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.

The favourites button

xxxx

* *

xxx xxx

Assigning the Favourites button

The Favourites button can be assigned a parameter from the following Setup menus:

This parameter can then be called up and changed directly on the control panel.

Select the desired parameter in the Setup menu

More information about the Setup menu can be found from page 89 onwards

To assign the selected parameter to the Favourites button, press the Favour-

ites button for approx. 5 seconds

A confirmation message is displayed.

Press the adjusting dial to confirm

Retrieving favourites

The selected parameter is now assigned to the Favourites button.

IMPORTANT! Saving a favourite overwrites the previously saved favourite without warning.

Press the Favourites button brieﬂy

The assigned parameter is displayed:

The retrieved parameter can be changed by turning the adjusting dial (blue background).

The new value takes effect immediately.

Press and turn the adjusting dial to choose from the available welding paramet-

50 A

ers.

Deleting favourites

Assigning EasyJobs to the Favourites button

Press the Favourites button for longer than 5 seconds

The assigned parameter is deleted and a message is displayed.

Press the adjusting dial to confirm

If the FP Job function package is present on the power source, EasyJobs can be assigned to the Favourites button.

IMPORTANT! If EasyJobs are assigned to the Favourites button, any previously saved favourite parameter will no longer be accessible using that button.

Select the Job menu from the Setup menu

More information about the Setup menu can be found from page 117 onwards

In the Job menu, set the "EasyJobs on favorites button" parameter to "on"

Press the Menu key

Five EasyJob buttons for the welding parameters are displayed as icons.

Press the Favourites button

50 A

1 2 3 4 5

The 5 EasyJob buttons are displayed and can be selected by turning and pressing the adjusting dial.

More information about using EasyJobs can be found in the "EasyJob mode" section starting on page 84.

Connections, switches and mechanical components

Front Rear

No. Function

(1) (-) current socket with integrated gas connection

To connect:

the TIG welding torch

the electrode cable for manual metal arc welding

Symbols on iWave DC power sources:

Symbols on iWave AC/DC power sources:

(2) TMC connection (TIG Multi Connector)

to connect the TIG welding torch control plug

to connect pedal remote controls

to connect the remote control during MMA welding

(3) USB port

For connecting USB ﬂash drives (such as service dongles and licence keys). IMPORTANT! The USB port is not electrically isolated from the welding circuit. This means that devices that establish an electrical connection with another device must not be connected to the USB port.

(4) (+) current socket

For connecting the grounding cable

Symbols on iWave DC power sources:

Symbols on iWave AC/DC power sources

(5) Mains switch

For switching the power source on and off

Mains switch for MV devices:

(6) Mains cable with strain relief device

On MV devices: Mains cable connection

(7) Shielding gas connection

(8) Blanking cover

for Ethernet option

Installation and commissioning

Minimum equipment needed for welding task

General Depending on which welding process you intend to use, a certain minimum equip-

ment level will be needed in order to work with the power source. The welding processes and the minimum equipment levels required for the welding task are then described.

TIG AC welding

TIG DC welding

MMA welding

Power source iWave AC/DC

Grounding cable

TIG welding torch with rocker switch

Gas connection (shielding gas supply), with pressure regulator

Filler metals (as required by the application)

Power source

Grounding cable

TIG welding torch

Shielding gas supply with pressure regulator

Filler metals (as required by the application)

Power source

Grounding (earthing) cable

Electrode holder

Rod electrodes (as required by the application)

Before installation and commissioning

Safety

Utilisation for intended purpose

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.

The power source is intended exclusively for TIG and MMA welding. Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose. The manufacturer shall not be liable for any damage resulting from such improper use.

Proper use also includes:

following all the information in the operating instructions

carrying out all the specified inspection and servicing work

Setup regulations

The device is tested to IP 23 protection, meaning:

Protection against penetration by solid foreign bodies with diameters > 12.5

mm (0.49 in.) Protection against spraywater at any angle up to 60° to the vertical

The device can be set up and operated outdoors in accordance with degree of protection IP 23. Avoid direct wetting (e.g. from rain).

WARNING!

Danger from machines toppling over or falling.

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

Set up the device securely on an even, solid surface.

▶

Check all screw connections are tightly fastened after installation.

▶

The venting duct is a very important safety device. When choosing the installation location, ensure that the cooling air can enter and exit unhindered through the air ducts on the front and back of the device. Electroconductive metallic dust must not be allowed to get sucked directly into the device (e.g. from grinding work).

Mains connection

The devices are designed for the mains voltage specified on the rating plate. If your version of the appliance does not come with mains cables and plugs readyfitted, these must be fitted in accordance with national regulations and standards. For details of fuse protection of the mains lead, please see the technical data.

CAUTION!

Generatorpowered operation

Danger due to insufficiently dimensioned electrical installations.

This can result in damage to property.

Dimension the mains lead and its fuse to suit the local power supply.

▶

The technical data shown on the rating plate applies.

The power source is generator-compatible.

In order to dimension the required generator output, the maximum apparent power S

The maximum apparent power S

of the power source is required.

1max

of the power source can be calculated as

follows: S

= I

1max

See device rating plate or technical data for I

The generator apparent power S

1max

x U

and U1 values

1max

needed is calculated using the following rule

GEN

of thumb: S

GEN

= S

1max

x 1.35

A smaller generator may be used when not welding at full power.

IMPORTANT! The generator apparent power S

the maximum apparent power S

of the power source.

1max

must always be higher than

GEN

When using single-phase devices with a 3-phase generator, note that the specified generator apparent power is often only available as a whole across all three phases of the generator. If necessary, obtain further information on the singlephase power of the generator from the generator manufacturer.

NOTE!

The voltage delivered by the generator must never exceed the upper or lower limits of the mains voltage tolerance range.

Details of the mains voltage tolerance can be found in the "Technical data" section.

Connecting the mains cable

General If power sources are delivered without a mains cable fitted, a mains cable that is

suitable for the connection voltage must be connected to the power source before commissioning. The mains cable in included in the scope of supply of the power source.

Safety

Connecting the mains cable

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.

Connect the mains cable:

Plug in the mains cable

Turn the mains cable 45° to

the right until you hear it latch into place

Start-up

Safety

Remarks on the cooling unit

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger of electrical current due to electrically conductive dust in the device.

