FRONIUS WF 15i User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

/ Perfect Charging / Perfect Welding / Solar Energy

WF 15i

WF 15i n.S.

WF 25i

WF 30i

Operating instructions

42,0426,0116,EN 035-18112021

Contents

Safety rules 5

Explanation of safety notices 5

General 5

Proper use 5

Environmental conditions 6

Obligations of the operator 6

Obligations of personnel 6

Mains connection 6

Protecting yourself and others 7

Danger from toxic gases and vapours 7

Danger from flying sparks 8

Risks from mains current and welding current 8

Meandering welding currents 9

EMC Device Classifications 10

EMC measures 10

EMF measures 11

Specific hazards 11

Requirement for the shielding gas 12

Danger from shielding gas cylinders 12

Danger from escaping shielding gas 13

Safety measures at the installation location and during transport 13

Safety measures in normal operation 13

Commissioning, maintenance and repair 14

Safety inspection 14

Disposal 15

Safety symbols 15

Data protection 15

General 17

General 19

Device concept 19

Warning notices on the device 19

Controls, connections and mechanical components 21

Controls, connections and mechanical components 23

Safety 23

Front of wire-feed unit 23

Rear of wire-feed unit 24

Wire-feed unit side 24

Wire-feed unit underside 25

Optional control panels 26

Safety 26

OPT/i WF POT control panel 26

OPT/i WF gas test & wire threading 27

OPT/i WF Standard control panel 29

Installation and commissioning 35

Before installation and commissioning 37

Safety 37

Proper use 37

Setup regulations 37

Placing wire-feed unit on swivel pin holder 38

Safety 38

Placing wire-feed unit on swivel pin holder 38

Connecting wire-feed unit to power source 39

Safety 39

General information 39

Connecting the wirefeeder to the power source 39

Connecting the extension hosepack 40

Connecting the welding torch 42

Safety 42

Connecting MIG/MAG welding torches 42

Inserting/replacing feed rollers 43

Safety 43

General 43

Inserting/replacing feed rollers 43

Inserting the wirespool, inserting the basket-type spool 45

Safety 45

Inserting the wirespool 45

Installing the basket-type spool 46

Threading the wire electrode 48

General 48

Preparatory work 48

Threading the wire electrode 49

Setting the contact pressure 49

Adjust the brake 51

General 51

Adjusting the brake 51

Design of the brake 52

Start-up 53

Safety 53

Prerequisites 53

General 53

Troubleshooting, maintenance and disposal 55

Troubleshooting 57

Safety 57

Troubleshooting 57

Care, maintenance and disposal 61

General 61

Safety 61

Every start-up 61

Every 6 months 61

Disposal 62

Technical data 63

Technical data 65

WF 15i 65

WF 15i n.S. 65

WF 25i 66

WF 30i 66

HP 70i 67

HP 95i 67

HP 120i 67

HP 70i, HP PC Cable HD 70 68

Safety rules

Explanation of

safety notices DANGER!

Indicates immediate danger.

▶If not avoided, death or serious injury will result.

WARNING!

Indicates a potentially hazardous situation.

▶If not avoided, death or serious injury may result.

CAUTION!

Indicates a situation where damage or injury could occur.

▶If not avoided, minor injury and/or damage to property may result.

NOTE!

Indicates a risk of flawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to recog-

nised 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 com-

pany,

- inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the device

must:

- be suitably qualified,

- have sufficient knowledge of welding and

- read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In

addition to the operating instructions, attention must also be paid to any generally applic-

able and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

- must be in a legible state,

- must not be damaged,

- must not be removed,

- must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section

headed "General" in the operating instructions for the device.

Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the welding processes specified on the rating plate.

Any use above and beyond this purpose is deemed improper. The manufacturer shall not

be held liable for any damage arising from such usage.

Proper use includes:

- carefully reading and following all the instructions given in the operating instructions

- studying and obeying all safety and danger notices carefully

- performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

- Thawing out pipes

- Charging batteries

- Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts

no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

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 shall not be held liable for any

damage arising from such usage.

Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)

- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:

- up to 50% at 40 °C (104 °F)

- up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc.

Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of the

operator

The operator must only allow persons to work with the device who:

- are familiar with the fundamental instructions regarding safety at work and accident

prevention and have been instructed in how to use the device

- have read and understood these operating instructions, especially the section

"safety rules", and have confirmed as much with their signatures

- are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a

safety-conscious manner.

Obligations of

personnel

Before using the device, all persons instructed to do so undertake:

- to observe the basic instructions regarding safety at work and accident prevention

- to read these operating instructions, especially the "Safety rules" section and sign to

confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm

in your absence.

Mains connection Devices with a higher rating may affect the energy quality of the mains due to their cur-

rent consumption.

This may affect a number device types in terms of:

- Connection restrictions

-Criteria with regard to the maximum permissible mains impedance *)

-Criteria with regard to the minimum short-circuit power requirement *)

*) at the interface with the public grid

see "Technical data"

In this case, the plant operator or the person using the device should check whether the

device may be connected, where appropriate by discussing the matter with the power

supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Protecting your-

self and others

Anyone working with the device exposes themselves to numerous risks, e.g.

- flying sparks and hot pieces of metal

- Arc radiation, which can damage eyes and skin

- Hazardous electromagnetic fields, which can endanger the lives of those using car-

diac pacemakers

- Risk of electrocution from mains current and welding current

- Greater noise pollution

- Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The protective

clothing must have the following properties:

- Flame-resistant

- Insulating and dry

- Covers the whole body, is undamaged and in good condition

- Safety helmet

- Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

- Protect eyes and face from UV rays, heat and sparks using a protective visor and

regulation filter

- Wear regulation protective goggles with side protection behind the protective visor

- Wear stout footwear that provides insulation even in wet conditions

- Protect the hands with suitable gloves (electrically insulated and providing protection

against heat)

- Wear ear protection to reduce the harmful effects of noise and to prevent injury

Keep all persons, especially children, out of the working area while any devices are in

operation or welding is in progress. If, however, there are people in the vicinity:

- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying

sparks, harmful welding fumes, noise, possible risks from mains current and welding

current, etc.)

- Provide suitable protective equipment

- Alternatively, erect suitable safety screens/curtains.

Danger from tox-

ic gases and va-

pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the

International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.

If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

- must not be breathed in

- must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least

20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured

toxic emission values should be compared with the permissible limit values.

The following components are responsible, amongst other things, for the degree of tox-

icity of welding fumes:

- Metals used for the workpiece

- Electrodes

- Coatings

- Cleaners, degreasers, etc.

- Welding process used

The relevant material safety data sheets and manufacturer's specifications for the listed

components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identify-

ing working conditions can be found on the European Welding Association website under

Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation

area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

Danger from fly-

ing sparks

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or

alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or

openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near

sealed tanks, vessels or pipes unless these have been prepared in accordance with the

relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases,

propellants, mineral oils or similar products. Residues pose an explosive hazard.

Risks from mains

current and weld-

ing current

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed

rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insu-

lated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or

cover for the earth or ground potential. This base or cover must extend over the entire

area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimen-

sioned. Replace loose connections and scorched, damaged, or inadequately dimen-

sioned cables and leads immediately.

Use the handle to ensure the power connections are tight before every use.

In the case of power cables with a bayonet connector, rotate the power cable around the

longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must

- never be immersed in liquid for cooling

- Never touch the electrode when the power source is switched on.

Double the open circuit voltage of a power source can occur between the welding elec-

trodes of two power sources. Touching the potentials of both electrodes at the same time

may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician to ensure

the ground conductor is functioning properly.

Protection class I devices require a mains supply with ground conductor and a connector

system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket

without ground conductor contact is only permitted if all national regulations for protective

separation are observed.

Otherwise, this is considered gross negligence. The manufacturer shall not be held liable

for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent

anyone from plugging the mains plug back in and switching it on again.

After opening the device:

- Discharge all live components

- Ensure that all components in the device are de-energised.

