Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are not taken.
Indicates the possibility of flawed results and damage to the equipment.
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are not taken.
Indicates the possibility of flawed results and damage to the equipment.
The Operating Instructions must always be at hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.
All safety and danger notices on the device mustFor 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.
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.
This may affect a number of device types in terms of:*) 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.
Temperature range of the ambient air:Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The safety-conscious work of the personnel must be checked regularly.
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.
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation in relation to the maximum permitted operating point at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be specified because this value depends on the welding process and the environmental conditions. It is influenced by a wide range of parameters, such as the welding process itself (MIG/MAG, TIG welding), the selected current type (direct current, alternating current), the power range, the type of weld metal, the resonance properties of the workpiece, the workplace environment, and many other factors.
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph 118 from the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are: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.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)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.
After opening the device:If work is needed on voltage-carrying parts, bring in a second person who will switch off the main switch at the correct time.
Ensure that the workpiece clamp is securely connected to the workpiece.
Secure the workpiece clamp as close to the spot to be welded as possible.
Position the device with sufficient insulation against electrically conductive environments, e.g., insulation against electrically conductive floors or electrically conductive mounts.
Observe the following when using power distribution boards, twin-head mounts, etc.: Even the electrode of the welding torch/electrode holder not in use carries electric potential. Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the welding wire drum, large spool, or wirespool to the wirefeeder with insulation.
EMC device 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.
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side panels must only be opened/removed during maintenance and repair work.
During operationThe 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.
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.
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.
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.
Before transporting the device, completely drain the coolant and dismantle the following components:It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage repaired by trained service technicians before commissioning the device.
Safety 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.
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.
A safety inspection by a certified electrician is recommended: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.
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 iWave 300i / 400i / 500i DC and iWave 300i / 400i / 500i AC/DC power sources are fully digitized, microprocessor-controlled inverter power sources.
A modular design and easy ability to extend the system guarantee a high degree of flexibility. The devices can be adapted to any situation.
The iWave 300i / 400i / 500i DC and iWave 300i / 400i / 500i AC/DC power sources are fully digitized, microprocessor-controlled inverter power sources.
A modular design and easy ability to extend the system guarantee a high degree of flexibility. The devices can be adapted to any situation.
The iWave 300i / 400i / 500i DC and iWave 300i / 400i / 500i AC/DC power sources are fully digitized, microprocessor-controlled inverter power sources.
A modular design and easy ability to extend the system guarantee a high degree of flexibility. The devices can be adapted to any situation.
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.
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:
FCC
This device conforms to the limit values for an EMC device class A digital device, pursuant to Part 15 of the FCC regulations. These limit values are designed to provide reasonable protection against harmful interference when operating in a commercial environment. This device generates and uses high-frequency energy and, if not installed and used in accordance with the Operating Instructions, may interfere with radio communications.
Operation of this device in residential areas is likely to cause harmful interference, in which case the user is required to correct the interference at his own expense.
FCC ID: QKWSPBMCU2
Industry Canada RSS
This device complies with Industry Canada license-exempt RSS standards. Operation is subject to the following conditions:
(1) | The device must not cause any harmful interference. |
(2) | The device must not be affected by external sources of interference, including interference that may impair operation. |
IC: 12270A-SPBMCU2
EU
Compliance with Directive 2014/53/EU - Radio Equipment Directive (RED)
The antennas used for this transmitter must be installed in such a way that a minimum distance of 20 cm from all persons is maintained. They must not be installed or operated in conjunction with another antenna or transmitter. OEM integrators and end users must ensure the operating conditions of the transmitter comply with radio frequency exposure guidelines.
ANATEL / Brazil
This device is operated on a secondary basis. It does not claim to offer protection against harmful interference, even from devices of the same type.
This device can not cause interference in primarily operated systems.
This device complies with ANATEL's specific absorption rate limit values for exposure to high-frequency electrical, magnetic, and electromagnetic fields.
IFETEL / Mexico
Operation of this device is subject to the following two conditions:
(1) | The device must not cause any harmful interference; |
(2) | The device must accept any interference, including interference that may cause undesired operation. |
NCC / Taiwan
According to the NCC regulations for low-power equipment that generates radio frequency radiation:
Article 12
Certified low-power equipment that generates radio frequency radiation shall not change frequency, increase power or alter the characteristics and functions of the original design without approval.
Article 14
The use of low-power equipment that generates radio frequency radiation shall not adversely affect flight safety and legally operated communication equipment.
An identified malfunction must be deactivated and corrected immediately. All malfunctions must be eliminated.
The legal notice in the preceding paragraph refers to radio communications equipment operated in accordance with the provisions of the Telecommunications Act. Low-power 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:
Do not use the functions described here until you have fully read and understood the following documents:
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
* | MIG/MAG options - only in conjunction with the options OPT/i TIG DC MultiProzess PRO or OPT/i TIG AC MultiProzess PRO |
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.
Because of firmware updates, certain functions may be available for your device but not described in these Operating Instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. These operating elements function in exactly the same way, however.
Operating the device incorrectly can cause serious injury and damage to property.
Do not use the functions described here until you have fully read and understood the Operating Instructions.
Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, especially the safety rules.
Because of firmware updates, certain functions may be available for your device but not described in these Operating Instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. These operating elements function in exactly the same way, however.
Operating the device incorrectly can cause serious injury and damage to property.
Do not use the functions described here until you have fully read and understood the Operating Instructions.
Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, especially the safety rules.
Because of firmware updates, certain functions may be available for your device but not described in these Operating Instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. These operating elements function in exactly the same way, however.
Operating the device incorrectly can cause serious injury and damage to property.
Do not use the functions described here until you have fully read and understood the Operating Instructions.
Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, especially the safety rules.
No. | Function |
---|---|
(1) | USB port For connecting USB thumb drives (service dongle, license key, etc.). IMPORTANT! The USB port is not electrically isolated from the welding circuit. Devices that make an electrical connection to another device must therefore not be connected to the USB port! |
(2) | Selection dial with rotary/push button function For selecting elements, setting values, and scrolling through lists |
(3) | Display (with touch function)
|
(4) | Reading zone for NFC keys
NFC key = NFC card or NFC key fob |
(5) | Wire-threading button For threading the wire electrode / welding wire into the torch hosepack without gas or current |
(6) | Gas-test button To set the required quantity of gas on the gas pressure regulator. After pressing the gas-test button, gas flows for 30 s. Pressing the button again ends the process early. |
Touch the display
Touch the display to
When you touch and thus select an element on the display, the element is highlighted.
Turn the selection dial
Selecting items on the display:
Changing values:
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
No. | Function |
---|---|
(1) | Status bar Contains information about:
The content of the status bar varies according to the selected welding process. |
(2) | Left sidebar The left sidebar contains the following buttons:
The left sidebar is operated by touching the display. |
(3) | Indicator bar Overview of the currently available welding parameters; the individual welding parameters can be selected directly by touching the display. The currently selected parameter is highlighted in blue. Welding current curve Balance (1) Electrode diameter Cap mode (1) Polarity (1) (1) only with iWave AC/DC power sources (2) only with iWave TIG AC/DC power sources and if polarity is set to AC. |
(4) | Main area The main area displays welding parameters, EasyJobs, graphics, lists or navigation elements. The main area is divided up differently depending on the application and populated with elements. The main area is operated
|
(5) | Right sidebar The right sidebar can be used as follows, depending on the button selected in the left sidebar:
The right sidebar is operated by touching the display. |
No. | Function |
---|---|
(1) | Status bar Contains information about:
The content of the status bar varies according to the selected welding process. |
(2) | Left sidebar The left sidebar contains the following buttons:
The left sidebar is operated by touching the display. |
(3) | Indicator bar Overview of the currently available welding parameters; the individual welding parameters can be selected directly by touching the display. The currently selected parameter is highlighted in blue. Welding current curve Balance (1) Electrode diameter Cap mode (1) Polarity (1) (1) only with iWave AC/DC power sources (2) only with iWave TIG AC/DC power sources and if polarity is set to AC. |
(4) | Main area The main area displays welding parameters, EasyJobs, graphics, lists or navigation elements. The main area is divided up differently depending on the application and populated with elements. The main area is operated
|
(5) | Right sidebar The right sidebar can be used as follows, depending on the button selected in the left sidebar:
The right sidebar is operated by touching the display. |
The display is shown in full screen mode:
No. | Function |
---|---|
(1) | TMC connection
|
(2) | (-) current socket with integrated gas connection For connecting the TIG welding torch Symbols: |
(3) | TMC 4-pin connection To connect a CrashBox line |
(4) | Control panel with display and control panel cover For operating the power source |
(5) | (-) current socket with bayonet latch HF-free current socket for manual metal arc welding Symbols: |
(6) | (+) current socket For connecting the TIG return lead cable Symbols: |
(7) | SpeedNet connection For connecting
Symbol: |
(8) | Mains cable with strain relief Depending on version |
(9) | Power switch For switching the power source on and off |
(10) | Dummy cover / Robot interface RI FB Inside /i or SpeedNet connections or External sensor options |
(11) | Ethernet connection |
(12) | Dummy cover/second (-) current socket with bayonet latch (option) MIG/MAG ground to wirefeeder |
(13) | TIG shielding gas connection socket Main gas solenoid valve |
(14) | Dummy cover/auxiliary gas connection Additional gas solenoid valve |
(15) | Dummy cover/second SpeedNet connection (option) or external sensor (option) |
(16) | Dummy cover/second SpeedNet connection (option) or external sensor (option) |
(17) | AC inverter (only with iWave AC/DC power sources) |
No. | Function |
---|---|
(1) | TMC connection
|
(2) | (-) current socket with integrated gas connection For connecting the TIG welding torch Symbols: |
(3) | TMC 4-pin connection To connect a CrashBox line |
(4) | Control panel with display and control panel cover For operating the power source |
(5) | (-) current socket with bayonet latch HF-free current socket for manual metal arc welding Symbols: |
(6) | (+) current socket For connecting the TIG return lead cable Symbols: |
(7) | SpeedNet connection For connecting
Symbol: |
(8) | Mains cable with strain relief Depending on version |
(9) | Power switch For switching the power source on and off |
(10) | Dummy cover / Robot interface RI FB Inside /i or SpeedNet connections or External sensor options |
(11) | Ethernet connection |
(12) | Dummy cover/second (-) current socket with bayonet latch (option) MIG/MAG ground to wirefeeder |
(13) | TIG shielding gas connection socket Main gas solenoid valve |
(14) | Dummy cover/auxiliary gas connection Additional gas solenoid valve |
(15) | Dummy cover/second SpeedNet connection (option) or external sensor (option) |
(16) | Dummy cover/second SpeedNet connection (option) or external sensor (option) |
(17) | AC inverter (only with iWave AC/DC power sources) |
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
The power source is only intended for TIG welding, MIG/MAG welding and MMA welding. Any other use is deemed to be "not in accordance with the intended purpose." The manufacturer shall not be liable for any damage resulting from such improper use.
