FRO­NIUS FK 5000 MV User manual

42,0426,0079,EN 012009
FK 5000
FK 5000 MV Operating instructions
Cooling unit
GB

ud_fr_st_et_00493 012004
Dear Reader
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! n 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.
Introduction

1
Table of contents
General ......................................................................................................................................................... 2
Device concept......................................................................................................................................... 2
Variants .................................................................................................................................................... 2
Scope of supply ........................................................................................................................................ 2
Field of application ................................................................................................................................... 2
Warning notices affixed to the device ...................................................................................................... 3
Options .......................................................................................................................................................... 4
General .................................................................................................................................................... 4
Return temperature and flow monitoring .................................................................................................. 4
Coolant filter ............................................................................................................................................. 4
Control elements and connections ................................................................................................................ 5
Front ......................................................................................................................................................... 5
Rear ......................................................................................................................................................... 5
Fitting the cooling unit to the trolley ............................................................................................................... 6
General .................................................................................................................................................... 6
Fitting the cooling unit to the trolley .......................................................................................................... 6
Installation ..................................................................................................................................................... 7
Connecting the cooling unit and the power source .................................................................................. 7
Connecting the interconnecting hosepack to the cooling unit .................................................................. 8
Before commissioning ................................................................................................................................... 9
Safety ....................................................................................................................................................... 9
Setup regulations ..................................................................................................................................... 9
Information on the coolant........................................................................................................................ 9
Guarantee provisions regarding the coolant pump .................................................................................. 9
Utilisation in accordance with „intended purpose“ .................................................................................. 10
Putting the cooling unit into service .............................................................................................................. 11
General ................................................................................................................................................... 11
Filling the cooling unit .............................................................................................................................. 11
Bleeding the cooling unit ......................................................................................................................... 11
Putting the cooling unit into service ........................................................................................................ 12
Care, maintenance and disposal ................................................................................................................. 13
General .................................................................................................................................................. 13
Symbols for care and maintenance of the cooling unit........................................................................... 13
At every start-up ..................................................................................................................................... 13
Once a week .......................................................................................................................................... 14
Every 2 months ...................................................................................................................................... 14
Every 6 months ...................................................................................................................................... 14
Every 6 months - in 3-shift operation...................................................................................................... 14
Every 12 months .................................................................................................................................... 17
Service life of the coolant pump ............................................................................................................. 19
Disposal ................................................................................................................................................. 19
Validity of „General Delivery and Payment Conditions“ .......................................................................... 19
Troubleshooting ........................................................................................................................................... 20
Service codes displayed on the wire-feed unit ....................................................................................... 20
FK 5000 / FK 5000 MV ........................................................................................................................... 20
Tightening the coolant pump shaft ......................................................................................................... 21
Technical data ............................................................................................................................................. 23
General .................................................................................................................................................. 23
FK 5000, FK 5000 MV ............................................................................................................................ 23

2
Variants
The cooling unit fits perfectly into the
modular product concept of the TransSteel
3500 / 5000 power sources.
The cooling unit and the power source form
a unit. As with the standalone power
source, the power source/cooling unit
combination can be mounted on the trolley.
The FK 5000 / FK 5000 MV cooling unit can be used for:
- water-cooled MIG/MAG manual welding torches
- water-cooled MIG/MAG machine welding torches
- water-cooled MIG/MAG robot welding torches
General
Device concept
Field of applicati-
on
Two versions of the cooling unit are produced:
- FK 5000 (basic version)
- FK 5000 MV (Multivoltage version)
The FK 5000 MV adapts itself automatically to the mains voltage.
The Multivoltage version is available only from the factory.
The scope of supply comprises:
- Cooling unit
- 5 l coolant
- Four 5x25mm self-tapping screws
- Operating instructions
Scope of supply

3
Warning notices
affixed to the
device
A number of safety symbols can be seen on the cooling unit rating plate. The 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.
Do not use the functions until you have read all the operating
instructions.
Do not dispose of used cooling units with domestic waste. Dispose of them
according to safety rules.

4
Options
Return tempera-
ture and flow
monitoring
Return temperature monitoring:
A temperature sensor monitors the return temperature of the coolant.
- If the coolant temperature exceeds 75 °C, the sensor interrupts the welding current.
The wire-feed unit outputs the error message „hot | H2O“.
- The temperature sensor restores the welding current when the coolant temperature
falls to 65 °C again.
Flow monitoring:
A flow sensor monitors the coolant flow during welding. The cooling unit will switch off if
the coolant flow is disrupted. The wire-feed unit outputs the error message „No | H2O“.
These two components form part of an installation kit.
Coolant filter The coolant filter is equipped with a CrNi screen, and its function is to filter dirt particles
above 100 micrometers in size from the coolant. This ensures that no coarse dirt partic-
les can pass into the coolant circuit. The coolant filter is installed on the cooling unit
housing from the outside.
The options listed below are available for all cooling unit variants.General

5
(1) (2)
(1)
No. Function
(1) Water flow connection blanking cover
(black)
(2) Water return connection blanking
cover (red)
(3) Screw cap for coolant container
(4) Operation and maintenance instruc-
tions
(5) Coolant inspection window
No. Function
(1) Power source connecting plug
(2) Rating plate
(3) Water flow connection (black)
(4) Water return connection (red)
Control elements and connections
Front
(5)
Rear
(3) (4)
(2)
(4) (3)

6
Fitting the cooling unit to the trolley
General The welding system can be fitted to a PickUp 5000 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.
Fitting the coo-
ling unit to the
trolley
CAUTION! Risk of damage to the cooling unit. To ensure that the cooling unit is
properly insulated there must be no electrical conductor connecting the base
plate of the cooling unit to the bottom of the trolley.

