• 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

• 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.

• 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!

The device is to be used exclusively for its intended purpose.

The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use.

• 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

• 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.

Devices with a high output can influence the energy quality of the grid due to their current consumption.

• 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!

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.

• 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)

• 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.)

• 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.

• Follow the basic regulations for occupational safety and accident prevention
• Read these Operating Instructions, especially the section "Safety Rules," and confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can occur in one's absence.

Local regulations and national guidelines may mean that a residual current circuit breaker is required when connecting a device to the public grid.
The residual current circuit breaker recommended for the device by the manufacturer can be found in the technical data.

• Flying sparks and pieces of hot metal
• Arc radiation that poses a risk of injury to the eyes and skin

• Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers

• Electrical risks from grid current and welding current

• Increased noise exposure

• Harmful welding fumes and gases

• Flame resistant
• Insulating and dry
• Covering the entire body and in good condition with no damage
• Safety helmet
• Cuffless pants

• 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

• 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.

The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation in relation to the maximum permitted operating point at standard loading in accordance with EN 60974-1.

A workplace-specific emission value for welding (and cutting) cannot be specified because this value depends on the welding process and the environmental conditions. It is influenced by a wide range of parameters, such as the welding process itself (MIG/MAG, TIG welding), the selected current type (direct current, alternating current), the power range, the type of weld metal, the resonance properties of the workpiece, the workplace environment, and many other factors.

The fumes produced during welding contain toxic gases and vapors.

Welding fumes contain substances that cause cancer, as stated in monograph 118 from the International Agency for Research on Cancer.

Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.

Keep your head out of the welding fumes and gases.

• 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 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.

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.

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.

• 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.

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.

• 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.

• 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.

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• 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.

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.

• Safety devices
• Grid power lines, signal lines, and data transfer lines
• IT and telecommunications equipment
• Devices for measuring and calibrating

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).

1. Welding power-leads
   • Keep them as short as possible
   • Route them close together (also to avoid EMF problems)
   • Route them far from other lines

1. Equipotential bonding

1. Workpiece grounding
   • If necessary, establish grounding using suitable capacitors.

1. Shield, if necessary
   • Shield other devices in the vicinity
   • Shield the entire welding installation

• 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

• 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.

• 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.

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.

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding gas cylinders are an integral part of the welding equipment, so they must be handled very carefully.

Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.

Mount the shielding gas cylinders vertically and secure them in accordance with instructions so they cannot fall over.

Keep shielding gas cylinders away from welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion: Never weld on a compressed shielding gas cylinder.

Always use suitable shielding gas cylinders for the application in question and the correct matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders and accessories that are in good condition.

If a valve on a shielding gas cylinder is open, turn your face away from the outlet.

When no welding is taking place, close the valve of the shielding gas cylinder.

Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.

Follow the manufacturer's instructions and applicable national and international provisions for shielding gas cylinders and accessories.

Risk of asphyxiation due to uncontrolled shielding gas leak

Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.

• Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour.
• Please observe the safety and maintenance information for the shielding gas cylinder or the main gas supply.
• When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
• Always check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before each start-up.

• The maximum permitted tilt angle is 10°.

• 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.

• 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.

• 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.

It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

• Use only original spare and wearing parts (also applies to standard parts).
• Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
• Components that are not in perfect condition must be replaced immediately.
• When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.

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.

• 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.

To comply with European directives and national law, waste electrical and electronic equipment must be collected separately and sent for environmentally-friendly recycling. Used devices must be returned to a distributor or an approved collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.

Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the volume of cardboard.

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.

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 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.

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.

• 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.

• 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.

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.

• a precise welding process
• exact reproducibility of all results
• excellent weld properties.

The devices are used in commercial and industrial applications for manual and automated TIG and MIG/MAG welding of unalloyed and low-alloyed steel, high-alloyed chrome/nickel steel, aluminum, aluminum alloys, and magnesium. The power sources are designed for:

• Automotive and supply industry,
• Mechanical engineering and rail vehicle manufacturing,
• Chemical plant construction,
• Machine construction,
• Shipyards,
• etc.

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:

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:

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 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

The word mark Bluetooth^® and the Bluetooth^® logos are registered trademarks and property of Bluetooth SIG, Inc. and are used by the manufacturer under license. Other trademarks and trade names are the property of their respective owners.

Warning notices and safety symbols can be found on power sources with the CSA test mark for use in the North American region (USA and Canada). These warning notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and property damage.

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

WP TIG DynamicWire
The Welding Package enables the TIG DynamicWire process.

OPT/i TIG gas regulator

OPT/i TIG 4 Switch SpeedNet
Option if more than one additional SpeedNet connection is required.

OPT/i TIG Gas flow rate sensor

OPT/i TIG external sensor

OPT/i TIG PowerConnector
2. Current socket on the rear of the power source

OPT/i TIG Gas changeover

OPT/i TIG 2nd SpeedNet
Second SpeedNet connection

OPT/i TIG DC MultiProzess PRO

OPT/i TIG AC MultiProzess PRO

OPT/i TIG 2nd NT242
When using a CU 1400 cooling unit, the OPT/i TIG 2nd NT242 option must be installed in the power sources.

OPT/i TIG NT601

OPT/i TPS dust filter

IMPORTANT! The use of the OPT/i TPS dust filter option on iWave power sources will reduce the duty cycle!

