Fronius iWave 300i Air Cooled Multi Process Welding Machine User Manual
- June 10, 2024
- Fronius
Table of Contents
iWave 300i Air Cooled Multi Process Welding Machine
iWave Welding System
Product Information
The iWave Welding System is available in three models: 300i,
400i, and 500i. The 300i and 400i models are DC only, while the
500i model is both AC and DC. The system is designed for TIG
welding and has various modes, such as 2-step, 4-step, and spot
welding. The system components include the power source, cooling
unit, and welding torch. The system also has Bluetooth connectivity
and can be locked and unlocked using an NFC key.
Product Usage Instructions
Before Installation and Initial Operation
-
Ensure that the system is used in accordance with the safety
instructions provided in the user manual. -
Ensure that the mains cable is connected correctly and
safely. -
Ensure that the gas cylinder and welding torch are connected
properly. -
Establish a ground earth connection to the workpiece.
TIG Operating Modes
-
The iWave Welding System has various TIG operating modes,
including 2-step, 4-step, and special 4-step modes. -
Refer to the user manual for detailed information on each
mode.
TIG Welding
-
Refer to the user manual for recommended welding parameters for
TIG welding. -
Ignite the arc using high-frequency (HF) ignition, contact
ignition, or high-frequency contact (Touch-HF) ignition. -
Use the electrode overload function to prevent electrode
damage. -
Use the TIG pulsing function for improved welding quality.
-
Use the tacking function for better control of the weld
spot. -
Use the CycleTIG function for repetitive welding tasks.
Please refer to the user manual for additional information on
using the iWave Welding System.
/ Perfect Charging / Perfect Welding / Solar Energy
iWave 300i / 400i / 500i DC iWave 300i / 400i / 500i AC/DC
EN-US
Operating instructions
42,0426,0360,EA 002-16122021
EN-US
Table of contents
Safety Instructions
10
Explanation of Safety Instructions
10
General
10
Intended Use
10
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
17
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
19
Safety Inspection
20
Disposal
20
Safety symbols
20
Data backup
20
Copyright
20
Intended use
21
General information
23
General
25
Device concept
25
Functional principle
25
Application areas
25
Conformities
26
Bluetooth trademarks
27
Warning notices on the device
27
Options
29
Operating controls, connections and mechanical components
31
Control Panel
33
General
33
Control panel
33
Input options
34
Display
36
Display
36
Switching to full screen
38
Connections, Switches, and Mechanical Components
39
Connections and mechanical components
39
Before installation and initial operation
43
Before installation and initial operation
45
Safety
45
Intended use
45
Setup regulations
45
3
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 for manual applications
59
Notes on the cooling unit
59
Minimum equipment for welding operations
60
TIG AC welding
60
TIG DC welding
60
Commissioning
61
Safety
61
General
61
Assembling the system components (overview)
62
Connecting the gas cylinder
64
Connecting the welding torch to the power source and cooling unit
65
Establishing a ground earth connection to the workpiece
66
TIG Operating Modes
67
Safety
67
Symbols and explanations
67
2-step mode
68
4-step mode
68
Special 4-step mode: Version 1
69
Special 4-step mode: Version 2
70
Special 4-step mode: Version 3
71
Special 4-step mode: Version 4
72
Special 4-step mode: Version 5
73
Special 4-step mode: Version 6
74
Spot welding
75
TIG welding
76
Safety
76
TIG welding
76
Welding parameters for TIG welding
78
Igniting the arc
84
General
84
Igniting the arc using high frequency(HF ignition)
84
Contact ignition
85
Igniting the arc using high-frequency contact(Touch-HF)
86
Electrode overload
87
End of welding
87
TIG special functions
88
Ignition timeout function
88
TIG pulsing
88
Tacking function
89
CycleTIG
90
TIG process parameters
91
TIG process parameters
91
Process parameters for TIG pulse
91
Process parameters for TIG AC
93
General TIG process parameters
94
Process parameters for ignition and operating mode
96
CycleTIG
99
4
EN-US
Wire speed setting
100
TIG gas settings
101
Conducting an R/L alignment
102
MIG/MAG
105
Welding packages, welding characteristics and welding processes
107
General
107
Welding Packages
107
Welding characteristics
107
Brief description of MIG/MAG pulsed synergic welding
111
Summary of MIG/MAG standard synergic welding
111
Summary of the PMC process
111
Summary of the LSC process
111
Summary of SynchroPulse welding
111
Summary of the CMT process
112
Brief description of the CMT Cycle Step welding process
112
System components
113
Overview
113
Minimum equipment for welding operations
114
General
114
Gas-cooled MIG/MAG welding
114
Water-cooled MIG/MAG welding
114
Automated MIG/MAG welding
114
CMT welding manual
114
CMT welding automated
115
MIG/MAG Operating Modes
116
General
116
Symbols and their explanations
116
2-step mode
117
4-step mode
117
Special 4-step mode
118
Special 2-step mode
118
Spot welding
119
MIG/MAG and CMT welding
120
Safety
120
MIG/MAG and CMT welding – Overview
120
Switching on the power source
120
Selecting the welding process and operating mode
121
Selecting the filler metal and shielding gas
122
Setting the welding parameters
123
Setting the shielding gas flow rate
124
MIG/MAG or CMT welding
124
MIG/MAG and CMT welding parameters
125
Welding parameters for MIG/MAG pulse-synergic welding, for CMT welding and for PMC welding 125
Welding parameters for MIG/MAG standard synergic welding and LSC welding
126
Welding parameters for MIG/MAG standard manual welding
127
Explanation of footnotes
127
Spot welding
128
Spot welding
128
MIG/MAG process parameters
131
MIG/MAG process parameters
131
Process parameters for weld start / weld end
131
Process parameters for gas setup
133
Process parameters for process control
133
Penetration stabilizer
134
Arc length stabilizer
136
Combination of penetration stabilizer and arc length stabilizer
138
Process parameters for SynchroPulse
139
Process parameters for Process Mix
141
Process parameters for CMT Cycle Step
144
Process parameters for spot welding
144
5
R/L alignment
144
Manual Metal Arc Welding, CEL, Arc air gouging
147
System components
149
Safety
149
System components
149
Minimum equipment for welding operations
150
MMA welding
150
Commissioning
151
Preparation
151
Manual Metal Arc Welding
152
Safety
152
Manual metal arc welding
152
Welding parameters for manual metal arc welding and CEL welding
154
Hot-Start, Soft-Start, Anti-Stick Functions
156
Starting current > 100 % (HotStart)
156
Starting current < 100 % (SoftStart)
156
Anti-stick function
157
Stick electrode / CEL Process parameters
158
Stick electrode / CEL Process parameters
158
Process parameters for stick electrode
158
Process parameters for CEL
161
Arc air gouging (iWave 500 DC and iWave 500 AC/DC)
162
Safety
162
Preparation
162
Arc air gouging
163
Job Mode
165
EasyJob mode
167
General
167
Activating EasyJob mode
167
Storing EasyJob operating points
167
Retrieving EasyJob operating points
168
Deleting EasyJob operating points
168
Job Mode
169
General
169
Saving settings as a job
169
Welding job – retrieving jobs
170
Optimizing a job
171
Renaming a job
172
Deleting a job
173
Loading a job
174
Job process parameters
175
JOB process parameters
175
Process parameters for “Optimize Job”
175
Setting correction limits for a job
179
Pre-settings for “Save as Job”
181
Process parameters
183
Overview
185
Overview
185
Process parameters – Components & monitoring
186
Process parameters – Components & Monitoring
186
Process parameters for components
186
Draining/filling the torch hosepack
189
System adjustment
190
Arc break watchdog
191
Wire stick contact tip
191
Wire stick workpiece
192
Welding circuit coupling
192
Wire end monitoring
192
6
EN-US
Gas monitoring
193
Motor force monitoring
194
Defaults
195
Defaults
197
General
197
Overview
197
Defaults – View
198
Defaults screen
198
Selecting the language
198
Selecting units/standards
198
Setting the date and time
198
Retrieving system data
199
Displaying characteristics
201
Parameter view setup
202
Parameter view iJob
203
Defaults – System
204
Defaults – System
204
Retrieving device information
204
Restoring factory settings
204
Restoring the website password
205
Setup mode
205
Setting network parameters manually
207
Setting up WLAN
207
Bluetooth setup
208
Power source configuration
210
Wirefeeder setup
210
Interface setup
210
TWIN Setup
210
Defaults – Documentation
212
Defaults – Documentation
212
Setting the sample rate
212
Viewing the logbook
212
Switching limit value monitoring on/off
213
Defaults Administration
214
Defaults Administration
214
User management
215
General
215
Explanation of terms
215
Predefined roles and users
215
User administration overview
216
Create administrator and roles
217
Recommendation for creating roles and users
217
Creating an administrator key
218
Creating roles
218
Copying roles
219
Creating users
220
Creating users
220
Copying users
220
Editing roles/users, deactivating user management
222
Editing roles
222
Deleting roles
222
Editing users
222
Deleting users
223
Deactivating user management
223
Lost administrator NFC key?