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

Only operate the device if an air filter is fitted. The air filter is a very import-

▶

ant safety device for achieving IP 23 protection.

The iWave 230i DC and iWave 230i AC/DC power sources can be operated with a cooling unit. A cooling unit is recommended for the following applications:

Hosepacks over 5 m long

TIG AC welding

In general, where welding is performed in higher power ranges

The cooling unit is powered from the power source. The cooling unit is ready for operation when the mains switch of the power source is in the "I" position. More information on the cooling unit can be found in the Operating Instructions for the cooling unit.

General This section describes how to commission the power source:

for the main TIG welding application

with reference to a standard configuration for a TIG welding system

The standard configuration consists of the following system components:

Power source

TIG manual welding torch

Pressure regulator

Gas cylinder

Fitting the system components

For more detailed information about installing and connecting the system components, please refer to the appropriate Operating Instructions.

Connecting the gas cylinder

WARNING!

There is a high risk of very serious injury and damage if a gas cylinder falls over.

Place gas cylinders on a solid, level surface in such a way that they remain

▶

stable. Secure gas cylinders to prevent them from toppling over: Fix the safety strap

▶

at the same height as the top part of the cylinder. Never fix the safety strap around the neck of the cylinder.

▶

Observe the safety rules of the gas cylinder manufacturer.

▶

1 2

Connecting the welding torch to the power source and the cooling unit

When using a TIG welding torch with an integral gas connection:

Use the gas hose to connect the pressure regulator to the shielding gas con-

nection on the rear of the power source

Tighten the union nut on the gas hose

When using a TIG welding torch with no integral gas connection:

Connect the TIG welding torch gas hose to the pressure regulator

NOTE!

When using a MultiControl (MC) cooling unit, please see the Operating Instructions of the cooling unit for a description of the gas connection.

NOTE!

Do not use pure tungsten electrodes (colour-coded green) on iWave DC power sources.

Set up the welding torch in accordance with the welding torch Operating In-

structions

During welding, check at regular intervals that the coolant is ﬂowing properly.

NOTE!

Before each start-up:

Check the sealing ring on the

▶

welding torch connection. Check coolant level.

▶

Establishing a ground earth connection to the workpiece

Turn the mains switch to the "O" position

Locking and unlocking the power source using the

NFC key

General NFC key = NFC card or NFC key ring

The power source can be locked using an NFC key, e.g. to prevent unauthorised access or welding parameters being changed without permission.

A contactless system on the control panel allows the power source to be locked and unlocked.

The power source must be switched on before it can be locked or unlocked.

Limitations Locking and unlocking of the power source is only permitted in certified coun-

tries.

Locking and unlocking the power source using the NFC key

Locking the power source

Hold the NFC key on the NFC key

reader

The key icon in the status bar lights up.

The power source is now locked. Only the welding parameters can be viewed and adjusted using the adjusting dial.

Any attempt to call a locked function will result in a notification being displayed.

Unlocking the power source

Hold the NFC key on the NFC key reader

The key icon in the status bar is no longer lit. All functions of the power source are available again without restriction.

NOTE!

More information about locking and unlocking the power source can be found in the "Defaults - Management / Administration" section on page 136.

Welding

TIG modes

(1) (2) (3)

(4) (5)

Safety

Symbols and their explanations

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely

▶

understood these Operating Instructions. Do not use the functions described here until you have fully read and under-

▶

stood all of the Operating Instructions for the system components, in particular the safety rules!

See the "The Setup menu" section for information on the settings, setting range and units of measurement of the available welding parameters.

(1) Pull back and hold the torch trigger (2) Release the torch trigger (3) Pull back the torch trigger brieﬂy (< 0.5 s)

(4) Push forward and hold the torch trigger (5) Release the torch trigger

GPr Gas pre-ﬂow

SPt Spot welding time

Starting current:

Carefully warm up with low welding current to position the filler metal correctly

Final current:

To avoid local overheating of the base material by heat accumulation at the end of the welding. This eliminates any risk of weld seam dropthrough.

UpSlope:

The starting current is steadily increased until it reaches the main current (welding current) I

DownSlope:

DOWN

Continuous reduction of the welding current until it reaches the final current

GPo

GPr t

DOWN

GPr

DOWN

GPo

Main current (welding current):

Uniform thermal input into the base material heated by advancing heat

2-step mode

Reduced current:

Intermediate lowering of the welding current in order to prevent any local overheating of the base material

GPO Gas post-ﬂow

Welding: Pull back and hold the torch trigger

End of welding: Release the torch trigger

2-step mode

4-step mode

Start of welding with starting current IS: Pull back and hold the torch trigger

Welding with main current I1: Release the torch trigger

Lowering to final current IE: Pull back and hold the torch trigger

End of welding: Release the torch trigger

4-step mode

*) Intermediate lowering

Intermediate lowering during the main current phase reduces the welding cur-

GPr

down

GPo

rent to the specified reduced current I-2.

To activate intermediate lowering, push forward and hold the torch trigger

To revert to the main current, release the torch trigger

Special 4-step mode: Variant 1

Brieﬂy pull back the torch trigger to start intermediate lowering to the specified reduced current I2. Brieﬂy pull back the torch trigger a second time, to restore

the main current I1.

Special 4-step mode: Variant 1

Variant 1 of the special 4-step mode is activated with the following parameter setting:

Starting current time = off

Final current time = off

Reduced current slope 1 = off

Reduced current slope 2 = off

Operating mode defaults

I2 via torch trigger = on

Reduced current button function = I2

Special 4-step

GPr

down

GPo

mode: Variant 2

Intermediate lowering takes place in variant 2 on the basis of the selected reduced current slope 1/2 values:

Push forward and hold the torch trigger: the welding current continuously

drops at the set reduced current slope 1 value until it reaches the specified reduced current I2. It remains at the reduced current value I2 until the torch

trigger is released. When the torch trigger is released: the welding current rises at the specified

reduced current slope 2 value until it reaches the main current value I1.

Special 4-step mode: Variant 2

Variant 2 of the special 4-step mode is activated with the following parameter setting:

Starting current time = off

Final current time = off

Reduced current slope 1 = on

Reduced current slope 2 = on

Operating mode defaults

I2 via torch trigger = off

Reduced current button function = I2

Special 4-step

GPr

GPo

mode: Variant 3

In variant 3, push forward and hold the torch trigger to start intermediate lowering of the welding current. Release the torch trigger to resume the main current I1.

