Fronius WF 25i FlexDrive Operating Instruction [EN]

Operating
Instructions

WF 25i FlexDrive
WF 25i FlexDrive JM

EN-US

Operating instructions

42,0426,0397,EA 002-27092022

Table of contents

Safety Instructions 5

General 5
Intended Use 5
Environmental Conditions 6
Obligations of the Operating Company 6
Obligations of Personnel 6
Grid Connection 6
Personal Protection and Protection of Others 6
Danger from toxic gases and vapors 7
Danger from Flying Sparks 8
Risks from grid current and welding current 8
Stray welding currents 9
EMC Device Classifications 9
EMC measures 10
EMF measures 10
Particular hazard areas 10
Requirement for the shielding gas 12
Danger from Shielding Gas Cylinders 12
Danger Posed by Shielding Gas Leak 12
Safety Measures at the Setup Location and During Transport 13
Safety Measures in Normal Operation 13
Maintenance and repair 14
Safety Inspection 14
Disposal 14
Safety symbols 15
Data backup 15
Copyright 15

General 16

Device concept 16
Intended use 16
Warning notices on the device 17
System overview 18
Options 19
Selection of cooling units 19

Operating controls, connections and mechanical components 21

Safety 21
Operating controls, connections, and mechanical components 21
Function of the gas-test, wire-return, and wire-threading buttons 23
Function of the LED inside the feed roller 24

Before installation and initial operation 25

Safety 25
Setup regulations 25

Installing Optional Equipment 26

Mounting the protective cage 26
Mounting the runners 28

Installing the inner liner in the extension hosepack 29

Installing the inner liner in the extension hosepack 29

Connecting the extension hosepack 31

Safety 31
Connecting the extension hosepack 31

Connecting the welding torch 32

Safety 32
Connecting the welding torch 32

Inserting / changing the feed rollers and wirefeeder 33

Safety 33
General 33
Inserting/changing feed rollers 33
Inserting / changing the wirefeeder 35

Threading the Wire Electrode 38

General 38

EN-US

3

Threading the wire electrode 38
Setting the contact pressure 40

Commissioning 41

Safety 41
Requirements 41
Filling water-cooled welding systems with coolant 41
Conducting system calibration and R/L comparison 42
Commissioning 42

Troubleshooting 43

Safety 43
Troubleshooting 43

Service, maintenance and disposal 47

General 47
Safety 47
At every start-up 47
Every 6 months 47
Disposal 48

Technical data 49

WF 25i FlexDrive 49

4

Safety Instructions

General The device has been manufactured using state-of-the-art technology and ac-

cording to recognized safety standards. If used incorrectly or misused, however,
it can cause

Injury or death to the operator or a third party

-

Damage to the device and other material assets belonging to the operating

-

company
Inefficient operation of the equipment

-

All persons involved in the commissioning, operation, maintenance, and servicing
of the device must

Be suitably qualified

-

Have knowledge of welding

-

Have completely read and followed these Operating Instructions

-

The Operating Instructions must always be at hand wherever the device is being
used. In addition to the Operating Instructions, all applicable local rules and 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

-

EN-US

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!

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.

5

Environmental
Conditions

Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no 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.)

Obligations of
the Operating
Company

The operating company must only allow persons to work with the device if they

Are familiar with the basic occupational safety and accident prevention regu-

-

lations and are trained in handling the device
Have read and understood these Operating Instructions, especially the sec-

-

tion "Safety Rules," and have confirmed this with their signature
Are trained according to the requirements for the work results

-

The safety-conscious work of the personnel must be checked regularly.

Obligations of
Personnel

All persons who are assigned to work with the device must do the following 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.

Personal Protec­tion and Protec­tion of Others

6

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!

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

-

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.

-

EN-US

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

-

7

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.

Danger from Fly­ing Sparks

Risks from grid
current and
welding current

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the
arc or protected with a certified cover.

Keep suitable, tested fire extinguishers on hand.

Sparks and pieces of hot metal may also get into surrounding areas through
small cracks and openings. Take appropriate measures to ensure that there is no
risk of injury or fire.

Do not undertake welding in areas at risk of fire and explosion, or on sealed
tanks, drums, or pipes if these have not been prepared in accordance with 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.

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.

-

8

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.

EN-US

Stray welding
currents

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.

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.

EMC Device
Classifications

In automated MIG/MAG applications, only guide the wire electrode from the
welding wire drum, large spool, or wirespool to the wirefeeder with insulation.

