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Summary of Contents for Fronius CWF 25i
- Page 1 Operating Instructions CWF 25i EN-US Operating instructions 42,0426,0392,EA 002-27092022...
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Page 3: Table Of Contents
Table of contents Safety Instructions Explanation of Safety Instructions General Intended Use Environmental Conditions Obligations of the Operating Company Obligations of Personnel Grid Connection Personal Protection and Protection of Others Data on noise emission values Danger from toxic gases and vapors Danger from Flying Sparks Risks from grid current and welding current Stray welding currents... - Page 4 Adjusting the brake Design of the brake Commissioning Safety Requirements Commissioning Troubleshooting Safety Troubleshooting Service, maintenance and disposal General Safety At every start-up Every 6 months Disposal Technical data CWF 25i Water-cooled interconnecting hosepack - HP 70i CWF CON /W Disposal...
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Page 5: Safety Instructions
Safety Instructions Explanation of DANGER! Safety Instruc- tions Indicates an immediate danger. ▶ Death or serious injury may result if appropriate precautions are not taken. WARNING! Indicates a possibly dangerous situation. ▶ Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur. -
Page 6: Intended Use
Intended Use The device is to be used exclusively for its intended purpose. The device is intended exclusively for the welding process specified on the rating plate. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose."... -
Page 7: Grid Connection
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current consumption. This may affect a number of device types in terms of: connection restrictions criteria regarding maximum permissible grid impedance criteria regarding the minimum required short-circuit power both at the interface with the public grid See technical data In this case, the operator or the person using the device should check whether or... -
Page 8: Danger From Toxic Gases And Vapors
A workplace-specific emission value for welding (and cutting) cannot be spe- cified because this value depends on the welding process and the environmental conditions. It is influenced by a wide range of parameters, such as the welding process itself (MIG/MAG, TIG welding), the selected current type (direct cur- rent, alternating current), the power range, the type of weld metal, the resonance properties of the workpiece, the workplace environment, and many other factors. -
Page 9: Risks From Grid Current And Welding Current
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes if these have not been prepared in accordance with cor- responding national and international standards. Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/were stored. -
Page 10: Stray Welding Currents
After opening the device: Discharge all electrically charged components Ensure that all components are disconnected from the power supply. If work is needed on voltage-carrying parts, bring in a second person who will switch off the main switch at the correct time. Stray welding If the following instructions are not observed, stray welding currents may occur, currents... -
Page 11: Emf Measures
Supporting measures to avoid EMC problems: Grid power supply If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter). Welding power-leads Keep them as short as possible Route them close together (also to avoid EMF problems) Route them far from other lines Equipotential bonding Workpiece grounding... -
Page 12: Requirement For The Shielding Gas
Special regulations apply in areas at risk of fire or explosion – follow the appropriate national and international regulations. Power sources for work in areas with increased electrical hazard (e.g., boilers) must be labeled with the symbol (Safety). However, the power source may not be located in such areas. -
Page 13: Danger Posed By Shielding Gas Leak
Never hang a welding torch on a shielding gas cylinder. Never touch a shielding gas cylinder with an electrode. Risk of explosion: Never weld on a compressed shielding gas cylinder. Always use suitable shielding gas cylinders for the application in question and the correct matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders and accessories that are in good condition. -
Page 14: Safety Measures In Normal Operation
It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage re- paired by trained service technicians before commissioning the device. Safety Measures Only operate the device when all safety devices are fully functional. If the safety in Normal Oper- devices are not fully functional, there is a danger of: ation... -
Page 15: Safety Inspection
Copyright Copyright of these Operating Instructions remains with the manufacturer. Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you... - Page 16 have any suggestions for improvement, or can point out any mistakes that you have found in the Operating Instructions, we will be most grateful for your com- ments.
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Page 17: General
Due to its compact design, the wirefeeder is a versatile product. Field of applica- The CWF 25i wirefeeder can be used for all TIG welding operations in combina- tion tion with the iWave 300i - 500i power sources. The wirefeeder is suitable for all commercially available shielding gases. - Page 18 These Operating Instructions All system component Operating Instructions, especially the safety rules Welding is dangerous. To ensure that this device can be used correctly and safely, the following basic requirements must be met: Adequate welding qualifications Appropriate protective equipment Keep unauthorized people away from the wirefeeder and the welding process Dispose of old devices in accordance with safety rules and not in normal domest- ic waste.
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Page 19: Operating Controls, Connections And Mechanical Components
Operating controls, connections and mechanical components 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. -
Page 20: Left Side, Bottom
Coolant supply connection (blue) Option * For connecting the coolant supply hose from the interconnecting hosep- The optional connections are present if the "OPT/i CWF TMC Torch" op- tion is installed on the wirefeeder. Left side, bottom CWF 25i – left side... - Page 21 Wirespool cover Wire drive cover 4-roller drive with red protective cover Pressure lever For adjusting the contact pressure Clamping lever Gas-test button For setting the required quantity of gas on the gas pressure regulator. After pressing the gas-test button, gas is released for 30 s. Pressing the button again ends the process early.