When the torch trigger is pulled back, welding ends immediately without DownSlope and final current.

Special 4-step mode: Variant 3

Variant 3 of the special 4-step mode is activated with the following parameter setting:

Starting current time = off

Final current time = 0.01 s

Reduced current slope 1 = off

Reduced current slope 2 = off

Operating mode defaults

I2 via torch trigger = off

Reduced current button function = I2

Special 4-step

GPr

down

GPo

mode: Variant 4

Welding start-up and welding: brieﬂy pull back and release the torch trigger -

the welding current will rise at the specified UpSlope value from the starting current IS until it reaches the main current value I1.

Push forward and hold the torch trigger for intermediate lowering

Release the torch trigger to resume the main current I

End of welding: brieﬂy pull back and release the torch trigger

Special 4-step mode: Variant 4

Variant 4 of the special 4-step mode is activated with the following parameter setting:

Starting current time = on

Final current time = on

Reduced current slope 1 = off

Reduced current slope 2 = off

Operating mode defaults

I2 via torch trigger = off

Reduced current button function = I2

Special 4-step

GPr t

down

GPo

I1 >

I1 <

mode: Variant 5

Variant 5 allows the welding current to be increased and reduced without an Up/ Down torch.

The longer the torch trigger is held in the forward position during welding,

the more the welding current increases (up to the maximum). The welding current remains constant when the torch trigger is released.

The longer the torch trigger is pushed forward again, the more the welding

current decreases.

Special 4-step mode: Variant 5

Variant 5 of the special 4-step mode is activated with the following parameter setting:

Starting current time = off

Final current time = off

Reduced current slope 1 = off

Reduced current slope 2 = off

Operating mode defaults

I2 via torch trigger = off or on

Reduced current button function = I1

Special 4-step

GPr

down

GPo

< 0,5 s

> 0,5 s

mode: Variant 6

Welding start-up with starting current IS and UpSlope: Pull back and hold

the torch trigger Intermediate lowering to I2 and changing from I2 back to the main current I1:

brieﬂy press (< 0.5 s) and release the torch trigger End the welding process: press the torch trigger for longer (> 0.5 s) and re-

lease.

The process is automatically ended after the DownSlope phase and the final current phase.

If the torch trigger is pressed brieﬂy (< 0.5 s) and released during either the DownSlope phase or the final current phase, then an UpSlope will take effect until it reaches the main current and the welding process will continue.

Special 4-step mode: Variant 6

Variant 6 of the special 4-step mode is activated with the following parameter setting:

Starting current time = off

Final current time = on

Reduced current slope 1 = off

Reduced current slope 2 = off

Operating mode defaults

I2 via torch trigger = on Reduced current button function = I2

Spot welding When the spot welding operating mode is selected, the symbol for spot welding

GPr

DOWN

SPt

GPo

appears on the status indicator next to the welding process symbol:

Welding: brieﬂy pull back the torch trigger

The welding time corresponds to the value set for the spot welding time setup parameter. To end the welding process prematurely: pull the torch trigger back again

CycleTIG

(1)(2)

(3)

(4)

I [A]

t [ms]

(2)

(1)

CycleTIG

Enhanced stitch welding process for DC welding

When the CycleTIG function is activated, the following parameters are available:

(1) Interval time (2) Interval break time (3) Interval cycles

CycleTig activated

(4) Base current

NOTE!

For more details on CycleTIG, see from page 75. Description of the CycleTIG parameters from page 64.

TIG welding

Safety

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.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation

Plug in the mains plug

CAUTION!

Risk of injury and damage to property from electric shock.

As soon as the mains switch is in the "I" position, the tungsten electrode of the welding torch is live.

Ensure that the tungsten electrode does not touch any persons or electric-

▶

ally conductive or earthed parts (e.g. housing, etc.).

Move the mains switch to the "I" position

The Fronius logo appears on the display.

TIG welding

Press the welding process / operating mode key

The welding processes and operating modes are displayed.

Select the desired welding process by turning the adjusting dial

Confirm the selection by pressing the adjusting dial

Select the desired operating mode by turning the adjusting dial

Confirm the selection by pressing the adjusting dial

After a short period of time or after pressing the welding process / operating mode key, the available TIG welding parameters are displayed.

Turn the adjusting dial to select the required parameter

Press the adjusting dial

The value of the welding parameter is highlighted in blue and can now be changed.

Turn the adjusting dial: change the value of the parameter

Press the adjusting dial

If required, set further parameters in the Setup menu

(For details, see the "Setup settings" chapter, starting on page 89)

Open the gas cylinder valve

Press the Gas-test button

The test gas ﬂow lasts for a maximum of 30 seconds. Press the button again to stop the gas ﬂow prematurely.

Turn the adjusting screw on the underside of the pressure regulator until the

manometer indicates the desired shielding gas ﬂow rate

NOTE!

50%

xxA

50%

xxA

0.5 s

Welding parameters for TIG DC welding

All welding parameter set values that have been set using the adjusting dial remain stored until the next time they are changed.

This applies even if the power source was switched off and on again in the interim.

Start welding (ignite the arc)

The polarity welding parameter is only available on iWave AC/DC power sources. If the polarity welding parameter is set to DC-, the following welding parameters are available:

xxA = actual current value depending on the specified main current

Starting current

Starting current, 2-step mode and spot welding

Setting range: 0 - 200% (of main current) Factory setting: 50%

IMPORTANT! The starting current is saved separately for TIG AC welding and TIG DC- welding.

UpSlope

UpSlope, 2-step mode and spot welding

Setting range: off; 0.1 - 30.0 s Factory setting: 0.5 s

IMPORTANT! The saved UpSlope value applies to both the 2-step and 4-step modes.

Starting current, 4-step mode

UpSlope, 4-step mode

Main current (I1)

50 A

50%

xxA

150%

xxA

Slope1 Slope2

I

I < 100 %

I > 100 %

Slope1

Slope2

Main current, 2-step mode and spot welding

Setting range: 3 - 190 A ... iWave 190i, 3 - 230 A ... iWave 230i Factory setting: -

IMPORTANT! On welding torches with the Up/Down Function, the entire setting range can be selected while the device is idling.