OPT/i CycleTIG
Advanced TIG stitch welding

OPT/i Synergic Lines *
Option to enable all available special characteristics of TPSi power sources;
any special characteristics created in the future are thus automatically enabled.

OPT/i GUN Trigger *
Option for special functions in connection with the torch trigger

OPT/i Jobs
Option for Job Mode

OPT/i Documentation
Option for the documentation function

OPT/i Puls Pro

OPT/i Interface Designer *
Option for individual interface configuration

OPT/i WebJobEdit
Option to edit jobs via the SmartManager of the power source

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

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

OPT/i CMT Cycle Step *
Option for adjustable, cyclic CMT welding process

OPT/i OPC-UA
Standardized data interface protocol

OPT/i MQTT
Standardized data interface protocol

OPT/i SpeedNet Repeater
Signal amplifier if interconnecting hosepacks or connections from power source to wirefeeder exceed 50 m

KRIS 13 Gouging Machine
Electrode holder with compressed air connection for arc air gouging

OPT/i Wire Sense *
Seam tracking / edge detection using wire electrode for automated applications
only in conjunction with CMT hardware

OPT/i Synchropulse 10 Hz *
To increase the SynchroPulse frequency from 3 Hz to 10 Hz

IMPORTANT! The OPT/i Safety Stop PL d safety function was developed as Category 3 according to EN ISO 13849-1:2008 + AC:2009.
A two-channel feed-in of the input signal is required for this.
Bridging the two-channel capability (e.g. by means of a short-circuit bracket) is not permitted and results in the loss of the PL d.

Function overview

The OPT/i Safety Stop PL d option ensures a safety stop of the PL d power source with a controlled end of welding in less than a second.
Each time the power source is switched on, the Safety Stop PL d safety function performs a self-test.

IMPORTANT! This self-test must be performed at least once a year to check the function of the safety shutdown.

If the voltage drops at least one of two inputs, the Safety Stop PL d stops the current welding operation; the wirefeeder motor and the welding voltage is switched off.
The power source outputs an error code. Communication via the robot interface or bus system continues.
In order to restart the welding system, the voltage must be applied again. An error must be acknowledged via the torch trigger, display or interface and the start of welding must be executed again.

A non-simultaneous shutdown of the two inputs (> 750 ms) is output by the system as a critical, non-acknowledgeable error.
The power source remains permanently switched off.
A reset is performed by switching the power source off/on.

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 counterclockwise highlights the item above.

Changing values:

• Turning the dial clockwise increases the value to be set.
• Turning the dial counterclockwise decreases the value to be set.
• Turning the selection dial slowly will also change the value to be set slowly, e.g., for fine adjustments.
• Turning the selection dial quickly disproportionately changes the value to be set, which means that large changes in value can be entered quickly.

For some parameters, a value that has been changed by turning the selection dial is automatically applied without having to press the selection dial.

Press the selection dial

• Apply selected elements, e.g., to change the value of a welding parameter.
• Apply values of specific parameters.

1

The display is shown in full screen mode:

2Exit full screen mode:

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.

• Following all the instructions in these Operating Instructions
• Carrying out all the specified inspection and maintenance work

• 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.

The ventilation channel is a very important safety device. When selecting the setup location, ensure that the cooling air can enter or exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g., from grinding work) must not be allowed to be sucked directly into the system.

• The devices are designed for the mains voltage specified on the rating plate.
• Devices with a nominal voltage of 3 x 575 V must be operated on three-phase systems with earthed star point.
• If your version of the appliance does not come with mains cables and mains plugs ready-fitted, these must be fitted by a qualified person in accordance with national standards.
• The fuse protection for the mains lead is indicated in the technical data.

The power source is generator-compatible.

The maximum apparent power S_1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S_1max of the power source is calculated for 3-phase devices as follows:

S_1max = I_1max x U₁ x √3

I_1max and U₁ according to the device rating plate and technical data

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 can be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must not be less than the maximum apparent power S_1max of the power source!

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.

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.

Europe:

USA & Canada:

1

2

3

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

6

Push the mains cable toward the open side in order to access the strain-relief device clamping screw.

7

8

9

10

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.

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.

Lock the power source

The key symbol appears briefly on the display.

The key symbol is then displayed in the status bar.

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

If the operator attempts to access a locked function, a corresponding message is displayed.

Unlock the power source

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.

• 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.

• iWave AC/DC power source
• Return lead cable
• TIG welding torch
• Shielding gas supply with gas pressure regulator
• Filler metal depending on application

• iWave AC/DC power source
• Return lead cable
• TIG welding torch
• Shielding gas supply with gas pressure regulator
• Filler metal depending on application

• Power source
• Return lead cable
• TIG welding torch
• Shielding gas supply with gas pressure regulator
• Filler metal depending on application

With TIG DynamicWire, the voltage between the workpiece and the welding wire is measured, allowing the wirefeeder to be actively controlled.
The wire speed automatically adapts to the amperage, arc length, weld seam profile, or to the air gap to be bridged.

TIG DynamicWire works in Synergic operation. Current and wire speed do not have to be set separately.
The wire speed can be optimized via the "TIG wire correction" process parameter.

The Welding Package TIG DynamicWire provides characteristics for the most common filler metals.

With TIG DynamicWire, the voltage between the workpiece and the welding wire is measured, allowing the wirefeeder to be actively controlled.
The wire speed automatically adapts to the amperage, arc length, weld seam profile, or to the air gap to be bridged.

