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Fronius prints on 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
Operating Instructions
EN
Wire-feed unit
[
42,0426,0116,EN 034-11022020
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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN
Explanation of
safety notices
DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
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Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 8
Danger from toxic gases and vapours .................................................................................................. 9
Danger from flying sparks ..................................................................................................................... 10
Risks from mains current and welding current...................................................................................... 10
Meandering welding currents................................................................................................................ 11
EMC Device Classifications .................................................................................................................. 11
EMC measures ..................................................................................................................................... 11
EMF measures...................................................................................................................................... 12
Specific hazards.................................................................................................................................... 12
Requirement for the shielding gas ........................................................................................................ 13
Danger from shielding gas cylinders..................................................................................................... 13
Danger from escaping shielding gas..................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 14
Safety measures in normal operation ................................................................................................... 15
Commissioning, maintenance and repair.............................................................................................. 15
Safety inspection................................................................................................................................... 16
Disposal ................................................................................................................................................ 16
Safety symbols...................................................................................................................................... 16
Data protection...................................................................................................................................... 16
Copyright............................................................................................................................................... 16
EN
General 17
General ...................................................................................................................................................... 19
Device concept ..................................................................................................................................... 19
Warning notices on the device.............................................................................................................. 19
Controls, connections and mechanical components 21
Controls, connections and mechanical components.................................................................................. 23
Safety.................................................................................................................................................... 23
Front of wire-feed unit ........................................................................................................................... 23
Rear of wire-feed unit............................................................................................................................ 24
Wire-feed unit side ................................................................................................................................ 24
Wire-feed unit underside....................................................................................................................... 25
Optional control panels .............................................................................................................................. 26
Safety.................................................................................................................................................... 26
OPT/i WF POT control panel ................................................................................................................ 26
OPT/i WF gas test & wire threading...................................................................................................... 27
OPT/i WF Standard control panel ......................................................................................................... 29
Installation and commissioning 33
Before installation and commissioning....................................................................................................... 35
Safety.................................................................................................................................................... 35
Proper use ............................................................................................................................................ 35
Setup regulations .................................................................................................................................. 35
Placing wire-feed unit on swivel pin holder ................................................................................................ 36
Safety.................................................................................................................................................... 36
Placing wire-feed unit on swivel pin holder ........................................................................................... 36
Connecting wire-feed unit to power source................................................................................................ 37
Safety.................................................................................................................................................... 37
General information .............................................................................................................................. 37
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Connecting the wirefeeder to the power source ................................................................................... 37
Connecting the extension hosepack..................................................................................................... 38
Connecting the welding torch..................................................................................................................... 40
Safety.................................................................................................................................................... 40
Connecting MIG/MAG welding torches................................................................................................. 40
Inserting/replacing feed rollers................................................................................................................... 41
Safety.................................................................................................................................................... 41
General ................................................................................................................................................. 41
Inserting/changing the feed rollers........................................................................................................ 41
Inserting the wirespool, inserting the basket-type spool ............................................................................ 43
Safety.................................................................................................................................................... 43
Inserting the wirespool .......................................................................................................................... 43
Inserting the basket-type spool............................................................................................................. 44
Threading the wire electrode ..................................................................................................................... 46
General ................................................................................................................................................. 46
Preparatory work................................................................................................................................... 46
Threading the wire electrode ................................................................................................................ 47
Setting the contact pressure ................................................................................................................. 48
Adjust the brake ......................................................................................................................................... 49
General ................................................................................................................................................. 49
Adjusting the brake ............................................................................................................................... 49
Design of the brake............................................................................................................................... 50
Start-up ...................................................................................................................................................... 51
Safety.................................................................................................................................................... 51
Prerequisites ......................................................................................................................................... 51
General ................................................................................................................................................. 51
Troubleshooting, maintenance and disposal 53
Troubleshooting ......................................................................................................................................... 55
Safety.................................................................................................................................................... 55
Troubleshooting .................................................................................................................................... 55
Care, maintenance and disposal ............................................................................................................... 59
General ................................................................................................................................................. 59
Safety.................................................................................................................................................... 59
Every start-up........................................................................................................................................ 59
Every 6 months ..................................................................................................................................... 60
Disposal ................................................................................................................................................ 60
Technical data 61
Technical data............................................................................................................................................ 63
WF 15i................................................................................................................................................... 63
WF 15i n.S. ........................................................................................................................................... 63
WF 25i................................................................................................................................................... 64
WF 30i................................................................................................................................................... 64
HP 70i ................................................................................................................................................... 65
HP 95i ................................................................................................................................................... 65
HP 120i ................................................................................................................................................. 65
HP 70i, HP PC Cable HD 70................................................................................................................. 65
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Safety rules
General The device is manufactured using state-of-the-art technology and according to recognised
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 device.