Reduced current (I2)

only in 4-step mode

Reduced current I2 < Main current I

Setting range: 0 - 200% (of main current I1) Factory setting: 50%

Main current, 4-step mode

Reduced current I2 > Main current I

I2 < 100% short-term, adapted reduction of the welding current

(e.g. when changing the welding wire during the welding process)

I2 > 100% short-term, adjusted increase in welding current

(e.g. to weld over tacked spots at higher power)

The values for Slope1 and Slope2 can be set using the TIG menu.

DownSlope

0.5 s

30%

xxA

30%

xxA

2.4mm

DownSlope, 2-step mode and spot welding

Setting range: off; 0.1 - 30.0 s Factory setting: 1.0 s

IMPORTANT! The saved DownSlope value applies to both the 2-step and 4-step modes.

Final current

Final current, 2-step mode and spot welding

Setting range: 0 - 100% (of main current) Factory setting: 30%

Electrode diameter

DownSlope, 4-step mode

Final current, 4-step mode

Setting range: off; 1.0 - 4.0 mm Factory setting: 2.4 mm

Polarity

DC-

Setting range: DC-/AC Factory setting: DC-

CycleTIG welding parameters

If the CycleTIG function is activated, the CycleTIG welding parameters are displayed after the main current for the TIG DC welding parameters:

Interval cycles

for setting how many cycles are to be repeated

Setting range: Permanent / 1 - 2000 Factory setting: Permanent

Interval time

for setting the length of time the welding current I1 is active

Setting range: 0.02 - 2.00 s Factory setting: 0.5 s

Interval break time

for setting the length of time the base current is active

Setting range: 0.02 - 2.00 s Factory setting: 0.5 s

Base current

for setting the interval base current to which the current is reduced during the interval break time

Setting range: off / 3 - max. A Factory setting: off

Welding para-

50%

xxA

50%

xxA

0.5 s

50 A

meters for TIG AC welding

The polarity welding parameter is only available on iWave AC/DC power sources. If the polarity welding parameter is set to AC, the following welding parameters are available:

xxA = actual current value depending on the specified main current

Starting current

Starting current, 2-step mode and spot welding

Setting range: 0 - 200% (of main current) Factory setting: 50%

IMPORTANT! The starting current is saved separately for TIG AC welding and TIG DC- welding.

UpSlope

UpSlope, 2-step mode and spot welding

Setting range: off; 0.1 - 30.0 s Factory setting: 0.5 s

IMPORTANT! The saved UpSlope value applies to both the 2-step and 4-step modes.

Starting current, 4-step mode

UpSlope, 4-step mode

Main current (I1)

Main current, 2-step mode and spot welding

Setting range: 3 - 190 A ... iWave 190i, 3 - 230 A ... iWave 230i Factory setting: -

IMPORTANT! On welding torches with the Up/Down Function, the entire setting range can be selected while the device is idling.

Main current, 4-step mode

Reduced current (I2)

50%

xxA

150%

xxA

Slope1 Slope2

I

I < 100 %

I > 100 %

Slope1

Slope2

0.5 s

only in 4-step mode

Reduced current I2 < Main current I

Setting range: 0 - 200% (of main current I1) Factory setting: 50%

I2 < 100% short-term, adapted reduction of the welding current

(e.g. when changing the welding wire during the welding process)

I2 > 100% short-term, adjusted increase in welding current

(e.g. to weld over tacked spots at higher power)

The values for Slope1 and Slope2 can be set using the TIG menu.

DownSlope

Reduced current I2 > Main current I

DownSlope, 2-step mode and spot welding

Setting range: off; 0.1 - 30.0 s Factory setting: 1.0 s

IMPORTANT! The saved DownSlope value applies to both the 2-step and 4-step modes.

DownSlope, 4-step mode

Final current

30%

xxA

30%

xxA

15%

35%

50%

t (s)

I (A)

35% 50% 15%

Final current, 2-step mode and spot welding

Setting range: 0 - 100% (of main current) Factory setting: 30%

Balance

on iWave AC/DC only

Balance = 15%

Final current, 4-step mode

Balance = 35%

Balance = 50%

Setting range: 15 - 50% Factory setting: 35%

15: highest fusing power, lowest cleaning action

50: highest cleaning action, lowest fusing power

Effect of the balance on the waveshape:

Electrode diameter

2.4mm

off

(2)(1)

Setting range: off; 1.0 - 4.0 mm Factory setting: 2.4 mm

Cap mode

on iWave AC/DC only

Setting range: off / on Factory setting: off

off Automatic cap-shaping function is deactivated

on For the entered diameter of the tungsten electrode, the optimum cap is formed during the welding start. A separate cap-shaping action on a test workpiece is not required. After this, the automatic cap-shaping function is reset and deactivated again.

(1) ... before ignition (2) ... after ignition

Cap mode must be activated separately for each tungsten electrode.

NOTE!

The automatic cap-shaping function is not necessary if a sufficiently large cap has already formed at the tip of the tungsten electrode.

Polarity

Setting range: DC-/AC Factory setting: DC-

Igniting the arc

General To ensure the best ignition sequence in the TIG AC welding process, the iWave

AC/DC power sources take account of:

the diameter of the tungsten electrode

the current temperature of the tungsten electrode with reference to the pre-

ceding welding and weld-off times

Igniting the arc using high frequency (HF ignition)

CAUTION!

Risk of injury due to shock caused by electric shock

Although Fronius devices comply with all relevant standards, high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.

Use prescribed protective clothing, especially gloves!

▶

Only use suitable, completely intact and undamaged TIG hosepacks!

▶

Do not work in damp or wet environments!

▶

Take special care when working on scaffolding, work platforms, in forced po-

▶

sitions (out-of-position welding), in tight, difficult to access or exposed areas!

HF ignition is activated when a time value has been set for the ignition timeout setup parameter in the HF menu. The HF ignition indicator lights up in the status bar on the control panel.

Unlike touchdown ignition, HF ignition eliminates the risk of contamination of the tungsten electrode and the workpiece.

Procedure for HF ignition:

Place the gas nozzle down on the

ignition location, ensuring there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece Gap exists.