TIG DynamicWire works in Synergic operation. Current and wire speed do not have to be set separately.
The wire speed can be optimized via the "TIG wire correction" process parameter.

The Welding Package TIG DynamicWire provides characteristics for the most common filler metals.

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.

iWave DC power sources

iWave AC/DC power sources

For a TIG cold wire feeder

Follow the guidelines referring to setting, setting range, and units of measurement for the available parameters in the "Setup Menu" section.

Follow the guidelines referring to setting, setting range, and units of measurement for the available parameters in the "Setup Menu" section.

• Welding: Pull back the torch trigger and hold it in this position
• End of welding: Release the torch trigger

2-step mode

• Start of welding with starting current I_S: Pull back the torch trigger and hold it in this position
• Welding with main current I₁: Release the torch trigger
• Lowering to final current I_E: Pull back the torch trigger and hold it in this position
• End of welding: Release the torch trigger

4-step mode

*) Intermediate lowering

With intermediate lowering, the welding current is lowered to the set lowering current I-2  during the main current phase.

• To activate intermediate lowering, push the torch trigger forward and hold it in this position
• Release the torch trigger to resume the main current

Intermediate lowering to the set lowering current I₂ is effected by briefly pulling back the torch trigger. Briefly pull back the torch trigger again to return to the main current I₁.

Special 4-step mode: Version 1

Version 1 of special 4-step mode is activated by the following parameter setting:

• Starting current time = off
• Final current time = off

• Lowering current slope 1 = off
• Lowering current slope 2 = off

• I2 via torch trigger = on
• Lowering current button function = I2

• 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.

Special 4-step mode: Version 2

Version 2 of special 4-step mode is activated by the following parameter setting:

• Starting current time = off
• Final current time = off

• Lowering current slope 1 = on
• Lowering current slope 2 = on

• I2 via torch trigger = off
• Lowering current button function = I2

Intermediate lowering of the welding current in version 3 is triggered by pushing the torch trigger forward and holding it in this position. Following the release of the torch trigger, the main current I₁ is once again available.

Pull back the torch trigger to immediately end welding without a downslope and final current.

Special 4-step mode: Version 3

Version 3 of special 4-step mode is activated using the following parameter setting:

• Starting current time = off
• Final current time = 0.01 s

• Lowering current slope 1 = off
• Lowering current slope 2 = off

• I2 via torch trigger = off
• Lowering current button function = I2

• Start of welding and welding: Briefly pull back the torch trigger and release - the welding current rises from the starting current I_S 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

Special 4-step mode: Version 4

Version 4 of special 4-step mode is activated using the following parameter setting:

• Starting current time = on
• Final current time = on

• Lowering current slope 1 = off
• Lowering current slope 2 = off

• I2 via torch trigger = off
• Lowering current button function = I2

• The longer the torch trigger is pressed forward during welding, the further the welding current increases (up to the maximum).
• After releasing the torch trigger, the welding current remains constant.
• The longer the torch trigger is pressed forward again, the further the welding current is reduced.

Special 4-step mode: Version 5

Version 5 of special 4-step mode is activated using the following parameter setting:

• Starting current time = off
• Final current time = off

• Lowering current slope 1 = off
• Lowering current slope 2 = off

• I2 via torch trigger = off or on
• Lowering current button function = I1

• Start of welding with starting current_IS 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.

Special 4-step mode: Version 6

Version 6 of special 4-step mode is activated by the following parameter setting:

• Starting current time = off
• Final current time = on

• Lowering current slope 1 = off
• Lowering current slope 2 = off

• I2 via torch trigger = on
• Lowering current button function = I2

• 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

An overview of available welding processes is displayed.

An overview of operating modes is displayed.

The TIG welding parameters are displayed.

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

11Turn the selection dial: change the value of the parameter

12If necessary, set the process parameters for user- or application-specific settings on the welding system

13Open the gas cylinder valve

14Press 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.

Start current (AC / DC-)

Start current: 2-step mode | 4-step mode

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

IMPORTANT! The start current is stored separately for TIG AC welding and TIG DC- welding.

Up-Slope (AC / DC-)

Up-Slope: 2-step mode and spot welding | 4-step mode

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

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

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.

Drop current I₂ (AC / DC-)
only in 4-step mode

Drop current I₂ < Main current I₁ | Drop current I₂ > Main current I₁

Setting range: 0 - 250 % (of the main current I₁)
Factory setting: 50 %

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

I₂ > 100%
Brief, adapted increase in the welding current
(e.g., for welding over tacking points with a higher power level)

The values for Slope1 and Slope2 can be set in the process parameters.

Down-Slope (AC / DC-)

Down-Slope: 2-step mode and spot welding | 4-step mode

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

IMPORTANT! The stored Down-Slope value applies to the 2-step and 4-step modes.

End current (AC / DC-)

End current: 2-step mode and spot welding | 4-step mode

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

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:

Electrode diameter (AC / DC-)

Setting range: off; 1.0 - 6.4 mm
Factory setting: 2.4 mm

Cap shaping (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) ... before ignition
(2) ... after ignition

Cap shaping must be activated separately for each tungsten electrode.

