Explanation of Safety Instructions10
General10
Intended Use11
Grid Connection11
Environmental Conditions11
Obligations of the Operating Company12
Obligations of Personnel12
Residual current circuit breaker12
Personal Protection and Protection of Others12
Data on noise emission values13
Danger from toxic gases and vapors13
Danger from Flying Sparks14
Risks from grid current and welding current14
Stray welding currents15
EMC Device Classifications15
EMC measures15
EMF measures16
Particular hazard areas16
Requirement for the shielding gas17
Danger from Shielding Gas Cylinders18
Danger Posed by Shielding Gas Leak18
Safety Measures at the Setup Location and During Transport18
Safety Measures in Normal Operation19
Maintenance and repair20
Safety Inspection20
Disposal20
Safety symbols20
Data backup21
Copyright21
Intended use21
EN-US
General information23
General25
Device concept25
Functional principle25
Application areas25
Conformities26
Bluetooth trademarks27
Warning notices on the device27
Options29
OPT/i Safety Stop PL d option30
Operating controls, connections and mechanical components31
Control Panel33
General33
Control panel33
Input options34
Display36
Display36
Switching to full screen38
Connections, Switches, and Mechanical Components39
General47
Safety47
Specified mains cable47
Connecting the mains cable for nc power sources49
Connecting the mains cable for MV power sources50
Locking and unlocking the power source using the NFC key54
General54
Locking and unlocking the power source using the NFC key54
TIG57
System components59
System components59
Notes on the cooling unit59
Minimum equipment for TIG welding60
Minimum equipment for TIG AC welding60
Minimum equipment for TIG DC welding60
TIG welding processes61
TIG DynamicWire61
Commissioning62
Safety62
General62
Assembling the system components (overview)63
Connecting the gas cylinder65
Connecting the welding torch to the power source and cooling unit66
Establishing a ground earth connection to the workpiece68
Other activities69
TIG Operating Modes70
Safety70
Symbols and explanations70
2-step mode71
4-step mode71
Special 4-step mode: Version 172
Special 4-step mode: Version 273
Special 4-step mode: Version 374
Special 4-step mode: Version 475
Special 4-step mode: Version 576
Special 4-step mode: Version 677
Spot welding78
TIG welding79
Safety79
TIG welding79
Welding parameters for TIG welding81
Igniting the arc87
General87
Igniting the arc using high frequency(HF ignition)87
Contact ignition88
Igniting the arc using high-frequency contact(Touch-HF)89
Electrode overload90
End of welding90
TIG process parameters94
Process parameters for TIG pulse94
4
Process parameters for TIG AC96
General TIG process parameters98
Process parameters for ignition and operating mode99
CycleTIG103
Wire speed setting104
TIG gas settings105
Conducting an R/L alignment106
Manual Metal Arc Welding, CEL, Arc air gouging109
Minimum equipment for MMA and CEL welding and for arc air gouging111
Minimum equipment for MMA and CEL welding111
Minimum equipment for arc air gouging111
Commissioning112
Preparation112
Manual Metal Arc Welding113
Safety113
Manual metal arc welding113
Welding parameters for manual metal arc welding and CEL welding115
Hot-Start, Soft-Start, Anti-Stick Functions117
Starting current > 100 % (HotStart)117
Starting current < 100 % (SoftStart)117
Anti-stick function118
Stick electrode / CEL Process parameters119
Stick electrode / CEL Process parameters119
Process parameters for stick electrode119
Process parameters for CEL122
Arc air gouging (iWave 500 DC and iWave 500 AC/DC)123
Brief description of the gouging (Arc Air Gouging)123
Safety123
Preparation123
Arc air gouging124
General139
Symbols and their explanations139
2-step mode140
4-step mode140
Special 4-step mode141
Special 2-step mode141
Spot welding142
Preparing for MIG/MAG welding143
Safety143
5
Correct routing of the interconnecting hosepack143
Context144
Setting up MIG/MAG system components (overview)145
MIG/MAG and CMT welding147
Safety147
Selecting the welding process and operating mode147
Selecting the filler metal and shielding gas148
Setting the welding parameters149
Setting the shielding gas flow rate150
MIG/MAG or CMT welding151
MIG/MAG and CMT welding parameters152
Welding parameters for MIG/MAG pulse-synergic welding, for CMT welding and for PMC
welding
Welding parameters for MIG/MAG standard synergic welding and LSC welding153
Welding parameters for MIG/MAG standard manual welding154
Explanation of footnotes154
Spot welding155
Spot welding155
MIG/MAG process parameters158
MIG/MAG process parameters158
Process parameters for weld start / weld end158
Process parameters for gas setup160
Process parameters for process control160
Penetration stabilizer161
Arc length stabilizer163
Combination of penetration stabilizer and arc length stabilizer165
Process parameters for SynchroPulse166
Process parameters for Process Mix168
Process parameters for CMT Cycle Step 171
Process parameters for spot welding171
R/L alignment171
General177
Saving settings as a job177
Welding job - retrieving jobs178
Optimizing a job179
Renaming a job180
Deleting a job181
Loading a job182
Job process parameters183
JOB process parameters183
Process parameters for "Optimize Job"183
Setting correction limits for a job188
Pre-settings for "Save as Job"189
Process parameters191
Overview193
Overview193
Process parameters - Components & monitoring194
Process parameters - Components & Monitoring194
Process parameters for components194
Draining/filling the torch hosepack197
System adjustment198
6
Arc break watchdog199
Wire stick contact tip199
Wire stick workpiece200
Welding circuit coupling200
Wire end monitoring201
Gas monitoring202
Motor force monitoring203
Defaults205
Defaults207
General207
Overview207
Defaults - View208
Defaults screen208
Selecting the language208
Selecting units/standards208
Setting the date and time208
Retrieving system data209
Displaying characteristics211
Parameter view setup212
Parameter view iJob213
Defaults - System214
Defaults - System214
Retrieving device information214
Restoring factory settings214
Restoring the website password215
Setup mode215
Setting network parameters manually217
Setting up WLAN218
Bluetooth setup218
Power source configuration221
Wirefeeder setup221
Interface setup221
TWIN Setup222
Defaults - Documentation223
Defaults - Documentation223
Setting the sample rate223
Viewing the logbook223
Switching limit value monitoring on/off224
Defaults Administration225
Defaults Administration225
User management226
General226
Explanation of terms226
Predefined roles and users226
User administration overview227
Create administrator and roles228
Recommendation for creating roles and users228
Creating an administrator key229
Creating roles229
Copying roles230
Creating users231
Creating users231
Copying users231
Editing roles/users, deactivating user management233
Editing roles233
Deleting roles233
Editing users233
Deleting users234
Deactivating user management234
Lost administrator NFC key?235
EN-US
7
CENTRUM - Central User Management236
Activating the CENTRUM server236
SmartManager – The Website of the Power Source237
SmartManager – The Website of the Power Source239
General239
Opening and logging into the SmartManager for the power source239
Help functions if logging in does not work240
Changing the password/logging out240
Settings241
Selecting the language241
Status indicator242
Fronius242
Current system data243
Current system data243
Documentation, logbook244
Documentation244
Job data246
Job data246
Job overview246
Editing a job246
Importing a job247
Exporting a job247
Exporting job(s) as ...247
Power source settings249
Process parameters249
Designation & location249
Save and restore250
General250
Save and restore250
Automatic backup251
User management252
General252
Users252
User roles252
Export & import253
CENTRUM253
Overview254
Overview254
Expanding all groups/collapsing all groups254
Saving as an xml file254
Update255
Update255
Finding the update file (performing an update)255
Fronius WeldConnect256
Function packages257
Function packages257
Welding packages257
Options257
Loading a function package257
Screenshot258
Screenshot258
Troubleshooting and Maintenance259
Troubleshooting261
General261
Safety261
Power Source Troubleshooting261
Service, maintenance and disposal265
General265
Safety265
8
At every start-up265
Every 2 months265
Every 6 months265
Updating firmware265
Disposal266
Appendix267
Average consumption values during welding269
Average shielding gas consumption during TIG welding269
Average shielding gas consumption during MIG/MAG welding269
Average wire electrode consumption during MIG/MAG welding269
Technical data270
Explanation of the term duty cycle270
Special Voltage270
iWave 300i DC271
iWave 300i DC /nc273
iWave 300i DC /MV/nc275
iWave 400i DC277
iWave 400i DC /nc279
iWave 400i DC /MV/nc281
iWave 500i DC283
iWave 500i DC /nc285
iWave 500i DC /MV/nc287
iWave 300i AC/DC289
iWave 300i AC/DC /nc291
iWave 300i AC/DC /MV/nc293
iWave 400i AC/DC295
iWave 400i AC/DC /nc297
iWave 400i AC/DC /MV/nc299
iWave 500i AC/DC301
iWave 500i AC/DC /nc303
iWave 500i AC/DC /MV/nc305
Radio parameters307
Overview with critical raw materials, year of production of the device307
EN-US
9
Safety Instructions
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
▶
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are
▶
not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
GeneralThe device has been manufactured using state-of-the-art technology and ac-
cording to recognized safety standards. If used incorrectly or misused, however,
it can cause
Injury or death to the operator or a third party
-
Damage to the device and other material assets belonging to the operating
-
company
Inefficient operation of the equipment
-
All persons involved in the commissioning, operation, maintenance, and servicing
of the device must
Be suitably qualified
-
Have knowledge of welding
-
Have completely read and followed these Operating Instructions
-
The Operating Instructions must always be at hand wherever the device is being
used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also
be followed.
