maintenance and disposal
General
WARNING! An electric shock can be fatal. Before opening the device:
Turn power source mains switch to position „O“
Unplug the power source from the mains
Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
Using a suitable measuring instrument, check to make sure that electrically
charged components (e.g. capacitors) have been discharged
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. The following activities must only be carried out by trained and qualified personnel. Take note of the „Safety rules“ chapter in the instructions for the
power source and cooling unit.
Under normal operating conditions the cooling unit requires only a minimum of care and
maintenance. However, it is vital to observe some important points to ensure the welding
system remains in a usable condition for many years.
Symbols for care
and maintenance
of the cooling
unit
Change coolant
The relevant maintenance intervals are
described in detail on the following pages.
Blow out
cooler
Read operating instructions
At every start-up
-
Check welding torch, interconnecting hosepack and grounding (earthing) connection
for signs of damage
Check that there is a gap of 0.5 m (1ft. 7.69 in.) all around the machine to ensure
that cooling air can flow and escape unhindered
NOTE! Air inlets and outlets must never be covered, not even partially.
CAUTION!! Danger of scalding by hot coolant. Do not check the water connections until the coolant has had time to cool down.
-
Check the welding torch water connections for leaks
Monitor the water return in the coolant container
If no water is returning, check the cooling unit and bleed if necessary
NOTE! If water-cooled torches are operated without coolant, this will normally
result in a fault in the torch body or hosepack. Fronius shall not be liable for any
damage resulting from such action. In addition, no warranty claims will be
entertained.
13
Every week
CAUTION!! Danger of scalding by hot coolant. Do not check the water connections until the coolant has had time to cool down.
-
Check coolant level and cleanliness.
If the coolant level is below the „min“ mark, top up with coolant.
NOTE! Use only original Fronius coolant (40,0009,0046) when filling cooling
units. Other coolants are not recommended for electrical conductivity and
compatibility reasons.
Every 2 months
Every 6 months
-
Check the return for dirt and clean if necessary
If present: Check that coolant filter and flow monitor are working properly and are
not contaminated; clean if necessary
Blow out cooling unit
NOTE! Risk of damage to electronic components. Do not bring
air nozzle too close to electronic
components.
1
-
Remove the side panels
and clean the water
cooler
If a large amount of dust has
accumulated:
- Dismantle machine side
panels and clean inside of
machine with dry reduced
compressed air
Every 6 months in 3-shift operation
Blow out cooling unit
NOTE! Risk of damage to electronic components. Do not bring
air nozzle too close to electronic
components.
1
-
Remove the side panels
and clean the water cooler
If a large amount of dust has
accumulated:
- Remove side panels and
clean inside of machine with
dry reduced compressed air
14
Every 6 months in 3-shift operation
(continued)
Change coolant
CAUTION!! Danger of scalding by hot coolant. Never change the coolant until it
has cooled down.
Important! Coolant must not be disposed of in the public sewage system.
NOTE! Use only original Fronius coolant (item no. 40,0009,0046) when refilling
the cooling unit.
1
2
1
2
1
2
4
4
3
1
2
3
4
3
3
1
2
2
3
1
4
min.
WARNING! An electric shock can be fatal. Before restarting the cooling unit,
first make sure that:
there is no water inside the cooling unit
all the hose connections are present and correct
15
Every 6 months in 3-shift operation
(continued)
5
6
1
2
3
2
max.
3
4
4
Bleed the cooling unit
CAUTION!! Danger of scalding by hot coolant. Never bleed the cooling unit until
it has been allowed to cool down.
1
3
1
2
2
2
1
ma
.23 x. 6
6 i mm
nc
h
4
3
4
3
5
4
1
1
1
2
16
Change coolant
Every 12 months
CAUTION!! Danger of scalding by hot coolant. Never change the coolant until it
has cooled down.
Important! Coolant must not be disposed of in the public sewage system.
NOTE! Use only original Fronius coolant (item no. 40,0009,0046) when refilling
the cooling unit.
