iWave 190i - 230i

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

The full text of the EU Declaration of Conformity can be found at
https://www.fronius.com .

Devices with the CSA mark satisfy the requirements of the relevant standards in Canada and the USA.

Copyright of these operating instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information regarding any discrepancies in the operating instructions.

The device has been manufactured in line with the state of the art and according to recognised safety standards.

The welding machine may only be used for TIG and manual metal arc welding in combination with Fronius components.

Use for any other purpose, or in any other manner, is deemed not in accordance with the intended use.

The device has been manufactured in line with the state of the art and according to recognised safety standards.

The welding machine may only be used for TIG and manual metal arc welding in combination with Fronius components.

Use for any other purpose, or in any other manner, is deemed not in accordance with the intended use.

IMPORTANT! Utilisation for any other purpose, or in any other manner, shall be deemed to be improper use.

The iWave 230i DC, iWave 190i AC/DC and iWave 230i AC/DC TIG welding machines are fully digitised, microprocessor-controlled inverter welding machines.

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

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

The iWave welding machines are equipped with a TIG pulsed arc function with a wide frequency range.

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

The iWave 230i DC, iWave 190i AC/DC and iWave 230i AC/DC TIG welding machines are fully digitised, microprocessor-controlled inverter welding machines.

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

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

The iWave welding machines are equipped with a TIG pulsed arc function with a wide frequency range.

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

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

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

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

FCC

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

FCC ID: QKWBCU2

Industry Canada RSS

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

IC: 12270A-BCU2

EU

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

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

NOM / Mexico

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

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

Depending on the device firmware, in some cases "power source" may still be shown on the display.

Power source = welding machine

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

* MV welding machines: 1 ~ 100 - 230 V

Safety symbols on the rating plate:

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

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

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

* MV welding machines: 1 ~ 100 - 230 V

Safety symbols on the rating plate:

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

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

The iWave DC and iWave AC/DC welding machines can be used with a wide variety of system extensions and options.

The iWave DC and iWave AC/DC welding machines can be used with a wide variety of system extensions and options.

OPT/i Ethernet iWave 190i/230i
Option for a permanent network connection

Carrying strap option

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

OPT/i Jobs
Function package for Job mode (EasyJobs, save and edit jobs)

OPT/i Documentation
Option for the documentation function

OPT/i Limit Monitoring
Option for specifying the limit values for the welding current, welding voltage and wire speed

OPT/i CycleTIG
Enhanced TIG stitch welding

OPT/i Custom NFC - ISO 14443A
Option to use a customer-specific frequency band for key cards

OPT/i OPC-UA
Standardised data interface protocol

OPT/i MQTT
Standardised data interface protocol

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

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

1Select the desired parameter in the Setup menu

More information about the Setup menu can be found from page (→) onwards

2To assign the selected parameter to the Favourites button, press the Favourites button for approx. 5 seconds

A confirmation message is displayed.

The selected parameter is now assigned to the Favourites button.

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

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

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

1Select the desired parameter in the Setup menu

More information about the Setup menu can be found from page (→) onwards

2To assign the selected parameter to the Favourites button, press the Favourites button for approx. 5 seconds

A confirmation message is displayed.

The selected parameter is now assigned to the Favourites button.

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

1Press the Favourites button briefly

The assigned parameter is displayed:

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

The new value takes effect immediately.

Press and turn the adjusting dial to choose from the available welding parameters.

1Press the Favourites button for longer than 5 seconds

The assigned parameter is deleted and a message is displayed.

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

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

1Select the Job menu from the Setup menu

More information about the Setup menu can be found from page (→) onwards

2In the Job menu, set the “EasyJobs on Favourites button” parameter to “on”

3Press the Menu key

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

4Press the Favourites button

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

More information about using EasyJobs can be found in the “EasyJob mode” section starting on page (→).

Depending on the welding process, a certain minimum equipment level is required in order to work with the welding machine.
The welding processes and the corresponding minimum equipment for the welding operation are described in the following.

Depending on the welding process, a certain minimum equipment level is required in order to work with the welding machine.
The welding processes and the corresponding minimum equipment for the welding operation are described in the following.

Depending on the welding process, a certain minimum equipment level is required in order to work with the welding machine.
The welding processes and the corresponding minimum equipment for the welding operation are described in the following.

The welding system is generator-compatible.

In order to dimension the required generator output, the maximum apparent power S_1max of the welding system is required.

The maximum apparent power S_1max of the welding system can be calculated as follows:
S_1max = I_1max x U₁

See device rating plate or technical data for I_1max and U₁ values

The generator apparent power S_GEN needed is calculated using the following rule of thumb:
S_GEN = S_1max x 1.35

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

IMPORTANT! The generator apparent power S_GEN must always be higher than the maximum apparent power S_1max of the welding system.

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

IMPORTANT! Ensure that the mains connection is earthed properly!

Due to local regulations and national guidelines, a residual current circuit breaker may be required when connecting a device to the public grid. The type of residual current circuit breaker recommended for the device is specified in the technical data.