All safety and danger notices on the device must
Be kept in a legible state
-
Not be damaged/marked
-
Not be removed
-
Not be covered, pasted, or painted over
-
For the location of the safety and danger notices on the device, refer to the section headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
10
Your personal safety is at stake!
Intended UseThe device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating
plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be
"not in accordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means
Completely reading and obeying all instructions in the Operating Instruc-
-
tions
Completely reading and obeying all safety instructions and danger notices
-
Carrying out all the specified inspection and servicing work
-
Never use the device for the following applications:
Thawing pipes
-
Charging batteries
-
Starting motors
-
The device is designed for operation in industry and business. The manufacture
shall not be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
EN-US
Grid ConnectionDevices with a high output can influence the energy quality of the grid due to
their current consumption.
This may affect a number of device types in terms of:
connection restrictions
-
-
criteria regarding maximum permissible grid impedance
-
criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
*)
*)
See technical data
In this case, the operator or the person using the device should check whether or
not the device is allowed to be connected, where appropriate through discussion
with the power supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.
Temperature range of the ambient air:
During operation: -10°C to +40°C (14°F to 104°F)
-
During transport and storage: -20°C to +55°C (-4°F to 131°F)
-
Relative humidity:
Up to 50% at 40°C (104°F)
-
Up to 90% at 20°C (68°F)
-
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
11
Obligations of
the Operating
Company
The operating company must only allow persons to work with the device if they
Are familiar with the basic occupational safety and accident prevention regu-
-
lations and are trained in handling the device
Have read and understood these Operating Instructions, especially the sec-
-
tion "Safety Rules," and have confirmed this with their signature
Are trained according to the requirements for the work results
-
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
Residual current
circuit breaker
Personal Protection and Protection of Others
All persons who are assigned to work with the device must do the following before beginning the work:
Follow the basic regulations for occupational safety and accident prevention
-
Read these Operating Instructions, especially the section "Safety Rules," and
-
confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage
can occur in one's absence.
Local regulations and national guidelines may mean that a residual current circuit breaker is required when connecting a device to the public grid.
The residual current circuit breaker recommended for the device by the manufacturer can be found in the technical data.
You are exposed to numerous hazards while handling the device, for example:
Flying sparks and pieces of hot metal
-
Arc radiation that poses a risk of injury to the eyes and skin
-
Hazardous electromagnetic fields that pose a risk of death for individuals
-
with pacemakers
Electrical risks from grid current and welding current
-
Increased noise exposure
-
Harmful welding fumes and gases
-
Wear suitable protective clothing when dealing with the device. The protective
clothing must have the following properties:
Flame resistant
-
Insulating and dry
-
Covering the entire body and in good condition with no damage
-
Safety helmet
-
Cuffless pants
-
Protective clothing involves the following:
Protecting the face and eyes from UV radiation, heat and flying sparks with a
-
face guard featuring a regulation-compliant filter
Wearing regulation-compliant protective goggles with side protection behind
-
the face guard
Wearing rigid, wet-insulating footwear
-
Protecting hands with appropriate gloves (featuring electrical insulation and
-
thermal protection)
Wearing ear protection to reduce noise exposure and protect against injury
-
12
Keep persons, especially children, away during the operation of the devices and
during the welding process. If persons are in the vicinity, however:
Instruct them about all hazards (blinding hazard due to arcs, risk of injury
-
from flying sparks, welding fumes hazardous to health, noise exposure, possible hazard due to grid current or welding current, etc.)
Provide suitable protective equipment or
-
Construct suitable protective walls and curtains.
-
EN-US
Data on noise
emission values
Danger from toxic gases and vapors
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation in relation to the maximum permitted operating point at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be specified because this value depends on the welding process and the environmental
conditions. It is influenced by a wide range of parameters, such as the welding
process itself (MIG/MAG, TIG welding), the selected current type (direct current, alternating current), the power range, the type of weld metal, the resonance
properties of the workpiece, the workplace environment, and many other factors.
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph
118 from the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
Do not breathe them in.
-
Extract them from the work area using appropriate equipment.
-
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding
fumes are:
The metals used for the workpiece
-
Electrodes
-
Coatings
-
Cleaning agents, degreasers, and the like
-
The welding process used
-
Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.
Recommendations for exposure scenarios, risk management measures and
identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or
the main gas supply.
13
Danger from Flying Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the
arc or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through
small cracks and openings. Take appropriate measures to ensure that there is no
risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed
tanks, drums, or pipes if these have not been prepared in accordance with corresponding national and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and
the like are/were stored. Residues pose a risk of explosion.
Risks from grid
current and
welding current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the
feed rollers, as well as all pieces of metal that are in contact with the welding
wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with
sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at
least 180° around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
Never immerse it in liquids to cool it
-
Never touch it when the power source is switched on.
-
14
The open circuit voltage of a welding system may double, for example, between
the electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.
Protection class I devices require a grid with a ground conductor and a connector
system with ground conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket
without a ground conductor contact is only permitted if all national regulations
for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no liability for any damage resulting from improper use.
Stray welding
currents
Use suitable equipment to ensure that the workpiece is sufficiently grounded if
necessary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched
on again by applying a clearly legible and understandable warning sign.
After opening the device:
Discharge all electrically charged components
-
Ensure that all components are disconnected from the power supply.
-
If work is needed on voltage-carrying parts, bring in a second person who will
switch off the main switch at the correct time.
If the following instructions are not observed, stray welding currents may occur,
which pose a risk of the following:
Fire
-
Overheating of parts connected to the workpiece
-
Irreparable damage to ground conductors
-
Damage to the device and other electrical equipment
-
EN-US
EMC Device
Classifications
Ensure that the workpiece clamp is securely connected to the workpiece.
Secure the workpiece clamp as close to the spot to be welded as possible.
Position the device with sufficient insulation against electrically conductive environments, e.g., insulation against electrically conductive floors or electrically conductive mounts.
Observe the following when using power distribution boards, twin-head mounts,
etc.: Even the electrode of the welding torch/electrode holder not in use carries
electric potential. Ensure that there is sufficient insulation when the unused
welding torch/electrode holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the
welding wire drum, large spool, or wirespool to the wirefeeder with insulation.
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 grid.
EMC device classification as per the rating plate or technical data.
EMC measuresIn 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
15
there is sensitive equipment at the same location, or if the site where the device
is installed is close to either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.
Test and assess the immunity of equipment in the vicinity of the device in accordance with national and international provisions. Examples of interferenceprone equipment that could be affected by the device:
Safety devices
-
Grid power lines, signal lines, and data transfer lines
-
IT and telecommunications equipment
-
Devices for measuring and calibrating
-
Supporting measures to avoid EMC problems:
Grid power supply
1.
If electromagnetic interference occurs despite a grid connection that
-
complies with regulations, take additional measures (e.g., use a suitable
grid filter).
Welding power-leads
2.
Keep them as short as possible
-
Route them close together (also to avoid EMF problems)
-
Route them far from other lines
-
Equipotential bonding
3.
Workpiece grounding
4.
If necessary, establish grounding using suitable capacitors.
-
Shield, if necessary
5.
Shield other devices in the vicinity
-
Shield the entire welding installation
-
EMF measuresElectromagnetic fields may cause health problems that are not yet known:
Effects on the health of persons close by, e.g., those with pacemakers and
-
hearing aids
Persons with pacemakers must seek advice from their doctor before staying
-
in the immediate vicinity of the device and the welding process
Keep distances between welding power-leads and the head/torso of the
-
welder as great as possible for safety reasons
Do not carry welding power-leads and hosepacks over your shoulder or wrap
-
them around your body or body parts
Particular hazard areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
Fans
-
Gears
-
Rollers
-
Shafts
-
Wirespools and welding wires
-
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side panels must only be opened/removed during maintenance and
repair work.
During operation
Ensure that all covers are closed, and all side parts have been mounted prop-
-
erly.
Keep all covers and side parts closed.
-
16
The protrusion of welding wire from the welding torch represents a high risk of
injury (cuts to the hand, facial and eye injuries, etc.).
Therefore, always hold the welding torch away from the body (devices with
wirefeeder) and use suitable protective goggles.
Do not touch the workpiece during or after welding – risk of burns.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant
protective equipment when reworking workpieces and ensure that other persons
are sufficiently protected.
Leave the welding torch and other parts with a high operating temperature to
cool before working on them.
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g., boilers)
must be labeled with the symbol (Safety). However, the power source may not be
located in such areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data
sheet. The coolant safety data sheet can be obtained from your service center or
via the manufacturer's website.
Only use suitable load-carrying equipment from the manufacturer to transport
devices by crane.
Attach chains or ropes to all designated attachments of the suitable load-
-
carrying equipment.
Chains or ropes must be the smallest angle possible from vertical.
