Operating
Instructions
CWF 25i
EN-US
Operating instructions
42,0426,0392,EA 002-27092022
Table of contents
Safety Instructions 5
Explanation of Safety Instructions 5
General 5
Intended Use 6
Environmental Conditions 6
Obligations of the Operating Company 6
Obligations of Personnel 6
Grid Connection 7
Personal Protection and Protection of Others 7
Data on noise emission values 7
Danger from toxic gases and vapors 8
Danger from Flying Sparks 8
Risks from grid current and welding current 9
Stray welding currents 10
EMC Device Classifications 10
EMC measures 10
EMF measures 11
Particular hazard areas 11
Requirement for the shielding gas 12
Danger from Shielding Gas Cylinders 12
Danger Posed by Shielding Gas Leak 13
Safety Measures at the Setup Location and During Transport 13
Safety Measures in Normal Operation 14
Maintenance and repair 14
Safety Inspection 15
Disposal 15
Safety symbols 15
Data backup 15
Copyright 15
General 17
Device concept 17
Field of application 17
Warning notices on the device 17
Operating controls, connections and mechanical components 19
Safety 19
Front, back 19
Left side, bottom 20
Before installation and initial operation 23
Safety 23
Intended use 23
Setup regulations 23
Placing the wirefeeder on the swivel pin holder 24
Safety 24
Placing the wirefeeder on the swivel pin holder 24
Connecting the wirefeeder to the power source 25
Safety 25
General 25
Connecting the wirefeeder to the power source 25
Connecting the wirefeeding hose/welding torch 28
Safety 28
Connecting the wirefeeding hose 28
Connecting the welding torch 28
Inserting/changing feed rollers 30
Safety 30
General 30
Inserting/changing feed rollers 30
Inserting the wirespool/basket-type spool 32
Safety 32
Inserting the wirespool 32
Installing the basket-type spool 33
EN-US
3
Threading in the welding wire 35
Threading in the welding wire 35
Setting the contact pressure 36
Adjusting the brake 37
General 37
Adjusting the brake 37
Design of the brake 38
Commissioning 39
Safety 39
Requirements 39
Commissioning 39
Troubleshooting 40
Safety 40
Troubleshooting 40
Service, maintenance and disposal 43
General 43
Safety 43
At every start-up 43
Every 6 months 43
Disposal 44
Technical data 45
CWF 25i 45
Water-cooled interconnecting hosepack - HP 70i CWF CON /W 46
Disposal 46
4
Safety Instructions
EN-US
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
▶
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are
▶
not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
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 regulations 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 section 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!
5
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 responsible 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.
Environmental
Conditions
Obligations of
the Operating
Company
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 liability 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.)
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
6
All persons who are assigned to work with the device must do the following before 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!
EN-US
Personal Protection and Protection 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
-
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
-
Data on noise
emission values
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, possible hazard due to grid current or welding current, etc.)
Provide suitable protective equipment or
-
Construct suitable protective walls and curtains.
-
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation in relation to the maximum permitted operating point at standard loading in accordance with EN 60974-1.
7
A workplace-specific emission value for welding (and cutting) cannot be specified because this value depends on the welding process and the environmental
conditions. It is influenced by a wide range of parameters, such as the welding
process itself (MIG/MAG, TIG welding), the selected current type (direct current, alternating current), the power range, the type of weld metal, the resonance
properties of the workpiece, the workplace environment, and many other factors.
Danger from toxic gases and vapors
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 ventilation 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, compare 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
-
Danger from Flying Sparks
Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.
Recommendations for exposure scenarios, risk management measures and
identifying working conditions can be found on the European Welding Association 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.
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.
8
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 corresponding 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.
EN-US
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 insulating wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with
sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. 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.
-
The open circuit voltage of a welding system may double, for example, between
the electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure 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 liability 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.
9
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
EMC Device
Classifications
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 environments, e.g., insulation against electrically conductive floors or electrically conductive 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.
