Table of Contents
Related Manuals for Fronius WF 25i REEL R /SA/2R/G/W
Summary of Contents for Fronius WF 25i REEL R /SA/2R/G/W
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions WF 25i REEL R /SA/2R/G/W Wire-feed unit 42,0426,0160,EN 017-11092020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Contents Safety rules Explanation of safety notices General Proper use Environmental conditions Obligations of the operator Obligations of personnel Mains connection Protecting yourself and others Danger from toxic gases and vapours Danger from flying sparks Risks from mains current and welding current Meandering welding currents EMC Device Classifications EMC measures... - Page 4 Disposal Troubleshooting General Safety LED indicators in the event of a fault Fault diagnosis Technical data WF 25i REEL R /SA/2R/G/W...
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Page 5: Safety Rules
Safety rules Explanation of DANGER! safety notices 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. ▶... -
Page 6: Environmental Conditions
The device is intended solely for the welding processes specified on the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. Proper use includes: carefully reading and following all the instructions given in the operating instructions studying and obeying all safety and danger notices carefully performing all stipulated inspection and maintenance work. -
Page 7: Protecting Yourself And Others
This may affect a number device types in terms of: Connection restrictions Criteria with regard to the maximum permissible mains impedance Criteria with regard to the minimum short-circuit power requirement at the interface with the public grid see "Technical data" In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company. -
Page 8: Danger From Flying Sparks
Fumes and hazardous gases must not be breathed in must be extracted from the working area using appropriate methods. Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times. Otherwise, a welding helmet with an air supply must be worn. -
Page 9: Meandering Welding Currents
Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or ground potential. All cables and leads must be secured, undamaged, insulated and adequately dimen- sioned. -
Page 10: Emc Device Classifications
Position the device with sufficient insulation against electrically conductive environments, e.g. Insulation against conductive floor or insulation to conductive racks. If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated. -
Page 11: Emf Measures
EMF measures Electromagnetic fields may pose as yet unknown risks to health: effects on the health of others in the vicinity, e.g. wearers of pacemakers and hear- ing aids wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress for safety reasons, keep distances between the welding cables and the welder's head/torso as large as possible... -
Page 12: Requirement For The Shielding Gas
If the wire-feed unit is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices). If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist. -
Page 13: Danger From Escaping Shielding Gas
Danger from Risk of suffocation from the uncontrolled escape of shielding gas escaping shield- Shielding gas is colourless and odourless and, in the event of a leak, can displace the ing gas oxygen in the ambient air. Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour. Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply. -
Page 14: Commissioning, Maintenance And Repair
Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane. Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.). -
Page 15: Disposal
(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 follow- ing address: http://www.fronius.com... -
Page 16: General
Proper use The device is designed exclusively for wirefeeding in automated MIG/MAG welding applications in conjunction with Fronius system components. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any dam- age arising from such usage. -
Page 17: Application Example
Application example (12) (13) (10) (11) (14) (15) (1) (2) Power source Unreeling wire-feed unit control line (option) Robot interface (10) Wirefeeding hose from unreeling wire-feed unit to robot wire-feed unit Cooling unit (11) Interconnecting hosepack Robot control (12) Robot wire-feed unit Welding wire drum (13) Torch hosepack... - Page 18 40,0006,3035 WF 25i REEL R /sa/2R/G/W 4,049,039,850 Part No.: www.fronius.com 24060701 Ser.No.: IEC 60 974-5/-10 Cl.A IP 21 100 - 240 V 1.7 - 0.7 A 3,15 A 50/60 Hz 1 - 25 m/min 40 - 984 ipm Caution: Parts may be at welding voltage Attention: Les pièces peuvent être...
- Page 19 Wear eye protection...
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Page 20: Description Of Warning Notices On The Device
Description of On certain device versions, warning notices are attached to the device. Warning Notices on the Device The arrangement of the symbols may vary. Warning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation Keep hands and metal objects away. - Page 21 Welding sparks can cause explosion or fire. Keep flammables away from welding. Don’t weld near flammables. Welding sparks can cause fires.Have a fire extinguisher nearby and have a watchperson ready to use it. Do not weld on drums or any closed containers. Arc rays can burn eyes and injure skin.
