The warnings and safety instructions in these instructions are intended to protect people from possible injury and the product from damage.
Indicates an immediately dangerous situation
Serious injury or death will result if appropriate precautions are not taken.
Action step to escape the situation
Indicates a potentially dangerous situation
Death or serious injury may result if appropriate precautions are not taken.
Action step to escape the situation
Indicates a potentially dangerous situation
Minor or moderate injury may result if appropriate precautions are not taken.
Action step to escape the situation
Indicates impaired work results and/or damage to the device and components
The warnings and safety instructions are an integral part of these instructions and must always be observed to ensure the safe and proper use of the product.
The warnings and safety instructions in these instructions are intended to protect people from possible injury and the product from damage.
Indicates an immediately dangerous situation
Serious injury or death will result if appropriate precautions are not taken.
Action step to escape the situation
Indicates a potentially dangerous situation
Death or serious injury may result if appropriate precautions are not taken.
Action step to escape the situation
Indicates a potentially dangerous situation
Minor or moderate injury may result if appropriate precautions are not taken.
Action step to escape the situation
Indicates impaired work results and/or damage to the device and components
The warnings and safety instructions are an integral part of these instructions and must always be observed to ensure the safe and proper use of the product.
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the deviceFor the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
The device is to be used exclusively for its intended purpose.
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 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.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose.
Ambient temperature range:The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.
Devices with a higher rating may affect the energy quality of the mains due to their current consumption.
This may affect a number device types in terms of:*) 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.
IMPORTANT! Ensure that the mains connection is earthed properly
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974-1.
It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the 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.
Keep your face away from welding fumes and gases.
Fumes and hazardous gasesEnsure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.
The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the feed rollers and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
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 pretension.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) mustDouble the open circuit voltage of a welding system can occur between the welding electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.
Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.
Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.
After opening the device:If work on live parts is required, have a second person switch off the main switch at the right moment.
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive floor or insulation to conductive racks.
If power distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
EMC device classification as per the rating plate or technical data.
In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
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.
During operationThe welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
Therefore, always keep the welding torch facing away from the body (devices with wirefeeder) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Welding machines for work in areas with increased electrical risk (e.g. near boilers) must carry the 'Safety' sign. However, the welding machine must not be located in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.
If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
Welding with the device during crane transport is only permitted if this is clearly stated in the intended use of the device.
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.
All lifting tackle (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.
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.
Use filters if necessary.
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.
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.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
Do not lift or transport operational devices. Switch off and disconnect devices from the grid before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following components:After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
Any safety devices that are not functioning properly must be repaired before switching on the device.
Never bypass or disable safety devices.
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.
Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain 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. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.
The manufacturer recommends that a safety inspection of the device be performed at least once every 12 months.
The manufacturer recommends that the welding machines be calibrated at the same 12-monthly interval.
A safety inspection should be carried out by a qualified electricianFor safety inspections, follow the appropriate national and international standards and directives.
Further details on the safety inspection and calibration can be obtained from your Fronius branch or your Fronius partner. They will provide you with any documents you may require, on request.
Waste electrical and electronic equipment must be collected separately and recycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Correct disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.
Packaging materialsThe full text of the EU Declaration of Conformity can be found at
https://www.fronius.com .
Devices with the CSA mark satisfy the requirements of the relevant standards in Canada and the USA.
Copyright of these operating instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information regarding any discrepancies in the operating instructions.
Danger from using non-permitted coolant.
This can result in serious damage to property.
Only use coolant available from the manufacturer.
Do not mix different coolants.
When changing the coolant, make sure all the coolant is replaced.
When switching from ethanol-based coolant to FCL 10 coolant, Change Kit FCL10 must be used and the instructions provided must be followed.
The following information on leaks does not apply to the FK 4000 Rob.
The shaft sealing surfaces inside the coolant pump are lubricated by the coolant, meaning 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. An increased leakage flow can occur during this warm-up phase. The leakage flow will normally sink back down to a low level after the warm-up phase. If this is not the case then contact After-Sales Service.