Devices in emission class A:
Are only designed for use in industrial settings
-
Can cause line-bound and radiated interference in other areas
-
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 lowvoltage 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 action to rectify the situation.
Test and assess the immunity of equipment in the vicinity of the device in accordance with national and international provisions. Examples of interferenceprone 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
-
10
Supporting measures to avoid EMC problems:
Grid power supply
1.
If electromagnetic interference occurs despite a grid connection that
-
complies with regulations, take additional measures (e.g., use a suitable
grid filter).
Welding power-leads
2.
Keep them as short as possible
-
Route them close together (also to avoid EMF problems)
-
Route them far from other lines
-
Equipotential bonding
3.
Workpiece grounding
4.
If necessary, establish grounding using suitable capacitors.
-
Shield, if necessary
5.
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
EN-US
Particular hazard areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
Fans
-
Gears
-
Rollers
-
Shafts
-
Wirespools and welding wires
-
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side panels must only be opened/removed during maintenance and
repair work.
During operation
Ensure that all covers are closed, and all side parts have been mounted prop-
-
erly.
Keep all covers and side parts closed.
-
The protrusion of welding wire from the welding torch represents a high risk of
injury (cuts to the hand, facial and eye injuries, etc.).
Therefore, always hold the welding torch away from the body (devices with
wirefeeder) and use suitable protective goggles.
Do not touch the workpiece during or after welding – risk of burns.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant
protective equipment when reworking workpieces and ensure that other persons
are sufficiently protected.
Leave the welding torch and other parts with a high operating temperature to
cool before working on them.
11
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g., boilers)
must be labeled with the symbol (Safety). However, the power source may not be
located in such areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data
sheet. The coolant safety data sheet can be obtained from your service center or
via the manufacturer's website.
Only use suitable load-carrying equipment from the manufacturer to transport
devices by crane.
Attach chains or ropes to all designated attachments of the suitable load-
-
carrying equipment.
Chains or ropes must be the smallest angle possible from vertical.
-
Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
-
In the event of crane attachment of the wirefeeder during welding, always use a
suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand. The carrier belt is not suitable for transport by crane,
counterbalanced lift truck, or other mechanical lifting tools.
Requirement for
the shielding gas
Danger from
Shielding Gas
Cylinders
All lifting equipment (belts, buckles, chains, etc.), which is used in association
with the device or its components, must be checked regularly (e.g., for mechanical damage, corrosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an
adapter is used for the shielding gas connection. Use suitable Teflon tape to seal
the thread of the shielding gas connection adapter on the device side before installation.
Especially with ring lines, contaminated shielding gas can cause damage to
equipment and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
Solid particle size < 40 µm
-
Pressure condensation point < -20 °C
-
Max. oil content < 25 mg/m³
-
Use filters if necessary.
Shielding gas cylinders contain compressed gas and may explode if damaged.
Shielding gas cylinders are an integral part of the welding equipment, so they
must be handled very carefully.
12
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with
instructions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the
correct matching accessories (controller, hoses, and fittings, etc.) Only use
shielding gas cylinders and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not
connected.
Follow the manufacturer's instructions and applicable national and international
provisions for shielding gas cylinders and accessories.
EN-US
Danger Posed by
Shielding Gas
Leak
Safety Measures
at the Setup
Location and
During Transport
Risk of asphyxiation due to uncontrolled shielding gas leak
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.
Ensure there is a sufficient supply of fresh air with a ventilation flow rate of
-
at least 20 m³ per hour.
Please observe the safety and maintenance information for the shielding gas
-
cylinder or the main gas supply.
When no welding is taking place, close the valve of the shielding gas cylinder
-
or the main gas supply.
Always check the shielding gas cylinder or main gas supply for uncontrolled
-
gas leakage before each start-up.
A toppling device can be deadly! Set up the device securely on an even, solid surface
The maximum permitted tilt angle is 10°.
