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Table of Contents
Troubleshooting
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Summary of Contents for Fronius FK 4000
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions FK 4000 FK 4000 R Cooling unit FK 4000 R US FK 4000 R FC FK 4000 Rob 42,0426,0017,EN 011-01062021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Information about the coolant Information on leaks Warning notices on the device Application areas FK 4000 FK 4000 R, FK 4000 Rob, FK 4000 R FC, FK 4000 R US Options FK 4000 auto-transformer FK 4000 R flow sensor with coolant filter Thermostat... - Page 4 Possible mains voltages for FK 4000, FK 4000 R, FK 4000 Rob and FK 4000 R FC Possible mains voltages for FK 4000 R US Adapting the cooling unit to the respective mains voltage Fitting the cooling unit to the trolley...
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Page 5: Safety Rules
Safety rules Explanation of DANGER! safety notices 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. ▶... -
Page 6: Environmental Conditions
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. -
Page 7: Protecting Yourself And Others
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. -
Page 8: Danger From Toxic Gases And Vapours
Danger from The fumes produced during welding contain harmful gases and vapours. toxic gases and Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the vapours 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. -
Page 9: Risks From Mains Current And Welding Current
Risks from mains An electric shock is potentially life threatening and can be fatal. current and weld- Do not touch live parts either inside or outside the device. ing current 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. -
Page 10: Meandering Welding Currents
Meandering weld- If the following instructions are ignored, meandering welding currents can develop with ing currents 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. -
Page 11: Emf Measures
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 hear- ing aids wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress... -
Page 12: Requirement For The Shielding Gas
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). -
Page 13: Danger From Escaping Shielding Gas
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories. Danger from Risk of suffocation from the uncontrolled escape of shielding gas escaping shield- Shielding gas is colourless and odourless and, in the event of a leak, can displace the ing gas oxygen in the ambient air. -
Page 14: Commissioning, Maintenance And Repair
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. -
Page 15: Disposal
(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 follow- ing address: http://www.fronius.com... -
Page 16: General
With regard to cooling units, the "General Delivery and Payment Conditions" according to eral Delivery and the price list only apply under the following conditions: Payment Condi- Max. 8 hrs/day operation (single-shift operation) / FK 4000 Rob: 24 hrs/day opera- tions" tion (three-shift operation) Only original coolant from the manufacturer is used... -
Page 17: Information On Leaks
Information on The following information on leaks does not apply to the FK 4000 Rob. leaks The shaft sealing surfaces inside the coolant pump are lubricated by the coolant, mean- ing that a certain leakage flow should always be expected. A low leakage flow is permit- ted. -
Page 18: Application Areas
TransSynergic 5000 and TransPuls Synergic 5000, max. length of the interconnect- ing hosepack 1.2 m (4 ft.) NOTE! The cooling unit is supplied with the auto-transformer FK 4000 option as standard. FK 4000 R, FK The cooling units are recommended for use with:... -
Page 19: Options
5 in.) FK 4000 R The FK 4000 R US, FK 4000 R FC and FK 4000 Rob cooling units are fitted with the flow sensor with coolant filter option as standard. How it works: The option monitors the coolant flow during welding If the coolant flow falls below 0.7l/min (0.18 gal./min [US]), "no | H2"... -
Page 20: Coolant Filter
The thermostat option monitors the coolant temperature If the coolant temperature rises to above 70°C (185°F), the "hot | H2" indicator is automatically displayed and the welding current is interrupted. The cooling unit remains operational The thermostat restores the welding current when the temperature falls to 65°C (149°F). -
Page 21: Control Elements And Connections
Control elements and connections Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. All functions described in this document must only be used by trained and qualified per- sonnel. Do not use any of the functions described until you have thoroughly read and understood the following documents: ▶... -
Page 22: Before Installation And Commissioning
Before installation and commissioning Safety 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. -
Page 23: Information About The Coolant
Information about The cooling unit is delivered empty. the coolant 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 provi- The coolant pump may only be used with original coolant supplied by the manufacturer. -
Page 24: Fitting Coolant Connections To The Front Of The Unit
Fitting coolant connections to the front of the unit Safety WARNING! An electric shock can be fatal. Before starting work: ▶ turn the power source mains switch to the "O" position ▶ disconnect the power source from the mains ▶ ensure that the power source remains disconnected from the mains until all work has been completed After opening the device, use a suitable measuring instrument to check that electrically... - Page 25 (3) (4) Remove blanking covers (5) from the front and attach to the rear NOTE! Fit the coolant return connection (1) at the top and secure using the red plastic nut (coolant return is indicated by red insulating tape). Feed the coolant connection (1) and (2) from the inside outwards through the housing and secure to the front of the unit using the previously...
