WF 25i Dual Operating instructions

• 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

• 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.

• 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 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!

1. Safety Instructions

• 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

• 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.

• 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 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!

1. Safety Instructions

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.

• Completely reading and obeying all instructions in the Operating Instructions
• Completely reading and obeying all safety instructions and danger notices
• Carrying out all the specified inspection and servicing work

• 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.

1. Safety Instructions

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.

• 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)

• 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.)

1. Safety Instructions

• Are familiar with the basic occupational safety and accident prevention regulations and are trained in handling the device
• Have read and understood these Operating Instructions, especially the section "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.

1. Safety Instructions

• 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.

1. Safety Instructions

Devices with a high output can influence the energy quality of the grid due to their current consumption.

• 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!

1. Safety Instructions

• 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

• Flame resistant
• Insulating and dry
• Covering the entire body and in good condition with no damage
• Safety helmet
• Cuffless pants

• 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

• 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.

1. Safety Instructions

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.

• 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 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 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.

1. Safety Instructions

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.

1. Safety Instructions

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 wire spool, 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.

• Never immerse it in liquids to cool it
• Never touch it when the welding system 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 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 mains plug.

Secure the device to prevent the mains plug from being connected and switched on again by applying a clearly legible and understandable warning sign.

• 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.

1. Safety Instructions

• 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.

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

1. Safety Instructions

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• 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.

1. Safety Instructions

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.

• Safety devices
• Grid power lines, signal lines, and data transfer lines
• IT and telecommunications equipment
• Devices for measuring and calibrating

1. Grid power supply
   • If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
   • Keep them as short as possible
   • Route them close together (also to avoid EMF problems)
   • Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
   • If necessary, establish grounding using suitable capacitors.
5. Shield, if necessary
   • Shield other devices in the vicinity
   • Shield the entire welding installation

1. Safety Instructions

• 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

1. Safety Instructions

• 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.

• Ensure that all covers are closed, and all side parts have been mounted properly.
• Keep all covers and side parts closed.

The welding wire protruding from the welding torch poses 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.

Welding machines for work in areas with increased electrical hazard (e.g., boilers) must be labeled with the symbol (Safety). However, the welding machine 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).

Welding with the device during crane transport is only permitted if this is clearly stated in the intended use of the device.

If the device is equipped with a carrier strap or handle, then this is used exclusively for transport by hand. The carrier strap is not suitable for transport by crane, counterbalanced lift truck, or other mechanical lifting tools.

All lifting equipment (straps, 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.

1. Safety Instructions

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

1. Safety Instructions

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.

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

1. Safety Instructions

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.

1. Safety Instructions

• The maximum permitted tilt angle is 10°.

• 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 and disconnect devices from the grid before transport or lifting.

• Wirefeeder
• Wire spool
• shielding gas cylinder

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.

1. Safety Instructions

• 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.

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 flammable 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.

1. Safety Instructions

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.

1. Safety Instructions

The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.

The manufacturer recommends calibrating welding systems within the same 12-month interval.

• After changes
• After alterations
• After repair, service, and maintenance
• At least every twelve 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.

1. Safety Instructions

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally sound manner in accordance with the European Directive and national law. Used equipment must be returned to the distributor or through a local authorized collection and disposal system. Proper disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.

• Collect separately
• Observe local regulations
• Crush cardboard boxes

1. Safety Instructions

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.

1. Safety Instructions

• backing up any changes made to the factory settings
• saving and storing personal settings

1. Safety Instructions

Copyright of these operating instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information on any discrepancies in the operating instructions.

The WF 25i Dual enables the joint use of two welding process lines with one power source. The welding process lines can be changed using the torch trigger, on the power source, via the operating controls on the wirefeeder, or on a remote control.

