How it Works
Fronius
Loading...
I
J
K
L
Loading...
Loading...
iWave 300i - 500i

Fronius iWave 300i - 500i Operating Instruction [EN]

Download
Operating Instructions
iWave 300i / 400i / 500i DC iWave 300i / 400i / 500i AC/DC
EN-US
Operating instructions
42,0426,0360,EA 004-23022023
Table of contents
Explanation of Safety Instructions 10 General 10 Intended Use 11 Grid Connection 11 Environmental Conditions 11 Obligations of the Operating Company 12 Obligations of Personnel 12 Residual current circuit breaker 12 Personal Protection and Protection of Others 12 Data on noise emission values 13 Danger from toxic gases and vapors 13 Danger from Flying Sparks 14 Risks from grid current and welding current 14 Stray welding currents 15 EMC Device Classifications 15 EMC measures 15 EMF measures 16 Particular hazard areas 16 Requirement for the shielding gas 17 Danger from Shielding Gas Cylinders 18 Danger Posed by Shielding Gas Leak 18 Safety Measures at the Setup Location and During Transport 18 Safety Measures in Normal Operation 19 Maintenance and repair 20 Safety Inspection 20 Disposal 20 Safety symbols 20 Data backup 21 Copyright 21 Intended use 21
EN-US
General information 23
Device concept 25 Functional principle 25 Application areas 25 Conformities 26 Bluetooth trademarks 27 Warning notices on the device 27 Options 29 OPT/i Safety Stop PL d option 30
Operating controls, connections and mechanical components 31
General 33 Control panel 33 Input options 34
Display 36 Switching to full screen 38
Connections, Switches, and Mechanical Components 39
Connections and mechanical components 39
Before installation and initial operation 43
Safety 45 Intended use 45
3
Setup regulations 45 Mains connection 45 Generator-powered operation 46
Connecting the Mains Cable 47
General 47 Safety 47 Specified mains cable 47 Connecting the mains cable for nc power sources 49 Connecting the mains cable for MV power sources 50
Locking and unlocking the power source using the NFC key 54
General 54 Locking and unlocking the power source using the NFC key 54
TIG 57
System components 59
System components 59 Notes on the cooling unit 59
Minimum equipment for TIG welding 60
Minimum equipment for TIG AC welding 60 Minimum equipment for TIG DC welding 60
TIG welding processes 61
TIG DynamicWire 61
Safety 62 General 62 Assembling the system components (overview) 63 Connecting the gas cylinder 65 Connecting the welding torch to the power source and cooling unit 66 Establishing a ground earth connection to the workpiece 68 Other activities 69
Safety 70 Symbols and explanations 70 2-step mode 71 4-step mode 71 Special 4-step mode: Version 1 72 Special 4-step mode: Version 2 73 Special 4-step mode: Version 3 74 Special 4-step mode: Version 4 75 Special 4-step mode: Version 5 76 Special 4-step mode: Version 6 77 Spot welding 78
TIG welding 79
Safety 79 TIG welding 79 Welding parameters for TIG welding 81
Igniting the arc 87
General 87 Igniting the arc using high frequency(HF ignition) 87 Contact ignition 88 Igniting the arc using high-frequency contact(Touch-HF) 89 Electrode overload 90 End of welding 90
Ignition timeout function 91 TIG pulsing 91 Tacking function 92 CycleTIG 93
TIG process parameters 94
TIG process parameters 94 Process parameters for TIG pulse 94
4
Process parameters for TIG AC 96 General TIG process parameters 98 Process parameters for ignition and operating mode 99 CycleTIG 103 Wire speed setting 104 TIG gas settings 105 Conducting an R/L alignment 106
Manual Metal Arc Welding, CEL, Arc air gouging 109
Minimum equipment for MMA and CEL welding and for arc air gouging 111
Minimum equipment for MMA and CEL welding 111 Minimum equipment for arc air gouging 111
Preparation 112
Manual Metal Arc Welding 113
Safety 113 Manual metal arc welding 113 Welding parameters for manual metal arc welding and CEL welding 115
Starting current > 100 % (HotStart) 117 Starting current < 100 % (SoftStart) 117 Anti-stick function 118
Stick electrode / CEL Process parameters 119 Process parameters for stick electrode 119 Process parameters for CEL 122
Arc air gouging (iWave 500 DC and iWave 500 AC/DC) 123
Brief description of the gouging (Arc Air Gouging) 123 Safety 123 Preparation 123 Arc air gouging 124
EN-US
Multiprocess PRO - MIG/MAG 127
General 129 System components 129
Minimum equipment for MIG/MAG welding 131
MIG/MAG welding processes 132
MIG/MAG pulse synergic welding 132 MIG/MAG standard synergic welding 132 PMC process 132 LSC process 132 SynchroPulse welding 132 CMT process 132 CMT Cycle Step welding process 133
General 134 Welding Packages 134
MIG/MAG welding characteristics 135
Welding characteristics 135
General 139 Symbols and their explanations 139 2-step mode 140 4-step mode 140 Special 4-step mode 141 Special 2-step mode 141 Spot welding 142
Preparing for MIG/MAG welding 143
Safety 143
5
Correct routing of the interconnecting hosepack 143 Context 144 Setting up MIG/MAG system components (overview) 145
MIG/MAG and CMT welding 147
Safety 147 Selecting the welding process and operating mode 147 Selecting the filler metal and shielding gas 148 Setting the welding parameters 149 Setting the shielding gas flow rate 150 MIG/MAG or CMT welding 151
