Table of Contents
Summary of Contents for Fronius FK 2200
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions FK 2200 FK 2200 FC Cooling unit 42,0426,0035,EN 004-15012020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
- 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
Contents Safety rules ..............................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.................. - Page 6 Every 12 months in 3-shift operation with FCL 10/20 coolant............... Every 24 months in single-shift operation with FCL 10/20 coolant ............Applicability of the “General Terms of Delivery and Payment” ............. Disposal ..............................Troubleshooting ............................General remarks ........................... Troubleshooting ............................ Technical data............................General ..............................FK 2200 ..............................
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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
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 Protective clothing refers to a variety of different items. Operators should: Protect eyes and face from UV rays, heat and sparks using a protective visor and reg- ulation filter Wear regulation protective goggles with side protection behind the protective visor... -
Page 10: Danger From Flying Sparks
The following components are responsible, amongst other things, for the degree of toxicity of welding fumes: Metals used for the workpiece Electrodes Coatings Cleaners, degreasers, etc. Welding process used The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully. -
Page 11: Meandering Welding Currents
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. Double the open circuit voltage of a power source can occur between the welding elec- trodes of two power sources. -
Page 12: Emc Measures
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. EMC device classification as per the rating plate or technical data. EMC measures In certain cases, even though a device complies with the standard limit values for emis- sions, it may affect the application area for which it was designed (e.g. - Page 13 Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. During operation Ensure that all covers are closed and all side panels are fitted properly. Keep all covers and side panels closed. The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
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Page 14: Requirement For The Shielding Gas
Requirement for Especially with ring lines, contaminated shielding gas can cause damage to equipment and the shielding gas reduce welding quality. Meet the following requirements regarding shielding gas quality: Solid particle size < 40 µm Pressure condensation point < -20 °C Max. -
Page 15: Safety Measures In Normal Operation
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out. Only set up and operate the device in accordance with the degree of protection shown on the rating plate. 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. -
Page 16: Commissioning, Maintenance And Repair
(e.g. relevant product standards of the EN 60 974 se- ries). 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 17: Copyright
Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the ba- sis for any claims whatsoever on the part of the purchaser. -
Page 18: General
“temperature limit controller“. If the cooling unit is fitted with these options or if you have a FK 2200 FC variant with a flow sensor, the power source will always switch off for process reliability reasons if one of the following events occur: The flowrate drops below a determined flowrate value (e.g. -
Page 19: Information On Leaks
Information on The shaft sealing surfaces inside the coolant pump are lubricated by the coolant, meaning leaks that a certain leakage flow should always be expected. A low leakage flow is permitted. The coolant pump requires a certain warm-up time after being started for the first time or upon restarting after a long period of downtime. -
Page 20: Options
Options Installation kit The optional flow controller with water filter controls the coolant flowrate during welding. If “flow controller“ an error with regards to the coolant flowrate occurs, the optional flow controller emits a sig- with water filter nal. The power source switches off. A coolant flowrate error can be caused by not sufficient coolant cooling circulation not vented sufficiently... -
Page 21: Control Elements And Connections
Control elements and connections Rear side Guard window “coolant“ Bushing for coolant pump shaft Coolant pump fuse Screw cap / filler FK 2200 connections on the rear side Front side Plug-in connection water flow (black) Plug-in connection water return (red) Control display ... -
Page 22: Fitting The Cooling Unit To The Trolley
Fitting the cooling unit to the trolley General remarks In order to increase the mobility of the entire welding machine incl. cooling unit, it is possi- ble to mount the welding machine on a carriage. NOTE! The cooling unit is always installed on the bottom. Mount cooling Switch mains switch in position “O“... -
Page 23: Connecting The Cooling Unit To The Power Source
Connecting the cooling unit to the power source Connect power Switch mains switch in position “O“ source with cool- Place power source on cooling unit: ing unit Leave the power source suspended from a suitable lifting device over the cooling unit Pull connection plug (8) of the power source as far as possible through the opening at the bottom... -
Page 24: Connecting The Welding Torch
Connecting the welding torch Connect welding Connect welding torch with power source (see operating instructions “Power Source“). torch with power source Connect welding Connect water connections of the wel- torch with cooling ding torch with the connections of wa- unit ter flow (5) - black - and water return (6) - red - of the cooling unit. -
Page 25: Putting The Cooling Unit Into Service
The manufacturer accepts no liability for damage caused in such cases. Information on Only use original Fronius coolant for the filling of the cooling unit. Other antifreezers cannot the coolant be recommended due to their electric conductivity and compatibility. -
Page 26: Start Operation Of Cooling Unit
Check water hoses for tightness Repeat purge until proper return flow to the filler neck is ensured. Start operation of NOTE! cooling unit Before any start-up of the cooling unit, check the coolant level as well as the coolant purity. Connect supply of power source(s) Switch mains switch of the power source(s) in position “I”... -
Page 27: Care, Maintenance And Disposal
Care, maintenance and disposal General remarks Under normal operating conditions the cooling unit requires only a minimum of care and maintenance. However, it is indispensable to follow some important points to ensure the operationality of the welding machine for many years. Safety WARNING! An electric shock can be fatal. -
Page 28: Every Start-Up
Every start-up Check welding torch, interconnection cable assembly and bondings for damage Check whether the allround distance of 0.5 m (1.6 ft.) is kept to ensure that the cooling air can easily flow and escape. NOTE! Furthermore, air inlets and outlets must in no case be covered, not even covered partly. -
Page 29: Every 6 Months For 3-Shift Operation With Ethanol-Based Coolant
Payment” max. 8 operating hours per day (single-shift operation) only Fronius coolant may be used the unit is given regular maintenance and the coolant is changed regularly Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 30: Troubleshooting
Troubleshooting General remarks If the cooling unit is equipped with one of the following options, the corresponding error message is displayed on the operating panel of the power source: flow controller ... no | H2O (coolant flow error) temperature controller... hot | H2O (excess coolant temperature) Coolant pump fuse Fushing for rotating motor shaft if the coolant pump is blocked... - Page 31 Cooling capacity too low Cause: Fan defective Remedy: Replace fan Cause: Cooling pump defective Remedy: Replace coolant pump Cause: Cooler contaminated Remedy: Clean cooler with dry compressed air Cause: Cooling capacity of cooling unit too low Remedy: Use cooling unit with higher cooling capacity High operating noise level Cause: Coolant level too low...
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Page 32: Technical Data
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 2200 Supply voltage 230 V AC Supply voltage tolerance -30% / +15%... - Page 36 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, 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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