1
2
1
2
1
2
4
4
3
1
2
3
4
3
3
1
2
2
3
1
4
min.
WARNING! An electric shock can be fatal. Before restarting the cooling unit,
first make sure that:
there is no water inside the cooling unit
all the hose connections are present and correct
17
Every 12 months
(continued)
5
6
1
2
3
2
max.
3
4
4
Bleed the cooling unit
CAUTION!! Danger of scalding by hot coolant. Never bleed the cooling unit until
it has been allowed to cool down.
1
3
1
2
2
2
1
ma
.23 x. 6
6 i mm
nc
h
4
3
4
3
5
4
1
1
1
2
18
Service life of the
coolant pump
Important! If used properly the coolant pump will offer a service life of approx. 10,000
operating hours. After the end of its nominal service life, the coolant pump may develop
a fault. To avoid the possibility of a lengthy work disruption the pump should be scheduled for replacement after approx. 10,000 operating hours.
Disposal
Dispose of in accordance with the applicable national and local regulations.
Validity of „General Delivery and
Payment Conditions“
With regard to cooling units, the „General Delivery and Payment Conditions“ shown in
the price list only apply under the following conditions:
-
Max. 8 hrs/day operation (single-shift operation)
Original Fronius coolant used exclusively (item number 40,0009,0046 or
40,0009,0075)
Regular maintenance and regular change of coolant
19
Troubleshooting
Service codes
displayed on the
wire-feed unit
hot | H2O
The optional cooling unit temperature sensor has tripped.
Cause:
Remedy:
Coolant temperature too high
Wait until the end of the cooling phase, i.e. until „hot | H2O“ is no longer
displayed.
ROB 5000 or field bus coupler for robot control: Before resuming welding,
set the „Source error reset“ signal.
no | H2O
The optional cooling unit temperature sensor has tripped.
FK 5000 / FK
5000 MV
Cause:
Remedy:
Coolant flow problem
Check coolant level, cleanliness and proper return; bleed cooling unit if
necessary, top up with coolant
Cause:
Remedy:
Coolant filter (option) displaced when connecting water return
Clean coolant filter using clean tap water or change filter element
Water flow too low or non-existent
Cause:
Remedy:
Coolant level too low
Top up coolant
Cause:
Remedy:
Constriction or foreign body in cooling circuit
Remove constriction or foreign body
Cause:
Remedy:
Coolant pump defective
Contact service team
Cause:
Remedy:
Coolant pump sticking
Tighten the coolant pump shaft - Contact the service team
Cause:
Remedy:
Coolant filter (option) displaced when connecting water return
Clean coolant filter using clean tap water or change filter element
After tightening the coolant pump shaft, coolant pump not working
Cause:
Remedy:
Thermostatic switch on coolant pump has tripped
Wait until the end of coolant pump’s cooling phase (2 - 3 minutes)
Insufficient cooling
Cause:
Remedy:
Faulty fan
Contact service team
Cause:
Remedy:
Coolant pump defective
Contact service team
Cause:
Remedy:
Cooler contaminated
Blow out cooler with dry compressed air
20
FK 5000 / FK
5000 MV
(continued)
High operating noise level
Cause:
Remedy:
Coolant level too low
Top up coolant
Cause:
Remedy:
Coolant pump defective
Contact service team
The welding torch becomes very hot
Cause:
Remedy:
The design dimensions of the torch are not sufficient for this task
Observe the duty cycle and loading limits
Cause:
Remedy:
Inadequate coolant flow
Check coolant level, flow rate, contamination, etc., Coolant pump blocked:
Tighten the coolant pump shaft
Tighten the
coolant pump
shaft
WARNING! An electric shock can be fatal. Before opening the device:
Turn power source mains switch to position „O“
Disconnect power source from mains supply
Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
Using a suitable measuring instrument, check to make sure that electrically
charged components (e.g. capacitors) have discharged
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. The following activities must only be carried out by trained and qualified personnel. Take note of the „Safety rules“ chapter in the instructions for the
power source and cooling unit.