224
CENTRUM – Central User Management
225
Activating the CENTRUM server
225
SmartManager The Website of the Power Source
227
SmartManager The Website of the Power Source
229
7
General
229
Opening and logging into the SmartManager for the power source
229
Help functions if logging in does not work
230
Changing the password/logging out
230
Settings
231
Selecting the language
231
Status indicator
232
Fronius
232
Current system data
233
Current system data
233
Documentation, logbook
234
Documentation
234
Job data
236
Job data
236
Job overview
236
Editing a job
236
Importing a job
237
Exporting a job
237
Exporting job(s) as …
237
Power source settings
238
Process parameters
238
Designation & location
238
Save and restore
239
General
239
Save and restore
239
Automatic backup
240
User management
241
General
241
Users
241
User roles
241
Export & import
242
CENTRUM
242
Overview
243
Overview
243
Expanding all groups/collapsing all groups
243
Saving as an xml file
243
Update
244
Update
244
Finding the update file (performing an update)
244
Fronius WeldConnect
245
Function packages
246
Function packages
246
Welding packages
246
Options
246
Loading a function package
246
Screenshot
247
Screenshot
247
Troubleshooting and Maintenance
249
Troubleshooting
251
General
251
Safety
251
Power Source Troubleshooting
251
Service, maintenance and disposal
255
General
255
Safety
255
At every start-up
255
Every 2 months
255
Every 6 months
255
Updating firmware
255
Disposal
256
8
EN-US
Appendix
257
Average consumption values during welding
259
Average shielding gas consumption during TIG welding
259
Average shielding gas consumption during MIG/MAG welding
259
Average wire electrode consumption during MIG/MAG welding
259
Technical data
260
Explanation of the Term Duty Cycle
260
Special Voltage
260
iWave 300i DC
261
iWave 300i DC /nc
263
iWave 300i DC /MV/nc
265
iWave 400i DC
267
iWave 400i DC /nc
269
iWave 400i DC /MV/nc
271
iWave 500i DC
273
iWave 500i DC /nc
275
iWave 500i DC /MV/nc
277
iWave 300i AC/DC
279
iWave 300i AC/DC /nc
281
iWave 300i AC/DC /MV/nc
283
iWave 400i AC/DC
285
iWave 400i AC/DC /nc
287
iWave 400i AC/DC /MV/nc
289
iWave 500i AC/DC
291
iWave 500i AC/DC /nc
293
iWave 500i AC/DC /MV/nc
295
Radio parameters
297
Overview with critical raw materials, year of production of the device
297
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
according 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.
Your personal safety is at stake!
Intended Use
The device is to be used exclusively for its intended purpose.
10
EN-US
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 Instructions – 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.
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
regulations
and are trained in handling the device – Have read and understood these
Operating Instructions, especially the section
“Safety Rules,” and have confirmed this with their signature – Are trained
according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of Personnel
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 con-
firm 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.
Residual current circuit breaker
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.
Personal Protection and Protection of Others
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 pace-
makers – 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
EN-US
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.
Data on noise emission values
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.
Danger from toxic gases and vapors
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.
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.
14
EN-US
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.
Stray welding currents
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
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.
EMC Device Classifications
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 low-voltage
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 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.
15
Test and assess the immunity of equipment in the vicinity of the device in
accordance with national and international provisions. Examples of
interference-prone 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: 1. Grid power supply
– If electromagnetic interference occurs despite a grid connection that
complies with regulations, take additional measures (e.g., use a suitable grid
filter).
2. Welding power-leads – Keep them as short as possible – Route them close
together (also to avoid EMF problems) – Route them far from other lines
3. Equipotential bonding 4. Workpiece grounding
– If necessary, establish grounding using suitable capacitors. 5. Shield, if
necessary
– Shield other devices in the vicinity – Shield the entire welding
installation
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 properly. – Keep all covers and side parts closed.
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.
16
EN-US
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).
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.
Requirement for the shielding gas
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.
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.
17
Mount the shielding gas cylinders vertically and secure them in accordance
with instructions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question
and the correct matching accessories (controller, hoses, and fittings, etc.)
Only use shielding gas cylinders and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the
outlet.
When no welding is taking place, close the valve of the shielding gas
cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is
not connected.
Follow the manufacturer’s instructions and applicable national and
international provisions for shielding gas cylinders and accessories.
Danger Posed by Shielding Gas Leak
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 cylin-
der 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.
Safety Measures at the Setup Location and During Transport
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.
Use instructions and checks within the company to ensure that the vicinity of
the workplace is always clean and organized.
Only set up and operate the device in accordance with the protection class
shown on the rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5
m (1 ft. 7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and
accident prevention regulations are observed when transporting the device,
especially guidelines concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before
transport or lifting.
18
EN-US
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.
Safety Measures in Normal Operation
Only operate the device when all safety devices are fully functional. If the
safety devices are not fully functional, there is a 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
Safety devices that are not fully functional must be repaired before the
device is switched on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable
damage and functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting
by crane.
Only the original coolant from the manufacturer is suitable for use in our
devices due to its properties (electrical conductivity, anti-freeze, material
compatibility, flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit
circuit.
If there is damage due to use of other system components or other coolants,
the manufacturer accepts no liability for this and all warranty claims are
forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is
flammable in certain conditions. Only transport the coolant in closed original
containers and keep away from sources of ignition.
Properly dispose of used coolant according to national and international
regulations. The coolant safety data sheet can be obtained from your service
center or via the manufacturer’s website.
When the system is cool, always check the coolant level before starting
welding.
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 manu-
facturer’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.
19
Only use original housing screws in the correct number and tightened to the specified torque.
Safety Inspection
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 12-month
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.
