FRONIUS KD Supply 2500 User manual

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KD Supply 2500

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

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

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.

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.

US machine with additional warning notices

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

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.

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)

(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.

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)

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