The cooling unit is fitted with safety symbols and a rating plate. The rating plate and 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.
 | Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:
|
 | Do not use the functions described here until you have thoroughly read and understood the following documents:
|
 | Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules. |
The cooling unit is supplied with the auto-transformer FK 4000 option as standard.
The cooling unit is supplied with the auto-transformer FK 4000 option as standard.
The FK 4000 and FK 4000 R US cooling units are equipped with the FK 4000 auto-transformer option as standard.
The FK 4000 and FK 4000 R US cooling units are equipped with the FK 4000 auto-transformer option as standard.
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.
The FK 4000 Rob cooling unit has a thermostat option as standard.
The coolant filter is equipped with a CrNi screen; its function is to filter dirt particles above 100 micrometres in size from the coolant. This ensures that no coarse dirt particles can pass into the coolant circuit. The coolant filter is fitted to the coolant return connection on the cooling unit.
Operating the equipment incorrectly can cause serious injury and damage.
All functions described in this document must only be used by trained and qualified personnel. Do not use any of the functions described until you have thoroughly read and understood the following documents:
this document
all the operating instructions for the system components, especially the safety rules
Operating the equipment incorrectly can cause serious injury and damage.
All functions described in this document must only be used by trained and qualified personnel. Do not use any of the functions described until you have thoroughly read and understood the following documents:
this document
all the operating instructions for the system components, especially the safety rules
| (1) | Fill nozzle with screw cap |
| (2) | Fuse for coolant pump |
| (3) | Blanking cover or coolant return connection (red) |
| (4) | Connector |
| (5) | Blanking cover or coolant flow connection (blue) |
| (6) | Rating plate |
| (7) | Operating and maintenance instructions |
| (8) | Viewing window for coolant level |
| (9) | Blanking cover or coolant return connection (red) |
| (10) | Mounting plate for coolant filter (included in scope of supply of flow sensor with coolant filter option) |
| (11) | Coolant filter (included in scope of supply of flow sensor with coolant filter option) |
| (12) | Drain hose |
| (13) | Blanking cover or coolant flow connection (blue) |
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
Danger from machines falling or toppling over.
This can result in serious injury and damage to property.
Place all system components on a solid, level surface in such a way that they remain stable.
Danger from electric current.
An electric shock can be fatal.
Ensure the cooling unit is properly insulated.
Always ensure that there is no electrically conductive connection between the base plate of the cooling unit and the surface.
Before installing the cooling unit, remove all electrically conductive parts between the base plate of the cooling unit and the surface.
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. Ensure that there is always an all-round clearance of 0.5 m (1 ft 7.69 in.) around the device.
Risk from insufficient cooling air supply.
This can result in serious damage to property.
Air inlets and outlets must never be covered, not even partially.
Dust
Ensure that any metallic dust, for example from grinding work, is not sucked into the system by the fan.
Outdoor operation
The device can be set up and operated outdoors in accordance with degree of protection IP23. Avoid direct wetting (e.g. from rain).
The cooling unit is delivered empty.
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.
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. The manufacturer accepts no liability for damage caused in such cases.
The device is intended solely for use in conjunction with Fronius system components.
The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper.
Proper use also includes: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.
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. capacitors) have been discharged.
An inadequate ground conductor connection can cause serious injury or damage.
The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
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. capacitors) have been discharged.
An inadequate ground conductor connection can cause serious injury or damage.
The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
The coolant connections can be installed either at the front of the cooling unit or at the rear, thanks to the different central connectors.
When using the cooling unit with a TPS 2700, the coolant connections are to be moved from the rear to the front of the cooling unit.
Make sure that no coolant enters the device.
If there is any coolant on the exterior of the device, remove it immediately.
Fit the coolant return connection (1) at the top and secure using the red plastic nut (coolant return is indicated by red insulating tape).