Disposal
Do not dispose of this device with normal domestic waste! To comply with the European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must be returned to your dealer, or you must locate the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!
Safety symbols
Devices with the CE 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.
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.
20
EN-US
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.
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
EN-US
General
Device concept
The iWave 300i / 400i / 500i DC and iWave 300i / 400i / 500i AC/DC
multiprocess 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.
Functional principle
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.
Application areas
The devices are used in commercial applications for manual and automated MIG/MAG and TIG welding with unalloyed and low-alloyed steel, high-alloyed chrome/nickel steel, aluminum, aluminum alloys and magnesium. The power sources are designed for: – Automotive and supply industry, – Engineering and rail vehicle manufacturing, – Chemical plant construction, – Equipment engineering, – Shipyards, – etc.
25
Conformities 26
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, including in-
terference that may impair operation.
IC: 12270A-SPBMCU2
EU Compliance with Directive 2014/53/EU – Radio Equipment Directive (RED)
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.
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
EN-US
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
Bluetooth trademarks
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 on the device
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
OPT/i TIG gas regulator
OPT/i TIG 4 Switch SpeedNet Option if more than one additional SpeedNet
connection is required.
OPT/i TIG C 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 Gas changeover
OPT/i TIG 2nd SpeedNet Second SpeedNet connection
OPT/i TIG DC Multiprozess PRO
OPT/i TIG AC Multiprocess 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.
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 conjunction with the torch
trigger
OPT/i Jobs Option for Job Mode
OPT/i Documentation Option for the documentation function
OPT/i Interface Designer Option to design a personalized interface
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 customer-specific frequency band
for key cards
OPT/i CMT Cycle Step Option for adjustable, cyclic CMT welding process
OPT/i OPC-UA Standardized data interface protocol
29
EN-US
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
30
Operating controls, connections and mechanical components
31
32
EN-US
Control Panel
General
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
understood the Operating Instructions.
Do not use the functions described here until you have fully read and
understood all of the Operating Instructions for the system components,
especially the safety rules.
Control panel
(1)
43,0001,3547
(2)
(3)
(4) (5) (6)
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
assigned 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
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 coun-
terclockwise highlights the item above. Changing values:
34
EN-US
– 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.
35
Display
Display (1)
(2)
(5)
(3)
(4)
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.
(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.
36
EN-US
Welding current curve
Balance (1)
(2)
Electrode diameter
Cap mode (1)
Polarity (1) (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. 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
screen
1 The display is shown in full screen mode:
2 Exit full screen mode: 2
38
EN-US
Connections, Switches, and Mechanical Components
Connections and mechanical components
(9)
(10)
(3)
(11)
(8)
(2)
(4)
(5)
(7)
(12) (13)
(14)
(1)
(6)
(15)
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:
iWave DC
iWave AC/DC
(3) Control panel with display and control panel cover For operating the power
source
(4) (-) Power connection with bayonet latch HF-free current socket for manual
metal arc welding Symbols:
iWave DC
iWave AC/DC
39
(5) (+) Current socket For connecting the grounding cable Symbols:
iWave DC
iWave AC/DC
(6) SpeedNet connection For connecting – remote controls and external sensors – wirefeeders (for automated applications) Symbol:
(7) Connection for MIG/MAG interconnecting hosepack
(8) Power switch For switching the power source on and off
(9) Dummy cover/robot interface RI FB Inside /i (option)
(10) Ethernet connection
(11) Dummy cover/second (-) current socket with bayonet latch (option) TIG
ground to wirefeeder
(12) TIG shielding gas connection socket Main gas solenoid valve
(13) Dummy cover/auxiliary gas connection Additional gas solenoid valve
(14) Dummy cover/second SpeedNet connection (option) or external sensor
(option)
(15) Dummy cover/second SpeedNet connection (option) or external sensor
(option)
40
EN-US
(16) AC inverter (only with iWave AC/DC power sources)
iWave 300i – 500i AC/DC
(16)
41
42
Before installation and initial operation
43
44
EN-US
Before installation and initial operation
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 equipment
and all system components.
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 – Following all the instructions in these Operating
Instructions – Carrying out all the specified inspection and maintenance work
Setup regulations
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! Toppling or falling devices can be deadly.
Set up devices, upright brackets and trolleys so that they are stable on a
flat and solid surface.
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.
Mains connection – 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 S1max of the power source must be known in order to
select the correct generator output. The maximum apparent power S1max of the
power source is calculated for 3-phase devices as follows:
S1max = I1max x U1 x 3
I1max and U1 according to the device rating plate and technical data
The generator apparent power SGEN needed is calculated using the following
rule of thumb:
SGEN = S1max x 1.35
A smaller generator can be used when not welding at full power.
IMPORTANT! The generator apparent power SGEN must not be less than the maximum
apparent power S1max of the power source!
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
EN-US
Connecting the Mains Cable
General Safety
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.
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
personnel. 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.
Specified mains cable
Europe:
Power source Mains voltage
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
Mains cable
H07RN-F 4G4 H07RN-F 4G4
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
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
USA & Canada:
Power source Mains voltage
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
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
Mains cable
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
Mains cable
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
4 x AWG 10 4 x AWG 10
4 x AWG 6 4 x AWG 10
4 x AWG 8 4 x AWG 8
48
EN-US
Power source Mains voltage
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
Connecting the
1
mains cable for
nc power sources
Mains cable
4 x AWG 4 4 x AWG 8
4 x AWG 8 4 x AWG 8
4 x AWG 4 4 x AWG 8
2 100 mm 3.9 inch min. 8 mm min. 0.3 inch
min. 8 mm min. 0.3 inch
140 mm 5.5 inch
3 1 2
49
4
5
4321
1
5
GND – L1 – L2 – L3; 4x TX20, 1.5 Nm / 1.11 lb-ft 6
Connecting the
1
mains cable for
MV power
sources
2 150 mm 5.9 inch min. 8 mm min. 0.3 inch
min. 8 mm min. 0.3 inch
170 mm 6.7 inch
50
3
EN-US
Cut the strain-relief device to length according to the outer diameter of the
mains cable
4
IMPORTANT! When inserting the mains cable, ensure that the cable sheath
protrudes 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
1 Hold the NFC key over the reading zone for NFC keys The key symbol appears
briefly on the display. The key symbol is then displayed in the status bar.
54
EN-US
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 1 Hold
the NFC key over the reading zone for NFC keys 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 214.
55
56
TIG
57
58
EN-US
System components
System components for manual applications
(2b)
(2a)
(1)
(3)
(1) Cooling unit (2a) iWave DC power source (2b) iWave AC/DC power source (3) Grounding 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
(6) (7)
(5) (4)
(8) (9)
Notes on the cooling unit
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.
59
Minimum equipment for welding operations
TIG AC welding
– iWave AC/DC power source – Grounding cable – TIG welding torch – Shielding gas supply with gas pressure regulator – Filler metal depending on application
TIG DC welding
– Power source – Grounding cable – TIG welding torch – Shielding gas supply with gas pressure regulator – Filler metal depending on application
60
EN-US
Commissioning
Safety
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
electric-
ally charged components (such as capacitors) have been discharged.
WARNING! Danger of electrical current due to electrically conductive dust in
the device. This can result in severe personal injury and damage to property.
Only operate the device if an air filter is fitted. The air filter is a very
important safety device for achieving IP 23 protection.
General
The start-up of the power sources for TIG welding is described on the basis of
a manual, water-cooled TIG application.