Intended use also meansThe device can be set up and operated outdoors in accordance with protection class IP23. Direct moisture (e.g., from rain) must be avoided.
Danger from machines toppling over or falling.
This can result in serious personal injury and damage to property.
Set up the device securely on an even, solid surface.
Check all screw connections are tightly fastened after installation.
The ventilation channel is a very important safety device. When selecting the setup location, ensure that the cooling air can enter or exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g., from grinding work) must not be allowed to be sucked directly into the system.
An inadequately dimensioned electrical installation can cause serious damage.
The mains lead and its fuse protection must be dimensioned to suit the local power supply.
The technical data shown on the rating plate applies.
The power source is generator-compatible.
The maximum apparent power S1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S1max of the power source is calculated for 3-phase devices as follows:
S1max = I1max x U1 x √3
I1max and U1 according to the device rating plate and technical data
The generator apparent power SGEN needed is calculated using the following rule of thumb:
SGEN = S1max x 1.35
A smaller generator can be used when not welding at full power.
IMPORTANT! The generator apparent power SGEN must not be less than the maximum apparent power S1max of the power source!
The voltage delivered by the generator must never fall outside of the mains voltage tolerance range.
The mains voltage tolerance is specified in the "Technical data" section.
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.
Danger from work that is not carried out properly.
This can result in severe personal injury and damage to property.
The work described below may only be performed by trained specialist personnel.
Follow national standards and guidelines.
Danger from improperly prepared mains cable.
Short circuits and damage to property may result.
Fit ferrules to all phase conductors and the ground conductor of the stripped mains cable.
Europe:
Power source | Mains cable |
---|---|
iWave 300i /nc DC |
|
iWave 300i /MV/nc DC |
|
iWave 300i /nc AC/DC |
|
iWave 300i /MV/nc AC/DC |
|
iWave 400i /nc DC |
|
iWave 400i /MV/nc DC |
|
iWave 400i /nc AC/DC |
|
iWave 400i /MV/nc AC/DC |
|
iWave 500i /nc DC |
|
iWave 500i /MV/nc DC |
|
iWave 500i /nc AC/DC |
|
iWave 500i /MV/nc AC/DC |
|
USA & Canada:
Power source | Mains cable |
---|---|
iWave 300i /nc DC |
|
iWave 300i /MV/nc DC |
|
iWave 300i /nc AC/DC |
|
iWave 300i /MV/nc AC/DC |
|
iWave 400i /nc DC |
|
iWave 400i /MV/nc DC |
|
iWave 400i /nc AC/DC |
|
iWave 400i /MV/nc AC/DC |
|
iWave 500i /nc DC |
|
iWave 500i /MV/nc DC |
|
iWave 500i /nc AC/DC |
|
iWave 500i /MV/nc AC/DC |
|
Cut the strain-relief device to length according to the outer diameter of the mains cable
IMPORTANT! When inserting the mains cable, ensure that the cable sheath protrudes approx. 5 - 10 mm beyond the strain-relief device into the device.
* | Only loosen the 4 TX20 screws, do not remove them |
Push the mains cable toward the open side in order to access the strain-relief device clamping screw.
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.
Further information on locking the power source can be found in under "Defaults - Administration" starting on page (→).
| Other system components (not shown):
|
| Other system components (not shown):
|
| Other system components (not shown):
|
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.
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.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger of electrical current due to electrically conductive dust in the device.
This can result in severe personal injury and damage to property.
Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger of electrical current due to electrically conductive dust in the device.
This can result in severe personal injury and damage to property.
Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.
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.
For more detailed information about installing and connecting the system components, please refer to the corresponding Operating Instructions for the system components.
iWave DC power sources
iWave AC/DC power sources
Danger of severe injury and damage to property if gas cylinders fall over.
Place gas cylinders on a solid, level surface so that they remain stable.
Secure the gas cylinders to prevent them from falling over: Secure the safety strap at the height of the upper part of a gas cylinder.
Never secure the safety strap to the neck of the cylinder.
Observe the safety rules of the gas cylinder manufacturer.
When using a TIG welding torch with integrated gas connection:
When using a TIG welding torch without integrated gas connection:
The gas connection when using a MultiControl (MC) cooling unit is described in the Operating Instructions for the cooling unit.
Do not use pure tungsten electrodes for TIG DC power sources (color code: green).
Before every start-up:
Check the O-ring at the welding torch connection,
Check the coolant level
IMPORTANT! Check the coolant flow at regular intervals during welding.
When establishing a ground earth connection, observe the following points:
Use a separate return lead cable for each power source
Keep the torch hosepack and return lead cable as close together as possible for as long as possible
Physically separate the welding circuits of individual power sources
Do not route several return lead cables in parallel;
if parallel routing cannot be avoided, keep a minimum distance of 30 cm between the welding circuits
Keep the return lead cables as short as possible and use cables with a large cross-section
Do not cross over return lead cables
Avoid ferromagnetic materials between the return lead cables and the interconnecting hosepack
Do not reel up long return lead cables - coil effect!
Route long return lead cables in loops
Do not route return lead cables in iron pipes, metal cable trays, or along steel beams, avoid cable ducts;
(routing positive cables and return lead cables together in an iron pipe does not cause any problems)
If several return lead cables are being used, separate the grounding points on the component as far as possible and do not allow crossed current paths between the individual arcs.
Use compensated interconnecting hosepacks (interconnecting hosepacks with integrated return lead cable)
For a TIG cold wire feeder
For details on mounting or connecting the TIG components, refer to the Installation Instructions and Operating Instructions of the respective system components.
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
Do not use the functions described here until you have fully read and understood the Operating Instructions.
Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules.
Follow the guidelines referring to setting, setting range, and units of measurement for the available parameters in the "Setup Menu" section.
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
Do not use the functions described here until you have fully read and understood the Operating Instructions.
Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules.
Follow the guidelines referring to setting, setting range, and units of measurement for the available parameters in the "Setup Menu" section.
GPr | Gas pre-flow |
SPt | Spot welding time |
IS | Starting current: the temperature is raised gently at low welding current, so that the filler metal can be positioned correctly |
IE | Final current: to avoid local overheating of the parent material caused by heat accumulation at the end of welding. This prevents possible sagging of the weld seam. |
tUP | UpSlope: steady rise of the starting current to the main current (welding current) I1 |
tDOWN | DownSlope: steady lowering of the welding current until it reaches the final current |
I1 | Main current (welding current): uniform thermal input into the parent material, whose temperature is raised by the advancing heat |
I2 | Lowering current: intermediate lowering of the welding current to avoid local overheating of the parent material |
GPO | Gas post-flow |
*) Intermediate lowering
With intermediate lowering, the welding current is lowered to the set lowering current I-2 during the main current phase.