-
Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
-
EN-US
Requirement for
the shielding gas
In the event of crane attachment of the wirefeeder during welding, always use a
suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand. The carrier belt is not suitable for transport by crane,
counterbalanced lift truck, or other mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association
with the device or its components, must be checked regularly (e.g., for mechanical damage, corrosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an
adapter is used for the shielding gas connection. Use suitable Teflon tape to seal
the thread of the shielding gas connection adapter on the device side before installation.
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.
17
Danger from
Shielding Gas
Cylinders
Shielding gas cylinders contain compressed gas and may explode if damaged.
Shielding gas cylinders are an integral part of the welding equipment, so they
must be handled very carefully.
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with
instructions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the
correct matching accessories (controller, hoses, and fittings, etc.) Only use
shielding gas cylinders and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not
connected.
Danger Posed by
Shielding Gas
Leak
Safety Measures
at the Setup
Location and
During Transport
Follow the manufacturer's instructions and applicable national and international
provisions for shielding gas cylinders and accessories.
Risk of asphyxiation due to uncontrolled shielding gas leak
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.
Ensure there is a sufficient supply of fresh air with a ventilation flow rate of
-
at least 20 m³ per hour.
Please observe the safety and maintenance information for the shielding gas
-
cylinder or the main gas supply.
When no welding is taking place, close the valve of the shielding gas cylinder
-
or the main gas supply.
Always check the shielding gas cylinder or main gas supply for uncontrolled
-
gas leakage before each start-up.
A toppling device can be deadly! Set up the device securely on an even, solid surface
The maximum permitted tilt angle is 10°.
-
Special regulations apply in areas at risk of fire or explosion
Follow the appropriate national and international regulations.
-
18
Use instructions and checks within the company to ensure that the vicinity of the
workplace is always clean and organized.
Only set up and operate the device in accordance with the protection class
shown on the rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m
(1 ft. 7.69 in.) to allow cooling air to circulate unhindered.
Safety Measures
in Normal Operation
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or
lifting.
Before transporting the device, completely drain the coolant and dismantle the
following components:
wirefeeder
-
wirespool
-
shielding gas cylinder
-
It is essential to conduct a visual inspection of the device to check for damage
after it has been transported but before commissioning. Have any damage repaired by trained service technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a danger of:
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
-
EN-US
Safety devices that are not fully functional must be repaired before the device is
switched on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by
crane.
Only the original coolant from the manufacturer is suitable for use in our devices
due to its properties (electrical conductivity, anti-freeze, material compatibility,
flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the
manufacturer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flam-mable in certain conditions. Only transport the coolant in closed original containers and keep away from sources of ignition.
Properly dispose of used coolant according to national and international regulations. The coolant safety data sheet can be obtained from your service center or
via the manufacturer’s website.
When the system is cool, always check the coolant level before starting welding.
19
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
DisposalTo comply with European directives and national law, waste electrical and elec-
The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.
The manufacturer recommends calibrating power sources within the same 12month interval.
A safety inspection by a certified electrician is recommended:
After changes
-
After alterations
-
After repair, care, and maintenance
-
At least every 12 months
-
For the safety inspection, follow the appropriate national and international
standards and guidelines.
You can obtain more information about the safety inspection and calibration
from your service center. The service center will provide the necessary documents upon request.
tronic equipment must be collected separately and sent for environmentallyfriendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.
Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.
Safety symbolsDevices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (e.g., relevant product standards of
the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on the
following website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.
20
Data backupThe user is responsible for backing up any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
CopyrightCopyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves 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 Operating Instructions, we will be most grateful for your comments.
Intended useThe device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating
plate and in the Operating Instructions.
Utilization for any other purpose, or in any other manner, shall be deemed to be
"not in accordance with the intended purpose." The manufacturer accepts no liability for any damage resulting from improper use.
Intended use also means
Reading and adhering to all instructions in the Operating Instructions
-
Carefully reading and obeying all safety instructions and danger notices
-
Carrying out all the specified inspection and maintenance work.
-
EN-US
Never use the device for the following applications:
Thawing pipes
-
Charging batteries
-
Starting motors
-
The device is designed for operation in commercial applications. The manufacturer shall not be liable for any damage resulting from use in a living area.
The manufacturer shall also not be liable for faulty or incorrect work results.
21
22
General information
23
24
General
Device conceptThe iWave 300i / 400i / 500i DC and
iWave 300i / 400i / 500i AC/DC power
sources are fully digitized, microprocessor-controlled inverter power
sources.
A modular design and easy ability to
extend the system guarantee a high
degree of flexibility. The devices can be
adapted to any situation.
EN-US
Functional principle
Application
areas
The central control and regulation unit of the power sources is coupled with a digital signal processor. The central control and regulation unit and the 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 commercial and industrial applications for manual and
automated TIG and MIG/MAG welding of unalloyed and low-alloyed steel, highalloyed chrome/nickel steel, aluminum, aluminum alloys, and magnesium. The
power sources are designed for:
Automotive and supply industry,
-
Mechanical engineering and rail vehicle manufacturing,
-
Chemical plant construction,
-
Machine construction,
-
Shipyards,
-
etc.
-
25
ConformitiesFCC
This device conforms to the limit values for an EMC device class A digital device,
pursuant to Part 15 of the FCC regulations. These limit values are designed to
provide reasonable protection against harmful interference when operating in a
commercial environment. This device generates and uses high-frequency energy
and, if not installed and used in accordance with the Operating Instructions, may
interfere with radio communications.
Operation of this device in residential areas is likely to cause harmful interference, in which case the user is required to correct the interference at his own expense.
FCC ID: QKWSPBMCU2
Industry Canada RSS
This device complies with Industry Canada license-exempt RSS standards. Operation is subject to the following conditions:
(1)The device must not cause any harmful interference.
(2)The device must not be affected by external sources of interference, in-
IC: 12270A-SPBMCU2
EU
Compliance with Directive 2014/53/EU - Radio Equipment Directive (RED)
cluding interference that may impair operation.
The antennas used for this transmitter must be installed in such a way that a
minimum distance of 20 cm from all persons is maintained. They must not be installed or operated in conjunction with another antenna or transmitter. OEM integrators and end users must ensure the operating conditions of the transmitter
comply with radio frequency exposure guidelines.
ANATEL / Brazil
This device is operated on a secondary basis. It does not claim to offer protection
against harmful interference, even from devices of the same type.
This device can not cause interference in primarily operated systems.
This device complies with ANATEL's specific absorption rate limit values for exposure to high-frequency electrical, magnetic, and electromagnetic fields.
IFETEL / Mexico
Operation of this device is subject to the following two conditions:
(1)The device must not cause any harmful interference;
(2)The device must accept any interference, including interference that may
cause undesired operation.
NCC / Taiwan
According to the NCC regulations for low-power equipment that generates radio
frequency radiation:
Article 12
Certified low-power equipment that generates radio frequency radiation shall
not change frequency, increase power or alter the characteristics and functions
of the original design without approval.
26
Article 14
The use of low-power equipment that generates radio frequency radiation shall
not adversely affect flight safety and legally operated communication equipment.
An identified malfunction must be deactivated and corrected immediately. All
malfunctions must be eliminated.
The legal notice in the preceding paragraph refers to radio communications
equipment operated in accordance with the provisions of the Telecommunications Act. Low-power equipment that generates radio frequency radiation must
be able to withstand interference from legally operated communication channels
or radiological, radiation electrical devices used in industrial, scientific and medical applications.
Thailand
EN-US
Bluetooth trademarks
Warning notices
on the device
The word mark Bluetooth® and the Bluetooth® logos are registered trademarks
and property of Bluetooth SIG, Inc. and are used by the manufacturer under license. Other trademarks and trade names are the property of their respective
owners.
Warning notices and safety symbols can be found on power sources with the
CSA test mark for use in the North American region (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 property
damage.
27
Safety symbols on the rating plate:
Welding is dangerous. The following basic requirements must be met:
Adequate welding qualifications
-
Appropriate protective equipment
-
Exclusion of unauthorized persons
-
Do not use the functions described here until you have fully read and understood
the following documents:
These Operating Instructions
-
All system component Operating Instructions, especially the safety rules
-
28
Options
WP TIG DynamicWire
The Welding Package enables the TIG DynamicWire process.
OPT/i TIG gas regulator
OPT/i TIG 4 Switch SpeedNet
Option if more than one additional SpeedNet connection is required.
OPT/i TIG Gas flow rate sensor
OPT/i TIG external sensor
OPT/i TIG PowerConnector
2. Current socket on the rear of the power source
OPT/i TIG Gas changeover
OPT/i TIG 2nd SpeedNet
Second SpeedNet connection
OPT/i TIG DC MultiProzess PRO
OPT/i TIG AC MultiProzess PRO
OPT/i TIG 2nd NT242
When using a CU 1400 cooling unit, the OPT/i TIG 2nd NT242 option must be installed in the power sources.
EN-US
OPT/i TIG NT601
OPT/i TPS dust filter
IMPORTANT! The use of the OPT/i TPS dust filter option on iWave power
sources will reduce the duty cycle!
OPT/i CycleTIG
Advanced TIG stitch welding
OPT/i Synergic Lines *
Option to enable all available special characteristics of TPSi power sources;
any special characteristics created in the future are thus automatically enabled.