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.
61
Assembling the 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
4x
4
5 3 2 1
62
EN-US
iWave AC/DC power sources
4x
5
6 3 1
4 2
63
Connecting the 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.
1 Place the gas cylinder on the base of the trolley
2 Attach the cylinder strap to the upper part of the gas cylinder (but not to
the neck of the cylinder) to prevent the cylinder from falling over
3 4
3 Remove the protective cap from the gas cylinder
4 Briefly open the gas cylinder valve to remove any dirt
4
64
EN-US
6 5
7
5 Inspect the seal on the gas pressure regulator
6 Screw the pressure regulator onto the gas cylinder and tighten it
When using a TIG welding torch with integrated gas connection:
7 Use a gas hose to connect the gas pressure regulator and shielding gas
connection to the rear of the power source
8 Tighten the union nut of the gas hose
When using a TIG welding torch without integrated gas connection:
6 Connect the gas hose of the TIG welding torch to the gas pressure regulator
NOTE!
The gas connection when using a MultiControl (MC) cooling unit is described in
the Operating Instructions for the cooling unit.
Connecting the welding torch to the power source and 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
1 Fit parts to the welding torch according to the Operating Instructions for the welding torch
2
IMPORTANT! Check the coolant flow at
regular intervals during welding.
65
Establishing a ground earth connection to the workpiece
1 Set the power switch to – O –
2
1 2
3
66
EN-US
TIG Operating Modes
Safety
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
understood the Operating Instructions.
Do not use the functions described here until you have fully read and
understood 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.
Symbols and ex-
(1)
(2)
(3)
planations
(1) Pull back and hold the torch trigger (2) Release the torch trigger (3) Briefly pull back the torch trigger (< 0.5 s)
(4)
(5)
(4) Push the torch trigger forward and hold (5) Release the torch trigger
GPr Gas pre-flow
SPt Spot welding time
IS
Starting current:
the temperature is raised gently at low welding current, so that the filler metal can
be positioned correctly
IE
Final current:
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.
tUP UpSlope: steady rise of the starting current to the main current (welding current) I1
tDOWN DownSlope: steady lowering of the welding current until it reaches the final current
I1
Main current (welding current):
uniform thermal input into the parent material, whose temperature is raised by
the advancing heat
67
I2
Lowering current:
intermediate lowering of the welding current to avoid local overheating of the par-
ent material
GPO Gas post-flow
2-step mode
– Welding: Pull back the torch trigger and hold it in this position – End of welding: Release the torch trigger
I
I 1
GPr
t
UP
2-step mode
t
DOWN
t GPo
4-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 position – End of
welding: Release the torch trigger
I I
S
I
I
1
1
I 2 *)
I
E
t
GPr
t
UP
4-step mode
t
DOWN
GPo
*) Intermediate lowering
With intermediate lowering, the welding current is lowered to the set lowering current I-2 during the main current phase.
68
EN-US
– To activate intermediate lowering, push the torch trigger forward and hold
it 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.
I1
I1
I
I 2
IE IS
t
GPr
tup
Special 4-step mode: Version 1
tdown
GPo
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
69
Special 4-step 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 current 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
current I1 using the set lowering current slope 2.
I
I1
I1
I2
IE IS
GPr
tup
Special 4-step mode: Version 2
tdown
t GPo
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
70
EN-US
Special 4-step 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.
I1
I1
I
I 2
IS
GPr
tup
Special 4-step mode: Version 3
t
GPo
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
71
Special 4-step 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 I1 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
I
I1
I1
I2
IS
GPr
tS
tup
Special 4-step mode: Version 4
tdown
IE
t
tE
GPo
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
72
EN-US
Special 4-step 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 weld-
ing 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.
I
I1 IS
GPr
tup
Special 4-step mode: Version 5
I1 > I1 <
tdown
IE
t
GPo
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
73
Special 4-step 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.
< 0,5 s
< 0,5 s
< 0,5 s
0,5 s < 0,5 s
I IS
I1
I1
I2
I1 I
E
GPr
tup
Special 4-step mode: Version 6
tdown
GPo
t
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
74
EN-US
Spot welding
– 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
I 1
I
GPr
t
UP
SPt
t
DOWN
t GPo
75
TIG welding
Safety
WARNING! Danger from incorrect operation and work that is not carried out
properly. This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out
by technically trained and qualified personnel.
Read and understand this document in full. Read and understand all safety
rules and user documentation for this equipment
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
electric-
ally 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.).
1 Set the power switch to – I –
76
EN-US
3 4 2
5
2 Select “Welding process” 3 Select “Process” An overview of available welding
processes is displayed. 4 Select “TIG” 5 Select “Mode” An overview of
operating modes is displayed.
7 6
6 Select the desired operating mode 7 Select “TIG welding” The TIG welding
parameters are displayed.
77
8 Turn the selection dial (or touch the welding parameters symbol in the
indicator bar): Select welding parameters
9 Press the selection dial
The value of the parameter is highlighted in blue and can now be changed.
10 Turn the selection dial: Change the value of the parameter 11 If necessary,
select the process parameters for user- or application-specific settings
on the welding system 12 Open the gas cylinder valve 13 Press the gas-test
button
The gas pre-flow test lasts for 30 seconds at the most. Press the button again
to stop the gas flow prematurely.
14 Turn the adjusting screw on the bottom of the gas pressure regulator until
the manometer displays the desired quantity of gas
15 Commence the welding process (ignite arc)
NOTE!
Under certain circumstances, it may not be possible to change parameters that
have been set on the control panel of a system component (e.g. wirefeeder or
remote control) on the control panel of the power source.
Welding parameters for TIG welding
AC Welding parameters for TIG AC welding DC- Parameters for TIG DC- welding
Starting current (AC / DC-)
Starting current: 2-step mode | 4-step mode
Setting range: 0 – 200% (of the main current) Factory setting: 50% IMPORTANT!
The starting current is stored separately for TIG AC welding and TIG
DCwelding.
78
EN-US
UpSlope (AC / DC-)
UpSlope: 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. Main current I1 (AC /
DC-)
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. Lowering current
I2 (AC / DC-) only in 4-step mode
Lowering current I2 < Main current I1 | Lowering current I2 > Main current I1
Setting range: 0 – 200% (of the main current I1) Factory setting: 50%
79
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)
Slope1
Slope2
I > 100 % I
Slope1
I < 100 % Slope2
The values for Slope1 and Slope2 can be set in the process parameters. DownSlope (AC / DC-)
DownSlope: 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 DownSlope value applies to the 2-step and 4-step modes.
Final current (AC / DC-)
Final current: 2-step mode and spot welding | 4-step mode
Setting range: 0 – 100% (of the main current) Factory setting: 30%
80
EN-US
AC balance (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:
I (A)
35% + –
50%
15% t (s)
Electrode diameter (AC / DC-)
DC-
AC
Setting range: off; 1.0 – 6.4 mm Factory setting: 2.4 mm
81
Cap mode (AC) 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.
(1)
(2)
(1) … before ignition (2) … after ignition
Cap mode 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.
82
EN-US
Polarity (AC) only with iWave AC/DC
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 202 onwards.
83
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
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, difficult 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:
1 Position the gas nozzle at the ignition 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.
84
EN-US
2 Increase the tilt angle of the welding torch and press the torch trigger
according to the selected operating mode
The arc ignites without coming into contact with the workpiece.
