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
4

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