Increase the tilt angle of the weld-

ing torch and actuate the torch trigger according to the mode you have selected

The arc ignites without the electrode touching down on the workpiece.

Tilt the welding torch back into the

normal position

Carry out welding

Touchdown ignition

If the ignition timeout setup parameter is set to off, HF ignition is deactivated. The welding arc is ignited by touching the workpiece with the tungsten electrode.

Procedure for igniting the arc using touchdown ignition:

Place the gas nozzle down on the

ignition location, ensuring there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece Gap exists

Actuate the torch trigger

shielding gas ﬂows

Gradually tilt the welding torch up

until the tungsten electrode touches the workpiece

Raise the welding torch and rotate

it into its normal position

The arc ignites.

Carry out welding

Electrode overload

End of welding

If the tungsten electrode is overloaded, material can detach from the electrode that then contaminates the weld pool.

If the tungsten electrode is overloaded, the "Electrode overload" indicator in the status bar of the control panel lights up. The "Electrode overload" indicator depends on the electrode diameter and welding current that have been set.

Depending on the set mode, finish welding by releasing the torch trigger

Wait for the set gas post-ﬂow and hold welding torch in position over the end

of the weld seam

TIG special functions

(1)

I [A]

t [s]

(2)

(3)

(4)

(5)

(6)

(7)

(8)

Ignition timeout

The power source has an ignition timeout function.

function

Once the torch trigger is pressed, gas pre-ﬂow begins immediately. Ignition then begins. If an arc does not appear within the time specified in the Setup menu, the power source cuts out automatically.

The settings for the parameter Ignition timeout are described in the section "The HF menu" from page 106 onwards.

TIG pulsing The welding current set at the start of welding is not always ideal for the welding

process as a whole:

if the amperage is too low, the base material will not melt sufficiently

if overheating occurs, the liquid weld pool may drip

The TIG pulsing function (TIG welding with pulsing welding current) offers a remedy: a low base current (2) rises steeply to the significantly higher pulse current and, depending on the set duty cycle (5), drops back to the base current (2). In TIG pulsing, small sections of the welding location melt quickly and then solidify again quickly. In manual applications using TIG pulsing, the welding wire is applied in the maximum current phase (only possible in the low frequency range: 0.25 - 5 Hz). Higher pulse frequencies are mainly used in automatic mode to stabilise the arc.

TIG pulsing is used for out-of-position welding of steel pipes or when welding thin sheets.

Mode of operation of TIG pulsing when TIG DC welding is selected:

TIG pulsing - welding current curve

Legend: (1) Main current, (2) Base current, (3) Starting current, (4) UpSlope, (5) Pulse frequency *) (6) Duty cycle, (7) DownSlope, (8) Final current

*) (1/F-P = time interval between two pulses)

Tacking function The tacking function is available for the TIG DC welding process.

I [A]

t [s]

(1)

(2)

(3)

(4)

(5)

(6)

When a time period is specified for the tacking setup parameter (4), the tacking function is assigned to 2-step mode and 4-step mode. The operating sequence of the modes remains unchanged. The tacking (TAC) indicator lights up in the status bar on the display:

During this period, there is a pulsed welding current that makes the weld pool run together better when two parts are being tacked.

Mode of operation of tacking function for TIG DC welding:

Tacking function - welding current curve

Legend: (1) Main current, (2) Starting current, (3) UpSlope, (4) Duration of pulsed welding current for tacking, (5) DownSlope, (6) Final current

NOTE!

The following points apply to the pulsed welding current:

The power source automatically regulates the pulsing parameters depending on the set main current (1). There is no need to set any pulsing parameters.

The pulsed welding current begins

after the end of the starting-current phase (2)

with the UpSlope phase (3)

Depending on what tacking period has been set, the pulsed welding current may continue up to and including the final current phase (6) (tacking setup parameter (4) set to "on").

After the tacking time has elapsed, welding continues at a constant welding current, and any pulsing parameters that may have been set continue to be available.

CycleTIG The CycleTIG stitch welding process is available for the TIG DC welding process.

The welding result is inﬂuenced and controlled by different parameter combinations.

The main advantages of CycleTIG are easy control of the weld pool, targeted heat input and fewer temper colours.

CycleTIG variations

CycleTIG + low base current

For out-of-position welding, edge applications and orbital welding

Well suited to joins on heavy/light-gauge sheets

Excellent weld characteristics

HF ignition only at welding start

Long electrode service life

Good control of the weld pool

Targeted heat input

CycleTIG + reversed polarity ignition = on + base current = off

For repair work (e.g. edge applications)

Targeted heat input

Biggest advantage in combination with the HF ignition ignition setting =

Touch HF HF ignition at every cycle (!)

Very short electrode service life (!)

Recommendation: iWave AC/DC with the reversed polarity ignition ignition setting = auto

CycleTIG + tacking

For tacking light-gauge sheets, orbital applications and for joins on heavy and

light-gauge sheets HF ignition only at welding start

Long electrode service life

Good control of the weld pool

Targeted heat input

Excellent seam appearance

Tacking function generates automatic pulse setting

CycleTIG + pulse

CycleTIG can be used individually with all pulse settings. This allows pulsing in both the high power and low power phases.

For tacking light-gauge sheets and for cladding applications

For joins on heavy/light-gauge sheets

HF ignition only at welding start

Long electrode service life

Good control of the weld pool

Targeted heat input

Excellent seam appearance

Individual pulse settings possible

More parameters to set

Manual metal arc welding, CEL welding

Safety

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.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation

Move the mains switch to the "O" position

Disconnect the mains plug

Remove the TIG welding torch

IMPORTANT! Observe the instructions on the packaging of the rod electrode

when selecting the appropriate type of current and for correctly connecting the electrode cable and grounding cable.

Plug in and latch the grounding cable:

in the (+) current socket ... for DC- welding (=/-) in the (-) current socket ... for DC+ welding (=/+)

Use the other end of the grounding cable to establish a connection to the

workpiece

Plug in the electrode cable and turn it clockwise to latch it in place:

in the (-) current socket ... for DC- welding (=/-) in the (+) current socket ... for DC+ welding (=/+)

Plug in the mains plug

CAUTION!

Risk of injury and damage to property from electric shock.

As soon as the mains switch is in the "I" position, the rod electrode in the electrode holder is live.