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. capacitors) have been discharged.
An inadequate ground conductor connection can cause serious injury or damage.
The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
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. capacitors) have been discharged.
An inadequate ground conductor connection can cause serious injury or damage.
The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
The TS 4000 MV / 5000 MV and TPS 2700 MV / 4000 MV / 5000 MV power sources can be operated as standard at a mains voltage of 3 x 200-240V / 3 x 380-460V (+/-10%). The mains voltage switching in the power source takes place automatically.
The cooling units are factory-configured for the following mains voltages: | ||
FK 4000 | = | 3 x 230 / 400 V, 50 / 60 Hz, +/-10% |
FK 4000 R | = | 3 x 400 V, 50 / 60 Hz, +/-10% |
FK 4000 Rob | = | 3 x 400 V, 50 / 60 Hz, +/-10% |
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. | ||
The auto-transformer is available as an option for the FK 4000 R, FK 4000 Rob and FK 4000 R FC cooling units.
For the FK 4000 and FK 4000 R US cooling units, the auto-transformer is fitted as standard.
The auto-transformer in the FK 4000, FK 4000 R and FK 4000 Rob cooling units can be configured for the following mains voltages:
Mains frequency in each case 50 / 60 Hz, mains voltage tolerance +/- 10%. |
The auto-transformer in the FK 4000 R US cooling unit can be configured for the following mains voltages:
Mains frequency in each case 50 / 60 Hz, mains voltage tolerance +/- 10%. |
To adapt the FK 4000 R, FK 4000 Rob and FK 4000 R FC cooling units for the respective mains voltage, the optional auto-transformer must be installed on the cooling unit.
The welding system can be fitted to a trolley to make the entire system more mobile.
If the welding system is not equipped with an auto-transformer, the cooling unit must be installed right at the bottom.
The welding system can be fitted to a trolley to make the entire system more mobile.
If the welding system is not equipped with an auto-transformer, the cooling unit must be installed right at the bottom.
The fixing brackets must be placed within the plastic feet (2) of the cooling unit.
(* | Trolley scope of supply |
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
| (* | Cooling unit scope of supply |
Risk of short circuit from kinked or damaged cables.
When positioning the power source, ensure that the cable is not kinked.
When positioning the power source, the cooling unit fixing bars must be placed within the plastic feet of the power source.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
For TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources, the power source (1) must be connected to the cooling unit using an interconnecting hosepack.
A water-cooled welding torch with an external coolant connection is required for welding with a TPS 2700 power source and cooling unit.
The coolant flow and return connections must be moved to the front of the cooling unit (see "Fitting coolant connections to the front of the unit").
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
The cooling unit is delivered without any coolant.
The coolant is supplied separately in a canister. Fill and bleed the cooling unit before start-up.
Make sure that no coolant enters the device.
If there is any coolant on the exterior of the device, remove it immediately.
The coolant level and cleanliness of the coolant must always be checked before commissioning the cooling unit.
During welding, check at regular intervals that the coolant is flowing properly.
You should be able to see a steady return flow of coolant through the fill nozzle.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger due to insufficient ground conductor connection.
This can result in serious personal injury and damage to property.
The housing screws provide a suitable ground conductor connection for grounding the housing.
The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.
Danger from coolant leakage.
This can result in serious personal injury and damage to property.
Immediately remove any coolant that enters the device or spills onto its exterior during the work described in the following.
Danger from hot coolant.
This can result in serious burns or scalding.
Before carrying out any work, allow the coolant to cool to +25 °C / +77 °F.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this device and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger due to insufficient ground conductor connection.
This can result in serious personal injury and damage to property.
The housing screws provide a suitable ground conductor connection for grounding the housing.
The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.
Danger from coolant leakage.
This can result in serious personal injury and damage to property.
Immediately remove any coolant that enters the device or spills onto its exterior during the work described in the following.
Danger from hot coolant.
This can result in serious burns or scalding.
