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Summary of Contents for Fronius FK 2500
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions FK 2500 FK 2500 FC Cooling unit FK 2500 MV FK 2500 MV FC FK 2500 Rob FK 2500 MV Rob 42,0426,0047,EN 007-09062021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Contents Safety rules Explanation of safety notices 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 Meandering welding currents EMC Device Classifications EMC measures... - Page 4 Changing the coolant Disposal Troubleshooting Safety Troubleshooting Twisting the coolant pump shaft Safety Turning the coolant pump shaft Technical data General FK 2500, FK 2500 FC FK 2500 MV, FK 2500 MV FC FK 2500 Rob, FK 2500 MV Rob...
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Page 5: Safety Rules
Safety rules Explanation of DANGER! safety notices Indicates immediate danger. ▶ If not avoided, death or serious injury will result. WARNING! Indicates a potentially hazardous situation. ▶ If not avoided, death or serious injury may result. CAUTION! Indicates a situation where damage or injury could occur. ▶... -
Page 6: Environmental Conditions
The device is intended solely for the welding processes specified on the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. Proper use includes: carefully reading and following all the instructions given in the operating instructions studying and obeying all safety and danger notices carefully performing all stipulated inspection and maintenance work. -
Page 7: Protecting Yourself And Others
This may affect a number device types in terms of: Connection restrictions Criteria with regard to the maximum permissible mains impedance Criteria with regard to the minimum short-circuit power requirement at the interface with the public grid see "Technical data" In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company. -
Page 8: Danger From Toxic Gases And Vapours
Danger from The fumes produced during welding contain harmful gases and vapours. toxic gases and Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the vapours International Agency for Research on Cancer. Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device. -
Page 9: Risks From Mains Current And Welding Current
Risks from mains An electric shock is potentially life threatening and can be fatal. current and weld- Do not touch live parts either inside or outside the device. ing current During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers and all pieces of metal that are in contact with the welding wire are live. -
Page 10: Meandering Welding Currents
Meandering weld- If the following instructions are ignored, meandering welding currents can develop with ing currents the following consequences: Fire hazard Overheating of parts connected to the workpiece Irreparable damage to ground conductors Damage to device and other electrical equipment Ensure that the workpiece is held securely by the workpiece clamp. -
Page 11: Emf Measures
Shielding, if necessary Shield off other nearby devices Shield off entire welding installation EMF measures Electromagnetic fields may pose as yet unknown risks to health: effects on the health of others in the vicinity, e.g. wearers of pacemakers and hear- ing aids wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress... -
Page 12: Requirement For The Shielding Gas
Hook chains and/or ropes onto all suspension points provided on the load-carrying equipment. Chains and ropes must be at the smallest angle possible to the vertical. Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices). If the wire-feed unit is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices). -
Page 13: Danger From Escaping Shielding Gas
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories. Danger from Risk of suffocation from the uncontrolled escape of shielding gas escaping shield- Shielding gas is colourless and odourless and, in the event of a leak, can displace the ing gas oxygen in the ambient air. -
Page 14: Commissioning, Maintenance And Repair
Before switching on the device, ensure that no one is likely to be endangered. Check the device at least once a week for obvious damage and proper functioning of safety devices. Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane. -
Page 15: Disposal
(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 follow- ing address: http://www.fronius.com... -
Page 16: General
TransTig 2500 / 3000 series MagicWave 2500 / 3000 series Application areas The FK 2500 cooling unit can be used for: manual and automated applications with the MagicWave 2500/3000 and TransTig 2500/3000 power sources TIG cold-wire welding... -
Page 17: Thermostat Function
Delivery and the price list only apply under the following conditions: Payment Condi- FK 2500, FK 2500 FC, FK 2500 MV FC: Max. 8 hrs/day operation (single shift oper- tions" ation) FK 2500 Rob, FK 2500 MV Rob: 24 hrs/day operation (multi-shift operation) -
Page 18: Information About The Coolant
Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules. Information on The following information on leaks does not apply to the FK 2500 Rob, FK 2500 MV Rob. leaks... - Page 19 The shaft sealing surfaces inside the coolant pump are lubricated by the coolant, mean- ing that a certain leakage flow should always be expected. A low leakage flow is permit- ted. 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.
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Page 20: 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 understood the following documents: ▶... -
Page 21: Before Installation And Commissioning
Before installation and commissioning Safety WARNING! Danger due to incorrect operation and incorrectly performed work. This can result in severe personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out and used by trained and qualified personnel. -
Page 22: 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 material compatibility reasons. Guarantee provi- The coolant pump may only be used with original coolant supplied by the manufacturer. -
Page 23: 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- If there are no fixing brackets fitted to ing unit to the... -
Page 24: Connecting The Cooling Unit To The Power Source
Connecting the cooling unit to the power source Safety WARNING! Danger from electric current. An electric shock can be fatal. ▶ 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. -
Page 25: Putting The Cooling Unit Into Service
Putting the cooling unit into service Safety WARNING! Danger from electric current. An electric shock can be fatal. ▶ 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. -
Page 26: Connecting The Welding Torch
Connecting the Connect the red welding torch coolant welding torch hose to the coolant return connection on the cooling unit Connect the blue coolant hose to the coolant flow connection on 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. -
Page 27: Care, Maintenance And Disposal
Care, maintenance and disposal Safety WARNING! Danger due to work that has been carried out incorrectly. All the work described below must only be carried out by trained and qualified personnel. ▶ Fully read and understand this document. ▶ Fully read and understand all the Operating Instructions for the system components, especially the safety rules. -
Page 28: Symbols For Care And Maintenance Of The Cooling Unit
If water-cooled system components are operated without coolant, this will normally result in the failure of the system components. 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 7.69 in.) to ensure that cool-... -
Page 29: Gas Purging The Cooler
Changing the coolant: coolant NOTE! The coolant must not be disposed of in the public sewage system. Dispose of coolant in accordance with the applicable local and national regulations. NOTE! Use only original Fronius coolant when refilling the cooling unit. -
Page 30: Disposal
Undo the screw cap on the fill nozzle Place a suitable container underneath the cooling unit drain hose to catch the coolant Pull the drain hose out of the upper recess of the cooling unit and hold it in the con- tainer Remove the drain hose cap Allow the coolant to flow into the container... -
Page 31: Troubleshooting
Troubleshooting Safety WARNING! Danger due to work that has been carried out incorrectly. This can result in serious injury and damage to property. ▶ All the work described below must only be carried out by trained and qualified per- sonnel. ▶... - Page 32 hot l H2O The cooling unit thermostat has tripped. Cause: Coolant temperature too high Remedy: Wait until the end of the cooling phase, i.e. until "hot | H2O" is no longer dis- played. If using a ROB 5000 or field bus coupler for robot control: After completion of troubleshooting and before resuming welding, set the "Source error reset"...
- Page 33 Insufficient cooling power Cause: Faulty fan Remedy: Contact after-sales service Cause: Coolant pump defective Remedy: Contact after-sales service Cause: Cooler contaminated Remedy: Gas purge cooler with dry compressed air Cause: Cooling capacity of connected cooling unit not high enough Remedy: Use a cooling unit with a greater cooling power High operating noise level Cause:...
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Page 34: Twisting The Coolant Pump Shaft
Twisting the coolant pump shaft Safety WARNING! Danger due to work that has been carried out incorrectly. This can result in severe personal injury and damage to property ▶ All the work described below must only be carried out by trained and qualified per- sonnel. -
Page 35: Technical Data
Flow rate Q (l/min) - The flow rate Q depends on the length of the interconnecting hosepack and the diameter of the hose. FK 2500, FK 2500 FK 2500 FC FK 2500 FC Mains voltage 400 V AC 400 V AC... -
Page 36: Fk 2500 Mv, Fk 2500 Mv Fc
FK 2500 MV, FK 2500 MV FK 2500 MV FC FK 2500 MV FC Mains voltage 200-230/400-480 V AC 200-230/400-480 V AC Mains voltage tolerance -10% / +10% -10% / +10% Mains frequency 50 / 60 Hz 50 / 60 Hz Current consumption 0.6 A -1.4 A... - Page 37 FK 2500 Rob FK 2500 MV Rob Cooling power at Q = 1 l/min + 25°C (77°F) 800 W 800 W Q = 1 l/min + 40°C (104°F) 500 W 500 W Q = max. + 25°C (77°F) 1160 W 1160 W Q = max.
- Page 40 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@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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