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Page 22: Controls, Connections And Mechanical Components
Controls, connections and mechanical components Safety WARNING! Danger from incorrect operation. This can result in severe personal injury and damage to property. ▶ All the functions described may only be used by trained and qualified personnel. ▶ Fully read and understand this document. ▶... -
Page 23: Control Panel
Wire feed speed potentiometer 1 - 15 m/min (39.4 - 590.6 ipm.) for wire threading and wire retraction Torque potentiometer 10 - 100% (10% = 5 N, 100% = 50 N) Factory setting: 40% Opening for optional sash lock Control panel Robot control connection (option) Mains switch... - Page 24 Function Wire retract button retraction of wire electrode without accompanying flow of gas or current Press and hold the button After about 0.1 seconds, the wirefeeder reaches the wire feed speed value set on the wire feed speed potentiometer which is then used for wire retraction NOTE! Do not allow long lengths of wire electrode to be retracted, as the wire electrode is...
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Page 25: Fitting The Wire-Feed Unit
Fitting the wire-feed unit Fitting the wire- WARNING! feed unit An electric shock can be fatal. If the power source is connected to the mains supply while the work described below is being carried out, there is a high risk of very serious injury and damage. Only carry out the work described below when: ▶... -
Page 26: Inserting/Replacing Feed Rollers
Inserting/replacing feed rollers Safety WARNING! An electric shock can be fatal. If the power source is connected to the mains supply while the work described below is being carried out, there is a high risk of very serious injury and damage. Only carry out the work described below when: ▶... -
Page 28: Feeding In The Wire Electrode
Feeding in the wire electrode Insulated routing WARNING! of wire electrode to wirefeeder Risk of serious injury and damage or an inferior weld as a result of earth contact or short-circuit of a non-insulated wire electrode. ▶ In the case of automated applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder (e.g. -
Page 29: 2-Roller Drive - Setting The Contact Pressure
Slide the wire electrode from the welding wire drum through the wirefeeding hose and up to the feed rollers on the unreeling wirefeeder CAUTION! Risk of injury from wire electrode emerging at speed. A wire jam may lead to the wire electrode protruding, especially with thin or soft wire electrodes. - Page 30 AlMg 3 - 5 Al, AlSi 2 - 4 Tubular cored elec- 3 - 5 trodes...
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Page 31: Start-Up
Start-up Commissioning Once the wire electrode has been threaded, the unreeling wirefeeder is ready to use. Press the Mode / Start button Mode Start Torque mode is activated, the mains supply LED lights up green and the torque mode LED flashes green. The unreeling wirefeeder starts feeding the wire. -
Page 32: Led Indicators In Normal Operation
Reconnect the wirefeeding hose to the robot wirefeeder Welding start depending on the application To finish wirefeeding, press the Mode / Start button Mode Start The unreeling wirefeeder switches to threading mode, the "Wire retract" and "Wire threading" buttons are active and can be used. LED indicators in When operating normally, the LEDs will flash green or will show a steady green. - Page 33 NOTE! If the OPT/i WF ext. start signal installation kit is provided, the unreeling wirefeeder sends a feedback signal regarding its current status to the robot by way of a relay output. Before an external start is possible with the OPT/i WF ext. start signal option fitted, torque mode must first be selected on the wirefeeder by pressing the Mode button.
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Page 34: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions, the welding system requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years. Safety WARNING! An electric shock can be fatal. -
Page 35: Troubleshooting
Troubleshooting General The devices are equipped with an intelligent safety system. This means that to a large extent it has been possible to dispense with melting-type fuses. Melting-type fuses there- fore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again. -
Page 36: Fault Diagnosis
Drive system faulty Torque mode: Motor does not reach the specified feed force Wire end Contact-pressure lever open Insufficient contact pressure Threading mode: Feed rollers blocked Encoder fault The signal can be reset by pressing the Mode / Start button. Overtemperature on SR63 power module board The signal can be reset by pressing the Mode / Start button. - Page 37 Remedy Replace faulty parts Cause Mains fuse Remedy Change the mains fuse protection Irregular wire feed speed 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.
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Page 38: Technical Data
Technical data WF 25i REEL R Supply voltage 100 - 240 V AC /SA/2R/G/W Mains voltage tolerance -10% / +10% Mains frequency 50/60 Hz Current input 1.7 - 0.7 A Fuse 3.15 A slow-blow Fault current protection device Type A Wire feed speed 1 - 25 m/min 39.37 - 984.3 ipm. - Page 40 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations.
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