3 Tilt the welding torch to the normal position
4 Carry out welding
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:
1 Position the gas nozzle at the ignition 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
85
2 Press the torch trigger Shielding gas flows 3 Gradually tilt the welding
torch up until
the tungsten electrode touches the workpiece
4 Raise the welding torch and rotate it into its normal position
The arc ignites. 5 Carry out welding
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 positions, 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.
86
EN-US
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
1 Depending on the set operating mode, end welding by releasing the torch
trigger
2 Wait for the set gas post-flow and hold the welding torch in position over
the end of the weld seam.
87
TIG special functions
Ignition timeout function
The power source has an ignition timeout 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 96.
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:
I [A]
(5) (6)
(1) (2)
(3) (4)
(8)
(7)
t [s]
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
) (1/F-P = Time between two pulses)
88
EN-US
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:
I [A]
(4)
(1) (2)
(3)
(6)
(5)
t [s]
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.
89
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 (!)
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
90
EN-US
TIG process parameters
TIG process parameters
2
1
TIG process parameters: TIG pulse, AC, General, Ignition & trigger mode,
CycleTIG, Wirefeeder setup, Gas, R/Lcheck / alignment
Process parameters for Components and Monitoring see page 186.
Process parameters for TIG pulse
Tacking Tacking function – duration of the pulsed welding current at the start
of the tacking pro-
cess
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
The Tacking (TAC) indicator lights up in the status bar on the if a value has been set.
91
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
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 applications
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
Hard rectangle: Purely rectangular curve;
92
EN-US
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
Effect of AC frequency on current flow:
I (A)
–
t (s)
60 Hz 120 Hz
AC current offset
-70 to +70% Factory setting: 0%
+70% Wide arc with shallow heat input
-70% Narrow arc, deep heat input, higher welding speed
93
Effect of AC current offset on current flow: I (A)
t (s)
–
0
+70%
-70%
- 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)
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
General TIG process parameters
Welding start / welding end settings
94
EN-US
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 69 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 69 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 4step 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 69 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 69 onwards).
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
95
Spot welding time (only if the mode is set to spot welding)
0.02 – 120 s Factory setting: 5.0 s
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, the 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, difficult to
access or exposed places, or when welding out-of-position!
HF ignition delay time Time after touching the workpiece with the tungsten
electrode after which high-frequency 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
96
EN-US
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
IMPORTANT! Reversed polarity ignition is not recommended for welding light-
gage 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 “TIG welding”. 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.
error An error message is displayed on the power source and must be
acknowledged.
Operating mode settings
Torch trigger Start welding by pressing the torch trigger
on/off Factory setting: on
on Welding is started using the torch trigger
on Welding is started by touching the workpiece with the tungsten electrode;
especially suitable for welding torches without torch triggers, ignition
sequence depends on ignition parameters
97
The symbol for the deactivated torch trigger is shown in the status bar of the
display, the option of selecting the operating mode is deactivated.
I2 using torch trigger to activate / deactivate whether it is possible to
switch over to the lowering current I2 using the torch trigger
The setting of the I2 using torch trigger parameter also influences versions 1 – 6 of special 4-step mode (see page 69 onwards).
on / off Factory setting: off
Lowering current button function
The setting of the Lowering current button function parameter also influences versions 1 – 6 of special 4-step mode (see page 69 onwards).
I1 / I2 Factory setting: I2
Arc break voltage To set a voltage value at which the welding process can be
ended by lifting the TIG welding torch slightly. The higher the break voltage
value, the higher the arc can be lifted.
The arc break voltage values for 2-step mode, 4-step mode and operation with a footoperated remote control are all stored together. If the “Torch trigger” parameter is set to “off”, the values are stored separately.
off / 6.0 – 90.0 V Factory setting: off
Comfort stop sensitivity The parameter is only available if the “Torch
trigger” parameter is set to “off”.
off / 0.1 – 10.0 V Factory setting: off
At the end of the welding process, an automatic shutdown of the welding current follows a significant increase of the arc length. This prevents the arc from having to be unnecessarily lengthened when lifting the TIG welding torch.
Process:
1
2
3
45
98
EN-US
CycleTIG
1 Welding 2 Briefly lift the welding torch at the end of welding
The arc lengthens significantly.
3 Lower the welding torch – The arc shortens significantly – The Comfort stop
function has been activated
4 Maintain height of the welding torch – The welding current ramps down
continuously (DownSlope). – The arc goes out.
IMPORTANT! The DownSlope is fixed and cannot be adjusted.
5 Lift the welding torch from the workpiece
CycleTIG to activate / deactivate the CycleTIG function (extended interval
welding process for DC welding)
I [A] (3)
I1
(2)
(1)
(2)
(4)
Setting range: on / off Factory setting: off
(1) Interval time To set how long the welding current I1 is active
Setting range: 0.02 – 2.00 s Factory setting: 0.5 s
(2) Interval pause time To set how long the base current (4) is active
Setting range: 0.02 – 2.00 s Factory setting: 0.5 s
(1)
(2)
t [ms]
99
(3) Interval cycles to set how many cycles are to be repeated
Setting range: Constant / 1 – 2000 Factory setting: Constant
(4) base current (DC-) To set the interval base current (4) to which the
current is reduced during the interval pause time (2)
Setting range: off / 3 – max. A Factory setting: off
NOTE!
For more details on CycleTIG, see page 90 onwards.
Wire speed setting
Wire speed 1 Set value for wire speed
off / 0.1 – 50.0 m/min Factory setting: 5 m/min
Wire speed 2 Wire speed 2
0 – 100% (of wire speed 1) Factory setting: 50%
If a value is set for each of the “Wire speed 2” and “Pulse frequency” setup
parameters, the wire speed changes between wire speed 1 and wire speed 2
synchronously with the pulse frequency of the welding current.
Main current Welding current I1
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: –
Pulse frequency
off / 0.20 – 5000 Hz, 5000 – 10,000 Hz Factory setting: off
Wire start-up delay Feed delay of welding wire from start of main current
phase
off / 0.1 – 9.9 s Factory setting: 5.0 s
Wire end delay Feed delay of welding wire from end of main current phase
off / 0.1 – 9.9 s Factory setting: 5.0 s
Wire retraction end How far the welding wire is retracted after the end of
welding
100
EN-US
off / 1 – 50 mm Factory setting: 3 mm
Wire position start How far the welding wire is from the workpiece before
welding starts
off / 1 – 50 mm Factory setting: 3 mm
Feeder inching speed
0.5 – 100.0 m/min Factory setting: 5.0 m/min
TIG gas settings
Gas pre-flow To set the gas flow time before ignition of the arc
0.0 – 9.9 s Factory setting: 0.4 s
Gas post-flow To set the gas flow time after the end of the arc
auto / 0 – 60 s Factory setting: auto
auto Depending on the electrode diameter and welding current, the power source
calculates and automatically adjusts the optimal gas post-flow time.
TIG Ar He changeover for individual selection of the gas shield
auto / 1 / 2 Factory setting: auto
auto: – The shielding gas (gas 1) is used during the starting-current phase
and during the
UpSlope. – When the main current phase is reached, shielding gas (gas 2) is
used. – When the welding process is finished, the shielding gas (gas 1) is
used during the
DownSlope and the final current phase.
1: Shielding gas (gas 1) is used for the entire welding process.
2: Working gas (gas 2) is used for the entire welding process.