Two spool holders and different options are available for the WF 25i Dual:

WF 25i Dual with D300 spool holder and spool cover
for D300 mm wirespools
(with the Trabant, remote control, tool tray, crane transport, and hosepack holder options)

WF 25i Dual with D450 spool holder without spool cover
for large D450 mm spools
(with the Trabant, remote control, tool tray, and crane transport options)

1. General

The WF 25i Dual enables the joint use of two welding process lines with one power source. The welding process lines can be changed using the torch trigger, on the power source, via the operating controls on the wirefeeder, or on a remote control.

Two spool holders and different options are available for the WF 25i Dual:

WF 25i Dual with D300 spool holder and spool cover
for D300 mm wirespools
(with the Trabant, remote control, tool tray, crane transport, and hosepack holder options)

WF 25i Dual with D450 spool holder without spool cover
for large D450 mm spools
(with the Trabant, remote control, tool tray, and crane transport options)

1. General

In order for the WF 25i Dual dual-head wirefeeder to work properly, the power source must have the following firmware version:
official_TPSi_iWave_3.5.2-xxx.ffw or higher

1. General

The wirefeeder 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.

		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
		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. During operation Ensure that all covers are closed, and all side parts have been mounted properly. Keep all covers and side parts closed.

An electric shock can be fatal!
Do not touch any exposed live parts!

Also see page (→)!

1. General

Warning notices are attached to the device for certain device versions.

The arrangement of the symbols may vary.

Not pictured:

• Euro connection conversion kit
• SpeedNet cable 5 m
• SpeedNet cable 10 m

1. Options and components

Not pictured:

• Euro connection conversion kit
• SpeedNet cable 5 m
• SpeedNet cable 10 m

1. Options and components

Required for setup on the trolley:

• TU Car 4 Pro trolley
• OPT/TU Mounting Set WF Dual H510 option (for gas-cooled systems)
  or
  OPT/TU Mounting Set WF Dual H740 option (for water-cooled systems)

WF 25i Dual with D300 spool holder on the trolley

An alternative setup on the trolley could include the WF 25i Dual with D450 spool holder.

Details on setting up the dual-head wirefeeder on the trolley can be found in the "OPT/TU Mounting Set WF Dual" Installation Instructions (42,0410,2636).

1. System configurations

Required for setup on the trolley:

• TU Car 4 Pro trolley
• OPT/TU Mounting Set WF Dual H510 option (for gas-cooled systems)
  or
  OPT/TU Mounting Set WF Dual H740 option (for water-cooled systems)

WF 25i Dual with D300 spool holder on the trolley

An alternative setup on the trolley could include the WF 25i Dual with D450 spool holder.

Details on setting up the dual-head wirefeeder on the trolley can be found in the "OPT/TU Mounting Set WF Dual" Installation Instructions (42,0410,2636).

1. System configurations

The OPT/WF Boom Mounting Kit Dual option is required for setup on the welding boom.
The use of welding wire drums is recommended.

WF 25i Dual with boom mounting kit option, mounted on the welding boom (schematic presentation)

1. System configurations

The OPT/WF Lift Bail Dual option is required for setup on the crane.

WF 25i Dual with D300 spool holder for crane setup

IMPORTANT! Setup and operation on the crane are only permitted for the WF 25i Dual with D300 spool holder.

1. System configurations

Depending on the welding system, the following data must be observed for water-cooled system components.

Welding system with WF 25i Dual and TPS 320i - 600i (MIG/MAG):

Welding system with WF 25i Dual and iWave 300i - 500i MP (MIG/MAG + TIG):

IMPORTANT! A water-cooled TIG extension hosepack cannot be used in conjunction with a WF 25i Dual.

The following safety sticker is attached to the crane transport option OPT/WF Lift Bail Dual:

a) b) c)

1. The WF 25i Dual may only be transported with the OPT/WF Lift Bail Dual option mounted on the crane.
   
   For details, see page (→).
   
2. Crane transport of a welding system mounted on the trolley with WF 25i Dual is only permitted in conjunction with the OPT/TU Mounting Set WF Dual option.
   
   For details, see page (→).
   
