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Manual FK2500 Cooling Unit
Manual FK2500 Cooling Unit
FK 2500 FC
FK 2500 MV
FK 2500 MV FC
FK 2500 Rob
Operating Instructions
FK 2500 MV Rob GB
Spare parts list
Cooling unit
42,0426,0047,EN 012011
Dear Reader
Introduction Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
ud_fr_st_et_00493 012004
Contents
General remarks ........................................................................................................................................... 2
Overview .................................................................................................................................................. 2
Machine concept ...................................................................................................................................... 2
Field of application ................................................................................................................................... 2
Equipment ..................................................................................................................................................... 3
Return temperature monitoring ................................................................................................................ 3
Flow sensor (FK 2500 FC) ....................................................................................................................... 3
MV Multivoltage ........................................................................................................................................ 3
Controls and connections .............................................................................................................................. 4
Safety ....................................................................................................................................................... 4
Front ......................................................................................................................................................... 4
Rear ......................................................................................................................................................... 4
Fitting the cooling unit to the trolley ............................................................................................................... 5
General remarks ...................................................................................................................................... 5
Fitting the cooling unit to the base of the trolley ....................................................................................... 5
Connecting the power source and the cooling unit ........................................................................................ 6
Safety ....................................................................................................................................................... 6
Connecting the power source and the cooling unit .................................................................................. 6
Before commissioning ................................................................................................................................... 7
General remarks ...................................................................................................................................... 7
Setup requirements .................................................................................................................................. 7
Coolant information .................................................................................................................................. 7
Guarantee provisions regarding the coolant pump .................................................................................. 7
Putting the cooling unit into service ............................................................................................................... 8
General remarks ...................................................................................................................................... 8
Filling the cooling unit ............................................................................................................................... 8
Connecting the welding torch ................................................................................................................... 8
Bleeding the cooling unit .......................................................................................................................... 8
Putting the cooling unit into service .......................................................................................................... 9
Care, maintenance and disposal ................................................................................................................. 10
General remarks .................................................................................................................................... 10
Safety ..................................................................................................................................................... 10
Symbols for care and maintenance of the cooling unit ........................................................................... 10
Every start-up ......................................................................................................................................... 10
Every 2 months ....................................................................................................................................... 11
Every week .............................................................................................................................................. 11
Every 6 months ....................................................................................................................................... 11
Every 12 months .................................................................................................................................... 12
Disposal ................................................................................................................................................. 12
Validity of „General Delivery and Payment Conditions“ .......................................................................... 12
Troubleshooting ........................................................................................................................................... 13
Service codes displayed on the power source ....................................................................................... 13
FK 2500.................................................................................................................................................. 13
Technical data ............................................................................................................................................. 15
General remarks .................................................................................................................................... 15
FK 2500, FK 2500 FC ............................................................................................................................ 15
FK 2500 MV, FK 2500 MV FC ................................................................................................................ 16
1
General remarks
Overview The FK 2500 cooling unit can be used with the following power sources:
- TransTig 2500/3000
- TransTig 2500/3000 Job
- MagicWave 2500/3000
- MagicWave 2500/3000 Job
The FK 2500 cooling unit is equipped with a return temperature monitoring system. The
FK2500 FC version also has a flow sensor.
If required for process safety reasons, the cooling unit switches the power source off.
This happens when:
- the coolant return temperature exceeds a certain level
(e.g. welding torch overheating)
- the flow rate falls below a certain level
(e.g. liquid level in coolant container too low)
2
Equipment
Return tempera- A temperature sensor monitors the return temperature of the coolant.
ture monitoring - If the coolant temperature exceeds 75 °C, the sensor interrupts the welding current.
The power source outputs the error message „hot | H2O“.
- The temperature sensor restores the welding current when the coolant temperature
falls to 65 °C again.
Flow sensor The flow sensor monitors the coolant flow during welding. Should a fault occur in the
(FK 2500 FC) coolant flow, the power source outputs the error message „No | H2O“.
A fault in the coolant flow can be caused by:
- coolant level too low
- insufficient bleeding of the cooling circuit
- contaminated coolant
- leak in the cooling circuit
- defective coolant pumps
- frozen coolant (welding when temperature is too low)
Sealless pump A sealless, magnetically-coupled centrifugal pump ensures that operation is extremely
(FK 2500 Rob) reliable in multi-shift operation. The pump has been designed to last 15,000 operating
hours.
The FK 2500 Rob and FK 2500 MV Rob cooling units, which are equipped as standard
with a flow sensor and a temperature sensor, are specifically designed for robot operati-
on and automated applications.
MV Multivoltage The cooling unit adapts itself automatically to the mains voltage.
3
Controls and connections
Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage.
