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FK 5000, FK 5000 MV
Operating instructions
EN
Cooling unit
42,0426,0079,EN 035-13082021
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
EN
General 17
General 19
Device concept 19
Variants 19
Scope of supply 19
Field of application 19
Validity of "General Delivery and Payment Conditions" 19
Service life of the coolant pump 19
Information about the coolant 20
Information on leaks 20
General 20
Warning notices on the device 20
Options 22
General 22
Coolant temperature monitoring and flow monitoring 22
Coolant filter 22
Front coolant connections 22
Duo filter mounting / coolant connections 22
Connections and mechanical components 23
Connections and mechanical components 25
Connections and mechanical components 25
Installation and commissioning 27
Before installation and commissioning 29
Safety 29
Setup regulations 29
Information about the coolant 30
3
Guarantee provisions regarding the coolant pump 30
Proper use 30
Fitting the cooling unit to the trolley 31
General 31
Fitting the cooling unit to the trolley 31
Connecting the cooling unit to the power source 32
Safety 32
Connecting the cooling unit to the power source 32
Connect the coolant hoses to the cooling unit 34
Safety 34
Connecting interconnecting hosepack coolant hoses to the cooling unit 34
Connecting welding torch coolant hoses to the cooling unit 34
Filling and starting up the cooling unit 35
Filling the cooling unit 35
Commissioning the cooling unit 36
Fitting the coolant filter option 37
Safety 37
Fitting the coolant filter option 37
Troubleshooting 39
Troubleshooting 41
Safety 41
Troubleshooting 41
Displayed service codes 43
Twisting the coolant pump shaft 44
Safety 44
Twisting the coolant pump shaft 44
Care, maintenance and disposal 45
Care, maintenance and disposal 47
Safety 47
General 47
Symbols for care and maintenance of the cooling unit 48
Maintenance intervals, maintenance work 48
Gas purging the cooler 49
Changing the coolant 49
Disposal 53
Technical data 55
Technical data 57
General 57
FK 5000, FK 5000 MV 57
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
16
General
17
18
General
Device concept The cooling unit fits perfectly into the mod-
ular product design of the TransSteel
power sources.
The cooling unit and power source
together form a unit. As with the standalone power source, the power source/
cooling unit combination can be mounted
on the trolley.
Variants Two versions of the cooling unit are available:
- FK 5000 (basic version)
- FK 5000 MV (Multivoltage version)
EN
The FK 5000 MV adapts itself automatically to the mains voltage. The Multivoltage version is available only from the factory.
Scope of supply The scope of supply comprises:
- Cooling unit
- 5 l coolant in a canister
- Four 5x25mm self-tapping screws
- Operating instructions
Field of application
Validity of "General Delivery and
Payment Conditions"
The cooling unit can be used for:
- water-cooled MIG/MAG manual welding torches
With regard to cooling units, the "General Delivery and Payment Conditions" according to
the price list only apply under the following conditions:
- Max. 8 hrs/day operation (single shift operation)
- Only original coolant from the manufacturer is used
- Regular maintenance and regular change of coolant
Service life of the
coolant pump
NOTE!
If used properly the coolant pump will have a service life of approx. 10,000 operating hours. After the end of its nominal service life, the coolant pump may develop
a fault. To avoid a lengthy period of work disruption, the pump should be scheduled for replacement after approx. 10,000 operating hours.
19
Information about
0.42 MPa (4.2 bar) 1.0 kW
P1l/min
1~
50 Hz
IEC 60 974-2/-10 Cl.A IP 23
0.7 A
U1
400 V
pmax
I1
www.fronius.com
Ser.No.:
Part No.:
pmax
I1
the coolant
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.
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.
General As a result of firmware updates, you may find that your device has certain functions that
are not described in these operating instructions, or vice versa. Certain illustrations may
also differ slightly from the actual controls on your device, but these controls function in
exactly the same way.
Warning notices
on the device
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.
20
Welding is dangerous. The following basic requirements must be met to
ensure the equipment is used properly:
- Welders must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the cooling unit and the welding process
Do not use the functions described here until you have thoroughly read
and understood the following documents:
- this document
- all documents relating to the system components, especially the safety
rules
Do not dispose of used devices with domestic waste. Dispose of them
according to the safety rules.
EN
21
Options
General The options listed below are available for all cooling unit variants.
Coolant temperature monitoring
and flow monitoring
Coolant temperature monitoring and flow monitoring are parts of an installation set and
cannot be ordered separately.
