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FK 2200
FK 2200 FC
Operating instructions
EN
Cooling unit
42,0426,0035,EN 005-07062021
Contents
Safety rules 5
Explanation of safety notices 5
General 5
Proper use 5
Environmental conditions 6
Obligations of the operator 6
Obligations of personnel 6
Mains connection 6
Protecting yourself and others 7
Noise emission values 7
Danger from toxic gases and vapours 8
Danger from flying sparks 8
Risks from mains current and welding current 9
Meandering welding currents 10
EMC Device Classifications 10
EMC measures 10
EMF measures 11
Specific hazards 11
Requirement for the shielding gas 12
Danger from shielding gas cylinders 12
Danger from escaping shielding gas 13
Safety measures at the installation location and during transport 13
Safety measures in normal operation 13
Commissioning, maintenance and repair 14
Safety inspection 14
Disposal 15
Safety symbols 15
Data protection 15
Copyright 15
General 16
Equipment concept 16
Overview 16
Area of application 16
Information about the coolant 16
Information on leaks 17
Options 18
Installation kit “flow controller“ with water filter 18
Installation kit “temperature limit controller“ 18
Control elements and connections 19
Rear side 19
Front side 19
Fitting the cooling unit to the trolley 20
General remarks 20
Mount cooling unit on carriage bottom 20
Connecting the cooling unit to the power source 21
Connect power source with cooling unit 21
Transport of cooling unit and power source 21
Connecting the welding torch 22
Connect welding torch with power source 22
Connect welding torch with cooling unit 22
Putting the cooling unit into service 23
Connect welding torch with power source 23
Guarantee provisions regarding the coolant pump 23
Information on the coolant 23
Fill cooling unit 23
Purge cooling unit 23
Start operation of cooling unit 24
Changing the welding torch 24
Care, maintenance and disposal 25
General remarks 25
EN
3
Safety 25
Symbols for care and maintenance of the cooling unit 25
Every start-up 25
Every week 26
Every 2 months 26
Every 6 months 26
Every 6 months for 3-shift operation with ethanol-based coolant 26
Every 12 months for single-shift operation with ethanol-based coolant 27
Every 12 months in 3-shift operation with FCL 10/20 coolant 27
Every 24 months in single-shift operation with FCL 10/20 coolant 27
Applicability of the “General Terms of Delivery and Payment” 27
Disposal 27
Troubleshooting 28
General remarks 28
Troubleshooting 28
Technical data 30
General 30
FK 2200 30
4
Safety rules
EN
Explanation of
safety notices
DANGER!
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.
If not avoided, minor injury and/or damage to property may result.
▶
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to recog-
nised safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
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 instructions carefully.
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 device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For 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.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
5
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.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
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.
Environmental
conditions
Obligations of the
operator
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer shall not be held liable for any
damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and 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 altitudes of up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section
"safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their cur-
6
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating 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 any harm
in your absence.
rent consumption.
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.
IMPORTANT! Ensure that the mains connection is earthed properly
EN
Protecting yourself and others
Anyone working with the device exposes themselves to numerous risks, e.g.
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and 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 conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Noise emission
values
Keep all persons, especially children, out of the working area while any devices are in
operation or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
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.
7
Danger from
toxic gases and
vapours
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 gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure 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:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
- Welding process used
Danger from flying sparks
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.
8
Risks from mains
current and welding current
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 wirespool, 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.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
EN
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. 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. The manufacturer shall not be held liable
for any damage arising from such usage.
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:
- Discharge all live components
- Ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
9
Meandering welding currents
If the following instructions are ignored, meandering welding currents can develop with
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.
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,
e.g. Insulation against conductive floor or insulation to conductive racks.
If 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 Classifications
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the 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 the rating plate or technical data.
sions, 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.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
10
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addi-
tional measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. 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 hearing aids
- wearers of pacemakers must seek advice from their doctor before approaching the
device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's
head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
EN
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 operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The 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 away from the body (devices with wire-feed
unit) 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.
Power sources for work in areas with 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 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.
11
- 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).
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 accessories (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.
Requirement for
the shielding gas
Danger from
shielding gas cylinders
Especially with ring lines, contaminated shielding gas can cause damage to equipment
and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
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.
12
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.
EN
Danger from
escaping shielding gas
Safety measures
at the installation
location and during transport
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.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the
main gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage
before every start-up.
A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
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.
Safety measures
in normal operation
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 devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
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.
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
13
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.
The manufacturer accepts no liability for damage resulting from use of other system
components or a different coolant. In addition, all warranty claims will be forfeited.
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.