Do not use the functions described here until you have read and completely
understood all of the following documents:
- these Operating Instructions
- all the operating instructions for the system components, especially the
safety regulations
Front
(1) (2) (3) (4) No. Function
(1) Coolant sight glass
(2) Fill nozzle with screw cap
(3) Water flow connection (blue)
(4) Water return connection (red)
Type:
Art. Nr.
A 4600 Wels, Günter-Fronius-Straße 1
Made in Austria
(5) Rating plate
5.N.
tions
(6) (5)
Fig. 2 FK 2500 - Connections on front
Rear
(7) (8) (9) No. Function
(7) Coolant pump fuse
(8) Blanking cover for plug connection
(9) Blanking cover for plug connection
(10) Bushing for coolant pump shaft
(11) Hose with screw cap
for draining off coolant
(11) (10)
Fig. 3 FK 2500 - Connections on rear
4
Fitting the cooling unit to the trolley
General remarks The welding system can be fitted to a trolley to make the system (incl. cooling unit) more
mobile.
Important! If the welding system is not equipped with an auto-transformer, the cooling
unit must be installed right at the bottom.
5
Connecting the power source and the cooling unit
Safety
WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the machine when
- the mains switch is in the „O“ position,
- the machine is unplugged from the mains.
CAUTION! Risk of short circuit from kinked or damaged cable. When positio-
ning the power source, ensure that the cable is not kinked.
CAUTION!! Danger from machines falling or toppling over. Ensure that all
screw connections are tight.
6
Before commissioning
General remarks
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. You should not use the functions described until you have thoroughly
read and understood the following documents:
- these Operating Instructions
- all the operating instructions for the system components, especially the
safety regulations
Setup require-
ments WARNING! If one of these machines topples over or falls it could cause
serious or even fatal injury. Place machine on a solid, level surface so that it
remains stable.
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.
Dust
Ensure that any metallic dust, for example from grinding work, is not sucked into the
system by the fan.
Outdoor operation
The system can be set up and used outdoors. The built-in electrical parts must, however,
be protected from direct wetting (e.g. external wet cleaning).
Coolant informa- The cooling unit is delivered without any coolant - this is provided separately in a 5l
tion canister. Fill the cooling unit with coolant before commissioning the unit.
Use only original Fronius coolant (item no. 40,0009,0046) when filling the cooling unit.
Other anti-freeze products are not recommended for electrical conductivity or compatibi-
lity reasons.
Guarantee provi- The coolant pump may only be used with original coolant supplied by the manufacturer.
sions regarding Do not allow the coolant pump to run dry (even for a very short time), as this will destroy
the coolant pump the coolant pump. Warranty claims will not be entertained in such cases.
7
Putting the cooling unit into service
General remarks The cooling unit is powered from the power source. If the power source mains switch is
turned to position „1“, the cooling unit also switches on.
A 4600
Type: Wels,
2.
Günter-
Art. Made Fronius
Nr. in Austria
-Straße
5.N. 1
U1
50-60 I1
Hz
IP
Pmax
Machin 4,2 bar 1-400
23 V
e P1 l/min 0,6/0,7
Options connec
ted 0,75 A
: at: kW
Pmax
0,95
kW
Filling the coo- 1. Undo the screw cap on the fill nozzle
ling unit 2. Fill with coolant
3. Screw the cap on again - the cooling unit is now ready to use
NOTE! If the cooling unit is being filled with coolant for the first time, it must be
bled before it is used.
3. Pull back the locking ring on the water flow connection (blue)
4. Disconnect the water flow hose
5. Using a wooden or plastic pin, carefully press in and hold the sealing cone in the
centre of the water flow connector
6. Release the cone when coolant starts to emerge
7. Connect the water flow hose again
8. Check the outside water connections for leaks
Bleed as often as necessary until an unimpeded return flow can be seen in the fill
nozzle.
8
Putting the NOTE! The coolant level and cleanliness of the coolant must always be che-
cooling unit into cked before starting the cooling unit.
service
1. Plug in the power source or turn on the power supply
2. Turn the mains switch to position „I“
3. Check the coolant flow until it is clear that the coolant is flowing properly. Bleed the
cooling unit if necessary.
NOTE! During welding, check at regular intervals that the coolant is flowing
properly. You should be able to see a steady flow of coolant through the fill
nozzle.
Changing the
CAUTION! Excess pressure will damage the cooling unit. Before blowing out
welding torch
the welding torch with compressed air, undo the screw cap on the fill nozzle.
9
Care, maintenance and disposal
General remarks Under normal operating conditions the cooling unit requires only a minimum of care and
maintenance. However, it is vital to observe some important points to ensure the welding
machine remains in a usable condition for many years.