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 instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
EN
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, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
Environmental
conditions
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
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Ambient temperature range:
- 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)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
consumption.
Protecting yourself and others
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance
- Criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
*)
*)
see "Technical data"
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Anyone working with the device exposes themselves to numerous risks, e.g.
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
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Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with 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 regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
EN
Danger from toxic
gases and vapours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the measured toxic
emission values should be compared with the permissible limit values.
The following components are responsible, amongst other things, for the degree of toxicity
of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
- Welding process used
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
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Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Danger from flying sparks
Risks from mains
current and welding current
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or al-
ternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed
tanks, vessels or pipes unless these have been prepared in accordance with the relevant
national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers
and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated
wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry temporary
backing or cover for the earth or ground potential. This temporary backing or cover must
extend over the entire area between the body and the earth or 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.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
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The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.
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Operating the device on a grid without a ground conductor and in a socket without a ground
conductor contact will be deemed gross negligence. The manufacturer shall not be held
liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
EN
Meandering welding currents
EMC Device Classifications
If the following instructions are ignored, meandering welding currents can develop with the
following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient insulating ma-
terial to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The elec-
trode of the welding torch / electrode holder that is not used is also live. Make sure that the
welding torch / electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeed unit.
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 low-voltage mains.
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 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 the site where the device is installed is close to
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either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work is
being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
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The welding wire emerging from the welding torch poses a high risk of injury (piercing of
the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with wire-feed unit)
and wear suitable protective goggles.
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Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool
down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the
manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
EN
Requirement for
the shielding gas
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the
shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
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
Danger from
shielding gas cylinders
Use filters if necessary.
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
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Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any 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 attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and inter-
national regulations for shielding gas cylinders and accessories.
Danger from escaping shielding
gas
Safety measures
at the installation
location and during transport
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the ox-
ygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main
gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before every start-up.
A device toppling over could easily kill someone. Place the device on a solid, level surface
such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
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When setting up the device, ensure 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 accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Page 15
Before transporting the device, allow coolant to drain completely and detach the following
components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
EN
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 risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
Commissioning,
maintenance and
repair
The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
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.
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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.
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).
Fronius 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 following
address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of 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.
The text and illustrations are all technically correct at the time of printing. We reserve 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 have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.
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General
Page 18
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General
40,0006,3035
Caution: Parts may be at welding
voltage
Attention: Les pièces peuvent être
à la tension de soudage
1 - 25 m/min 40-984 ipm
360A/100% 450A/60% 500A/40%I
2
1.2 AI
11
U11
60 V
U
12 I12 0.5 A24 V
IEC 60 974-5/-10 Cl.A IP 23
www.fronius.com
Ser.No.:
Part No.:
EN
Device concept
The wire-feed units WF 15i, WF 25i, WF 30i
are fitted with a cover for wirespools with an
outer diameter of up to 300 mm (11.81 in).
Also available is the WF 15i n.S. (no Spool)
variant without an integrated wirespool holder. The WF 15i n.S. (no Spool) variant is
particularly suitable for robot and automated applications with an external wire feeder.
The standard 4-roller drive has excellent wirefeeding properties. The wire-feed units are
also suitable 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. The safety symbols and
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.
WF 15i, WF 25i, WF 30i
19
Page 20
40,0006,3035
Caution: Parts may be at welding
voltage
Attention: Les pièces peuvent être
à la tension de soudage
1 - 25 m/min 40-984 ipm
360A/100% 450A/60% 500A/40%I
2
1.2 AI
11
U
11
60 V
U
12
I
12
0.5 A24 V
IEC 60 974-5/-10 Cl.A IP 20
www.fronius.com
Ser.No.:
Part No.:
WF 15i n.S.
Do not use the functions described here until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the
safety rules
Welding is dangerous. The following basic requirements must be met to ensure 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 wirefeed 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, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
- Wirespools and wire electrodes
20
ponents.
Covers and side panels may only be opened/removed while maintenance or
repair work is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
Page 21
Controls, connections and mechani-
cal components
Page 22
Page 23
Controls, connections and mechanical components
(1)
(4)
(2)
(3)
EN
Safety
Front of wire-feed
unit
WARNING!
Danger from incorrect operation.
This can result in severe personal injury and damage to property.
► All the functions described may only be used by trained and qualified personnel.
► Fully read and understand this document.