-
Special regulations apply in areas at risk of fire or explosion
Follow the appropriate national and international regulations.
-
Use instructions and checks within the company to ensure that the vicinity of the
workplace is always clean and organized.
Only set up and operate the device in accordance with the protection class
shown on the rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m
(1 ft. 7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or
lifting.
Before transporting the device, completely drain the coolant and dismantle the
following components:
wirefeeder
-
wirespool
-
shielding gas cylinder
-
13
It is essential to conduct a visual inspection of the device to check for damage
after it has been transported but before commissioning. Have any damage repaired by trained service technicians before commissioning the device.
Safety Measures
in Normal Operation
Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a danger of:
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 device
-
Safety devices that are not fully functional must be repaired before the device is
switched on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by
crane.
Only the original coolant from the manufacturer is suitable for use in our devices
due to its properties (electrical conductivity, anti-freeze, material compatibility,
flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Maintenance and
repair
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the
manufacturer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flam-
mable in certain conditions. Only transport the coolant in closed original containers and keep away from sources of ignition.
Properly dispose of used coolant according to national and international regulations. The coolant safety data sheet can be obtained from your service center or
via the manufacturer’s website.
When the system is cool, always check the coolant level before starting welding.
It is impossible 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 standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the spare parts list, as well as the serial number of your device.
14
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.
EN-US
Safety Inspection
Disposal To comply with European directives and national law, waste electrical and elec-
The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.
The manufacturer recommends calibrating power sources within the same 12month interval.
A safety inspection by a certified electrician is recommended:
After changes
-
After alterations
-
After repair, care, and maintenance
-
At least every 12 months
-
For the safety inspection, follow the appropriate national and international
standards and guidelines.
You can obtain more information about the safety inspection and calibration
from your service center. The service center will provide the necessary documents upon request.
tronic equipment must be collected separately and sent for environmentallyfriendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.
Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.
Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (e.g., relevant product standards of
the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on the
following website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves the
right to make changes. The contents of the Operating Instructions shall not
provide the basis for any claims whatsoever on the part of the purchaser. If you
15
have any suggestions for improvement, or can point out any mistakes that you
have found in the Operating Instructions, we will be most grateful for your comments.
16
General
40,0006,3035
Caution: Parts may be at welding
voltage
Attention: Les pièces peuvent être
à la tension de soudage
0.1-25 m/min
40-984 ipm
360A/100% 450A/60% 500A/40%I2
1.2 A
I11
U11
60 V
U12 I12 0.5 A24 V
IEC 60 974-5/-10 Cl.A IP 23
www.fronius.com
Ser.No.:
Part No.:
Device concept The CWF 25i wirefeeder is designed
for use with wirespools with a maximum diameter of 300 mm (11.81 inch).
The standard 4-roller drive offers good
wirefeeding characteristics. The
wirefeeder is also suitable for long
hosepacks.
Due to its compact design, the
wirefeeder is a versatile product.
EN-US
Field of application
Warning notices
on the device
The CWF 25i wirefeeder can be used for all TIG welding operations in combination with the iWave 300i - 500i power sources. The wirefeeder is suitable for all
commercially available shielding gases.
The wirefeeder has safety symbols and a rating plate fitted. These safety symbols
and the rating plate must not be removed or painted over. The safety symbols
warn against operating the equipment incorrectly, as this may result in serious injury and damage to property.
Do not use the functions described here until you have fully read and understood
the following documents:
17
These Operating Instructions
-
All system component Operating Instructions, especially the safety rules
-
Welding is dangerous. To ensure that this device can be used correctly and safely,
the following basic requirements must be met:
Adequate welding qualifications
-
Appropriate protective equipment
-
Keep unauthorized people away from the wirefeeder and the welding process
-
Dispose of old devices in accordance with safety rules and not in normal domestic waste.
