FRO­NIUS FK 4000 User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0017,EN 008-04032019
FK 4000
FK 4000 R
FK 4000 R US
FK 4000 R FC
FK 4000 Rob
Operating Instructions
Spare parts list
Cooling unit
EN

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3
EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety symbols DANGER!
Indicates immediate and real danger.
If it is not avoided, death or serious injury will result.
WARNING!
Indicates a potentially dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
If it is not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.

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EN
Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 8
Noise emission values .......................................................................................................................... 9
Danger from toxic gases and vapours .................................................................................................. 9
Danger from flying sparks ..................................................................................................................... 10
Risks from mains current and welding current...................................................................................... 10
Meandering welding currents................................................................................................................ 11
EMC Device Classifications .................................................................................................................. 12
EMC measures ..................................................................................................................................... 12
EMF measures...................................................................................................................................... 12
Specific hazards.................................................................................................................................... 13
Factors affecting welding results........................................................................................................... 14
Danger from shielding gas cylinders..................................................................................................... 14
Danger from escaping shielding gas..................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 15
Safety measures in normal operation ................................................................................................... 15
Commissioning, maintenance and repair.............................................................................................. 16
Safety inspection................................................................................................................................... 16
Disposal ................................................................................................................................................ 16
Safety symbols...................................................................................................................................... 17
Data protection...................................................................................................................................... 17
Copyright............................................................................................................................................... 17
General ...................................................................................................................................................... 18
Device concept ..................................................................................................................................... 18
Scope of supply .................................................................................................................................... 18
Validity of "General Delivery and Payment Conditions"........................................................................ 18
Information about the coolant ............................................................................................................... 18
Warning notices on the device.............................................................................................................. 19
Application areas ....................................................................................................................................... 20
FK 4000 ................................................................................................................................................ 20
FK 4000 R, FK 4000 Rob, FK 4000 R FC, FK 4000 R US ................................................................... 20
Options....................................................................................................................................................... 21
FK 4000 auto-transformer..................................................................................................................... 21
FK 4000 R flow sensor with coolant filter.............................................................................................. 21
Thermostat............................................................................................................................................ 21
Coolant filter.......................................................................................................................................... 22
Control elements and connections............................................................................................................. 23
Safety.................................................................................................................................................... 23
Control elements and connections........................................................................................................ 23
Before installation and commissioning....................................................................................................... 24
Safety.................................................................................................................................................... 24
Setup regulations .................................................................................................................................. 24
Information about the coolant ............................................................................................................... 25
Guarantee provisions regarding the coolant pump ............................................................................... 25
Proper use ............................................................................................................................................ 25
Fitting coolant connections to the front of the unit ..................................................................................... 26
Safety.................................................................................................................................................... 26
General ................................................................................................................................................. 26
Fitting coolant connections to the front of the unit ................................................................................ 26
Adapting the cooling unit to the respective mains voltage ......................................................................... 28
Safety.................................................................................................................................................... 28
General ................................................................................................................................................. 28
Possible mains voltages for FK 4000, FK 4000 R, FK 4000 Rob and FK 4000 R FC .......................... 29
Possible mains voltages for FK 4000 R US .......................................................................................... 29

