Fronius WF 25i Case D200 Operating Instructions/Spare Parts List
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Summary of Contents for Fronius WF 25i Case D200
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions WF 25i Case D200 Spare parts list WF 25i Case D300 Wire-feed unit 42,0426,0187,EN 015-25012018...
- Page 3 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.
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Page 5: Table Of Contents
Device concept ............................. Warning notices on the device......................Crane transport ............................. Controls, connections and mechanical components WF 25i Case D200 controls, connections and mechanical components ........... Safety..............................Front of wire-feed unit ........................... Wire-feed unit side ..........................WF 25i Case D300 controls, connections and mechanical components ........... - Page 6 General ..............................Safety..............................Every start-up............................Every 6 months ............................. Disposal ..............................Technical data Technical data............................WF 25i Case D200..........................WF 25i Case D300..........................HP 70i Case............................HP 95i Case............................Appendix Spare parts list: WF 25i Case D200, WF 25i D300..................
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Page 7: Safety Rules
Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operat- ing company, inefficient operation of the device. -
Page 8: Environmental Conditions
Environmental Operation or storage of the device outside the stipulated area will be deemed conditions as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage. Ambient temperature range: during operation: -10 °C to + 40 °C (14 °F to 104 °F) during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F) Relative humidity:... -
Page 9: Protecting Yourself And Others
Protecting your- Persons involved with welding expose themselves to numerous risks, e.g.: self and others flying sparks and hot pieces of metal arc radiation, which can damage eyes and skin hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers risk of electrocution from mains current and welding current greater noise pollution... -
Page 10: Danger From Flying Sparks
Otherwise, a protective mask with an air supply must be worn. Close the shielding gas cylinder valve or main gas supply if no welding is tak- ing place. If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values. -
Page 11: Meandering Welding Currents
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged or inade- quately dimensioned cables and leads immediately. Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180°... -
Page 12: Emc Device Classifications
EMC Device Clas- Devices in emission class A: sifications Are only designed for use in industrial settings Can cause line-bound and radiated interference in other areas Devices in emission class B: Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is sup- plied from the public low-voltage mains. -
Page 13: Specific Hazards
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example: Fans Cogs Rollers Shafts Wirespools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive com- ponents. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. - Page 14 During operation Ensure that all covers are closed and all side panels are fitted properly. Keep all covers and side panels closed. The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.). Therefore always keep the welding torch away from the body (devices with wire-feed unit) and wear suitable protective goggles.
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Page 15: Factors Affecting Welding Results
Factors affecting The following requirements with regard to shielding gas quality must be met if welding results the welding system is to operate in a correct and safe manner: Size of solid matter particles < 40 μm Pressure dew point < -20 °C Max. -
Page 16: Safety Measures At The Installation Location And During Transport
Safety measures A device toppling over could easily kill someone. Place the device on a solid, at the installation level surface such that it remains stable location and dur- The maximum permissible tilt angle is 10°. ing transport Special regulations apply in rooms at risk of fire or explosion Observe relevant national and international regulations. -
Page 17: Commissioning, Maintenance And Repair
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ig- nite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition. Used coolant must be disposed of properly in accordance with the relevant na- tional and international regulations. -
Page 18: Safety Symbols
(e.g. relevant product standards of the EN 60 974 series). Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com Devices marked with the CSA test mark satisfy the requirements of the rele- vant standards for Canada and the USA. -
Page 19: General
General... -
Page 21: General
General Device concept The WF 25i Case D200 / WF 25i Case D300 wire-feed unit is contained in a fully sealed plastic housing and is suitable for wirespools with max. diameter 200 mm (7.87 in.) / 300 mm (11.81 in.). - Page 22 Do not use the functions described here until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safety rules Welding is dangerous. The following basic requirements must be met to en- sure the equipment is used properly: Welders must be sufficiently qualified Suitable protective equipment must be used...
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Page 23: Crane Transport
Crane transport The wirefeeder can be transported by crane using its handle. The maximum load-bearing capacity of the handle is dependent upon the model: D200: 15 kg (33.07 lb.) D300: 35 kg (77.16 lb.) WARNING! Falling equipment can cause death or serious injury. Only use a suitable lifting tackle when transporting devices by crane (e.g. -
Page 25: Controls, Connections And Mechanical Components
Controls, connections and mechani- cal components... -
Page 27: Wf 25I Case D200 Controls, Connections And Mechanical Components
WF 25i Case D200 controls, connections and me- chanical components Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. All the functions described may only be used by trained and qualified personnel. Do not use the functions described until you have thoroughly read and... -
Page 28: Wire-Feed Unit Side
Wire-feed unit side (4) (5) (6) (7) (8)(9) (10) (11) (12) (13) SpeedNet connection for connecting the SpeedNet cable from the interconnecting hosepack (+) - current socket with fine-pitch thread for connecting the power cable from the interconnecting hosepack Coolant return connection (red) - option for connecting the coolant hose from the interconnecting hosepack Shielding gas connection Coolant flow connection (blue) - option... -
Page 29: Wf 25I Case D300 Controls, Connections And Mechanical Components
WF 25i Case D300 controls, connections and me- chanical components Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. All the functions described may only be used by trained and qualified personnel. Do not use the functions described until you have thoroughly read and understood the following documents: this document all the operating instructions for the system components, especially the safe-... -
Page 30: Wire-Feed Unit Side
Wire-feed unit side (10) (11) (12) (5) (6) SpeedNet connection for connecting the SpeedNet cable from the interconnecting hosepack Coolant return connection (red) - option for connecting the coolant hose from the interconnecting hosepack Coolant flow connection (blue) - option for connecting the coolant hose from the interconnecting hosepack Shielding gas connection (+) - current socket with fine-pitch thread... -
Page 31: Optional Control Panels
General NOTE! Optional control panels are available for the WF 25i Case D200 and WF 25i Case D300 wire-feed units. The design and position of the control panels are identical for both wire-feed units. -
Page 32: Opt/I Wf Gas Test & Wire Threading
OPT/i WF gas test Function & wire threading OPT/i WF gas test & wire threading Operating status LED lights green when the device is ready for use Gas-test button for setting the required gas flow rate on the pressure regulator Gas will flow out for 30 s after pressing the gas-test button. - Page 33 Function Wire threading button to thread the wire electrode into the torch hosepack with no accompanying flow of gas or current There are two wire threading variants available: Variant 1 threading the wire electrode using the preset feeder inching speed: Press and hold the wire threading button.
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Page 34: Opt/I Wf Standard Control Panel
OPT/i WF Stand- ard control panel (10) (14) (11) (13) (12) - Page 35 Parameter selection button (left) for selecting the parameters listed below. The corresponding indicator lights up when a parameter is select- Material thickness *) in mm or inches Current *) current in A Before the start of welding, the machine automatically displays a standard value based on the programmed parameters.
- Page 36 Parameter selection button (right) for selecting the parameters listed below. The corresponding indicator lights up when a parameter is select- Arc length correction for correcting the arc length - ... shorter arc length 0 ... neutral arc length + ... longer arc length Voltage *) in V Before the start of welding, the machine automatically displays a...
- Page 37 Welding process button for selecting the welding process PULS SYNERGIC - MIG/MAG pulse synergic welding SYNERGIC - MIG/MAG standard synergic welding MANUAL - MIG/MAG standard manual welding JOB - Job Mode STICK - Manual metal arc welding SP (SP = special programs: LSC, PMC, TIG, etc.) - Depending on which package of functions is enabled, various welding pro- cesses can be selected.
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Page 39: Installation And Commissioning
Installation and commissioning... -
Page 41: Before Installation And Commissioning
Proper use The device is intended exclusively for wire feeding in MIG/MAG welding in conjunction with Fronius system components. Utilisation for any other purpose, or in any other manner, shall be deemed to be not in ac- cordance with the intended purpose. -
Page 42: Connecting The Interconnecting Hosepack And Mig/Mag Welding Torches
Connecting the interconnecting hosepack and MIG/ MAG welding torches Safety WARNING! An electric shock can be fatal. Before starting the work described be- low: turn the power source mains switch to the "O" position disconnect the power source from the mains ensure that the power source remains disconnected from the mains until all work has been completed General informa-... -
Page 43: Connecting A Mig/Mag Welding Torch
Connecting a MIG/MAG welding CAUTION! Risk of injury and torch damage from loose connections. All cables, lines and hosepacks must be properly secured, undam- aged, insulated and adequately di- mensioned at all times. Only if the coolant connections are fitted in the wirefeeder and when using a water-cooled welding torch... -
Page 44: Inserting/Replacing Feed Rollers
Inserting/replacing feed rollers Safety WARNING! An electric shock can be fatal. Before starting the work described be- low: turn the power source mains switch to the "O" position disconnect the power source from the mains ensure that the power source remains disconnected from the mains until all work has been completed General The feed rollers are not installed in the device when it is first delivered. -
Page 46: Inserting The Wirespool, Inserting The Basket-Type Spool
Inserting the wirespool, inserting the basket-type spool Safety WARNING! An electric shock can be fatal. Before starting the work described be- low: turn the power source mains switch to the "O" position disconnect the power source from the mains ensure that the power source remains disconnected from the mains until all work has been completed CAUTION! Risk of injury from springiness of spooled wire electrode. -
Page 47: Inserting A Basket-Type Spool: D300 Device
Inserting a bas- CAUTION! Risk of injury and material damage from falling basket-type spool. ket-type spool: Place the basket-type spool on the adapter provided in such a way that the bars D300 device on the spool are inside the adapter guideways. -
Page 48: Threading The Wire Electrode
Threading the wire electrode General NOTE! If there is no wire threading button on the wire-feed unit, use the wire threading button of another of the manufacturer's system components to thread the wire, for example the power source wire threading button. The wire threading button functions in the same way for all system components from the manufactur- NOTE! Further details on the function of the wire threading button can be found in its description ("Optional control panels"... -
Page 49: Setting The Contact Pressure
Lay the torch hosepack out straight Setting the con- tact pressure NOTE! Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeed. See the standard values on the sticker on the protective cover for setting the contact pressure. -
Page 50: Adjust The Brake
Adjust the brake General CAUTION! Risk of injury and material damage from the welding current and ac- cidental ignition of an arc. Before starting work, disconnect the ground earth con- nection between the welding system and the workpiece. CAUTION! Risk of injury and damage from wire electrode emerging. While work- ing: hold the welding torch with the point directed away from the face and body wear suitable protective goggles... -
Page 51: Setting The Brake: D300 Device
Setting the brake: D300 device STOP STOP Brake setup: WARNING! Fitting the equipment incorrectly can cause serious injury and dam- D200 device age. Do not dismantle the brake. Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only. -
Page 52: Brake Setup: D300 Device
Brake setup: WARNING! Fitting the equipment D300 device incorrectly can cause serious inju- ry and damage. Do not dismantle the brake. Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only. The brake is only available as a complete unit. -
Page 53: Start-Up
Start-up Safety WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All work described in this document must only be carried out by trained and qualified personnel. All functions described in this document must only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents: this document... -
Page 55: Troubleshooting, Maintenance And Disposal
Troubleshooting, maintenance and disposal... -
Page 57: Troubleshooting
Troubleshooting Safety WARNING! Work that is carried out incorrectly can cause serious injury or dam- age. All the work described below must only be carried out by trained and quali- fied personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: this document all the operating instructions for the system components, especially the safe-... - Page 58 Nothing happens when the torch trigger is pressed Power source mains switch is ON and indicators are lit up Cause: Only for welding torches with an external control plug: The control plug is not plugged in Remedy: Plug in the control plug Cause: Welding torch or welding torch control line is faulty Remedy:...
- Page 59 Irregular wire feed speed Cause: Braking force has been set too high Remedy: Loosen the brake Cause: Hole in the contact tip is too narrow Remedy: Use a suitable contact tip Cause: Faulty inner liner in welding torch Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary Cause: The feed rollers are not suitable for the wire electrode being used Remedy:...
- Page 60 Poor weld properties Cause: Incorrect welding parameters Remedy: Check the settings Cause: Poor ground earth connection Remedy: Ensure good contact to workpiece Cause: Inadequate or no protective gas shield Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con- nection, etc.
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Page 61: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions, the device requires only a minimum of care and main- tenance. However, it is vital to observe some important points to ensure the welding sys- tem remains in a usable condition for many years. Safety WARNING! Work that is carried out incorrectly can cause serious injury or dam- age. -
Page 63: Technical Data
Technical data... -
Page 65: Technical Data
Technical data WF 25i Case D200 Supply voltage 24 V DC / 60 V DC Nominal current 0.5 A / 1.2 A Welding current at 10 min/40 °C (104 °F) 40% D.C.* 60 % D.C.* 100 % D.C.* 500 A... -
Page 66: Hp 70I Case
Wirespool weight max. 19 kg max. 41.89 Ib. Degree of protection IP 23 Mark of conformity S, CE Dimensions l x w x h 613 x 244 x 437 mm 24.13 x 9.61 x 17.2 in. Weight 14.8 kg 32.63 Ib. *) D.C. -
Page 67: Appendix
Appendix... -
Page 68: Spare Parts List: Wf 25I Case D200, Wf 25I D300
Spare parts list: WF 25i Case D200, WF 25i D300... - Page 76 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...
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