7
WARNING! An electric shock can be fatal. If the power source is connected to
the mains electricity supply during installation, there is a high risk of very se-
rious injury and damage. Only carry out work on the device when
- the power source mains switch is in the - O - position,
- the power source is unplugged from the mains.
CAUTION! Risk of short circuit from kinked or damaged cables. When connec-
ting the power source to the cooling unit, ensure that the cables are not kinked.
CAUTION!! Danger from machines falling or toppling over. Ensure that all
screw connections are secure.
Installation
Connecting the
cooling unit and
the power source
4
6
7
1
3
2
4
5
6
1
3
1
2
5
4
6
7
2
1
2
22
1
3
3
1

8
Connecting the
interconnecting
hosepack to the
cooling unit

9
Before commissioning
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do 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 rules
WARNING! If one of these machines topples over or falls it could cause
serious or even fatal injury. Place device on a solid, level surface in such a way
that it remains stable.
Setup regulations
Safety
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 contact with fluids (e.g. external wet cleaning).
The cooling unit is delivered empty. The coolant is supplied separately in a 5 l 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 coolants are not recommended for electrical conductivity and compatibility reasons.
Guarantee provi-
sions regarding
the coolant pump
Information on
the coolant
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. Warranty claims will not be entertained in such cases.

10
Utilisation in
accordance with
„intended purpo-
se“
The device is intended exclusively for cooling Fronius hosepacks and welding torches.
The cooling unit is to be used exclusively for its intendedpurpose.
Utilisation for any other purpose, or in any other manner, shall be deemed to be „not in
accordance with the intended purpose“. The manufacturer is not liable for any damage,
inadequate or incorrect results arising out of such misuse.
Utilisation in accordance with the „intended purpose“ also comprises
- carefully reading and following the operating instructions and all safety and danger
notices
- performing all stipulated inspection and servicing 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.

11
3
max. 6 mm
.236 inch
4
1
2
5
2
3
2
1
4
1
Bleeding the
cooling unit
Bleed the cooling unit:
- when it has just been filled
- if the coolant is not circulating, even though the coolant pump is working
CAUTION!! Danger of scalding by hot coolant. Never bleed the cooling unit until
it has been allowed to cool down.
Putting the cooling unit into service
Filling the coo-
ling unit
General 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.
NOTE! If the cooling unit is being
filled with coolant for the first
time, it must be bled before it is
used.
2
1
3
6
5
max.

12
1
2
4
1
1
3
NOTE! During welding, check at
regular intervals that the coolant
is flowing through properly. You
should be able to see a steady
return flow of coolant into the
coolant container.
Putting the
cooling unit into
service
NOTE! The coolant level and
cleanliness of the coolant must
always be checked before star-
ting the cooling unit.
Bleeding the
cooling unit
(continued)
2
1
3
6
5
max.

13
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
system remains in a usable condition for many years.
WARNING! An electric shock can be fatal. Before opening the device:
- Turn power source mains switch to position „O“
- Unplug the power source from the 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
The relevant maintenance intervals are
described in detail on the following pages.
Read operating instructions
Change coolant Blow out
cooler
- 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.
- Check the welding torch water connections for leaks
- Monitor the water return in the coolant container
- If no water is returning, check the cooling unit and bleed if necessary
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.
CAUTION!! Danger of scalding by hot coolant. Do not check the water connec-
tions until the coolant has had time to cool down.
Care, maintenance and disposal
Symbols for care
and maintenance
of the cooling
unit
At every start-up
General
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. The following activities must only be carried out by trained and quali-
fied personnel. Take note of the „Safety rules“ chapter in the instructions for the
power source and cooling unit.

14
- Check coolant level and cleanliness.
- 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 and
compatibility reasons.
NOTE! Risk of damage to elec-
tronic components. Do not bring
air nozzle too close to electronic
components.
- Remove the side panels
and clean the water
cooler
If a large amount of dust has
accumulated:
- Dismantle machine side
panels and clean inside of
machine with dry reduced
compressed air
CAUTION!! Danger of scalding by hot coolant. Do not check the water connec-
tions until the coolant has had time to cool down.
Every week
Every 6 months
Every 2 months - Check the return for dirt and clean if necessary
- If present: Check that coolant filter and flow monitor are working properly and are
not contaminated; clean if necessary
1
Every 6 months -
in 3-shift operati-
on
NOTE! Risk of damage to elec-
tronic components. Do not bring
air nozzle too close to electronic
components.
- Remove the side panels
and clean the water cooler
If a large amount of dust has
accumulated:
- Remove side panels and
clean inside of machine with
dry reduced compressed air
Blow out cooling unit
Blow out cooling unit
1

15
2
1
1
4
2
3
1
2
1
3
4
min.
3
3
1
2
4
1
3
2
4
2
CAUTION!! Danger of scalding by hot coolant. Never change the coolant until it
has cooled down.
NOTE! Use only original Fronius coolant (item no. 40,0009,0046) when refilling
the cooling unit.
WARNING! An electric shock can be fatal. Before restarting the cooling unit,
first make sure that:
- there is no water inside the cooling unit
- all the hose connections are present and correct
Important! Coolant must not be disposed of in the public sewage system.
Change coolantEvery 6 months -
in 3-shift operati-
on
(continued)

16
2
3
4
5
1
4
3
max.
2
6
Every 6 months -
in 3-shift operati-
on
(continued)
Bleed the cooling unit
CAUTION!! Danger of scalding by hot coolant. Never bleed the cooling unit until
it has been allowed to cool down.
3
max. 6 mm
.236 inch
4
1
2
5
2
3
2
1
4
1
1
2
4
1
1
3