6
Adapting the cooling unit to the respective mains voltage .................................................................... 29
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
Connecting the hosepacks to the cooling unit ........................................................................................... 34
Safety.................................................................................................................................................... 34
Connect the interconnecting hosepack coolant hoses to the cooling unit (TS/TPS 4000/5000) .......... 34
Connecting the welding torch coolant hoses to the cooling unit (TPS 2700)........................................ 34
Putting the cooling unit into service ........................................................................................................... 35
Safety.................................................................................................................................................... 35
General ................................................................................................................................................. 35
Filling the cooling unit ........................................................................................................................... 35
Commissioning the cooling unit ............................................................................................................ 36
Care, maintenance and disposal ............................................................................................................... 37
Safety.................................................................................................................................................... 37
General ................................................................................................................................................. 37
Symbols for care and maintenance of the cooling unit ......................................................................... 38
Maintenance intervals, maintenance work............................................................................................ 38
Gas purge the cooler ............................................................................................................................ 39
Changing the coolant ............................................................................................................................ 40
Notes on changing the welding torch.................................................................................................... 41
Disposal ................................................................................................................................................ 41
Troubleshooting 43
Troubleshooting ......................................................................................................................................... 45
Safety.................................................................................................................................................... 45
General ................................................................................................................................................. 45
Fuse-protecting the cooling unit............................................................................................................ 46
Troubleshooting .................................................................................................................................... 46
Twisting the coolant pump shaft ................................................................................................................ 49
Safety.................................................................................................................................................... 49
Turning the coolant pump shaft ............................................................................................................ 49
Technical data............................................................................................................................................ 50
General ................................................................................................................................................ 50
FK 4000 ................................................................................................................................................ 50
FK 4000 R, FK 4000 R FC.................................................................................................................... 50
FK 4000 Rob......................................................................................................................................... 51
FK 4000 R US....................................................................................................................................... 51
Appendix 53
Spare parts list: FK 4000, FK 4000 R, FK 4000 R US, FK 4000 Rob........................................................ 54
Spare parts list: Options............................................................................................................................. 55

7
EN
Safety rules
General The device is manufactured using state-of-the-art technology and according to recognised
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 applica-
ble 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.
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
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age arising from such usage.

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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.)
Obligations of the
operator
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
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.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
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 sup-
ply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your-
self 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

9
EN
Noise emission
values
Danger from toxic
gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances, cause birth de-
fects or cancer.
Keep your face away from welding fumes and gases.
- 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 protec-
tive 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
Keep all persons, especially children, out of the working area while any devic-
es 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 per-
missible 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.

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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 with a ventilation rate of at least 20 m³/hour.
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
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.
Amongst others, the following components are responsible for the degree of toxicity of
welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Danger from fly-
ing sparks
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 al-
ternatively 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.
Risks from mains
current and weld-
ing 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 temporary
backing or cover for the earth or ground potential. This temporary backing 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 dimen-
sioned. Replace loose connections and scorched, damaged or inadequately dimensioned
cables and leads immediately.

11
EN
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 pre-load.
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.
Double the open circuit voltage of a power source can occur between the welding elec-
trodes 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.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.
Operating the device on a grid without a ground conductor and in a socket without a ground
conductor contact will be deemed gross negligence. The manufacturer shall not be held
liable for any damage arising from such usage.
If necessary, provide an adequate earth connection 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 any-
one 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.
Meandering weld-
ing 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.
If the floor is electrically conductive, the device must be set up with sufficient insulating ma-
terial to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The elec-
trode 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 elec-
trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wire-
feed unit.

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EMC Device Clas-
sifications
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.
EMC measures
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 de-
vice 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
In certain cases, even though a device complies with the standard limit values
for emissions, 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 rec-
tify 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
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connec-
tion, additional measures are necessary (e.g. use a suitable line fil-
ter).
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

13
EN
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
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 cool-
ant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The cool-
ant 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.
- 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 chang-
es caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.

14
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.
Factors affecting
welding results
Danger from
shielding gas cyl-
inders
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, mechan-
ical 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.
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 cylin-
ders 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 inter-
national regulations for shielding gas cylinders and accessories.
Danger from es-
caping shielding
gas
The following requirements with regard to shielding gas quality must be met if
the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can dis-
place 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 cylin-
der 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.

15
EN
Safety measures
at the installation
location and dur-
ing transport
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.
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 ac-
cident prevention regulations. This applies especially to guidelines regarding the risks aris-
ing 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 com-
missioning the device.
Safety measures
in normal opera-
tion
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.
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 prop-
erties (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 com-
ponents or a different coolant. In addition, all warranty claims will be forfeited.

16
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer-
tain 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 least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12-
month period.
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 di-
rectives.
Further details on safety inspection and calibration can be obtained from your service cen-
tre. 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 af-
fects on the environment and your health!
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made of them, or that they satisfy safety require-
ments.
- 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 immedi-
ately.
- 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.