Devices in emission class A:

Are only designed for use in industrial settings

-

Can cause line-bound and radiated interference in other areas

-

9

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

-

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

Particular haz­ard areas

10

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.

Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.

EN-US

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.

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.

11

Requirement for
the shielding gas

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.

Danger from
Shielding Gas
Cylinders

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.

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.

Danger Posed by
Shielding Gas
Leak

Follow the manufacturer's instructions and applicable national and international
provisions for shielding gas cylinders and accessories.

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.

12

Safety Measures
at the Setup
Location and
During Transport

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

-

EN-US

Safety Measures
in Normal Oper­ation

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.

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.

13

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.

Maintenance and
repair

Safety Inspec­tion

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.

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.

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.

Disposal To comply with European directives and national law, waste electrical and elec-

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.

14

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.

EN-US

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
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.

15

General

Device concept

WF 25i FlexDrive JM with protective cage and rollers

The WF 25i FlexDrive is a small portable intermediate drive that is integrated in
the welding system between the welding torch and the wirefeeder.
This extends the radius of action between the wirefeeder and the welding point
up to 25 m / 82 ft.

The WF 25i FlexDrive is available in two versions:

WF 25i FlexDrive (standard version)

-

WF 25i FlexDrive JM (with JobMaster control unit)

-

Intended use The device is intended exclusively for end of wirefeeding with MIG/MAG welding

in combination with Fronius system components.
Any other use does not constitute proper use.
The manufacturer shall not be held liable for any loss resulting from improper
use.

Intended use also means

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

-

16

Warning notices
on the device

The intermediate drive 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.

Rating plate

Do not use the functions described here until you have fully read and understood
the following documents:

These Operating Instructions

-

All system component Operating Instructions, especially the safety rules

-

EN-US

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 wire electrodes

-

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.

17

System overview

3.5 / 4.5 m
11 ft. 5.80 in.
14 ft. 9.17 in.

max. 33 m
max. 108 ft. 3.21 in.

10 / 15 / 20 m
32 ft. 9.70 in.
49 ft. 2.55 in.
65 ft. 7.40 in.

max. 8 m
max. 26 ft. 2.96 in.

During operation

Ensure that all covers are closed, and all side parts have been mounted prop-

-

erly.
Keep all covers and side parts closed.

-

(1) Welding wire drum

Optional:

(2) TPSi welding system

with firmware version 3.2.0
with WF 25i wirefeeder
with OPT/i WF PushPull option, built into the wirefeeder

When using a welding wire drum, the OPT/i WF noSpool option
(4,101,144) is also required.

For water-cooled welding systems, the required cooling capacity depends
on the maximum welding current of the welding torch and the length of
the extension hosepack.
Details on the selection of the cooling unit can be found in the following
section on page 19.

(3) Extension hosepack

from the wirefeeder to the WF 25i FlexDrive
10 m, 15 m, 20 m / 32 ft. 9.7 in., 49 ft. 2.55 in., 65 ft. 7.40 in.

(4) WF 25i FlexDrive

18

(5) Welding torch

Standard, UpDown or JobMaster

3.5 m, 4.5 m / 11 ft 5.80 in., 14 ft 9.17 in.

Options

EN-US

Selection of
cooling units

Protective cage with rollers
The front roller can be swiveled 360° and is
equipped with a brake as standard.

Runners

It is possible to mount either the protective cage or runners on the WF 25i
FlexDrive.

The following table gives an overview of the cooling unit selection depending on
the maximum welding current at the welding torch and the length of the exten­sion hosepack.

I

[A]

max

CU 800t

CU 1100i

CU 1400i Pro

CU 1400i PRO MC

CU 2000i Pro MC Single

CU 2000i Pro MC TWIN

10 m 10 m 10 m 10 m 10 m 10 m

200 - 15 m 15 m 15 m 15 m 15 m

- 20 m 20 m 20 m 20 m 20 m

- 10 m 10 m 10 m 10 m 10 m

240 - - 15 m 15 m 15 m 15 m

- - 20 m 20 m 20 m 20 m

- - 10 m 10 m 10 m 10 m

280 - - - - 15 m 15 m

- - - - - 20 m

- - - - 10 m 10 m

320 - - - - - 15 m

- - - - - 20 m

The values apply for a duty cycle ED = 100%

19

I

... maximum welding current at the welding torch, L = 4.50 m / 14 ft. 9.17 in.

max

10 / 15 / 20 m ... Length of extension hosepack
CU ... cooling unit to be selected

10 m = 32 ft. 9.70 in., 15 m = 49 ft. 2.55 in., 20 m = 65 ft. 7.40 in.