3. Crane transport of a welding system mounted on the trolley with WF 25i Dual on the crane transport option OPT/WF Lift Bail Dual is not permitted.
   
   For details, see page (→) or the Installation Instructions for the OPT/TU Mounting Set WF Dual option (42,0410,2636).

The crane transport option OPT/WF Lift Bail Dual also has a rating plate indicating the maximum load capacity:

1. Crane transport

The following safety sticker is attached to the crane transport option OPT/WF Lift Bail Dual:

a) b) c)

1. The WF 25i Dual may only be transported with the OPT/WF Lift Bail Dual option mounted on the crane.
   
   For details, see page (→).
   
2. Crane transport of a welding system mounted on the trolley with WF 25i Dual is only permitted in conjunction with the OPT/TU Mounting Set WF Dual option.
   
   For details, see page (→).
   
3. Crane transport of a welding system mounted on the trolley with WF 25i Dual on the crane transport option OPT/WF Lift Bail Dual is not permitted.
   
   For details, see page (→) or the Installation Instructions for the OPT/TU Mounting Set WF Dual option (42,0410,2636).

The crane transport option OPT/WF Lift Bail Dual also has a rating plate indicating the maximum load capacity:

1. Crane transport

The OPT/WF Lift Bail Dual crane transport option is required for crane transport of the WF 25i Dual with D300 spool holder.

1. Crane transport

The OPT/WF Lift Bail Dual crane transport option is required for crane transport of the WF 25i Dual with D450 spool holder without spool cover.

1. Crane transport

The WF Dual mounting set trolley option is required for crane transport of the welding system mounted on the trolley.

Details on crane transport can be found in the Installation Instructions for the OPT/TU Mounting Set WF Dual (42,0410,2636) option.

1. Operating controls, connections and mechanical components

1. Operating controls, connections and mechanical components

1. Operating controls, connections and mechanical components

The wirespools are not included in the scope of supply.

1. Operating controls, connections and mechanical components

1. Operating controls, connections and mechanical components

Illustration without covers and side parts shown

The described elements are located on both sides of the wirefeeder.

1. Operating controls, connections and mechanical components

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

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.)

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.)

1. Before installation and initial operation

1. Before installation and initial operation

The device is intended exclusively for end of wirefeeding with MIG/MAG welding in combination with Fronius system components.
The wirefeeder is designed for welding operation during crane transport (e.g., on the crane boom, on the balancer, on movable mountings, etc.).
Any other use does not constitute proper use.
The manufacturer shall not be held liable for any loss resulting from improper use.

• 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

1. Before installation and initial operation

The dual-head wirefeeder and the dual-head wirefeeder with the D300 spool holder with cover have been tested according to protection class IP 23. This means:

• Protection against the penetration of solid foreign bodies with a diameter of more than 12.5 mm (0.49 in.)
• Protection against spraywater at any angle up to 60° from the vertical

The wirefeeder and wirefeeder with D300 spool holder can be set up and operated outdoors in accordance with protection class IP 23. Avoid the effects of direct moisture (from rain, for example).

The dual-head wirefeeder with the D450 spool holder without cover has been tested according to protection class IP 20. 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 wirefeeder with the D450 spool holder must only be set up and operated in closed rooms.

1. Installing optional equipment

1. Installing optional equipment

1

Use screws from the scope of supply of the spool holder

2

2 x M5 x 12 mm, tightening torque = 3 Nm / 2.21 lb-ft

3

4Repeat work steps 2 and 3 on the other side of the wirefeeder

1. Installing optional equipment

1

Use screws from the scope of supply of the spool holder

2

4 x M5 x 12 mm, tightening torque = 3 Nm / 2.21 lb-ft

3

4Repeat work steps 2 and 3 on the other side of the wirefeeder

1. Installing optional equipment

1

6 x M8 x 20 mm, tightening torque = 21 Nm / 15.49 lb-ft;
Crane transport option mounted on D300 spool holder

Screws and mounting material from the scope of supply of the crane transport option.