► Fully read and understand all the Operating Instructions for the system components,
especially the safety rules.
No. Function
(1) Welding torch connection
for connecting the welding torch
(2) Coolant flow connection (blue) -
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 welding torch hosepack
No. Function
(3) 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 welding torch hosepack
(4) SpeedNet connection
for connecting system add-ons - for example, a remote control unit
23
Page 24
Rear of wire-feed
(1)
(2)
(3)
(4)
(5)
(6)
unit
No. Function
(1) (+) - current socket with fine-
pitch thread
for connecting the interconnecting
hosepack power cable
(2) Blanking cover
(3) SpeedNet connection
for connecting the interconnecting
hosepack SpeedNet 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 interconnecting hosepack
(6) Coolant flow connection (blue) - 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 interconnecting hosepack
Wire-feed unit
side
(1)
(3)(2) (4)
No. Function
(1) Wirespool holder (not in the case of WF 15i n.S.)
for holding standard wirespools with a max. outer diameter of 300 mm (11.81 in)
and max. weight of 19 kg (41.89 lbs.)
24
Page 25
(2) 4-roller drive
Wire-feed unit underside
(3) Protective cover for the 4-roller drive
(4) Clamping lever
for setting the contact pressure of the feed rollers
(1)
EN
No. Function
(1) Socket for swivel pin (not in the
case of WF 15i n.S.)
for placing the wire-feed unit on the
swivel pin in the swivel pin holder
25
Page 26
Optional control panels
(2)(1)
Safety
OPT/i WF POT
control panel
WARNING!
Danger from incorrect operation.
This can result in severe personal injury and damage to property.
► All the functions described may only be used by trained and qualified personnel.
► Fully read and understand this document.
► Fully read and understand all the Operating Instructions for the system components,
especially the safety rules.
The adjusters perform different functions depending on the application.
No. Adjuster function during MIG/MAG welding
(the remote control performs different functions depending on the welding
process)
(1) - Setting the welding power
(during MIG/MAG synergic welding - Standard, Pulse, PMC, LSC)
- Setting the wire speed
(during MIG/MAG standard manual welding)
(2) - Correcting the arc length
(during MIG/MAG synergic welding - Standard, Pulse, PMC, LSC)
- = shorter arc length
0 = neutral arc length
+ = longer arc length
- Setting the welding voltage
(during MIG/MAG standard manual welding)
No. Adjuster functions during electrode welding
(1) Setting the welding current
(2) Influencing the arc-force dynamic:
- 0 = soft, low-spatter arc
- 10 = harder, more stable arc
26
Page 27
No. Adjuster functions during TIG welding
(2)
(1)
(3)
(4)
(5)
(1) Setting the welding current
(2) Not active
EN
OPT/i WF gas test
& wire threading
No. Function
(1) OPT/i WF gas test & wire threading
(2) Operating status LED
lights up green when the device is
ready for use
(3) Gas-test button
for setting the required gas flow rate
on the pressure regulator
- Gas will flow out for 30 seconds
after the gas-test button is
pressed. Press the button again
to stop the gas flow 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
Retracting the wire electrode using the preset wire retract speed:
- Press and hold the wire retract button
- The wire electrode will be retracted 1 mm (0.039 in.) after the wire retract but-
ton is pressed
- After a short pause, the wirefeeder continues to retract the wire electrode. If
the wire retract button remains pressed, the speed will increase every second at a rate of 10 m/min (393.70 ipm) until the preset wire retract speed is
reached
Method 2
Retracting the wire electrode in 1 mm increments (0.039 in. increments) – always
press the wire retract button for less than one second (tap)
NOTE!
Risk when retracting the wire electrode.
No winding onto the wirespool.
► Do not allow long lengths of wire electrode to be retracted, as the wire electrode is not
wound onto the wirespool when retracted.
If there was a ground earth connection with the contact tip before the wire retract
button was pressed, the wire electrode will be retracted when the button is pressed
until it is short-circuit-free - it retracts by no more than 10 mm (0.39 in.) with each
press of the button.
If the wire electrode still needs to be retracted further, press the wire retract button again.
27
Page 28
No. Function
(5) Wire threading button
to thread the wire electrode into the torch hosepack with no accompanying flow
of gas or current
Wire threading can be performed using one of two methods:
Method 1
Threading the wire electrode using the preset feeder inching speed:
- Press and hold the wire threading button
- The wire electrode will be threaded 1 mm (0.039 in.) after the wire threading
button is pressed
- After a short pause, the wirefeeder continues to thread the wire electrode. If
the wire threading button remains pressed, the speed will increase 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 contact with a ground earth connection, the
wirefeeding will be stopped and the wire electrode will be retracted again by
1 mm (0.039 in.)