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.
Version 1 of special 4-step mode is activated by the following parameter setting:
Process parameters / General / 2-step settingsVersion 2 of special 4-step mode is activated by the following parameter setting:
Process parameters / General / 2-step settingsIntermediate 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.
Version 3 of special 4-step mode is activated using the following parameter setting:
Process parameters / General / 2-step settingsVersion 4 of special 4-step mode is activated using the following parameter setting:
Process parameters / General / 2-step settingsVersion 5 of special 4-step mode is activated using the following parameter setting:
Process parameters / General / 2-step settingsThe 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.
Version 6 of special 4-step mode is activated by the following parameter setting:
Process parameters / General / 2-step settingsDanger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger of injury and damage from electric shock.
When the power switch is switched to position - I -, the tungsten electrode of the welding torch is live.
Ensure that the tungsten electrode is not touching anyone or any electrically conductive or grounded parts (housing, etc.).
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.
The gas pre-flow test lasts for 30 seconds at the most. Press the button again to stop the gas flow prematurely.
Under certain circumstances, it may not be possible to change the set welding parameters of a system component - such as wirefeeder or remote control - on the control panel of the power source.
AC | Welding parameters for TIG AC welding |
DC- | Welding parameters for TIG DC- welding |
Start current (AC / DC-)
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-)
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-)
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
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-)
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-)
Setting range: 0 - 100 % (of the main current)
Factory setting: 30 %
AC Balance (AC)
only with iWave AC/DC
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.
Cap shaping must be activated separately for each tungsten electrode.
The automatic cap-shaping function is not required if a sufficiently large cap is formed on the tungsten electrode.
Polarity (AC)
only with iWave AC/DC
Danger due to applied welding potential with MultiProzess-PRO power sources and with existing dual-head wirefeeder WF 25i Dual!
This can result in serious personal injury and damage to property.
Disconnect the dual-head wirefeeder from the welding system before setting the polarity to AC!
Setting range: DC- / AC
Factory setting: DC-
To add more parameters to the welding parameters, go to Defaults / View / Parameter view setup.
More information can be found from page (→) onwards.
Risk of injury due to an electric shock
Although Fronius devices comply with all the relevant standards, high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.
Use prescribed protective clothing, especially gloves!
Only use suitable, completely intact and undamaged TIG hosepacks!
Do not work in damp or wet environments!
Take special care when working on scaffolding, work platforms, in tight, difficult to access or exposed places, or when welding out-of-position!
HF ignition is activated when the "HF ignition" setup parameter is set to "on" under process parameters/ignition parameters.
The HF ignition indicator lights up on the status bar.
Unlike contact ignition, there is no risk of contaminating the tungsten electrode and workpiece during HF ignition.
Procedure for HF ignition:
The arc ignites without coming into contact with the workpiece.
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:
Shielding gas flows
The arc ignites.
Risk of injury due to an electric shock
Although Fronius devices comply with all relevant standards, the high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.
Use prescribed protective clothing, especially gloves!
Only use suitable, completely intact and undamaged TIG hosepacks!
Do not work in damp or wet environments!
Take special care when working on scaffolds, work platforms, in forced positions, in tight, difficult to access or exposed places!
The welding process is initiated by briefly touching the workpiece with the tungsten electrode. The high-frequency ignition is performed after the set HF ignition delay time has elapsed.
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:
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:
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:
Key:
(1) Main current, (2) Starting current, (3) UpSlope, (4) Duration of pulsed welding current for tacking process, (5) DownSlope, (6) Final current
When using a pulsed welding current:
The power source automatically controls the pulse parameters according to the set main current (1).
No pulse parameters need to be set.
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
CycleTIG + RPI = on + base current = off
Recommendation: iWave AC/DC with reversed polarity ignition setting = auto
CycleTIG + Tacking
CycleTIG + Pulse
CycleTIG can be used individually with all pulse settings. This allows pulsing in both the high current and low current phases.
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:
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
* | The parameters are available if the OPT/I-Puls Pro option is present on the power source. |
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.
Risk of injury due to an electric shock
Although Fronius devices comply with all the relevant standards, high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.
Use prescribed protective clothing, especially gloves!
Only use suitable, completely intact, and undamaged TIG hosepacks!
Do not work in damp or wet environments!
Take special care when working on scaffolding, work platforms, in tight, difficult to access or exposed places, or when welding out-of-position!
HF ignition delay time
Time after touching the workpiece with the tungsten electrode after which high-frequency ignition takes place.
0.1 - 5.0 s
Factory setting: 1.0 s
Reversed polarity ignition
(only with iWave AC/DC power sources)
To ensure an optimum ignition sequence during TIG DC welding, the polarity is reversed briefly at the start of the welding process. Electrons emerge from the workpiece and hit 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
For more details on CycleTIG, see page (→) onwards.
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:
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
The R/L alignment must be carried out separately for each welding process.
Welding circuit resistance R [mOhm]
The welding circuit resistance is calculated to provide information about the total resistance of the torch hosepack, welding torch, workpiece and grounding cable.
If, for example, the welding circuit resistance increases after the welding torch has been changed, the following components may be faulty:
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:
In addition to the iWave power source, the following components are required for MMA and CEL welding:
In addition to the iWave power source, the following components are required for MMA and CEL welding:
In addition to the iWave power source, the following components are required for arc air gouging:
All TIG components connected to and set up on the power source can remain on the power source.
The TIG components do not have to be isolated for MMA welding.
Check the packaging or labeling on the stick electrode to determine whether the stick electrodes are to be welded on the positive pole (+) or the negative pole (-)
iWave AC/DC power sources can reverse polarity automatically.
For iWave DC power sources, the current socket for MMA welding is always polarized to DC-.
All TIG components connected to and set up on the power source can remain on the power source.
The TIG components do not have to be isolated for MMA welding.
Check the packaging or labeling on the stick electrode to determine whether the stick electrodes are to be welded on the positive pole (+) or the negative pole (-)
iWave AC/DC power sources can reverse polarity automatically.
For iWave DC power sources, the current socket for MMA welding is always polarized to DC-.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger of injury and damage from electric shock.
When the power switch is in position - I -, the stick electrode in the electrode holder is live.
Ensure that the stick electrode is not touching anyone or any electrically conductive or grounded parts (housing, etc.)
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.
Under certain circumstances, it may not be possible to change the set welding parameters of a system component - such as wirefeeder or remote control - on the control panel of the power source.
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
(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
(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.
(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
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) |
(7) | Example of set arc-force dynamic with selected characteristic (4) |
(8) | Example of set arc-force dynamic with selected characteristic (5) or (6) |
I-constant (constant welding current)
0.1 - 20.0 A/V (drooping characteristic with adjustable slope)
P-constant (constant welding power)
(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) |
(7) | Example of set arc-force dynamic with selected characteristic (5) or (6) |
(8) | Possible current change with selected characteristic (5) or (6) depending on the welding voltage (arc length) |
(a) | Operating point with high arc length |
(b) | Operating point with set welding current IH |
(c) | Operating point with low arc length |
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 (IH), 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 IH.
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.
If the welding process regularly comes to an unintentional end, set the break voltage parameter to a higher value.
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
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.
If the welding process regularly comes to an unintentional end, set the break voltage parameter to a higher value.
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:
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:
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
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.
Danger of injury and damage from electric shock.
When the power switch is switched to position - I -, the electrode in the arc air gouging torch is live.
Ensure that the electrode is not touching anyone or any electrically conductive or grounded parts (housing, etc.)
Risk of personal injury due to loud operating noise.
Use suitable hearing protection during arc air gouging!
The settings for break voltage and starting current time are ignored.
If the MMA welding process is selected, any cooling unit that is present is automatically deactivated. It is not possible to turn it on.
Under certain circumstances, it may not be possible to change the set welding parameters of a system component - such as wirefeeder or remote control - on the control panel of the power source.
The arc air gouging parameters are displayed.
At higher amperages, use both hands to guide the arc air gouging torch!
Use a suitable welding helmet.
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:
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:
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:
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
For water-cooled welding systems, the coolant connections on the cooling unit must be doubled: 2x flow connections, and 2x return connections.
The total hosepack length must not exceed 14 m / 45 feet 11 inches for multiprocess welding systems.
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.
Danger due to live wire electrode and current sockets!
With MultiProzess-PRO units, the wire electrode and current sockets of a connected MIG/MAG wirefeeder are live even during TIG operation!
If touched this can result in serious personal injury and damage to property.
Do not touch the wire electrode and current sockets.
Ensure that the wire electrode and current sockets cannot be touched.