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
Gears
-
Feed rollers
-
Wirespools and welding wires
-
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side panels must only be opened/removed during maintenance and
repair work.
During operation
Ensure that all covers are closed, and all side parts have been mounted prop-
-
erly.
Keep all covers and side parts closed.
-
18
Operating controls, connections and mechanical
(1)
(2)
(3)
(4) (5)
(6)
(7)
(10)
(8)
(9)
(11)
components
Safety
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶
▶
▶
Front, back
EN-US
WARNING!
All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
(1) Coolant return connection (red)
Option *
(2) Coolant supply connection (blue)
Option *
(3) Wirefeed connection
FSC-T connection
(4) TMC connection
Option *
Standardized connection socket for system add-ons (e.g., remote control,
JobMaster welding torch, etc.)
19
(5) Welding torch connection / gas/current socket with bayonet latch
(1)
(2)
(3) (4) (5)
(6)
(7)
(8)
(9)
Option *
In combination with an iWave 300i - 500i AC/DC power source to connect:
a TIG welding torch
-
the electrode cable for manual metal arc welding
-
In combination with an iWave 300i - 500i DC power source to connect:
a TIG welding torch
-
the electrode cable or grounding cable for manual metal arc welding
-
(depending on the type of electrode used)
(6) SpeedNet connection
For connecting the SpeedNet cable from the interconnecting hosepack
(7) Position for options
For example, wire end sensor
(8) Gas/current socket with bayonet latch
For connecting the gas/power cable from the interconnecting hosepack
(9) Shielding gas connection socket
For connecting the shielding gas hose from the interconnecting hosepack
Left side, bottom
(10) Coolant return connection (red)
Option *
For connecting the coolant return hose from the interconnecting hosepack
(11) Coolant supply connection (blue)
Option *
For connecting the coolant supply hose from the interconnecting hosepack
* The optional connections are present if the "OPT/i CWF TMC Torch" op-
tion is installed on the wirefeeder.
20
CWF 25i – left side
(1) Wirespool cover
(2) Wire drive cover
(3) 4-roller drive
with red protective cover
(4) Pressure lever
For adjusting the contact pressure
(5) Clamping lever
(6) Gas-test button
For setting the required quantity of gas on the gas pressure regulator.
After pressing the gas-test button, gas is released for 30 s. Pressing the
button again ends the process early.
(7) Wire-return button
For retracting the welding wire without gas or current
There are two options available for retracting the welding wire:
Option 1
Retract the welding wire at the preset wire-return speed:
Press and hold the wire-return button
After pressing the wire-return button, the welding wire is retracted by
-
1 mm (0.039 in.)
After a brief pause, the wirefeeder continues retracting the welding
-
wire – if the wire-return button is kept pressed down, then the speed
increases with each further second by 10 m/min (393.70 ipm) until
the preset wire-return speed is reached
EN-US
Option 2
Retract the welding wire in 1 mm steps (0.039 in. steps) – always press the
wire-return button for less than 1 second (tap)
(8) Wire-threading button
For threading the welding wire into the torch hosepack without gas or current
There are two options available for the wire threading:
Option 1
Thread the welding wire at the preset feeder inching speed:
Press and hold the wire-threading button
-
After pressing the wire-threading button, the welding wire will be
-
threaded in by 1 mm (0.039 in.)
After a brief pause, the wirefeeder continues threading in the welding
-
wire – if the wire-threading button is kept pressed down, then the
speed increases with each further second by 10 m/min (393.70 ipm)
until the preset feeder inching speed is reached
21
Option 2
(10)
Thread the welding wire in 1 mm steps (0.039 in. steps) – always press the
wire-threading button for less than 1 second (tap)
(9) Operating status LED
Lights up green when the device is ready for operation
(10) Swivel pin holder
22
Before installation and initial operation
EN-US
Safety
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶
▶
▶
Intended use The device is intended exclusively for wirefeeding with TIG welding in combina-
tion with Fronius system components.