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Page 26: Adapting The Cooling Unit To The Respective Mains Voltage
The auto-transformer is available as an option for the FK 4000 R, FK 4000 Rob and FK 4000 R FC cooling units. For the FK 4000 and FK 4000 R US cooling units, the auto-transformer is fitted as stand- ard. -
Page 27: Possible Mains Voltages For Fk 4000, Fk 4000 R, Fk 4000 Rob And Fk 4000 R Fc
Adapting the NOTE! cooling unit to the respective To adapt the FK 4000 R, FK 4000 Rob and FK 4000 R FC cooling units for the respective mains voltage, the optional auto-transformer must be installed on the mains voltage cooling unit. - Page 28 (3) to the required mains voltage (the image to the left shows the reconnection of the auto-transformer using the FK 4000 R US as an example. The reconnection (440 V) is carried out in the same way for other units;...
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Page 29: Fitting The Cooling Unit To The Trolley
Fitting the cooling unit to the trolley General The welding system can be fitted to a trolley to make the entire system more mobile. NOTE! If the welding system is not equipped with an auto-transformer, the cooling unit must be installed right at the bottom. Fitting the cool- ing unit to the trolley... -
Page 30: Connecting The Cooling Unit To The Power Source
Connecting the cooling unit to the power source Safety 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. - Page 31 NOTE! When positioning the power source, the cooling unit fixing bars must be placed within the plastic feet of the power source. Placing the power source on the cooling unit Secure the power source to the cooling unit fixing bars using the Allen screws provided (4), two at the front and two at the back...
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Page 32: Connecting The Hosepacks To The Cooling Unit
Connecting the hosepacks to the cooling unit Safety 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. - Page 33 Connect the red welding torch hose (2) to the coolant return connection on the cooling unit Connect the blue welding torch hose (3) to the coolant flow connection on the cooling unit...
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Page 34: Putting The Cooling Unit Into Service
Putting the cooling unit into service Safety 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. -
Page 35: Commissioning The Cooling Unit
Commissioning NOTE! the cooling unit The coolant level and cleanliness of the coolant must always be checked before commissioning the cooling unit. Connect the power source to the mains Turn the power source mains switch to the "I" position The coolant pump starts up Check the coolant flow until you can see a steady return flow of coolant through the fill nozzle NOTE! -
Page 36: Care, Maintenance And Disposal
Care, maintenance and disposal 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. -
Page 37: Symbols For Care And Maintenance Of The Cooling Unit
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 cool-... -
Page 38: Gas Purge The Cooler
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. Undo the screw cap on the fill nozzle... -
Page 39: Notes On Changing The Welding Torch
Place a suitable container underneath the cooling unit drain hose to catch the coolant Pull the drain hose out of the upper recess of the cooling unit and hold it in the con- tainer Remove the drain hose cap Allow the coolant to flow into the container Dispose of used coolant properly Place the cap on the drain hose Return the drain hose to its original position... -
Page 41: Troubleshooting
Troubleshooting... -
Page 43: Troubleshooting
Troubleshooting 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. ▶... -
Page 44: Fuse-Protecting The Cooling Unit
Fuse-protecting The cooling unit is protected by three fuses: the cooling unit Coolant pump fuse (1) on the front of cooling unit (fuse blows if the coolant pump becomes overloaded or blocked) Two fuses (2) inside the unit, above the fan (fuses blow if there is a short circuit to earth) Fuse on front of the unit Fuses above the fan... - Page 45 Remedy: Clean coolant filter using clean tap water or change filter element Cause: Coolant pump is jammed (FK 4000 R, FK 4000 R US and FK 4000 Rob only) Remedy: Turn coolant pump shaft (see operating instructions, "Turning coolant pump shaft"...
- Page 46 High operating noise level Cause: Coolant level too low Remedy: Top up coolant Cause: Coolant pump defective Remedy: Contact After-Sales Service no l H2O The cooling unit flow sensor has tripped. The error message appears on the power source control panel. Cause: Coolant flow problem Remedy:...
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Page 47: Twisting The Coolant Pump Shaft
Twisting the coolant pump shaft Safety 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. -
Page 48: Technical Data
Dimensions l/w/h 725/290/230 mm 28.54/11.42/9.06 in. Weight (without coolant) 14.1 kg 31.09 Ib. Mark of conformity FK 4000 R, FK Mains voltage 3 x 400 V AC 4000 R FC Mains voltage tolerance -10% / +10% Mains frequency 50 / 60 Hz Current consumption 0.6 A... -
Page 49: Fk 4000 Rob
Protection class IP 23 Dimensions l/w/h 725/290/230 mm 28.54/11.42/9.06 in. Weight (without coolant) 13.3 kg 29.32 Ib. Mark of conformity FK 4000 R US Mains voltage 200 - 230 / 400 - 460 V AC Mains voltage tolerance -10% / +10%... - Page 50 Mains frequency 50 / 60 Hz Current consumption 1.3 A / 0.5 A Cooling power at Q = 1 l/min + 25°C (77°F) 1360 W Q = 1 l/ min + 40°C (104°F) 870 W Max. delivery head 33 m 108 ft.
- Page 52 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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