Commissioning,
maintenance and
repair
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at
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.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
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.
least once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12month period.
14
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and
directives.
Further details on safety inspection and calibration can be obtained from your service
centre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as
national law, electrical equipment that has reached the end of its life must be collected
separately and returned to an approved recycling facility. Any device that you no longer
require must either be returned to your dealer or given to one of the approved collection
and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility 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 Declaration of Conformity can be found at the following address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.
EN
Data protection The user is responsible for the safekeeping of any 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 and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the
basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.
15
General
Equipment
concept
Overview The cooling unit perfectly fits in the modu-
The cooling unit FK 2200 is suitable for the following power sources:
- TransTig 2200
- MagicWave 1700/2200
lar product concept of the power sources
TransTig 2200 and MagicWave
1700/2200.
The cooling unit is combined with the
power source to form a unit. As in the case
of the power source, the combination of
power source and cooling unit is also suitable for being mounted on the carriage.
The cooling unit FK 2200 can also be equipped with the optional “flow controller“ and the
“temperature limit controller“. If the cooling unit is fitted with these options or if you have
a FK 2200 FC variant with a flow sensor, the power source will always switch off for process reliability reasons if one of the following events occur:
- The flowrate drops below a determined flowrate value (e.g. the coolant level in the
coolant container is too low)
- A determined water return temperature is exceeded (e.g. welding torch overheated)
Area of application
Information about
the coolant
A corresponding alarm message is displayed on the operating panel of the power
source.
The cooling unit FK 2200 can be used for:
- MagicWave 1700
- TransTig / MagicWave 2200
- Water-cooled manual TIG torch, also for TIG cold-wire welding
- Water-cooled machine TIG torch, also for TIG cold-wire welding
The maximum cable assembly lengths for the welding torches are as follows:
- 18 m (59 ft.) in the case of MagicWave 1700
- 18 m (59 ft.) in the case of TransTig / MagicWave 2200
CAUTION!
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.
16
Information on
leaks
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.
EN
17
Options
Installation kit
“flow controller“ with water filter
Installation kit
“temperature
limit controller“
The optional flow controller with water filter controls the coolant flowrate during welding.
If an error with regards to the coolant flowrate occurs, the optional flow controller emits a
signal. The power source switches off.
A coolant flowrate error can be caused by
- not sufficient coolant
- cooling circulation not vented sufficiently
- contaminated coolant
- leaks in the cooling circulation
- defective coolant pumps
- frozen coolant (operating temperature too low)
The optional temperature limit controller controls the coolant temperature. If the temperature of the coolant is too high, the optional temperature limit controller emits a signal.
The power source switches off.
18
Control elements and connections
(1)
(3)(4)
(2)
(6)
(5)
(7)
EN
Rear side
Front side
(1) Guard window “coolant“
(2) Bushing for coolant pump shaft
(3) Coolant pump fuse
(4) Screw cap / filler
FK 2200 connections on the rear side
(5) Plug-in connection water flow
(black)
(6) Plug-in connection water return
(red)
FK 2200 connections on the front side
(7) Control display ... illuminated if
coolant pump running
19
Fitting the cooling unit to the trolley
General remarks In order to increase the mobility of the entire welding machine incl. cooling unit, it is pos-
sible to mount the welding machine on a carriage.
NOTE!
The cooling unit is always installed on the bottom.
Mount cooling
unit on carriage
bottom
Switch mains switch in position “O“
1
Mount mounting angles with three
2
Extrude-Tite screws each on the carriage bottom.
Place cooling unit on carriage bottom
3
Screw cooling unit with two Extrude-
4
Tite screws each to the front and rear
mounting angle on the carriage bottom.
IMPORTANT!
The mounting of the power source on the carriage (without cooling unit) is
identical with the procedure described above.
20
Connecting the cooling unit to the power source
(8)
(9)
(10)
EN
Connect power
source with cooling unit
Switch mains switch in position “O“
1
Place power source on cooling unit:
2
Leave the power source suspended
from a suitable lifting device over the
cooling unit
Pull connection plug (8) of the power
3
source as far as possible through the
opening at the bottom
Plug-type connection between power source and
cooling unit
Connect plug-type connection (9) between power source and cooling unit
4
CAUTION!
Kinked or damaged cables can cause short circuits.
When positioning the power source, prevent the connection plug and the cable from getting kinked or damaged.
Carefully place the power source on the cooling unit
5
Fix power source with enclosed
6
screws (10) at front and rear side of
the cooling unit
Transport of cooling unit and
power source
CAUTION!
Danger caused by overturning or falling
devices.
