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Contents

Safety rules

Explanation of safety notices

General

Proper use

Environmental conditions

Obligations of the operator

Obligations of personnel

Mains connection

Protecting yourself and others

Danger from toxic gases and vapours

Danger from flying sparks

Risks from mains current and welding current

Meandering welding currents

EMC Device Classifications

EMC measures

EMF measures

Specific hazards

Requirement for the shielding gas

Danger from shielding gas cylinders

Danger from escaping shielding gas

Safety measures at the installation location and during transport

Safety measures in normal operation

Commissioning, maintenance and repair

Warning notices on the device

Controls, connections and mechanical components

Controls, connections and mechanical components

Safety

Front of wire-feed unit

Rear of wire-feed unit

Wire-feed unit side

Wire-feed unit underside

Optional control panels

Safety

OPT/i WF POT control panel

OPT/i WF gas test & wire threading

OPT/i WF Standard control panel

Installation and commissioning

Before installation and commissioning

Safety

Proper use

Setup regulations

Placing wire-feed unit on swivel pin holder

Safety

Placing wire-feed unit on swivel pin holder

Connecting wire-feed unit to power source

Safety

General information

Содержание WF 15i

Страница 1: ...n elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy WF 15i WF 15i n S WF 25i WF 30i EN Operating instructions 42 0426 0116...

Страница 2: ......

Страница 3: ...13 Commissioning maintenance and repair 14 Safety inspection 14 Disposal 15 Safety symbols 15 Data protection 15 Copyright 15 General 17 General 19 Device concept 19 Warning notices on the device 19...

Страница 4: ...Threading the wire electrode 48 General 48 Preparatory work 48 Threading the wire electrode 49 Setting the contact pressure 49 Adjust the brake 51 General 51 Adjusting the brake 51 Design of the brak...

Страница 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...

Страница 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...

Страница 7: ...o 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 regulation...

Страница 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...

Страница 9: ...e a mains 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 with...

Страница 10: ...ven 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...

Страница 11: ...he body devices with wirefeeder 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 equip...

Страница 12: ...25 mg m Use filters if necessary Danger from shielding gas cyl inders Shielding gas cylinders contain gas under pressure and can explode if damaged As the shielding gas cylinders are part of the weld...

Страница 13: ...there is an all round clearance of 0 5 m 1 ft 7 69 in to ensure that cooling air can flow in and out freely When transporting the device observe the relevant national and local guidelines and ac ciden...

Страница 14: ...to guarantee that bought in parts are designed and manufactured to meet the demands made of them or that they satisfy safety requirements Use only original spare and wearing parts also applies to sta...

Страница 15: ...ronius 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 follow ing address http www froni...

Страница 16: ...16...

Страница 17: ...General 17...

Страница 18: ...18...

Страница 19: ...for long hosepacks Due to their compact size the wire feed units can be used in many different ways Warning notices on the device The wire feed unit is fitted with safety symbols and a rating plate Th...

Страница 20: ...re the equipment is used properly Welders must be sufficiently qualified Suitable protective equipment must be used All persons not involved must be kept at a safe distance from the wire feed unit and...

Страница 21: ...Controls connections and mechan ical components 21...

Страница 22: ...22...

Страница 23: ...d user documentation for this device and all system components Front of wire feed unit 1 4 2 3 No Function 1 Welding torch connection for connecting the welding torch 2 Coolant flow connection blue is...

Страница 24: ...peedNet cable 4 Shielding gas connection No Function 5 Coolant return connection red is fitted as standard on WF 15i WF 15i n S WF 30i as an option for WF 25i for connecting the coolant hose from the...

Страница 25: ...and max weight of 19 kg 41 89 lbs 2 4 roller drive 3 Protective cover for the 4 roller drive 4 Clamping lever for setting the contact pressure of the feed rollers Wire feed unit un derside 1 No Funct...

Страница 26: ...WF POT control panel 2 1 The adjusters perform different func tions depending on the application No Adjuster function during MIG MAG welding the remote control performs different functions depending o...

Страница 27: ...w prematurely No Function 4 Wire retract button to retract the wire electrode with no accompanying flow of gas or current The wire electrode can be retracted using one of two methods Method 1 Retracti...

Страница 28: ...he wire threading button remains pressed the speed will in crease every second at a rate of 10 m min 393 70 ipm until the preset feeder inching speed is reached If the wire electrode comes into contac...

Страница 29: ...OPT i WF Stand ard control panel 1 9 8 5 6 10 11 12 2 3 4 7 14 13 29 EN...

Страница 30: ...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 Pene...

