Related Manuals for Fronius WF 25i FlexDrive
Summary of Contents for Fronius WF 25i FlexDrive
- Page 1 Operating Instructions WF 25i FlexDrive WF 25i FlexDrive JM EN-US Operating instructions 42,0426,0397,EA 002-27092022...
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Page 3: Table Of Contents
Table of contents Safety Instructions General Intended Use Environmental Conditions Obligations of the Operating Company Obligations of Personnel Grid Connection Personal Protection and Protection of Others Danger from toxic gases and vapors Danger from Flying Sparks Risks from grid current and welding current Stray welding currents EMC Device Classifications EMC measures... - Page 4 Setting the contact pressure Commissioning Safety Requirements Filling water-cooled welding systems with coolant Conducting system calibration and R/L comparison Commissioning Troubleshooting Safety Troubleshooting Service, maintenance and disposal General Safety At every start-up Every 6 months Disposal Technical data WF 25i FlexDrive...
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Page 5: Safety Instructions
Safety Instructions General The device has been manufactured using state-of-the-art technology and ac- cording to recognized 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 operating company Inefficient operation of the equipment All persons involved in the commissioning, operation, maintenance, and servicing... -
Page 6: Environmental Conditions
Environmental Operation or storage of the device outside the stipulated area will be deemed as Conditions not in accordance with the intended purpose. The manufacturer accepts no liab- ility for any damage resulting from improper use. Temperature range of the ambient air: 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 7: Danger From Toxic Gases And Vapors
Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers Electrical risks from grid current and welding current Increased noise exposure Harmful welding fumes and gases Wear suitable protective clothing when dealing with the device. The protective clothing must have the following properties: Flame resistant Insulating and dry... -
Page 8: Danger From Flying Sparks
Consult the corresponding material safety data sheets and manufacturer's in- structions for the components listed above. Recommendations for exposure scenarios, risk management measures and identifying working conditions can be found on the European Welding Associ- ation website under Health & Safety (https://european-welding.org). Keep flammable vapors (such as solvent vapors) out of the arc radiation range. -
Page 9: Stray Welding Currents
The open circuit voltage of a welding system may double, for example, between the electrodes of two welding systems. Touching the potentials of both elec- trodes at the same time may be life-threatening in some cases. Have the grid and device supply lead regularly inspected by an electrician to en- sure that the ground conductor is functioning properly. -
Page 10: Emc Measures
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 supplied from the public low- voltage grid. EMC device classification as per the rating plate or technical data. EMC measures In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g., when... - Page 11 Do not reach into rotating gears of the wire drive or into rotating drive parts. Covers and side panels must only be opened/removed during maintenance and repair work. During operation Ensure that all covers are closed, and all side parts have been mounted prop- erly.
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Page 12: Requirement For The Shielding Gas
Requirement for Especially with ring lines, contaminated shielding gas can cause damage to the shielding gas equipment and reduce welding quality. Meet the following requirements regarding shielding gas quality: Solid particle size < 40 µm Pressure condensation point < -20 °C Max. -
Page 13: Safety Measures At The Setup Location And During Transport
Safety Measures A toppling device can be deadly! Set up the device securely on an even, solid sur- at the Setup face Location and The maximum permitted tilt angle is 10°. During Transport Special regulations apply in areas at risk of fire or explosion Follow the appropriate national and international regulations. -
Page 14: Maintenance And Repair
