Fronius iWave 190i - 230i Operating Instruction [EN]

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Operating Instructions

iWave 190i AC/DC iWave 230i AC/DC iWave 230i DC

Operating instructions

42,0426,0250,EN 013-29082022

Contents

Safety rules 8

Explanation of safety notices 8 General 8 Proper use 9 Environmental conditions 9 Obligations of the operator 9 Obligations of personnel 9 Mains connection 10 Protecting yourself and others 10 Danger from toxic gases and vapours 11 Danger from ﬂying sparks 11 Risks from mains current and welding current 12 Meandering welding currents 13 EMC Device Classifications 13 EMC measures 13 EMF measures 14 Specific hazards 14 Requirement for the shielding gas 15 Danger from shielding gas cylinders 15 Danger from escaping shielding gas 16 Safety measures at the installation location and during transport 16 Safety measures in normal operation 17 Noise emission values 17 Commissioning, maintenance and repair 17 Safety inspection 18 Disposal 18 Safety symbols 18 Data protection 18 Copyright 19

General information 21

General 23

Device concept 23 Functional principle 23 Application areas 23 Conformities 24 Bluetooth trademarks 24 Warning notices on the device 24

System components 26

General 26 Overview 26 Options 26

Control elements and connections 27

Control panel 29

General 29 Safety 29 Control panel 29

The favourites button 31

Assigning the Favourites button 31 Retrieving favourites 31 Deleting favourites 32 Assigning EasyJobs to the Favourites button 32

Connections, switches and mechanical components 34

Installation and commissioning 37

Minimum equipment needed for welding task 39

General 39 TIG AC welding 39 TIG DC welding 39 MMA welding 39

Before installation and commissioning 40

Safety 40 Utilisation for intended purpose 40 Setup regulations 40 Mains connection 40 Generator-powered operation 41

Connecting the mains cable 42

General 42 Safety 42 Connecting the mains cable 42

Start-up 43

Safety 43 Remarks on the cooling unit 43 General 43 Fitting the system components 43 Connecting the gas cylinder 44 Connecting the welding torch to the power source and the cooling unit 44 Establishing a ground earth connection to the workpiece 45

Locking and unlocking the power source using the NFC key 46

General 46 Limitations 46 Locking and unlocking the power source using the NFC key 46

Welding 47

TIG modes 49

Safety 49 Symbols and their explanations 49 2-step mode 50 4-step mode 50 Special 4-step mode: Variant 1 51 Special 4-step mode: Variant 2 52 Special 4-step mode: Variant 3 53 Special 4-step mode: Variant 4 54 Special 4-step mode: Variant 5 55 Special 4-step mode: Variant 6 56 Spot welding 57 CycleTIG 58

TIG welding 59

Safety 59 Preparation 59 TIG welding 60 Welding parameters for TIG DC welding 61 CycleTIG welding parameters 64 Welding parameters for TIG AC welding 65

Igniting the arc 70

General 70 Igniting the arc using high frequency(HF ignition) 70 Touchdown ignition 71 Electrode overload 72 End of welding 72

TIG special functions 73

Ignition timeout function 73 TIG pulsing 73 Tacking function 74 CycleTIG 75

Manual metal arc welding, CEL welding 76

Safety 76

Preparation 76 Manual metal arc welding, CEL welding 77 Welding parameters for manual metal arc welding 78 Welding parameters for MMA welding with cellulose electrodes 79 Starting current > 100 % (HotStart) 82 Starting current < 100 % (SoftStart) 82 Anti-stick function 83

EasyJob mode 84

Storing EasyJob operating points 84 Retrieving EasyJob operating points 85 Deleting EasyJob operating points 85

Welding job 86

Safety 86 Preparation 86 Welding a job 87

Setup settings 89

The Setup menu 91

General 91 Accessing the Setup menu 91 Overview 92 Changing menus and parameters 93

The TIG menu 95

Parameters in the TIG DC menu 95 Parameters in the TIG AC menu 98

The MMA menu 102

Parameters in the rod electrode menu 102

The CEL menu 105

Parameters in the CEL menu 105

Ignition and mode settings 106

Ignition parameters 106 Arc monitoring 107 Operating mode defaults 108

The gas menu 110

Parameters in the Gas menu 110

The components menu 111

Parameters in the Components menu 111 Emptying the torch hosepack 112 Filling the torch hosepack 113