Method 2
Threading the wire electrode in 1 mm increments (0.039 in. increments) – always
press the wire threading button for less than one second (tap)
- If the wire electrode comes into contact with a ground earth connection, the
wirefeeding will be stopped and the wire electrode will be retracted again by
1 mm (0.039 in.)
If there was a ground earth connection with the contact tip before the wire threading
button was pressed, the wire electrode will be retracted when the button is pressed
until it is short-circuit-free – it retracts by no more than 10 mm (0.39 in.) with each
press of the button.
If there is still a ground earth connection with the contact tip after 10 mm (0.39 in.) of wire
retraction, pressing the wire threading button again will cause the wire electrode to be retracted again by a maximum of 10 mm (0.39 in.). The process will be repeated until there
is no longer a ground earth connection with the contact tip.
28
Page 29
OPT/i WF Stand-
(1)
(9)(8)
(5)(6)
(10)
(11)
(12)
(2)
(3)
(4)
(7)
(14)
(13)
ard control panel
EN
29
Page 30
Number
(1) Parameter selection button (left)
Control
Indicator
Function
for selecting the parameters listed below.
The corresponding indicator lights up when a parameter is selected.
Material thickness *)
in mm or inches
Current *)
current in A
Before the start of welding, the machine automatically displays a
standard value based on the programmed parameters. During
welding, the actual value is displayed.
Wire feed speed *)
in m/min or ipm
Special function
can only be selected if the SP 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:
- Penetration stabiliser
- Arc length stabiliser
As soon as F1 is selected, the current adjustable process control
parameter is marked with an arrow on the display. Press the "Parameter selection" button (left) (1) again to select the second process control parameter.
The following special functions can be selected depending on the
configuration.
*) = Synergic parameter
When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.
30
Page 31
Number
(2) Parameter selection button (right)
Control
Indicator
Function
for selecting the parameters listed below.
The corresponding indicator lights up when a parameter is selected.
Arc length correction
for correcting the arc length
- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length
Voltage *)
in V
Before the start of welding, the machine automatically displays a
standard 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 detachment force
0 ... neutral droplet detachment force
+ ... increased droplet detachment force
EN
Job number
(can only be selected if the JOB welding process has first been selected using the "Welding process" button (5))
for selecting a job number
*) = Synergic parameter
When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.
(3) Adjusting dial with turn/press function
- for changing the arc length correction, voltage, pulse/dynamic
correction parameters
- for selecting the job number
(4) EasyJob button
for saving, opening and deleting EasyJobs.
The LED in the button indicates that EasyJob is selected
How it works:
- Press and hold the button for 3 seconds = save EasyJob (all
current settings are saved). After saving, the LED in the button
lights up and 'Store' is shown on the display
- Press and hold the button for 5 seconds = delete EasyJob.
'Store' is shown on the display after 3 seconds, 'Clear' is
shown after 5 seconds and the LED in the button goes out
- Press the button = select the saved EasyJob
31
Page 32
Number
(5) Welding process button
(6) Mode button
(7) Adjusting dial with turn/press function
Control
Indicator
Function
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 - Manual metal arc welding
- SP (SP = special programs: LSC, PMC, TIG, etc.) - Depending
on which package of functions is enabled, various welding processes can be selected. Press the button to see the available
welding processes shown on the display one after the other
for selecting the operating mode
2-step mode
4-step mode
Depending on the function package, various special operating
modes can be selected. Press the button to see the available operating modes shown on the display one after the other
- for changing the material thickness, current, wire feed speed
and special function parameters
- for selecting and changing parameters in the Setup menu
Number
(8) Hold indicator
(9) Intermediate arc indicator
(10) SFI (Spatter Free Ignition) indicator
(11) SynchroPuls indicator
(12) VRD (Voltage Reduction Device) indicator
(13) Penetration stabiliser indicator
(14) Arc length stabiliser indicator
Indicator
Function
the actual values are displayed automatically at the end of each welding
operation (current, voltage, wire feed speed, etc.). The actual values are
displayed through the HOLD indicator lighting up.
a spatter-prone intermediate arc occurs between the short arc and the
spray arc. The intermediate arc indicator lights up to draw attention to this
critical area.
lights up when the Spatter Free Ignition function is active
lights up when the SynchroPuls function is active
lights up when the voltage reduction device (VRD) is active
lights up when the penetration stabiliser function is active
lights up when the arc length stabiliser function is active
32
Page 33
Installation and commissioning
Page 34
Page 35
Before installation and commissioning
EN
Safety
Danger due to incorrect operation and incorrectly performed work.