Polarity (AC)
only with iWave AC/DC

Polarity

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

• The diameter of the tungsten electrode
• The current temperature of the tungsten electrode, taking into account the previous welding time and break

• The diameter of the tungsten electrode
• The current temperature of the tungsten electrode, taking into account the previous welding time and break

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:

1Position 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.

2Increase 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.

3Tilt the welding torch to the normal position

4Carry out welding

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:

1Position 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

2Press 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

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.

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.

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 (→).

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 (→).

The welding current set at the start of welding may not always be ideal for the entire welding process:

• If the amperage is too low, the parent material will not be sufficiently melted,
• If overheating occurs, there is a danger that the liquid weld pool may drip.

The TIG pulsing function is able to help with this (TIG welding with a pulsing welding current):
A low base current (2) rises steeply to a significantly higher pulse current and falls again in line with the set duty cycle (5) to the base current (2).
During TIG pulsing, small sections of the welding area are quickly melted and then allowed to quickly solidify again.
During manual applications, the welding wire is applied in the maximum current phase during TIG pulsing (only possible in the low-frequency range from 0.25 - 5 Hz). Higher pulse frequencies are mostly used in automated applications and mainly serve to stabilize the arc.

TIG pulsing is used to weld steel pipes when welding out-of-position or to weld thin sheet metal.

TIG pulsing in operation with TIG DC welding selected:

TIG pulsing - welding current curve

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

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

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

Whenever a period of time is set for the "Tacking" (4) parameter under process parameters/TIG DC settings, the tacking function is assigned to the 2-step and 4-step modes. The sequence of operating modes remains unchanged.
The Tacking (TAC) indicator lights up on the status bar:

During this time, a pulsed welding current is available, which optimizes the merging of the weld pool when tacking two components.

How the tacking function works during TIG DC welding:

Tacking function - welding current curve

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

• 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.

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

TIG process parameters:
TIG pulse, AC, General, Ignition & trigger mode, CycleTIG, Wirefeeder setup, Gas, R/L-check / alignment

Process parameters for Components and Monitoring see page (→).

TIG process parameters:
TIG pulse, AC, General, Ignition & trigger mode, CycleTIG, Wirefeeder setup, Gas, R/L-check / alignment

Process parameters for Components and Monitoring see page (→).

Tacking
Tacking function - duration of the pulsed welding current at the start of the tacking process

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

off
Tacking function is switched off

0.1 - 9.9 s
The selected time begins with the UpSlope phase. After the selected time has passed, further welding is carried out at a constant welding current. The set pulse parameters are available if applicable.

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

The Tacking (TAC) indicator lights up in the status bar on the if a value has been set.

Pulse frequency

off / 0.20 - 2000 Hz (10,000 Hz with OPT/I-Puls Pro option)
Factory setting: off

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

The selected pulse frequency is also used for the lowering current.

The Pulsing indicator lights up in the status bar if a value for the pulse frequency has been entered.

Base current *

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

Duty cycle *
Relationship between pulse duration and base current duration at the set pulse frequency

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;
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

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:

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

Effect of AC current offset on current flow:

* Factory setting: 0 (corresponds to a 10% shift to negative)

Positive half-wave waveform

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

Hard rectangle
Purely rectangular curve (stable but loud arc)

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

Welding start / welding end settings

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

The setting of the Starting current time parameter also influences versions 1 - 6 of special 4-step mode (see page (→) 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 (→) onwards).

off / 0.01 - 30 s
Factory setting: off

IMPORTANT! The final current time is only valid for 2-step mode and spot welding. In 4-step mode, the duration of the final current phase is determined by the torch trigger (section "TIG operating modes").

4-mode settings

Lowering current Slope 1

The setting of the Lowering current slope 1 parameter also influences versions 1 - 6 of special 4-step mode (see page (→) 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 (→) 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

Spot welding time
(only if the mode is set to spot welding)

0.02 - 120 s
Factory setting: 5.0 s

Ignition parameters

HF ignition

on/off/Touch-HF/external
Factory setting: on

on
High-frequency ignition at the start of welding is activated

off
No high-frequency ignition at the start of welding.
In this case, welding is started by means of contact ignition.

Touch-HF
The welding process is initiated by briefly touching the workpiece with the tungsten electrode. The high-frequency ignition is performed after the set HF ignition delay time has elapsed.

External
Start with an external ignition device, e.g., plasma welding

The HF ignition indicator lights up in the status bar if HF ignition has been set to on.

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 the tungsten electrode. This results in rapid heating of the tungsten electrode - an essential prerequisite for optimum ignition properties.

off/on/auto
Factory setting: off

 Reversed polarity ignition is recommended for welding light-gauge sheets.

Arc monitoring

Ignition timeout
Period of time until the safety cut-out following failed ignition.

0.1 - 9.9 s
Factory setting: 5 s

IMPORTANT! Ignition timeout is a safety function and cannot be deactivated.
The ignition timeout function is described in the "TIG welding" section.

Arc break filter time
Period of time until the safety cut-out following an arc break

If no current flows during the set period of time following an arc break, the power source automatically switches off.
Press any button on the control panel or the torch trigger to restart the welding process.

0.00 - 2.00 s
Factory setting: 0.20 s

Arc break watchdog
Reaction if no current flows within the arc break time

ignore/error
Factory setting: ignore

ignore
The interruption is ignored.

