FRO­NIUS KD Supply 2500 User manual

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KD Supply 2500
EN
Operating instructions
42,0426,0049,EN 002-09112021

Contents
General 4
Introduction 4
Explanation of safety notices 4
Machine concept 4
Safety symbols on the rating plate 5
Warning notices affixed to the machine 5
Controls, connections and mechanical components 7
Safety 7
KD Supply 2500 - front 7
KD Supply 2500 - rear 7
Fitting the KD Supply 2500 to the trolley 8
General remarks 8
Fitting the KD Supply 2500 to the base of the trolley 8
Connecting the KD Supply 2500 to the cooling unit and power source 9
Safety 9
Connecting the KD Supply 2500 to the cooling unit and power source 9
Establishing a LocalNet connection between the KD Supply 2500 and the power source 10
Connecting the KD Supply 2500 to the cold wire feeder, commissioning 11
Connecting the KD Supply 2500 to the cold wire feeder, commissioning 11
Commissioning 11
Care, maintenance and disposal 12
General remarks 12
Every start-up 12
Every 6 months 12
Disposal 12
Technical data 13
KD Supply 2500 13
3
EN

General
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. Care-
ful handling of the product will repay you with years of safe and reliable operation. These
are essential prerequisites for excellent results.
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
Machine concept
KD Supply 2500
The KD Supply 2500 enables the TIG
power sources TT 2500 / 3000 Job and
MW 2500 / 3000 Job to be used with a
cold wire feeder. The built-in switched-
mode power supply supplies the feeder
motor.
The KD Supply 2500 simultaneously func-
tions as an active LocalNet distributor. In
addition to providing an interface to the
cold wire feeder, the KD Supply 2500 also
has an additional LocalNet interface, e.g.
for a remote control unit.
4

Safety symbols
on the rating
plate
The KD Supply 2500 has safety symbols on the rating plate. The safety symbols must
NOT be removed or painted over. The symbols warn against operating the equipment in-
correctly, which can cause serious injury and damage.
Welding is dangerous. The following basic requirements must be met:
- Welders must be sufficiently qualified
- Suitable protective equipment
- Keep all persons not involved in the welding process at a safe distance
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
Warning notices
affixed to the ma-
chine
Machines destined for the USA have additional warning notices. The warning notices
must NOT be removed or painted over.
5
EN

US machine with additional warning notices
6

Controls, connections and mechanical components
Safety WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶All the work and functions described in this document must only be carried out by
technically trained and qualified personnel.
▶Read and understand this document in full.
▶Read and understand all safety rules and user documentation for this device and all
system components.
KD Supply 2500 -
front
(1) (2)
(1) LocalNet X9.1 interface
Standard connection socket for the
power source
(2) LocalNet X9.2 interface
Standard connection socket for
system add-ons (e.g. KD 4000-D,
KD 7000-D, remote control, etc.)
KD Supply 2500 -
rear
(3) (4)
(5)
(3) lanking cover
(4) LocalNet X9.3 interface
Standard connection socket for
system add-ons (e.g. KD 4000-D,
KD 7000-D, remote control, etc.)
(5) Blanking cover
7
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Fitting the KD Supply 2500 to the trolley
General remarks The welding system can be fitted to a trolley to increase the mobility of the system.
IMPORTANT!
If the welding system is not equipped with an auto-transformer or a cooling unit,
the KD Supply 2500 must be installed right at the bottom.
- If a cooling unit is present, fit it right at the bottom and place the KD Supply on top of
it.
Fitting the KD
Supply 2500 to
the base of the
trolley
1If there are no fastening brackets on
the trolley:
Attach two fastening brackets to the
base of the trolley and secure each
one using three „Extrude-Tite“ screws.
2Place the KD Supply 2500 on the
base of the trolley.
3Using „Extrude-Tite“ screws, fasten
the KD Supply 2500 at the front and
back to the fastening brackets on the
base of the trolley.
8