This can result in severe personal injury and damage to property.
► All the work and functions described in this document must only be carried out and
► Fully read and understand this document.
► Fully read and understand all the Operating Instructions for the system components,
Proper use The device is intended exclusively for wire feeding in MIG/MAG welding in conjunction with
Fronius system components.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose.
The manufacturer shall not be held liable for any damages arising from 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 maintenance work
WARNING!
used by trained and qualified personnel.
especially the safety rules.
Setup regulations
WARNING!
Danger from machines falling or toppling over.
This can result in severe personal injury and damage to property.
► Place all system components, upright consoles and trolleys on a solid, level surface in
such a way that they remain stable.
► If a swivel pin holder is being used, make sure that the wirefeeder is seated securely.
The WF 15i, WF 25i and WF 30i wirefeeders are tested to IP23 protection, meaning:
- protection against penetration by solid foreign bodies with diameters exceeding 12.5
mm (0.49 in.)
- protection against spraywater at any angle up to 60° to the vertical
The WF 15i, WF 25i and WF 30i wirefeeders can be set up and operated outdoors in accordance with degree of protection IP23. Avoid direct wetting (e.g. from rain).
The WF 15i n.S. wirefeeder without an integrated wirespool holder is tested to IP20 protection, meaning:
- protection against penetration by solid foreign bodies with diameters exceeding 12.5
mm (0.49 in.)
- no protection against water
The WF 15i n.S. wirefeeder without an integrated wirespool holder may only be set up
and operated in closed areas.
35
Page 36
Placing wire-feed unit on swivel pin holder
1
Safety
Placing wire-feed
unit on swivel pin
holder
WARNING!
Danger from electric current.
This can result in severe personal injury and damage to property.
► Turn the power 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.
1
1
36
Page 37
Connecting wire-feed unit to power source
2
EN
Safety
General information
Connecting the
wirefeeder to the
power source
WARNING!
Danger from electric current.
This can result in severe personal injury and damage to property.
► Turn the power 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.
The wire-feed unit is connected to the power source using the interconnecting hosepack.
CAUTION!
Danger from electric current due to inadequate connections.
This can result in severe personal injury and damage to property.
► All cables, leads and hosepacks must be properly connected, undamaged, correctly in-
sulated and adequately dimensioned.
1 2
1
1
2
3
4
* only if the coolant connections are fitted in the wirefeeder and there is a water-
cooled interconnecting hosepack
NOTE!
Risk due to damaged connections.
This can result in serious damage to property.
► A strain-relief device is not provided for 1.2 m (3 ft 11.24 in.) interconnecting hose-
packs.
► During installation, make sure that the cables form a loop towards the inside (to the
wirefeeder) to avoid damage.
37
Page 38
Connecting the
1
extension hosepack
CAUTION!
Danger from electric current due to inadequate connections.
This can result in severe personal injury and damage to property.
► All cables, leads and hosepacks must be properly connected, undamaged, correctly in-
sulated and adequately dimensioned.
1
* Only on water-cooled hosepack
CON = interconnecting hosepack
EXT = extension hosepack
38
Page 39
1
2
EN
39
Page 40
Connecting the welding torch
3
5
7
8
9
4
6
*
2
1
Safety
Connecting MIG/
MAG welding
torches
WARNING!
Danger from electric current.
This can result in severe personal injury and damage to property.
► Turn the power 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.
1
1
CAUTION!
Danger from electric current due to inadequate connections.
This can result in severe personal injury
and damage to property.
► All cables, leads and hosepacks must
be properly connected, undamaged,
correctly insulated and adequately dimensioned.
* Only if the coolant connections are
fitted in the wirefeeder and when
using a water-cooled welding torch
40
Page 41
Inserting/replacing feed rollers
2
1
4
4
5
6
3
2
EN
Safety
WARNING!
Danger from electric current.
This can result in severe personal injury and damage to property.
► Turn the power 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.
General The feed rollers 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!
Risk from inadequate feed rollers.
This can result in poor weld properties.
► Only use feed rollers that match the wire electrode.
Inserting/changing the feed rollers
An overview of the feed rollers available and their possible areas of use can be found in
the Spare Parts Lists.
CAUTION!
Danger from feed roller holders flying upwards.
This can result in severe injuries.
► When unlocking the clamping lever, keep fingers away from the area to the left and
right of the lever.
1 2
1
4
5
31
2
3
6
7
41
Page 42
CAUTION!
3
8
6
7
9
3
1
2
2
5
4
4
4
Danger from exposed feed rollers.