If welding machines are delivered without a mains cable fitted, a mains cable that is suitable for the connection voltage must be connected to the welding machine before commissioning.
The mains cable is included in the scope of supply of the welding machine.

If welding machines are delivered without a mains cable fitted, a mains cable that is suitable for the connection voltage must be connected to the welding machine before commissioning.
The mains cable is included in the scope of supply of the welding machine.

The device can be set up and operated outdoors in accordance with protection class IP23.
Avoid direct wetting (e.g. from rain).

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

Electromagnetic compatibility (EMC) describes the unwanted reciprocal influence of electrical/electronic devices.

The EMC device classification is stated on the rating plate of the device or in the technical data.

Despite compliance with the standardised emission limit values, electrical devices can influence each other in special cases in the intended area of application.

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

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

The welding machine acts as the power supply for the cooling unit. The cooling unit is ready for operation when the mains switch of the welding machine is in the “I” position.
More information on the cooling unit can be found in the Operating Instructions for the cooling unit.

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

1

2

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

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

NFC key = NFC card or NFC key ring

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

A contactless system on the control panel allows the welding machine to be locked and unlocked.

The welding machine must be switched on before it can be locked or unlocked.

NFC key = NFC card or NFC key ring

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

A contactless system on the control panel allows the welding machine to be locked and unlocked.

The welding machine must be switched on before it can be locked or unlocked.

Locking and unlocking of the welding machine is only permitted in certified countries.

Locking the welding machine

1Hold the NFC key on the NFC key reader

The key icon in the status bar lights up.

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

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

Unlocking the welding machine

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

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

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

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

4-step mode

*) Intermediate lowering

With intermediate lowering, the welding current is lowered to the set lowering current I₂  during the main current phase.

Briefly pull back the torch trigger to start intermediate lowering to the specified reduced current I₂. Briefly pull back the torch trigger a second time, to restore the main current I₁.

Special 4-step mode: Variant 1

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

Special 4-step mode: Variant 2

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

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

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

Special 4-step mode: Variant 3

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

Special 4-step mode: Variant 4

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

Special 4-step mode: Variant 5

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

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

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

Special 4-step mode: Variant 6

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

When the spot welding operating mode is selected, the symbol for spot welding appears on the status indicator next to the welding process symbol:

CycleTIG
Enhanced stitch welding process for DC welding

CycleTig activated

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

(1)	Interval time
(2)	Interval break time
(3)	Interval cycles
(4)	Base current

The Fronius logo appears on the display.

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

xxA = actual current value depending on the specified main current

Starting current

Starting current, 2-step mode and spot welding

Starting current, 4-step mode

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

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

UpSlope

UpSlope, 2-step mode and spot welding

UpSlope, 4-step mode

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

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

Main current (I₁)

Main current, 2-step mode and spot welding

Main current, 4-step mode

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

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

Reduced current (I₂)
only in 4-step mode

Reduced current I₂ < Main current I₁

Reduced current I₂ > Main current I₁

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

I₂ < 100%
short-term, adapted reduction of the welding current
(e.g. when changing the welding wire during the welding process)

I₂ > 100%
short-term, adjusted increase in welding current
(e.g. to weld over tacked spots at higher power)

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

DownSlope

DownSlope, 2-step mode and spot welding

DownSlope, 4-step mode

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

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

Final current

Final current, 2-step mode and spot welding

Final current, 4-step mode

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

Electrode diameter

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

Polarity

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

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

Interval cycles
for setting how many cycles are to be repeated

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

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

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

Interval break time
for setting the length of time the base current is active

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

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

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

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

xxA = actual current value depending on the specified main current

Starting current

Starting current, 2-step mode and spot welding

Starting current, 4-step mode

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

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

UpSlope

UpSlope, 2-step mode and spot welding

UpSlope, 4-step mode

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

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

Main current (I₁)

Main current, 2-step mode and spot welding

Main current, 4-step mode

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

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

Reduced current (I₂)
only in 4-step mode

Reduced current I₂ < Main current I₁

Reduced current I₂ > Main current I₁

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

I₂ < 100%
short-term, adapted reduction of the welding current
(e.g. when changing the welding wire during the welding process)

I₂ > 100%
short-term, adjusted increase in welding current
(e.g. to weld over tacked spots at higher power)

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

DownSlope

DownSlope, 2-step mode and spot welding

DownSlope, 4-step mode

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

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

Final current

Final current, 2-step mode and spot welding

Final current, 4-step mode

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

Balance
only on iWave AC/DC

Balance = 15%

Balance = 35%

Balance = 50%

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

15: highest fusing power, lowest cleaning action

50: highest cleaning action, lowest fusing power

Effect of the balance on the waveshape:

Electrode diameter

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

Cap mode
only iWave AC/DC

Setting range: off / on
Factory setting: off

off
Automatic cap-shaping function is deactivated

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

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

Cap mode must be activated separately for each tungsten electrode.