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

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 drop 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 (→) onwards).

on / off
Factory setting: off

Drop current button function

The setting of the drop current button function parameter also influences versions 1 - 6 of special 4-step mode (see page (→) 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 foot-operated 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:

CycleTIG
to activate / deactivate the CycleTIG function
(extended interval welding process for DC welding)

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

(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

Wire speed correction
For fine adjustment of the wire speed with TIG DynamicWire

The correction value indicates how quickly the welding wire re-enters the weld pool after the short circuit is broken.

-10 - +10
Factory setting: 0

-10 = slow immersion, +10 =fast immersion

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

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

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!

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

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

In addition to the iWave power source, the following components are required for MMA and CEL welding:

• Return lead cable
• Electrode holder with welding power-lead
• Stick or cellulose electrodes

In addition to the iWave power source, the following components are required for MMA and CEL welding:

• Return lead cable
• Electrode holder with welding power-lead
• Stick or cellulose electrodes

In addition to the iWave power source, the following components are required for MMA and CEL welding:

• Return lead cable
• Electrode holder with welding power-lead
• Stick or cellulose electrodes

In addition to the iWave power source, the following components are required for arc air gouging:

• OPT/i TIG PowerConnector option installed on the power source
• Return lead cable 120i PC
• PowerConnector - Dinse adapter
• KRIS 13 arc air gouging torch
• Compressed air supply

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.

The welding voltage is applied to the welding socket with a three second delay.

If the MMA or CEL welding process is selected, a cooling unit, if present, is automatically deactivated. It is not possible to turn it on.

The MMA welding parameters are displayed.

Hot start current

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

Main current

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:-

Dynamic

To obtain the best possible welding results, the arc-force dynamic will sometimes need to be adjusted.

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

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

Functional principle:
At the moment of droplet transfer or in event of a short circuit, a short-term increase in the amperage will occur. To maintain a stable arc, the welding current temporarily rises. If the stick electrode is at risk of sinking into the weld pool, this action prevents the weld pool from solidifying, as well as reducing the duration of the arc's short circuit. The risk of the stick electrode sticking is therefore largely ruled out.

Polarity

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

Advantages

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of parent material in the start phase, therefore less neutralization
• Slag inclusions largely avoided

Example of 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 = set welding current I1

Operation
During the set starting current time (1), the welding current I₁ (3) rises to the starting current (2).

The starting current time is set in the Setup menu.

Advantages

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of parent material in the start phase, therefore less neutralization
• Slag inclusions largely avoided

Example of 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 = set welding current I1

Operation
During the set starting current time (1), the welding current I₁ (3) rises to the starting current (2).

The starting current time is set in the Setup menu.

A starting current of < 100% (SoftStart) is suitable for basic electrodes. Ignition is carried out with a low welding current. As soon as the arc is stable, the welding current increases until it reaches the set welding current command value.

Example of a starting current < 100% (SoftStart)

Advantages:

• Improvement of ignition properties with electrodes that ignite at a low welding current
• Slag inclusions largely avoided
• Reduction of welding spatter
  

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

The starting current time is set in the MMA 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 power source 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 under:
Process parameters / Common TIG/MMA/CEL / Electrode.

Stick electrode / CEL Process parameters:
Electrode, CEL

Process parameters for Components and Monitoring see page (→).

Stick electrode / CEL Process parameters:
Electrode, CEL

Process parameters for Components and Monitoring see page (→).

Starting current time
HotStart

0.0 - 2.0 s
Factory setting: 0.5 s

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of parent material in the start phase, therefore less neutralization
• Slag inclusions largely avoided

Characteristic
For selecting the electrode characteristic

I-constant / 0.1 - 20.0 A/V / P-constant / Arc air gouging (iWave 500 DC and AC/DC only)
Factory setting: I-constant

(1)	Working line for stick electrode
(2)	Working line for stick electrode with increased arc length
(3)	Working line for stick electrode with reduced arc length
(4)	Characteristic for selected parameter "I-constant" (constant welding current)
(5)	Characteristic for selected parameter "0.1 -20" (drooping characteristic with adjustable gradient)
(6)	Characteristic for selected parameter "P-constant" (constant welding power)

I-constant (constant welding current)

• If the "I-constant" parameter is set, the welding current is kept constant regardless of the welding voltage. The result is a vertical characteristic (4).
• The "I-constant" parameter is particularly suitable for rutile electrodes and basic electrodes.

0.1 - 20.0 A/V (drooping characteristic with adjustable slope)

• A drooping characteristic (5) can be set using parameter "0.1 - 20". The setting range is from 0.1 A/V (very steep) to 20 A/V (very flat).
• Setting a flat characteristic (5) is only recommended for cellulose electrodes.

P-constant (constant welding power)

• If the "P-constant" parameter is set, the welding power is kept constant regardless of the welding voltage and current. The result is a hyperbolic characteristic (6).
• The "P-constant" parameter is particularly suitable for cellulose electrodes.

• Special characteristic for arc air gouging with a carbon electrode
  (for iWave 500 DC and iWave 500 AC/DC only)

(1)	Working line for stick electrode
(2)	Working line for stick electrode with increased arc length
(3)	Working line for stick electrode with reduced arc length
(4)	Characteristic for selected parameter "I-constant" (constant welding current)
(5)	Characteristic for selected parameter "0.1 -20" (drooping characteristic with adjustable gradient)
(6)	Characteristic for selected parameter "P-constant" (constant welding power)

The characteristics (4), (5) and (6) shown apply when using a stick electrode whose characteristic at a certain arc length corresponds to the working line (1).