This can result in severe injuries.
► Always fit the protective cover of the 4-roller drive after inserting or replacing a feed roll-
er.
1 2
3
3
2
4
1
5
5
6
42
Page 43
Inserting the wirespool, inserting the basket-type
spool
Safety
EN
WARNING!
Danger from electric current.
An electric shock can be fatal.
► Turn the power 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.
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 avoid injuries caused by the wire electrode springing back.
CAUTION!
Inserting the wirespool
Danger from falling wirespool/basket-type spool.
This can result in severe injuries.
► Ensure that the wirespool/basket-type spool and basket-type spool adapter are always
seated securely on the wirespool holder.
CAUTION!
Danger from the wirespool falling because the locking ring has been placed the
wrong way around.
This can result in severe personal injury and damage to property.
► Always position the locking ring as shown in the diagram on the left.
43
Page 44
1
1
Inserting the basket-type spool
CAUTION!
Danger from falling basket-type spool.
This can result in severe personal injury and damage to property.
► When working with basket-type spools, only use the basket-type spool adapter includ-
ed in the scope of supply.
CAUTION!
Danger from the basket-type spool falling because the locking ring has been placed
the wrong way around.
This can result in severe personal injury and damage to property.
► Always position the locking ring as shown in the diagram on the left.
44
CAUTION!
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.
Page 45
1 2
2
1
EN
45
Page 46
Threading the wire electrode
General
Preparatory work
NOTE!
If there is no wire threading button on the wire-feed unit, use the wire threading button of another of the manufacturer's system components to thread the wire, for example the power source wire threading button.
The wire threading button functions in the same way for all system components from the
manufacturer.
NOTE!
Further details on the function of the wire threading button can be found in its description ("Optional control panels" section, "OPT/i WF gas test & wire threading"
sub-section).
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 earth connection between the welding sys-
tem and the workpiece.
CAUTION!
Danger from sharp end of wire electrode.
This can result in severe personal injury and damage to property.
► Deburr the end of the wire electrode well before threading in.
CAUTION!
Danger from elasticity of the spooled wire electrode.
This can result in severe personal injury and damage to property.
► When inserting the wire electrode into the 4-roller drive, hold the end of the wire elec-
trode firmly to avoid injuries caused by the wire springing back.
46
Page 47
1 2
2
1
4
3
2
1
4
6
7
5
3
2
1
3
1
EN
2
1
Threading the
wire electrode
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 earth connection between the welding sys-
tem and the workpiece.
CAUTION!
Danger from emerging wire electrode.
This can result in severe personal injury and damage to property.
► 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 any conductive or earthed parts (e.g.
housing).
Lay the torch hosepack out straight
3 4
2
1
2
1
47
Page 48
Setting the con-
1
1
tact pressure
NOTE!
Risk from excessive contact pressure.
This can result in severe damage to property and poor weld properties.
► Set the contact pressure in such a way that the wire electrode is not deformed but nev-
ertheless ensures proper wirefeeding.
1
Contact pressure
standard values
U-groove rollers
Steel 4 - 5
CrNi 4 - 5
Tubular cored electrodes 2 - 3
48
Page 49
Adjust the brake
1
4
5
STOP
6
7
3
1
2
2
EN
General
Adjusting the
brake
NOTE!
Risk from brake lag.
This can result in serious damage to property.
► After releasing the torch trigger / wire threading button the wirespool must stop unreel-
ing.
► If it continues unreeling, readjust the brake.
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 earth connection between the welding sys-
tem and the workpiece.
CAUTION!
Danger from emerging wire electrode.
This can result in severe personal injury and damage to property.
► 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 any conductive or earthed parts (e.g.
housing).
1 2
1
2
1
49
Page 50
Design of the
2
4
STOP
OK
3
1
brake
3
3
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.
This illustration is for information purposes
only.
50
Page 51
Start-up
EN
Safety
Danger due to incorrect operation and incorrectly performed work.
This can result in severe personal injury and damage to property.
► All the functions described may only be used by trained and qualified personnel.
► Fully read and understand this document.
► Fully read and understand all the Operating Instructions for the system components,
Prerequisites When commissioning the wire-feed 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 the wire-feed unit
- Wirespool/basket-type spool with basket-type spool adapter inserted into wire-feed
- Wire electrode threaded in
- Feed roller contact pressure set
- Brake set (not for WF 15i n.S.)
- All covers closed, all side panels in place, all protection devices intact and in their
WARNING!
especially the safety rules.
unit (not for WF 15i n.S.)
proper place
General The wire-feed unit is started by pressing the torch trigger (for manual applications) or by
means of a welding start-up signal (for automatic applications).