In addition to the iWave power source, the following components are required for MIG/MAG welding:
Additionally required for CMT applications:
Additionally required for water-cooled applications:
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:
Additionally required for CMT applications:
Additionally required for water-cooled applications:
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:
The CMT process is suitable for:
A CMT reference book with sample applications is available,
ISBN 978-3-8111-6879-4.
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:
* | only in combination with Welding Package Standard |
** | only in combination with Welding Package Pulse |
*** | only in combination with Welding Package Standard and Welding Package Pulse |
IMPORTANT! On a power source without any Welding Packages, only MIG/MAG standard manual welding is available.
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:
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)
** | Mixed process characteristics |
*** | Welding characteristics with special properties due to additional hardware |
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:
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)
** | Mixed process characteristics |
*** | Welding characteristics with special properties due to additional hardware |
Danger from incorrect operation.
Possible serious injury and damage to property.
Do not use the functions described here until you have read and completely understood these Operating Instructions.
Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules!
See the Setup menu for information on settings, setting range and units of measurement for the available parameters.
Danger from incorrect operation.
Possible serious injury and damage to property.
Do not use the functions described here until you have read and completely understood these Operating Instructions.
Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules!
See the Setup menu for information on settings, setting range and units of measurement for the available parameters.
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"
"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.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all the devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
Danger of electrical current due to electrically conductive dust in the device.
This can result in severe personal injury and damage to property.
Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all the devices and components involved and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
Danger of electrical current due to electrically conductive dust in the device.
This can result in severe personal injury and damage to property.
Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.
Risk of damage to welding system components due to overheating caused by an incorrectly routed interconnecting hosepack.
Do not form any loops when routing the interconnecting hosepack
Do not cover the interconnecting hosepack
Do not wind the interconnecting hosepack as you get near the gas cylinder and do not wrap it around the gas cylinder
IMPORTANT!
The power source is built for TIG welding:
All TIG components connected to and set up on the power source can remain on the power source.
The TIG components do not need to be terminated for MIG/MAG welding.
For details on mounting or connecting the MIG/MAG components, refer to the Installation Instructions and Operating Instructions of the respective system components.
Danger of severe injury and damage to property if gas cylinders fall over.
Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from falling over.
Observe the safety rules of the gas cylinder manufacturer.
Impaired welding results due to a ground earth connection being shared by several power sources!
If several power sources are all welding one component, a common ground earth connection can have a significant effect on the welding results.
Disconnect welding circuits!
Provide a separate ground earth connection for each welding circuit!
Do not use a common grounding cable!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
Read and understand this document in full.
Read and understand all safety rules and user documentation for this equipment and all system components.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
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:
The available characteristics for each process are not displayed if only one characteristic is available for the selected filler metal.
The confirmation step of the filler metal wizard follows directly, steps 10 - 14 are omitted.
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:
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.
If there is a WF 25i Dual dual-head wirefeeder in the welding system, set the welding parameters and process parameters for both welding process lines separately.
Danger due to emerging wire electrode.
Serious personal injuries may result.
Hold the welding torch so that the tip of the welding torch points away from the face and body.
Wear suitable protective goggles.
Do not point the welding torch at people.
Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.
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.
Under certain circumstances, it may not be possible to change the set welding parameters of a system component - such as wirefeeder or remote control - on the control panel of the power source.
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.
1) | Synergic parameters If a synergic parameter is changed, all other synergic parameters are automatically set as well due to the synergic function. The actual setting range depends on the power source and wire speed, as well as which welding program was selected. |
2) | The actual setting range depends on the selected welding program. |
3) | The maximum value depends on the actual wire speed. |
4-step mode is set by default for spot welding.
Press torch trigger - The spot welding process runs until end of the spot welding time - pressing again stops spot welding prematurely
The spot welding parameter can be changed to 2-step under Defaults / System / Mode Setup
(further information on 2-step and 4-step mode for spot welding can be found from page (→) onwards)
Danger due to emerging wire electrode.
Serious personal injuries may result.
Hold the welding torch so that the tip of the welding torch points away from the face and body.
Wear suitable protective goggles.
Do not point the welding torch at people.
Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.
Procedure for creating a welding spot:
The selected weld start and weld end parameters are also active when spot welding.
Under Process parameters / General MIG/MAG / Weld-Start/Weld-End, a weld start/weld end treatment can thus be stored for spot welding.
If final current time is active, the end of welding is not after the set spot welding time, but only after the set slope and final current times have elapsed.
4-step mode is set by default for spot welding.
Press torch trigger - The spot welding process runs until end of the spot welding time - pressing again stops spot welding prematurely
The spot welding parameter can be changed to 2-step under Defaults / System / Mode Setup
(further information on 2-step and 4-step mode for spot welding can be found from page (→) onwards)
Danger due to emerging wire electrode.
Serious personal injuries may result.
Hold the welding torch so that the tip of the welding torch points away from the face and body.
Wear suitable protective goggles.
Do not point the welding torch at people.
Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.
Procedure for creating a welding spot:
The selected weld start and weld end parameters are also active when spot welding.
Under Process parameters / General MIG/MAG / Weld-Start/Weld-End, a weld start/weld end treatment can thus be stored for spot welding.
If final current time is active, the end of welding is not after the set spot welding time, but only after the set slope and final current times have elapsed.
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
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.
0.0 - 10.0
Factory setting: 0.0
Ignition current (manual)
To set the ignition current for MIG/MAG standard manual welding
100 - 550 A (TPS 320i)
100 - 600 A (TPS 400i, TPS 400i LASC ADV)
100 - 650 A (TPS 500i, TPS 600i)
Factory setting: 500 A
Wire retraction (manual)
To set the wire retraction value (= combined value from wire retraction and a time) during MIG/MAG standard manual welding
The wire retraction depends on the equipment on the welding torch.
0.0 - 10.0
Factory setting: 0.0
The following process parameters can be set and displayed for the gas setup:
Gas pre-flow
To set the gas flow time before the arc is ignited
0 - 9.9 s
Factory setting: 0.1 s
Gas post-flow
To set the gas flow time after the arc has gone out
0 - 60 s
Factory setting: 0.5 s
Gas set value
Shielding gas flow rate
(only in conjunction with OPT/i gas flow sensor option)
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
Depends on the shielding gas used
(only in conjunction with the OPT/i gas controller option)
auto / 0.90 - 20.00
Factory setting: auto
(for standard gases from the Fronius welding database, the correction factor is set automatically)
In Job Mode, the values of the above parameters can be saved individually for each job.
The following process parameters can be set and displayed for process control:
The penetration stabilizer is used to set the max. permitted change in the wire speed to ensure that the welding current and hence the penetration is kept stable or constant with variable stick out.
The penetration stabilizer parameter is only available when the WP PMC (Welding Process Pulse Multi Control) or WP LSC (Welding Process Low Spatter Control) option has been enabled on the power source.
0 - 10.0 m/min (ipm)
Factory setting: 0 m/min
0
The penetration stabilizer is not activated.
The wire speed remains constant.
0.1 - 10.0
The penetration stabilizer is activated.
The welding current remains constant.
Application examples
Penetration stabilizer = 0 m/min (not activated)
Changing the contact tube distance (h) alters the resistance in the welding circuit due to the longer stick out (s2).
The constant voltage control for constant arc length causes a reduction in the mean current value and hence a smaller penetration (x2).
Penetration stabilizer = n m/min (activated)
Specifying a value for the penetration stabilizer ensures a constant arc length without large current variations if the stick out is changed (s1 ==> s2).
The penetration (x1, x2) remains virtually unchanged and stable.
Penetration stabilizer = 0.5 m/min (activated)
To minimise the change in welding current if the stick out is changed (s1 ==> s3), the wire speed is increased or reduced by 0.5 m/min.
In the example shown, the stabilising effect is obtained without a change in current up to the set value of 0.5 m/min (Position 2).
I ... Welding current vD ... Wire speed
Arc length stabilizer
The arc length stabilizer uses short-circuit control to force short arcs that are advantageous for welding and keeps them stable even with a variable stick-out or in the event of external disturbances.
The arc length stabilizer parameter is only available if the WP PMC (Welding Process Pulse Multi Control) option is enabled on the power source.
0.0 - 5.0 (action of the stabilizer)
Factory setting: 0.0
0.0
The arc length stabilizer is deactivated.
0.1 - 5.0
The arc length stabilizer is activated.
The arc length is reduced until short circuits occur.
Application examples
Arc length stabilizer = 0 / 0.5 / 2.0
Arc length stabilizer = 0
Arc lengths stabilizer = 0.5
Arc lengths stabilizer = 2
Activating the arc length stabilizer reduces the arc length until short circuits occur. This allows the advantages of a short, stably controlled arc to be better exploited.
Increasing the arc length stabilizer causes a further shortening of the arc length (L1 ==> L2 ==> L3). The advantages of a short, stably controlled arc can be better exploited.
