Related Manuals for Fronius FK 4000
Summary of Contents for Fronius FK 4000
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions FK 4000 Spare parts list FK 4000 R Cooling unit FK 4000 R US FK 4000 R FC FK 4000 Rob 42,0426,0017,EN 008-04032019...
- Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
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Page 5: Table Of Contents
Adapting the cooling unit to the respective mains voltage ................. Safety..............................General ..............................Possible mains voltages for FK 4000, FK 4000 R, FK 4000 Rob and FK 4000 R FC ......Possible mains voltages for FK 4000 R US .................. - Page 6 General ..............................FK 4000 ..............................FK 4000 R, FK 4000 R FC........................FK 4000 Rob............................FK 4000 R US............................Appendix Spare parts list: FK 4000, FK 4000 R, FK 4000 R US, FK 4000 Rob ............Spare parts list: Options..........................
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Page 7: Safety Rules
Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operating company, inefficient operation of the device. -
Page 8: Obligations Of The Operator
Ambient temperature range: during operation: -10 °C to + 40 °C (14 °F to 104 °F) during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F) Relative humidity: up to 50% at 40 °C (104 °F) up to 90% at 20 °C (68 °F) The surrounding air must be free from dust, acids, corrosive gases or substances, etc. -
Page 9: Noise Emission Values
Risk of electrocution from mains current and welding current Greater noise pollution Harmful welding fumes and gases Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties: Flame-resistant Insulating and dry Covers the whole body, is undamaged and in good condition Safety helmet Trousers with no turn-ups... -
Page 10: Danger From Flying Sparks
Fumes and hazardous gases must not be breathed in must be extracted from the working area using appropriate methods. Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour. Otherwise, a protective mask with an air supply must be worn. Close the shielding gas cylinder valve or main gas supply if no welding is taking place. -
Page 11: Meandering Welding Currents
Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pre-load. Do not wrap cables or leads around the body or parts of the body. The electrode (rod electrode, tungsten electrode, welding wire, etc.) must never be immersed in liquid for cooling Never touch the electrode when the power source is switched on. -
Page 12: Emc Device Classifications
EMC Device Clas- Devices in emission class A: sifications Are only designed for use in industrial settings Can cause line-bound and radiated interference in other areas Devices in emission class B: Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains. -
Page 13: Specific Hazards
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example: Fans Cogs Rollers Shafts Wirespools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive components. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. -
Page 14: Factors Affecting Welding Results
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape. Factors affecting The following requirements with regard to shielding gas quality must be met if welding results the welding system is to operate in a correct and safe manner: Size of solid matter particles <... -
Page 15: Safety Measures At The Installation Location And During Transport
Safety measures A device toppling over could easily kill someone. Place the device on a solid, level surface at the installation such that it remains stable location and dur- The maximum permissible tilt angle is 10°. ing transport Special regulations apply in rooms at risk of fire or explosion Observe relevant national and international regulations. -
Page 16: Commissioning, Maintenance And Repair
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer- tain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition. Used coolant must be disposed of properly in accordance with the relevant national and international regulations. -
Page 17: Safety Symbols
(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 Devices marked with the CSA test mark satisfy the requirements of the rele- vant standards for Canada and the USA. -
Page 18: General
With regard to cooling units, the "General Delivery and Payment Conditions" according to eral Delivery and the price list only apply under the following conditions: Payment Condi- Max. 8 hrs/day operation (single-shift operation) / FK 4000 Rob: 24 hrs/day operation tions" (three-shift operation) Only original coolant from the manufacturer is used... -