51
Page 52
52
Page 53
Troubleshooting, maintenance and
disposal
Page 54
Page 55
Troubleshooting
EN
Safety
WARNING!
Danger due to work that has been carried out incorrectly.
This can result in severe personal injury and damage to property.
► All the work described below must only be carried out by trained and qualified person-
nel.
► Fully read and understand this document.
► Fully read and understand all the Operating Instructions for the system components,
especially the safety rules.
WARNING!
Danger from electric current.
An electric shock can be fatal.
► Turn the power 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 the device, use a suitable measuring instrument to check that electrically
charged components (e.g. capacitors) have been discharged.
CAUTION!
Danger from hot system components.
This can result in severe personal injury and damage to property.
► Before starting work, allow all hot system components to cool down to room tempera-
ture (+25 °C, +77 °F). For example:
Examples of hot system components include
- Coolant.
- Water-cooled system components.
- Wirefeeder drive motor.
Troubleshooting Make a note of the serial number and configuration of the device and contact our After-
Sales Service team with a detailed description of the error, if
- errors occur that are not listed below
- the troubleshooting measures listed are unsuccessful
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Power source has no function
Mains switch is on, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains lead, ensure that the mains plug is plugged in
Cause: Mains socket or mains plug faulty
Remedy: Replace faulty parts
Cause: Mains fuse protection
Remedy: Change the mains fuse protection
Nothing happens when the torch trigger is pressed
Power source mains switch is ON and indicators are lit up
Cause: Only for welding torches with an external control plug: The control plug is not
plugged in
Remedy: Plug in the control plug
Cause: Welding torch or welding torch control line is faulty
Remedy: Replace welding torch
No welding current
Mains switch is ON and indicators are lit up
Cause: Grounding (earthing) connection is incorrect
Remedy: Check the grounding (earthing) connection for correct polarity
Cause: There is a break in the power cable in the welding torch
Remedy: Replace the welding torch
No protective gas shield
All other functions are OK
Cause: Gas cylinder is empty
Remedy: Change the gas cylinder
Cause: The gas pressure regulator is faulty
Remedy: Replace the gas pressure regulator
Cause: Gas hose is not fitted or is damaged
Remedy: Fit or change the gas hose
Cause: Welding torch is faulty
Remedy: Change the welding torch
56
Cause: Gas solenoid valve is faulty
Remedy: Contact After-Sales Service
Page 57
Irregular wire feed speed
Cause: Braking force has been set too high
Remedy: Loosen the brake
Cause: Hole in the contact tip is too narrow
Remedy: Use a suitable contact tip
Cause: Faulty inner liner in welding torch
Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary
Cause: The feed rollers are not suitable for the wire electrode being used
Remedy: Use suitable feed rollers
Cause: Feed rollers have the wrong contact pressure
Remedy: Optimise the contact pressure
Wirefeed problems
when using long hosepacks
Cause: Incorrect arrangement of hosepack
Remedy: Arrange the hosepack in as straight a line as possible, avoid tight bends
EN
Welding torch becomes very hot
Cause: The specification of the welding torch is inadequate
Remedy: Observe the duty cycle and loading limits
Cause: Only on water-cooled systems: Inadequate coolant flow
Remedy: Check coolant level, coolant flow, for coolant contamination, etc. For further
information refer to the cooling unit operating instructions.
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Poor weld properties
Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Poor ground earth connection
Remedy: Ensure good contact to workpiece
Cause: Inadequate or no protective gas shield
Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con-
nection, etc.
Cause: Welding torch is leaking
Remedy: Change the welding torch
Cause: Wrong contact tip, or contact tip is worn out
Remedy: Replace the contact tip
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check the wire electrode that has been inserted
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check weldability of the base material
Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas
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Care, maintenance and disposal
General Under normal operating conditions, the device requires only a minimum of care and main-
tenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.
EN
Safety
WARNING!
Danger due to work that has been carried out incorrectly.
This can result in severe personal injury and damage to property.
► All the work described below must only be carried out by trained and qualified person-
nel.
► Fully read and understand this document.
► Fully read and understand all the Operating Instructions for the system components,
especially the safety rules.
WARNING!
Danger from electric current.
An electric shock can be fatal.
► Turn the power 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 the device, use a suitable measuring instrument to check that electrically
charged components (e.g. capacitors) have been discharged.
CAUTION!
Danger from hot system components.
This can result in severe personal injury and damage to property.
► Before starting work, allow all hot system components to cool down to room tempera-
ture (+25 °C, +77 °F). For example:
Examples of hot system components include
- Coolant.