If work on live parts is required, appoint a second person to switch off the main switch at

the right moment.

Meandering weld-

ing currents

If the following instructions are ignored, meandering welding currents can develop with

the following consequences:

- Fire hazard

- Overheating of parts connected to the workpiece

- Damage to ground conductors

- Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments,

such as insulation against conductive floor or insulation to conductive racks.

If power distribution boards, twin-head mounts, etc., are being used, note the following:

The electrode of the welding torch / electrode holder that is not used is also live. Make

sure that the welding torch / electrode holder that is not used is kept sufficiently insu-

lated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire elec-

trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the

wirefeeder.

EMC Device Clas-

sifications

Devices in emission class A:

- Are only designed for use in industrial settings

- Can cause line-bound and radiated interference in other areas

Devices in emission class B:

- Satisfy the emissions criteria for residential and industrial areas. This is also true for

residential areas in which the energy is supplied from the public low-voltage mains.

EMC device classification as per the rating plate or technical data.

EMC measures In certain cases, even though a device complies with the standard limit values for emis-

sions, it may affect the application area for which it was designed (e.g. when there is

sensitive equipment at the same location, or if the site where the device is installed is

close to either radio or television receivers).

If this is the case, then the operator is obliged to take appropriate action to rectify the

situation.

Check and evaluate the immunity to interference of nearby devices according to national

and international regulations. Examples of equipment that may be susceptible to interfer-

ence from the device include:

- Safety devices

- Network, signal and data transfer lines

- IT and telecommunications devices

- Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

1. Mains supply

- If electromagnetic interference arises despite the correct mains connection, ad-

ditional measures are necessary (e.g. use of a suitable line filter)

2. Welding power-leads

- must be kept as short as possible

- must be laid close together (to avoid EMF problems)

- must be kept well apart from other leads

3. Equipotential bonding

4. Earthing of the workpiece

- If necessary, establish an earth connection using suitable capacitors.

5. Shield, if necessary

- Shield other devices nearby

- Shield the entire welding installation

This manual suits for next models

Table of contents

Other FRONIUS Welding System manuals

FRONIUS

FRONIUS TPS 320i User manual

FRONIUS

FRONIUS Virtual Welding 2.0 MobileCase User manual

FRONIUS

FRONIUS TransPocket 150 User manual

FRONIUS

FRONIUS CMT drive User manual

FRONIUS

FRONIUS Selectiva 2100 User manual

FRONIUS

FRONIUS TransSteel 3000c Pulse User manual

FRONIUS

FRONIUS TS 4000 User manual

FRONIUS

FRONIUS TransPocket 150 TIG User manual

FRONIUS

FRONIUS TransPocket 180 RC HW User manual

FRONIUS

FRONIUS Robacta Reamer V Comfort User manual

FRONIUS

FRONIUS TransPocket 150 User manual

FRONIUS

FRONIUS VARIOSTAR 357 User manual

FRONIUS

FRONIUS TransPocket 4000 CEL User manual

FRONIUS

FRONIUS VarioStar 1500 User manual

FRONIUS

FRONIUS TransPocket 150 User manual

FRONIUS

FRONIUS F Series User manual

FRONIUS

FRONIUS Robacta MTG 3500 User manual

FRONIUS

FRONIUS TransSteel 2700c User manual

FRONIUS

FRONIUS CWF 25i User manual

FRONIUS

FRONIUS PullMig AL216 User manual

FRONIUS

FRONIUS MagicWave 190 User manual

FRONIUS

FRONIUS AccuPocket 150/400 User manual

FRONIUS

FRONIUS DeltaSpot User manual

FRONIUS

FRONIUS MTG 2500 S User manual

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

Lincoln Electric

Lincoln Electric HANDYMIG 170I Operator's manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

Lincoln Electric

Lincoln Electric INVERTEC V350-PRO CE Technical specifications

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual

FRO­NIUS WF 15i User manual

Popular Welding System manuals by other brands

FRONIUS WF 15i User manual