Fronius WF 25i Case D200 Operating Instructions Manual Download Page 36 | Manualshive

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Number

Indicator

Function

(9)

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

(12)

VRD (Voltage Reduction Device) indicator

lights up when the voltage reduction device (VRD) is active

(13)

Penetration stabiliser indicator

lights up when the penetration stabiliser function is active

(14)

Arc length stabiliser indicator

lights up when the arc length stabiliser function is active

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Summary of Contents for WF 25i Case D200

Page 1: ...tal chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy WF 25i Case D200 WF 25i Case D300 EN Operating instructions Wire feed unit 42 0...

Page 2: ......

Page 3: ...sioning maintenance and repair 14 Safety inspection 14 Disposal 14 Safety symbols 15 Data protection 15 Copyright 15 General 17 General 19 Device concept 19 Warning notices on the device 19 Crane tran...

Page 4: ...lectrode 46 General 46 Preparations 46 Threading the wire electrode 47 Setting the contact pressure 47 Adjust the brake 48 General 48 Setting the brake D200 device 48 Setting the brake D300 device 49...

Page 5: ...evice All persons involved in commissioning operating maintaining and servicing the device must be suitably qualified have sufficient knowledge of welding and read and follow these operating instructi...

Page 6: ...storage 20 C to 55 C 4 F to 131 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F The surrounding air must be free from dust acids corrosive gases or substances etc Can be used at alti...

Page 7: ...no turn ups Protective clothing refers to a variety of different items Operators should Protect eyes and face from UV rays heat and sparks using a protective visor and regulation filter Wear regulatio...

Page 8: ...supply if no welding is taking place Danger from fly ing sparks Flying sparks may cause fires or explosions Never weld close to flammable materials Flammable materials must be at least 11 metres 36 f...

Page 9: ...ins supply with ground conductor and a connector system with ground conductor contact for proper operation Operation of the device on a mains supply without ground conductor and on a socket without gr...

Page 10: ...though a device complies with the standard limit values for emis sions it may affect the application area for which it was designed e g when there is sensitive equipment at the same location or if th...

Page 11: ...feed unit and wear suitable protective goggles Never touch the workpiece during or after welding risk of burns Slag can jump off cooling workpieces The specified protective equipment must therefore a...

Page 12: ...pment they must be handled with the greatest of care Protect shielding gas cylinders containing compressed gas from excessive heat mech anical impact slag naked flames sparks and arcs Mount the shield...

Page 13: ...and local guidelines and accident prevention regulations This applies especially to guidelines regarding the risks arising during transport Do not lift or transport operational devices Switch off dev...

Page 14: ...s to standard parts Do not carry out any modifications alterations etc to the device without the manu facturer s consent Components that are not in perfect condition must be replaced immediately When...

Page 15: ...of Conformity can be found at the follow ing address http www fronius com Devices marked with the CSA test mark satisfy the requirements of the relevant stand ards for Canada and the USA Data protecti...

Page 16: ...16...

Page 17: ...General 17...

Page 18: ...18...

Page 19: ...notices on the device NOTE The wire feed unit is fitted with safety symbols and a rating plate The safety symbols and rating plate must not be removed or painted over The safety symbols warn against o...

Page 20: ...nvolved must be kept at a safe distance from the wire feed unit and the welding process Do not dispose of used devices with domestic waste Dispose of them according to the safety rules Keep hands hair...

Page 21: ...crane e g belt with round slings The lifting tackle must be undamaged and in perfect condition Always attach the lifting tackle to both ends of the handle see diagram below Do not transport any other...

Page 22: ...22...

Page 23: ...Controls connections and mechan ical components 23...

Page 24: ...24...

Page 25: ...personnel Fully read and understand this document Fully read and understand all the Operating Instructions for the system components especially the safety rules Front of wire feed unit 1 2 3 1 Weldin...

Page 26: ...ding gas connection 5 Coolant flow connection blue option for connecting the coolant hose from the interconnecting hosepack 6 Blanking cover for optional gas flow meter 7 Blanking cover for optional c...

Page 27: ...ating Instructions for the system components especially the safety rules Front of wire feed unit 1 4 3 5 2 1 SpeedNet connection option for connecting optional compon ents for example a remote con tro...

Page 28: ...ing hosepack 4 Shielding gas connection 5 current socket with fine pitch thread for connecting the power cable from the interconnecting hosepack 6 Blanking cover for optional component 7 Blanking cove...

Page 29: ...e 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 control panel 3 1 2 No Funct...

Page 30: ...er the wire retract button is pressed After a short pause the wire feed unit continues to retract the wire elec trode If the wire retract button remains pressed the speed will increase every second at...