OPT/i GUN Trigger *
Option for special functions in connection with the torch trigger
OPT/i Jobs
Option for Job Mode
OPT/i Documentation
Option for the documentation function
OPT/i Puls Pro
OPT/i Interface Designer *
Option for individual interface configuration
OPT/i WebJobEdit
Option to edit jobs via the SmartManager of the power source
OPT/i Limit Monitoring
Option to set limit values for welding current, welding voltage, and wire speed
OPT/i Custom NFC - ISO 14443A
Option to use a custom frequency band for key cards
29
OPT/i CMT Cycle Step *
Option for adjustable, cyclic CMT welding process
OPT/i OPC-UA
Standardized data interface protocol
OPT/i MQTT
Standardized data interface protocol
OPT/i SpeedNet Repeater
Signal amplifier if interconnecting hosepacks or connections from power source
to wirefeeder exceed 50 m
KRIS 13 Gouging Machine
Electrode holder with compressed air connection for arc air gouging
OPT/i Wire Sense *
Seam tracking / edge detection using wire electrode for automated applications
only in conjunction with CMT hardware
OPT/i Synchropulse 10 Hz *
To increase the SynchroPulse frequency from 3 Hz to 10 Hz
*MIG/MAG options - only in conjunction with the options OPT/i TIG DC
MultiProzess PRO or OPT/i TIG AC MultiProzess PRO
OPT/i Safety
Stop PL d option
IMPORTANT! The OPT/i Safety Stop PL d safety function was developed as Cat-
egory 3 according to EN ISO 13849-1:2008 + AC:2009.
A two-channel feed-in of the input signal is required for this.
Bridging the two-channel capability (e.g. by means of a short-circuit bracket) is
not permitted and results in the loss of the PL d.
Function overview
The OPT/i Safety Stop PL d option ensures a safety stop of the PL d power
source with a controlled end of welding in less than a second.
Each time the power source is switched on, the Safety Stop PL d safety function
performs a self-test.
IMPORTANT! This self-test must be performed at least once a year to check the
function of the safety shutdown.
If the voltage drops at least one of two inputs, the Safety Stop PL d stops the
current welding operation; the wirefeeder motor and the welding voltage is
switched off.
The power source outputs an error code. Communication via the robot interface
or bus system continues.
In order to restart the welding system, the voltage must be applied again. An error must be acknowledged via the torch trigger, display or interface and the start
of welding must be executed again.
30
A non-simultaneous shutdown of the two inputs (> 750 ms) is output by the system as a critical, non-acknowledgeable error.
The power source remains permanently switched off.
A reset is performed by switching the power source off/on.
Operating controls, connections
and mechanical components
31
32
Control Panel
(1)
(2)
(5)(6)
(4)(3)
EN-US
General
Control panel
NOTE!
Because of firmware updates, certain functions may be available for your device
but not described in these Operating Instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. These operating elements function in exactly the same way,
however.
WARNING!
Operating the device incorrectly can cause serious injury and damage to property.
Do not use the functions described here until you have fully read and under-
▶
stood the 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, especially the safety rules.
43,0001,3547
33
No.Function
(1)USB port
For connecting USB thumb drives (service dongle, license key, etc.).
IMPORTANT! The USB port is not electrically isolated from the welding
circuit. Devices that make an electrical connection to another device must
therefore not be connected to the USB port!
(2)Selection dial with rotary/push button function
For selecting elements, setting values, and scrolling through lists
(3)Display (with touch function)
For direct operation of the power source by touching the display
-
For displaying values
-
For navigating through the menu
-
(4)Reading zone for NFC keys
For locking/unlocking the power source using NFC keys
-
For logging in different users (with active user management and as-
-
signed NFC keys)
NFC key = NFC card or NFC key fob
(5)Wire-threading button
For threading the wire electrode / welding wire into the torch hosepack
without gas or current
(6)Gas-test button
To set the required quantity of gas on the gas pressure regulator.
After pressing the gas-test button, gas flows for 30 s. Pressing the button
again ends the process early.
Input optionsTouch the display
Touch the display to
navigate,
-
activate functions,
-
select options
-
When you touch and thus select an element on the display, the element is highlighted.
Turn the selection dial
34
Selecting items on the display:
Turning the dial clockwise selects the next item in a sequence.
-
Turning the dial counterclockwise selects the previous item in a sequence.
-
In a vertical list, turning the dial clockwise highlights the item below; turning
-
it counterclockwise highlights the item above.
Changing values:
Turning the dial clockwise increases the value to be set.
-
Turning the dial counterclockwise decreases the value to be set.
-
Turning the selection dial slowly will also change the value to be set slowly,
-
e.g., for fine adjustments.
Turning the selection dial quickly disproportionately changes the value to be
-
set, which means that large changes in value can be entered quickly.
For some parameters, a value that has been changed by turning the selection dial
is automatically applied without having to press the selection dial.
Press the selection dial
Apply selected elements, e.g., to change the value of a welding parameter.
-
Apply values of specific parameters.
-
EN-US
35
Display
(1)
(2)
(4)
(5)
(3)
Display
No.Function
(1)Status bar
Contains information about:
Currently selected welding process
-
Currently selected operating mode
-
Currently selected polarity
-
Currently selected ignition procedure
-
Cap mode
-
Pulse mode
-
Electrode overload
-
Bluetooth status indicator
-
Currently logged in user (when user management is activated)
-
or
the key symbol when the power source is switched off (e.g., if profile/
role "locked" is activated)
Time and date
-
The content of the status bar varies according to the selected welding
process.
36
(2)Left sidebar
The left sidebar contains the following buttons:
Welding
-
Welding process
-
Process parameters
-
Defaults
-
The left sidebar is operated by touching the display.
(3)Indicator bar
Overview of the currently available welding parameters;
the individual welding parameters can be selected directly by touching the
display. The currently selected parameter is highlighted in blue.
Welding current curve
(2)
EN-US
Balance
Electrode diameter
Cap mode
Polarity
(1)
only with iWave AC/DC power sources
(2)
only with iWave TIG AC/DC power sources and if polarity is set to AC.
(4)Main area
The main area displays welding parameters, EasyJobs, graphics, lists or
navigation elements. The main area is divided up differently depending on
the application and populated with elements.
(1)
(1)
(1)
The main area is operated
via the selection dial,
-
by touching the display.
-
(5)Right sidebar
The right sidebar can be used as follows, depending on the button selected in the left sidebar:
As a function bar, consisting of application and function buttons
-
To navigate to the 2nd menu level
-
The right sidebar is operated by touching the display.
37
Switching to full
1
2
screen
1
The display is shown in full screen mode:
Exit full screen mode:
2
38
Connections, Switches, and Mechanical Compon-
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(11)
(9)
(10)
(16)
(15)
(14)
(13)
(12)
iWave DCiWave AC/DC
ents
Connections and
mechanical components
EN-US
Front/back
No.Function
(1)TMC connection
For connecting the control plug of the TIG welding torch
-
For connecting foot-operated remote controls
-
For connecting remote controls
-
(2)(-) current socket with integrated gas connection
For connecting the TIG welding torch
Symbols:
(3)TMC 4-pin connection
To connect a CrashBox line
(4)Control panel with display and control panel cover
For operating the power source
39
(5)(-) current socket with bayonet latch
iWave DCiWave AC/DC
iWave DCiWave AC/DC
HF-free current socket for manual metal arc welding
Symbols:
(6)(+) current socket
For connecting the TIG return lead cable
Symbols:
(7)SpeedNet connection
For connecting
remote controls and external sensors
-
wirefeeders (for automated applications)
-
Symbol:
(8)Mains cable with strain relief
Depending on version
(9)Power switch
For switching the power source on and off
(10)Dummy cover / Robot interface RI FB Inside /i or SpeedNet connections
or External sensor options
(11)Ethernet connection
(12)Dummy cover/second (-) current socket with bayonet latch (option)
MIG/MAG ground to wirefeeder
(13)TIG shielding gas connection socket
Main gas solenoid valve
(14)Dummy cover/auxiliary gas connection
Additional gas solenoid valve
40
(15)Dummy cover/second SpeedNet connection (option) or external sensor
(option)
(16)Dummy cover/second SpeedNet connection (option) or external sensor
(option)
(17)
iWave 300i - 500i AC/DC
(17)AC inverter
(only with iWave AC/DC power
sources)
EN-US
41
42
Before installation and initial oper-
ation
43
44
Before installation and initial operation
EN-US
Safety
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶
▶
▶
Intended useThe power source is only intended for TIG welding, MIG/MAG welding and MMA
welding. Any other use is deemed to be "not in accordance with the intended purpose." The manufacturer shall not be liable for any damage resulting from such
improper use.
Intended use also means
-
-
WARNING!
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 equipment and all system components.
Following all the instructions in these Operating Instructions
Carrying out all the specified inspection and maintenance work
Setup regulations
Mains connection
The device has been tested according to degree of protection IP23. This means:
Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
-
Protection against spraywater at any angle up to 60° from the vertical
-
The device can be set up and operated outdoors in accordance with protection
class IP23. Direct moisture (e.g., from rain) must be avoided.