MIG/MAG and CMT welding parameters 152
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 welding 153 Welding parameters for MIG/MAG standard manual welding 154 Explanation of footnotes 154
Spot welding 155
MIG/MAG process parameters 158
MIG/MAG process parameters 158 Process parameters for weld start / weld end 158 Process parameters for gas setup 160 Process parameters for process control 160 Penetration stabilizer 161 Arc length stabilizer 163 Combination of penetration stabilizer and arc length stabilizer 165 Process parameters for SynchroPulse 166 Process parameters for Process Mix 168 Process parameters for CMT Cycle Step 171 Process parameters for spot welding 171 R/L alignment 171
152
Job Mode 173
General 175 Activating EasyJob mode 175 Storing EasyJob operating points 175 Retrieving EasyJob operating points 176 Deleting EasyJob operating points 176
General 177 Saving settings as a job 177 Welding job - retrieving jobs 178 Optimizing a job 179 Renaming a job 180 Deleting a job 181 Loading a job 182
Job process parameters 183
JOB process parameters 183 Process parameters for "Optimize Job" 183 Setting correction limits for a job 188 Pre-settings for "Save as Job" 189
Process parameters 191
Overview 193
Process parameters - Components & monitoring 194
Process parameters - Components & Monitoring 194 Process parameters for components 194 Draining/filling the torch hosepack 197 System adjustment 198
6
Arc break watchdog 199 Wire stick contact tip 199 Wire stick workpiece 200 Welding circuit coupling 200 Wire end monitoring 201 Gas monitoring 202 Motor force monitoring 203
Defaults 205
General 207 Overview 207
Defaults - View 208
Defaults screen 208 Selecting the language 208 Selecting units/standards 208 Setting the date and time 208 Retrieving system data 209 Displaying characteristics 211 Parameter view setup 212 Parameter view iJob 213
Defaults - System 214
Defaults - System 214 Retrieving device information 214 Restoring factory settings 214 Restoring the website password 215 Setup mode 215 Setting network parameters manually 217 Setting up WLAN 218 Bluetooth setup 218 Power source configuration 221 Wirefeeder setup 221 Interface setup 221 TWIN Setup 222
Defaults - Documentation 223
Defaults - Documentation 223 Setting the sample rate 223 Viewing the logbook 223 Switching limit value monitoring on/off 224
Defaults Administration 225
Defaults Administration 225
User management 226
General 226 Explanation of terms 226 Predefined roles and users 226 User administration overview 227
Create administrator and roles 228
Recommendation for creating roles and users 228 Creating an administrator key 229 Creating roles 229 Copying roles 230
Creating users 231 Copying users 231
Editing roles/users, deactivating user management 233
Editing roles 233 Deleting roles 233 Editing users 233 Deleting users 234 Deactivating user management 234 Lost administrator NFC key? 235
EN-US
7
CENTRUM - Central User Management 236
Activating the CENTRUM server 236
SmartManager – The Website of the Power Source 237
SmartManager – The Website of the Power Source 239
General 239 Opening and logging into the SmartManager for the power source 239 Help functions if logging in does not work 240 Changing the password/logging out 240 Settings 241 Selecting the language 241 Status indicator 242 Fronius 242
Current system data 243
Documentation 244
Job data 246 Job overview 246 Editing a job 246 Importing a job 247 Exporting a job 247 Exporting job(s) as ... 247
Process parameters 249 Designation & location 249
General 250 Save and restore 250 Automatic backup 251
User management 252
General 252 Users 252 User roles 252 Export & import 253 CENTRUM 253
Overview 254 Expanding all groups/collapsing all groups 254 Saving as an xml file 254
Update 255 Finding the update file (performing an update) 255 Fronius WeldConnect 256
Function packages 257 Welding packages 257 Options 257 Loading a function package 257
Screenshot 258
Troubleshooting and Maintenance 259
Troubleshooting 261
General 261 Safety 261 Power Source Troubleshooting 261
Service, maintenance and disposal 265
General 265 Safety 265
8
At every start-up 265 Every 2 months 265 Every 6 months 265 Updating firmware 265 Disposal 266
Appendix 267
Average consumption values during welding 269
Average shielding gas consumption during TIG welding 269 Average shielding gas consumption during MIG/MAG welding 269 Average wire electrode consumption during MIG/MAG welding 269
Explanation of the term duty cycle 270 Special Voltage 270 iWave 300i DC 271 iWave 300i DC /nc 273 iWave 300i DC /MV/nc 275 iWave 400i DC 277 iWave 400i DC /nc 279 iWave 400i DC /MV/nc 281 iWave 500i DC 283 iWave 500i DC /nc 285 iWave 500i DC /MV/nc 287 iWave 300i AC/DC 289 iWave 300i AC/DC /nc 291 iWave 300i AC/DC /MV/nc 293 iWave 400i AC/DC 295 iWave 400i AC/DC /nc 297 iWave 400i AC/DC /MV/nc 299 iWave 500i AC/DC 301 iWave 500i AC/DC /nc 303 iWave 500i AC/DC /MV/nc 305 Radio parameters 307 Overview with critical raw materials, year of production of the device 307
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.