Any other use does not constitute proper use.
The manufacturer shall not be held liable for any damage resulting from improper use.
Intended use also means
-
-
-
WARNING!
All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Reading these Operating Instructions in their entirety
Following all instructions and safety rules in these Operating Instructions
Carrying out all the specified inspection and maintenance work
Setup regulations
WARNING!
Danger from devices falling or toppling over.
This can result in severe personal injury and damage to property.
Set up all system components, upright brackets, and trolleys so that they are
▶
stable on a flat and solid surface.
When using a swivel pin holder, always ensure that the wirefeeder is firmly
▶
seated.
The wirefeeder has been tested according to protection class IP 23. This means:
Protection against the penetration of solid foreign bodies with a diameter of
-
more than 12.5 mm (0.49 in.)
Protection against spraywater at any angle up to 60° from the vertical
-
The wirefeeder can be set up and operated outdoors in accordance with protection class IP23. Direct moisture (e.g., from rain) must be avoided.
23
Placing the wirefeeder on the swivel pin holder
1
Safety
Placing the
wirefeeder on
the swivel pin
holder
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting 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 suitable measuring instrument to check that
▶
electrically charged components (such as capacitors) have been discharged.
1
24
Connecting the wirefeeder to the power source
EN-US
Safety
Danger from electrical current.
This can result in serious personal injury and damage to property.
▶
▶
▶
General The wirefeeder is connected to the power source by means of the interconnect-
ing hosepack.
Connecting the
wirefeeder to the
power source
Danger from electric current due to defective system components and incorrect operation.
This can result in serious personal injury and damage to property.
▶
▶
WARNING!
Before starting 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 suitable measuring instrument to check that
electrically charged components (such as capacitors) have been discharged.
WARNING!
All cables, leads, and hosepacks must always be securely connected, undamaged, and correctly insulated.
Only use adequately dimensioned cables, leads, and hosepacks.
Connecting the control line
1
25
2
3
4
26
Connecting the interconnecting hosepack
1
2
3
*
(only if OPT/i CWF TMC Torch option is present)
1
* External gas supply (option)
2
EN-US
CAUTION!
Risk due to damage to connections.
This can result in damage to property.
For interconnecting hosepacks with a length of 1.2 m (3 ft. 11.24 in.), no
▶
strain-relief device is provided.
To avoid damage, make sure that the cables form a "loop inwards" (towards
▶
the wirefeeder) when installed.
27
Connecting the wirefeeding hose/welding torch
Safety
Connecting the
wirefeeding hose
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting 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 suitable measuring instrument to check that
▶
electrically charged components (such as capacitors) have been discharged.
1
Connecting the
welding torch
If the OPT/i WF TMC option is present on the wirefeeder, the welding torch can
be connected directly to the wirefeeder.
If the option is not present, the welding torch is connected 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 to property.
All cables, leads, and hosepacks must always be securely connected, undam-
▶
aged, and correctly insulated.
Only use adequately dimensioned cables, leads, and hosepacks.
▶
NOTE!
A damaged O-ring on the welding torch can lead to contamination of the shielding gas, resulting in a defective weld.
Before each start-up, ensure that the O-ring on the welding torch is undam-
▶
aged.
28
Fit parts to the welding torch according to the Operating Instructions for the
3
2
4
5
6
1
welding torch
2
EN-US
29
Inserting/changing feed rollers
2
1
4
4
5
6
3
6
3
31
2
4
5
7
Safety
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting 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 suitable measuring instrument to check that
▶
electrically charged components (such as capacitors) have been discharged.
General The feed rollers are not inserted in the system when first delivered.
In order to achieve optimum welding wire feed, the feed rollers must be suitable
for the diameter and alloy of the wire being welded.
NOTE!
Incorrectly designed feed rollers can cause poor weld properties.
Only use feed rollers appropriate for the welding wire.