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 ventilation channel is a very important safety device. When selecting the
setup location, ensure that the cooling air can enter or exit unhindered through
the vents on the front and back. Any electrically conductive dust (e.g., from
grinding work) must not be allowed to be sucked directly into the system.
The devices are designed for the mains voltage specified on the rating plate.
-
Devices with a nominal voltage of 3 x 575 V must be operated on three-phase
-
systems with earthed star point.
If your version of the appliance does not come with mains cables and mains
-
plugs ready-fitted, these must be fitted by a qualified person in accordance
with national standards.
The fuse protection for the mains lead is indicated in the technical data.
-
45
CAUTION!
An inadequately dimensioned electrical installation can cause serious damage.
The mains lead and its fuse protection must be dimensioned to suit the local
▶
power supply.
The technical data shown on the rating plate applies.
Generatorpowered operation
The power source is generator-compatible.
The maximum apparent power S
of the power source must be known in order
1max
to select the correct generator output.
The maximum apparent power S
of the power source is calculated for 3-
1max
phase devices as follows:
S
= I
1max
I
and U1 according to the device rating plate and technical data
1max
The generator apparent power S
1max
x U1 x √3
needed is calculated using the following rule
GEN
of thumb:
S
GEN
= S
1max
x 1.35
A smaller generator can be used when not welding at full power.
IMPORTANT! The generator apparent power S
maximum apparent power S
of the power source!
1max
must not be less than the
GEN
NOTE!
The voltage delivered by the generator must never fall outside of the mains
voltage tolerance range.
The mains voltage tolerance is specified in the "Technical data" section.
46
Connecting the Mains Cable
GeneralIf no mains cable is connected, a mains cable that is suitable for the connection
voltage must be fitted before start-up.
A universal strain-relief device for cable diameters of 12 - 30 mm (0.47 - 1.18 in.)
is mounted on the power source.
Strain-relief devices for other cable cross-sections must be designed accordingly.
EN-US
Safety
Specified mains
cable
WARNING!
Danger from work that is not carried out properly.
This can result in severe personal injury and damage to property.
The work described below may only be performed by trained specialist per-
▶
sonnel.
Follow national standards and guidelines.
▶
CAUTION!
Danger from improperly prepared mains cable.
Short circuits and damage to property may result.
Fit ferrules to all phase conductors and the ground conductor of the
▶
stripped mains cable.
Europe:
Power source
Mains voltageMains cable
iWave 300i /nc DC
3 x 400 V
3 x 460 V
H07RN-F 4G4
H07RN-F 4G4
iWave 300i /MV/nc DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 300i /nc AC/DC
3 x 400 V
3 x 460 V
iWave 300i /MV/nc AC/DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 400i /nc DC
3 x 400 V
3 x 460 V
iWave 400i /MV/nc DC
3 x 200 - 230 V
3 x 400 - 575 V
H07RN-F 4G6
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G6
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G10
H07RN-F 4G4
47
Power source
Mains voltageMains cable
iWave 400i /nc AC/DC
3 x 400 V
3 x 460 V
iWave 400i /MV/nc AC/DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 500i /nc DC
3 x 400 V
3 x 460 V
iWave 500i /MV/nc DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 500i /nc AC/DC
3 x 400 V
3 x 460 V
iWave 500i /MV/nc AC/DC
3 x 200 - 230 V
3 x 400 - 575 V
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G10
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G10
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G4
H07RN-F 4G10
H07RN-F 4G4
USA & Canada:
Power source
Mains voltageMains cable
iWave 300i /nc DC
3 x 400 V
3 x 460 V
iWave 300i /MV/nc DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 300i /nc AC/DC
3 x 400 V
3 x 460 V
iWave 300i /MV/nc AC/DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 400i /nc DC
3 x 400 V
3 x 460 V
iWave 400i /MV/nc DC
3 x 200 - 230 V
3 x 400 - 575 V
4 x AWG 10
4 x AWG 10
4 x AWG 8
4 x AWG 10
4 x AWG 10
4 x AWG 10
4 x AWG 8
4 x AWG 10
4 x AWG 10
4 x AWG 10
4 x AWG 6
4 x AWG 10
48
iWave 400i /nc AC/DC
3 x 400 V
3 x 460 V
iWave 400i /MV/nc AC/DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 500i /nc DC
3 x 400 V
3 x 460 V
4 x AWG 10
4 x AWG 10
4 x AWG 6
4 x AWG 10
4 x AWG 8
4 x AWG 8
Power source
100 mm
3.9 inch
min. 8 mm
min. 0.3 inch
min. 8 mm
min. 0.3 inch
140 mm
5.5 inch
1
2
Mains voltageMains cable
Connecting the
mains cable for
nc power
sources
iWave 500i /MV/nc DC
3 x 200 - 230 V
3 x 400 - 575 V
iWave 500i /nc AC/DC
3 x 400 V
3 x 460 V
iWave 500i /MV/nc AC/DC
3 x 200 - 230 V
3 x 400 - 575 V
1
4 x AWG 4
EN-US
4 x AWG 8
4 x AWG 8
4 x AWG 8
4 x AWG 4
4 x AWG 8
2
3
49
1
5
2
3
4
4
1
150 mm
5.9 inch
min. 8 mm
min. 0.3 inch
min. 8 mm
min. 0.3 inch
170 mm
6.7 inch
GND - L1 - L2 - L3; 4x TX20, 1.5 Nm / 1.11 lb-ft
6
5
Connecting the
mains cable for
MV power
sources
1
2
50
3
Cut the strain-relief device to length according to the outer diameter of the
mains cable
4
EN-US
IMPORTANT! When inserting the mains cable, ensure that the cable sheath pro-
trudes approx. 5 - 10 mm beyond the strain-relief device into the device.
5
*Only loosen the 4 TX20 screws, do not remove them
51
6
Push the mains cable toward the open
side in order to access the strain-relief
device clamping screw.
7
8
52
910
EN-US
53
Locking and unlocking the power source using the
NFC key
GeneralNFC key = NFC card or NFC key fob
The power source can be locked by means of an NFC key, e.g., to prevent unauthorized access or the modification of welding parameters.
Locking and unlocking is a contactless operation on the power source control
panel.
To lock and unlock the power source, the power source must be turned on.
Locking and unlocking the
power source using the NFC key
Lock the power source
54
Hold the NFC key over the reading zone for NFC keys
1
The key symbol appears briefly on the display.
The key symbol is then displayed in the status bar.
The power source is now locked.
Only the welding parameters can be viewed and set using the selection dial.
If the operator attempts to access a locked function, a corresponding message is
displayed.
Unlock the power source
Hold the NFC key over the reading zone for NFC keys
1
The crossed-out key symbol appears briefly on the display.
The key symbol is no longer displayed in the status bar.
All power source functions power source are available again without restriction.
NOTE!
Further information on locking the power source can be found in under "Defaults - Administration" starting on page 225.
EN-US
55
56
TIG
57
58
System components
(8)
(9)
(1)
(2b)
(3)
(4)
(5)
(6)
(7)
(2a)
System components
EN-US
Notes on the
cooling unit
(1)Cooling unit
(2a)iWave DC power source
(2b)iWave AC/DC power source
(3)Return lead cable
(4)Trolley and gas cylinder holder
(5)Swivel pin holder
(6)Cold wire feeder
(7)Welding torch
(8)Remote controls
(9)Foot-operated remote controls
A cooling unit is recommended for the following applications:
JobMaster TIG welding torch
-
Robot mode
-
Hosepacks over 5 m in length
-
TIG AC welding
-
General welding in the higher power range
-
The cooling unit is supplied with power via the power source. If the power
source's power switch is switched to position - I -, the cooling unit is ready for operation.
For more information on the cooling unit, refer to the Operating Instructions for
the cooling unit.
Other system components (not
shown):
Cold-wire feed
-
MIG/MAG wirefeeder
-
MIG/MAG welding torch
-
Twin-head wirefeeder holder
-
Interconnecting hosepacks
-
Extension hosepacks
-
Robot interface
-
59
Minimum equipment for TIG welding
Minimum equipment for TIG AC
welding
Minimum equipment for TIG DC
welding
iWave AC/DC power source
-
Return lead cable
-
TIG welding torch
-
Shielding gas supply with gas pressure regulator
-
Filler metal depending on application
-
Power source
-
Return lead cable
-
TIG welding torch
-
Shielding gas supply with gas pressure regulator
-
Filler metal depending on application
-
60
TIG welding processes
EN-US
TIG DynamicWire
With TIG DynamicWire, the voltage between the workpiece and the welding wire
is measured, allowing the wirefeeder to be actively controlled.
The wire speed automatically adapts to the amperage, arc length, weld seam profile, or to the air gap to be bridged.
TIG DynamicWire works in Synergic operation. Current and wire speed do not
have to be set separately.
The wire speed can be optimized via the "TIG wire correction" process parameter.
The Welding Package TIG DynamicWire provides characteristics for the most
common filler metals.
61
Commissioning
Safety
Danger from electrical current.
This can result in serious personal injury and damage to property.
▶
▶
▶
Danger of electrical current due to electrically conductive dust in the device.
This can result in severe personal injury and damage to property.