20

Operating controls, connections and mechanical

(1)

(2) (3) (4)

(5) (6)

(7)

(15)

(14)

(13)

(12)

(19)(18)(17)(16)

(11)(10)

(8)

(9)

(6)

(7)

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.

▶
▶

▶

Operating con­trols, connec­tions, and mech­anical compon­ents

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) Clamping lever

Welding torch side

(2) FSC

Fronius System Connector - Welding torch side

(3) Coolant supply

Welding torch side

(4) Coolant return

Welding torch side

(5) Drive roller cover

+ LED for lighting the interior

Functional description of the LED from page 24.

When the cover is open, it is not possible to start welding; a notification is
generated and the "System not ready bit" is output.
An active welding process is not interrupted when the cover is opened.
The gas-test button, wire-return, and wire-threading buttons also work
when the cover is open.

21

(6) JobMaster control unit

(only for WF 25i FlexDrive JM)

(7) Gas test / wire threading control unit

(8) Clamping lever

Wirefeeder side

(9) FSC

Fronius System Connector - Wirefeeder side

(10) Coolant return

Wirefeeder side

(11) Coolant supply

Wirefeeder side

(12) Display

Shows the current parameter and value

(13) Left arrow key

(14) Right arrow key

The desired parameters are chosen via arrow keys at the power source

(15) +/- key

Use the +/- key to change the selected parameters

(16) Operating status LED

Lights up green when the device is ready for operation

(17) Gas-test button

For setting the required gas volume on the pressure regulator

(18) Wire-threading button

For threading the wire electrode into the torch hosepack without gas or
current

(19) Wire-return button

For retracting the wire electrode without gas or current

22

Function of the
gas-test, wire­return, and wire­threading but­tons

Operating status LED

Lights up green when the device is ready for operation

Gas-test button

After pressing the gas-test button, gas is released for 30 s. Pressing the button
again will end the process prematurely.

Wire-return button

There are two options available for retracting the wire electrode:

Option 1
Withdraw wire electrode at the preset wire return speed:

Press and hold the wire-return button

-

After pressing the wire-return button, the wire electrode is retracted by

-

1 mm (0.039 in.)
After a brief pause, the wirefeeder continues retracting the wire electrode –

-

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

Option 2
Withdraw wire electrode in 1 mm steps (0.039 in. steps)

Always press (touch) the wire-return button for less than 1 second

-

EN-US

NOTE!

Only retract the wire electrode a small amount at a time, to avoid the wire elec­trode becoming entangled on the wirespool during retraction.

NOTE!

If there is a ground earth connection with the contact tip, before the wire-re­turn button is pressed, the wire electrode is retracted by pressing the wire-re­turn button until the wire electrode is short-circuit-free—however, this must
not exceed 10 mm (0.39 in.) each time the button is pressed.

If the wire electrode needs to be retracted further, press the wire-return button
again.

Wire-threading button

There are two options available for the wire threading:

Option 1
Thread the wire electrode at the preset feeder inching speed:

Press and hold the wire-threading button

-

After pressing the wire-threading button, the wire electrode will be threaded

-

in by 1 mm (0.039 in.)
After a brief pause, the wirefeeder continues threading in the wire electrode

-

– 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
If the wire electrode meets a ground earth connection, then the wirefeeding

-

is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)

23

Option 2
Thread the wire electrode in 1 mm steps (0.039 in. steps)

Always press (touch) the wire-threading button for less than 1 second

-

If the wire electrode meets a ground earth connection, then the wirefeeding

-

is stopped and the wire electrode is retracted again by 1 mm (0.039 in.)

NOTE!

If there is a ground earth connection with the contact tip, before the wire­threading button is pressed, the wire electrode is retracted by pressing the wire­threading button until the wire electrode is short-circuit-free—however, this
must not exceed 10 mm (0.39 in.) each time the button is pressed.

If after the 10 mm (0.39 in.) wire retraction there is still a ground earth connec­tion with the contact tip, then when the wire-threading button is pressed again,
the wire electrode is retracted again by a maximum of 10 mm (0.39 in.). The pro­cess is repeated until there is no longer any ground earth connection with the
contact tip.

Function of the
LED inside the
feed roller

There is an LED under the drive roller cover to illuminate the feed roller interior.
When the cover is opened, the LED lights up for 2 minutes.