Make sure the rod electrode does not touch any persons or electrically con-

▶

ductive or earthed parts (e.g. the housing, etc.).

Move the mains switch to the "I" position

The Fronius logo appears on the display.

Manual metal arc welding, CEL welding

Press the Mode button

The welding processes and operating modes are displayed.

Select the electrode (Stick / MMA) or CEL welding process (turn and press

the adjusting dial)

If the MMA welding process is selected, any cooling unit present is automatically deactivated. It is not possible to switch it on.

Turn the adjusting dial to select the Polarity parameter:

DC- / DC+ / AC ... during MMA welding DC- / DC+ ... during MMA welding with cellulose electrodes

Press the adjusting dial

Set the polarity for the rod electrodes to be used by turning the adjusting

dial

Confirm the selection by pressing the adjusting dial

Turn the adjusting dial to select further welding parameters

Press the adjusting dial

The value of the parameter is highlighted in blue and can now be changed.

Turn the adjusting dial: change the value of the parameter

Press the adjusting dial

If required, set further parameters in the Setup menu

(For details, see the "Setup settings" chapter, starting on page 89)

NOTE!

All welding parameter set values that have been set using the adjusting dial remain stored until the next time they are changed.

This applies even if the power source was switched off and on again in the interim.

Start welding

Welding para-

* *

50%

xxA

* *

100%

xxA

* *

150%

xxA

130 A

* *

130 A

* *

130 A

* *

meters for manual metal arc welding

* Depending on the selected current type, (+), (-) or the alternating current

symbol is displayed here.

xxA = actual current value depending on the specified main current

Starting current

Starting current: starting current < main current ("SoftStart")

Starting current: starting current > main current ("HotStart")

Setting range: 0 - 200% (of main current) Factory setting: 150%

Main current

Starting current: starting current = main current

Main current: starting current < main current ("SoftStart")

Main current: starting current > main current ("HotStart")

Setting range: 0 - 190 A ... iWave 190i, 0 - 230 A ... iWave 230i Factory setting:-

Main current: starting current = main current

Arc-force dynamic

* *

DC-

DC+

To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force dynamic.

Setting range: 0 - 100% (of main current) Factory setting: 20

0 ... soft and low-spatter arc 100 ... harder and more stable arc

Functional principle: At the instant of droplet transfer or in the event of a short circuit, there is a momentary rise in amperage. In order to obtain a stable arc, the welding current is temporarily increased. If the rod electrode threatens to sink into the weld pool, this measure prevents the weld pool solidifying, as well as preventing more prolonged short circuiting of the arc. This largely prevents the rod electrode from sticking.

Polarity

Polarity, set to DC-

Polarity, set to AC

Setting range: DC- / DC+ / AC Factory setting: DC-

Polarity, set to DC+

Welding parameters for MMA welding with cellulose electrodes

* Depending on the selected current type, (+) or (-) is displayed here.

xxA = actual current value depending on the specified main current

Starting current

* *

50%

xxA

* *

100%

xxA

* *

150%

xxA

130 A

* *

130 A

* *

130 A

* *

Starting current: starting current < main current ("SoftStart")

Starting current: starting current > main current ("HotStart")

Setting range: 0 - 200% (of main current) Factory setting: 150%

Main current

Starting current: starting current = main current

Main current: starting current < main current ("SoftStart")

Main current: starting current > main current ("HotStart")

Setting range: 0 - 190 A ... iWave 190i, 0 - 230 A ... iWave 230i Factory setting: -

Main current: starting current = main current

Arc-force dynamic

* *

DC-

DC+

To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force dynamic.

Setting range: 0 - 100% (of main current) Factory setting: 20

0 ... soft and low-spatter arc 100 ... harder and more stable arc

Polarity

Polarity, set to DC-

Setting range: DC- / DC+ Factory setting: DC-

Polarity, set to DC+

Starting current

I (A)

t (s)

0,5 1 1,5

(1)

(3)

(2)

100

150

I (A)

90A

30A

(1)

(3)

(2)

> 100 % (HotStart)

Advantages

Improved ignition properties, even when using electrodes with poor ignition

properties Better fusion of the base material in the start-up phase, meaning fewer cold-

shut defects Largely prevents slag inclusions

(1) Starting current time

0-2 s, factory setting 0.5 s

(2) Starting current

0-200%, factory setting 150%

(3) Main current = pre-set welding

current I

Mode of operation

during the specified starting current time (1), the welding current I1 (3) is

increased to the starting current (2).

Starting current < 100 % (SoftStart)

Example with a starting current > 100% (HotStart)

The starting current time is set in the Setup menu.

A starting current < 100% (SoftStart) is intended for basic electrodes. Ignition takes place at a low welding current. Once the arc is stable, the welding current continues to rise until it reaches the welding current command value.

Benefits:

Improved ignition properties for

electrodes that ignite at low welding currents Largely prevents slag inclusions

Reduces welding spatter

(1) Starting current (2) Starting current time (3) Main current

The starting current time is set in the rod electrodes menu.

Example with a starting current < 100% (SoftStart)

Anti-stick function

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to stick. This may also cause the rod electrode to burn out.

Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode begins to stick, the power source immediately switches the welding current off. After the rod electrode has been detached from the workpiece, the welding process can be continued without any problems.

The anti-stick function can be activated and deactivated in the rod electrodes menu.

EasyJob mode

Storing EasyJob operating points

NOTE!

The EasyJobs are stored under job numbers 1 - 5 and can also be retrieved from the Job menu.

Storing an EasyJob overwrites any other job saved under the same number!

Prerequisite: EasyJobs must be assigned to the Favourites button (see "Assigning EasyJobs to the Favourites button", starting on page 32.

Set the welding process, mode and welding parameters

Press the Favourites button

The 5 EasyJob buttons are opened.

Turn the adjusting dial and select the desired storage location

To save the current welding settings, press and hold the adjusting dial for

about 3 seconds

The size and colour of the button changes.

After about 3 seconds, the button is displayed in green.

The settings have now been stored. The most recently stored settings will be active. An active EasyJob is indicated by a ﬂag on the EasyJob button.

An occupied storage location is displayed in black, e.g.: Storage location 1 ... occupied and active Storage location 2 ... selected Storage location 3 ... free Storage location 4 ... free Storage location 5 ... free

Retrieving EasyJob operating points

Press the Favourites button

The 5 EasyJob buttons are opened.