▶
GeneralThe start-up of the power sources for TIG welding is described on the basis of a
manual, water-cooled TIG application.
WARNING!
Before starting work, switch off all devices and components involved, and
disconnect 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!
Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.
The following diagrams show an overview of how the individual system components are put together.
For detailed information about the individual steps, please refer to the corresponding Operating Instructions for the system components.
62
Assembling the
5
2
3
1
4x
4
system components (overview)
NOTE!
For more detailed information about installing and connecting the system components, please refer to the corresponding Operating Instructions for the system components.
iWave DC power sources
EN-US
63
iWave AC/DC power sources
6
2
1
3
4
4x
5
64
Connecting the
4
3
4
gas cylinder
WARNING!
Danger of severe injury and damage to property if gas cylinders fall over.
Place gas cylinders on a solid, level surface so that they remain stable.
▶
Secure the gas cylinders to prevent them from falling over: Secure the safety
▶
strap at the height of the upper part of a gas cylinder.
Never secure the safety strap to the neck of the cylinder.
▶
Observe the safety rules of the gas cylinder manufacturer.
▶
Place the gas cylinder on the base
1
of the trolley
Attach the cylinder strap to the
2
upper part of the gas cylinder (but
not to the neck of the cylinder) to
prevent the cylinder from falling
over
EN-US
Remove the protective cap from
3
the gas cylinder
Briefly open the gas cylinder valve
4
to remove any dirt
65
6
5
7
NOTE!
Inspect the seal on the gas pres-
5
sure regulator
Screw the pressure regulator onto
6
the gas cylinder and tighten it
When using a TIG welding torch with
integrated gas connection:
Use a gas hose to connect the gas
7
pressure regulator and shielding
gas connection to the rear of the
power source
Tighten the union nut of the gas
8
hose
When using a TIG welding torch
without integrated gas connection:
Connect the gas hose of the TIG
6
welding torch to the gas pressure
regulator
Connecting the
welding torch to
the power source
and cooling unit
The gas connection when using a MultiControl (MC) cooling unit is described in
the Operating Instructions for the cooling unit.
NOTE!
Do not use pure tungsten electrodes for TIG DC power sources (color code:
green).
NOTE!
Before every start-up:
Check the O-ring at the welding torch connection,
▶
Check the coolant level
▶
Fit parts to the welding torch according to the Operating Instructions for the
1
welding torch
66
2
IMPORTANT! Check the coolant flow
at regular intervals during welding.
EN-US
67
Establishing a
ground earth
connection to
the workpiece
NOTE!
When establishing a ground earth connection, observe the following points:
Use a separate return lead cable for each power source
▶
Keep the torch hosepack and return lead cable as close together as possible
▶
for as long as possible
Physically separate the welding circuits of individual power sources
▶
Do not route several return lead cables in parallel;
▶
if parallel routing cannot be avoided, keep a minimum distance of 30 cm
between the welding circuits
Keep the return lead cables as short as possible and use cables with a large
▶
cross-section
Do not cross over return lead cables
▶
Avoid ferromagnetic materials between the return lead cables and the inter-
▶
connecting hosepack
Do not reel up long return lead cables - coil effect!
▶
Route long return lead cables in loops
Do not route return lead cables in iron pipes, metal cable trays, or along steel
▶
beams, avoid cable ducts;
(routing positive cables and return lead cables together in an iron pipe does
not cause any problems)
If several return lead cables are being used, separate the grounding points
▶
on the component as far as possible and do not allow crossed current paths
between the individual arcs.
Use compensated interconnecting hosepacks (interconnecting hosepacks
▶
with integrated return lead cable)
Set the power switch to - O -
1
68
1
3
2
2
Other activitiesFor a TIG cold wire feeder
Set up the components required for TIG welding on the trolley (e.g., swivel
1
pin holder, etc.)
Connect the control line to the wirefeeder
2
Connect the control line to the TMC socket on the front of the power source
3
EN-US
Only if the OPT/i CWF TMC welding torch option is present on the wirefeed-
4
er:
Connect the wirefeeder to the power source using the interconnecting
hosepack
Set up cold-wire feed on TIG welding torch
5
Connect wirefeeding hose to wirefeeder
6
Insert suitable feed rollers for the TIG application into the wirefeeder
7
Set up suitable wear parts for the TIG application on the welding torch
8
Insert wirespool or basket-type spool and its adapter into the wirefeeder
9
NOTE!
For details on mounting or connecting the TIG components, refer to the Installation Instructions and Operating Instructions of the respective system
components.
Connect the power source to the grid and switch on
10
Feed in the welding wire
11
Set the contact pressure
12
Adjust the brake
13
Perform R/L adjustment
14
For details, see from page 106.
69
TIG Operating Modes
(1)(2)(3)
(4)(5)
Safety
Symbols and explanations
WARNING!
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
Do not use the functions described here until you have fully read and under-
▶
stood the Operating Instructions.
Do not use the functions described here until you have fully read and under-
▶
stood all of the Operating Instructions of the system components, especially
the safety rules.
Follow the guidelines referring to setting, setting range, and units of measurement for the available parameters in the "Setup Menu" section.
(1) Pull back and hold the torch trigger (2) Release the torch trigger (3) Briefly pull back the torch
trigger (< 0.5 s)
(4) Push the torch trigger forward and hold (5) Release the torch trigger
GPrGas pre-flow
SPtSpot welding time
I
I
t
t
I
Starting current:
S
the temperature is raised gently at low welding current, so that the filler
metal can be positioned correctly
Final current:
E
to avoid local overheating of the parent material caused by heat accumulation at the end of welding. This prevents possible sagging of the weld
seam.
UpSlope:
UP
steady rise of the starting current to the main current (welding current) I
DownSlope:
DOWN
steady lowering of the welding current until it reaches the final current
Main current (welding current):
1
uniform thermal input into the parent material, whose temperature is
raised by the advancing heat
1
70
I
I
t
I
1
GPo
GPrt
DOWN
t
UP
I
t
I
1
GPr
I
S
t
DOWN
t
UP
I
E
I
2
GPo
I
1
*)
Lowering current:
2
intermediate lowering of the welding current to avoid local overheating of
the parent material
GPOGas post-flow
EN-US
2-step mode
4-step mode
Welding: Pull back the torch trigger and hold it in this position
-
End of welding: Release the torch trigger
-
2-step mode
Start of welding with starting current IS: Pull back the torch trigger and hold
-
it in this position
Welding with main current I1: Release the torch trigger
-
Lowering to final current IE: Pull back the torch trigger and hold it in this po-
-
sition
End of welding: Release the torch trigger
-
4-step mode
*) Intermediate lowering
With intermediate lowering, the welding current is lowered to the set lowering
current I-2 during the main current phase.
71
To activate intermediate lowering, push the torch trigger forward and hold it
I
t
I
1
GPr
I
S
t
down
I
E
GPo
I
1
I
2
t
up
-
in this position
Release the torch trigger to resume the main current
-
Special 4-step
mode:
Version 1
Intermediate lowering to the set lowering current I2 is effected by briefly pulling
back the torch trigger. Briefly pull back the torch trigger again to return to the
main current I1.
Special 4-step mode: Version 1
Version 1 of special 4-step mode is activated by the following parameter setting:
In version 2, intermediate lowering is also carried out using the set lowering current slope 1/2 values:
Push the torch trigger forward and hold it in this position: the welding cur-
-
rent steadily falls using the set lowering current slope 1 to the set lowering
current value I2. The lowering current I2 continues until the torch trigger is
released.
After releasing the torch trigger: the welding current rises to the main cur-
-
rent I1 using the set lowering current slope 2.
EN-US
Special 4-step mode: Version 2
Version 2 of special 4-step mode is activated by the following parameter setting:
Intermediate lowering of the welding current in version 3 is triggered by pushing
the torch trigger forward and holding it in this position. Following the release of
the torch trigger, the main current I1 is once again available.
Pull back the torch trigger to immediately end welding without a downslope and
final current.
Special 4-step mode: Version 3
Version 3 of special 4-step mode is activated using the following parameter setting:
Start of welding with starting currentIS and UpSlope: Pull back the torch
-
trigger and hold it in this position
Intermediate lowering to I2 and change from I2 back to main current I1:
-
briefly press (< 0.5 s) and release torch trigger
End the welding process: long press (> 0.5 s) and release the torch trigger.
-
The process is automatically terminated after the DownSlope phase and the final
current phase.
If the torch trigger is pressed briefly (< 0.5 s) and released during the DownSlope
or final current phase, an UpSlope to the main current is initiated and the welding process continues.
EN-US
Special 4-step mode: Version 6
Version 6 of special 4-step mode is activated by the following parameter setting:
The duration of welding corresponds to the value that was entered for the
"Spot welding time" setup parameter.
Premature ending of the welding process: Pull the torch trigger back again
-
78
TIG welding
4
2
3
5
4
4
EN-US
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 equip-
▶
ment 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
▶
disconnect 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.
TIG welding
CAUTION!
Danger of injury and damage from electric shock.
When the power switch is switched to position - I -, the tungsten electrode of the
welding torch is live.
Ensure that the tungsten electrode is not touching anyone or any electrically
▶
conductive or grounded parts (housing, etc.).
