Fronius WF 25i Dual Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Fronius Manuals
  4. Wire Feeders
  5. WF 25i
  6. Operating instructions manual
Fronius WF 25i Dual Operating Instructions Manual

Fronius WF 25i Dual Operating Instructions Manual

Hide thumbs Also See for WF 25i Dual:
Table of Contents

Advertisement

Quick Links

Operating
Instructions
WF 25i Dual
EN-US
Operating instructions
42,0426,0427,EA
001-03022023

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the WF 25i Dual and is the answer not in the manual?

Questions and answers

Related Manuals for Fronius WF 25i Dual

Summary of Contents for Fronius WF 25i Dual

  • Page 1 Operating Instructions WF 25i Dual EN-US Operating instructions 42,0426,0427,EA 001-03022023...

  • Page 3: Table Of Contents

    Crane transport safety sticker Crane transport of the WF 25i Dual with D300 spool holder Crane transport of the WF 25i Dual with D450 spool holder without spool cover Crane transport of the WF 25i Dual mounted on the trolley...
  • Page 4 Adjusting the brake on the WF 25i Dual D450 Design of the D450 brake Commissioning Safety Warning of electrically live (hot), exposed parts on WF 25i Dual with spool holder D450 without spool cover Requirements for commissioning Commissioning Note for TIG AC applications...
  • Page 5 HP 95i...

  • Page 6: 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 7: 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 8: 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 9: 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 10: 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 11: 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 12 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.

  • Page 13: 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 14: 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 15: 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 16: 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 17: General

    General Device concept The WF 25i Dual enables the joint use of two welding process lines with one power source. The welding process lines can be changed using the torch trigger, on the power source, via the operating controls on the wirefeeder, or on a remote control.

  • Page 18: Warning Notices On The Device

    Warning notices The wirefeeder has safety symbols and a rating plate fitted. These safety symbols on the device and the rating plate must not be removed or painted over. The safety symbols warn against operating the equipment incorrectly, as this may result in serious in- jury and damage to property.
  • Page 19 Keep hands, hair, loose clothing, and tools away from moving parts, such as: Gears Feed rollers Wirespools and wire electrodes 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 main- tenance and repair work.

  • Page 20: Description Of The Warnings On The Device

    Description of Warning notices are attached to the device for certain device versions. the warnings on the device The arrangement of the symbols may vary. Warning! Caution! The symbols represent possible dangers. Drive rollers can injure fingers. The welding wire and drive parts are under welding voltage during opera- tion.
  • Page 21 Use forced-air ventilation or local extraction to remove welding fumes. Remove welding fumes with a fan. Welding sparks can cause an explosion or fire. Keep flammable materials away from the welding process. Do not perform welding near flammable materials. Welding sparks can cause a fire. Have fire extinguishers ready. If neces- sary, have a supervisor ready who can operate the fire extinguisher.

  • Page 22: Options And Components

    Two-part, only in conjunction with D300 spool holder with cover OPT/WF Hosepack Holder Dual D300 spool holder with cover OPT/WF Spool Holder D300 Dual Dual-head wirefeeder WF 25i Dual No Spool /4R/G/FSC Remote control option RC Panel Standard, RC Panel Pro Coolant connections option OPT/WF Water Connection Dual...
  • Page 23 D450 spool holder without cover OPT/WF Spool Holder D450 Dual (without wirespools) Trabant trolley option OPT/TU Trabant (10) Boom mounting kit option OPT/WF Boom Mounting Kit Dual Not pictured: Euro connection conversion kit SpeedNet cable 5 m SpeedNet cable 10 m...

  • Page 24: Trolley Options

    Trolley options TU Car 4 Pro trolley incl. gas cylinder holder WF Dual mounting set option OPT/TU Mounting Set WF Dual incl.: Storage vessel b) Tubular frame 2 x insulated torch holder d) Second gas cylinder holder and cylinder strap Mounting material...

  • Page 25: System Configurations

    OPT/TU Mounting Set WF Dual H740 option (for water-cooled systems) WF 25i Dual with D300 spool holder on the trolley An alternative setup on the trolley could include the WF 25i Dual with D450 spool holder. Details on setting up the dual-head wirefeeder on the trolley can be found in the...

  • Page 26: Setup On The Welding Boom (Welding-Boom)

    5 m / 16 ft. 4.85 in. max. 9 ft. 10.11 in. WF 25i Dual with boom mounting kit option, mounted on the welding boom (schematic presentation) Max. delivery head 3 m / 9 ft. 10.11 in. Max. conveying length, horizontal 5 m / 16 ft.

  • Page 27: Setup On The Crane

    The OPT/WF Lift Bail Dual option is required for setup on the crane. crane WF 25i Dual with D300 spool holder for crane setup IMPORTANT! Setup and operation on the crane are only permitted for the WF 25i Dual with D300 spool holder.

  • Page 28: System Limits

    Max. 25 m / 82 ft. 0.25 in. Torch hosepack 2 x max. 6 m / 19 ft. 8.22 in. Welding system with WF 25i Dual and iWave 300i - 500i MP (MIG/MAG + TIG): Suitable cooling units CU 1400i Pro Interconnecting hosepack * Max.

