FRO­NIUS KD Supply 2500 User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0049,EN 001-16012019
KD Supply 2500 Operating Instructions
Spare parts list
System extension
EN

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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 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.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
This does not indicate a potentially hazardous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.

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Contents
General ...................................................................................................................................................... 7
Machine concept................................................................................................................................... 7
Safety symbols on the rating plate........................................................................................................ 7
Warning notices affixed to the machine ................................................................................................ 8
Controls, connections and mechanical components.................................................................................. 9
Safety.................................................................................................................................................... 9
KD Supply 2500 - front.......................................................................................................................... 9
KD Supply 2500 - rear .......................................................................................................................... 9
Fitting the KD Supply 2500 to the trolley.................................................................................................... 10
General remarks .................................................................................................................................. 10
Fitting the KD Supply 2500 to the base of the trolley............................................................................ 10
Connecting the KD Supply 2500 to the cooling unit and power source ..................................................... 11
Safety.................................................................................................................................................... 11
Connecting the KD Supply 2500 to the cooling unit and power source ................................................ 11
Establishing a LocalNet connection between the KD Supply 2500 and the power source................... 12
Connecting the KD Supply 2500 to the cold wire feeder, commissioning.................................................. 13
Connecting the KD Supply 2500 to the cold wire feeder, commissioning............................................. 13
Commissioning ..................................................................................................................................... 13
Care, maintenance and disposal ............................................................................................................... 14
General remarks .................................................................................................................................. 14
Every start-up........................................................................................................................................ 14
Every 6 months ..................................................................................................................................... 14
Disposal ................................................................................................................................................ 14
Technical data............................................................................................................................................ 15
KD Supply 2500 .................................................................................................................................... 15
Appendix 17
Spare parts list: KD Supply 2500 ............................................................................................................... 18

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General
Machine concept
KD Supply 2500
The KD Supply 2500 enables the TIG pow-
er sources TT 2500 / 3000 Job and MW
2500 / 3000 Job to be used with a cold wire
feeder. The built-in switchedmode 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.
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 incorrect-
ly, 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

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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.
US machine with additional warning notices

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EN
Controls, connections and mechanical components
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 regula-
tions
KD Supply 2500 -
front (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) 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
(1) (2)
(3) (4)
(5)

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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
If 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.
Place the KD Supply 2500 on the base
of the trolley.
Using „Extrude-Tite“ screws, fasten the
KD Supply 2500 at the front and back
to the fastening brackets on the base
of the trolley.
1
2
3

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Connecting the KD Supply 2500 to the cooling unit
and power source
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.
Connecting the
KD Supply 2500
to the cooling unit
and power source
Turn the power source mains switch to
the „O“ position
Unplug power source mains plug
Remove protective cover from the un-
derside of the power source
Firmly press four M5 hexagonal nuts
(supplied with the KD Supply 2500)
from the inside into the hexagonal
recesses (1) in the fastening bars
If a cooling unit is present:
Remove the protective cover from the
underside of the KD Supply 2500
FIrmly press four M5 hexagonal nuts
(supplied with cooling unit) from the in-
side into the hexagonal recesses (2) in
the fastening bars
Hold the KD Supply 2500 over the coo-
ling unit
Pull the KD Supply 2500 connector as
far as possible through the opening on
the underside of the power source
Establish connection between KD Sup-
ply 2500 and cooling unit
CAUTION!
Risk of short circuit from kinked or damaged cables.
► When positioning the KD Supply 2500, ensure that the cables are not kinked.
Carefully place the KD Supply 2500 on the cooling unit
(1)
(1)
(1)
(1)
(2)
(2)
(2)
(2)
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2
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4
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Using two „Extrude-Tite“ screws, fasten the KD Supply to the fastening bars (2) on the
front and back of the cooling unit
Position the power source over the KD Supply 2500 using a suitable hoisting device
Pull the power source connector as far as possible through the opening on the under-
side of the power source
Make connection between power source and cooling unit
CAUTION!
Risk of short circuit from kinked or damaged cables.
► When positioning the KD Supply 2500, ensure that the cables are not kinked.
Carefully place power source on KD Supply 2500
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.
► Ensure that all screw connections are secure.
Establishing a Lo-
calNet connec-
tion between the
KD Supply 2500
and the power
source
Connect 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)
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Connecting the KD Supply 2500 to the cold wire
feeder, commissioning
Connecting the
KD Supply 2500
to the cold wire
feeder, commis-
sioning
Connect the LocalNet cable or the
LocalNet cable from the interconnec-
ting hosepack to the LocalNet interface
of the cold wire feeder
Connect the LocalNet cable or the
LocalNet cable from the interconnec-
ting 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
Connect the power source and the cold wire feeder using the interconnecting hose-
pack
Connect the welding torch
Carry out steps 1 and 2 as described in the power source and cold wire feeder oper-
ating instructions
Plug in the power source mains lead
Turn power source mains switch to position „I“
The KD Supply 2500 is now ready.
a)
b)
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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 weld-
ing system remains in a usable condition for many years.
WARNING!
An electric shock can be fatal.
Before opening the machine
► Turn power source mains switch to position „O“n
► Disconnect the machine 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
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
NOTE!
Risk of damage to electronic components.
Do not bring the air nozzle too close to electronic components.
Disposal Dispose of in accordance with the applicable national and local regulations.

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Technical data
KD Supply 2500 Mains voltage 230 / 460 V
Mains frequency 50 / 60 Hz
Primary current I1 2,4 / 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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Appendix

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Spare parts list: KD Supply 2500

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FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: [phone], Fax: [phone]
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