Gas regulator 1
Gas set value 1 – TIG shielding gas Shielding gas flow (only in conjunction
with option OPT/i TIG gas flow sensor)
off / 0.5 – 30.0 l/min Factory setting: 15.0 l/min
IMPORTANT! If the set value for the shielding gas flow rate is high (e.g., 30
l/min), ensure that the gas line is adequately dimensioned!
101
Gas factor 1 – TIG shielding gas depends on the shielding gas used (only in
connection with the OPT/i TIG gas regulator option)
auto / 0.90 / 20.0 Factory setting: auto
Gas regulator 2
Gas set value 2 – TIG working gas
off / 0.5 – 30.0 l/min Factory setting: 15.0 l/min
Gas factor 2 – TIG working gas
0.90 – 20.0 Factory setting: 11.82
Conducting an R/L alignment
NOTE!
The R/L alignment must be carried out separately for each welding process.
Welding circuit resistance R [mOhm] The welding circuit resistance is
calculated to provide information about the total resistance of the torch
hosepack, welding torch, workpiece and grounding cable.
If, for example, the welding circuit resistance increases after the welding
torch has been changed, the following components may be faulty: – Torch
hosepack – Welding torch – Ground earth connection to the workpiece –
Grounding cable
Welding circuit inductance L [µH] The routing of the hosepack has a
significant impact on the weld properties. A high degree of welding circuit
inductance can occur, especially during pulsing and AC welding, depending on
the length and routing of the hosepack. The increase in current is limited.
The welding result can be optimized by changing the routing of the torch
hosepack. The hosepack must always be routed as shown.
Perform R/L alignment
102
EN-US
1 Process parameters / General / R/L-check / alignment The current values are
displayed.
2 Select Next The 2nd R/L alignment screen is displayed.
3 Follow the instructions on the screen 4 Select Next
The 3rd R/L alignment screen is displayed. 5 Follow the instructions on the
screen 6 Select Next
The current values are determined. After R/L alignment has been performed, a
confirmation and the current values are displayed.
103
104
MIG/MAG
105
106
EN-US
Welding packages, welding characteristics and welding processes
General
The power sources have a number of different Welding Packages, welding characteristics and welding processes so that the broadest range of materials can be effectively processed.
Welding Packages
The following Welding Packages are available: – Welding Package Standard
(enables MIG/MAG standard synergic welding) – Welding Package Pulse
(enables MIG/MAG pulse-synergic welding) – Welding Package LSC
(enables the LSC process) – Welding Package PMC
(enables the PMC process) – Welding Package CMT
(enables the CMT process)
only in combination with Welding Package Standard
**
only in combination with Welding Package Pulse
*** only in combination with Welding Package Standard and Welding Package Pulse
IMPORTANT! On a power source without any Welding Packages, only MIG/MAG standard manual welding is available.
Welding characteristics
Depending on the welding process and shielding gas combination, various
process-optimized welding characteristics are available when selecting the
filler metal.
Examples of welding characteristics: – MIG/MAG 3700 PMC Steel 1,0mm M21 – arc
blow – MIG/MAG 3450 PMC Steel 1,0mm M21 – dynamic – MIG/MAG 3044 pulse
AlMg5 1.2 mm I1 – universal * – MIG/MAG 2684 Standard Steel 0.9 mm M22 – root
- The welding process suffix (*) provides information about special properties
and the use of the welding characteristic. The characteristics are described
as follows:
Name Process Properties
ADV *** CMT
Also required: Inverter module for an alternating current process
Negatively poled process phase with less heat input and higher deposition rate
107
ADV * LSC
Also required: Electronic switch for current interruption
Maximum current reduction by opening the circuit in any desired process phase
Only in conjunction with TPS 400i LSC ADV
arc blow PMC Characteristics with improved arc break properties through
deflection when exposed to external magnetic fields
arcing Standard Characteristics for a special form of hardfacing on dry and
wet substrates (e.g., on crushing rollers in the sugar and ethanol industries)
braze: CMT, LSC, PMC Characteristics for brazing processes (high brazing
speed, reliable wetting and good flow of braze material)
braze+ CMT Optimized characteristics for brazing processes using the special
“Braze+” gas nozzle (narrow gas nozzle opening, high shielding gas flow rate)
cladding: CMT, LSC, PMC Characteristics for cladding with low penetration, low
dilution and wide weld flow for improved wetting
dynamic CMT, PMC, Pulse, Standard Characteristics for high welding speeds with
concentrated arc
flanged edge CMT Characteristics for flanged welds with adjustment of
frequency and energy input; The edge is fully detected but not melted down.
galvanized CMT, LSC, PMC, Pulse, Standard Characteristics for galvanized sheet
surfaces (low risk of zinc pores, reduced zinc burnoff)
galvannealed PMC Characteristics for iron-zinc coated sheet surfaces
gap bridging CMT, PMC Characteristics with very low heat input for best gap-
bridging ability
hotspot CMT Characteristics with hot start sequence, especially for plug welds
and MIG/MAG spot welds
mix * / PMC
108
EN-US
Also required: Pulse and PMC Welding Packages
Characteristics with a process change between pulsed and dip transfer arc
Especially for welding vertical-up seams with cyclic change between a hot and
cold supporting process phase.
mix /** CMT
Also required: CMT Drive Unit WF 60i Robacta Drive CMT Pulse, Standard and CMT
Welding Packages
Characteristics with a process change between pulsed and CMT, where the CMT
process is initiated by a reversal of the wire movement.
mix drive PMC
Also required: WF 25i Robacta Drive PushPull drive unit or WF 60i Robacta
Drive CMT Pulse and PMC Welding Packages
Characteristics with a process change between pulsed and dip transfer arc,
where the dip transfer arc is initiated by a reversal of the wire movement.
multi arc PMC Characteristics for parts being welded by multiple interacting
arcs
PCS ** PMC Pulse Controlled Sprayarc – Direct transition from concentrated
pulsed to short spray arc. PCS combines the advantages of pulsed and standard
arcs in one characteristic.
pipe PMC Characteristics for pipe applications and positional welding on
narrow gap applications
retro CMT, Pulse, PMC, Standard Characteristics with the properties of
TransPuls Synergic (TPS), the previous device series
ripple drive *** PMC Also required: CMT drive unit, WF 60i Robacta Drive CMT
Characteristics with a behavior like interval operation for pronounced seam
rippling, especially with aluminum
root CMT, LSC, Standard Characteristics for root passes with a powerful arc
seam track PMC, pulse Characteristics with a more powerful seam tracking
signal, especially when using multiple welding torches on one part.
TIME PMC
109
Characteristics for welding with long stick-out and TIME shielding gases
(T.I.M.E. = Transferred Ionized Molten Energy)
TWIN PMC Synchronized characteristics for two wire electrodes in a common weld
pool (tandem welding process)
universal CMT, PMC, pulse, standard Characteristics for conventional welding
tasks
WAAM CMT Characteristics with reduced heat input and more stability with
higher deposition rate for bead to bead welding of adaptive structures
weld+ CMT Characteristics for welding with short stick out and the Braze+ gas
nozzle (gas nozzle with small orifice and high flow rate)
**
Mixed process characteristics
*** Welding characteristics with special properties due to additional hardware
110
EN-US
Brief description of MIG/MAG pulsed synergic welding
MIG/MAG pulsed synergic
MIG/MAG pulsed synergic welding is a pulsed arc process with a controlled
material transfer. In the base current phase, the energy input is reduced to
such an extent that the arc barely burns steadily and the surface of the
workpiece is preheated. In the pulsing current phase, an accurately timed
current pulse guarantees a precise detachment of the weld material droplet.