  • Page 29: Crane Transport

    Lift Bail Dual: 42,0409,1255 a) b) c) The WF 25i Dual may only be transported with the OPT/WF Lift Bail Dual op- tion mounted on the crane. For details, see page 30. b) Crane transport of a welding system mounted on the trolley with WF 25i Dual is only permitted in conjunction with the OPT/TU Mounting Set WF Dual option.

  • Page 30: Crane Transport Of The Wf 25I Dual With D300 Spool Holder

    Crane transport The OPT/WF Lift Bail Dual crane transport option is required for crane transport of the WF 25i of the WF 25i Dual with D450 spool holder without spool cover. Dual with D450 spool holder WARNING!

  • Page 31: Crane Transport Of The Wf 25I Dual Mounted On The Trolley

    ▶ For the WF 25i Dual with D450 spool holder without spool cover, remove the wirespools before transporting by crane. ▶ Transport the welding system on the trolley only at the marked positions.

  • Page 32: Operating Controls, Connections And Mechanical Components

    ▶ Read and understand this document in full. ▶ Read and understand all safety rules and user documentation for this equip- ment and all system components. WF 25i Dual with D300 spool hold- (16) (15) (14) (13)
  • Page 33 For use on the crane The wirefeeder hangs on the crane during welding work, the wirespools are in the wirefeeder, the side parts of the spool holder are closed and se- cured. (Also see System configurations/Setup on the crane from page 27) Tool tray option OPT/WF Tool Tray Dual Remote control holder...

  • Page 34: Wf 25I Dual With D450 Spool Holder

    WF 25i Dual with D450 spool hold- (14) (13) (12) (10) (11) Crane transport option OPT/WF Lift Bail Dual For transport by crane The wirespools must be removed for transport by crane. Tool tray option OPT/WF Tool Tray Dual Remote control holder...
  • Page 35 Coolant return connection (red) * Option Welding process line 1 SpeedNet connection For connecting the remote control (10) Coolant supply connection (blue) * Option Welding process line 2 (11) Coolant return connection (red) * Option Welding process line 2 (12) Trabant trolley option OPT/TU Trabant (13)

  • Page 36: Wirefeeder Rear

    Wirefeeder rear WF 25i Dual + D300 WF 25i Dual + D450 (7) (8) (9) (3) (4) (5) Strain-relief device for the interconnecting hosepack Wire infeed tube Welding process line 2 Coolant return connection (red) Option For connecting the coolant return hose from the interconnecting hosep-...

  • Page 37: Wirefeeder Side

    Wirefeeder side WF 25i Dual + D300 (3) (4) (5) (6) WF 25i Dual + D450 Illustration without covers and side parts shown Basket-type spool adapter Wirespool holder with brake Operating status LED Lights up green when the device is ready for operation...

  • Page 38: 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 39 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 40: Before Installation And Initial Operation

    Intended use The device is intended exclusively for end of wirefeeding with MIG/MAG welding in combination with Fronius system components. Any other use does not constitute proper use. The manufacturer shall not be held liable for any loss resulting from improper use.

  • Page 41: Setup Regulations

    Setup regula- WARNING! tions Danger from devices falling or toppling over. This can result in severe personal injury and damage to property. ▶ Set up all system components, upright brackets, and trolleys so that they are stable on a flat and solid surface. ▶...

  • Page 42: Installing Optional Equipment

    Installing Optional Equipment 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 43: Mounting The D450 Spool Holder Without Cover

    Repeat work steps 2 and 3 on the other side of the wirefeeder Mounting the D450 spool hold- er without cover Use screws from the scope of supply of the spool holder 4 x M5 x 12 mm, tightening torque = 3 Nm / 2.21 lb-ft...

  • Page 44: Mounting The Crane Transport Option

    Repeat work steps 2 and 3 on the other side of the wirefeeder Mounting the Screws and mounting material from crane transport the scope of supply of the crane trans- option port option. The option is mounted on the D450 spool holder without spool cover in the same way.

  • Page 45: Mounting The Tool Tray Option

    Mounting the tool tray option 4 x M5x12 mm 4 x brass spacer M5x12 mm, tightening torque = 2.1 Nm / 1.55 lb-ft 4 x M5 x 12 mm, tightening torque = 3 Nm / 2.21 lb-ft Mounting the boom mounting kit option 4 x M8 x 25 mm + M8 washer + NL8 4 x M8 x 30 mm + M8 washer + NL8...

  • Page 46: Connecting The Wirefeeder To The Power Source

    Connecting the wirefeeder to the wirefeeder to the power source is described with refer- power source ence to the WF 25i Dual with D300 spool holder. The WF 25i Dual with D450 spool holder is connected to the power source in the same way.
  • Page 47 Gas 2 Push wirefeeder to the front; Guide interconnecting hosepack and gas 2 through the spool holder Connect the interconnecting hosepack and gas 2 to the wirefeeder Push the wirefeeder back into the original position...

  • Page 48: Connecting The Extension Hosepack

    2 x M5 x 12 mm, tightening torque = 3 Nm / 2.21lb-ft Repeat work step 7 on the other side of the wirefeeder Fix the strain-relief device of the interconnecting hosepack to the wirespool holder with 2 M5 x 12 mm screws Tightening torque = 3 Nm / 2.21 lb-ft Connecting the WARNING!
  • Page 49 For water-cooled hosepack only CON = interconnecting hosepack = extension hosepack...

  • Page 50: 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 51 only if the coolant connections are installed in the wirefeeder and for wa- ter-cooled welding torches; Observe the color coding of the coolant connections! CAUTION! Danger due to lack of coolant. If the coolant hoses of one welding torch are terminated, the other welding torch is also no longer supplied with coolant.

  • Page 52: 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 53 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.

  • Page 54: Remounting The D450 Brake For Operation With A D300 Wirespool

    Mounting position of the brake when using wirespools with a diameter of 300 mm Remove M16 screw at the rear of the brake WF 25i Dual with D450 spool holder Re-fix the brake in the new position using the M16 screw NOTE! When using a D300 wirespool on the D450 spool holder, the braking force of the D450 brake must also be adjusted.

  • Page 55: Inserting The Wirespool/Basket-Type Spool

    Inserting the wirespool/basket-type spool 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 56: Inserting The D300 Basket-Type Spool

    Inserting the WARNING! D300 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 58: Inserting The D450 Wirespool

    This can result in severe personal injury and damage to property. ▶ Always position the locking ring as shown below. NOTE! Use appropriate spool adapters for applications with 60 lb flux core wire spools. Spool adapters for 60 lb flux core wire spools are not available from Fronius.

  • Page 59: Threading The Wire Electrode

    Threading the Wire Electrode General NOTE! The wire electrode can be threaded using any wire-threading button of another system component – for example, the wire-threading button of the power source. The function of the wire-threading button is the same for all system components of the manufacturer.

  • Page 60: Threading The Wire Electrode

    Threading the WARNING! wire electrode Danger due to emerging wire electrode. Serious personal injuries may result. ▶ Hold the welding torch so that the tip of the welding torch points away from the face and body. ▶ Wear suitable protective goggles. ▶...

  • Page 61: Setting The Contact Pressure

    Setting the con- CAUTION! tact pressure Danger from excessive contact pressure. This can result in 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. Contact pressure standard values for U-groove rollers: Steel: 4 - 5...

  • Page 62: 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! D300 brake Danger due to emerging wire electrode.

  • Page 63: Design Of The D300 Brake

    STOP Design of the WARNING! D300 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.
  • Page 64 STOP STOP...

  • Page 65: Design Of The D450 Brake

    Design of the The brake is only available as a complete unit. D450 brake The illustration of the brake is for information purposes only. Preliminary design of the D450 brake WARNING! Danger from incorrect installation. This can result in severe personal injury and damage to property. ▶...

  • Page 66: Commissioning

    Read and understand all safety rules and user documentation for this equip- ment and all system components. Warning of elec- Only for WF 25i Dual with spool holder D450 without spool cover: trically live (hot), exposed parts on When the dual head wirefeeder is con-...

  • Page 67: Commissioning

    Requirements The following requirements must be fulfilled for commissioning of the wirefeed- for commission- Wirefeeder connected to power source by means of interconnecting hosep- Welding torch connected to wirefeeder Feed rollers inserted into wirefeeder Wirespools/basket-type spools and their adapters inserted into wirefeeder Wire electrodes threaded in Contact pressure of the feed rollers set Brakes adjusted...

  • Page 68: Selecting The Welding Process Line

    Selecting the welding process line Selecting the The welding process line can be selected in the following ways: welding Using the torch trigger on the welding torch process line Using the button/LED on the wirefeeder Using the gas-test, wire-return, and wire-threading buttons on the wirefeeder On the power source Using the RC Panel Standard or RC Panel Pro remote control NOTE!

  • Page 69: Selecting The Welding Process Line On The Power Source Or Using Rc Panel Pro Remote

    Selecting the If one of the gas-test, wire-return, or wire-threading buttons is pressed on one welding process side of the wirefeeder, this welding process line is activated. line using the The LED of the corresponding button on the wirefeeder lights up. gas-test, wire- return, and wire- threading but-...

  • Page 70: 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 71 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 72 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 73 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 pressure regulator, gas hose, gas solenoid valve, welding torch gas connection, etc. Cause: Welding torch leaks Remedy:...

  • Page 74: 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 75: 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 76: Technical Data

    Technical data WF 25i Dual Supply voltage 24 V DC / 60 V DC Nominal current 0.5 A / 1.2 A Welding current 40% ED* / 500 A at 10 min/40 °C (104 °F) 60% ED* / 450 A 100% ED* / 360 A...

  • Page 77: D300 Spool Holder With Cover

    D300 spool hold- Wirespool diameter Max. 300 mm er with cover Max. 11.81 in. Wirespool weight Max. 19 kg Max. 41.89 Ib. Protection class IP 23 Dimensions l × w × h 620 x 557 x 444 mm 24.37 x 21.93 x 17.48 in. Weight - kg - Ib.

Table of Contents