If the cover is closed and opened again, the LED switch-on time increases by 5
minutes each time.

When welding is started, the LED switch-on time is reset to 2 minutes.

Further functions of the LED

Flashes in case of error

-

Lights up when the wire-return and wire-threading buttons are pressed;

-

2 minutes delay time after releasing the buttons
Is off during welding

-

24

Before installation and initial operation

EN-US

Safety

Setup regula­tions

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.

The WF 25i FlexDrive intermediate drive has been tested according to degree of
protection IP23. This means:

Protection against the penetration of solid foreign bodies with a diameter of

-

more than 12.5 mm (0.49 in.)
No protection against water

-

The intermediate drive WF 25i FlexDrive may only be set up and operated in
closed areas.

25

Installing Optional Equipment

Mounting the
protective cage

Disconnect the welding torch hosepack from the WF 25i FlexDrive

1

See page 32.

Disconnect the extension hosepack from the WF 25i FlexDrive

2

See page 31.

NOTE!

Before mounting the protective cage, note the wirefeeding direction from the
wirefeeder to the welding torch.

The wirefeeding direction is indicated by arrows on the bottom of the protective
cage.

26

M6 x 10 mm

x4

10 Nm

7.38 ft·lb

*

2

1

2

2

2

3

2

1

3

1

2

3

3

3

4

M10 x 20 mm

x1

M10

M8 x 50 mm

x2

M8

* Safety rope with carabiner

The carabiner is hooked onto the protective cage.

4

Connect the extension hosepack

-

to the WF 25i FlexDrive
See page 31.

Hook the carabiner of the safety

-

rope onto the wirefeeder-side anti­kink spring

EN-US

The protective cage can also be used without rollers.
In this case, the protective cage is equipped with 8 sliding elements.

Dismantling the rollers:

1

The protective cage without rollers is
assembled as described in the previous
steps.

27

Mounting the

M6 x 20 mm

x4

10 Nm

7.38 ft·lb

1

2

3

3

4

5

6

6

runners

1

28

Installing the inner liner in the extension hosep-

1

ack

Installing the in­ner liner in the
extension hosep­ack

On delivery, a universal inner liner is mounted in the extension hosepack. The in­ner liner is suitable for all wire diameters and materials.
The inner liner is pre-assembled on the WF 25i FlexDrive side with the brass
clamping nipple and protrudes approx. 20 mm from the FSC at the other end of
the hosepack.
The assembly activities for a pre-assembled inner liner start at step 5.

NOTE!

To ensure that the inner liner can be fitted correctly, lay the hosepack out
straight when fitting the inner liner.
Use lubricant when inserting the inner liner into 15 m and 20 m hosepacks.

1

2

EN-US

3

WF 25i FlexDrive side

* Screw the brass clamping

nipple onto the inner liner as far
as it will go. The inner liner
needs to be visible through the
hole in the cap.

29

4

**

***

1

2

2

2

1

****

5

WF 25i FlexDrive side

Wirefeeder side

** Push the steel inner liner into the hosepack with light pressure and trim it

flush to length

*** Push the plastic inner liner into the hosepack with light pressure and trim

it flush to length

6

**** Screw the wire-specific clamp-

ing nipple from the Basic Kit
onto the inner liner as far as it
will go. The inner liner needs to
be visible through the hole in
the cap.

30

Wirefeeder side

7

Wirefeeder side

Connecting the extension hosepack

2

1

3

**

5

4

EN-US

Safety

Connecting the
extension hosep­ack

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.

IMPORTANT! When connecting the extension hosepack, note:

Existing coolant hoses must always be on the underside of the FSC.

-

The hosepack end with the brass clamping nipple is always connected to the

-

WF 25i FlexDrive.
The hosepack end with the wire-specific clamping nipple is connected to the

-

wirefeeder.

1

** ... Brass clamping nipple

The extension hosepack is disconnected in reverse order.

31

Connecting the welding torch

2

3

1

4

5

Safety

Connecting the
welding torch

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

The welding torch hosepack is disconnected in reverse order.

32

Inserting / changing the feed rollers and

1

2

3

2

1

wirefeeder

Safety

Danger from electrical current.

This can result in serious personal injury and damage to property.

▶
▶
▶

General The feed rollers are not inserted in the system when 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.

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.

NOTE!

EN-US

Inserting/chan­ging feed rollers

Danger due to deficient feed rollers.

This can result in poor-quality weld properties.