Connecting the KD Supply 2500 to the cooling unit
and power source
Safety WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
▶Before starting work, switch off all devices and components involved and disconnect
them from the grid.
▶Secure all devices and components involved so they cannot be switched back on.
▶After opening the device, use a suitable measuring instrument to check that electric-
ally charged components (such as capacitors) have been discharged.
Connecting the
KD Supply 2500
to the cooling
unit and power
source
(1)
(1)
(1)
(1)
(2)
(2)
(2)
(2)
1Turn the power source mains switch to
the „O“ position
2Unplug power source mains plug
3Remove protective cover from the un-
derside of the power source
4Firmly press four M5 hexagonal nuts
(supplied with the KD Supply 2500)
from the inside into the hexagonal re-
cesses (1) in the fastening bars
If a cooling unit is present:
5Remove the protective cover from the
underside of the KD Supply 2500
6FIrmly press four M5 hexagonal nuts
(supplied with cooling unit) from the in-
side into the hexagonal recesses (2) in
the fastening bars
7Hold the KD Supply 2500 over the
cooling unit
8Pull the KD Supply 2500 connector as
far as possible through the opening on
the underside of the power source
9Establish connection between KD
Supply 2500 and cooling unit
CAUTION!
Risk of short circuit from kinked or damaged cables.
This can result in serious personal injury and damage to property.
▶When positioning the KD Supply 2500, ensure that the cables are not kinked.
9
EN

10 Carefully place the KD Supply 2500 on the cooling unit
11 Using two „Extrude-Tite“ screws, fasten the KD Supply to the fastening bars (2) on
the front and back of the cooling unit
12 Position the power source over the KD Supply 2500 using a suitable hoisting device
13 Pull the power source connector as far as possible through the opening on the un-
derside of the power source
14 Make connection between power source and cooling unit
CAUTION!
Risk of short circuit from kinked or damaged cables.
This can result in serious personal injury and damage to property.
▶When positioning the KD Supply 2500, ensure that the cables are not kinked.
15 Carefully place power source on KD Supply 2500
16 Using two „Extrude-Tite“ screws, fasten the power supply to the fastening bars (1) on
the front and back of the KD Supply 2500.
CAUTION!
Danger from machines falling or toppling over.
This can result in serious personal injury and damage to property.
▶Ensure that all screw connections are secure.
Establishing a
LocalNet connec-
tion between the
KD Supply 2500
and the power
source
1Connect the power source and the KD
Supply 2500 using the LocalNet cable
supplied with the KD Supply 2500:
- Power source: LocalNet interface
- KD Supply 2500: LocalNet X9.1 inter-
face (front)
10

Connecting the KD Supply 2500 to the cold wire
feeder, commissioning
Connecting the
KD Supply 2500
to the cold wire
feeder, commis-
sioning
a)
b)
1Connect the LocalNet cable or the
LocalNet cable from the interconnect-
ing hosepack to the LocalNet interface
of the cold wire feeder
2Connect the LocalNet cable or the
LocalNet cable from the interconnect-
ing hosepack to the KD Supply 2500:
a) LocalNet X9.2 interface (front) or
b) LocalNet X9.3 interface (rear)
Commissioning Power for the KD Supply 2500 is supplied by the power source
1Connect the power source and the cold wire feeder using the interconnecting hosep-
ack
2Connect the welding torch
Carry out steps 1 and 2 as described in the power source and cold wire feeder oper-
ating instructions
3Plug in the power source mains lead
4Turn power source mains switch to position „I“
The KD Supply 2500 is now ready.
11
EN

Care, maintenance and disposal
General remarks Under normal operating conditions the KD Supply 2500 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!
Danger from electrical current.
This can result in serious personal injury and damage to property.
▶Before starting work, switch off all devices and components involved and disconnect
them from the grid.
▶Secure all devices and components involved so they cannot be switched back on.
▶After opening the device, use a suitable measuring instrument to check that electric-
ally charged components (such as capacitors) have been discharged.
Every start-up - Check welding torch, interconnecting hosepack and ground earth connection for
signs of damage
- Perform a visual check on the feed rollers and inner liners for signs of damage
- Check contact pressure of feed rollers and adjust if necessary
- Check brake and adjust if necessary
Every 6 months - Dismantle device side panels and clean inside of device with dry, reduced com-
pressed air
CAUTION!
Danger due to the effect of compressed air.
This can result in damage to property.
▶Do not bring the air nozzle too close to electronic components.
Disposal Dispose of in accordance with the applicable national and local regulations.
12

Technical data
KD Supply 2500 Mains voltage 230 / 460 V
Mains frequency 50 / 60 Hz
Primary current I12,4 / 1,3 A
Secondary voltage U255 V
Secondary current I24 A
Protection IP 23
Measurements l x w x h 625 x 240 x 225 mm
24.61 x 9.45 x 8.86 in.
Weight 4,7 kg
10.36 lb.
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Austria
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