Coolant temperature monitoring
A temperature sensor monitors the coolant return temperature during welding.
How it works:
- If the temperature of the coolant exceeds 70 °C (158 °F):
• the wire-feed unit/power source outputs the service code "hot l H2O"
• the temperature sensor interrupts the welding current
• the cooling unit remains operational
- The temperature sensor restores the welding current when the coolant temperature falls to 65 °C (149 °F)
Flow monitoring
A flow sensor monitors the coolant flow during welding.
How it works:
- If the coolant flow drops below 0.7 l/min (0.18 gal./min [US])
• the wire-feed unit/power source outputs the service code "no l H2O"
• flow rate monitoring interrupts the welding current
• the cooling unit is switched off
Coolant filter The coolant filter is equipped with a CrNi screen, and its function is to filter dirt particles
above 150 micrometers 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.
Front coolant
connections
Duo filter mounting / coolant connections
The front coolant connections allow the cooling unit to be used in conjunction with power
sources with an integrated wire drive (compact power sources).
The kit adds two additional coolant connections to the cooling unit. This allows the
coolant filter to be mounted on the rear in a protected location and the welding torch to
remain connected to the front as usual (compact power sources).
22
Connections and mechanical com-
ponents
23
24
Connections and mechanical components
(1)
(2) (3) (4)
(5)
(6)
(7)
(8)
(9)
0.42 MPa (4.2 bar) 1.0 kWP1l/min
1~
50 Hz
IEC 60 974-2/-10 Cl.A IP 23
0.7 AU1400 V
pmax
I1
www.fronius.com
Ser.No.:
Part No.:
pmax
I1
Connections and
mechanical components
EN
Front of cooling unit
Rear of cooling unit
(1) Blanking cover
- if the front coolant connections option is installed, then this is the coolant
flow connection (blue)
(2) Blanking cover
- if the front coolant connections option is installed, then this is the coolant
return 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)
- if the front coolant connections option is installed, a blanking cover will be
present
(9) Coolant flow connection (blue)
- if the front coolant connections option is installed, a blanking cover will be
present
25
26
Installation and commissioning
27
28
Before installation and commissioning
EN
Safety
Setup regulations
WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in severe personal injury and damage to property.
All the work and functions described in this document must only be carried out and
▶
used 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.
WARNING!
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.
WARNING!
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.
The device is tested to IP 23 protection, meaning:
- Protection against penetration by solid foreign bodies with diameters > 12.5 mm
(0.49 in.)
- Protection against spraywater at any angle up to 60° to the vertical
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.
CAUTION!
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).
29
Information about
the coolant
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.
Guarantee provisions regarding
the coolant pump
Proper use The device is intended solely for use in conjunction with Fronius system components.
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 to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer is not
liable for any damage, or unexpected or incorrect results arising out of such misuse.
Proper use also includes:
- carefully reading these operating instructions
- following all the instructions and safety rules in these operating instructions
- performing all stipulated inspection and maintenance work
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.
30
Fitting the cooling unit to the trolley
*)
*)
*)
*)
2
3
4
5
1
General The welding system can be fitted to a trolley to make the system (incl. cooling 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 cooling unit must
▶
be installed right at the bottom.
EN
Fitting the cooling unit to the
trolley
*) TU Car 4 Pro scope of supply
31
Connecting the cooling unit to the power source
7
8
6
5
3
4
9
*)
*)
*)
*)
2
3
4
5
1
Safety
WARNING!
Danger from electric current.
An electric shock can be fatal.
Before starting the work described below:
▶
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 electric-
▶
ally 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 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.
Connecting the
cooling unit to
the power source
CAUTION!
Risk of short circuit from kinked or damaged cables.
When connecting the power source to the cooling unit, ensure that the cables are not
kinked.
1
*) Cooling unit scope of supply
2
32
2
1
3
6
5
4
1
3
2
4
EN
33
Connect the coolant hoses to the cooling unit
Safety
Connecting interconnecting
hosepack coolant
hoses to the
cooling unit
WARNING!
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.
1
NOTE!
Connect the colour-coded coolant
hoses to the corresponding coolant
flow and return connections on the
cooling unit.
Connecting welding torch coolant
hoses to the
cooling unit
1
NOTE!
Connect the coloured coolant hoses to
the corresponding coolant flow and
return connections on the cooling unit.