- Page 22 Option 2 Thread the welding wire in 1 mm steps (0.039 in. steps) – always press the wire-threading button for less than 1 second (tap) Operating status LED Lights up green when the device is ready for operation (10) Swivel pin holder (10)
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Page 23: Before Installation And Initial Operation
Intended use The device is intended exclusively for wirefeeding with TIG welding in combina- tion with Fronius system components. Any other use does not constitute proper use. The manufacturer shall not be held liable for any damage resulting from improp- er use. -
Page 24: Placing The Wirefeeder On The Swivel Pin Holder
Placing the wirefeeder on the swivel pin holder Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved, and disconnect them from the grid. ▶... -
Page 25: Connecting The Wirefeeder To The Power Source
Connecting the wirefeeder to the power source Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved, and disconnect them from the grid. ▶... - Page 27 Connecting the interconnecting hosepack (only if OPT/i CWF TMC Torch option is present) * External gas supply (option) CAUTION! Risk due to damage to connections. This can result in damage to property. ▶ For interconnecting hosepacks with a length of 1.2 m (3 ft. 11.24 in.), no strain-relief device is provided.
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Page 28: Connecting The Wirefeeding Hose/Welding Torch
Connecting the wirefeeding hose/welding torch Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved, and disconnect them from the grid. ▶ Secure all devices and components involved so they cannot be switched back ▶... - Page 29 Fit parts to the welding torch according to the Operating Instructions for the welding torch...
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Page 30: Inserting/Changing Feed Rollers
Inserting/changing feed rollers Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved, and disconnect them from the grid. ▶ Secure all devices and components involved so they cannot be switched back ▶... - Page 31 CAUTION! Danger due to open feed rollers. This could result in injury. ▶ After inserting/changing the feed rollers, always install the protective cover of the 4-roller drive.
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Page 32: Inserting The Wirespool/Basket-Type Spool
Inserting the wirespool/basket-type spool Safety WARNING! Danger from electrical current. This may result in serious injuries or death. ▶ Before starting work, switch off all the devices and components involved and disconnect them from the grid. ▶ Secure all devices and components involved so they cannot be switched back CAUTION! Danger from springiness of the coiled welding wire. -
Page 33: Installing The Basket-Type Spool
Installing the WARNING! basket-type spool Danger from falling basket-type spool due to missing basket-type spool ad- apter. This can result in severe personal injury and damage to property. ▶ When working with basket-type spools, only use the basket-type spool ad- apter supplied with the device. - Page 34 WARNING! Danger due to falling basket-type spool as a result of the locking ring being fit- ted the wrong way round. This can result in severe personal injury and damage to property. ▶ Always position the locking ring as shown below.
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Page 35: Threading In The Welding Wire
Threading in the welding wire Threading in the CAUTION! welding wire Danger due to sharp end of the welding wire. Personal injury and damage to property may result. ▶ Deburr the end of the welding wire before insertion. CAUTION! Danger from springiness of the coiled welding wire. Personal injury and damage to property may result. -
Page 36: Setting The Contact Pressure
Threading in the welding wire Setting the con- NOTE! tact pressure Excessive contact pressure can result in damage to property and poor weld properties. ▶ Set the contact pressure in such a way that the welding wire is not deformed but nevertheless ensures proper wirefeeding. -
Page 37: Adjusting The Brake
Adjusting the brake General NOTE! Overrunning of the brake can result in damage to property. ▶ After releasing the torch trigger/wire-threading button, the wirespool must stop unreeling. ▶ If it continues unreeling, readjust the brake. Adjusting the WARNING! brake Danger due to emerging welding wire. This can result in severe personal injury and damage to property. -
Page 38: Design Of The Brake
Design of the WARNING! brake Danger from incorrect installation. This can result in severe personal in- jury and damage to property. ▶ 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 com- plete unit. -
Page 39: Commissioning
Commissioning 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. -
Page 40: Troubleshooting
Troubleshooting 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. - Page 41 Power source not working Power source switched on; displays and indicators do not illuminate Cause: Mains lead damaged or broken, mains plug not inserted Remedy: Check mains lead, if necessary insert mains plug Cause: Mains socket or mains plug faulty Remedy: Replace faulty parts Cause:...
- Page 42 Irregular wire speed Cause: Braking force has been set too high Remedy: Loosen the brake Cause: Inner liner in the welding torch faulty Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary Cause: Feed rollers not suitable for welding wire used Remedy: Use suitable feed rollers Cause:...
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Page 43: Service, Maintenance And Disposal
Service, maintenance and disposal General The device only requires minimal of service and maintenance under normal oper- ating conditions. However, several points must be observed for the welding sys- tem to remain operational for years to come. 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. -
Page 44: Disposal
Open covers, dismantle device side panels, and blow the inside of the device clean with dry, reduced compressed air. After cleaning, restore the system to its original condition. Disposal Materials should be disposed of according to valid local and national regulations. -
Page 45: Technical Data
Technical data CWF 25i Supply voltage 24 V DC / 60 V DC Current consumption 0.5 A / 1.2 A Wire speed 0.1 - 25 m/min 3.94 - 984.25 ipm Wire drive 4-roller drive Wire diameter 0.8 - 1.6 mm 0.03 - 0.06 in. -
Page 46: Water-Cooled Interconnecting Hosepack - Hp 70I Cwf Con /W
Water-cooled in- DC welding current at 40% ED / 400 A terconnecting 10 min / 40°C (104°F) 60% ED / 365 A hosepack - HP 100% ED / 320 A 70i CWF CON /W AC welding current at 40% ED / 400 A 10 min / 40°C (104°F) 60% ED... - Page 48 SPAREPARTS ONLINE Fronius International GmbH Froniusstraße 1 4643 Pettenbach Austria contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the adresses of all Fronius Sales & Service Partners and locations.
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