Turn the adjusting dial and select the desired storage location

To retrieve a saved EasyJob operating point, press the adjusting dial brieﬂy (<

3 seconds)

The size and colour of the button changes.

The EasyJob buttons are then minimised and the active EasyJob is indicated by a ﬂag.

Deleting EasyJob operating points

Press the Favourites button

The 5 EasyJob buttons are opened.

Turn the adjusting dial and select the storage location to be deleted

To delete an EasyJob operating point, press and hold the adjusting dial for

about 5 seconds

The button

first changes its size and colour;

it changes to a green colour after about 3 seconds;

The saved operating point is overwritten with the current settings. is highlighted in red (= delete) after a total of 5 seconds.

The EasyJob operating point has been deleted.

Welding job

Safety

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.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation

Set up and install the power source in accordance with the welding job

Plug in the mains plug

CAUTION!

Risk of injury and damage to property from electric shock.

As soon as the mains switch is in the "I" position, the tungsten electrode of the welding torch is live.

Ensure that the tungsten electrode does not touch any persons or electric-

▶

ally conductive or earthed parts (e.g. housing, etc.).

Move the mains switch to the "I" position

Welding a job

Press the Mode button

The welding processes and operating modes are displayed.

Select "JOB" (turn adjusting dial and press)

The welding parameters of the previously opened job are displayed after a short time. The job number is selected.

Press the adjusting dial

The job number can now be modified.

Select the job number of the welding job (turn adjusting dial and press)

The welding parameters of the selected job are displayed and the job can now be welded.

Setup settings

The Setup menu

General The Setup menu provides easy access to the knowledge base in the power source

and to additional functions. The Setup menu can be used to make simple adjustments to the welding parameters to suit the various job settings.

The following can be found in the Setup menu:

all setup parameters that have an immediate effect on the welding process,

all setup parameters needed for making the preliminary settings on the

welding system.

The display of the parameters and the ability to change them depends on the selected menu and the current settings for the welding process and operating mode. Parameters that are not relevant to the current settings are greyed out and cannot be selected.

Accessing the Setup menu

Press Menu key

The Setup menu appears.

To leave the Setup menu, press the Menu key again

The current welding parameters will be displayed.

Overview

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

(11)

(7)

(14)(15) (13)

(12)

(9)

(10)(8)

Item Description

(1) TIG menu

for setting the TIG parameters for TIG DC and TIG AC

(2) Rod electrode menu

for setting rod electrode parameters

(3) CEL menu

for setting the parameters for manual metal arc welding with cellulose electrodes

(4) Ignition and mode settings

for setting the

Ignition parameters

Arc monitoring

Operating mode defaults

(5) Gas menu

for setting the shielding gas parameters

(6) Component settings

for setting the cooling unit mode

(7) Documentation menu

(only with OPT/i documentation option present)

to display welds, events, logbook

for setting the sampling rate and limit value monitoring

(8) Job menu

(only if OPT/i Jobs function package is present)

to save, load and delete jobs

to assign EasyJobs to the Favourites button

(9) Defaults

for setting the

display (backlighting, languages, date & time, etc.)

system (power source configuration, factory setting, etc.)

network settings (Bluetooth, network setup, WLAN, etc.)

user management (create user, create role, etc.)

management (trial license)

For a detailed overview of the defaults, see page 124.

(10) System information

to view device information such as software version or IP address (if power source is integrated into a network)

Changing menus and parameters

(11) Scroll bar

(if there are several parameters)

(12) Available menus

The number of menus available may vary depending on the firmware version and available options.

(13) Value, unit

(14) Setup parameters

Depending on the selected menu and the current settings for the welding process and operating mode, parameters that are not relevant are greyed out and cannot be selected.

(15) Indication of the currently selected menu

Taking into account the current settings for welding process and operating mode

* Menu currently being adjusted (blue background) ** Position of the currently selected menu

Selected menu

Selected parameter

Change the menu

Set the parameter

Selecting a menu

If a parameter is selected (blue frame, white background):

Turn the adjusting dial until the parameter's higher-level menu is selected

Press the adjusting dial

The background of the selected menu becomes blue.

Turn the adjusting dial and select the desired menu (blue background)

Setting parameters

Press the adjusting dial in the selected menu

The first parameter in the menu is selected.

Turn the adjusting dial and select the desired parameter

Press the adjusting dial to change the parameter

The background of the parameter value becomes blue.

Turn the adjusting dial and set the value of the parameter

The change in the parameter value takes effect immediately

Press the adjusting dial to select other parameters

The TIG menu

Parameters in the TIG DC menu

Tacking

Tacking function – duration of the pulsed welding current at the start of tacking

off / 0.1 - 9.9 s / on Factory setting: off

on The pulsed welding current remains until the end of the tacking process

0.1 - 9.9 s

The set time begins with the UpSlope phase. After the set time has elapsed, welding is continued with a constant welding current; the pulse parameters, if any, are available

off Tacking function switched off

The tacking indicator (TAC) in the status bar on the display lights up provided that a value has been set.

Pulse frequency

off / 0.20 - 2000 Hz (10,000 Hz with FP Pulse Pro option) Factory setting: off

IMPORTANT! If the pulse frequency is set to "off", the Base current and Duty cycle parameters cannot be selected.

The set pulse frequency is also used for the reduced current.

The pulse indicator in the status bar on the display lights up provided a value has been specified for the pulse frequency.

