Fronius FK 5000 Operating Instructions Manual Download Page 1

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Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

/ Perfect Charging /

Perfect Welding

/ Solar Energy

42,0426,0079,EN 032-25052020

FK 5000, FK 5000 MV

[

Operating Instructions

Cooling unit

Summary of Contents for FK 5000

Page 1: ...n elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0079 EN 032 25052020 FK 5000 FK 5000 MV Operating Instructions...

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Page 3: ...to ensure greater safety when using the product Careful handling of the product will repay you with years of safe and reliable operation These are essential prerequisites for excellent results Explan...

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Page 5: ...peration 15 Commissioning maintenance and repair 16 Safety inspection 16 Disposal 16 Safety symbols 16 Data protection 17 Copyright 17 General 19 General 21 Device concept 21 Variants 21 Scope of supp...

Page 6: ...ng and starting up the cooling unit 37 Filling the cooling unit 37 Commissioning the cooling unit 38 Fitting the coolant filter option 39 Safety 39 Fitting the coolant filter option 39 Troubleshooting...

Page 7: ...General in the operating instructions for the device Before switching on the device rectify any faults that could compromise safety This is for your personal safety Proper use The device is to be use...

Page 8: ...ing instructions especially the Safety rules section and sign to confirm that they have understood them and will follow them Before leaving the workplace ensure that people or property cannot come to...

Page 9: ...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...

Page 10: ...ire 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...

Page 11: ...rly legible and easy to understand warning sign to the device to prevent any one from plugging the mains plug back in and switching it on again After opening the device Discharge all live components E...

Page 12: ...to interfer ence from the device include Safety devices Power signal and data transfer lines IT and telecommunications devices Measuring and calibrating devices Supporting measures for avoidance of E...

Page 13: ...increased electric risk e g near boilers must carry the Safety sign However the power source must not be located in such areas Risk of scalding from escaping coolant Switch off cooling unit before dis...

Page 14: ...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 appli...

Page 15: ...before commissioning Any damage must be repaired by trained service technicians before com missioning the device Safety measures in normal opera tion Only operate the device when all safety devices a...

Page 16: ...ction The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months The manufacturer recommends that the power source be calibrated during the same 12 m...

Page 17: ...changes made to the factory settings The manufacturer accepts no liability for any deleted personal settings Copyright Copyright of these operating instructions remains with the manufacturer The text...

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Page 19: ...General...

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Page 21: ...elf tapping screws Operating instructions Field of applica tion The cooling unit can be used for water cooled MIG MAG manual welding torches Validity of Gen eral Delivery and Payment Condi tions With...

Page 22: ...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 p...

Page 23: ...be sufficiently quali fied Suitable protective equipment must be used All persons not involved must be kept at a safe distance from the cooling unit and the welding pro cess Do not use the functions d...

Page 24: ...o be mounted on the rear in a protected location and the welding torch to remain con nected to the front as usual compact power sources Coolant temperature monitoring and flow monitoring are parts of...

Page 25: ...Connections and mechanical compo nents...

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Page 27: ...eturn connection red 3 Screw cap for coolant container 4 Operating and maintenance instructions 5 Coolant viewing window 6 Power source connecting plug 7 Rating plate 8 Coolant return connection red i...

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Page 29: ...Installation and commissioning...

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Page 31: ...ctive 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 t...

Page 32: ...no 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 purpo...

Page 33: ...oling unit more mobile CAUTION Risk due to work that has been carried out incorrectly This can result in serious damage to property If the welding system is not equipped with an auto transformer the c...

Page 34: ...ically charged components e g capacitors have been discharged WARNING Danger from inadequate ground conductor connections This can result in severe personal injury and damage to property The housing s...

Page 35: ...35 EN 1 2 1 3 3 2 4 5 6 1 4...

Page 36: ...isconnected from the mains until all work has been completed Connecting inter connecting hose pack coolant hoses to the cool ing unit 1 NOTE Connect the colour coded coolant ho ses to the correspondin...

Page 37: ...l all work has been completed CAUTION Risk from coolant leakage This can result in serious damage to property If there is any coolant on the exterior of the cooling unit remove it immediately Make sur...

Page 38: ...s clean and uncontaminated NOTE During welding check at regular intervals that the coolant is flowing properly You should be able to see a steady return flow of coolant into the coolant container The...

Page 39: ...rom hot coolant This can result in severe scalds Wait until the coolant has cooled down before carrying out any of the activities de scribed below Fitting the cool ant filter option NOTE Make sure tha...

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Page 41: ...Troubleshooting...

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Page 43: ...citors 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...

Page 44: ...After Sales Service if the coolant pump shaft proves impossible to turn Cause Coolant pump defective Remedy Contact After Sales Service Coolant pump does not work after turning the coolant pump shaft...

Page 45: ...urn Displayed service codes NOTE Depending on the welding system the service codes are displayed on the power source or the wire feed unit hot l H2O The optional coolant temperature sensor in the cool...

Page 46: ...ully read and understand this document Fully read and understand all the Operating Instructions for the system components especially the safety rules WARNING Danger from electric current An electric s...

Page 47: ...Care maintenance and disposal...

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Page 49: ...have 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 connecti...

Page 50: ...e 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 cooling air can flow in and out freely Check the screw con...

Page 51: ...without the power source However the power source can remain on the cooling unit when gas purging the cooler Every 2 months If present check the coolant filter for dirt and clean it re place the filt...

Page 52: ...ing work disconnect the ground earth connection between the welding system and the work piece remove the wire electrode from the welding torch being used depending on the system remove the wirespool o...

Page 53: ...tle coolant as pos sible enters the device Immediately remo ve any coolant that enters the device or spills onto its exterior 2 3 NOTE If the coolant connections are on the front of the cooling unit c...

Page 54: ...54 1 2 3 4 5 Ensure that all hose connections are properly established and are not leaking 1 5 6 4 3 max 2 1 7 8 9 10...

Page 55: ...55 EN Ensure that there is no coolant inside the device or on its exterior 6 Disposal Dispose of in accordance with the applicable national and local regulations 11 1 2 3 12...

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Page 57: ...Technical data...

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Page 59: ...500 W 1000 W 1000 W 800 W 1500 W 1000 W Max delivery head 35 m 114 ft 9 95 in 35 m 114 ft 9 95 in Max delivery rate 3 5 l min 0 92 gal min 3 5 l min 0 92 gal min Max pump pressure 4 2 bar 60 89 psi 4...

Page 60: ...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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