Only use feed rollers which match the wire electrode.

▶

The following feed rollers are available for the WF 25i FlexDrive:

A Rollers with semicircular groove, for aluminum, AlSi, AlMg
S Rollers with 60° groove, for steel, CrNi, CuSi
R Rollers with knurled groove, for flux core wires

1

2

33

1

3

2

1

3

2

3

1

3

2

4

4

5

Installation is carried out in reverse or­der.

CAUTION!

Danger due to exposed mechanically moving parts.

Personal injury and damage to property may result.

Only operate the device when all covers are closed and/or completely moun-

▶

ted.

34

Inserting / chan-

1

2

2

1

2

1

3

3

2

3

1

1

2

*

*

1

35.5 mm

1.40 inch

ging the
wirefeeder

Two different wirefeeders are available for the WF 25i FlexDrive:

for aluminum (with pressed-in plastic inner liner)

-

for steel

-

EN-US

1

3

2

4

* The two set screws do not have to be unscrewed completely, loosening the

set screws approx. two turns is sufficient.

1

35

1

28.5 mm

1.12 inch

2

2

3

1

4

5

2

1

3

5

4

**

3

4

** ... Brass clamping nipple

36

4

1

2

3

***

***

6

5

5

2

1

3

*** ... Push the wirefeeder back as far as it will go

6

EN-US

37

Threading the Wire Electrode

General

Threading the
wire electrode

NOTE!

The wire threading button can also be used on another system component for
wire threading from the manufacturer - for example, the wire threading button
of the power source.

The function of the wire threading button is the same for all system components
of the manufacturer.

For more information on the function of the wire threading button, see page .

▶

CAUTION!

Danger due to welding current and unintentional 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 system and workpiece.

CAUTION!

Danger due to sharp end of the wire electrode.

This can result in severe personal injury and damage to property.

Thoroughly deburr the end of the wire electrode before inserting.

▶

CAUTION!

Danger from springiness of 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 electrode firmly to avoid injuries caused by the wire electrode springing
back.

Lay the extension hosepack to the WF 25i FlexDrive and the welding torch

1

hosepack out straight

Engage feed rollers in the wirefeeder and in the WF 25i FlexDrive (close

2

clamping lever)

38

3

4

5

3

2

1

6

Thread the wire electrode on the wirefeeder

CAUTION!

Danger due to emerging wire electrode.

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 suitable protective goggles.

▶

Do not point the welding torch at people.

▶

Make sure that the wire electrode does not touch any conductive or groun-

▶

ded parts (e.g., housing, etc.).

EN-US

4

39

Setting the con-

2
1

1

2

tact pressure

CAUTION!

Risk of contact pressure being too high.

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 de-

▶

formed but nevertheless ensures proper wirefeeding.

1

Contact pressure standard values:

A-roller / AlSi ... 1 - 2

-

A-roller / AlMg ... 2 - 3

-

S-roller / CuSi ... 2 - 3

-

S-roller / steel ... 3 - 4

-

S-roller / CrNi ... 3 - 4

-

R-roller / FCW ... 1.5 - 2.5

-

40

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 satisfied before starting up a welding system

with WF 25i FlexDrive:

-

-

-

-

-

-

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
WF 25i Flex Drive connected to wirefeeder by means of extension hosepack
The wirefeed-side clamping lever must be closed.
Torch hosepack connected to WF 25i FlexDrive
The clamping lever on the welding torch side must be closed

Only when using a protective cage:
The carabiner of the safety rope must be hooked onto the wirefeed-side anti­kink spring of the extension hosepack.

Filling water­cooled welding
systems with
coolant

Feed rollers engaged in wirefeeder and WF 25i FlexDrive

-

Wirespool / basket-type spool with basket-type spool adapter engaged in

-

wirefeeder
or
wirefeeding hose from welding wire drum connected to "No Spool" wirefeed­er option
Wire electrode threaded in

-

Contact pressure of the feed rollers set

-

Brake set on the wirefeeder

-

All covers closed, all side parts mounted, and all protection devices in good

-

order and installed in the location intended
For water-cooled welding systems:

-

Extension hosepack and welding torch hosepack filled with coolant
Min. shielding gas pressure 1.0 bar / 14.5 psi

-

or 20 L/min / 5.28 gal (US)/min

NOTE!

After longer welding pauses (> 1 h), press the gas-test button and flush the
hosepack before starting welding again.