Arc length stabilizer for weld seam profile and position changes
Arc length stabilizer not activated
Weld seam profile or welding position changes can negatively influence the welding result
Arc length stabilizer activated
Since the number and duration of the short circuits are controlled, the properties of the arc remain the same when the weld seam profile or welding position is changed.
I ... Welding current vD ... Wire speed U ... Welding voltage
* ... Number of short circuitsExample: Stick out change
Arc length stabilizer without penetration stabilizer
The advantages of a short arc are maintained even if the stick out is changed, since the short-circuit properties stay the same.
Arc length stabiliser with penetration stabilizer
If the stick out is changed with the penetration stabilizer activated, the penetration also stays the same.
The short circuit behaviour is controlled by the arc length stabilizer.
I ... Welding current vD ... Wire speed U ... Welding voltage
* ... Number of short circuits Δs ... Stick out changeThe following process parameters can be set for SynchroPulse welding:
(1) SynchroPulse
To activate/deactivate SynchroPulse
off/on
Factory setting: on
(2) Wire speed
To set the average wire speed and therefore the welding power for SynchroPulse
For example: 2 - 25 m/min (ipm)
(Depending on wire speed and welding characteristic)
Factory setting: 5.0 m/min
(3) Delta wire feed
To set the delta wire feed:
With SynchroPulse, the set wire speed is alternately increased/decreased by the delta wire feed. The parameters concerned are modified accordingly to match the acceleration/deceleration of the wire speed.
0.1 - 6.0 m/min / 5 - 235 ipm
Factory setting: 2.0 m/min
(4) Frequency
To set the SynchroPulse frequency
0.5 - 3.0 Hz
Factory setting: 3.0 Hz
(5) Duty Cycle (high)
For weighting the duration of the higher operating point in a SynchroPulse period
10 - 90%
Factory setting: 50 Hz
(6) Arc correction high
For correcting the arc length with SynchroPulse at the higher operating point (= average wire speed plus delta wire feed)
-10.0 - +10.0
Factory setting: 0.0
- ... short arc
0 ... uncorrected arc length
+ ... longer /arc
(7) Arc correction low
For correcting the arc length with SynchroPulse at the lower operating point (= average wire speed less delta wire feed)
-10.0 - +10.0
Factory setting: 0.0
- ... short arc
0 ... uncorrected arc length
+ ... longer /arc
For mixing processes, the following process parameters can be set under Process Mix:
Wire speed vD *
Wire speed
1.0 - 25.0 m/min / 40 - 985 ipm
The wire speed value is taken from the welding parameters or can be specified and changed in the Process Mix parameters.
Arc length correction
-10.0 - +10.0
The arc length correction value is taken from the welding parameters or can be specified and changed in the Process Mix parameters.
Pulse/dynamic correction
For changing the pulse energy in the pulsed arc process phase
-10.0 - +10.0
The pulse/dynamic correction value is taken from the welding parameters or can be specified and changed in the Process Mix parameters.
Upper power time correction (3) *
To set the duration of the hot process phase in a mixed process
-10.0 - +10.0
Factory setting: 0
Upper and lower power time correction is used to define the relationship between the hot and cold process phases.
If the lower power time correction is increased, the process frequency reduces and the PMC process phase becomes longer.
If the lower power time correction is reduced, the process frequency increases and the PMC process phase becomes shorter.
Lower power time correction (2) *
To set the duration of the cold process phase in a mixed process
-10.0 - +10.0
Factory setting: 0
Upper and lower power time correction is used to define the relationship between the hot and cold process phases.
If the lower power time correction is increased, the process frequency reduces and the LSC process phase becomes longer or, in the case of CMT mix, the CMT process phase becomes longer.
If the lower power time correction is reduces, the process frequency increases and the LSC process phase becomes shorter or, in the case of CMT mix, the CMT process phase becomes shorter.
Lower power correction (1) *
To set the energy input in the cold process phase in a mixed process
-10.0 - +10.0
Factory setting: 0
If the lower power correction is increased, this results in a higher wire speed and therefore a higher energy yield in the cold LSC process phase or the cold CMT process phase.
* Representation of the parameters in the following diagrams
(1) | Lower power correction |
(2) | Lower power time correction |
(3) | Upper power time correction |
vD | Wire speed |
CMT Cycle Step
To activate / deactivate the function CMT Cycle Step
On/Off
Wire feed
Wire speed, defines the deposition rate in the welding process phase and thus the size of the welding spot;
Setting range: in m/min (ipm), depending on the welding characteristic
The value for the wire speed is applied; it can also be specified or changed in the CMT Cycle Step parameters.
Cycles (spot size)
To set the number of CMT cycles (welding droplets) for a spot;
The number of CMT cycles and the set wire speed define the size of the welding spot.
1 - 2000
Interval pause time
To set the time between the individual welding spots
0.01–2.00 s
The higher the value for the interval pause time, the cooler the welding process (coarser rippling).
Interval cycles
To set the number of CMT cycle repetitions incl. pause until the end of welding
Continuous / 1 - 2000
Continuous
The repetitions are continued continuously;
Welding stop e.g., via "Arc Off"
Spot welding time
0.1 - 10.0 s
Factory setting: 1.0 s
Align the welding circuit resistance (R) and inductance (L) if one of the following welding system components is changed:
Prerequisites for R/L alignment:
The welding system must be complete: closed welding circuit with welding torch and torch hosepack, wirefeeders, grounding cable, interconnecting hosepacks.
Perform R/L alignment:
The actual values for welding circuit inductance and welding circuit resistance are displayed.
The second step of the R/L alignment wizard is displayed.
The third step of the R/L alignment wizard is displayed.
The fourth step of the R/L alignment wizard is displayed.
The actual values are displayed when the measurement is complete.
When EasyJob mode is activated, the display shows 5 additional buttons that enable fast saving of up to 5 operating points.
The current welding-relevant settings are saved.
When EasyJob mode is activated, the display shows 5 additional buttons that enable fast saving of up to 5 operating points.
The current welding-relevant settings are saved.
When EasyJob mode is activated, the display shows 5 additional buttons that enable fast saving of up to 5 operating points.
The current welding-relevant settings are saved.
The overview for activating/deactivating EasyJob mode is displayed.
EasyJob mode is activated, the defaults are displayed.
The five EasyJob buttons are displayed with the welding parameters.
The EasyJobs are stored under job numbers 1 - 5 and can also be retrieved via job mode.
Storing an EasyJob overwrites a job stored under the same job number!
The button initially changes in size and color. After approx. 3 seconds, the button changes color again.
The settings have now been stored.
The most recently stored settings are enabled. An active EasyJob is displayed by a check mark on the EasyJob button.
Unused EasyJob buttons are shown in dark gray.
The button briefly changes in size and color and is then displayed with a check mark:
If no check mark is displayed after touching an EasyJob button, an operating point is not stored under this button.
The button
The EasyJob operating point has been deleted.
Up to 1000 jobs can be stored and reproduced on the power source.
This eliminates the need to manually document the welding parameters.
Job mode thereby increases the quality of automated and manual applications.
Jobs can only be saved during welding mode. In addition to the current welding settings, the process parameters and certain machine defaults are also taken into account when saving jobs.
Up to 1000 jobs can be stored and reproduced on the power source.
This eliminates the need to manually document the welding parameters.
Job mode thereby increases the quality of automated and manual applications.
Jobs can only be saved during welding mode. In addition to the current welding settings, the process parameters and certain machine defaults are also taken into account when saving jobs.
The list of jobs is displayed.
To overwrite an existing job, select the job by turning and pressing the selection dial (or select "Next page").
After a prompt appears, the selected job can be overwritten.
For a new job, select "Create a new Job"
The next free job number is displayed.
The keyboard is displayed.
The name is applied and confirmation that the job has been saved is displayed.
Before retrieving a job, ensure that the welding system is set up and installed according to the job in question.
Job mode is activated.
"Welding job" and the data for the last job retrieved are displayed.
IMPORTANT! In job mode, only the "Job number" welding parameter can be changed; the remaining welding parameters can only be viewed.
The overview of the last optimized job is displayed.
The list of jobs is displayed.
The keyboard is displayed.
The job name has been changed and the list of jobs is displayed.
The list of jobs is displayed.
The prompt to delete the job is displayed.
The job has been deleted and the list of jobs is displayed.
Use the Load Job function to load the data for a stored job or EasyJob into the Welding area. The corresponding data for the job is displayed in the welding parameters and can be welded, modified or saved as a new job or EasyJob.
The list of jobs is displayed.
The Load Job information is displayed.
The data for the selected job is loaded in the Welding area.
The data for the loaded job can now be welded (no job mode), modified or saved as a new job or EasyJob.
Process parameters for Components and Monitoring see page (→).
Process parameters for Components and Monitoring see page (→).
