Fronius WF 25i Case D200 Operating Instructions Manual
Wire-feed unit
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- Operating instructions/spare parts list (76 pages) ,
- Operating instructions manual (68 pages)
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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 WF 25i Case D300 Wire-feed unit 42,0426,0187,EN 017-14092020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: 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 4 Safety Prerequisites General Troubleshooting, maintenance and disposal Troubleshooting Safety Troubleshooting Care, maintenance and disposal 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...
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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). All lifting accessories (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors). -
Page 13: Safety Measures At The Installation Location And During Transport
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. Close the shielding gas cylinder valve or main gas supply if no welding is taking place. -
Page 14: Commissioning, Maintenance And Repair
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.). Only use suitable original coolant from the manufacturer. Do not mix the manufacturer's original coolant with other coolants. Only connect the manufacturer's system components to the cooling circuit. -
Page 15: 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 follow- ing address: http://www.fronius.com... -
Page 17: General
General... -
Page 19: 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 20 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 ensure the equipment is used properly: Welders must be sufficiently qualified Suitable protective equipment must be used...
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Page 21: 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. ▶... -
Page 23: Controls, Connections And Mechanical Components
Controls, connections and mechan- ical components... -
Page 25: Wf 25I Case D200 Controls, Connections And Mechanical Components
WF 25i Case D200 controls, connections and mech- anical 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. -
Page 26: 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 27: Wf 25I Case D300 Controls, Connections And Mechanical Components
WF 25i Case D300 controls, connections and mech- anical 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. ▶... -
Page 28: 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 29: 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. OPT/i WF POT... -
Page 30: Opt/I Wf Gas Test & Wire Threading
OPT/i WF gas test Function & wire threading OPT/i WF gas test & wire thread- 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 31 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 32: Opt/I Wf Standard Control Panel
OPT/i WF Stand- ard control panel (10) (14) (11) (13) (12) - Page 33 Parameter selection button (left) for selecting the parameters listed below. The corresponding indicator lights up when a parameter is selec- ted. 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 34 Parameter selection button (right) for selecting the parameters listed below. The corresponding indicator lights up when a parameter is selec- ted. 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 35 EasyJob button for saving, opening and deleting EasyJobs. The LED in the button indicates that EasyJob is selected How it works: Press and hold the button for 3 seconds = save EasyJob (all current settings are saved). After saving, the LED in the button lights up and 'Store' is shown on the display Press and hold the button for 5 seconds = delete EasyJob.
- Page 36 Intermediate arc indicator a spatter-prone intermediate arc occurs between the short arc and the spray arc. The intermediate arc indicator lights up to draw attention to this critical area. (10) SFI (Spatter Free Ignition) indicator lights up when the Spatter Free Ignition function is active (11) SynchroPuls indicator lights up when the SynchroPuls function is active...
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Page 37: Installation And Commissioning
Installation and commissioning... -
Page 39: 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 accordance with the intended purpose. -
Page 40: Connecting The Interconnecting Hosepack And Mig/Mag Welding Torches
Connecting the interconnecting hosepack and MIG/MAG welding torches Safety WARNING! Danger from electric current. This can result in severe personal injury and damage to property. ▶ Turn the power source mains switch to the "O" position. ▶ Disconnect the power source from the mains. ▶... -
Page 41: Connecting A Mig/Mag Welding Torch
Connecting a MIG/MAG welding CAUTION! torch Risk of injury and damage from loose connections. All cables, lines and hosepacks must be properly secured, undamaged, insulated and adequately dimensioned at all times. Only if the coolant connections are fitted in the wirefeeder and when using a water-cooled welding torch... -
Page 42: Inserting/Replacing Feed Rollers
Inserting/replacing feed rollers Safety WARNING! Danger from electric current. This can result in severe personal injury and damage to property. ▶ 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. - Page 43 CAUTION! Risk of crushing by exposed feed rollers. Always fit the protective cover of the 4-roller drive after inserting or replacing a feed roller.
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Page 44: Inserting The Wirespool, Inserting The Basket-Type Spool
Inserting the wirespool, inserting the basket-type spool Safety WARNING! Danger from electric current. An electric shock can be fatal. ▶ 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. -
Page 45: Inserting A Wirespool: D300 Device
Inserting a wirespool: D300 device Inserting a bas- CAUTION! ket-type spool: D300 device Risk of injury and material damage from falling basket-type spool. Place the basket-type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways. -
Page 46: 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 manufacturer. -
Page 47: Threading The Wire Electrode
Threading the CAUTION! wire electrode Danger from welding current and accidental ignition of an arc. This can result in severe personal injury and damage to property. ▶ Before starting work, disconnect the ground earth connection between the welding system and the workpiece. CAUTION! Danger from emerging wire electrode. -
Page 48: Adjust The Brake
Adjust the brake General CAUTION! Risk of injury and material damage from the welding current and accidental igni- tion of an arc. Before starting work, disconnect the ground earth connection between the welding sys- tem and the workpiece. CAUTION! Risk of injury and damage from wire electrode emerging. While working: ▶... -
Page 49: Setting The Brake: D300 Device
STOP Setting the brake: D300 device STOP STOP... -
Page 50: Brake Setup: D200 Device
Brake setup: WARNING! D200 device Fitting the equipment incorrectly can cause serious injury and damage. ▶ Do not dismantle the brake. ▶ Maintenance and servicing of brakes is to be carried out by trained, qualified person- nel only. The brake is only available as a complete unit. This illustration is for information purposes only. -
Page 51: Start-Up
Start-up Safety WARNING! Danger due to incorrect operation and incorrectly performed work. 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 53: Troubleshooting, Maintenance And Disposal
Troubleshooting, maintenance and disposal... -
Page 55: Troubleshooting
Troubleshooting Safety WARNING! Danger due to work that has been carried out incorrectly. This can result in severe personal injury and damage to property. ▶ All the work described below must only be carried out by trained and qualified per- sonnel. - Page 56 Power source does not function Mains switch is on, but indicators are not lit up Cause: There is a break in the mains lead; the mains plug is not plugged in Remedy: Check the mains lead, ensure that the mains plug is plugged in Cause: Mains socket or mains plug faulty Remedy:...
- Page 57 No protective gas shield All other functions are OK Cause: Gas cylinder is empty Remedy: Change the gas cylinder Cause: The gas pressure regulator is faulty Remedy: Replace the gas pressure regulator Cause: Gas hose is not fitted or is damaged Remedy: Fit or change the gas hose Cause:...
- Page 58 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 59: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions, the device 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! Danger due to work that has been carried out incorrectly. -
Page 60: Every 6 Months
Every 6 months CAUTION! Danger of damage to electronic components. ▶ Do not bring the air nozzle too close to electronic components. Open covers, remove device side panels and clean inside of device with dry reduced compressed air. After cleaning, restore device to its original state. Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 61: Technical Data
Technical data... -
Page 63: Technical Data
D.C.* 500 A 450 A 360 A Maximum shielding gas pressure 7 bar 101.53 psi Coolant Original Fronius Maximum coolant pressure 5 bar 72.53 psi Wire feed speed 1 - 25 m/min 39.37 - 984.25 ipm Wire drive 4-roller drive Wire diameter 0.8 - 1.6 mm... -
Page 64: Hp 70I Case
Wire diameter 0.8 - 1.6 mm 0.03 - 0.06 in. Wirespool diameter max. 300 mm max. 11.81 in. 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. - Page 68 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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