▶
Inserting/changing feed rollers
An overview of the available feed rollers and their possible uses can be found in
the Spare Parts Lists.
CAUTION!
Danger due to feed roller holders shooting upwards.
This could result in injury.
When unlocking the clamping lever, keep fingers away from the area to the
▶
left and right of the clamping lever.
1
2
30
CAUTION!
3
8
6
7
9
3
1
2
2
5
4
4
4
5
5
6
1
2
3
Danger due to open feed rollers.
This could result in injury.
After inserting/changing the feed rollers, always install the protective cover
▶
of the 4-roller drive.
3
4
EN-US
31
Inserting the wirespool/basket-type spool
Safety
WARNING!
Danger from electrical current.
This may result in serious injuries or death.
Before starting work, switch off all the devices and components involved and
▶
disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back
▶
on.
CAUTION!
Danger from springiness of the coiled welding wire.
This could result in injury.
Wear safety goggles.
▶
When inserting the wirespool/basket-type spool, hold the end of the welding
▶
wire firmly to avoid injuries caused by the welding wire springing back.
CAUTION!
Danger from falling wirespool/basket-type spool.
Personal injury and damage to property may result.
Ensure that the wirespool/basket-type spool including basket-type spool ad-
▶
apter is always firmly seated on the wirespool holder.
Always secure the wirespool/basket-type spool including basket-type spool
▶
adapter with the supplied securing elements.
Inserting the
wirespool
1
WARNING!
Danger due to falling wirespool as a result of the locking ring being fitted the
wrong way round.
This can result in severe personal injury and damage to property.
Always position the locking ring as shown below.
▶
32
3
4
EN-US
Installing the
basket-type
spool
WARNING!
Danger from falling basket-type spool due to missing basket-type spool adapter.
This can result in severe personal injury and damage to property.
When working with basket-type spools, only use the basket-type spool ad-
▶
apter supplied with the device.
WARNING!
Danger from falling basket-type spool.
This can result in severe personal injury and damage to property.
Place the basket-type spool on the adapter provided in such a way that the
▶
bars on the spool are inside the adapter guideways.
1 2
33
WARNING!
Danger due to falling basket-type spool as a result of the locking ring being fitted the wrong way round.
This can result in severe personal injury and damage to property.
Always position the locking ring as shown below.
▶
34
Threading in the welding wire
EN-US
Threading in the
welding wire
CAUTION!
Danger due to sharp end of the welding wire.
Personal injury and damage to property may result.
Deburr the end of the welding wire before insertion.
▶
CAUTION!
Danger from springiness of the coiled welding wire.
Personal injury and damage to property may result.
Wear safety goggles.
▶
When inserting the welding wire into the 4-roller drive, hold the end of the
▶
welding wire firmly to avoid injuries caused by the welding wire springing
back.
1
NOTE!
The length of the wirefeeding hose must not exceed 4 m / 13 feet 1.48 inches
during active wire movement (Active Wire function).
WARNING!
Danger due to emerging welding wire.
This can result in severe personal injury and damage to property.
Hold the welding torch so that the tip of the welding torch points away from
▶
the face and body.
Wear safety goggles.
▶
Do not point the welding torch at people.
▶
35
5
1
2
1
Threading in the welding wire
3
Setting the contact pressure
NOTE!
Excessive contact pressure can result in damage to property and poor weld
properties.
Set the contact pressure in such a way that the welding wire is not deformed
▶
but nevertheless ensures proper wirefeeding.
1
Contact pressure standard values according to the imprint on the red protective cover
36
Adjusting the brake
1
4
5
STOP
6
7
3
1
2
2
1
2
4
STOP
OK
3
1
EN-US
General
Adjusting the
brake
NOTE!
Overrunning of the brake can result in damage to property.
After releasing the torch trigger/wire-threading button, the wirespool must
▶
stop unreeling.
If it continues unreeling, readjust the brake.