General The device has been manufactured using state-of-the-art technology and ac-
cording to recognized safety standards. If used incorrectly or misused, however, it can cause
Injury or death to the operator or a third party
-
Damage to the device and other material assets belonging to the operating
-
company Inefficient operation of the equipment
-
All persons involved in the commissioning, operation, maintenance, and servicing of the device must
Be suitably qualified
-
Have knowledge of welding
-
Have completely read and followed these Operating Instructions
-
The Operating Instructions must always be at hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and 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 Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating plate. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not 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 Connection Devices with a high output can influence the energy quality of the grid due to
their current consumption.
This may affect a number of device types in terms of:
connection restrictions
-
-
criteria regarding maximum permissible grid impedance
-
criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
*)
*)
See technical data
In this case, the operator or the person using the device should check whether or not the device is allowed to be connected, where appropriate through discussion with the power supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
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 measures In certain cases, even though a device complies with the standard limit values for
emissions, it may affect the application area for which it was designed (e.g., when
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 measures Electromagnetic 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
Disposal To 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 symbols Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (e.g., relevant product standards of the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.
20
Data backup The user is responsible for backing up any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright 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 use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating plate 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 concept The 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
Conformities FCC
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 options Touch 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 DC iWave 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 DC iWave AC/DC
iWave DC iWave 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 use The 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
General If 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 voltage Mains 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 voltage Mains 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 voltage Mains 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 voltage Mains 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
9 10
EN-US
53
Locking and unlocking the power source using the NFC key
General NFC 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.
▶
General The 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 activities For 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
GPr Gas pre-flow
SPt Spot 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
GPr t
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
GPO Gas 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:
Process parameters / General / 2-step settings
Starting current time = off
-
Final current time = off
-
Process parameters / General / 4-step settings
Lowering current slope 1 = off
-
Lowering current slope 2 = off
-
Process parameters / Ignition & operating mode / Operating mode settings
I2 via torch trigger = on
-
Lowering current button function = I2
-
72
Special 4-step
I
t
I
1
GPr
I
S
t
down
I
E
GPo
I
1
I
2
t
up
mode: Version 2
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:
Process parameters / General / 2-step settings
Starting current time = off
-
Final current time = off
-
Process parameters / General / 4-step settings
Lowering current slope 1 = on
-
Lowering current slope 2 = on
-
Process parameters / Ignition & operating mode / Operating mode settings
I2 via torch trigger = off
-
Lowering current button function = I2
-
73
Special 4-step
I
t
I
1
GPr
I
S
GPo
I
1
I
2
t
up
mode: Version 3
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:
Process parameters / General / 2-step settings
Starting current time = off
-
Final current time = 0.01 s
-
Process parameters / General / 4-step settings
Lowering current slope 1 = off
-
Lowering current slope 2 = off
-
Process parameters / Ignition & operating mode / Operating mode settings
I2 via torch trigger = off
-
Lowering current button function = I2
-
74
Special 4-step
I
t
I
1
GPr
I
S
t
down
I
E
GPo
I
1
I
2
t
up
t
E
t
S
mode: Version 4
Start of welding and welding: Briefly pull back the torch trigger and release -
-
the welding current rises from the starting current IS to the main current I using the set UpSlope.