Depending on the set welding current (I), the intersection (operating point) of the characteristics (4), (5) and (6) is shifted along the working line (1). The operating point provides information about the current welding voltage and current welding current.

With a fixed welding current (I_H), the operating point can travel along the characteristics (4), (5) and (6) depending on the current welding voltage. The welding voltage U depends on the arc length.

If the arc length changes, e.g., according to the working line (2), the operating point is the point where the corresponding characteristic (4), (5) or (6) intersect the working line (2).

Applies to characteristics (5) and (6): Depending on the welding voltage (arc length), the welding current (I) is also lower or higher, with a constant value for I_H.

Anti-stick

on/off
Factory setting: on

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 power source immediately switches the welding current off. The welding process can be resumed without problems once the stick electrode has been detached from the workpiece.

Break voltage
Limitation of the welding voltage

20 - 90 V
Factory setting: 20 V

In principle, the arc length depends on the welding voltage. To end the welding process, a significant lifting of the stick electrode is usually required. The parameter allows the welding voltage to be limited to a value, which permits the welding process to be ended by only slightly lifting the stick electrode.

AC frequency
Only for AC manual metal arc welding ("Polarity" welding parameter = AC)

40 - 250 Hz
Factory setting: 60 Hz

Starting current time
HotStart

0.0 - 2.0 s
Factory setting: 0.5 s

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of parent material in the start phase, therefore less neutralization
• Slag inclusions largely avoided

Anti-stick

on/off
Factory setting: on

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

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

Break voltage
Limitation of the welding voltage

20 - 90 V
Factory setting: 20 V

In principle, the arc length depends on the welding voltage. To end the welding process, a significant lifting of the rod electrode is usually required. The parameter allows the welding voltage to be limited to a value, which permits the welding process to be ended by only slightly lifting the rod electrode.

In arc air gouging, an arc is ignited between a carbon electrode and the workpiece; the parent material is melted and blown out with compressed air.
The operating parameters for arc air gouging are defined in a special characteristic.

Applications:

• Removal of shrink holes, pores, or slag inclusions from workpieces
• Detaching sprues or the processing of entire workpiece surfaces in foundries
• Edge preparation for heavy plates
• Preparation and repair of weld seams
• Finishing of roots or defects
• Production of air gaps

In arc air gouging, an arc is ignited between a carbon electrode and the workpiece; the parent material is melted and blown out with compressed air.
The operating parameters for arc air gouging are defined in a special characteristic.

Applications:

• Removal of shrink holes, pores, or slag inclusions from workpieces
• Detaching sprues or the processing of entire workpiece surfaces in foundries
• Edge preparation for heavy plates
• Preparation and repair of weld seams
• Finishing of roots or defects
• Production of air gaps

IMPORTANT! A grounding cable with a PowerConnector and a cable cross-section of 120 mm² is required for arc air gouging. For other grounding cables, the OPT/i TPS 2. Positive option must be installed at the power source.
Furthermore, a Dinse PowerConnector adapter is required for the connection of the gouger.

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

The arc air gouging parameters are displayed.

The contact angle of the carbon electrode and gouging speed determine the depth of a groove.

The parameters for arc air gouging correspond to the welding parameters for MMA welding, see page (→).

If the OPT/i TIG MultiProzess PRO option is installed on the power source, MIG/MAG welding processes are available without restriction in addition to TIG and MMA welding processes.

Switching between the individual welding processes takes place either:

• Using jobs
• On the control panel of the power source
• Using the torch trigger.

If the OPT/i TIG MultiProzess PRO option is installed on the power source, MIG/MAG welding processes are available without restriction in addition to TIG and MMA welding processes.

Switching between the individual welding processes takes place either:

• Using jobs
• On the control panel of the power source
• Using the torch trigger.

If the OPT/i TIG MultiProzess PRO option is installed on the power source, MIG/MAG welding processes are available without restriction in addition to TIG and MMA welding processes.

Switching between the individual welding processes takes place either:

• Using jobs
• On the control panel of the power source
• Using the torch trigger.

A MultiProzess-PRO-compatible power source can be operated with all iWave system components and, for the MIG/MAG welding process, with all TPSi system components.

Example:

iWave 500i AC/DC
+ OPT/i TIG AC MultiProzess PRO
+ CU 1400i Pro/MC cooling unit
+ I-set front water connection
+ Dual head distributor
+ WF 25i MIG/MAG wirefeeder
+ MHPi MIG/MAG welding torch
+ MHP CON interconnecting hosepack
+ CWF 25i TIG cold wire feeder
+ SpeedNet control cable
+ TIGi cold-wire feed
+ TTB / THP TIG welding torch
+ Electrode holder with welding power-lead
+ Return lead cable
+ TU Car4 Pro trolley
+ OPT/TU extension cylinder holder TU Car4 Pro

A MultiProzess-PRO welding system requires only one return lead cable.
With iWave AC power sources, the polarity is reversed automatically when the welding process is changed.

IMPORTANT! For iWave DC power sources, the return lead cable must be reconnected manually when changing processes.