Set the power switch to - I -
1
79
Select "Welding process"
6
7
2
Select "Process"
3
An overview of available welding processes is displayed.
Select "TIG" or "TIG-Coldwire" or "DynamicWire"
4
Select "Mode"
5
An overview of operating modes is displayed.
Select the desired operating mode
6
Only for cold wire and DynamicWire applications:
7
Select and set the "Filler metal"
Select "TIG welding"
8
The TIG welding parameters are displayed.
Turn the selection dial (or touch the welding parameters symbol in the indic-
9
ator bar): select welding parameter
Press the selection dial
10
The value of the parameter is highlighted in blue and can now be changed.
Turn the selection dial: change the value of the parameter
11
If necessary, set the process parameters for user- or application-specific set-
12
tings on the welding system
Open the gas cylinder valve
13
Press the gas-test button
14
80
The gas pre-flow test lasts for 30 seconds at the most. Press the button again to
stop the gas flow prematurely.
Turn the adjusting screw on the bottom of the gas pressure regulator until
15
the manometer displays the desired quantity of gas
Commence the welding process (ignite arc)
16
NOTE!
Under certain circumstances, it may not be possible to change the set welding
parameters of a system component - such as wirefeeder or remote control - on
the control panel of the power source.
EN-US
Welding parameters for TIG
welding
ACWelding parameters for TIG AC welding
DC-Welding parameters for TIG DC- welding
Start current (AC / DC-)
Start current: 2-step mode | 4-step mode
Setting range: 0 - 200% (of the main current)
Factory setting: 50 %
IMPORTANT! The start current is stored separately for TIG AC welding and TIG
DC- welding.
Up-Slope (AC / DC-)
Up-Slope: 2-step mode and spot welding | 4-step mode
Setting range: off;0.1 - 30.0 s
Factory setting: 0.5 s
IMPORTANT! The stored UpSlope value applies to the 2-step and 4-step modes.
81
Main Current I1 (AC / DC-)
Slope1Slope2
I
I < 100 %
I > 100 %
Slope1
Slope2
Main current: 2-step mode and spot welding | 4-step mode
Setting range: off; 1.0 - 6.4 mm
Factory setting: 2.4 mm
84
Cap shaping (AC)
(2)(1)
only with iWave AC/DC
Setting range: off / on
Factory setting: off
off
Automatic cap-shaping function is deactivated
on
The optimum cap for the entered diameter of the tungsten electrode is shaped
during the start of welding.
The automatic cap-shaping function is then reset and deactivated.
EN-US
(1) ... before ignition
(2) ... after ignition
Cap shaping must be activated separately for each tungsten electrode.
NOTE!
The automatic cap-shaping function is not required if a sufficiently large cap is
formed on the tungsten electrode.
Polarity (AC)
only with iWave AC/DC
WARNING!
Danger due to applied welding potential with MultiProzess-PRO power sources
and with existing dual-head wirefeeder WF 25i Dual!
This can result in serious personal injury and damage to property.
Disconnect the dual-head wirefeeder from the welding system before setting
▶
the polarity to AC!
85
Setting range: DC- / AC
Factory setting: DC-
Polarity
NOTE!
To add more parameters to the welding parameters, go to Defaults / View / Parameter view setup.
More information can be found from page 212 onwards.
▶
86
Igniting the arc
GeneralIn order to ensure an optimal ignition sequence during TIG AC welding, the TIG
AC/DC power sources take into account:
The diameter of the tungsten electrode
-
The current temperature of the tungsten electrode, taking into account the
-
previous welding time and break
EN-US
Igniting the arc
using high frequency
(HF ignition)
CAUTION!
Risk of injury due to an electric shock
Although Fronius devices comply with all the 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 tight, diffi-
▶
cult to access or exposed places, or when welding out-of-position!
HF ignition is activated when the "HF ignition" setup parameter is set to "on" under process parameters/ignition parameters.
The HF ignition indicator lights up on the status bar.
Unlike contact ignition, there is no risk of contaminating the tungsten electrode
and workpiece during HF ignition.
Procedure for HF ignition:
Position the gas nozzle at the igni-
1
tion point so that there is a gap of
approximately 2 to 3 mm (5/64 1/8 in.) between the tungsten electrode and the workpiece. A gap exists.
87
Increase the tilt angle of the weld-
2
ing torch and press the torch trigger according to the selected operating mode
The arc ignites without coming into
contact with the workpiece.
Tilt the welding torch to the nor-
3
mal position
Carry out welding
4
Contact ignitionWhen the "HF ignition" setup parameter is set to "off", HF ignition is deactivated.
The arc ignites when the workpiece makes contact with the tungsten electrode.
Procedure for igniting the arc using contact ignition:
Position the gas nozzle at the igni-
1
tion point so that there is a gap of
approximately 2 to 3 mm (5/64 to
1/8 in.) between the tungsten electrode and the workpiece. A gap exists
88
Press the torch trigger
2
Shielding gas flows
Gradually tilt the welding torch up
3
until the tungsten electrode
touches the workpiece
Raise the welding torch and rotate
4
it into its normal position
The arc ignites.
Carry out welding
5
EN-US
Igniting the arc
using high-frequency contact
(Touch-HF)
CAUTION!
Risk of injury due to an electric shock
Although Fronius devices comply with all relevant standards, the 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 scaffolds, work platforms, in forced posi-
▶
tions, in tight, difficult to access or exposed places!
The welding process is initiated by briefly touching the workpiece with the tungsten electrode. The high-frequency ignition is performed after the set HF ignition
delay time has elapsed.
89
Electrode overload
If the tungsten electrode is overloaded, this can result in material detachment
on the electrode, which can cause contamination to enter the weld pool.
If the tungsten electrode is overloaded, the "Electrode overloaded" indicator
lights up on the status bar of the control panel.
The "Electrode overloaded" indicator depends on the set electrode diameter and
the set welding current.
End of welding
Depending on the set operating mode, end welding by releasing the torch
1
trigger
Wait for the set gas post-flow and hold the welding torch in position over the
2
end of the weld seam.
90
TIG special functions
(1)
I [A]
t [s]
(2)
(3)
(4)
(5)
(6)
(7)
(8)
EN-US
Ignition timeout
The power source has an ignition timeout function.
function
If the torch trigger is pressed, gas pre-flow begins immediately and the ignition
procedure is then initiated. If no arc forms during one of the time periods specified under the ignition parameters, the power source automatically switches
off.
The setting of the "Ignition timeout" parameter is described in the Process parameters/ignition and operating mode settings section starting on page 99.
TIG pulsingThe welding current set at the start of welding may not always be ideal for the
entire welding process:
If the amperage is too low, the parent material will not be sufficiently
-
melted,
If overheating occurs, there is a danger that the liquid weld pool may drip.
-
The TIG pulsing function is able to help with this (TIG welding with a pulsing
welding current):
A low base current (2) rises steeply to a significantly higher pulse current and
falls again in line with the set duty cycle (5) to the base current (2).
During TIG pulsing, small sections of the welding area are quickly melted and
then allowed to quickly solidify again.
During manual applications, the welding wire is applied in the maximum current
phase during TIG pulsing (only possible in the low-frequency range from 0.25 - 5
Hz). Higher pulse frequencies are mostly used in automated applications and
mainly serve to stabilize the arc.
TIG pulsing is used to weld steel pipes when welding out-of-position or to weld
thin sheet metal.
TIG pulsing in operation with TIG DC welding selected:
TIG pulsing - welding current curve
Key:
(1) Main current, (2) Base current, (3) Starting current, (4) UpSlope, (5) Pulse frequency *)
(6) Duty cycle, (7) DownSlope, (8) Final current
91
*) (1/F-P = Time between two pulses)
I [A]
t [s]
(1)
(2)
(3)
(4)
(5)
(6)
Tacking functionThe tacking function is used for the TIG DC welding process.
Whenever a period of time is set for the "Tacking" (4) parameter under process
parameters/TIG DC settings, the tacking function is assigned to the 2-step and
4-step modes. The sequence of operating modes remains unchanged.
The Tacking (TAC) indicator lights up on the status bar:
During this time, a pulsed welding current is available, which optimizes the merging of the weld pool when tacking two components.
How the tacking function works during TIG DC welding:
Tacking function - welding current curve
Key:
(1) Main current, (2) Starting current, (3) UpSlope, (4) Duration of pulsed welding
current for tacking process, (5) DownSlope, (6) Final current
NOTE!
When using a pulsed welding current:
The power source automatically controls the pulse parameters according to the
set main current (1).
No pulse parameters need to be set.
The pulsed welding current starts
After the starting-current phase (2) has finished
-
With the UpSlope phase (3)
-
Depending on the set tacking duration, the pulsed welding current can be
stopped up to and including the final current phase (6) ("Tacking" (4) TIG DC
parameter to "on").
After the tacking time has passed, further welding is carried out at a constant
welding current. Set pulse parameters are available if applicable.
92
CycleTIGThe CycleTIG interval welding process is available for TIG DC welding.
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 colors.