OPT/i Pulse Pro

For setting the base current, duty cycle, pulse waveform and base current waveform parameters

Base current

0 - 100% (of main current I1) Factory setting: 50%

Duty cycle

Ratio of pulse duration to base current duration in cases where a pulse frequency has been set

10 - 90% Factory setting: 50%

Pulse waveform

To optimise the arc pressure

Hard rectangle / Soft rectangle / Sine Factory setting: Hard rectangle

Hard rectangle: Pure rectangular waveform; slightly louder arc noise. Rapid current changes Used for orbital welding, for example

Soft rectangle: Rectangular waveform with decreased edge steepness, for noise reduction compared to the pure rectangular waveform; universal applications

Sine: Sinusoidal waveform (default setting for low noise and stable arc); used for corner seams and cladding applications, for example

Optimising the arc pressure has the following effects:

Better wetting of the weld pool (improved welding of butt welds or corner

welds) Slow current rise or current drop (especially with fillet welds, high-alloy

steels or cladding applications, the filler material or the weld pool is not pushed away) Quieter welding thanks to smoother waveforms

Base current waveform

To optimise the arc pressure

Hard rectangle / Soft rectangle / Sine Factory setting: Hard rectangle

Hard rectangle: Pure rectangular waveform; slightly louder arc noise. Rapid current changes Used for orbital welding, for example

Soft rectangle: Rectangular waveform with decreased edge steepness, for noise reduction compared to the pure rectangular waveform; universal applications

Sine: Sinusoidal waveform (default setting for low noise and stable arc); used for corner seams and cladding applications, for example

Starting current time

The starting current time specifies the duration of the starting-current phase.

off / 0.01 - 30.0 s Factory setting: off

IMPORTANT! The starting current time only applies to 2-step mode and spot welding. In 4-step mode, the duration of the starting-current phase is controlled

using the torch trigger.

Final current time

The final current time specifies the duration of the final current phase.

off / 0.01 - 30 s Factory setting: off

IMPORTANT! The final current time only applies to 2-step mode and spot welding. In 4-step mode, the duration of the final current phase is controlled using the torch trigger (see "TIG operating modes").

Slope reduced current

To set the Slope1 reduced current and Slope2 reduced current parameters

Slope1 reduced current

off / 0.01 - 30 s Factory setting: off

If a time value has been entered for the Slope1 reduced current parameter, the short-term current reduction or current increase is not abrupt, but rather slow and adapted to the desired current curve. This reduces negative effects on the weld seam and component, especially for aluminium applications.

Slope2 reduced current

off / 0.01 - 30 s Factory setting: off

If a time value has been entered for the Slope2 reduced current parameter, the adaptation of the reduced current to the welding current is not abrupt, but rather slow and adapted to the desired current curve.

For example, during a current increase, the weld pool is heated slowly, not abruptly. This allows the weld pool to outgas and reduces pores during aluminium welding.

Spot welding time

(spot welding mode only)

0.02 - 120 s

Factory setting: 5.0 s

Parameters in the TIG AC menu

Pulse frequency

off / 0.20 - 2000 Hz (10,000 Hz with FP Pulse Pro option) Factory setting: off

IMPORTANT! If the pulse frequency is set to "off", the Base current and Duty cycle parameters cannot be selected.

The set pulse frequency is also used for the reduced current.

The pulse indicator in the status bar on the display lights up provided a value has been specified for the pulse frequency.

OPT/i Pulse Pro

For setting the base current, duty cycle, pulse waveform and base current waveform parameters

Base current

0 - 100% (of main current I1) Factory setting: 50%

Duty cycle

Ratio of pulse duration to base current duration in cases where a pulse frequency has been set

10 - 90% Factory setting: 50%

Pulse waveform

To optimise the arc pressure

Hard rectangle / Soft rectangle / Sine Factory setting: Hard rectangle

Hard rectangle: Pure rectangular waveform; slightly louder arc noise. Rapid current changes Used for orbital welding, for example

Soft rectangle: Rectangular waveform with decreased edge steepness, for noise reduction compared to the pure rectangular waveform; universal applications

Sine: Sinusoidal waveform (default setting for low noise and stable arc); used for corner seams and cladding applications, for example

Optimising the arc pressure has the following effects:

Better wetting of the weld pool (improved welding of butt welds or corner

welds) Slow current rise or current drop (especially with fillet welds, high-alloy

steels or cladding applications, the filler material or the weld pool is not pushed away) Quieter welding thanks to smoother waveforms

Base current waveform

To optimise the arc pressure

Hard rectangle / Soft rectangle / Sine Factory setting: Hard rectangle

Hard rectangle: Pure rectangular waveform; slightly louder arc noise. Rapid current changes Used for orbital welding, for example

Soft rectangle: Rectangular waveform with decreased edge steepness, for noise reduction compared to the pure rectangular waveform; universal applications

Sine: Sinusoidal waveform (default setting for low noise and stable arc); used for corner seams and cladding applications, for example

Starting current time

(only in 2-step mode and during spot welding) The starting current time specifies the duration of the starting-current phase.

off / 0.01 - 30.0 s Factory setting: off

IMPORTANT! The starting current time only applies to 2-step mode and spot

welding. In 4-step mode, the duration of the starting-current phase is controlled using the torch trigger.

Final current time

(only in 2-step mode and during spot welding) The final current time specifies the duration of the final current phase.

off / 0.01 - 30 s Factory setting: off

Slope reduced current

To set the Slope1 reduced current and Slope2 reduced current parameters

Slope1 reduced current

off / 0.01 - 30 s Factory setting: off

Slope2 reduced current

off / 0.01 - 30 s Factory setting: off

If a time value has been entered for the Slope2 reduced current parameter, the

t (s)

I (A)

60 Hz 120 Hz

adaptation of the reduced current to the welding current is not abrupt, but rather slow and adapted to the desired current curve.

For example, during a current increase, the weld pool is heated slowly, not abruptly. This allows the weld pool to outgas and reduces pores during aluminium welding.

Spot welding time

(spot welding mode only)

0.02 - 120 s Factory setting: 5.0 s

AC frequency

Syn / 40 - 250 Hz Factory setting: 60 Hz

Syn Setting for synchronous welding (both-sided, simultaneous welding with 2 power sources) For synchronous welding, the AC frequency must be set to "Syn" on both power sources. Synchronous welding is used for thick material thicknesses to achieve a high deposition rate and to minimise inclusions during welding.

IMPORTANT! Owing to the phasing of the input voltage, in some cases the synchronisation of the two power sources cannot be carried out properly. In this case, pull out the mains plug of the power source, turn it through 180° and plug it back in again.

Low frequency soft, wide arc with shallow heat input

High frequency focused arc with deep heat input

Effect of the AC frequency on the waveshape:

AC current offset

-70 to +70% Factory setting: 0%

100

+70% Wide arc with low heat input High stress on the tungsten electrode Good surface cleaning

-70% Narrow arc with high heat input

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

Specifications and Main Features

Frequently Asked Questions

User Manual