The following process parameters can be set for "Optimize Job":
Working parameters
Starting current | see page (→) |
UpSlope | see page (→) |
Main current | see page (→) |
Lowering current | see page (→) |
DownSlope | see page (→) |
Final current | see page (→) |
AC Balance | see page (→) |
Electrode diameter | see page (→) |
Welding process settings
TIG pulse settings
TIG AC Settings
(iWave AC/DC power sources only)
Wire speed settings
Ignition & operating mode settings
Arc monitoring
Ignition timeout | see page (→) |
Arc break filter time | see page (→) |
Arc break watchdog | see page (→) |
Lowering current for 4-step mode | see page (→) |
DownSlope | see page (→) |
Final current | see page (→) |
AC Balance | see page (→) |
Electrode diameter | see page (→) |
Operating mode defaults
TIG - General settings
TIG job correction limits
Upper main current limit | 0 - 50% |
Lower main current limit | -50 - 0% |
Job slope | 0.0 - 10.0 s |
CycleTIG
Limit Monitoring
Voltage setpoint | 0.0 - 100.0 V |
Lower voltage limit | -10.0 - 0.0 V |
Upper voltage limit | 0.0 - 10.0 V |
Maximum time of voltage deviation | off / 0.1 - 10.0 s |
Current setpoint | 0.0 - 1000.0 A |
Lower current limit | -100 - 0 A |
Upper current limit | 0 - 100 A |
Maximum time for current deviation | off / 0.1 - 10.0 s |
Wire speed setpoint | see page (→) |
Lower wire speed limit | -10.0 - 0.0 m/min |
Upper wire speed limit | 0.0 - 10.0 m/min |
Maximum time of wire feed deviation | off / 0.1 - 10.0 s |
Welding time setpoint | 0.0 - 999.9 s |
Lower welding time limit | -50.0 - 0.0 s |
Upper welding time limit | 0.0 - 50.0 s |
Monitor welding time | off/on |
Energy setpoint | 0.0 - max. kJ |
Lower energy limit | -100.0 - 0.0 kJ |
Upper energy limit | 0.0 - 100.0 kJ |
Monitor energy | off/on |
Reaction if exceeded | ignore/warning/error |
For each job, individual correction limits can be set for welding power and arc length.
If correction limits are set for a job, the welding power and arc length of the job can be corrected within the specified limits.
An overview of job correction limits for the most recently accessed job is displayed.
Under "Pre-settings for "Save as Job", you can set default values that are applied to each new job you create.
The pre-settings for saving new jobs are displayed.
Process parameters / Common TIG/MMA/CEL ... see page (→)
Process parameters / Common MIG/MAG ... see page (→)
Process parameters / Components & Monitoring ... see page (→)
Process parameters / JOB ... see page (→)
Process parameters / Common TIG/MMA/CEL ... see page (→)
Process parameters / Common MIG/MAG ... see page (→)
Process parameters / Components & Monitoring ... see page (→)
Process parameters / JOB ... see page (→)
Process parameters / Common TIG/MMA/CEL ... see page (→)
Process parameters / Common MIG/MAG ... see page (→)
Process parameters / Components & Monitoring ... see page (→)
Process parameters / JOB ... see page (→)
Process parameters - Components & Monitoring: Components, Empty / Fill torch hosepack, System adjustment, Arc break watchdog, Wire stick contact tip, Wire stick workpiece, Welding circuit coupling, Wire end monitoring, Gas monitoring, Motor force monitoring
Process parameters - Components & Monitoring: Components, Empty / Fill torch hosepack, System adjustment, Arc break watchdog, Wire stick contact tip, Wire stick workpiece, Welding circuit coupling, Wire end monitoring, Gas monitoring, Motor force monitoring
Cooling unit
Cooling unit operating mode
For controlling a cooling unit
eco / auto / on / off
Factory setting: auto
auto
When welding starts, the cooling unit starts to operate (fan and coolant pump running).
After the end of welding, the cooling unit continues to operate for 2 minutes. When the 2 minutes have elapsed, the cooling unit also switches off.
on
Continuous operation
As soon as the power source is switched on, the cooling unit starts to operate (fan and coolant pump running continuously)
off
No operation, even when welding starts
eco
The coolant pump starts to operate when welding starts.
The fan starts to operate from a coolant return temperature of 40 °C (104 °F) (only in conjunction with the flow temperature sensor option).
When filling the torch hosepack, the coolant pump will run for 10 seconds as soon as the flow reaches > 0.7 l/min.
After the end of welding, the cooling unit continues to operate for at least 15 seconds. As soon as the coolant return temperature reaches < 40 °C, the cooling unit shuts down.
The maximum after-run time is 2 minutes.
Flow sensor filter time
(only if the flow temperature sensor option is available on the cooling unit)
To set the time from when the flow sensor is triggered until a warning message is output
5 - 25 s
Factory setting: 10 s
Cooler flow warning limit
(only if the flow temperature sensor option is available on the cooling unit)
If the parameter is activated, a warning is generated when the value entered is undershot.
off / 0.75 / 0.8 / 0.85 / 0.9 / 0.95
Factory setting: off
Wirefeeder
Feeder inching speed
To set the wire speed at which the wire electrode or welding wire is fed into the torch hosepack
For example: 2 - 25 m/min / 20 - 3935 ipm
(depending on wire speed)
Factory setting: 10 m/min
Power source
Ignition timeout
Length of wire that is fed before the safety cut-out trips
off / 5 - 100 mm (0.2 - 3.94 in.)
factory setting: off
The Ignition timeout process parameter is a safety function.
At high wire speeds in particular, the length of wire fed until the safety cut-out trips can deviate from the set wire length.
How it works:
If the torch trigger is pressed, the gas pre-flow begins immediately. Wire feeding and the ignition process then begin. If there is no current flow within the specified fed wire length, the system switches off automatically.
Press the torch trigger again for a further attempt.
Sense line
off/on
Factory setting: off
Robot settings
TouchSensing sensitivity
To set the sensitivity of TouchSensing for the surfaces of different parts and to cater for external factors
(TouchSensing = finding the seam position by means of an applied sensor voltage during automated welding)
TouchSensing takes place via the gas nozzle or the wire electrode.
TouchSensing using the gas nozzle only works if the OPT/i WF gas nozzle position search option is installed in the robot wirefeeder and if the robot interface is present.
0 - 10
Factory setting: 1
0
for bare surfaces, long and dead short circuit, robust and immune to interference
10
for scaly surfaces, high measurement-related sensitivity to interference
Not suitable for welding with multiple power sources on one part!
Insulated surfaces cannot be detected.
Procedure for determining TouchSensing sensitivity:
Edge detection "WireSense"
to activate / set an edge detection using WireSense (option)
off / 0.5 - 20.0 mm
Factory setting: off
"WireSense" edge detection only works
WireSense is usually activated via a robot controller. As soon as a value > 0.5 mm is specified by the robot controller, the value set manually on the power source is overwritten.
If the Ignition timeout parameter is activated, this also applies to WireSense.
For higher-level robot controllers with a small signal range (e.g., linear trolleys), WireSense can be set manually on the power source.
Example Economy-Image:
Requirements for draining/filling the torch hosepack:
When draining long hosepacks > 4 m, a fully filled coolant tank can overflow - risk of slipping!
Observe the Operating Instructions and safety instructions for the cooling unit!
Draining the torch hosepack
If the coolant temperature is too high, a cooling phase is executed. During the cooling phase, the LED on the welding torch flashes approx. 2 x per second.
The draining process is then started. The draining process takes approx. 30 seconds. During the draining process, the LED on the welding torch flashes approx. 1 x per second
A confirmation is displayed after the draining process has been completed.
The torch body can now be changed.
If the torch hosepack is to be changed, the power source must be switched off first.
IMPORTANT! Welding is not possible if the torch hosepack has been drained.
Filling the torch hosepack
A confirmation is displayed after the filling process has been successfully completed.
If two motors are being used in a welding system, they must be calibrated to maintain process stability.
For welding systems with PushPull units or unreeling wirefeeders, a system adjustment must be carried out whenever the wirefeeders are installed or replaced.
A corresponding message is displayed.
The System adjustment wizard is started.
The system adjustment can also be started manually.
Perform system adjustment:
If a system adjustment is required, the System adjustment wizard is started. The first step of the System adjustment wizard is displayed:
A confirmation message is displayed once the system adjustment has finished.
The "Arc break watchdog" overview is displayed.
The "Wire stick contact tip - Setup menu" is displayed.
The "Wire stick workpiece - Setup menu" is displayed.
A confirmation message is displayed once the welding circuit is coupled.
The "Wire end monitoring setup menu" overview is displayed.
(1) | Wire end reaction for OPT/i WF R WE ring sensor 4,100,878,CK |
(2) | Wire end reaction for OPT/i WF R WE drum 4,100,879,CK |
(3) | Wire end reaction for OPT/i WF R wire end 4,100,869,CK |
The gas monitoring parameters are only available if the OPT/i gas flow sensor option is present on the wirefeeder or SplitBox.