For water-cooled welding systems, WF 25i FlexDrive and the extension hosepack
are delivered without coolant.
Only use the manufacturer's original coolant (Cooling Liquid FCL 10/20 or torch
coolant) to fill the cooling unit. Other coolants are not suitable due to their elec­trical conductivity and insufficient material compatibility.

41

If the "OPT/CU Torch Deflate" option is available on the cooling unit of the weld­ing system, the setup parameter "Empty / fill torch hosepack" is available in the
setup menu of the power source.

This function can be used to transport the coolant from the welding torch hosep­ack and extension hosepack back to the coolant tank, for example when changing
the torch body.
The power source does not have to be switched off.

NOTE!

When draining long hosepacks > 8 m, a fully filled coolant tank can overflow ­risk of slipping!

Check the level in the coolant tank before emptying the torch hosepack.

▶

Follow the Operating Instructions for the cooling unit and power source.

▶

Once the torch body has been replaced, the welding torch hosepack can be re­filled with coolant.

Procedure for filling long welding torch hosepacks (> 8 m, extension hosepack):

Connect the extension hosepack to the wirefeeder

1

Connect the extension hosepack to the WF 25i FlexDrive

2

Connect the torch hosepack to the WF 25i FlexDrive

3

Fill the coolant tank of the cooling unit to the maximum level

4

Fill the hosepack with coolant

5

Do not refill the differential quantity missing from the coolant tank, other-

6

wise the coolant tank may overflow when the hosepacks are emptied.

For more information on emptying / filling the torch hosepack, refer to the Oper­ating Instructions for the power source or the welding torch.

Conducting sys­tem calibration
and R/L compar­ison

Commissioning The wirefeeder is started up in manual applications by pressing the torch trigger

NOTE!

System calibration must be performed on welding systems with WF 25i
FlexDrive. The wire electrode must be threaded for the purpose of system calib­ration.

System calibration is carried out on the power source under:
Process parameters / Components & monitoring / System calibration

The R/L comparison is also performed on the power source under:
Process parameters / General / Next page / R/L comparison

For further information on system calibration and R/L comparison, refer to the
Operating Instructions of the power source.

and in automated applications by an active signal to start welding.

42

Troubleshooting

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!

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

-

43

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

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

44

Cause:
Remedy:

Gas solenoid valve faulty
Inform the service team

Irregular wire speed

Cause:
Remedy:

Braking force has been set too high
Loosen the brake

EN-US

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

Wirefeed issues

For applications with long hosepacks

Cause:
Remedy:

Welding torch gets very hot

Cause:
Remedy:

Contact tip hole too narrow
Use suitable contact tip

Inner liner in the welding torch faulty
Check the inner liner for kinks, dirt, etc. and replace if necessary

Feed rollers not suitable for wire electrode 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

Cause:
Remedy:

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

45

Poor-quality weld properties

Cause:
Remedy:

Incorrect welding parameters
Check settings

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

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 or heavily worn contact tip
Change contact tip

Incorrect wire alloy or incorrect wire diameter
Check wire electrode in use

Incorrect wire alloy or incorrect wire diameter
Check weldability of the base material

Shielding gas not suitable for wire alloy
Use correct shielding gas

46

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.

▶

47

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.

48

Technical data

EN-US

WF 25i FlexDrive

Welding current at 10 min / 40 °C
(104 °F)

Maximum pressure of shielding gas 7 bar

Coolant Original Fronius

Maximum pressure of coolant 5 bar

Wire speed 1 - 25 m/min

Wire drive 2-roller drive

Wire diameter 0.8 - 1.6 mm

Protection class IP 20

Mark of conformity S, CE, CSA

Dimensions l × w × h 404 x 104 x 128 mm

Dimensions I x w x h
(with protective cage, without rollers)

100% ED* / 320 A

60% ED* / 360 A

40% ED* / 400 A

101.53 psi

72.53 psi

39.37 - 984.25 ipm

0.03 - 0.06 in.

15.91 x 4.09 x 5.04 in.

736 x 156 x 149 mm

28.98 x 6.14 x 5.87 in.

Dimensions I x w x h
(with protective cage and rollers)

Weight 4.4 kg

Weight
(with protective cage, without rollers)

Weight
(with protective cage and rollers)

* ED = Duty cycle

736 x 303.5 x 235 mm

28.98 x 12.03 x 9.25 in.

9.70 Ib.

8.1 kg

17.86 Ib.

10.4 kg

22.93 Ib.

49

50

EN-US

51