▶
WARNING!
Danger due to emerging welding wire.
This can result in severe personal injury and damage to property.
Hold the welding torch so that the tip of the welding torch points away from
▶
the face and body.
Wear safety goggles.
▶
Do not point the welding torch at people.
▶
1
2
3
37
Design of the
brake
WARNING!
Danger from incorrect installation.
This can result 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, qualified personnel only.
The brake is only available as a complete unit.
The illustration of the brake is for information purposes only.
38
Commissioning
EN-US
Safety
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶
▶
▶
Requirements The following requirements must be fulfilled for commissioning of the wirefeed-
er:
-
-
-
-
-
-
-
-
-
WARNING!
All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Wirefeeder connected to power source by means of interconnecting hosepack
Welding torch connected to wirefeeder
Feed rollers inserted into wirefeeder
Wirespool/basket-type spool and its adapter inserted into wirefeeder
Welding wire threaded in
Contact pressure of the feed rollers set
Red protective cover fitted to the wire drive
Brake adjusted
All covers closed, all side parts mounted, and all protection devices in good
order and installed in the location intended
The power source must be set to TIG cold wire under Welding process / Process.
Commissioning The wirefeeder is started up in manual applications by pressing the torch trigger
and in automated applications by an active signal to start welding.
39
Troubleshooting
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equip-
▶
ment and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting 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 suitable measuring instrument to check that
▶
electrically charged components (such as capacitors) have been discharged.
WARNING!
Danger due to hot system components and/or equipment.
This can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to
▶
cool to +25°C/+77°F (e.g., coolant, water-cooled system components,
wirefeeder drive motor, etc.).
Wear suitable protective equipment (e.g., heat-resistant gloves, safety
▶
goggles, etc.) if cooling down is not possible.
Troubleshooting Make a note of the serial number and configuration of the device, and provide
the service team with a detailed error description if:
Errors occur that are not covered in this document
-
The troubleshooting measures provided in this document are unsuccessful
-
40
Power source not working
Power source switched on; displays and indicators do not illuminate
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
No function after pressing torch trigger
Power source power switch is ON and indicators are lit up
Cause:
Remedy:
Cause:
Remedy:
Mains lead damaged or broken, mains plug not inserted
Check mains lead, if necessary insert mains plug
Mains socket or mains plug faulty
Replace faulty parts
Mains fuse protection
Replace mains fuse
Short circuit on the 24 V power supply of the SpeedNet connection
or external sensor
Disconnect connected components
Only for welding torches with an external control plug: Control plug
not plugged in
Plug in control plug
Welding torch or welding torch control line faulty
Replace welding torch
EN-US
No welding current
Power source switched on, displays illuminate
Cause:
Remedy:
Cause:
Remedy:
no shielding gas
all other functions present
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Incorrect ground connection
Check ground connection for polarity
Power cable in welding torch damaged or broken.
Replace welding torch
Gas cylinder empty
Change gas cylinder
Gas pressure regulator faulty
Replace gas pressure reducer
Gas hose not attached, or damaged
Attach or replace gas hose
Welding torch faulty
Change welding torch
Cause:
Remedy:
Gas solenoid valve faulty
Inform the service team
41
Irregular wire speed
Cause:
Remedy:
Braking force has been set too high
Loosen the brake
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Wirefeed issues
For applications with long hosepacks
Cause:
Remedy:
Welding torch gets very hot
Cause:
Remedy:
Cause:
Remedy:
Inner liner in the welding torch faulty
Check the inner liner for kinks, dirt, etc. and replace if necessary
Feed rollers not suitable for welding wire used
Use suitable feed rollers
Feed rollers have the wrong contact pressure
Optimize contact pressure
Improper laying of the hosepack
Lay hosepack as straight as possible while avoiding tight bending radii
Welding torch is inadequately sized
Observe duty cycle and load limits
For water-cooled systems only: Coolant flow too low
Check coolant level, coolant flow rate, coolant contamination, etc.