The documentation menu 115

The Job menu 117

Saving a job 117 Saving a job via the Job menu 117 Saving a job using the adjusting dial 117 Loading a job 118 Deleting a job 119 Optimising job process parameters 119 Defaults for "Save job" 122 EasyJobs on Favourites button 123

Defaults 124

Overview 124

Display 125

Backlighting 125 Languages 125 Time & Date 125 Show system data 126 Display additional parameters 127 iJob parameter display 128

System 129

Power source configurations 129

Reset to factory settings 129 Reset website password 129 Torch trigger I2 - cap mode 129 Performing R/L alignment 130

Network settings 132

General 132 Bluetooth on 132 Configuring Bluetooth devices 133 Network setup 133 Activating WLAN 134 WLAN settings 134

User management 135

Overview 135

General 136

General remarks 136 Explanation of terms 136 Pre-defined roles and users 136 Recommendation for creating roles and users 137

Create users and roles 138

Creating a user 138 Creating roles 138

Edit user / roles, deactivate user administration 140

Editing users 140 Editing roles 140 Deactivating user management 140

CENTRUM - Central User Management 142

Activating the CENTRUM server 142

Management 143

Trial license 143 Activating the trial license 143

System informations 144

Device information 144

SmartManager - The power source website 145

SmartManager - The power source website 147

General 147 Calling up the power source SmartManager 147 Fronius 147 Changing password / logging off 147 Language 148

Current system data 149

Documentation, logbook 150

Logbook 150 Basic settings 151

Job-Data 152

Job data 152 Job overview 152 Editing a job 152 Importing a job 153 Exporting a job 153 Exporting job(s) as… 153

Backup & Restore 155

General 155 Backup & Restore 155

User management 156

General 156 Users 156 User roles 156 Export & import 157 CENTRUM 157

Overview 158

Overview 158 Expanding / reducing all groups 158 Export component overview as ... 158

Update 159

Function Packages 160

Function packages 160 Installing a function package 160

Screenshot 161

Troubleshooting and maintenance 163

Troubleshooting 165

General 165 Safety 165 Power source - troubleshooting 165

Care, maintenance and disposal 168

General 168 Safety 168 At every start-up 168 Every 2 months 168 Every 6 months 169 Disposal 169

Appendix 171

Average consumption values during welding 173

Average shielding gas consumption during TIG welding 173

Technical data 174

Overview with critical raw materials, year of production of the device 174 Special voltages 174 Versions of the appliance 174 iWave 190i AC/DC 174 iWave 190i AC/DC /MV 176 iWave 230i AC/DC 178 iWave 230i AC/DC /MV 180 iWave 230i DC 182 iWave 230i DC /MV 184 Explanation of footnotes 185 Radio parameters 186

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

recognised 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 device.

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

be suitably qualified,

have sufficient knowledge of automated welding, and

read and carefully follow these operating instructions as well as the operat-

ing instructions for all system components.

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 applicable 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 commissioning 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 in-

structions 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

Obligations of the operator

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.)

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 sec-

tion "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 pre-

vention 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

Protecting yourself and others

Devices with a higher rating may affect the energy quality of the mains due to their current 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

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 us-

ing cardiac 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 protect-

ive 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 in-

jury

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 toxic gases and vapours

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 toxicity of welding fumes:

Metals used for the workpiece

Electrodes

Coatings

Cleaners, degreasers, etc.

Welding process used

Danger from ﬂy- ing sparks

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 identifying 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.

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 welding 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, insulated 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 dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned 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 electrodes 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 welding currents

EMC Device Classifications

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 insulated.

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 lowvoltage 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

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 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 interference 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:

Mains supply

1. If electromagnetic interference arises despite the correct mains connec-

tion, additional measures are necessary (e.g. use of a suitable line filter)

Welding power-leads

2. must be kept as short as possible

must be laid close together (to avoid EMF problems)

must be kept well apart from other leads

Equipotential bonding

Earthing of the workpiece

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

Shield, if necessary

5. Shield other devices nearby

Shield the entire welding installation

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

Effects on the health of persons in the vicinity, e.g. those with pacemakers

and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-

proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the

welding power-leads and the head/torso of the welder Do not carry welding power-leads and hosepacks over the shoulders or wind

them around any part of the body

Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:

Fans

Cogs

Rollers

Shafts

Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.

