FRONIUS CWF 25i Bedienungsanleitung

Operating

Instructions

CWF 25i

42,0426,0392,EA 002-27092022

EN-US Operating instructions

Table of contents

Safety Instructions 5

Explanation of Safety Instructions 5

General 5

Intended Use 6

Environmental Conditions 6

Obligations of the Operating Company 6

Obligations of Personnel 6

Grid Connection 7

Personal Protection and Protection of Others 7

Data on noise emission values 7

Danger from toxic gases and vapors 8

Danger from Flying Sparks 8

Risks from grid current and welding current 9

Stray welding currents 10

EMC Device Classifications 10

EMC measures 10

EMF measures 11

Particular hazard areas 11

Requirement for the shielding gas 12

Danger from Shielding Gas Cylinders 12

Danger Posed by Shielding Gas Leak 13

Safety Measures at the Setup Location and During Transport 13

Safety Measures in Normal Operation 14

Maintenance and repair 14

Safety Inspection 15

Disposal 15

Safety symbols 15

Data backup 15

General 17

Device concept 17

Field of application 17

Warning notices on the device 17

Operating controls, connections and mechanical components 19

Safety 19

Front, back 19

Left side, bottom 20

Before installation and initial operation 23

Safety 23

Intended use 23

Setup regulations 23

Placing the wirefeeder on the swivel pin holder 24

Safety 24

Placing the wirefeeder on the swivel pin holder 24

Connecting the wirefeeder to the power source 25

Safety 25

General 25

Connecting the wirefeeder to the power source 25

Connecting the wirefeeding hose/welding torch 28

Safety 28

Connecting the wirefeeding hose 28

Connecting the welding torch 28

Inserting/changing feed rollers 30

Safety 30

General 30

Inserting/changing feed rollers 30

Inserting the wirespool/basket-type spool 32

Safety 32

Inserting the wirespool 32

Installing the basket-type spool 33

EN-US

Threading in the welding wire 35

Setting the contact pressure 36

Adjusting the brake 37

General 37

Adjusting the brake 37

Design of the brake 38

Commissioning 39

Safety 39

Requirements 39

Commissioning 39

Troubleshooting 40

Safety 40

Troubleshooting 40

Service, maintenance and disposal 43

General 43

Safety 43

At every start-up 43

Every 6 months 43

Disposal 44

Technical data 45

CWF 25i 45

Water-cooled interconnecting hosepack - HP 70i CWF CON /W 46

Disposal 46

Safety Instructions

Explanation of

Safety Instruc-

tions

DANGER!

Indicates an immediate danger.

▶Death or serious injury may result if appropriate precautions are not taken.

WARNING!

Indicates a possibly dangerous situation.

▶Death or serious injury may result if appropriate precautions are not taken.

CAUTION!

Indicates a situation where damage or injury could occur.

▶Minor injury or damage to property may result if appropriate precautions are

not taken.

NOTE!

Indicates the possibility of ﬂawed results and damage to the equipment.

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

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

it can cause

-Injury or death to the operator or a third party

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

company

-Inefficient operation of the equipment

All persons involved in the commissioning, operation, maintenance, and servicing

of the device must

-Be suitably qualified

-Have knowledge of welding

-Have completely read and followed these Operating Instructions

The Operating Instructions must always be at hand wherever the device is being

used. In addition to the Operating Instructions, all applicable local rules and reg-

ulations regarding accident prevention and environmental protection must also

be followed.

All safety and danger notices on the device must

-Be kept in a legible state

-Not be damaged/marked

-Not be removed

-Not be covered, pasted, or painted over

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

tion 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!

EN-US

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 respons-

ible for any damage resulting from improper use.

Proper use also means

-Completely reading and obeying all instructions in the Operating Instruc-

tions

-Completely reading and obeying all safety instructions and danger notices

-Carrying out all the specified inspection and servicing work

Never use the device for the following applications:

-Thawing pipes

-Charging batteries

-Starting motors

The device is designed for operation in industry and business. The manufacture

shall not be liable for any damage resulting from use in a living area.

The manufacture shall also not be liable for faulty or incorrect work results.

Environmental

Conditions

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 liab-

ility 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 be-

fore beginning the work:

-Follow the basic regulations for occupational safety and accident prevention

-Read these Operating Instructions, especially the section "Safety Rules," and

confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage

can occur in one's absence.