34
Filling and starting up the cooling unit
4
EN
Filling the cooling unit
WARNING!
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.
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 sure that no coolant gets into the device.
▶
CAUTION!
Risk due to work that has been carried out incorrectly
This can result in serious damage to property.
If the coolant connections are on the front of the cooling unit, carry out the following
▶
steps as shown – but at the front coolant flow connection (blue).
1 2
35
3
2
max.
1
3 4
5
Commissioning
the cooling unit
NOTE!
Before starting up the cooling unit, first check that it contains an adequate amount
of coolant and that the coolant is 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 cooling unit is powered from the power source. If the power source mains switch is
turned to position "I", the cooling unit will also start to operate.
36
Fitting the coolant filter option
4
5
3
2
1
EN
Safety
Fitting the
coolant filter
option
WARNING!
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.
CAUTION!
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.
NOTE!
Make sure that no coolant enters the device.
If there is any coolant on the exterior of the device, remove it immediately.
▶
NOTE!
If the coolant connections are on the front of the cooling unit, fit the coolant filter
in the same way.
Connect the coolant filter to the coolant return connection (red) on the front of the
▶
cooling unit.
1
37
38
Troubleshooting
39
40
Troubleshooting
EN
Safety
WARNING!
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 per-
▶
sonnel.
Fully 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 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 electric-
▶
ally charged components (e.g. capacitors) 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 connection for earthing the
▶
housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
CAUTION!
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.
CAUTION!
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.
▶
Troubleshooting 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
- errors occur that are not listed below
- the troubleshooting measures listed are unsuccessful
41
Insufficient or no coolant flow
Cause:
Remedy:
Coolant level too low
Top up coolant
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Coolant pump does not work after turning the coolant pump shaft
Cause:
Remedy:
Insufficient cooling power
Cause:
Remedy:
Constriction or foreign body in cooling circuit
Remove constriction or foreign body
Coolant contaminated
Change the coolant
Coolant filter (option) misplaced when connecting coolant return
Clean coolant filter/replace filter element
Coolant pump sticking
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
Coolant pump defective
Contact After-Sales Service
Temperature switch on coolant pump has tripped
Wait until the end of the coolant pump's cooling phase (2 - 3 minutes)
Cooler contaminated
Gas purge cooler with dry compressed air
Cause:
Remedy:
Cause:
Remedy:
High operating noise level
Cause:
Remedy:
Cause:
Remedy:
Faulty fan
Contact After-Sales Service
Coolant pump defective
Contact After-Sales Service
Coolant level too low
Top up coolant
Coolant pump defective
Contact After-Sales Service
42
The welding torch becomes very hot
Cause:
Remedy:
The specification of the cooling unit is inadequate
Observe the duty cycle and loading limits
EN
Displayed service
codes
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
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 cooling unit has tripped.
The specification of the welding torch is inadequate
Observe the duty cycle and loading limits
Inadequate coolant flow
Check coolant level. Top up with coolant if necessary.
Check coolant for contamination. Change the coolant if necessary
Inadequate coolant flow
Coolant pump sticking: 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:
Remedy:
no l H2O
The optional cooling unit flow sensor has tripped.
Cause:
Remedy:
Cause:
Remedy:
Coolant temperature too high
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: After completion
of troubleshooting and before resuming welding, set the "Source error reset"
signal.
Coolant flow problem
Check coolant level. Top up with coolant if necessary.
Check coolant for contamination. Change the coolant if necessary
Coolant filter (option) misplaced when connecting coolant return
Clean coolant filter/replace filter element
43
Twisting the coolant pump shaft
㻝
max.
5
3
4
2
1
6
7
Safety
Twisting the
coolant pump
shaft
WARNING!
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 per-
▶
sonnel.
Fully 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 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.
1
44
Care, maintenance and disposal
45
46
Care, maintenance and disposal
EN
Safety
WARNING!
Danger due to work that has been carried out incorrectly.
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.
WARNING!
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 electric-
▶
ally charged components (e.g. capacitors) 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 connection for earthing the
▶
housing and must NOT be replaced by any other screws that do not provide a reliable ground conductor connection.
CAUTION!
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.
CAUTION!
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.
▶
General 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.
47
Symbols for care
(1)
(2)
(3)
and maintenance
of the cooling
unit
(1) Changing the coolant
(2) Gas purging the cooler
(3) Read operating instructions
The relevant maintenance intervals and
maintenance work are described in detail
over the following pages.