Check all screwed connections for tight
seat.
Mounting angles for mounting the power source
CAUTION!
There is danger of injury due to dropping devices.
For the transport of the power source with the cooling mounted fixed it is required that
the power source is equipped with a “transport handle“.
21
Connecting the welding torch
(6)
(5)
Connect welding
torch with power
source
Connect welding
torch with cooling unit
Connect welding torch with power source (see operating instructions “Power
1
Source“).
Connect water connections of the
1
welding torch with the connections of
water flow (5) - black - and water
return (6) - red - of the cooling unit.
Water connections for the welding torch
22
Putting the cooling unit into service
EN
Connect welding
torch with power
source
Guarantee provisions regarding
the coolant pump
Information on
the coolant
Fill cooling unit
Connect welding torch with power source (see operating instructions “Power
1
Source“).
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.
Only use original Fronius coolant for the filling of the cooling unit. Other antifreezers cannot be recommended due to their electric conductivity and compatibility.
IMPORTANT!
The cooling unit is delivered without coolant.
The coolant is delivered separately in a 5l can. Fill in the coolant before you start cooling
unit operation!
Purge cooling
unit
Filling of coolant:
Switch mains switch of the power source in position “O“
1
Unscrew screw cap
2
Fill in coolant
3
Screw screw cap again - the cooling unit is ready for operation
4
NOTE!
When the cooling unit is filled with the coolant for the first time, it is required to
purge the cooling unit before the start-up.
.
Purge the cooling unit
- after the first filling,
- if there is no coolant circulation although the cooling pump works.
Purge cooling unit:
Plug in mains plug or connect power supply
1
Switch mains switch in position “I“ - the cooling unit is ready for operation
2
Shift back safety ring on the plug-type connection of water flow - black
3
Disconnect water flow hose
4
Press in carefully and hold conical nipple in the centre of the plug-type connection of
5
the water flow by means of a wooden or plastic pin
Release conical nipple as soon as liquid penetrates
6
23
Reconnect water flow hose
7
Check water hoses for tightness
8
Repeat purge until proper return flow to the filler neck is ensured.
Start operation of
cooling unit
Changing the
welding torch
NOTE!
Before any start-up of the cooling unit, check the coolant level as well as the
coolant purity.
Connect supply of power source(s)
1
Switch mains switch of the power source(s) in position “I” - the cooling pump starts
2
operation.
Check coolant flow until proper flow is ensured. If necessary, deairate coolant circu-
3
lation.
NOTE!
During welding check coolant flow at regular intervals - a proper return flow must
be visible in the filler neck.
CAUTION!
Excess pressure will damage the cooling unit.
Before blowing out the welding torch with compressed air, undo the screw cap on the fill
nozzle.
24
Care, maintenance and disposal
(1)
(2) (3)
(4)
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.
EN
Safety
WARNING!
An electric shock can be fatal.
Before opening up the 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. The casing screws are a suitable protective conductor connection for grounding the casing. The screws must not be replaced by other
screws without reliable protective conductor connection.
CAUTION!
Danger of scalding from hot coolant fluid.
Do not inspect the coolant connection points until the coolant has been allowed to cool.
IMPORTANT!
The coolant must not be disposed of via the sewerage!
NOTE!
For refilling the cooling unit only use coolant of the manufacturer.
Symbols for care
and maintenance
of the cooling
unit
Every start-up - Check welding torch, interconnection cable assembly and bondings for damage
- Check whether the allround distance of 0.5 m (1.6 ft.) is kept to ensure that the cooling air can easily flow and escape.
(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.
25
NOTE!
Furthermore, air inlets and outlets must in no case be covered, not even covered
partly.
CAUTION!
Danger of scalding from hot coolant fluid.
Do not inspect the coolant connection points until the coolant has been allowed to cool.
If water-cooled welding torch is used:
- Check water connections for tightness
- Control water return flowrate in coolant container
- If there is no water return flow, check cooling unit and purge if necessary
NOTE!
If water-cooled welding torches are operated without cooling water, this mostly
causes a defect of the torch body or the hose pack.
The manufacturer does not accept responsibility for any consequential damages. Any
warranty claims expire.
Every week
Every 2 months
Every 6 months
Every 6 months
for 3-shift operation with ethanolbased coolant
Check the coolant level as well as the coolant purity.
1
If the coolant level drops below the “min“ mark ... refill coolant.
2
Check the coolant level as well as the coolant purity.
1
If the coolant level drops below the “min“ mark ... refill coolant.
2
Dismantle machine side panels and clean machine inside with dry reduced com-
1
pressed air
NOTE!
