Fronius VarioStar 2500 User Manual

1
EN
Table of contents
General remarks ........................................................................................................................................... 3
Principle of the VarioStar series ............................................................................................................... 3
Machine concept...................................................................................................................................... 3
Areas of utilisation ................................................................................................................................... 3
Warning notices affixed to the machine ................................................................................................... 4
Controls and connections ............................................................................................................................. 5
General remarks ...................................................................................................................................... 5
Controls and connections on the front ..................................................................................................... 5
Controls inside the machine .................................................................................................................... 6
Before commissioning .................................................................................................................................. 7
General remarks ...................................................................................................................................... 7
Utilisation in accordance with „intended purpose“ ................................................................................... 7
Set-up regulations.................................................................................................................................... 7
VarioStar 1500/2500/3100 mains connection .......................................................................................... 7
VarioStar 2500 CSA/3100 CSA mains connection .................................................................................. 8
Commissioning ............................................................................................................................................. 9
General remarks ...................................................................................................................................... 9
Overview .................................................................................................................................................. 9
Symbols used .......................................................................................................................................... 9
Checking the mains voltage........................................................................................................................ 10
General remarks .................................................................................................................................... 10
Checking VarioStar 1500/2500/3100 mains voltage .............................................................................. 10
Checking VarioStar 2500 CSA/3100 CSA mains voltage ...................................................................... 10
Connecting the welding torch/connecting the gas cylinder ........................................................................12
Safety ..................................................................................................................................................... 12
Connecting the welding torch ................................................................................................................ 12
Fitting and connecting the gas cylinder ................................................................................................. 12
Inserting/replacing feed rollers ................................................................................................................... 13
General remarks .................................................................................................................................... 13
Inserting/replacing feed rollers .............................................................................................................. 13
Correcting wire feed............................................................................................................................... 14
Inserting the wirespool/inserting the basket-type spool.............................................................................. 15
Safety ..................................................................................................................................................... 15
Inserting the wirespool ........................................................................................................................... 15
Inserting the basket-type spool.............................................................................................................. 15
Feeding in the welding wire ........................................................................................................................ 16
Safety ..................................................................................................................................................... 16
Feeding in the welding wire ................................................................................................................... 16
Setting the contact pressure .................................................................................................................. 17
Setting the shielding gas flow rate ......................................................................................................... 18
Adjusting the brake ..................................................................................................................................... 19
General remarks .................................................................................................................................... 19
Adjusting the brake ................................................................................................................................ 19
Design of the brake................................................................................................................................ 20
Operating modes ........................................................................................................................................ 21
General remarks .................................................................................................................................... 21
Symbols and abbreviations.................................................................................................................... 21
2-step mode ........................................................................................................................................... 21
4-step mode ........................................................................................................................................... 22
Spot welding .......................................................................................................................................... 22
Interval 2-step/4-step mode ................................................................................................................... 23
MIG/MAG welding ....................................................................................................................................... 24
General remarks .................................................................................................................................... 24

Fronius VarioStar 2500 Specifications

General

Brand	Fronius
Model	VarioStar 2500
Category	Welding System
Language	English