This principle guarantees low-spatter welding and precise operation throughout
the entire power range.
Summary of MIG/MAG standard synergic welding
MIG/MAG standard synergic
The MIG/MAG standard synergic welding process is a MIG/MAG welding process
across the entire power range of the power source with the following arc
types:
Short circuit arc Droplet transfer takes place during a short circuit in the
lower power range.
Intermediate arc The droplet increases in size on the end of the wire
electrode and is transferred in the mid-power range during the short circuit.
Spray arc A short circuit-free transfer of material in the high power range.
Summary of the PMC process
PMC = Pulse Multi Control
PMC is a pulsed arc welding process with high-speed data processing, precise
recording of the process status and improved droplet detachment. Faster
welding possible with a stable arc and even fusion penetration.
Summary of the LSC process
LSC = Low Spatter Control
LSC is a new, low-spatter dip transfer arc process.The current is reduced
before breaking the short-circuit bridge; re-ignition takes place at
significantly lower welding current values.
Summary of SynchroPulse welding
SynchroPulse is available for all processes (standard/pulsed/LSC/PMC). Due to the cyclical change of welding power between two operating points, SynchroPulse achieves a flaking seam appearance and non-continuous heat input.
111
Summary of the CMT process
CMT = Cold Metal Transfer
A special CMT drive unit is required for the CMT process.
The reversing wire movement in the CMT process results in a droplet detachment
with improved dip transfer arc properties. The advantages of the CMT process
are as follows – Low heat input – Less spattering – Reduced emissions – High
process stability
The CMT process is suitable for: – Joint welding, cladding and brazing
particularly in the case of high requirements in
terms of heat input and process stability – Welding on light-gauge sheet with
minimal distortion – Special connections, such as copper, zinc, and
steel/aluminium
NOTE!
A CMT reference book is available complete with typical applications; see ISBN
978-3-8111-6879-4.
Brief description of the CMT Cycle Step welding process
CMT Cycle Step is a further development of the CMT welding process. It also
requires a special CMT drive unit.
CMT Cycle Step is the welding process with the lowest heat input. The CMT
Cycle Step welding process alternates cyclically between CMT welding and
pauses of an adjustable duration. The welding pauses mean there is less heat
input, while the continuity of the weld is maintained. Individual CMT cycles
are also possible. The size of the CMT welding spots is determined by the
number of CMT cycles.
112
EN-US
System components
Overview
(7) (5)
(4)
(8)
(3)
(2)
(9)
(2a)
(1)
(6)
(1) Cooling units (2) iWave DC power sources (2a) iWave AC/DC power sources (3) Robot accessories (4) Interconnecting hosepacks (max. 50 m)* (5) Wirefeeders (6) Grounding cable (7) Welding torch (8) Wirefeeder holder (9) Trolley and gas cylinder holders
Interconnecting hosepacks > 50 m only in conjunction with the
OPT/i SpeedNet Repeater option
Other: – Remote controls – Dust filter – Additional current sockets
113
Minimum equipment for welding operations
General
Depending on the welding process, a minimum level of equipment is required to work with the power source. The following describes the welding processes and the corresponding minimum equipment for welding operations.
Gas-cooled
–
MIG/MAG welding –
–
–
–
–
–
Power source Grounding cable MIG/MAG welding torch, gas-cooled Shielding gas supply Wirefeeder Interconnecting hosepack Wire electrode
Water-cooled
–
MIG/MAG welding –
–
–
–
–
–
–
Power source Cooling unit Grounding cable MIG/MAG welding torch, water-cooled Shielding gas supply Wirefeeder Interconnecting hosepack Wire electrode
Automated
–
MIG/MAG welding –
–
–
Power source Robot interface or Fieldbus connection Grounding cable MIG/MAG robot welding torch or MIG/MAG machine welding torch
With water-cooled robot or machine welding torches, a cooling unit is also required.
– Gas connection (shielding gas supply) – Wirefeeder – Interconnecting hosepack – Wire electrode
CMT welding manual
– Power source – Standard, Pulse and CMT Welding Packages enabled on the power
source – Grounding cable – PullMig CMT welding torch incl. CMT drive unit and
CMT wire buffer
IMPORTANT! For water-cooled CMT applications, an additional cooling unit is
required!
– OPT/i PushPull – Wirefeeder – CMT interconnecting hosepack – Wire electrode
– Gas connection (shielding gas supply)
114
EN-US
CMT welding automated
– Power source – Standard, Pulse and CMT Welding Packages enabled on the power source – Robot interface or Fieldbus connection – Grounding cable – CMT welding torch incl. CMT drive unit – Cooling unit – Unreeling wirefeeder (WFi REEL) – Interconnecting hosepack – Torch hosepack – Wirefeeding hose – Media separation point (e.g., SB 500i R, SB 60i R) – CMT wire buffer (included with SB 60i R) – Wire electrode – Gas connection (shielding gas supply)
115
MIG/MAG Operating Modes
General
WARNING!
Danger from incorrect operation. Possible serious injury and damage to
property.
Do not use the functions described here until you have read and completely
understood these Operating Instructions.
Do not use the functions described here until you have fully read and
understood all of the Operating Instructions for the system components, in
particular the safety rules!
See the Setup menu for information on settings, setting range and units of
measurement for the available parameters.
Symbols and their explanations
Press the torch trigger | Hold the torch trigger | Release the torch trigger
GPr Gas pre-flow I-S Starting-current phase: the base material is heated up
rapidly, despite the high thermal dissipation that occurs at the start of
welding t-S Starting current time
S
Start arc length correction SL1 Slope 1: the starting current is steadily
lowered until it reaches the welding current I Welding-current phase: uniform
thermal input into the base material, whose temperature is raised by the
advancing heat I-E Final current phase: to prevent any local overheating of
the base material due to heat build-up towards the end of welding. This
eliminates any risk of weld seam drop-through. t-E Final current time
E
End arc length correction
116
EN-US
SL2 Slope 2: the welding current is steadily lowered until it reaches the
final current
GPo Gas post-flow
A detailed explanation of the parameters can be found in the section headed
“Process parameters”
2-step mode +
I
I
GPr
“2-step mode” is suitable for – Tacking work – Short weld seams – Automatic
and robot operation
4-step mode +
I
I
GPr “4-step mode” is suitable for longer weld seams.
t GPo
- t GPo
117
Special 4-step mode
I
I-S
S
GPr t-S SL1
I
I-E
E
t
SL2
t-E GPo
“Special 4-step mode” is ideal for welding aluminum materials. The high thermal conductivity of aluminum is taken into account by the special welding current profile.
Special 2-step mode
I
I-S S
GPr t-S SL1
I
I-E
E
t
SL2
t-E GPo
“Special 2-step mode” is ideal for welding in higher power ranges. In special 2-step mode, the arc starts at a lower power, which makes it easier to stabilize.
118
EN-US
Spot welding +
I I
GPr
SPt
t GPo
The “Spot welding” mode is suitable for welded joints on overlapped sheets.
119
MIG/MAG and CMT welding
Safety
WARNING! Danger from incorrect operation and work that is not carried out
properly. This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out
by technically trained and qualified personnel.