- Water-cooled system components.
- Wirefeeder drive motor.
Every start-up - Check all hosepacks and the ground earth connection for damage. Replace any dam-
aged components.
- Check feed rollers and inner liners for signs of damage. Replace any damaged com-
ponents.
- Check contact pressure of feed rollers and adjust if necessary.
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Every 6 months
Danger of damage to electronic components.
► Do not bring the air nozzle too close to electronic components.
- Open covers, remove device side panels and clean inside of device with dry reduced
Disposal Dispose of in accordance with the applicable national and local regulations.
CAUTION!
compressed air. After cleaning, restore device to its original state.
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Technical data
Page 62
Page 63
Technical data
EN
WF 15i
Supply voltage 24 V DC / 60 V DC
Nominal current 0,5 A / 1 A
Welding current at 10 min / 40 °C (104 °F) 40 % D.C.* 60 % D.C.* 100 % D.C.*
650 A 600 A 500 A
Maximum shielding gas pressure 7 bar
101.53 psi
Coolant Original Fronius
Maximum coolant pressure 5 bar
72.53 psi
Wire feed speed 0,5 - 15 m/min
19.68 - 590.55 ipm
Wire drive 4-roller drive
Wire diameter 0,8 - 2,4 mm
.03 - .09 in.
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.
Weight 13 kg
28.66 Ib.
*) D.C. = duty cycle
WF 15i n.S.
Supply voltage 24 V DC / 60 V DC
Nominal current 0,5 A / 1 A
Welding current at 10 min / 40 °C (104 °F) 40 % D.C.* 60 % D.C.* 100 % D.C.*
650 A 600 A 500 A
Maximum shielding gas pressure 7 bar
101.53 psi
Coolant Original Fronius
Maximum coolant pressure 5 bar
72.53 psi
Wire feed speed 0,5 - 15 m/min
19.68 - 590.55 ipm
Wire drive 4-roller drive
Wire diameter 0,8 - 2,4 mm
.03 - .09 in.
Degree of protection IP 20
Mark of conformity S / CE
Dimensions l x w x h 280 x 260 x 275 mm
11.02 x 10.24 x 10.83 in.
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Weight 6 kg
13.23 Ib.
*) D.C. = duty cycle
WF 25i
Supply voltage 24 V DC / 60 V DC
Nominal current 0,5 A / 1,2 A
Welding current at 10 min / 40 °C (104 °F) 40 % D.C.* 60 % D.C.* 100 % D.C.*
500 A 450 A 360 A
Maximum shielding gas pressure 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 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 / CSA
Dimensions l x w x h 658 x 282 x 362 mm
25.91 x 11.10 x 14.25 in.
Weight 12.9 kg
28.44 Ib.
*) D.C. = duty cycle
WF 30i
64
Supply voltage 24 V DC / 60 V DC
Nominal current 0,5 A / 1,4 A
Welding current at 10 min / 40 °C (104 °F) 40 % D.C.* 60 % D.C.* 100 % D.C.*
650 A 600 A 500 A
Maximum shielding gas pressure 7 bar
101.53 psi
Coolant Original Fronius
Maximum coolant pressure 5 bar
72.53 psi
Wire feed speed 1 - 30 m/min
39.37 - 1181.10 ipm
Wire drive 4-roller drive
Wire diameter 0,8 - 1,6 mm
.03 - .06 in.
Wirespool diameter max. 300 mm
max. 11.81 in.
Page 65
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.
Weight 13 kg
28.66 Ib.
*) D.C. = duty cycle
EN
HP 70i
HP 95i
HP 120i
Welding current at 10 min/40 °C (104 °F) 40% D.C.* / 400 A
60% D.C.* / 365 A
100% D.C.* / 320 A
* D.C. = Duty cycle
Welding current at 10 min/40 °C (104 °F) 40% D.C.* / 500 A
60% D.C* / 450 A
100% D.C.* / 360 A
* D.C. = Duty cycle
Welding current at 10 min/40 °C (104 °F) 40% D.C.* / 600 A
60% D.C.* / 530 A
100% D.C.* / 430 A
* D.C. = Duty cycle
HP 70i, HP PC Cable HD 70
Welding current at 10 min/40 °C (104 °F) 60% D.C.* / 600 A
100% D.C.* / 500 A
* D.C. = Duty cycle
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66
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EN
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FRONIUS INTERNATIONAL GMBH
Froniusstraße 1, A-4643 Pettenbach, Austria
E-Mail: sales@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses
of all Fronius Sales & Service Partners and locations
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