The option is mounted on the D450 spool holder without spool cover in the same way.

1. Installing optional equipment

1

8 x M5 x 12 mm, tightening torque = 3 Nm / 2.21 lb-ft

1. Installing optional equipment

1

2

4 x brass spacer M5x12 mm, tightening torque = 2.1 Nm / 1.55 lb-ft
4 x M5 x 12 mm, tightening torque = 3 Nm / 2.21 lb-ft

1. Installing optional equipment

1

4 x M8 x 25 mm + M8 washer + NL8
Tightening torque = 21 Nm / 15.49 lb-ft

2

4 x M8 x 30 mm + M8 washer + NL8
Tightening torque = 21 Nm / 15.49 lb-ft

1. Connecting the wirefeeder to the welding machine

1. Connecting the wirefeeder to the welding machine

The wirefeeder is connected to the power source by means of the interconnecting hosepack.

1. Connecting the wirefeeder to the welding machine

1

Connecting the wirefeeder to the power source is described with reference to the WF 25i Dual with D300 spool holder.
The WF 25i Dual with D450 spool holder is connected to the power source in the same way.

2

2 x M5 x 12 mm

3Repeat work steps 1 and 2 on the other side of the wirefeeder

4

Push wirefeeder to the front;
Guide interconnecting hosepack and gas 2 through the spool holder

5

Connect the interconnecting hosepack and gas 2 to the wirefeeder

6

Push the wirefeeder back into the original position

7

2 x M5 x 12 mm, tightening torque = 3 Nm / 2.21lb-ft

8Repeat work step 7 on the other side of the wirefeeder

9

10Fix the strain-relief device of the interconnecting hosepack to the wirespool holder with 2 M5 x 12 mm screws
Tightening torque = 3 Nm / 2.21 lb-ft

1. Connecting the wirefeeder to the welding machine

1

*	For water-cooled hosepack only
CON	= interconnecting hosepack
EXT	= extension hosepack

Connect all connections so they are hand-tight.
Check for tightness.

Tightening the power connection hand-tight corresponds to 7-8 Nm.

2

If the components are not bundled in the protective bag, all interfaces must be fixed so they are immovable.

1. Connecting the welding torch

1. Connecting the welding torch

1

2

3

4

5

6Repeat the work steps on the other side of the wirefeeder

1. Inserting/changing feed rollers

1. Inserting/changing feed rollers

The feed rollers are not inserted in the system when first delivered.

In order to guarantee optimum feeding of the wire electrode, the feed rollers must be adjusted to the wire diameter and the wire alloy to be welded.

An overview of the available feed rollers and their possible uses can be found in the Spare Parts Lists.

1. Inserting/changing feed rollers

1

2

3

4

If the D450 spool holder without spool cover is to be operated with a D300 wirespool, the brake must be remounted:

1Remove M16 screw at the rear of the brake

2

WF 25i Dual with D450 spool holder

3Re-fix the brake in the new position using the M16 screw

1. Remounting the D450 brake for operation with a D300 wirespool

If the D450 spool holder without spool cover is to be operated with a D300 wirespool, the brake must be remounted:

1Remove M16 screw at the rear of the brake

2

WF 25i Dual with D450 spool holder

3Re-fix the brake in the new position using the M16 screw

1. Inserting the wirespool/basket-type spool

1. Inserting the wirespool/basket-type spool

1

1. Inserting the wirespool/basket-type spool

1

2

1. Inserting the wirespool/basket-type spool

1

1. Threading the Wire Electrode

1. Threading the Wire Electrode

1

1. Threading the Wire Electrode

1Lay the torch hosepack straight

2

1. Threading the Wire Electrode

1

Contact pressure standard values for U-groove rollers:

• Steel: 4 - 5
• CrNi: 4 - 5
• Aluminum: 0.5 - 1.5
• Tubular covered electrodes: 2 - 3

Contact pressure standard values for knurled rollers:

• Tubular covered electrodes: 1 - 2

Observe the sticker on the wire drive!

