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Wire-feed unit
side

(1)
(2)

(3) (4) (5) (6) (7) (8)(9)

(12)

(11)

(13)

(10)

(1)

SpeedNet connection

for connecting the SpeedNet cable from the interconnecting hosepack

(2)

(+) - current socket with fine-pitch thread

for connecting the power cable from the interconnecting hosepack

(3)

Coolant return connection (red) - option

for connecting the coolant hose from the interconnecting hosepack

(4)

Shielding 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 component

(8)

Blanking cover

for optional component

(9)

Blanking cover

for optional component

(10)

Wirespool holder with brake

for holding standard wirespools with a max. diameter of 200 mm (7.87 in.) and
max. weight of 5 kg (11.02 lb.)

(11)

4-roller drive

(12)

Protective cover for the 4-roller drive

(13)

Clamping lever

for setting the contact pressure of the feed rollers

Содержание WF 25i Case D200

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

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: ...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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 16: ...16...

Страница 17: ...General 17...

Страница 18: ...18...

Страница 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...

Страница 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...

Страница 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...

Страница 22: ...22...

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

Страница 24: ...24...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 37: ...Installation and commissioning 37...

Страница 38: ...38...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 52: ...52...

Страница 53: ...Troubleshooting maintenance and disposal 53...

Страница 54: ...54...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 61: ...Technical data 61...

Страница 62: ...62...

Страница 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...

Страница 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...

Страница 65: ...65 EN...

Страница 66: ...66...

Страница 67: ...67 EN...

Страница 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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