A lower gas flow limit can be defined for gas monitoring. If the gas flow drops below a specified level for a defined time, an error message is immediately displayed and the welding process stops.
The "Gas monitoring" overview is displayed.
An incorrectly set gas factor can have a massive influence on the shielding gas quantity and thus on the welding result.
Under the "auto" setting, all standard gases from the Fronius welding database are taken into account.
Manual adjustment of the gas factor is only recommended for special gases and only after a discussion with Fronius.
The "Motor force monitoring" overview is displayed.
Because of firmware updates, certain functions may be available for your device but not described in these operating instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. However, the function of these operating elements is identical.
Operating the device incorrectly can cause serious injury and damage.
Do not use the functions described until you have thoroughly read and understood the following documents:
these operating instructions,
all operating instructions for system components, especially the safety rules.
Because of firmware updates, certain functions may be available for your device but not described in these operating instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. However, the function of these operating elements is identical.
Operating the device incorrectly can cause serious injury and damage.
Do not use the functions described until you have thoroughly read and understood the following documents:
these operating instructions,
all operating instructions for system components, especially the safety rules.
Because of firmware updates, certain functions may be available for your device but not described in these operating instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your device. However, the function of these operating elements is identical.
Operating the device incorrectly can cause serious injury and damage.
Do not use the functions described until you have thoroughly read and understood the following documents:
these operating instructions,
all operating instructions for system components, especially the safety rules.
The "Defaults" contain the following options:
The overview of units and standards is displayed.
The date and time can be assigned via NTP (Network Time Protocol) or set manually.
Setting the date and time via NTP
A DNS server must be reachable or must be configured when manually setting the network parameters (see Setting network parameters manually, page (→)).
The time of the NTP server is synchronized with the power source. If NTP is set, the time is also synchronized after the power source is restarted, provided a connection to the time server can be established.
Setting the date and time manually
To set the date and time manually, "Time & Date Automatic" must not be selected.
The View defaults are displayed.
The current system data is displayed.
Real-time arc power in kW If the welding speed is known, the electrical energy input can be calculated: E = IP / vs
| |||||||
Arc energy in kJ | |||||||
E = IE / L
Arc energy is generally used in manual welding to calculate the energy input. | |||||||
Current welding speed in cm/min | |||||||
Currently set job | |||||||
Current weld | |||||||
Duration of weld in s | |||||||
Present motor current in A, wirefeeder 1 | |||||||
Present motor current in A, wirefeeder 2 | |||||||
Present motor current in A, wirefeeder 3 | |||||||
Present motor force in N, wirefeeder motor 1 | |||||||
Present motor force in N, wirefeeder motor 2 | |||||||
Present motor force in N, wirefeeder motor 3 | |||||||
Present flow rate in l/min at the cooling unit Error output if the flow rate is < 0.7 l/min | |||||||
Present shielding gas flow | |||||||
Total shielding gas consumption | |||||||
Present coolant temperature in °C at the cooling unit Error output if the coolant temperature is > 70 °C | |||||||
Arc time in h | |||||||
Total operating hours of the power source in h |
The View defaults are displayed.
The options for displaying the characteristics are displayed.
The View defaults are displayed.
This function enables additional parameters or settings for the TIG welding parameters to be displayed.
Expand parameter view:
The parameter is displayed in the welding parameters, from where it can also be changed.
This function can be used to save additional parameters or settings for jobs.
Expand parameter view iJob:
The parameter is displayed with the jobs, from where it can also be changed.
The device information is displayed:
serial number, image version, software version, IP address
The confirmation prompt for the factory settings appears.
The process parameter and machine default values are reset to their factory settings and the overview of system defaults is displayed.
The confirmation prompt for resetting the website password appears.
The website password is reset to its factory setting:
User name = admin
Password = admin
The overview of system defaults is displayed.
MIG/MAG welding torch setup
Special 4-step = Guntrigger
In conjunction with a JobMaster welding torch and with the special 4-step mode selected, this function enables the torch trigger to be used to switch between jobs during welding. Job switching takes place within defined job groups.
A job group is defined by the next non-programmed job.
Example:
Job group 1: Job no. 3 / 4 / 5
Job no. 6 is not occupied ==> End of job group1
Job group 2: Job no. 7 / 8 / 9
Spot welding
2-step = Spot welding in 2-step mode:
The spot welding process runs while the torch trigger remains pressed and ends at the latest after the spot welding time has elapsed.
Releasing the torch trigger stops the spot welding process before the spot welding time has elapsed.
4-step = Spot welding in 4-step mode:
The spot welding process starts when the torch trigger is pressed and ends at the latest when the spot welding time has elapsed.
Pressing the torch trigger again stops the spot welding process before the spot welding time has elapsed.
For more information about spot welding:
Special JobMaster display = on
The following items can now be set and implemented on the Jobmaster welding torch:
Torch trigger job selection = on
The function enables the torch trigger to be used to switch to the next job. Switching takes place within defined job groups.
A job group is defined by the next non-programmed job.
Example:
Job group 1: Job no. 3 / 4 / 5
Job no. 6 is not occupied ==> End of job group1
Job group 2: Job no. 7 / 8 / 9
Switching can take place when idle or during welding.
TIG welding torch setup
Activate / deactivate cap mode via torch trigger
Torch trigger I2 - cap mode = on:
Cap mode can be activated by a long press of the torch trigger
Torch trigger I2 - cap mode = off:
Cap mode cannot be activated by a long press of the torch trigger.
The overview of network settings is displayed.
If DHCP is activated, the IP Address, Network Mask and Default Gateway network parameters are grayed out and cannot be set.
DHCP is deactivated and the network parameters can now be set.
The numeric keypad for the selected network parameter is displayed.
The value for the network parameter is applied and the overview of network settings is displayed.
The overview of WLAN settings is displayed.
Setting the country code
Activating WLAN
Adding a network
The available WLAN networks are displayed.
Deleting a network
General
Each Bluetooth device has its own MAC address. The MAC address allows the device to be assigned to a specific power source, thus preventing any mix-ups.
The power source can communicate with the following Bluetooth devices:
An active Bluetooth connection is indicated in the status bar of the display by a blue Bluetooth symbol.
In the case of Bluetooth devices of the same type, only one device can be actively connected to the power source for safety reasons.
Active Bluetooth connections to several Bluetooth devices of different types are possible.
An existing, active Bluetooth connection cannot be interrupted or influenced by another Bluetooth device.
Bluetooth remote controls have priority over wired remote controls or manual welding torches.
If the connection between wired or Bluetooth remote controls and the power source is interrupted during the welding process, the welding process is terminated.
Configuring the Bluetooth setup
The Bluetooth setup screen appears.
Activating or deactivating the Bluetooth function on the power source
Adding a Bluetooth device
Symbols displayed under Info:
Active Bluetooth connection
An active change can be made to the power source via the Bluetooth device.
Depending on the availability of the data, additional information such as battery status, signal strength, etc. of the Bluetooth device is displayed.
Paired
A Bluetooth device has already been actively connected to a power source and appears in the list of Bluetooth devices.
Inactive
A new Bluetooth device was found or the Bluetooth device was removed by the user.
Deleting a Bluetooth device
The power source configuration is displayed.
The keyboard is displayed.
The text is applied and the power source configuration is displayed.
In the wirefeeder setup, potentiometers present on a wire feeder can be activated or deactivated.
The interface setup allows you to define whether the welding parameters are specified externally by the robot controller or internally by the power source.
In TWIN Setup, welding lines 1 and 2 are assigned to the power sources.
The documentation overview is displayed.
The logbook is displayed.
The buttons can be used to display welds, events, errors, warnings or notifications.
The following data is logged:
(1) | Number of the weld |
(2) | Date (ddmmyy) |
(3) | Time (hhmmss) |
(4) | Duration of welding in s |
(5) | Welding current in A (average) |
(6) | Welding voltage in V (average) |
(7) | Wire speed in m/min |
(8) | Arc energy in kJ (for details see page (→)) |
(9) | Job No. |
Turn the selection dial to scroll through the list.
Limit value monitoring is only available in conjunction with the OPT/i LimitMonitoring option.
The documentation overview is displayed.
User management is useful if multiple users are working with the same power source.
User management is carried out using different roles and with the help of NFC keys.
Users are assigned different roles depending on their level of training or qualification.
User management is useful if multiple users are working with the same power source.
User management is carried out using different roles and with the help of NFC keys.
Users are assigned different roles depending on their level of training or qualification.
User management
User management includes all users registered on the power source. Users are assigned different roles depending on their level of training or qualification.
NFC card
An NFC card or and NFC key fob is assigned to a specific user who is registered on the power source.
NFC cards and NFC key fobs are commonly referred to as an NFC key in these Operating Instructions.