Safety
WARNING! An electric shock can be fatal. Before opening the machine
- Turn power source mains switch to position „O“
- Unplug power source from mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that electrically
charged components (e.g. capacitors) have been discharged
Every start-up - Check welding torch, interconnecting hosepack and grounding (earthing) connection
for signs of damage
- Check that there is a gap of 0.5 m (1ft. 7.69 in.) all around the machine to ensure
that cooling air can flow and escape unhindered
NOTE! Air inlets and outlets must never be covered, not even partially.
CAUTION!! Risk of scalding from hot coolant. Do not check the water connec-
tions until the coolant has had time to cool down.
NOTE! If water-cooled torches are operated without coolant, this will normally
result in a fault in the torch body or hosepack. Fronius shall not be liable for any
damage resulting from such action. In addition, no warranty claims will be
entertained.
10
Every week
CAUTION!! Risk of scalding from hot coolant. Do
not check the water connections until the coolant
has had time to cool down.
If the coolant level is below the „min“ mark, top up with coolant.
NOTE! Use only original Fronius coolant (40,0009,0046) when filling cooling
units. Other coolants are not recommended for electrical conductivity or compa-
tibility reasons.
Every 12 months
CAUTION!! Risk of scalding from hot coolant. Do not check the
water connections until the coolant has had time to cool down.
Replace coolant:
1. Turn power source mains switch to position „O“
2. Unplug power source mains plug
3. On the rear of the cooling unit, pull the coolant drain hose out of the upper recess
and hold it downwards.
11
Every 12 months 4. Remove the screw cap
(continued) 5. Allow the coolant to drain out
6. Dispose of used coolant properly.
NOTE! Use only original Fronius coolant (item no. 40,0009,0046) when refilling
the cooling unit.
Disposal Dispose of in accordance with the applicable national and local regulations.
Validity of „Gene- With regard to cooling units, the „General Delivery and Payment Conditions“ shown in
ral Delivery and the price list only apply under the following conditions:
Payment Conditi-
ons“ - Max. 8 hrs/day operation (single shift operation)
- Original Fronius coolant used exclusively (item number 40,0009,0046 or
40,0009,0075)
- Regular maintenance and regular change of coolant
12
Troubleshooting
Service codes
hot | H2O
displayed on the
Cooling unit temperature sensor has tripped.
power source
Cause: Coolant temperature too high
Remedy: Wait until the end of the cooling phase, i.e. until „hot | H2O“ is no longer
displayed.
ROB 5000 or field bus coupler for robot control: Before resuming welding,
set the „Source error reset“ signal.
no | H2O
FK 2500 FC only
Cause: Coolant flow problem
Remedy: Check coolant level, cleanliness and proper return; bleed cooling unit if
necessary, top up with coolant
FK 2500
Water flow too low or non-existent
Cause: Coolant level too low
Remedy: Top up with coolant
Insufficient cooling
Cause: Faulty ventilator
Remedy: Replace ventilator
13
FK 2500
Insufficient cooling
(continued)
Cause: Capacity of connected cooling unit not high enough
Remedy: Use a unit with a greater cooling capacity
14
Technical data
FK 2500,
FK 2500 FK 2500 FC
FK 2500 FC
Mains voltage 400 V AC 400 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 / 0.7 A
Fuse 2 A slow-blow 2 A slow-blow
Cooling capacity at
Q = 1 l/min + 25 °C (77 °F) 770 W 770 W
Q = 1 l/min + 40 °C (104 °F) 485 W 485 W
Q = max. + 25 °C (77 °F) 1020 W 1020 W
Q = max. + 40 °C (104 °F) 640 W 640 W
Max. delivery head 30 m 30 m
98 ft. 5.10 in. 98 ft. 5.10 in.
Max. delivery rate 3 l/min 3 l/min
0.79 gal./min 0.79 gal./min
Max. pump pressure 4.2 bar 4.2 bar
60.89 psi. 60.89 psi.
Pump Centrifugal pump Centrifugal pump
Pump service life approx. 8,000 hrs. approx. 8,000 hrs.
Coolant capacity 4l 4l
1.06 gal. 1.06 gal.
Protection IP 23 IP 23
Dimensions l/w/h 625/240/225 mm 625/240/225 mm
24.61/9.45/8.86 in. 24.61/9.45/8.86 in.
Weight (without coolant) 9 kg 9 kg
19.84 lb. 19.84 lb
Flow monitoring - sensor
Error below 0.7 l/min
Return temperature monitoring Error above 75 °C Error above 75 °C
Marks of conformity S, CE S, CE
15
FK 2500 MV,
FK 2500 MV FK 2500 FC MV
FK 2500 MV FC
Mains voltage AC 200-230/400-480 V 200-230/400-480 V
Mains voltage tolerance -10% / +10% -10% / +10%
Mains frequency 50/60 Hz 50/60 Hz
Current input 0.6 - 1.4 A 0.6 - 1.4 A
Fuse 2 A slow-blow 2 A slow-blow
Cooling capacity at
Q = 1 l/min + 25 °C (77 °F) 770 W 770 W
Q = 1 l/min + 40 °C (104 °F) 485 W 485 W
Q = max. + 25 °C (77 °F) 1020 W 1020 W
Q = max. + 40 °C (104 °F) 640 W 640 W
Max. delivery head 30 m 30 m
98 ft. 5.10 in. 98 ft. 5.10 in.