In addition to the iWave power source, the following components are required for MIG/MAG welding:

• OPT/i TIG MultiProzess PRO
• MIG/MAG wirefeeder
• MHP CON MIG/MAG interconnecting hosepack
• MTG MIG/MAG welding torch
• Wire electrode
• MIG/MAG shielding gas supply
• Return lead cable

Additionally required for CMT applications:

• Standard, Pulse, and CMT Welding Packages enabled on the power source
• CMT welding torch incl. CMT drive unit
• CMT wire buffer
• OPT/i PushPull installed in the MIG/MAG wirefeeder
• CMT interconnecting hosepack

Additionally required for water-cooled applications:

• Cooling unit with double coolant connections

The TIG components can remain connected to the power source during MIG/MAG welding.

In addition to the iWave power source, the following components are required for MIG/MAG welding:

• OPT/i TIG MultiProzess PRO
• MIG/MAG wirefeeder
• MHP CON MIG/MAG interconnecting hosepack
• MTG MIG/MAG welding torch
• Wire electrode
• MIG/MAG shielding gas supply
• Return lead cable

Additionally required for CMT applications:

• Standard, Pulse, and CMT Welding Packages enabled on the power source
• CMT welding torch incl. CMT drive unit
• CMT wire buffer
• OPT/i PushPull installed in the MIG/MAG wirefeeder
• CMT interconnecting hosepack

Additionally required for water-cooled applications:

• Cooling unit with double coolant connections

The TIG components can remain connected to the power source during MIG/MAG welding.

MIG/MAG pulse 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.

MIG/MAG pulse 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.

MIG/MAG standard synergic welding is a MIG/MAG welding process covering the entire power range of the power source with the following arc types:

Dip transfer arc
Droplet transfer occurs in the lower power range during the short circuit.

Intermediate arc
The droplet increases in size at 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.

PMC = Pulse Multi Control

PMC is a pulsed arc welding process with fast data processing, precise process condition detection, and improved droplet detachment. Faster welding with a stable arc and uniform penetration is possible.

LSC = Low Spatter Control

LSC is a low-spatter dip transfer arc process. Before the short-circuit bridge is broken, the current is lowered and reignition occurs at significantly lower welding current values.

SynchroPulse is available for all process (Standard / Pulse / LSC / PMC).
The cyclic change of the welding power between two operating points with SynchroPulse achieves a finely rippled weld appearance and a non-continuous heat input.

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 droplet detachment with improved dip transfer arc properties.
The advantages of the CMT process are:

• Low heat input
• Reduced spattering
• Emissions reduction
• High process stability

The CMT process is suitable for:

• Joint welding, overlay welding, and brazing, specifically with high demands in terms of heat input and process stability
• Light gauge sheet welding with low distortion
• Special joints, e.g., copper, zinc, steel/aluminum

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.

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.

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.

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)
  

IMPORTANT! On a power source without any Welding Packages, only MIG/MAG standard manual welding is available.

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

additive
CMT
Characteristics with reduced heat input and more stability with higher deposition rate for bead to bead welding on adaptive structures

ADV ***
CMT

Also required:
Inverter module for an alternating current process

Negatively poled process phase with less heat input and higher deposition rate

ADV ***
LSC

Also required:
Electronic switch for current interruption

Maximum current reduction by opening the circuit in any desired process phase

only in connection 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 overlay welding with low penetration, low dilution, and wide weld seam flow for improved wetting

dynamic
CMT, PMC, Puls, 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 covered but not melted down.

galvanized
CMT, LSC, PMC, Puls, Standard
Characteristics for galvanized sheet surfaces (low zinc pore risk, reduced zinc melting loss)

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

Also required:
Welding Packages Pulse and PMC

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.

LH
Characteristics for LaserHybrid applications (laser + MIG/MAG process)

marking
Characteristics for marking conductive surfaces

Marking is performed by spark erosion without significant power, triggered by a reversing wire electrode.

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 components being welded by multiple interacting arcs

open root
Characteristics for root welding with air gap and optimized root penetration without hollow beads.

PCS **
PMC
Pulse Controlled Sprayarc - Direct transition from concentrated pulsed arc to short spray arc. PCS combines the advantages of pulsed and standard arcs in one characteristic.

pin
Characteristics for welding pins to a surface
A withdrawal movement of the wire electrode in conjunction with the current path define the appearance of the pin.

pipe
PMC
Characteristics for pipe applications and positional welding on narrow gap applications

retro
CMT, Puls, PMC, Standard
Characteristics with the properties of the predecessor device series TransPuls Synergic (TPS)

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 powerful arc

seam track
PMC, Pulse
Characteristics with a more powerful seam tracking signal, especially when using multiple welding torches on one component.

TIME
PMC
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 shared weld pool (tandem welding process)

universal
CMT, PMC, Puls, Standard
Characteristics for conventional welding tasks

weld+
CMT
Characteristics for welding with short stick out and the Braze+ gas nozzle (gas nozzle with small orifice and high flow rate)

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

additive
CMT
Characteristics with reduced heat input and more stability with higher deposition rate for bead to bead welding on adaptive structures

ADV ***
CMT

Also required:
Inverter module for an alternating current process

Negatively poled process phase with less heat input and higher deposition rate

ADV ***
LSC

Also required:
Electronic switch for current interruption

Maximum current reduction by opening the circuit in any desired process phase

only in connection 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 overlay welding with low penetration, low dilution, and wide weld seam flow for improved wetting

dynamic
CMT, PMC, Puls, 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 covered but not melted down.

galvanized
CMT, LSC, PMC, Puls, Standard
Characteristics for galvanized sheet surfaces (low zinc pore risk, reduced zinc melting loss)

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

Also required:
Welding Packages Pulse and PMC

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.

