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Fronius FK 4000, Operating Instructions Manual, Page: 52 / 52

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Fronius FK 4000 Operating Instructions Manual Download Page 52

FRONIUS INTERNATIONAL GMBH

Froniusstraße 1

A-4643 Pettenbach

AUSTRIA

[email protected]

www.fronius.com

Under 

www.fronius.com/contact

you will find the addresses

of all Fronius Sales & Service Partners and locations

Summary of Contents for FK 4000

Page 1: ...ne free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy FK 4000 FK 4000 R FK 4000 R US FK 4000 R FC FK 4000 Rob EN Operating instructions Cooling...

Page 2: ......

Page 3: ...pection 14 Disposal 15 Safety symbols 15 Data protection 15 Copyright 15 General 16 Device concept 16 Scope of supply 16 Validity of General Delivery and Payment Conditions 16 Information about the co...

Page 4: ...Connecting the welding torch coolant hoses to the cooling unit TPS 2700 32 Putting the cooling unit into service 34 Safety 34 General 34 Filling the cooling unit 34 Commissioning the cooling unit 35 C...

Page 5: ...evice All persons involved in commissioning operating maintaining and servicing the device must be suitably qualified have sufficient knowledge of welding and read and follow these operating instructi...

Page 6: ...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 Can be used at alti...

Page 7: ...nd sparks using a protective visor and regulation filter Wear regulation protective goggles with side protection behind the protective visor Wear stout footwear that provides insulation even in wet co...

Page 8: ...specifications for the listed components should therefore be studied carefully Recommendations for trade fair scenarios risk management measures and for identify ing working conditions can be found o...

Page 9: ...ouch 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 Touching the potentials of both...

Page 10: ...he 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 th...

Page 11: ...g torch poses a high risk of injury piercing of the hand injuries to the face and eyes etc Therefore always keep the welding torch away from the body devices with wire feed unit and wear suitable prot...

Page 12: ...can cause damage to equipment and reduce welding quality Meet the following requirements regarding shielding gas quality Solid particle size 40 m Pressure condensation point 20 C Max oil content 25 m...

Page 13: ...lean 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...

Page 14: ...ded from the manufacturer s website Check the coolant level before starting to weld while the system is still cool Commissioning maintenance and repair It is impossible to guarantee that bought in par...

Page 15: ...ompatibility directives 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...

Page 16: ...Allen screws for securing the power source on the cooling unit Four M5 nuts for securing the power source on the cooling unit One 2 A fuse spare Operating instructions Validity of Gen eral Delivery a...

Page 17: ...d safety symbols must not be removed or painted over The symbols warn against operat ing the equipment incorrectly as this may result in serious injury and damage 4 bar 0 4 MPa 2 kW P1l min 1 50 60 Hz...

Page 18: ...over 1 2 m 4 ft PullMig or PushPull hosepacks Multilock hosepacks Robacta machine hosepacks Robacta or Robacta Drive robot hosepacks TIME and JobMaster welding torches MIG MAG pulsed arc welding Weldi...

Page 19: ...0 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 b...

Page 20: ...ains operational The thermostat restores the welding current when the temperature falls to 65 C 149 F Coolant filter The coolant filter is equipped with a CrNi screen its function is to filter dirt pa...

Page 21: ...trol elements and connections 1 2 3 4 5 6 7 8 9 10 11 12 13 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 coola...

Page 22: ...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 su...

Page 23: ...liability for damage caused in such cases Proper use The device is intended solely for use in conjunction with Fronius system components The device is to be used exclusively for its intended purpose A...

Page 24: ...not provide a reliable ground conductor connection General The coolant connections can be installed either at the front of the cooling unit or at the rear thanks to the different central connectors W...

Page 25: ...top and secure using the red plastic nut coolant return is indicated by red insulating tape 6 Feed the coolant connection 1 and 2 from the inside outwards through the housing and secure to the front o...

Page 26: ...any other screws that do not provide a reliable ground conductor connection General 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...

Page 27: ...x 200 400 V 3 x 200 440 V 3 x 200 460 V 3 x 230 400 V 3 x 230 440 V 3 x 230 460 V factory configuration Mains frequency in each case 50 60 Hz mains voltage tolerance 10 Adapting the cooling unit to th...