1
1
2
3
4
5
7
6
21
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.
FK 5000,
FK 5000 MV
FK 5000
FK 5000 MV
Mains voltage
400 V AC
200-230/400-480 V AC
Mains voltage tolerance
-10% / +10%
-10% / +10%
Mains frequency
50 / 60 Hz
50 / 60 Hz
Current input
0.6 / 1.4 A
0.6 / 0.7 A
Cooling power at
Q = 1 l/min
+ 25 °C (77 °F)
Q = 1 l/min
+ 40 °C (104 °F)
Q = max.
+ 25 °C (77 °F)
Q = max.
+ 40 °C (104 °F)
1100 W
800 W
1500 W
1000 W
1100 W
800 W
1500 W
1000 W
Max. delivery head
35 m
114 ft. 9.95 in.
35 m
114 ft. 9.95 in.
Max. delivery rate
3.5 l / min
0.92 gal./min
3.5 l / min
0.92 gal./min
Max. pump pressure
4.2 bar
60.89 psi.
4.2 bar
60.89 psi.
Pump
Centrifugal pump
Centrifugal pump
Pump service life
approx. 10,000 hrs.
approx. 10,000 hrs.
Coolant capacity
6l
1.59 gal.
6l
1.59 gal.
Degree of protection
IP 23
IP 23
Dimensions l/w/h
710 / 300 / 230 mm
27.95 / 11.81 / 9.06 in.
710 / 300 / 230 mm
27.95 / 11.81 / 9.06 in.
Weight (without coolant)
9 kg
19.84 lb.
9.1 kg
20.06 lb
Flow monitoring*
Sensor
Sensor
Error below 0.7 l/min Error below 0.7 l/min
Return temperature monitoring*
Error above 75 °C
Error above 75 °C
Marks of conformity
S, CE
S, CE
* Optional
22
D
GB
Ersatzteilliste
Schaltplan
Spare Parts List
Circuit Diagram
F
Liste de pièces de rechange
Schéma de connexions
I
Lista parti di ricambio
Schema
E
Lista de repuestos
Esquema de cableado
P
Lista de peças sobresselentes
Esquema de conexões
NL
Onderdelenlijst
Bedradingsschema
N
Reservdelsliste
Koblingsplan
CZ
RUS
SK
Seznam náhradních dílů
Schéma zapojení
Ñïèñîê çàïàñíûõ ÷àñòåé
Ýëåêòðè÷åñêàÿ ñõåìà
Zoznam náhradných dielov
Schéma zapojenia
ud_fr_st_tb_00149
012008
4,048,001
4,048,001,630
FK 5000
FK 5000 MV
42,0401,1119 (4x)
42,0401,1118 (2x)
BU2,0201,2972
option - 4,100,604
43,0009,0052
BU2,0201,2973
BU2,0201,2974
43,0001,1084
42,0401,1118 (6x)
option - 4,100,612
44,0001,1145
43,0001,1131
42,0402,0236
42,0405,0186 - RED
42,0405,0187 - BLACK
42,0201,0105
44,0001,1398
42,0401,0962
44,0001,1238
44,0001,1253
42,0405,0694
43,0006,0223
4,071,074,Z FKR2500
4,071,073,Z FKC2500 - MV
42,0300,2859
BU2,0201,2976
42,0405,0696
24,0450,1039
43,0006,0170
42,0405,0695
42,0300,2856
42,0401,1116 (4x)
42,0401,0937
42,0201,2969
42,0300,1564
33,0030,0114 - MV
42,0201,2975
42,0405,0693
40,0006,3004
40,0001,0496 -*
40,0009,0046
FK 5000
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi
el_fr_st_kg_01719
1/1
012009
FK 5000
FK 5000 MV
FRONIUS INTERNATIONAL GMBH
Buxbaumstraße 2, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: [email protected]
www.fronius.com
www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations.
ud_fr_st_so_00082
012008