Before carrying out any work, allow the coolant to cool to +25 °C / +77 °F.
Under normal operating conditions, the device 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.
| (1) | Check coolant level |
| (2) | Change the coolant |
| (3) | Gas purge the cooler |
| (4) | Read operating instructions |
The relevant maintenance intervals and work are described in detail in the following pages.
At every start-up
Risk due to start-up without coolant.
This can result in serious damage to property.
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.
Once a week
Risk from non-permitted coolant.
This can result in serious damage to property.
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.
Every 12 months in single-shift operation with ethanol-based coolant
Every 12 months in 3-shift operation with FCL 10/20 coolant
Every 24 months in single-shift operation with FCL 10/20 coolant
 |
| Gas purging the cooler: |
For the sake of clarity, the cooling unit is shown in the following figures without the power source.
However, the power source can remain on the cooling unit when gas purging the cooler.
Always follow the instructions in the "Safety" section at the start of the "Care, maintenance and disposal" chapter.
Risk of damage to electronic components.
Do not bring air nozzle too close to electronic components.
 |
| Changing the coolant: |
The coolant must not be disposed of in the public sewage system.
Dispose of coolant in accordance with the applicable local and national regulations.
Use only original Fronius coolant when refilling the cooling unit.
Excess pressure will damage the cooling unit.
Before gas purging the welding torch with compressed air, undo the screw cap on the fill nozzle.
Dispose of in accordance with the applicable national and local regulations.
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 personnel.
Fully read and understand this document.
Fully read and understand all the Operating Instructions for the system components, especially the safety rules.
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.
After opening the device, use a suitable measuring instrument to check that electrically charged components (e.g. capacitors) have been discharged.
Danger from inadequate ground conductor connections.
This can result in serious injury and damage to property.
The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
Danger from hot coolant.
This can result in severe scalds.
Wait until the coolant has cooled down before carrying out any of the activities described below.
Risk from coolant leakage.
This can result in serious damage to property.
Make sure that no coolant gets into the device.
If there is any coolant on the exterior of the cooling unit, remove it immediately.
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 personnel.
Fully read and understand this document.
Fully read and understand all the Operating Instructions for the system components, especially the safety rules.
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.
After opening the device, use a suitable measuring instrument to check that electrically charged components (e.g. capacitors) have been discharged.
Danger from inadequate ground conductor connections.
This can result in serious injury and damage to property.
The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
Danger from hot coolant.
This can result in severe scalds.
Wait until the coolant has cooled down before carrying out any of the activities described below.
Risk from coolant leakage.
This can result in serious damage to property.
Make sure that no coolant gets into the device.
If there is any coolant on the exterior of the cooling unit, remove it immediately.
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 personnel.
Fully read and understand this document.
Fully read and understand all the Operating Instructions for the system components, especially the safety rules.
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.
After opening the device, use a suitable measuring instrument to check that electrically charged components (e.g. capacitors) have been discharged.
Danger from inadequate ground conductor connections.
This can result in serious injury and damage to property.
The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
Danger from hot coolant.
This can result in severe scalds.
Wait until the coolant has cooled down before carrying out any of the activities described below.
Risk from coolant leakage.
This can result in serious damage to property.
Make sure that no coolant gets into the device.
If there is any coolant on the exterior of the cooling unit, remove it immediately.