LH
Characteristics for LaserHybrid applications (laser + MIG/MAG process)

marking
Characteristics for marking conductive surfaces

Marking is performed by spark erosion without significant power, triggered by a reversing wire electrode.

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 components being welded by multiple interacting arcs

open root
Characteristics for root welding with air gap and optimized root penetration without hollow beads.

PCS **
PMC
Pulse Controlled Sprayarc - Direct transition from concentrated pulsed arc to short spray arc. PCS combines the advantages of pulsed and standard arcs in one characteristic.

pin
Characteristics for welding pins to a surface
A withdrawal movement of the wire electrode in conjunction with the current path define the appearance of the pin.

pipe
PMC
Characteristics for pipe applications and positional welding on narrow gap applications

retro
CMT, Puls, PMC, Standard
Characteristics with the properties of the predecessor device series TransPuls Synergic (TPS)

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 powerful arc

seam track
PMC, Pulse
Characteristics with a more powerful seam tracking signal, especially when using multiple welding torches on one component.

TIME
PMC
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 shared weld pool (tandem welding process)

universal
CMT, PMC, Puls, Standard
Characteristics for conventional welding tasks

weld+
CMT
Characteristics for welding with short stick out and the Braze+ gas nozzle (gas nozzle with small orifice and high flow rate)

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

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

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

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

End arc length correction

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"

• Tacking work
• Short weld seams
• Automatic and robot operation

"4-step mode" is suitable for longer weld seams.

"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" 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.

The "Spot welding" mode is suitable for welded joints on overlapped sheets.

Correct routing of the interconnecting hosepack

IMPORTANT!

• The duty cycle values (D.C.) of the interconnecting hosepack can only be achieved if the hosepack is correctly routed.
• If the routing of a interconnecting hosepack changes, carry out an R/L alignment (see page (→))!
• Magnetically compensated interconnecting hosepacks enable routing changes to be made without changing the welding circuit inductance.
  Magnetically compensated interconnecting hosepacks are available from Fronius in lengths of 10 m and above.

The power source is built for TIG welding:

• Cooling unit, power source, and trolley options are assembled on the trolley.
• The TIG welding torch is connected to the power source and to the front of the cooling unit.
• The return lead cable is connected to the power source.
• The TIG shielding gas supply is connected to the power source.

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.

An overview of operating modes is displayed:

• 2-step mode
• 4-step mode
• Special 2-step mode
• Special 4-step mode
• Spot welding

The confirmation step of the filler metal wizard is displayed:

The selected filler metal and associated characteristics for each process are saved.

The value of the parameter is displayed as a horizontal scale:

e.g., wire feed speed parameter

The selected parameter can now be changed.

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.

1Select the currently selected welding process line in the status bar

2Set welding parameters and process parameters for both welding process lines

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.

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

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

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

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.

* 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 welding button is on the next page.

Procedure for creating a welding spot:

* 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 welding button is on the next page.

Procedure for creating a welding spot:

MIG/MAG process parameters:
Weld start / Weld end, Gas setup, Process control, SynchroPulse, Process mix, CMT Cycle Step, Spot welding, R/L-check / alignment

Process parameters for components and monitoring see page (→).

MIG/MAG process parameters:
Weld start / Weld end, Gas setup, Process control, SynchroPulse, Process mix, CMT Cycle Step, Spot welding, R/L-check / alignment

Process parameters for components and monitoring see page (→).

The following process parameters can be set and displayed for the start and end of welding:

Starting current 
To set the starting current for MIG/MAG welding (e.g., start of welding for aluminum)

0 - 200 % (of the welding current)
Factory setting: 135 %

Start arc length correction
For correcting arc length at weld start

-10.0 - +10.0% (of the welding voltage)
Factory setting: 0.0%

- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length

Starting current time
For specifying how long the starting current is to be active 

off / 0.1 - 10.0 s
Factory setting: off

Slope 1 
To set the time during which the starting current is reduced or increased to the welding current

0.0 - 9.9 s
Factory setting: 1.0 s

Slope 2 
To set the time during which the welding current is reduced or increased to the final current.

0.0 - 9.9 s
Factory setting: 1.0 s

Final current 
To set the final current in order to

1. prevent a build-up of heat at the end of welding and
2. fill the end-crater in the case of aluminum

0 - 200% (of the welding current)
Factory setting: 50 %

End arc length correction
For correcting the arc length at the end of welding

-10.0 - +10.0% (of the welding voltage)
Factory setting: 0.0%

- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length

Final current time
For specifying how long the final current is to be active

off / 0.1 - 10.0 s
Factory setting: off

SFI
To activate / deactivate the SFI function (Spatter Free Ignition of the arc)

off/on
Factory setting: off

SFI Hotstart
To set a HotStart time in conjunction with SFI ignition

During SFI ignition, a spray arc phase runs within the set HotStart time. This increases the heat input regardless of the operating mode and thus ensures a deeper penetration from the start of welding.

off / 0.01 - 2.00 s
Factory setting: off

Wire retraction 
To set the wire retraction value (= combined value from wire retraction and a time)
The wire retraction depends on the equipment on the welding torch.