Страница 31: ...tandard value based on the programmed parameters During welding the actual value is displayed Pulse dynamic correction for correcting the pulse energy during pulsed arc welding lower droplet detachmen...

Страница 32: ...ing process button for selecting the welding process PULS SYNERGIC MIG MAG pulse synergic welding SYNERGIC MIG MAG standard synergic welding MANUAL MIG MAG standard manual welding JOB Job Mode STICK M...

Страница 33: ...ntermediate 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...

Страница 34: ...34...

Страница 35: ...Installation and commissioning 35...

Страница 36: ...36...

Страница 37: ...rforming all stipulated inspection and maintenance work Setup regulations WARNING Danger from machines falling or toppling over This can result in severe personal injury and damage to property Place a...

Страница 38: ...ting 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 on After opening the device use a...

Страница 39: ...ack Connecting the wirefeeder to the power source WARNING Danger from electric current due to defective system components and incorrect operation This can result in serious personal injury and damage...

Страница 40: ...operation This can result in serious personal injury and damage to property All cables leads and hosepacks must always be securely connected undamaged and correctly insulated Only use adequately dimen...

Страница 41: ...2 41 EN...

Страница 42: ...evice use a suitable measuring instrument to check that electric ally charged components such as capacitors have been discharged Connecting MIG MAG welding torches 3 7 4 6 2 1 5 8 9 1 CAUTION Danger f...

Страница 43: ...s are not installed in the device when it 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...

Страница 44: ...ON Danger from exposed feed rollers This can result in injuries Always fit the protective cover of the 4 roller drive after inserting or replacing a feed roller 3 8 6 7 9 3 1 2 2 5 4 4 3 4 5 5 6 1 2 3...

Страница 45: ...lectrode This can result in serious personal injuries Wear safety goggles When inserting the wirespool basket type spool hold the end of the wire electrode firmly to avoid injuries caused by the wire...

Страница 46: ...ge to property When working with basket type spools only use the basket type spool adapter in cluded in the scope of supply WARNING Danger from falling basket type spool This can result in severe pers...

Страница 47: ...hr durch herabfallende Korbspule bei seitenverkehrt aufgesetztem Sicherung sring Schwerwiegende Personen und Sachsch den k nnen die Folge sein Den Sicherungsring immer wie nachfolgend dargestellt aufs...

Страница 48: ...ction Preparatory work CAUTION 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...

Страница 49: ...rty 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 touch...

Страница 50: ...1 1 Contact pressure preferred values for U groove rollers Steel 4 5 CrNi 4 5 Tubular cored electrodes 2 3 50...

Страница 51: ...evere 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 This c...

Страница 52: ...esult in severe personal injury and damage to property Do not dismantle the brake Maintenance and servicing of brakes is to be carried out by trained quali fied personnel only The brake is only availa...

Страница 53: ...d unit the following requirements must be met Wire feed unit connected to the power source using the interconnecting hosepack Welding torch connected to the wire feed unit Feed rollers inserted into t...

Страница 54: ...54...

Страница 55: ...Troubleshooting maintenance and disposal 55...

Страница 56: ...56...

Страница 57: ...ll devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally charged components such as capacitors hav...

Страница 58: ...he 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 Cause Remedy No welding current Mains switch is ON a...

Страница 59: ...ise the contact pressure Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Wirefeed problems when using long hosepacks Incorrect arrangement of hosepack Arrange the hosepack in as strai...

Страница 60: ...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...

Страница 61: ...isconnect them from the grid Secure all devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally char...

Страница 62: ...device side panels and clean inside of device with dry re duced compressed air After cleaning restore device to its original state Disposal Dispose of in accordance with the applicable national and l...

Страница 63: ...Technical data 63...

Страница 64: ...64...

Страница 65: ...n 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 658 x 282 x 362 mm 25 91 x 11 10 x 14 25 in...

Страница 66: ...e 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 03 06 in Wirespool d...

Страница 67: ...respool weight max 19 kg max 41 89 Ib Degree of protection IP 23 Mark of conformity S CE Dimensions l x w x h 658 x 282 x 362 mm 25 91 x 11 10 x 14 25 in Weight 13 kg 28 66 Ib D C duty cycle HP 70i We...

Страница 68: ...HP 70i HP PC Cable HD 70 Welding current at 10 min 40 C 104 F 60 ED 600 A 100 ED 500 A ED Duty cycle 68...

Страница 69: ...69 EN...

Страница 70: ...70...

Страница 71: ...71 EN...

Страница 72: ...Froniusstra e 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 spareparts fro...

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