Read and understand this document in full. Read and understand all safety
rules and user documentation for this equipment
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
electric-
ally charged components (such as capacitors) have been discharged.
MIG/MAG and CMT welding Overview
The “MIG/MAG and CMT welding” section includes the following steps: – Switch
on the power source – Select the welding process and operating mode – Select
the filler metal and shielding gas – Set the welding and process parameters –
Adjust the quantity of shielding gas – MIG/MAG or CMT welding
NOTE!
If using a cooling unit, observe the safety rules and operating conditions in
the Operating Instructions for the cooling unit.
Switching on the power source
1 Plug in the mains cable 2 Set the power switch to – I –
A cooling unit in the welding system starts to work.
IMPORTANT! For optimum welding results, the manufacturer recommends carrying
out an R/L alignment when using the device for the first time and whenever
changes are made to the welding system. Further information on the R/L
alignment can be found under “R/L alignment” in the section “Process
parameters” in the “MIG/MAG process parameters” chapter (page 144).
120
EN-US
Selecting the welding process and operating mode
Select the welding process
2 1
3
Next page: Electrode, CEL, Job
1 Select “Welding process” 2 Select “Process”
An overview of the welding processes is displayed. Various welding processes are available depending on the type of power source or the function package installed.
3 Select the desired welding process
Set the operating mode
5
4 Select “Mode” An overview of operating modes is displayed:
4 121
– 2-step mode – 4-step mode – Special 2-step mode – Special 4-step mode – Spot
welding 5 Select the desired operating mode
Selecting the filler metal and shielding gas
1
2
3
1 Select “Welding process” 2 Select “Filler metal” 3 Select “Change material
settings” 4 Turn the selection dial and select the desired filler metal 5
Select “Next”/press the selection dial 6 Turn the selection dial and select
the desired wire diameter 7 Select “Next”/press the selection dial 8 Turn the
selection dial and select the desired shielding gas 9 Select “Next”/press the
selection dial NOTE! The available characteristics for each process are not
displayed if only one characteristic is available for the selected filler
metal. The confirmation step of the filler metal wizard follows directly,
steps 10 – 14 are omitted.
10 Turn the selection dial and select the desired process 11 Press the
selection dial to select the desired characteristic (blue background) 12 Turn
the selection dial and select the desired characteristic 13 Press the
selection dial and accept the selected characteristic (white background) 14
Select “Next” The confirmation step of the filler metal wizard is displayed:
122
EN-US
15 Select “Save”/press the selection dial The selected filler metal and
associated characteristics for each process are saved.
Setting the welding parameters
1
2
3
1 Select “Welding” 2 Turn the selection dial to select the desired welding
parameter 3 Press the selection dial to change the parameter The value of the
parameter is displayed as a horizontal scale:
4
e.g., wire feed speed parameter
The selected parameter can now be changed. 4 Change the parameter by turning
the selection dial The new parameter value is applied immediately. If one of
the wire feed speed, sheet thickness, welding current or welding voltage
parameters is changed during Synergic welding, all the other parameters are
immediately modified accordingly. 5 Press the selection dial to access the
welding parameters overview 6 If necessary, select the process parameters for
user- or application-specific settings
on the welding system
123
Setting the shielding gas flow rate
1 Open the gas cylinder valve 2 Press the gas test button
Shielding gas flows out
3 Turn the adjusting screw on the underside of the pressure regulator until
the pressure gauge shows the required shielding gas flow rate
4 Press the gas test button
The flow of gas stops.
MIG/MAG or CMT welding
1
1 Select “Welding” to display the welding parameters
CAUTION! Danger of injury and damage from electric shock and from the wire
electrode emerging from the torch. When you press the torch trigger
Keep the welding torch away from your face and body Do not point the welding
torch at anyone Make sure that the wire electrode does not touch any
conductive or grounded parts
(e.g., housing, etc.)
2 Press the torch trigger and start welding At the end of each welding
operation, the actual values for welding current, welding voltage and wire
speed are stored – “HOLD” is displayed on the screen.
NOTE! Under certain circumstances, it may not be possible to change parameters
that have been set on the control panel of a system component (e.g. wirefeeder
or remote control) on the control panel of the power source.
124
EN-US
MIG/MAG and CMT welding parameters
Welding parameters for MIG/MAG pulse-synergic welding, for CMT welding and for PMC welding
For MIG/MAG pulse-synergic welding, CMT welding and PMC welding, the following
welding parameters can be set and displayed under the “Welding” button:
Current 1) [A] Setting range: depends on the selected welding process and
welding program
Before welding begins, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.
Voltage 1) [V]
Setting range: depends on the selected welding process and welding program
Before welding begins, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.
Material thickness 1)
0.1 – 30.0 mm 2) / 0.004 – 1.18 2) in. Wire speed 1)
0.5 – max 2) 3) m/min / 19.69 – max 2) 3) ipm.
Arc length correction For correcting the arc length;
-10 – +10 Factory setting: 0
– … shorter arc length 0 … neutral arc length + … longer arc length
Pulse/dynamic correction For correcting the pulse energy in the pulsed arc
-10 – +10 Factory setting: 0
– … lower droplet detachment force 0 … neutral droplet detachment force + … increased droplet detachment force
125
Welding parameters for MIG/MAG standard synergic welding and LSC welding
For MIG/MAG standard synergic welding and LSC welding, the following welding
parameters can be set and displayed in the “Welding” menu item:
Current 1) [A] Setting range: depends on the selected welding process and
welding program
Before welding begins, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.
Voltage 1) [V]
Setting range: depends on the selected welding process and welding program
Before welding begins, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.
Material thickness 1)
0.1 – 30.0 mm 2) / 0.004 – 1.18 2) in. Wire speed 1)
0.5 – max 2) 3) m/min / 19.69 – max 2) 3) ipm.
Arc length correction For correcting the arc length;
-10 – +10 Factory setting: 0
– … shorter arc length 0 … neutral arc length + … longer arc length
Pulse/dynamic correction For correcting the pulse energy in the pulsed arc
-10 – +10 Factory setting: 0
– … lower droplet detachment force 0 … neutral droplet detachment force + … increased droplet detachment force
126
EN-US
Welding parameters for MIG/MAG standard manual welding
For MIG/MAG standard manual welding, the following welding parameters can be
set and displayed in the “Welding” menu item:
Voltage 1) [V]
Setting range: depends on the selected welding process and welding program
Before welding begins, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.
Arc-force dynamic For influencing the short-circuiting dynamic at the instant
of droplet transfer
0 – 10 Factory setting: 0
0 … harder and more stable arc 10 … softer and low spatter arc
Wire speed 1) To set a harder and more stable arc
0.5 – max 2) m/min / 19.69 – max 2) ipm.
Explanation of footnotes
- Synergic parameters If a synergic parameter is changed, all other synergic
parameters are automatically set as well due to the synergic function.
The actual setting range depends on the power source and wire speed, as well as which welding program was selected. 2) The actual setting range depends on the selected welding program. 3) The maximum value depends on the actual wire speed.
127
Spot welding
Spot welding
1
1 Select “Welding process” 2 Select “Process” 3 Select the desired welding
process
2 3
4 6
5
4 Select “Mode” 5 Select “Spot welding” 6 Select “Process parameters”
128
EN-US
7
8
- Displayed only when the OPT/i CMT Cycle Step option is present on the power source. In TWIN mode, the TWIN Process control button is displayed after the Process Mix button. In this case, the Spot w
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>