Polarity

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

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

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

Procedure for HF ignition:

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

2Increase the slope of the welding torch and actuate the torch trigger according to the mode you have selected

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

3Tilt the torch back into the normal position

4Carry out welding

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

Procedure for igniting the arc using touchdown ignition:

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

2Actuate the torch trigger

shielding gas flows

3Gradually tilt the welding torch up until the tungsten electrode touches the workpiece

4Raise the welding torch and rotate it into its normal position

The arc ignites.

5Carry out welding

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

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

The welding machine has an ignition timeout function.

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

The settings for the parameter Ignition timeout are described in the “The HF menu” section from page (→) onwards.

The welding machine has an ignition timeout function.

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

The settings for the parameter Ignition timeout are described in the “The HF menu” section from page (→) onwards.

The welding current set at the start of welding is not always ideal for the welding process as a whole:

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

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

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

TIG pulsing - welding current curve

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

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

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

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

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

Mode of operation of tacking function for TIG DC welding:

Tacking function - welding current curve

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

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

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

The CycleTIG stitch welding process is available for the TIG DC welding process.
The welding result is influenced and controlled by different parameter combinations.

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

CycleTIG variations

CycleTIG + low base current

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

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

CycleTIG + tacking

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

IMPORTANT! Observe the instructions on the packaging of the rod electrode when selecting the appropriate type of current and for correctly connecting the electrode cable and grounding cable.

xxA = actual current value depending on the specified main current

Starting current

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

Starting current: starting current = main current

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

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

Main current

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

Main current: starting current = main current

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

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

Arc-force dynamic

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

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

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

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

Polarity

Polarity, set to DC-

Polarity, set to DC+

Polarity, set to AC

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

xxA = actual current value depending on the specified main current

Starting current

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

Starting current: starting current = main current

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

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

Main current

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

Main current: starting current = main current

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

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

Arc-force dynamic

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

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

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

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

Polarity

Polarity, set to DC-

Polarity, set to DC+

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

Advantages

Example with a starting current > 100% (HotStart)

(1)	Starting current time 0-2 s, factory setting 0.5 s
(2)	Starting current 0-200%, factory setting 150%
(3)	Main current = pre-set welding current I1

Mode of operation
during the specified starting current time (1), the welding current I₁ (3) is increased to the starting current (2).

The starting current time is set in the Setup menu.

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

Example with a starting current < 100% (SoftStart)

Benefits:

• Improved ignition properties for electrodes that ignite at low welding currents
• Largely prevents slag inclusions
• Reduces welding spatter
  

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

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

As the arc becomes shorter, the welding voltage may also fall so that the stick electrode is more likely to stick to the workpiece. This may also cause the stick electrode to burn out.

Electrode burn-out is prevented by activating the anti-stick function. If the stick electrode begins to stick, the welding machine immediately switches the welding current off. The welding process can be resumed without problems once the stick electrode has been detached from the workpiece.

The anti-stick function is activated and deactivated in the stick electrode menu.

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

3Turn the adjusting dial and select the desired storage location

4To save the current welding settings, press and hold the adjusting dial for about 3 seconds
The size and colour of the button changes.

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

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

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

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

3Turn the adjusting dial and select the desired storage location

4To save the current welding settings, press and hold the adjusting dial for about 3 seconds
The size and colour of the button changes.

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

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

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

The Setup menu provides easy access to the knowledge base in the welding machine and to additional functions. The Setup menu can be used to make simple adjustments to the welding parameters to suit the various job settings.

The following can be found in the Setup menu:

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

The Setup menu provides easy access to the knowledge base in the welding machine and to additional functions. The Setup menu can be used to make simple adjustments to the welding parameters to suit the various job settings.

The following can be found in the Setup menu:

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

The Setup menu provides easy access to the knowledge base in the welding machine and to additional functions. The Setup menu can be used to make simple adjustments to the welding parameters to suit the various job settings.

The following can be found in the Setup menu:

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

The Setup menu appears.

The current welding parameters will be displayed.

Selected menu

Selected parameter

Change the menu

Set the parameter

Selecting a menu

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

Setting parameters

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

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

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

0.1 - 9.9 s
The set time begins with the UpSlope phase. After the set time has elapsed, welding is continued with a constant welding current; the pulse parameters, if any, are available

off
Tacking function switched off

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

Pulse frequency

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

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

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

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

OPT/i Pulse Pro
For setting the base current, duty cycle, pulse waveform and base current waveform parameters

Base current

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

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

10 - 90%
Factory setting: 50%

Pulse waveform
To optimise the arc pressure

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

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

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

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

Optimising the arc pressure has the following effects:

Base current waveform
To optimise the arc pressure

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

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

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

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

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

off / 0.01 - 30.0 s
Factory setting: off

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

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

off / 0.01 - 30 s
Factory setting: off

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

Slope reduced current
To set the Slope1 reduced current and Slope2 reduced current parameters

Slope1 reduced current

off / 0.01 - 30 s
Factory setting: off

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

Slope2 reduced current

off / 0.01 - 30 s
Factory setting: off

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

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

Spot welding time
(spot welding mode only)

0.02 - 120 s
Factory setting: 5.0 s