Only connect system components from the manufacturer to the cooling unit cir- cuit. If there is damage due to use of other system components or other coolants, the manufacturer accepts no liability for this and all warranty claims are forfeited. Cooling Liquid FCL 10/20 is not flammable. -
Page 15: Safety Symbols
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: General
Device concept WF 25i FlexDrive JM with protective cage and rollers The WF 25i FlexDrive is a small portable intermediate drive that is integrated in the welding system between the welding torch and the wirefeeder. This extends the radius of action between the wirefeeder and the welding point up to 25 m / 82 ft. -
Page 17: Warning Notices On The Device
Warning notices The intermediate drive has safety sym- on the device bols and a rating plate fitted. These safety symbols and the rating plate must not be removed or painted over. The safety symbols warn against oper- ating the equipment incorrectly, as this may result in serious injury and dam- age to property. -
Page 18: System Overview
Details on the selection of the cooling unit can be found in the following section on page 19. Extension hosepack from the wirefeeder to the WF 25i FlexDrive 10 m, 15 m, 20 m / 32 ft. 9.7 in., 49 ft. 2.55 in., 65 ft. 7.40 in. WF 25i FlexDrive... -
Page 19: Options
Options Protective cage with rollers Runners The front roller can be swiveled 360° and is equipped with a brake as standard. It is possible to mount either the protective cage or runners on the WF 25i FlexDrive. Selection of The following table gives an overview of the cooling unit selection depending on cooling units the maximum welding current at the welding torch and the length of the exten- sion hosepack. - Page 20 ... maximum welding current at the welding torch, L = 4.50 m / 14 ft. 9.17 in. 10 / 15 / 20 m ... Length of extension hosepack CU ... cooling unit to be selected 10 m = 32 ft. 9.70 in., 15 m = 49 ft. 2.55 in., 20 m = 65 ft. 7.40 in.
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Page 21: Operating Controls, Connections And Mechanical Components
(11) (16) (17) (18) (19) Clamping lever Welding torch side Fronius System Connector - Welding torch side Coolant supply Welding torch side Coolant return Welding torch side Drive roller cover + LED for lighting the interior Functional description of the LED from page 24. - Page 22 JobMaster control unit (only for WF 25i FlexDrive JM) Gas test / wire threading control unit Clamping lever Wirefeeder side Fronius System Connector - Wirefeeder side (10) Coolant return Wirefeeder side (11) Coolant supply Wirefeeder side (12) Display Shows the current parameter and value...
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Page 23: Function Of The Gas-Test, Wire-Return, And Wire-Threading Buttons
Function of the Operating status LED gas-test, wire- return, and wire- Lights up green when the device is ready for operation threading but- tons Gas-test button After pressing the gas-test button, gas is released for 30 s. Pressing the button again will end the process prematurely. -
Page 24: Function Of The Led Inside The Feed Roller
Option 2 Thread the wire electrode in 1 mm steps (0.039 in. steps) Always press (touch) the wire-threading button for less than 1 second If the wire electrode meets a ground earth connection, then the wirefeeding is stopped and the wire electrode is retracted again by 1 mm (0.039 in.) NOTE! If there is a ground earth connection with the contact tip, before the wire- threading button is pressed, the wire electrode is retracted by pressing the wire-... -
Page 25: Before Installation And Initial Operation
IP23. This means: Protection against the penetration of solid foreign bodies with a diameter of more than 12.5 mm (0.49 in.) No protection against water The intermediate drive WF 25i FlexDrive may only be set up and operated in closed areas. -
Page 26: Installing Optional Equipment
Installing Optional Equipment Mounting the Disconnect the welding torch hosepack from the WF 25i FlexDrive protective cage See page 32. Disconnect the extension hosepack from the WF 25i FlexDrive See page 31. NOTE! Before mounting the protective cage, note the wirefeeding direction from the wirefeeder to the welding torch. - Page 27 10 Nm 7.38 ft·lb Safety rope with carabiner The carabiner is hooked onto the protective cage. Connect the extension hosepack to the WF 25i FlexDrive See page 31. Hook the carabiner of the safety rope onto the wirefeeder-side anti- kink spring The protective cage can also be used without rollers.