1. Adjusting the brake

1. Adjusting the brake

1

2

3

1. Adjusting the brake

The brake is only available as a complete unit.
The illustration of the brake is for information purposes only.

1. Adjusting the brake

1

2

3

1. Adjusting the brake

The brake is only available as a complete unit.
The illustration of the brake is for information purposes only.

Preliminary design of the D450 brake

1. Commissioning

1. Commissioning

Only for WF 25i Dual with spool holder D450 without spool cover:

When the dual head wirefeeder is connected to the power source and the power source is on, certain electrical live (hot) parts are exposed!

1. Commissioning

• Wirefeeder connected to power source by means of interconnecting hosepack
• Welding torch connected to wirefeeder
• Feed rollers inserted into wirefeeder
• Wirespools/basket-type spools and their adapters inserted into wirefeeder
• Wire electrodes threaded in
• Contact pressure of the feed rollers set
• Brakes adjusted
• All covers closed, all side parts mounted, and all protection devices in good order and installed in the location intended
• Welding process line selected

1. Commissioning

The wirefeeder is started up in manual applications by pressing the torch trigger and in automated applications by an active signal to start welding.

The following processes and parameters are available on the power source for operating the wirefeeder:

• TIG DynamicWire
• Wirefeeder setup
  (Process parameters / Common/TIG/MMA/CEL / Wirefeeder setup)

1. Commissioning

• Using the torch trigger on the welding torch
• Using the button/LED on the wirefeeder
• Using the gas-test, wire-return, and wire-threading buttons on the wirefeeder
• On the power source
• Using the RC Panel Standard or RC Panel Pro remote control

1. Selecting the welding process line

• Using the torch trigger on the welding torch
• Using the button/LED on the wirefeeder
• Using the gas-test, wire-return, and wire-threading buttons on the wirefeeder
• On the power source
• Using the RC Panel Standard or RC Panel Pro remote control

1. Selecting the welding process line

Press the corresponding torch trigger to switch to the other welding process line.

1. Selecting the welding process line

Press the corresponding button on the wirefeeder to switch to the other welding process line.
If the LED on the button lights up, this welding process line is activated.

1

Button/LED on the wirefeeder
1, 2 = welding process lines

1. Selecting the welding process line

If one of the gas-test, wire-return, or wire-threading buttons is pressed on one side of the wirefeeder, this welding process line is activated.
The LED of the corresponding button on the wirefeeder lights up.

1

1. Selecting the welding process line

The power source or the RC Panel Pro remote control detects when a dual-head wirefeeder is in the welding system. The status line of the power source display shows the active welding process line.

To change the welding process line, touch the welding process line displayed in the status line and confirm the subsequent confirmation prompt to change the welding process line.

For details on selecting the welding process line, refer to the power source Operating Instructions.

1. Selecting the welding process line

To change the welding process line, press the corresponding selection dial on the remote control twice:

• Left-hand selection dial = welding process line 1
• Right-hand selection dial = welding process line 2

The display of the remote control shows the change of the welding process line.

After the display goes out, the LED on the corresponding selection dial lights up to indicate the active welding process line.

1. Troubleshooting

1. 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

The device only requires minimal of service and maintenance under normal operating conditions. However, several points must be observed for the welding system to remain operational for years to come.

1. Service, maintenance and disposal

The device only requires minimal of service and maintenance under normal operating conditions. However, several points must be observed for the welding system to remain operational for years to come.

1. Service, maintenance and disposal

1. Service, maintenance and disposal

• 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 components.
• Check contact pressure of the feed rollers and adjust if necessary.

1. Service, maintenance and disposal

• 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.

1. Service, maintenance and disposal

Disposal must only be carried out in accordance with the section of the same name in the "Safety rules" chapter.

1. Technical data

1. Technical data

1. Technical data

1. Technical data

1. Technical data