During operation

Ensure that all covers are closed and all side panels are fitted properly.

Keep all covers and side panels closed.

The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).

Therefore, always keep the welding torch away from the body (devices with wirefeeder) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion

- observe relevant national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant ﬂow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

Hook chains or ropes onto all suspension points provided on the load-carry-

ing equipment. Chains and ropes must be at the smallest angle possible to the vertical.

Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

All lifting tackle (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors). The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teﬂon tape.

Requirement for the shielding gas

Danger from shielding gas cylinders

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.

Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked ﬂames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

Keep the shielding gas cylinders well away from any 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 attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

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

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.

Danger from escaping shielding gas

Safety measures at the installation location and during transport

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

Ensure an adequate supply of fresh air with a ventilation rate of at least

20 m³/hour. Observe safety and maintenance instructions on the shielding gas cylinder or

the main gas supply. Close the shielding gas cylinder valve or main gas supply if no welding is tak-

ing place. Check the shielding gas cylinder or main gas supply for uncontrolled gas

leakage before every start-up.

A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable

The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection shown on the rating plate.

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.

7.69 in.) to ensure that cooling air can ﬂow in and out freely.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Do not lift or transport operational devices. Switch off devices before transport or lifting.

Before transporting the device, allow coolant to drain completely and detach the following components:

Wirefeeder

Wirespool

Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

Safety measures in normal operation

Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of

injury or death to the operator or a third party

damage to the device and other material assets belonging to the operator

inefficient operation of the device

Any safety devices that are not functioning properly must be repaired before switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper functioning of safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, ﬂammability, etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Noise emission values

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

The device generates a maximum sound power level of > 80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cutting) as this is inﬂuenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

Commissioning, maintenance and repair

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.

Safety inspection

Disposal Do not dispose of this device with normal domestic waste! To comply with the

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

The manufacturer recommends that the power source be calibrated during the same 12-month period.

A safety inspection should be carried out by a qualified electrician

after any changes are made

after any additional parts are installed, or after any conversions

after repair, care and maintenance has been carried out

at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.

European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!

Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage

and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

Data protection The user is responsible for the safekeeping of any changes made to the factory

settings. The manufacturer accepts no liability for any deleted personal settings.

The text and illustrations are all technically correct at the time of printing. We reserve 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 instructions, we will be most grateful for your comments.

General information

General

Device concept The iWave 230i DC, iWave 190i AC/DC

and iWave 230i AC/DC TIG power sources are fully digitised, microprocessor-controlled inverter power sources.

Their modular design and potential for system add-ons ensure a high degree of ﬂexibility. The devices can be adap- ted to any situation.

The power sources are generator-compatible. They are exceptionally sturdy in day-to-day operation thanks to the protected control elements and their powder-coated housings.

The iWave-Stromquellen sind mit der Funktion eines have a TIG pulsed arc function with a wide frequency range.

Functional principle

Application areas

To optimise the ignition sequence in TIG AC welding, the iWave AC/DC takes into account not only the diameter of the electrode, but also its current temperature, calculated with reference to the preceding welding time and welding off-time.

The central control and regulation unit of the power sources is coupled with a digital signal processor. The central control and regulation unit and signal processor control the entire welding process. During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired target state is maintained.

This results in:

a precise welding process,

exact reproducibility of all results

excellent weld properties.

The devices are used in workshops and industry for manual TIG applications with unalloyed and low-alloy steel and high-alloy chrome-nickel steels.

The iWave AC/DC power sources perform exceptionally well when it comes to welding aluminium, aluminium alloys and magnesium due to the variable AC frequency.

Conformities FCC

This equipment complies with the limit values for an EMC device class A digital device pursuant to Part 15 of the FCC Rules. These limit values are intended to provide an adequate level of protection against harmful emissions when the device is being used in an industrial environment. This device generates and uses high-frequency energy and can cause interference to radio communications if it is not installed and used according to the Operating Instructions. The use of this device in residential areas will probably cause harmful interference, in which case the user will be obliged to correct the interference at their own expense.

FCC ID: QKWSPBBCU1

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This device complies with the Industry Canada licence-exempt RSS standards. Its use is subject to the following conditions:

(1) The device must not cause any harmful interference. (2) The device must be able to cope with any interference, including that

IC: 12270A-SPBBCU1

which could adversely affect its operation.

