Table of Contents
Troubleshooting
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Summary of Contents for Fronius FK 9000 R
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions FK 9000 R Cooling unit 42,0426,0019,EN 015-02062021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Safety Prepare cooling unit for the operation with two power sources Mount part 1 and part 2 of the FK 9000 R to the stand-console Connect Master power source with part 1 of the FK 9000 R Mount Master power source to part 1 of the FK 9000 R... - Page 4 Prepare cooling unit for the operation with two power sources Mount part 1 and part 2 of the FK 9000 R at the stand-console Connect Master power source with part 1 of the FK 9000 R Mount Master power source to part 1 of the FK 9000 R...
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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
FK 9000 R is loc- ated beneath a power source. The cooling unit FK 9000 R is equipped with the following sensors as a standard: temperature controller: at a cooling return temperature of more than 70 °C the ser- vice code “Hot | H2O“... -
Page 17: Information On Leaks
Information on The shaft sealing surfaces inside the coolant pump are lubricated by the coolant, mean- leaks 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. -
Page 18: Area Of Application
FK 9000 R in con- Use of the FK 9000 R cooling unit in conjunction with the TransTig / MagicWave 4000 / junction with a TT 5000 power source is recommended particularly when the application involves any of the... -
Page 19: Technical Data
FK 9000 R NOTE! Together with the Autotrafo option the cooling device FK 9000 R is also suitable for a mains frequency of 60 Hz. Supply voltage (supply via power source) 2 x 380-415 V, 50 Hz... -
Page 20: Control Elements And Connections
Coolant guard window Notes regarding maintenance and operation Data plate Dummy cover Dummy cover FK 9000 R - Part 1: Front view Part 2: Front view FK 9000 R - Part 2: Front view Part 1: Rear view Water drain Plug-type connection (blue) ... -
Page 21: Part 2: Rear View
(15) (12) (15) Screwed connection for connection line part 1 - part 2 FK 9000 R - Part 2: Rear view Part 1: Connec- (16) tion plug (17) Part 1: Connection plug at top casing panel Part 2: Connection plug at bottom casing panel... -
Page 22: Fk 9000 R For Parallel Operation Of Two Power Sources
Safety WARNING! Maloperation can cause severe damages to persons and objects. The following work may only be carried out by skilled personnel trained by Fronius! Stick to the safety instructions. WARNING! An electric shock can be fatal. Before opening up a machine, switch it off, unplug it from the mains and put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently switching the machine back on again. -
Page 23: Mount Part 1 And Part 2 Of The Fk 9000 R To The Stand-Console
Mount casing panel of part 1 of the FK 9000 R Mount part 1 and IMPORTANT! part 2 of the FK The installation of the FK 9000 R in connection with two power sources is 9000 R to the described by the example of the stand-console. stand-console... -
Page 24: Mount Master Power Source To Part 1 Of The Fk 9000 R
(27) as far as possible with part 2 of the of the opening at the bottom casing FK 9000 R panel. Pull out connection plug of part 2 (28) as far as possible of the opening at the top casing panel. -
Page 25: Mount Slave Power Source To Part 2 Of The Fk 9000 R
Position Slave power source on top of part 2 by means of suitable lifting device Connect connection plug of part 2 (28) with connection plug of Slave power source (27) Mount Slave Shift hexagon nut (25) supplied with (25) power source to part 2 from inside into the hexagon part 2 of the FK opening of the mounting frames (29) - Page 26 Connect connection hoses with screwed connection of part 1 (10) and screwed con- nection of part 2 (15) Connect flow line of the connection hose pack - at plug-type connection of water flow of part 1 (9) - blue - at plug-type connection of water flow (30) of the wire feeder Connect return line of the connection hose pack - at plug-type connection of water return of part 2 (14) - at plug-type connection of water return (31) of the wire feeder...
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Page 27: Fk 9000 R In Connection With Time Twin Digital
FK 9000 R in connection with Time TWIN digital Safety WARNING! Maloperation can cause severe damages to persons and objects. The following work may only be carried out by skilled personnel trained by Fronius! Stick to the safety instructions. WARNING! An electric shock can be fatal. -
Page 28: Mount Part 1 And Part 2 Of The Fk 9000 R At The Stand-Console
Mount part 1 and IMPORTANT! part 2 of the FK 9000 R at the The installation of the FK 9000 R in connection with two power sources is stand-console described by the example of the stand-console. NOTE! Danger of overheating of the cooling unit in spite of thermal controller. -
Page 29: Mount Master Power Source To Part 1 Of The Fk 9000 R
(27) as far as possible with part 2 of the of the opening at the bottom casing FK 9000 R panel. Pull out connecting plug part 2 (28) as far as possible of the opening at the top casing panel. -
Page 30: Mount Slave Power Source To Part 2 Of The Fk 9000 R
Position Slave power source on top of part 2 by means of suitable lifting device Connect connection plug of part 2 (28) with connection plug of Slave power source (27) Mount Slave Shift hexagon nut (25) supplied with (25) power source to part 2 from inside into the hexagon part 2 of the FK (29) - Page 31 Connect connection hose with screwed connection of part 1 (10) and screwed con- nection of part 2 (15) Connect flow line of the connection hose pack 1 - at plug-type connection of water flow part 1 (9) - blue - at plug-type connection of water flow (32) of the wire feeder 1 Connect return line of the connection hose pack 1 - at plug-type connection (33) of coupling line - at plug-type connection of water return (34) of the wire feeder 1...
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Page 32: Fk 9000 R In Connection With One Power Source
Insert the 2-pole Molex plug X5 (for thermo control) on the 2-pole Molex socket. IMPORTANT! Do not yet mount the casing panel of part 1 of the FK 9000 R. For carrying out the steps described in the chapter “Connect part 1 and part 2 of the FK 9000 R“, it is required that the casing of part 1 is open. -
Page 33: Preparing The Cooling Unit For Use With A Transtig / Magicwave 4000 / 5000 Power Source
The TransTig / MagicWave 4000 / 5000 power sources have water connections on the cooling unit for front of the housing. This means that both parts of the FK 9000 R underneath the power use with a Tran- source have to be rotated through 180°. In addition to the contents of the section „Pre- sTig / MagicWave pare cooling unit for use with a power source“, the following measures also need to be... -
Page 34: Fitting The Extension For The Gas Bottle Mount
It is not permitted to install TransTig / MagicWave 4000 / 5000 power sources on a trolley with both parts of the FK 9000 R stacked on top of each other. This type of configuration may only be carried out on an upright console that is bolted securely to the floor. -
Page 35: Mount Part 2 Of The Fk 9000 R To The Carriage
180° compared to the illustrations below. (40) (39) (40) (40) Mount part 2 of the FK 9000 R to the carriage Assemble carriage, mount mounting angle (38) to carriage bottom plate Position cooling unit on carriage bottom or on mounting angle (38) -
Page 36: Connect Part 1 And Part 2 Of The Fk 9000 R
(40) of suitable lifting device Pull connection plug of part 2 of the (28) FK 9000 R as far as possible through the opening at the bottom casing panel of part 1 Connect connection plug of part 1 (28) at the connection plug of part 1 (40) in... -
Page 37: Mount Part 1 Onto Part 2 Of The Fk 9000 R
When positioning the power source, prevent the connection plug and the cable from get- ting kinked or damaged. Position power source on top of part 1of the FK 9000 R by means of suitable lifting device Connect connection plug of part 1 (25) with connection plug of power source (24) -
Page 38: Mount Power Source Onto Part 1 Of The Fk 9000 R
1 of the FK 9000 opening of the mounting frames (29) (29) Place power source carefully onto part 1 of the FK 9000 R Mount Slave power source using the supplied Allen screws at the front and rear side of part 1... - Page 39 return line flow line (32) (34) connection hose (10) (14) (15) Fig.1 Coolant connections on TS / TPS 4000 / 5000 (rear view) return line flow line connection hose (10) (14) (15) Fig.2 Coolant connections on TT / MW 4000 / 5000 (front view)
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Page 40: Putting The Cooling Unit Into Service
Switch mains switch of the power source(s) in position “ON” - the cooling pump starts operation. Part 1 of the FK 9000 R: shift back the safety ring on the plug-type connection of water flow (blue) (9) Disconnect water flow hose... -
Page 41: Start Operation Of Cooling Unit
Check water connections 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 “ON”... -
Page 42: Configuration Of The Cooling Unit For Multi-Voltage Power Sources
1 of the FK 9000 R. The auto transformer in part 1 of the cooling unit FK 9000 R can be configured for the following supply voltages:... - Page 43 Dismantle casing panels of part 1 of the FK 9000 R Change terminals of auto transformer of the respective supply voltage according to the wiring schematic. Configuration of the supply voltage: view of the auto transformer fixed wiring factory configuration...
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Page 44: 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 45: Every Week
Payment” referred to in the pricelist shall only apply where the following conditions Terms of Delivery are fulfilled: and 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... -
Page 46: Disposal
Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 47: Troubleshooting
Troubleshooting General remarks The cooling unit FK 9000 R is equipped with the following sensors as a standard: Temperature controller: at a coolant return temperature of more than 70 °C the ser- vice code “Hot | H2O“ is shown on the operating panel Flow controller: at a flow of less than 0.7 l/min the service code “no | H2O“... -
Page 48: Start Rotation Of The Cooling Pump
(41) of the cooling pump and rotate the impeller replace cooling pump fuse (2) FK 9000 R - Part 1: Starting rotation of the cooling pump Troubleshooting Coolant flow too low or no flow... - Page 49 High operating noise level Cause: Coolant level too low Remedy: Refill coolant Cause: Cooling pump defective Remedy: Replace coolant pump no l H2O The flow watchdog (option) or flow sensor in the cooling unit has tripped. The error mes- sage is displayed on the operating panel of the power source. Cause: Cooling flow error Remedy:...
- Page 52 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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