Make a note of the serial number and configuration of the device and contact our After-Sales Service team with a detailed description of the error, if
| Cause: | Coolant level too low |
| Remedy: | Top up coolant |
| Cause: | Constriction or foreign body in cooling circuit |
| Remedy: | Remove constriction or foreign body |
| Cause: | Coolant pump fuse defective |
| Remedy: | Replace coolant pump fuse |
| Cause: | Coolant contaminated |
| Remedy: | Change the coolant |
| Cause: | Coolant filter displaced when connecting coolant return |
| 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" section). Contact after-sales service if the coolant pump shaft proves impossible to turn |
| Cause: | Coolant pump defective |
| Remedy: | Contact after-sales service |
| Cause: | Permitted duty cycle exceeded |
| Remedy: | Wait until the end of the coolant pump cooling phase |
| Cause: | Flow sensor has tripped, requesting parameter F3 from the welding system shows that there is nothing flowing through: Coolant pump defective |
| Remedy: | Contact after-sales service |
| Cause: | Flow sensor has tripped, requesting parameter F3 on the power source shows that there is still a small amount flowing through: coolant hoses kinked or coolant filter displaced when connecting coolant return |
| Remedy: | Repair coolant hoses, clean coolant filter using clean tap water or change filter element |
| 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 |
| Cause: | Coolant level too low |
| Remedy: | Top up coolant |
| Cause: | Coolant pump defective |
| Remedy: | Contact After-Sales Service |
| Cause: | Coolant flow problem |
| Remedy: | Check coolant level, cleanliness and proper return; change coolant if necessary |
| Cause: | Coolant filter displaced when connecting coolant return |
| Remedy: | Clean coolant filter using clean tap water or change filter element |
| Cause: | The coolant temperature is too high |
| Remedy: | Wait until the end of the cooling phase, i.e. until "hot | H2O" is no longer displayed. If using a ROB 5000 or field bus coupler for robot control: Before resuming welding, set the "Source error reset" signal. |
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 personnel.
Fully read and understand this document.
Fully read and understand all the Operating Instructions for the system components, especially the safety rules.
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.
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 personnel.
Fully read and understand this document.
Fully read and understand all the Operating Instructions for the system components, especially the safety rules.
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.
Mains voltage | 3 x 230 / 400 V AC |
Mains voltage tolerance | -10% / +10% |
Mains frequency | 50 / 60 Hz |
Current consumption | 0.9 A / 0.6 A |
Cooling power at |
|
Max. delivery head | 5 m |
Max. delivery rate | 1.6 l/min |
Max. pump pressure | 4 bar |
Pump | Oscillating armature pump |
Pump service life | approx. 3,000 hrs |
Coolant quantity | 5.5 l |
Protection class | IP 23 |
Dimensions l/w/h | 725/290/230 mm |
Weight (without coolant) | 14.1 kg |
Mark of conformity | CE |
Mains voltage | 3 x 400 V AC |
Mains voltage tolerance | -10% / +10% |
Mains frequency | 50 / 60 Hz |
Current consumption | 0.6 A |
Cooling power at |
|
Max. delivery head | 33 m |
Max. delivery rate | 3.5 l/min |
Max. pump pressure | 4 bar |
Pump | Centrifugal pump |
Pump service life | approx. 10,000 hrs |
Coolant quantity | 5.5 l |
Protection class | IP 23 |
Dimensions l/w/h | 725/290/230 mm |
Weight (without coolant) | 13.3 kg |
Mark of conformity | CE |
Mains voltage | 3 x 400 V AC |
Mains voltage tolerance | -10% / +10% |
Mains frequency | 50 / 60 Hz |
Current consumption | 0.6 A |
Cooling power at |
|
Max. delivery head | 33 m |
Max. delivery rate | 3.5 l/min |
Max. pump pressure | 4 bar |
Pump | Centrifugal pump |
Pump service life | approx. 15,000 hrs |
Coolant quantity | 5.5 l |
Protection class | IP 23 |
Dimensions l/w/h | 725/290/230 mm |
Weight (without coolant) | 13.3 kg |
Mark of conformity | CE |
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 |
Cooling power at |
|
Max. delivery head | 33 m |
Max. delivery rate | 3.5 l/min |
Max. pump pressure | 4 bar |
Pump | Centrifugal pump |
Pump service life | approx. 10,000 hrs |
Coolant quantity | 5.5 l |
Protection class | IP 23 |
Dimensions l/w/h | 725/290/230 mm |
Weight (without coolant) | 13.3 kg |
Mark of conformity | CSA |