Page 31: ...again by 1 mm 0 039 in Variant 2 threading the wire electrode in 1 mm stages 0 039 in stages always press the wire threading button for less than one second tap If the wire electrode comes into conta...

Page 32: ...OPT i WF Stand ard control panel 1 9 8 5 6 10 11 12 2 3 4 7 14 13 32...

Page 33: ...welding process and the LSC or PMC special program has first been selected using the Welding process button 5 The following process control parameters can be selected and adjusted on all devices Penet...

Page 34: ...value is displayed Pulse dynamic correction for correcting the pulse energy during pulsed arc welding lower droplet detachment force 0 neutral droplet detachment force increased droplet detachment for...

Page 35: ...ICK Manual metal arc welding SP SP special programs LSC PMC TIG etc Depending on which package of functions is enabled vari ous welding processes can be selected Press the button to see the available...

Page 36: ...on indicator lights up when the Spatter Free Ignition function is active 11 SynchroPuls indicator lights up when the SynchroPuls function is active 12 VRD Voltage Reduction Device indicator lights up...

Page 37: ...Installation and commissioning 37...

Page 38: ...38...

Page 39: ...m such usage Proper use includes carefully reading these operating instructions following all the instructions and safety rules in these operating instructions performing all stipulated inspection and...

Page 40: ...remains disconnected from the mains until all work has been completed General informa tion The wire feed unit is connected to the power source using the interconnecting hosepack Connecting the interco...

Page 41: ...njury 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 i...

Page 42: ...is first delivered In order to achieve optimum wire electrode feed the feed rollers must be suitable for the diameter and alloy of the wire being welded NOTE Risk from inadequate feed rollers This ca...

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 3 4 43 EN...

Page 44: ...n completed CAUTION Danger from elasticity of the spooled wire electrode This can result in severe injuries When inserting the wirespool basket type spool hold the end of the wire electrode firmly to...

Page 45: ...g a bas ket type spool D300 device CAUTION 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 spoo...

Page 46: ...control panels section OPT i WF gas test wire thread ing sub section Preparations CAUTION Risk of injury and material damage from the welding current and accidental igni tion of an arc Before startin...

Page 47: ...roperty Hold the welding torch with the end directed away from the face and body Wear suitable protective goggles Do not point the welding torch at people Make sure that the wire electrode does not to...

Page 48: ...om wire electrode emerging While working hold the welding torch with the point directed away from the face and body wear suitable protective goggles do not point the welding torch at people make sure...

Page 49: ...2 4 STOP OK 3 1 3 Setting the brake D300 device 1 4 5 STOP 6 7 3 1 2 1 2 1 2 2 4 STOP OK 3 1 3 49 EN...

Page 50: ...The brake is only available as a complete unit This illustration is for information purposes only Brake setup D300 device WARNING Fitting the equipment incorrectly can cause serious injury and damage...

Page 51: ...eed unit the following requirements must be met Wire feed unit connected to the power source using the interconnecting hosepack Welding torch connected to wire feed unit Feed rollers inserted in the w...

Page 52: ...52...

Page 53: ...Troubleshooting maintenance and disposal 53...

Page 54: ...54...

Page 55: ...ns disconnected from the mains until all work has been completed After opening the device use a suitable measuring instrument to check that electric ally charged components e g capacitors have been di...

Page 56: ...for welding torches with an external control plug The control plug is not plugged in Plug in the control plug Welding torch or welding torch control line is faulty Replace welding torch Cause Remedy...

Page 57: ...er liner for kinks dirt etc and replace if necessary The feed rollers are not suitable for the wire electrode being used Use suitable feed rollers Feed rollers have the wrong contact pressure Optimise...

Page 58: ...h is leaking Change the welding torch Wrong contact tip or contact tip is worn out Replace the contact tip Wrong wire alloy or wrong wire diameter Check the wire electrode that has been inserted Wrong...

Page 59: ...ower 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 After opening t...

Page 60: ...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 Dispo...

Page 61: ...Technical data 61...

Page 62: ...62...

Page 63: ...06 in Wirespool diameter max 200 mm max 7 87 in Wirespool weight max 5 kg max 11 02 Ib Degree of protection IP 23 Mark of conformity S CE Dimensions l x w x h 507 x 200 x 320 mm 19 96 x 7 87 x 12 6 i...

Page 64: ...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 Weight 14 8 kg 32 63 Ib D C Duty cycle HP 70i Case Welding current at 10 min 40 C 104 F 40 D C 60 D C 100 D...

Page 65: ...65 EN...

Page 66: ...66...

Page 67: ...67 EN...

Page 68: ...INTERNATIONAL GMBH Froniusstra e 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 lo...

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