17
EN
Safety symbols
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 ba-
sis 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.
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic 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 rele-
vant standards for Canada and the USA.

18
General
Device concept Five cooling units are available for cooling
the power sources listed below:
- FK 4000 with oscillating armature
pump and auto-transformer
- FK 4000 R with centrifugal pump
- FK 4000 R FC with centrifugal pump
and flow sensor with coolant filter
- FK 4000 R US with centrifugal pump,
auto-transformer and flow sensor with
coolant filter
- FK 4000 Rob with magnetically-cou-
pled centrifugal pump, flow sensor with
coolant filter and thermostat
The cooling units described in these instructions can be operated with all power sources
in the:
- TransSynergic 4000 / 5000 series
- TransPuls Synergic 2700 series
- TransPuls Synergic 3200 / 4000 / 5000 series
- TransTig 2200 / 4000 / 5000 series
- MagicWave 1700 / 2200 / 4000 / 5000 series
Scope of supply - Cooling unit
- 5 l coolant in a canister
- Four Allen screws (for securing the power source on the cooling unit)
- Four M5 nuts (for securing the power source on the cooling unit)
- One 2 A fuse (spare)
- Operating instructions
Validity of "Gen-
eral Delivery and
Payment Condi-
tions"
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) / FK 4000 Rob: 24 hrs/day operation
(three-shift operation)
- Only original coolant from the manufacturer is used
- Regular maintenance and regular change of coolant
Information about
the coolant CAUTION!
Risk of damage.
- Only use coolant available from the manufacturer.
- Do not mix different coolants.
- When changing the coolant, ensure to change all of it.
- When switching from ethanol-based coolant to FCL 10 coolant, Change Kit FCL10
must be used and the instructions provided must be followed.

19
EN
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.
Welding is dangerous. The following
basic requirements must be met to en-
sure the equipment is used properly:
- Welders must be sufficiently quali-
fied
- Suitable protective equipment
must be used
- All persons not involved must be
kept at a safe distance from the
cooling unit and the welding pro-
cess
Do not use the functions described here
until you have thoroughly read and un-
derstood the following documents:
- these operating instructions
- all the operating instructions for the
system components, especially
the safety rules
Do not dispose of used devices with do-
mestic waste. Dispose of them accord-
ing to the safety rules.
4 bar (0.4 MPa) 2 kWP
1l/min
1~
50-60 Hz
IEC 60 974-2/-10 Cl.A IP 23
0.6 A
U
1
400 V
p
max
A-4600 Wels
www.fronius.com
Ser.No.:
Part No.:
Type:
p
max
I max

20
Application areas
FK 4000 The cooling unit is recommended for use with:
- TransPuls Synergic 2700
- TransSynergic 4000 and TransPuls Synergic 4000, max. length of the interconnecting
hosepack 5 m (16 ft. 5 in.)
- TransSynergic 5000 and TransPuls Synergic 5000, max. length of the interconnecting
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
4000 Rob, FK
4000 R FC, FK
4000 R US
The cooling units are recommended for use with:
- TransSynergic 4000 and TransPuls Synergic 4000, length of the interconnecting
hosepack over 5 m (16 ft. 5 in.)
- TransSynergic 5000 and TransPuls Synergic 5000, length of the interconnecting
hosepack over 1.2 m (4 ft.)
- PullMig or PushPull hosepacks
- Multilock hosepacks
- Robacta machine hosepacks
- Robacta or Robacta Drive robot hosepacks
- TIME and JobMaster welding torches
- MIG/MAG pulsed arc welding
- Welding in a higher power range
- Robot welding
Additional information for FK 4000 R FC:
- The flow sensor with coolant filter option is fitted as standard in the cooling unit
Additional information for FK 4000 Rob:
- The flow sensor with coolant filter option is fitted as standard in the cooling unit
- The thermostat option is fitted as standard in the cooling unit
Additional information for FK 4000 R US:
- The flow sensor with coolant filter option is fitted as standard in the cooling unit
- The FK 4000 auto-transformer option is fitted as standard in the cooling unit
- The cooling unit is intended for the American market. The other cooling units are not
available on the American market