For more detailed information, refer to the Operating Instructions for
the cooling unit
Poor-quality weld properties
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Incorrect welding parameters
Check settings
Poor ground earth connection
Establish good contact with workpiece
Too little or no shielding gas
Check gas pressure regulator, gas hose, gas solenoid valve, welding
torch gas connection, etc.
Welding torch leaks
Change welding torch
Incorrect wire alloy or incorrect wire diameter
Check inserted welding wire
Incorrect wire alloy or incorrect wire diameter
Check the weldability of the parent material
Shielding gas not suitable for wire alloy
Use correct shielding gas
42
Service, maintenance and disposal
General The device only requires minimal of service and maintenance under normal oper-
ating conditions. However, several points must be observed for the welding system to remain operational for years to come.
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equip-
▶
ment and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting 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 suitable measuring instrument to check that
▶
electrically charged components (such as capacitors) have been discharged.
WARNING!
At every startup
Every 6 months
Danger due to hot system components and/or equipment.
This can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to
▶
cool to +25°C/+77°F (e.g., coolant, water-cooled system components,
wirefeeder drive motor, etc.).
Wear suitable protective equipment (e.g., heat-resistant gloves, safety
▶
goggles, etc.) if cooling down is not possible.
Check all hosepacks and the ground earth connection for damage. Replace
-
any damaged components.
Check feed rollers and inner liners for damage. Replace any damaged com-
-
ponents.
Check contact pressure of the feed rollers and adjust if necessary.
-
CAUTION!
Danger from compressed air at close range.
Electronic parts may be damaged.
Do not bring the air nozzle too close to electronic parts.
▶
43
Open covers, dismantle device side panels, and blow the inside of the device
-
clean with dry, reduced compressed air. After cleaning, restore the system to
its original condition.
Disposal Materials should be disposed of according to valid local and national regulations.
44
Technical data
EN-US
CWF 25i
Supply voltage 24 V DC / 60 V DC
Current consumption 0.5 A / 1.2 A
Wire speed 0.1 - 25 m/min
3.94 - 984.25 ipm
Wire drive 4-roller drive
Wire diameter 0.8 - 1.6 mm
0.03 - 0.06 in.
Wirespool diameter max. 300 mm
max. 11.81 in.
Wirespool weight max. 19 kg
max. 41.89 Ib.
Maximum pressure of shielding gas 7 bar
101.53 psi
Coolant Original Fronius
Maximum pressure of coolant 5 bar
72.53 psi
Protection class IP 23
Mark of conformity S, CE, CSA
Dimensions l × w × h 658 x 282 x 362 mm
25.91 x 11.10 x 14.25 in.
Weight (without options) 12.6 kg
27.78 Ib.
45
Water-cooled interconnecting
hosepack - HP
70i CWF
CON /W
DC welding current at
10 min / 40°C (104°F)
AC welding current at
10 min / 40°C (104°F)
40% ED1) / 400 A
60% ED1) / 365 A
100% ED1) / 320 A
40% ED1) / 400 A
60% ED1) / 365 A
100% ED1) / 320 A
Shielding gas
Argon
(Standard EN 439)
Length 2.0 / 5.0 / 10.0 m
6 feet 6.74 inch / 16 feet 4.85 inch /
32 feet 9.70 inch
Minimum coolant flow Q
min
1 l/min
0.26 gal. (US) / min
Minimum coolant pressure p
min
3 bar
43 psi
Maximum coolant pressure p
max
5.5 bar
79 psi
Maximum permitted open circuit
113 V
voltage (U0)
Maximum permitted striking voltage
10 kV
(UP)
1)
ED = Duty cycle
Disposal Materials should be disposed of according to valid local and national regulations.
46
EN-US
47
Fronius International GmbH
Froniusstraße 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.fronius.com
SPAREPARTS
ONLINE
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