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Page 28: Mounting The Runners
Mounting the runners M6 x 20 mm 10 Nm 7.38 ft·lb... -
Page 29: Installing The Inner Liner In The Extension Hosepack
The inner liner is pre-assembled on the WF 25i FlexDrive side with the brass clamping nipple and protrudes approx. 20 mm from the FSC at the other end of the hosepack. - Page 30 WF 25i FlexDrive side Wirefeeder side Push the steel inner liner into the hosepack with light pressure and trim it flush to length Push the plastic inner liner into the hosepack with light pressure and trim it flush to length...
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Page 31: Connecting The Extension Hosepack
Existing coolant hoses must always be on the underside of the FSC. The hosepack end with the brass clamping nipple is always connected to the WF 25i FlexDrive. The hosepack end with the wire-specific clamping nipple is connected to the wirefeeder. -
Page 32: Connecting The Welding Torch
Connecting the 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 33: Inserting / Changing The Feed Rollers And Wirefeeder
This can result in poor-quality weld properties. ▶ Only use feed rollers which match the wire electrode. The following feed rollers are available for the WF 25i FlexDrive: Rollers with semicircular groove, for aluminum, AlSi, AlMg Rollers with 60° groove, for steel, CrNi, CuSi... - Page 34 Installation is carried out in reverse or- der. CAUTION! Danger due to exposed mechanically moving parts. Personal injury and damage to property may result. ▶ Only operate the device when all covers are closed and/or completely moun- ted.
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Page 35: Inserting / Changing The Wirefeeder
Inserting / chan- Two different wirefeeders are available for the WF 25i FlexDrive: ging the for aluminum (with pressed-in plastic inner liner) wirefeeder for steel The two set screws do not have to be unscrewed completely, loosening the set screws approx. two turns is sufficient. - Page 36 28.5 mm 1.12 inch ** ... Brass clamping nipple...
- Page 37 *** ... Push the wirefeeder back as far as it will go...
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Page 38: Threading The Wire Electrode
Lay the extension hosepack to the WF 25i FlexDrive and the welding torch hosepack out straight Engage feed rollers in the wirefeeder and in the WF 25i FlexDrive (close... - Page 39 Thread the wire electrode on the wirefeeder CAUTION! Danger due to emerging wire electrode. This can result in severe personal injury and damage to property. ▶ Hold the welding torch so that the tip of the welding torch points away from the face and body.
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Page 40: Setting The Contact Pressure
Setting the con- CAUTION! tact pressure Risk of contact pressure being too high. This can result in severe damage to property and poor weld properties. ▶ Set the contact pressure in such a way that the wire electrode is not de- formed but nevertheless ensures proper wirefeeding. -
Page 41: Commissioning
After longer welding pauses (> 1 h), press the gas-test button and flush the hosepack before starting welding again. Filling water- For water-cooled welding systems, WF 25i FlexDrive and the extension hosepack cooled welding are delivered without coolant. systems with... -
Page 42: Conducting System Calibration And R/L Comparison
Procedure for filling long welding torch hosepacks (> 8 m, extension hosepack): Connect the extension hosepack to the wirefeeder Connect the extension hosepack to the WF 25i FlexDrive Connect the torch hosepack to the WF 25i FlexDrive Fill the coolant tank of the cooling unit to the maximum level... -
Page 43: 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 44 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 45 Irregular wire speed Cause: Braking force has been set too high Remedy: Loosen the brake Cause: Contact tip hole too narrow Remedy: Use suitable contact tip 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 wire electrode used Remedy:...
- Page 46 Poor-quality weld properties Cause: Incorrect welding parameters Remedy: Check settings Cause: Poor ground earth connection Remedy: Establish good contact with workpiece Cause: Too little or no shielding gas Remedy: Check gas pressure regulator, gas hose, gas solenoid valve, welding torch gas connection, etc. Cause: Welding torch leaks Remedy:...
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Page 47: 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 48: 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 49: Technical Data
Technical data WF 25i FlexDrive Welding current at 10 min / 40 °C 100% ED* / 320 A (104 °F) 60% ED* / 360 A 40% ED* / 400 A Maximum pressure of shielding gas 7 bar 101.53 psi Coolant...
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