CycleTIG variants
CycleTIG + low base current
For out-of-position welding, edge build-up and orbital welding
-
Well suited for thick/light-gage sheet connections
-
Excellent weld characteristics
-
HF ignition only at start of welding
-
Long electrode service life
-
Good control of the weld pool
-
Targeted heat input
-
CycleTIG + RPI = on + base current = off
For repair work (e.g., edge build-up)
-
Targeted heat input
-
Biggest advantage in combination with HF ignition setting = touch HF
-
HF ignition at every cycle (!)
-
Very short electrode service life (!)
-
EN-US
Recommendation: iWave AC/DC with reversed polarity ignition setting = auto
CycleTIG + Tacking
For tacking light gage sheets, orbital applications and for thick/light gage
-
sheet joints
HF ignition only at start of welding
-
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 current and low current phases.
For tacking light gage sheets and for cladding applications
Process parameters for Components and Monitoring see page 194.
Tacking
Tacking function - duration of the pulsed welding current at the start of the tacking process
off / 0.1 - 9.9 s / on
Factory setting: off
off
Tacking function is switched off
0.1 - 9.9 s
The selected time begins with the UpSlope phase. After the selected time has
passed, further welding is carried out at a constant welding current. The set
pulse parameters are available if applicable.
on
The pulsed welding current remains present until the end of the tacking process
94
The Tacking (TAC) indicator lights up in the status bar on the if a value has been
set.
Pulse frequency
off / 0.20 - 2000 Hz (10,000 Hz with OPT/I-Puls 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 selected pulse frequency is also used for the lowering current.
The Pulsing indicator lights up in the status bar if a value for the pulse frequency
has been entered.
Base current *
0 - 100% (of the main current I1)
Factory setting: 50%
Duty cycle *
Relationship between pulse duration and base current duration at the set pulse
frequency
EN-US
10 - 90%
Factory setting: 50%
Pulse waveform *
For optimizing the arc pressure
Hard rectangle/Soft rectangle/Sine
Factory setting: Hard rectangle
Hard rectangle:
Purely rectangular curve;
Slightly louder arc noise, rapid current changes
Used, for example, in orbital welding
Soft rectangle:
Rectangular curve with reduced edge steepness, for reduced noise in comparison
with the purely rectangular curve;
universal use
Sine:
Sinusoidal shape (default setting for low-noise and stable arc);
Used, for example, for corner seams and cladding applications
Optimizing the arc pressure results in:
A better flow out of the weld pool (improved welding of butt welds or corner
-
seams)
A slow rise or fall in current (for fillet welds, high-alloy steels or cladding ap-
-
plications in particular, the filler material or weld pool is not pushed away)
A reduction in the noise level during welding thanks to rounded waveforms
-
Base current waveform *
For optimizing arc pressure
Hard rectangle/Soft rectangle/Sine
Factory setting: Hard rectangle
95
Hard rectangle:
+
t (s)
I (A)
60 Hz120 Hz
Purely rectangular curve;
Slightly louder arc noise, rapid current changes
Used, for example, in orbital welding
Soft rectangle:
Rectangular curve with reduced edge steepness, for reduced noise in comparison
with the purely rectangular curve;
universal use
Sine:
Sinusoidal shape (default setting for low-noise and stable arc);
Used, for example, for corner seams and cladding applications
*The parameters are available if the OPT/I-Puls Pro option is present on
the power source.
Process parameters for TIG
AC
AC frequency
Syn/40 - 250 Hz
Factory setting: 60 Hz
Syn
Setting for synchronous welding (double-side, simultaneous welding with 2 power
sources)
For synchronous welding, the AC frequency must be set to "Syn" for both power
sources.
Synchronous welding is used for thick materials, to achieve a high deposition rate
and to minimize inclusions during welding.
IMPORTANT! Due to the phasing of the input voltage, in some cases the synchronization of the two power sources cannot be carried out correctly.
In this case, disconnect the mains plug of the power sources, turn 180°, and reconnect to the grid.
Low frequency
Soft, wide arc with shallow heat input
High frequency
Focused arc with deep heat input
96
Effect of AC frequency on current flow:
AC current offset
-70 to +70%
Factory setting: 0 %
+70%
Wide arc with shallow heat input
-70%
I (A)
t (s)
-70%+70%
+
-
0
*
Narrow arc, deep heat input, higher welding speed
Effect of AC current offset on current flow:
* Factory setting: 0 (corresponds to a 10% shift to negative)
Positive half-wave waveform
Hard rectangle/Soft rectangle/Triangle/Sine
Factory setting: Sine
Hard rectangle
Purely rectangular curve (stable but loud arc)
EN-US
Soft rectangle:
Rectangular curve with reduced edge steepness, for reduced noise in comparison
with the purely rectangular curve
Triangle
Triangular curve
Sine
Sinusoidal curve (default setting for low-noise arc)
Negative half-wave waveform
Hard rectangle/Soft rectangle/Triangle/Sine
Factory setting: Soft rectangle
Hard rectangle
Purely rectangular curve (stable but loud arc)
Soft rectangle:
Rectangular curve with reduced edge steepness, for reduced noise in comparison
with the purely rectangular curve
Triangle
Triangular curve
Sine
Sinusoidal curve (default setting for low-noise and stable arc)
Phase synchronization
Synchronizes two AC power sources (simultaneously on both sides)
0 - 5
Factory setting: 0
97
General TIG process parametersWelding start / welding end settings
Starting current time
The starting current time indicates the duration of the starting-current phase.
The setting of the Starting current time parameter also influences versions 1 - 6
of special 4-step mode (see page 72 onwards).
off / 0.01 - 30.0 s
Factory setting: off
IMPORTANT! The starting current time is only valid for 2-step mode and spot
welding. In 4-step mode, the duration of the starting-current phase is determined by the torch trigger.
Final current time
The final current time indicates the duration of the final current phase.
The setting of the Final current time parameter also influences versions 1 - 6 of
special 4-step mode (see page 72 onwards).
off / 0.01 - 30 s
Factory setting: off
IMPORTANT! The final current time is only valid for 2-step mode and spot welding. In 4-step mode, the duration of the final current phase is determined by the
torch trigger (section "TIG operating modes").
4-mode settings
Lowering current Slope 1
The setting of the Lowering current slope 1 parameter also influences versions 1
- 6 of special 4-step mode (see page 72 onwards).
off / 0.01 - 30 s
Factory setting: off
If a time value has been entered for the Lowering current Slope 1 parameter, the
brief current reduction or current increase is not abrupt, but slow and adapted.
This reduces negative influences on the weld and part, especially with aluminum
applications.
Lowering current Slope 2
The setting of the Lowering current slope 2 parameter also influences versions 1
- 6 of special 4-step mode (see page 72 onwards).
98
off / 0.01 - 30 s
Factory setting: off
If a time value has been entered for the Lowering current Slope 2 parameter, the
adaptation from the lowering current to the welding current is not abrupt, but
slow and adapted.
In the case of a current increase, for example, the weld pool is heated slowly and
not abruptly. This facilitates outgassing of the weld pool and reduces pores during aluminum welding.
Spot welding settings
Spot welding time
(only if the mode is set to spot welding)
0.02 - 120 s
Factory setting: 5.0 s
EN-US
Process parameters for ignition and operating mode
Ignition parameters
HF ignition
on/off/Touch-HF/external
Factory setting: on
on
High-frequency ignition at the start of welding is activated
off
No high-frequency ignition at the start of welding.
In this case, welding is started by means of contact ignition.
Touch-HF
The welding process is initiated by briefly touching the workpiece with the tungsten electrode. The high-frequency ignition is performed after the set HF ignition
delay time has elapsed.
External
Start with an external ignition device, e.g., plasma welding
The HF ignition indicator lights up in the status bar if HF ignition has been set to
on.
CAUTION!
Risk of injury due to an electric shock
Although Fronius devices comply with all the 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 tight, diffi-
▶
cult to access or exposed places, or when welding out-of-position!
99
HF ignition delay time
Time after touching the workpiece with the tungsten electrode after which highfrequency ignition takes place.
0.1 - 5.0 s
Factory setting: 1.0 s
Reversed polarity ignition
(only with iWave AC/DC power sources)
To ensure an optimum ignition sequence during TIG DC welding, the polarity is
reversed briefly at the start of the welding process. Electrons emerge from the
workpiece and hit the tungsten electrode. This results in rapid heating of the
tungsten electrode - an essential prerequisite for optimum ignition properties.
off/on/auto
Factory setting: off
Reversed polarity ignition is recommended for welding light-gauge sheets.
Arc monitoring
Ignition timeout
Period of time until the safety cut-out following failed ignition.
0.1 - 9.9 s
Factory setting: 5 s
IMPORTANT! Ignition timeout is a safety function and cannot be deactivated.
The ignition timeout function is described in the "TIG welding" section.
Arc break filter time
Period of time until the safety cut-out following an arc break
If no current flows during the set period of time following an arc break, the
power source automatically switches off.
Press any button on the control panel or the torch trigger to restart the welding
process.
0.00 - 2.00 s
Factory setting: 0.20 s
Arc break watchdog
Reaction if no current flows within the arc break time
ignore/error
Factory setting: ignore
ignore
The interruption is ignored.
100
error
An error message is displayed on the power source and must be acknowledged.
Operating mode settings
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