Risk of damage to electronic components.
Clean electronic components from a certain distance only.
Clean also the water coolers in the case of excessive dust
1
Gas purge the cooler
1
Change the coolant
2
26
Every 12 months
for single-shift
operation with
ethanol-based
coolant
Change the ethanol-based coolant
1
Dispose of coolant properly.
2
EN
Every 12 months
in 3-shift operation with FCL
10/20 coolant
Every 24 months
in single-shift
operation with
FCL 10/20
coolant
Applicability of
the “General
Terms of Delivery
and Payment”
Change the coolant
1
Dispose of coolant properly.
2
Change the coolant
1
Dispose of coolant properly.
2
With respect to cooling units, the warranty provisions of the “General Terms of Delivery
and Payment” referred to in the pricelist shall only apply where the following conditions
are fulfilled:
- 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
Disposal Dispose of in accordance with the applicable national and local regulations.
27
Troubleshooting
(7)
(2)
General remarks If the cooling unit is equipped with one of the following options, the corresponding error
message is displayed on the operating panel of the power source:
- flow controller ... no | H2O (coolant flow error)
- temperature controller... hot | H2O (excess coolant temperature)
Troubleshooting
Coolant pump fuse
Coolant flow too low or no flow
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Coolant level too low
Refill coolant
Throat or foreign substance in the cooling circulation
Remove throat or foreign substance
Cooling pump fuse defective
Replace coolant pump fuse
Cooling pump defective
Replace cooling pump
Cooling pump blocked
‑ Remove coolant pump fuse (7)
‑ Insert suitable screw driver through motor shaft bushing
‑ Rotate motor shaft (2)
‑ Replace coolant pump fuse (7)
Fushing for rotating motor shaft if the coolant pump is
blocked
28
Cause:
Remedy:
Cooling filter (option) at plug-type connection of water return line clogged
Clean cooling filter with clean tap water or replace filter insert
Cooling capacity too low
Cause:
Remedy:
Fan defective
Replace fan
EN
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
High operating noise level
Cause:
Remedy:
Cause:
Remedy:
no l H2O
The flow watchdog (option) or flow sensor in the cooling unit has tripped. The error message is displayed on the operating panel of the power source.
Cause:
Remedy:
Cooling pump defective
Replace coolant pump
Cooler contaminated
Clean cooler with dry compressed air
Cooling capacity of cooling unit too low
Use cooling unit with higher cooling capacity
Coolant level too low
Refill coolant
Cooling pump defective
Replace coolant pump
Cooling flow error
Check cooling unit; if necessary, refill coolant and purge water flow line
according to the Chapter “Start operation of the cooling unit“
Cause:
Remedy:
hot l H2O
The thermal controller of the cooling unit has responded. The error message is displayed
on the operating panel of the power source.
Cause:
Remedy:
Welding torch excessively hot
Cause:
Remedy:
Cause:
Remedy:
Water filter clogged
Clean or replace water filter
Excessive coolant temperature
Wait the cooling-down time until hot | H2O is no longer displayed.
ROB 5000 or fieldbus coupler for robot control: before welding is started
again, reset signal “source error reset“.
Welding torch dimensioned insufficiently
Pay attention to duty cycle and load limits
Only with water-cooled systems: water flowrate too low
Check water level, water flowrate, water contamination etc., coolant pump
blocked: rotate coolant pump shaft by means of screw driver (2)
29
Technical data
General The cooling capacity of a cooling unit depends on
- Ambient temperature
- Delivery head
- Flow rate Q (l/min) - The flow rate Q depends on the length of the interconnecting
hosepack and the diameter of the hose.
FK 2200
Supply voltage 230 V AC
Supply voltage tolerance -30% / +15%
Frequency 50 / 60 Hz
Current draw 1,35 A
Cooling capacity
Q = 1 l/min + 20 °C (68 °F)
Q = 1 l/ min + 40 °C (104 °F)
Q = max. + 20 °C (68 °F)
Q = max. + 40 °C (104 °F)
Max. rise 25 m
Max. flowrate 3 l/min
Max. pump pressure 4,3 bar
Pump centrifugal pump 24 V
Coolant contents 1,5 l
Enclosure protection IP 23
850 W
500 W
950 W
570 W
82 ft.
0.79 gal./min [US]
62 psi
0.4 gal. [US]
Measurements l/w/h 540/180/180 mm
21.3/7.1/7.1 in.
Weight (without coolant) 6,6 kg
14.5 Ib.
Weight (with minimum coolant) 7 kg
15.4 Ib.
Signs S, CE
30
EN
31
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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