Maintenance
intervals, maintenance work
At every start-up
CAUTION!
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.
- Ensure that all the hosepacks, the 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 connections between all system components for tightness
- Check all the coolant connections of the welding system for tightness
- Monitor the coolant return flow in the coolant container
- If no coolant is returning to the container, identify and remedy the cause
Once a week
- Check coolant level. If the coolant level is below the "min" mark, top up with coolant
- Check the purity of the coolant. Change the coolant if necessary
48
CAUTION!
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 compat-
▶
ibility reasons.
Every 2 months
- If present: Check the coolant filter for dirt and clean if necessary
Every 6 months
- Gas purge the cooler
Gas purging the
1
cooler
Every 6 months in 3-shift operation with ethanol-based coolant
- Gas purge the cooler
- Change the coolant
Every 12 months in single-shift operation with ethanol-based coolant
- Change the ethanol-based coolant
Every 12 months in 3-shift operation with FCL 10/20 coolant
- Change the coolant
Every 24 months in single-shift operation with FCL 10/20 coolant
- Change the coolant
CAUTION!
Risk from gas purging the cooler.
This may result in damage to electronic components.
Always follow the instructions in the "Safety" section at the start of the "Care, main-
▶
tenance and disposal" chapter.
Do not bring the air nozzle too close to electronic components.
▶
EN
Changing the
coolant
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.
- Remove the device side panels and
clean the cooler
If a large amount of dust has accumulated:
- remove device side panels and clean
inside of device with dry, reduced
compressed air.
To change the coolant:
49
CAUTION!
3
4
5
6
Risk of injury and material damage from the welding current and accidental ignition of an arc.
Before starting 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 or the basket-type spool from the
▶
power source or the wire-feed unit
NOTE!
The coolant must not be disposed of in the public sewage system.
Dispose of coolant in accordance with the applicable local and national regulations.
NOTE!
Use only original Fronius coolant when refilling the cooling unit.
1
NOTE!
Seal off the coolant hose as soon as it is pulled out of the coolant pump connection.
This will ensure that as little coolant as possible enters the device. Immediately remove
any coolant that enters the device or spills onto its exterior.
50
2
EN
3
4
NOTE!
If the coolant connections are on the front of the cooling unit, carry out the following steps as shown - but at the front coolant flow connection (blue).
51
5 6
7 8
9
Ensure that all hose connections are properly established and are not leaking
10
Ensure that there is no coolant inside the device or on its exterior
11
52
1
2
3
4
12
Disposal Dispose of in accordance with the applicable national and local regulations.
EN
53
54
Technical data
55
56
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.
EN
FK 5000, FK 5000
MV
FK 5000 FK 5000 MV
Mains voltage 400 V AC 200-230/400-480 V
AC
Mains voltage tolerance -10% / +10% -10% / +10%
Mains frequency 50 / 60 Hz 50 / 60 Hz
Current input 0.6 / 0.7 A 0.6 / 1.4 A
Cooling power at
Q = 1 l/min + 25 °C (77 °F)
Q = 1l / min + 40 °C (104 °F)
Q = max. + 25 °C (77 °F)
Q = max. + 40 °C (104 °F)
Max. delivery head 35 m
Max. delivery rate 3.5 l/min
Max. pump pressure 4.2 bar
Pump Centrifugal pump Centrifugal pump
Pump service life approx. 10,000 hrs approx. 10,000 hrs
1000 W
800 W
1500 W
1000 W
114 ft. 9.95 in.
0.92 gal./min [US]
60.89 psi
1000 W
800 W
1500 W
1000 W
35 m
114 ft. 9.95 in.
3.5 l/min
0.92 gal./min [US]
4.2 bar
60.89 psi
Coolant capacity 6 l
1.59 gal. [US]
Protection class IP 23 IP 23
Dimensions l/w/h 710/300/230 mm
27.95/11.81/9.06 in.
Weight (without coolant) 13.6 kg
29.98 Ib.
Flow monitoring* Sensor
error below 0.7 l/min
(0.18 gal./min)
Coolant temperature monitoring* Error above 70 °C
(158 °F)
Mark of conformity CE CE, CSA
* Optional
6 l
1.59 gal. [US]
710/300/230 mm
27.95/11.81/9.06 in.
16 kg
35.27 lb.
Sensor
error below 0.7 l/min
(0.18 gal./min)
Error above 70 °C
(158 °F)
57
58
EN
59
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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