Push forward the torch trigger and hold it in this position for intermediate
-
lowering Following the release of the torch trigger, the main current I1 is once again
-
available End of welding: Quickly pull back the torch trigger and release
-
1
EN-US
Special 4-step mode: Version 4
Version 4 of special 4-step mode is activated using the following parameter set­ting:
Process parameters / General / 2-step settings
Starting current time = on
-
Final current time = on
-
Process parameters / General / 4-step settings
Lowering current slope 1 = off
-
Lowering current slope 2 = off
-
Process parameters / Ignition & operating mode / Operating mode settings
I2 via torch trigger = off
-
Lowering current button function = I2
-
75
Special 4-step
GPr t
down
GPo
t
up
I
t
I
1
I
S
I
E
I1 >
I1 <
mode: Version 5
Version 5 allows the welding current to be increased and decreased without an Up/Down torch.
The longer the torch trigger is pressed forward during welding, the further
-
the welding current increases (up to the maximum). After releasing the torch trigger, the welding current remains constant.
-
The longer the torch trigger is pressed forward again, the further the welding
-
current is reduced.
Special 4-step mode: Version 5
Version 5 of special 4-step mode is activated using the following parameter set­ting:
Process parameters / General / 2-step settings
Starting current time = off
-
Final current time = off
-
Process parameters / General / 4-step settings
Lowering current slope 1 = off
-
Lowering current slope 2 = off
-
Process parameters / Ignition & operating mode / Operating mode settings
I2 via torch trigger = off or on
-
Lowering current button function = I1
-
76
Special 4-step
GPr
t
down
GPo
t
up
I
I
1
I
S
I
E
I
1
I
1
I
2
t
< 0,5 s
< 0,5 s
< 0,5 s
< 0,5 s
> 0,5 s
mode: Version 6
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:
Process parameters / General / 2-step settings
Starting current time = off
-
Final current time = on
-
Process parameters / General / 4-step settings
Lowering current slope 1 = off
-
Lowering current slope 2 = off
-
Process parameters / Ignition & operating mode / Operating mode settings
I2 via torch trigger = on
-
Lowering current button function = I2
-
77
Spot welding
I
t
I
1
GPr
t
UP
t
DOWN
SPt
GPo
Welding: Briefly pull back the torch trigger
-
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
AC Welding 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-)
Slope1 Slope2
I
I < 100 %
I > 100 %
Slope1
Slope2
Main current: 2-step mode and spot welding | 4-step mode
Setting range: iWave 300i DC, iWave 300i AC/DC: 3 - 300 A iWave 400i DC, iWave 400i AC/DC: 3 - 400 A iWave 500i DC, iWave 500i AC/DC: 3 - 500 A Factory setting: -
IMPORTANT! For welding torches with Up/Down Function, the full setting range can be selected while the device is on standby.
Drop current I2 (AC / DC-)
only in 4-step mode
Drop current I2 < Main current I1 | Drop current I2 > Main current I
1
Setting range: 0 - 250 % (of the main current I1) Factory setting: 50 %
I2 < 100% Brief, adapted reduction of the welding current
(e.g., when changing the welding wire during the welding process)
I2 > 100% Brief, adapted increase in the welding current
(e.g., for welding over tacking points with a higher power level)
The values for Slope1 and Slope2 can be set in the process parameters.
82
Down-Slope (AC / DC-)
Down-Slope: 2-step mode and spot welding | 4-step mode
Setting range: off;0.1 - 30.0 s Factory setting: 1.0 s
IMPORTANT! The stored Down-Slope value applies to the 2-step and 4-step modes.
End current (AC / DC-)
EN-US
End current: 2-step mode and spot welding | 4-step mode
Setting range: 0 - 100 % (of the main current) Factory setting: 30 %
83
AC Balance (AC)
+
-
t (s)
I (A)
35% 50% 15%
DC- AC
only with iWave AC/DC
Balance = 15% Balance = 35 %
Balance = 50 %
Setting range: 15 - 50 % Factory setting: 35 %
15: Highest melting capacity, lowest cleaning effect
50: Highest cleaning effect, lowest melting capacity
Effect of balance on current flow:
Electrode diameter (AC / DC-)
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
General In 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 ignition When 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 pulsing The 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 function The 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
CycleTIG The 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
-
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
-
Individual pulse settings possible
-
More welding parameters to set
-
93
TIG process parameters
1
2
TIG process parameters
Process para­meters for TIG pulse
TIG process parameters:
TIG pulse, AC, General, Ignition & trigger mode, CycleTIG, Wirefeeder setup, Gas, R/L-check / alignment
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 Hz 120 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 parameters Welding 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
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use