Max. delivery rate 3 l/min 3 l/min
0.79 gal./min 0.79 gal./min
Max. pump pressure 4.2 bar 4.2 bar
60.89 psi. 60.89 psi.
Pump Centrifugal pump Centrifugal pump
Pump service life approx. 8,000 hrs. approx. 8,000 hrs.
Coolant capacity 4l 4l
1.06 gal. 1.06 gal.
Protection IP 23 IP 23
Dimensions l/w/h 625/240/225 mm 625/240/225 mm
24.61/9.45/8.86 in. 24.61/9.45/8.86 in.
Weight (without coolant) 11.6 kg 11.7 kg
25.57 lb. 25.79 lb
Flow monitoring - sensor
Error below 0.7 l/min
Return temperature monitoring Error above 75 °C Error above 75 °C
Marks of conformity S, CE, CSA S, CE, CSA
16
FK 2500 Rob,
FK 2500 Rob FK 2500 MV Rob
FK 2500 MV Rob
Mains voltage AC 400 V 200-240/400-460 V
Mains voltage tolerance -10% / +10% -10% / +10%
Mains frequency 50/60 Hz 50/60 Hz
Current input 0.6 - 0.7 A 0.6 - 0.7 A
Fuse 2 A slow-blow 2 A slow-blow
Cooling capacity at
Q = 1 l/min + 25 °C (77 °F) 800 W 800 W
Q = 1 l/min + 40 °C (104 °F) 500 W 500 W
Q = max. + 25 °C (77 °F) 1160 W 1160 W
Q = max. + 40 °C (104 °F) 730 W 730 W
Max. delivery head 30 m 30 m
98 ft. 5.10 in. 98 ft. 5.10 in.
Max. delivery rate 3.5 l/min 3.5 l/min
0.92 gal./min 0.92 gal./min
Max. pump pressure 4.2 bar 4.2 bar
60.89 psi. 60.89 psi.
Pump Magnetically-coupled Magnetically-coupled
centrifugal pump centrifugal pump
Pump service life approx. 15,000 hrs. approx. 15,000 hrs.
Coolant capacity 4l 4l
1.06 gal. 1.06 gal.
Protection IP 23 IP 23
Dimensions l/w/h 625/240/225 mm 625/240/225 mm
24.61/9.45/8.86 in. 24.61/9.45/8.86 in.
Weight (without coolant) 9 kg 9.1 kg
19.84 lb. 20.06 lb
Flow monitoring sensor sensor
Error below 0.7 l/min Error below 0.7 l/min
Return temperature monitoring Error above 70 °C Error above 70 °C
Marks of conformity S, CE S, CE, CSA
17
18
Ersatzteilliste
D
Schaltplan
Lista de repuestos
E
Esquema de cableado
Onderdelenlijst
NL
Bedradingsschema
Reservdelsliste
N
Koblingsplan
Reservdelslistan
S
Kopplingsschema
Parça Listesi
TR
Baðlantý þemasý
Czyszczenie palnika
PL
Schemat połączeń
ud_fr_st_tb_00149 012010
FK 2500 4,045,985
FK 2500 FC 4,045,985,632
FK 2500 MV 4,045,985,800
FK 2500 MV FC 4,045,985,832
FK 2500 Rob 4,045,985,633
FK 2500 MV Rob 4,045,985,833
AM2,0201,2450
AM2,0201,2449
AM2,0201,2448
40,0009,0046
43,0006,0170
43,0006,0206 - Rob
42,0405,0593
43,0009,0048 - FC
41,0007,0169
42,0405,0546
41,0007,0158
41,0007,0161 - 2A
41,0007,0159
42,0401,0937
42,0401,0938
42,0407,0442
50
0 42,0300,2413
C2 00
FKR25
FK
40,0001,0008 - *
4,071,074,Z FKR2500
4,071,073,Z FKC2500 - MV 43,0006,0134
42,0201,2489
42,0405,0593
42,0407,0442
42,0405,0189
44,0001,1145
FK 2500
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/1
el_fr_st_kg_01372 012007
FK 2500 / FK 2500 FC / FK 2500 Rob
FK 2500 Rob
FK 2500 MV / FK 2500 MV FC / FK 2500 MV Rob
FK 2500 MV Rob
FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
www.fronius.com
www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations.
ud_fr_st_so_00082 012011