Page 19: Warning Notices On The Device
The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. Type: Part No.: A-4600 Wels Ser.No.: www.fronius.com IEC 60 974-2/-10 Cl.A IP 23 400 V 0.6 A 50-60 Hz 4 bar (0.4 MPa) -
Page 20: Application Areas
TransSynergic 5000 and TransPuls Synergic 5000, max. length of the interconnecting hosepack 1.2 m (4 ft.) NOTE! The cooling unit is supplied with the auto-transformer FK 4000 option as standard. FK 4000 R, FK The cooling units are recommended for use with:... -
Page 21: Options
5 in.) FK 4000 R The FK 4000 R US, FK 4000 R FC and FK 4000 Rob cooling units are fitted with the flow sensor with coolant filter option as standard. How it works: The option monitors the coolant flow during welding If the coolant flow falls below 0.7l/min (0.18 gal./min), "no | H2"... -
Page 22: Coolant Filter
The FK 4000 Rob cooling unit has a thermostat option as standard. The thermostat option monitors the coolant temperature If the coolant temperature rises to above 70°C (185°F), the "hot | H2" indicator is au- tomatically displayed and the welding current is interrupted. The cooling unit remains operational The thermostat restores the welding current when the temperature falls to 65°C... -
Page 23: Control Elements And Connections
Control elements and connections Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. All functions described in this document must only be used by trained and qualified per- sonnel. Do not use any of the functions described until you have thoroughly read and un- derstood the following documents: ►... -
Page 24: Before Installation And Commissioning
Before installation and commissioning Safety WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All work described in this document must only be carried out by trained and qualified per- sonnel. All functions described in this document must only be used by trained and qualified personnel. -
Page 25: 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 mate- rial compatibility reasons. -
Page 26: Fitting Coolant Connections To The Front Of The Unit
Fitting coolant connections to the front of the unit Safety WARNING! An electric shock can be fatal. Before starting work: ► 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 After opening the device, use a suitable measuring instrument to check that electrically charged components (e.g. - Page 27 (3) (4) Remove blanking covers (5) from the front and attach to the rear NOTE! Fit the coolant return connection (1) at the top and secure using the red plastic nut (coolant return is indicated by red in- sulating tape). Feed the coolant connection (1) and (2) from the inside outwards through the housing and secure to the front of...
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Page 28: Adapting The Cooling Unit To The Respective Mains Voltage
FK 4000 R FC = 3 x 400 V, 50 / 60 Hz, +/-10% FK 4000 R US = 3 x 230 / 460 V, 50 / 60 Hz, +/- 10% The cooling units are adapted accordingly for other mains voltages with the help of an auto-transformer. -
Page 29: Possible Mains Voltages For Fk 4000, Fk 4000 R, Fk 4000 Rob And Fk 4000 R Fc
NOTE! cooling unit to the respective mains To adapt the FK 4000 R, FK 4000 Rob and FK 4000 R FC cooling units for the respec- voltage tive mains voltage, the optional auto-transformer must be installed on the cooling unit. - Page 30 (the im- age to the left shows the reconnec- tion of the auto-transformer using the FK 4000 R US as an example. The (440 V) reconnection is carried out in the same way for other units; only the (460 V) possible voltages differ.
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Page 31: 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 entire system more mobile. NOTE! If the welding system is not equipped with an auto-transformer, the cooling unit must be installed right at the bottom. Fitting the cool- ing unit to the trolley... -
Page 32: Connecting The Cooling Unit To The Power Source
Connecting the cooling unit to the power source Safety WARNING! An electric shock can be fatal. Before starting the work described below: ► turn the power source mains switch to the "O" position ► disconnect the power source from the mains ►... - Page 33 NOTE! When positioning the power source, the cooling unit fixing bars must be placed within the plastic feet of the power source. Placing the power source on the cooling unit Secure the power source to the cooling unit fixing bars using the Allen screws pro- vided (4), two at the front and two at the back...
