Fronius DPS 2500 Trolley Instruction Manual
- August 7, 2024
- Fronius
Table of Contents
Fronius DPS 2500 Trolley
General
Machine concept
The DPS 2500 trolley was specially designed for the transport and the installation of the DPS 2500 plasma power sources. The stable tubular steel frame is divided into several levels. Depending on the version these levels are either provided for the installation of the DPS 2500 plasma power sources or equipped with an additional 19“ rack. Ergonomic recessed grips and a trolley with large wheels allow for an easy transport of the plasma power sources.
Area of application
The trolley is used for applications with high demands on flexibility and mobility.
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
WARNING
Danger from electric current.
This can result in serious personal injury and damage to property.
- Before starting work, switch off all the devices and components involved and disconnect them from the grid.
- Secure all the devices and components involved to prevent unintentional restarting.
Design versions
DPS 2500 trolley
This trolley can accommodate up to 4 DPS 2500 plasma power sources. Up to 3 DCG 100 plasma power sources can be installed in the 19“ rack in addition.
DPS 2500/6P trolley
This trolley can accommodate up to 6 DPS 2500 plasma power sources. Up to 3 DCG 100 plasma power sources can be installed in the 19“ rack in addition.
DPS 2500/8P trolley
This trolley can accommodate up to 8 DPS 2500 plasma power sources.
DPS 2500/2P-8SPU trolley
This trolley can accommodate up to 2 DPS 2500 plasma power sources. Up to 8 DCG 100 plasma power sources can be installed in the 19“ rack in addition.
DPS 2500/4P-1G-3SPU trolle
The trolley provides room for up to 4 DPS 2500 plasma power sources. In addition, up to 3 DCG 100 plasma power sources and 1 generator can be mounted in the 19” racks.
Trolley assembly
General
WARNING!
Danger from work that is not carried out properly.
This can cause severe injury and damage.
- Only carry out the detailed work and installation after having completely read and understood these operating instructions.
The assembly is explained by the example of the DPS 2500 trolley. The assembly of the other versions is carried out accord dangly.
Assembly of DPS 2500 power source
-
Check screwed connection of mounting brackets and trolley for tightness
-
Place power source onto mounting brackets
IMPORTANT! The mounting brackets must be inside the plastic feet of the power source. -
Fix power source with mounting brackets by means of enclosed “Extrude-Tite“ screws – two screws each at the front and rear side
-
Mount protective conductor connection
Assembly of DPS 2500 power source
- Dismantle mounting brackets for the DPS 2500 power source from the trolley
- Insert 19“ rack into the trolley
- Fix rack on the trolley by means of the 4 enclosed M8 x 30 screws
- Mount protective conductor terminal block (not included in the scope of supply) and connect protective conductor with rack.
Mounting the power sources in 19“ rack (optional)
- Remove dummy cover
- Insert power source in 19“ rack and tighten screws
- Thread power cable through traction release
- Connect power cable with power source
- Connect protective conductor with power source
- Tighten traction release
- Mount cover
IMPORTANT! Only fix cover by means of the two Extrude-Tite screws. The casing screws are a suitable protective conductor connection for grounding the cover. The screws must not be replaced by other screws without reliable protective conductor connection.
Mounting the generator housing (optional)
- Remove the DPS 2500 power source fastening bracket from the trolley
- Insert the generator housing into the 19” rack in the trolley
- Fasten the generator housing to the trolley with the 4 enclosed M8 x 30 screws
- Fit the earthing terminal strip (not supplied) and connect the earth lead to the generator housing
Mounting the traction release (optional)
At the rear side of the trolley there is a rail for mounting the traction releases for mains and power cables. The traction releases are not included in the scope of supply.
- Lay cable at the rear side of the trolley
- Hang traction release on the rail and tighten screws
Mounting the arc cut-off box (optional
At the rear side of the trolley there is a rail for mounting an arc cut-off box. Mounting angles are not included in the scope of supply.
- Mount mounting angles on arc cutoff box
- Hang arc cut-off box on mounting rail and tighten screws
- Connect arc cut-off box
- Connect protective conductor
Connecting and checking the protective conductor
Before putting the system into service:
- Check protective conductor connection of all power sources with the trolley or the 19“ rack for correctness.
- Check whether the trolley is provided with a suitable protective conductor connection (at least 6mm²).
- Check protective conductor on the trolley or the 19“ rack
Transport and place of installation
Safety
WARNING!
Danger of overturning during the transport and installing on declined surfaces.
This can result in serious personal injury and damage to property.
- Overturning and a transport on declined surfaces > 10° is not admissible
- Permanent installation of the trolley on a declined surface is not admissible
Place of installation
The following points must be taken into account for the installation of the trolley:
- Only install trolley on a level and solid ground
- Fix swing rollers by means of locking device at the place of installation.
Crane transport
NOTE!
When transporting the trolley by means of a crane make sure the following
points are taken into account:
- Dismantle power sources that are possibly mounted to platforms before the crane transport
- Take into account the maximum admissible total weight of the trolley
- Check crane suspension eyes for tightness
- Only use suitable load suspension devices and fix it with all 4 crane suspension eyes
- Choose an angle of suspension wider than 45°
Care, maintenance and disposal
General
Under normal operating conditions the trolley requires only a minimum of care and maintenance. In order to keep the trolley operational for years to come, you should observe the following points.
Safety
WARNING!
Danger from electric current.
This can result in serious personal injury and damage to property.
- Before starting work, switch off all the devices and components involved and disconnect them from the grid.
- Secure all the devices and components involved to prevent unintentional restarting.
WARNING!
Danger due to insufficient ground conductor connection.
This can result in serious personal injury and damage to property.
- The housing screws provide a suitable ground conductor connection for grounding the housing.
- The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.
Every start-up
- Check all cables for damage
- Check whether the cooling air can enter and escape unhindered.
NOTE!
Air inlets and outlets must never be covered, not even partially.
Disposal
Waste electrical and electronic equipment must be collected separately and recycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Proper disposal of the old device promotes sustainable recycling of material resources. Ignoring this may lead to potential health/environmental impacts.
Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume
of the box.
Technical data
DPS 2500 trolley| Measurements (without power sources) l/w/h|
847/730/1903 mm
---|---|---
Measurements (with power sources)| 847/730/1903 mm
Dead weight| 122 kg
Max. useful load| 218 kg
Max. total weight| 218 kg
DPS 2500/6P trolley| Measurements (without power sources) l/w/h|
847/840/1923 mm
Measurements (with power sources) l/w/h| 847/840/2400 mm
Rack measurements l/w/h| 720/570/465 mm
Dead weight| 155 kg
Max. useful load| 288 kg
Max. total weight| 443 kg
DPS 2500/8P trolley| Measurements (without power sources) l/w/h|
847/840/1923 mm
Measurements (with power sources) l/w/h| 847/840/2182 mm
Dead weight| 128 kg
Max. useful load| 280 kg
Max. total weight| 408 kg
DPS 2500/2P-8SPU trolley| Measurements (without power sources) l/w/h|
847/840/1923 mm
Measurements (with power sources) l/w/h| 847/840/2182 mm
Dead weight| 214 kg
Max. useful load| 278 kgkg
Max. total weight847/840/1923 mm| 492 kg
DPS 2500/4P-1G-3SPU trolley| Measurements (without power sources) l/w/h|
847/840/1923 mm
Measurements (with power sources) l/w/h| 847/840/2182 mm
Dead weight| 180 kg
Max. useful load| 280 kg
Max. total weight| 460 kg
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