Fronius WF 25i Case D200 Operating Instructions Manual
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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 Operating Instructions WF 25i Case D200 WF 25i Case D300 Operating Instructions 42,0426,0187,EN 019-16102024...
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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: Proper Use
Proper use The device is to be used exclusively for its intended purpose. 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 in- structions... -
Page 7: Mains Connection
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence. Mains connec- Devices with a higher rating may affect the energy quality of the mains due to tion their current consumption. 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... -
Page 8: Danger From Toxic Gases And Vapours
Danger from tox- The fumes produced during welding contain harmful gases and vapours. ic gases and va- Welding fumes contain substances that cause cancer, as stated in Monograph pours 118 of the International Agency for Research on Cancer. Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device. -
Page 9: Risks From Mains Current And Welding Current
Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard. Risks from mains An electric shock is potentially life threatening and can be fatal. current and Do not touch live parts either inside or outside the device. -
Page 10: Meandering Welding Currents
If work on live parts is required, have a second person switch off the main switch at the right moment. Meandering If the following instructions are ignored, meandering welding currents can devel- welding currents op with the following consequences: Fire hazard Overheating of parts connected to the workpiece Damage to ground conductors Damage to device and other electrical equipment... -
Page 11: Emf Measures
Supporting measures for avoidance of EMC problems: Mains supply If electromagnetic interference arises despite the correct mains connec- tion, additional measures are necessary (e.g. use of a suitable line filter) Welding power-leads must be kept as short as possible must be laid close together (to avoid EMF problems) must be kept well apart from other leads Equipotential bonding Earthing of the workpiece... -
Page 12: Requirement For The Shielding Gas
Power sources that are to be used in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be loc- ated in such areas. Risk of scalding from escaping coolant. Switch off cooling unit before discon- necting coolant flow or return lines. -
Page 13: Danger From Escaping Shielding Gas
Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition. Turn your face to one side when opening the valve of a shielding gas cylinder. Close the shielding gas cylinder valve if no welding is taking place. -
Page 14: Safety Measures In Normal Operation
Safety measures Only operate the device when all safety devices are fully functional. If the safety in normal opera- devices are not fully functional, there is a risk of tion injury or death to the operator or a third party damage to the device and other material assets belonging to the operator inefficient operation of the device Any safety devices that are not functioning properly must be repaired before... -
Page 15: Safety Inspection
(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 following address: http://www.fronius.com Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA. -
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 suit- able 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, espe- cially 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 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 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 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 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
Read and understand all safety rules and user documentation for this device and all system components. 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. -
Page 30: Opt/I Wf Gas Test & Wire Threading
OPT/i WF gas Function test & wire OPT/i WF gas test & wire threading threading 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 accompa- nying 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 Function Parameter selection button (left) for selecting the parameters listed below. The corresponding indicator lights up when a parameter is selected. Material thickness *) in mm or inches Current *) current in A Before the start of welding, the machine automatically dis- plays a standard value based on the programmed paramet- ers.
- Page 34 Function Parameter selection button (right) for selecting the parameters listed below. The corresponding indicator lights up when a parameter is selected. 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 dis-...
- Page 35 Function Adjusting dial with turn/press function for changing the arc length correction, voltage, pulse/ dynamic correction parameters for selecting the job number 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 Easy- Job (all current settings are saved).
- Page 36 Function Hold indicator the actual values are displayed automatically at the end of each welding operation (current, voltage, wire feed speed, etc.). The ac- tual values are displayed through the HOLD indicator lighting up. Intermediate arc indicator a spatter-prone intermediate arc occurs between the short arc and the spray arc.
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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 con- junction 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 electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved and dis- connect them from the grid. ▶... -
Page 41: Connecting A Mig/Mag Welding Torch
Connecting a CAUTION! MIG/MAG weld- ing torch Risk of injury and damage from loose connections. All cables, lines and hosepacks must be properly secured, undamaged, insu- lated 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 electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved and dis- connect them from the grid. ▶ Secure all devices and components involved so they cannot be switched back ▶... - 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 electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved and dis- connect them from the grid. ▶... -
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 ig- nition of an arc. Before starting work, disconnect the ground earth connection between the weld- ing system 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 personnel 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 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 53: Troubleshooting, Maintenance And Disposal
Troubleshooting, maintenance and disposal... -
Page 55: 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 56 Welding machine 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 connection, 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 from incorrect operation and work that is not carried out properly. -
Page 60: Disposal
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.
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