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
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Damage to the device and other material assets belonging to the operating
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company
Inefficient operation of the equipment
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All persons involved in the commissioning, operation, maintenance, and servicing
of the device must
Be suitably qualified
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Have knowledge of welding
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Have completely read and followed these Operating Instructions
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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
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Not be damaged/marked
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Not be removed
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Not be covered, pasted, or painted over
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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
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Carrying out all the specified inspection and servicing work
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Never use the device for the following applications:
Thawing pipes
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Charging batteries
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Starting motors
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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)
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During transport and storage: -20°C to +55°C (-4°F to 131°F)
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Relative humidity:
Up to 50% at 40°C (104°F)
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Up to 90% at 20°C (68°F)
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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-
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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
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Read these Operating Instructions, especially the section "Safety Rules," and
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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
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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
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Arc radiation that poses a risk of injury to the eyes and skin
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Hazardous electromagnetic fields that pose a risk of death for individuals
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with pacemakers
Electrical risks from grid current and welding current
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Increased noise exposure
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Harmful welding fumes and gases
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Wear suitable protective clothing when dealing with the device. The protective
clothing must have the following properties:
Flame resistant
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Insulating and dry
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Covering the entire body and in good condition with no damage
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Safety helmet
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Cuffless pants
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Protective clothing involves the following:
Protecting the face and eyes from UV radiation, heat and flying sparks with a
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face guard featuring a regulation-compliant filter
Wearing regulation-compliant protective goggles with side protection behind
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the face guard
Wearing rigid, wet-insulating footwear
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Protecting hands with appropriate gloves (featuring electrical insulation and
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thermal protection)
Wearing ear protection to reduce noise exposure and protect against injury
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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
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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
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Construct suitable protective walls and curtains.
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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.
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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
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Electrodes
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Coatings
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Cleaning agents, degreasers, and the like
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The welding process used
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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.
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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
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Overheating of parts connected to the workpiece
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Irreparable damage to ground conductors
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Damage to the device and other electrical equipment
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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
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Can cause line-bound and radiated interference in other areas
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9
Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
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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
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Grid power lines, signal lines, and data transfer lines
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IT and telecommunications equipment
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Devices for measuring and calibrating
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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
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Route them close together (also to avoid EMF problems)
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Route them far from other lines
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Equipotential bonding
3.
Workpiece grounding
4.
If necessary, establish grounding using suitable capacitors.
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Shield, if necessary
5.
Shield other devices in the vicinity
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Shield the entire welding installation
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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
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hearing aids
Persons with pacemakers must seek advice from their doctor before staying
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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
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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
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Gears
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Rollers
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Shafts
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Wirespools and welding wires
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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-
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erly.
Keep all covers and side parts closed.
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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.
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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
-
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