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Page 34: Connecting The Hosepacks To The Cooling Unit
Connecting the hosepacks to the cooling unit Safety WARNING! An electric shock can be fatal. Before starting the work described below: ► turn the power source mains switch to the "O" position ► disconnect the power source from the mains ►... -
Page 35: Putting The Cooling Unit Into Service
Putting the cooling unit into service Safety WARNING! An electric shock can be fatal. Before starting the work described below: ► 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 General NOTE! -
Page 36: Commissioning The Cooling Unit
Commissioning NOTE! the cooling unit The coolant level and cleanliness of the coolant must always be checked before commissioning the cooling unit. Connect the power source to the mains Turn the power source mains switch to the "I" position The coolant pump starts up Check the coolant flow until you can see a steady return flow of coolant through the fill nozzle NOTE! -
Page 37: Care, Maintenance And Disposal
Care, maintenance and disposal Safety WARNING! Work that is carried out incorrectly can cause serious injury or damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: ►... -
Page 38: Symbols For Care And Maintenance Of The Cooling Unit
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. -
Page 39: Gas Purge The Cooler
Every 2 months If present: Check the coolant filter for dirt and clean if nec- essary Every 6 months Gas purge the cooler Every 6 months Gas purge the cooler for 3-shift opera- Change the coolant tion with ethanol- based coolant Every 12 months Change the ethanol-based coolant for single-shift op-... -
Page 40: Changing The Coolant
Dispose of coolant in accordance with the applicable local and national regulations. NOTE! Use only original Fronius coolant when refilling the cooling unit. Undo the screw cap on the fill nozzle Place a suitable container underneath the cooling unit drain hose to catch the coolant... -
Page 41: Notes On Changing The Welding Torch
Notes on chang- CAUTION! ing the welding torch Excess pressure will damage the cooling unit. Before gas purging the welding torch with compressed air, undo the screw cap on the fill nozzle. Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 43: Troubleshooting
Troubleshooting... -
Page 45: Troubleshooting
Troubleshooting Safety WARNING! Work that is carried out incorrectly can cause serious injury or damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: ►... -
Page 46: Fuse-Protecting The Cooling Unit
Fuse-protecting The cooling unit is protected by three fuses: the cooling unit Coolant pump fuse (1) on the front of cooling unit (fuse blows if the coolant pump be- comes overloaded or blocked) Two fuses (2) inside the unit, above the fan (fuses blow if there is a short circuit to earth) Fuse on front of the unit Fuses above the fan... - Page 47 Remedy: Clean coolant filter using clean tap water or change filter element Cause: Coolant pump is jammed (FK 4000 R, FK 4000 R US and FK 4000 Rob only) Remedy: Turn coolant pump shaft (see operating instructions, "Turning coolant pump shaft"...
- Page 48 High operating noise level Cause: Coolant level too low Remedy: Top up coolant Cause: Coolant pump defective Remedy: Contact After-Sales Service no l H2O The cooling unit flow sensor has tripped. The error message appears on the power source control panel. Cause: Coolant flow problem Remedy:...
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Page 49: Twisting The Coolant Pump Shaft
Twisting the coolant pump shaft Safety WARNING! Work that is carried out incorrectly can cause serious injury or damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: ►... -
Page 50: Technical Data
Dimensions l/w/h 725/290/230 mm 28.54/11.42/9.06 in. Weight (without coolant) 14.1 kg 31.09 Ib. Mark of conformity FK 4000 R, FK Mains voltage 3 x 400 V AC 4000 R FC Mains voltage tolerance -10% / +10% Mains frequency 50 / 60 Hz Current consumption 0.6 A... -
Page 51: Fk 4000 Rob
725/290/230 mm 28.54/11.42/9.06 in. Weight (without coolant) 13.3 kg 29.32 Ib. Mark of conformity FK 4000 R US Mains voltage 200 - 230 / 400 - 460 V AC Mains voltage tolerance -10% / +10% Mains frequency 50 / 60 Hz Current consumption 1.3 A / 0.5 A... - Page 52 Pump Centrifugal pump Pump service life approx. 10,000 hrs Coolant quantity 5.5 l 1.21 gal. Protection class IP 23 Dimensions l/w/h 725/290/230 mm 28.54/11.42/9.06 in. Weight (without coolant) 13.3 kg 29.32 Ib. Mark of conformity...
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Page 53: Appendix
Appendix... -
Page 54: Spare Parts List: Fk 4000, Fk 4000 R, Fk 4000 R Us, Fk 4000 Rob
Spare parts list: FK 4000, FK 4000 R, FK 4000 R US, FK 4000 Rob... -
Page 55: Spare Parts List: Options
Spare parts list: Options... - Page 56 FRONIUS INTERNATIONAL GMBH Vorchdorfer Straße 40, A-4643 Pettenbach, Austria E-Mail: sales@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
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