Bluetooth trademarks

Conformity with Directive 2014/53 / EU - Radio Equipment Directive (RED)

When installing the antennae to be used for this transmitter, it is essential to maintain a minimum distance of 20 cm from all people. They must not be installed or operated with any other antenna or transmitter. OEM integrators and end users must be aware of the operating conditions of the transmitter in order to comply with the radio frequency exposure guidelines.

NOM / Mexico

Operation of this device is subject to the following two conditions:

(1) This device must not cause any harmful interference,

and

(2) This device must accept any interference received, including interference

that may cause undesired operation.

The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks by Fronius International GmbH is under license. Other trademarks and trade names are those of their respective owners.

Warning notices on the device

Warning notices and safety symbols are affixed to power sources with the CSA test mark for use in North America (USA and Canada). These warning notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and damage.

* MV power sources: 1 ~ 100 - 230 V

Safety symbols on the rating plate:

Welding is dangerous. The following basic requirements must be met:

Welders must be sufficiently qualified

Suitable protective equipment must be used

All persons not involved in the welding process must be kept at a safe dis-

tance

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

These Operating Instructions

All the Operating Instructions for the system components, especially the

safety rules

System components

(4)

General The iWave DC and iWave AC/DC power sources can be used with a wide variety

of system add-ons and options.

Overview

Options OPT/i Ethernet iWave 190i/230i

Option for a permanent network connection

Carrying strap option

OPT/i Pulse Pro

Function package for the extended pulse function (the Base current and Duty cycle parameters can be set, extended pulse frequency range)

(1) TIG welding torch (2) Power sources (3) Cooling units (only for iWave

230i DC and iWave 230i AC/DC)

(4) Trolley with gas cylinder holder

Not illustrated:

Remote controls

Pedal remote controls

Electrode cable

Grounding cable

OPT/i Jobs

Function package for Job mode (EasyJobs, save and edit jobs)

OPT/i Documentation

Option for the documentation function

OPT/i Limit Monitoring

Option for specifying the limit values for the welding current, welding voltage and wire speed

OPT/i CycleTIG

Enhanced TIG stitch welding

OPT/i Custom NFC - ISO 14443A

Option to use a customer-specific frequency band for key cards

OPT/i OPC-UA

Standardised data interface protocol

OPT/i MQTT

Standardised data interface protocol

Control elements and connections

Control panel

(1)(2)(3)(4)(5)(6)

(7) (8) (10)(9)

General

Safety

Control panel

NOTE!

Due to software updates, you may find that your device has certain functions that are not described in these Operating Instructions or vice versa.

Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this device

▶

and all system components.

No. Function

(1) Mode/welding process button

For selecting welding processes and mode

(2) Gas-test button

To set the required shielding gas ﬂow rate on the gas pressure regulator After pressing the gas-test button, shielding gas ﬂows for 30 seconds. Press the button again to stop the gas ﬂow prematurely.

(3) Key card reader for NFC keys

Only in certified countries To lock/unlock the power source using NFC keys

NFC key = NFC card or NFC key ring

(4) Adjusting dial with turn/press function

To select elements, set values and scroll through lists

To save jobs when the FP Job function package is present:

if the adjusting dial is pressed for more than 3 seconds, the selected welding parameters are saved as a job. An overview of the most important parameters will be displayed. For more about how to save a job, see Setup settings / the Job menu / Save job starting on page 117

(5) Menu key

To open the Setup menu

(6) Favourites button

To save/retrieve preferred settings

(7) Display

(8) Hold indicator - welding current

At the end of each welding operation, the actual values for the welding current and welding voltage are stored - HOLD lights up.

(9) Status bar

The status bar displays the following information:

Current welding process

Current operating mode

Selected current type

Active functions (e.g. high frequency ignition, tacking, pulsing, etc.)

Indication of electrode overload

Status of the power source (locked/unlocked)

Active Bluetooth connection

Time

Date

The information shown in the status bar varies according to which welding process has been selected.

(10) Hold indicator - welding voltage

At the end of each welding operation, the actual values for the welding current and welding voltage are stored - HOLD lights up.

+ 158 hidden pages

Fronius iWave 190i - 230i Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual