FRO­NIUS WF 25i FlexDrive User manual

Operating
Instructions
WF 25i FlexDrive
WF 25i FlexDrive JM
42,0426,0397,EA 002-27092022
EN-US Operating instructions

Table of contents
Safety Instructions 5
General 5
Intended Use 5
Environmental Conditions 6
Obligations of the Operating Company 6
Obligations of Personnel 6
Grid Connection 6
Personal Protection and Protection of Others 6
Danger from toxic gases and vapors 7
Danger from Flying Sparks 8
Risks from grid current and welding current 8
Stray welding currents 9
EMC Device Classifications 9
EMC measures 10
EMF measures 10
Particular hazard areas 10
Requirement for the shielding gas 12
Danger from Shielding Gas Cylinders 12
Danger Posed by Shielding Gas Leak 12
Safety Measures at the Setup Location and During Transport 13
Safety Measures in Normal Operation 13
Maintenance and repair 14
Safety Inspection 14
Disposal 14
Safety symbols 15
Data backup 15
Copyright 15
General 16
Device concept 16
Intended use 16
Warning notices on the device 17
System overview 18
Options 19
Selection of cooling units 19
Operating controls, connections and mechanical components 21
Safety 21
Operating controls, connections, and mechanical components 21
Function of the gas-test, wire-return, and wire-threading buttons 23
Function of the LED inside the feed roller 24
Before installation and initial operation 25
Safety 25
Setup regulations 25
Installing Optional Equipment 26
Mounting the protective cage 26
Mounting the runners 28
Installing the inner liner in the extension hosepack 29
Installing the inner liner in the extension hosepack 29
Connecting the extension hosepack 31
Safety 31
Connecting the extension hosepack 31
Connecting the welding torch 32
Safety 32
Connecting the welding torch 32
Inserting / changing the feed rollers and wirefeeder 33
Safety 33
General 33
Inserting/changing feed rollers 33
Inserting / changing the wirefeeder 35
Threading the Wire Electrode 38
General 38
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EN-US

Threading the wire electrode 38
Setting the contact pressure 40
Commissioning 41
Safety 41
Requirements 41
Filling water-cooled welding systems with coolant 41
Conducting system calibration and R/L comparison 42
Commissioning 42
Troubleshooting 43
Safety 43
Troubleshooting 43
Service, maintenance and disposal 47
General 47
Safety 47
At every start-up 47
Every 6 months 47
Disposal 48
Technical data 49
WF 25i FlexDrive 49
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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
of the device must
-Be suitably qualified
-Have knowledge of welding
-Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being
used. In addition to the Operating Instructions, all applicable local rules and reg-
ulations regarding accident prevention and environmental protection must also
be followed.
All safety and danger notices on the device must
-Be kept in a legible state
-Not be damaged/marked
-Not be removed
-Not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating
plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be
"not in accordance with the intended purpose." The manufacturer is not respons-
ible for any damage resulting from improper use.
Proper use also means
-Completely reading and obeying all instructions in the Operating Instruc-
tions
-Completely reading and obeying all safety instructions and danger notices
-Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
-Thawing pipes
-Charging batteries
-Starting motors
The device is designed for operation in industry and business. The manufacture
shall not be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
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EN-US

Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as
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:
-Up to 50% at 40°C (104°F)
-Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
Obligations of
the Operating
Company
The operating company must only allow persons to work with the device if they
-Are familiar with the basic occupational safety and accident prevention regu-
lations and are trained in handling the device
-Have read and understood these Operating Instructions, especially the sec-
tion "Safety Rules," and have confirmed this with their signature
-Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following be-
fore beginning the work:
-Follow the basic regulations for occupational safety and accident prevention
-Read these Operating Instructions, especially the section "Safety Rules," and
confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage
can occur in one's absence.
Grid Connection Devices with a high output can influence the energy quality of the grid due to
their current consumption.
This may affect a number of device types in terms of:
-connection restrictions
-criteria regarding maximum permissible grid impedance *)
-criteria regarding the minimum required short-circuit power *)
*) both at the interface with the public grid
See technical data
In this case, the operator or the person using the device should check whether or
not the device is allowed to be connected, where appropriate through discussion
with the power supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Personal Protec-
tion and Protec-
tion of Others
You are exposed to numerous hazards while handling the device, for example:
-Flying sparks and pieces of hot metal
-Arc radiation that poses a risk of injury to the eyes and skin
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-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
-Covering the entire body and in good condition with no damage
-Safety helmet
-Cuffless pants
Protective clothing involves the following:
-Protecting the face and eyes from UV radiation, heat and flying sparks with a
face guard featuring a regulation-compliant filter
-Wearing regulation-compliant protective goggles with side protection behind
the face guard
-Wearing rigid, wet-insulating footwear
-Protecting hands with appropriate gloves (featuring electrical insulation and
thermal protection)
-Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and
during the welding process. If persons are in the vicinity, however:
-Instruct them about all hazards (blinding hazard due to arcs, risk of injury
from flying sparks, welding fumes hazardous to health, noise exposure, pos-
sible hazard due to grid current or welding current, etc.)
-Provide suitable protective equipment or
-Construct suitable protective walls and curtains.
Danger from tox-
ic gases and va-
pors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph
118 from the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
-Do not breathe them in.
-Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventila-
tion flow rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, com-
pare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding
fumes are:
-The metals used for the workpiece
-Electrodes
-Coatings
-Cleaning agents, degreasers, and the like
-The welding process used
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EN-US

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.
When no welding is taking place, close the valve of the shielding gas cylinder or
the main gas supply.
Danger from Fly-
ing Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the
arc or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through
small cracks and openings. Take appropriate measures to ensure that there is no
risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed
tanks, drums, or pipes if these have not been prepared in accordance with cor-
responding national and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and
the like are/were stored. Residues pose a risk of explosion.
Risks from grid
current and
welding current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the
feed rollers, as well as all pieces of metal that are in contact with the welding
wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable in-
sulating wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with
sufficient insulation against the ground potential. The temporary backing or cov-
er must completely cover the entire area between the body and the ground po-
tential.
All cables and leads must be secured, undamaged, insulated, and adequately di-
mensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at
least 180° around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
-Never immerse it in liquids to cool it
-Never touch it when the power source is switched on.
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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.
Protection class I devices require a grid with a ground conductor and a connector
system with ground conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket
without a ground conductor contact is only permitted if all national regulations
for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no li-
ability for any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if
necessary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched
on again by applying a clearly legible and understandable warning sign.
After opening the device:
-Discharge all electrically charged components
-Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will
switch off the main switch at the correct time.
Stray welding
currents
If the following instructions are not observed, stray welding currents may occur,
which pose a risk of the following:
-Fire
-Overheating of parts connected to the workpiece
-Irreparable damage to ground conductors
-Damage to the device and other electrical equipment
Ensure that the workpiece clamp is securely connected to the workpiece.
Secure the workpiece clamp as close to the spot to be welded as possible.
Position the device with sufficient insulation against electrically conductive envir-
onments, e.g., insulation against electrically conductive floors or electrically con-
ductive mounts.
Observe the following when using power distribution boards, twin-head mounts,
etc.: Even the electrode of the welding torch/electrode holder not in use carries
electric potential. Ensure that there is sufficient insulation when the unused
welding torch/electrode holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the
welding wire drum, large spool, or wirespool to the wirefeeder with insulation.
EMC Device
Classifications
Devices in emission class A:
-Are only designed for use in industrial settings
-Can cause line-bound and radiated interference in other areas
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EN-US

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
there is sensitive equipment at the same location, or if the site where the device
is installed is close to either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate ac-
tion to rectify the situation.
Test and assess the immunity of equipment in the vicinity of the device in ac-
cordance with national and international provisions. Examples of interference-
prone equipment that could be affected by the device:
-Safety devices
-Grid power lines, signal lines, and data transfer lines
-IT and telecommunications equipment
-Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
1.Grid power supply
-If electromagnetic interference occurs despite a grid connection that
complies with regulations, take additional measures (e.g., use a suitable
grid filter).
2.Welding power-leads
-Keep them as short as possible
-Route them close together (also to avoid EMF problems)
-Route them far from other lines
3.Equipotential bonding
4.Workpiece grounding
-If necessary, establish grounding using suitable capacitors.
5.Shield, if necessary
-Shield other devices in the vicinity
-Shield the entire welding installation
EMF measures Electromagnetic fields may cause health problems that are not yet known:
-Effects on the health of persons close by, e.g., those with pacemakers and
hearing aids
-Persons with pacemakers must seek advice from their doctor before staying
in the immediate vicinity of the device and the welding process
-Keep distances between welding power-leads and the head/torso of the
welder as great as possible for safety reasons
-Do not carry welding power-leads and hosepacks over your shoulder or wrap
them around your body or body parts
Particular haz-
ard areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
-Fans
-Gears
-Rollers
-Shafts
-Wirespools and welding wires
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