Grid Connection Devices with a high output can inﬂuence the energy quality of the grid due to

their current consumption.

This may affect a number of device types in terms of:

-connection restrictions

-criteria regarding maximum permissible grid impedance *)

-criteria regarding the minimum required short-circuit power *)

*) both at the interface with the public grid

See technical data

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

not the device is allowed to be connected, where appropriate through discussion

with the power supply company.

IMPORTANT! Ensure secure grounding of the grid connection!

Personal Protec-

tion and Protec-

tion of Others

You are exposed to numerous hazards while handling the device, for example:

-Flying sparks and pieces of hot metal

-Arc radiation that poses a risk of injury to the eyes and skin

-Hazardous electromagnetic fields that pose a risk of death for individuals

with pacemakers

-Electrical risks from grid current and welding current

-Increased noise exposure

-Harmful welding fumes and gases

Wear suitable protective clothing when dealing with the device. The protective

clothing must have the following properties:

-Flame resistant

-Insulating and dry

-Covering the entire body and in good condition with no damage

-Safety helmet

-Cufﬂess pants

Protective clothing involves the following:

-Protecting the face and eyes from UV radiation, heat and ﬂying sparks with a

face guard featuring a regulation-compliant filter

-Wearing regulation-compliant protective goggles with side protection behind

the face guard

-Wearing rigid, wet-insulating footwear

-Protecting hands with appropriate gloves (featuring electrical insulation and

thermal protection)

-Wearing ear protection to reduce noise exposure and protect against injury

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, pos-

sible hazard due to grid current or welding current, etc.)

-Provide suitable protective equipment or

-Construct suitable protective walls and curtains.

Data on noise

emission values

The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling

and in the cooling phase following operation in relation to the maximum permit-

ted operating point at standard loading in accordance with EN 60974-1.

EN-US

A workplace-specific emission value for welding (and cutting) cannot be spe-

cified because this value depends on the welding process and the environmental

conditions. It is inﬂuenced by a wide range of parameters, such as the welding

process itself (MIG/MAG, TIG welding), the selected current type (direct cur-

rent, alternating current), the power range, the type of weld metal, the resonance

properties of the workpiece, the workplace environment, and many other factors.

Danger from tox-

ic gases and va-

pors

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 ventila-

tion 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, com-

pare 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

Consult the corresponding material safety data sheets and manufacturer's in-

structions for the components listed above.

Recommendations for exposure scenarios, risk management measures and

identifying working conditions can be found on the European Welding Associ-

ation 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 Fly-

ing Sparks

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 cor-

responding 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.

Risks from grid

current and

welding current

An electric shock can be fatal.

Do not touch voltage-carrying parts inside or outside the device.

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

feed rollers, as well as all pieces of metal that are in contact with the welding

wire, are live.

Always place the wirefeeder on a sufficiently insulated base or use a suitable in-

sulating wirefeeder holder.

Ensure suitable personal protection with dry temporary backing or cover with

sufficient insulation against the ground potential. The temporary backing or cov-

er must completely cover the entire area between the body and the ground po-

tential.

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

mensioned. Replace loose connections and scorched, damaged, or inadequately

dimensioned cables and leads immediately.

Before every use, check power connections for secure fit by hand.

In the case of power cables with bayonet connectors, turn the power cable by at

least 180° around the longitudinal axis and pretension.

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

Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)

-Never immerse it in liquids to cool it

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

The open circuit voltage of a welding system may double, for example, between

the electrodes of two welding systems. Touching the potentials of both elec-

trodes at the same time may be life-threatening in some cases.

Have the grid and device supply lead regularly inspected by an electrician to en-

sure 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 li-

ability 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

After opening the device:

-Discharge all electrically charged components

-Ensure that all components are disconnected from the power supply.

If work is needed on voltage-carrying parts, bring in a second person who will

switch off the main switch at the correct time.

Stray welding

currents

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 envir-

onments, e.g., insulation against electrically conductive ﬂoors or electrically con-

ductive 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

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 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 ac-

tion to rectify the situation.

Test and assess the immunity of equipment in the vicinity of the device in ac-

cordance with national and international provisions. Examples of interference-

prone 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

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