Page 28: ...voltage the image to the left shows the reconnection of the auto transformer using the FK 4000 R US as an example The reconnection is carried out in the same way for other units only the possible volt...

Page 29: ...cooling unit must be installed right at the bottom Fitting the cool ing unit to the trolley 3 2 1 1 Place the cooling unit on the trolley base and fixing bracket 1 NOTE The fixing brackets must be pla...

Page 30: ...uts provided 5 into the hexagon shaped openings on the fixing bars 1 from the inside 2 Unscrew the TX 25 screws from the protective cover on the underside of the power source and remove the pro tectiv...

Page 31: ...xing bars must be placed within the plastic feet of the power source 6 Placing the power source on the cooling unit 7 Secure the power source to the cooling unit fixing bars using the Allen screws pro...

Page 32: ...2 3 1 Plug in and secure the interconnecting hosepack strain relief device 1 in the opening provided on the base of the trolley see trolley operating instruc tions 2 Connect the red hose from the int...

Page 33: ...1 Connect the red welding torch hose 2 to the coolant return connection on the cooling unit 2 Connect the blue welding torch hose 3 to the coolant flow connection on the cooling unit 33 EN...

Page 34: ...is any coolant on the exterior of the device remove it immediately 1 Undo the screw cap on the fill nozzle 1 2 Locking ring on coolant flow connection sealing cone inside coolant flow connection 2 Pul...

Page 35: ...rce to the mains 2 Turn the power source mains switch to the I position The coolant pump starts up 3 Check the coolant flow until you can see a steady return flow of coolant through the fill nozzle NO...

Page 36: ...e been discharged WARNING Danger from inadequate ground conductor connection This can result in serious injury and damage to property The housing screws provide a suitable ground conductor connection...

Page 37: ...ere is an all round clearance of 0 5 m 1 ft 7 69 in to ensure that cool ing air can flow in and out freely Check the screw connections between all system components for tightness Check all the coolant...

Page 38: ...on the cooling unit when gas purging the cooler Always follow the instructions in the Safety section at the start of the Care mainten ance and disposal chapter NOTE Risk of damage to electronic compon...

Page 39: ...t go of the locking ring 1 10 Carefully push back the sealing cone 2 in the centre of the coolant flow connection using a wooden or plastic pin max 6 mm 0 236 in until it audibly engages 11 Fill to th...

Page 40: ...40...

Page 41: ...Troubleshooting 41...

Page 42: ...42...

Page 43: ...itors have been discharged WARNING Danger from inadequate ground conductor connections This can result in serious injury and damage to property The housing screws provide a suitable ground conductor c...

Page 44: ...ses 2 inside the unit above the fan fuses blow if there is a short circuit to earth 1 Fuse on front of the unit 2 Fuses above the fan Troubleshooting Make a note of the serial number and configuration...

Page 45: ...e Flow sensor has tripped requesting parameter F3 from the welding system shows that there is nothing flowing through Coolant pump defective Contact after sales service Flow sensor has tripped request...

Page 46: ...oolant if necessary Coolant filter displaced when connecting coolant return Clean coolant filter using clean tap water or change filter element Cause Remedy Cause Remedy hot l H2O The cooling unit the...

Page 47: ...NING 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 di...

Page 48: ...F 1120 W 700 W Max delivery head 5 m 16 ft 5 in Max delivery rate 1 6 l min 0 42 gal min US Max pump pressure 4 bar 58 psi Pump Oscillating armature pump Pump service life approx 3 000 hrs Coolant qu...

Page 49: ...erance 10 10 Mains frequency 50 60 Hz Current consumption 0 6 A Cooling power at Q 1 l min 25 C 77 F Q 1 l min 40 C 104 F 1360 W 870 W Max delivery head 33 m 108 ft 3 24 in Max delivery rate 3 5 l min...

Page 50: ...ery head 33 m 108 ft 3 24 in Max delivery rate 3 5 l min 0 92 gal min US Max pump pressure 4 bar 58 psi Pump Centrifugal pump Pump service life approx 10 000 hrs Coolant quantity 5 5 l 1 45 gal US Pro...

Page 51: ...51 EN...

Page 52: ...INTERNATIONAL GMBH Froniusstra e 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 lo...

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