IMPORTANT! Each user should be assigned their own NFC key.
Role
Roles are used to manage registered users (= user management). The roles define access rights and the work activities that users can perform.
Two roles are predefined in the factory under Defaults / Administration / User management:
Administrator
with all rights and options
The "Administrator" role cannot be deleted, renamed, or edited.
The "Administrator" role contains the predefined "admin" user, which cannot be deleted. The "Admin" user can be assigned a name, language, unit, web password, and NFC key.
Once "admin" has been assigned an NFC key, user management is activated.
Locked
Preset in the factory with access rights to the welding processes, without process parameters and defaults
The role "Locked":
NFC keys cannot be assigned to the "Locked" role.
If no NFC key is assigned to the predefined "Admin" user, each NFC key functions to lock and unlock the power source (no user management, see also section "Locking and unlocking the power source using an NFC key", page (→)).
User management contains the following sections:
A systematic procedure is required when creating roles and NFC keys.
Fronius recommends that you create one or two administrator keys. In the worst case scenario, a power source can no longer be operated without administrator rights.
Procedure
The loss of an administrator NFC key may affect power source usability, depending on your settings. Store one of the two administrator NFC keys in a safe place.
A systematic procedure is required when creating roles and NFC keys.
Fronius recommends that you create one or two administrator keys. In the worst case scenario, a power source can no longer be operated without administrator rights.
Procedure
The loss of an administrator NFC key may affect power source usability, depending on your settings. Store one of the two administrator NFC keys in a safe place.
If an NFC key is assigned to the predefined "Admin" user under Defaults / Administration / User management / Administrator, then user management is activated.
User management is displayed, "Administrator" is selected.
The info for transferring the NFC card is displayed.
The message confirming that user management is activated is displayed.
The number of the assigned NFC key is displayed under Admin / NFC card.
To create a 2nd administrator key:
User management is displayed.
The keyboard is displayed.
The functions that can be executed within a role are displayed.
Symbols:
... hidden | |
... read only | |
... read and write |
User management is displayed.
For data privacy reasons, only personal ID numbers and no full names should be entered when creating users.
User management is displayed.
The keyboard is displayed.
The info for transferring the NFC card is displayed.
For data privacy reasons, only personal ID numbers and no full names should be entered when creating users.
User management is displayed.
The keyboard is displayed.
The info for transferring the NFC card is displayed.
For data privacy reasons, only personal ID numbers and no full names should be entered when creating users.
User management is displayed.
User management is displayed.
The role opens, the functions can be changed:
If no user is stored for a role, the editing of the role can also be started by pressing the selection dial.
User management is displayed.
The role opens, the functions can be changed:
If no user is stored for a role, the editing of the role can also be started by pressing the selection dial.
User management is displayed.
The role and all assigned users are deleted.
User management is displayed.
The users assigned to the role are displayed.
User management is displayed.
The user is deleted.
The prompt to delete or replace the NFC card is displayed.
If the NFC card for the predefined "Admin" user is deleted, user management is deactivated.
User management is deactivated, the power source is locked.
The power source can be unlocked and locked again with any NFC key (see also page (→)).
Procedure if
CENTRUM is a piece of software used for central user management. For detailed information, refer to the CENTRUM Operating Instructions (42,0426.0338,xx).
THE CENTRUM server can also be activated directly on the power source as follows:
The Central User Management Server is displayed.
CENTRUM is a piece of software used for central user management. For detailed information, refer to the CENTRUM Operating Instructions (42,0426.0338,xx).
THE CENTRUM server can also be activated directly on the power source as follows:
The Central User Management Server is displayed.
With the SmartManager, the power sources have their own website.
Once the power source is connected to a computer via a network cable or is integrated into a network, the SmartManager of the power source can be accessed via the IP address of the power source.
IE 10 or higher or another modern browser is required in order to access the SmartManager.
The entries displayed on the SmartManager may vary depending on the system configuration, software extensions and options available.
Examples of displayed entries:
|
|
With the SmartManager, the power sources have their own website.
Once the power source is connected to a computer via a network cable or is integrated into a network, the SmartManager of the power source can be accessed via the IP address of the power source.
IE 10 or higher or another modern browser is required in order to access the SmartManager.
The entries displayed on the SmartManager may vary depending on the system configuration, software extensions and options available.
Examples of displayed entries:
|
|
With the SmartManager, the power sources have their own website.
Once the power source is connected to a computer via a network cable or is integrated into a network, the SmartManager of the power source can be accessed via the IP address of the power source.
IE 10 or higher or another modern browser is required in order to access the SmartManager.
The entries displayed on the SmartManager may vary depending on the system configuration, software extensions and options available.
Examples of displayed entries:
|
|
The SmartManager for the power source is displayed.
There are two help functions when logging into the SmartManager:
Start unlock function?
This feature allows you to unlock an unintentionally locked power source and enable it for all functions.
A .txt file with the following file name is saved in the computer's download folder:
unlock_SN[serial number]_YYYY_MM_DD_hhmmss.txt
Fronius will reply by e-mail with a one-time unlock file with the following file name:
response_SN[serial number]_YYYY_MM_DD_hhmmss.txt
The power source is unlocked once.
Forgot your password?
After clicking on "Forgot your password?", a note appears indicating that the password can be reset on the power source (see also "Restoring the website password", page (→)).
Click on this symbol to
Changing the password for the SmartManager:
Click on this symbol to expand the display of characteristics, material specifications and certain welding parameters on the SmartManager for the power source.
The settings depend on the user who is logged in.
Click on the language abbreviation to display the languages available for the SmartManager.
The currently set language is highlighted in white.
To change the language, click on the desired language.
The current status of the power source is displayed between the Fronius logo and the selected power source.
Caution/warning |
Error on the power source |
Power source is welding |
Power source is ready for use (online) |
Power source is not ready for use (offline) |
* | In the event of an error, a red error line with the error number appears above the line with the Fronius logo. After clicking on the error line, an error description is displayed. |
Click on the Fronius logo to open the Fronius homepage: www.fronius.com
The current data for the welding system is displayed according to the selected welding process.
For TIG AC, for example:
Machine name | Hall | Cell |
| ||
ACTUAL | ||
| ||
Main current | Lowering current | Balance |
Starting current | Final current | Electrode diameter |
UpSlope | DownSlope | Polarity |
|
| IP |
IE | ||
|
| Total gas quantity |
Arc time | Total operating hours | |
Operating mode | Polarity | Ignition procedure | Special functions
Set values, actual values, hold values for welding current and welding voltage, various other actual values as well as general system data are displayed.
The current data for the welding system is displayed according to the selected welding process.
For TIG AC, for example:
Machine name | Hall | Cell |
| ||
ACTUAL | ||
| ||
Main current | Lowering current | Balance |
Starting current | Final current | Electrode diameter |
UpSlope | DownSlope | Polarity |
|
| IP |
IE | ||
|
| Total gas quantity |
Arc time | Total operating hours | |
Operating mode | Polarity | Ignition procedure | Special functions
Set values, actual values, hold values for welding current and welding voltage, various other actual values as well as general system data are displayed.
The Documentation entry shows the last 100 logbook entries. These logbook entries can be welds, errors, warnings, notifications, and events.
The "Time filter" button can be used to filter the displayed data by a specific time period. This is entered with date (yyyy MM dd) and time (hh mm), each from - to.
An empty filter reloads the most recent welding operations.
The display of welding operations, errors, warnings, notifications, and events can be deactivated.
The following data is displayed:
(1) | Number of the weld |
(2) | Start time (date and time) |
(3) | Duration of welding in s |
(4) | Welding current in A (average) |
(5) | Welding voltage in V (average) |
(6) | Wire speed in m/min |
(7) | IP - arc power in W (based on real-time values according to ISO/TR 18491) |
(8) | IE - arc energy in kJ (as the total throughout the entire welding process according to ISO/TR 18491) |
If present in the system, robot speed and jobs are also displayed.
Clicking on a logbook entry will display the details for that entry.
Details for welds:
Section No.
(9) | Duration of the welding section in s |
(10) | Welding current in A (average) |
(11) | Welding voltage in V (average) |
(12) | Wire speed in m/min |
(13) | Welding speed (cm/min) |
(14) | Arc power from instantaneous values in W (for details see page (→)) |
(15) | Arc energy in kJ (for details see page (→)) |
(16) | Job No. |
(17) | Process |
Additional values can be also displayed by clicking on the "Insert column" button:
If the OPT/i Documentation option is present on the power source, individual sections of welds can also be displayed.
The documentation can be exported in the desired format using the "PDF" and "CSV" buttons.
For CSV exports, the OPT/i documentation option must be present on the power source.
The Documentation entry shows the last 100 logbook entries. These logbook entries can be welds, errors, warnings, notifications, and events.
The "Time filter" button can be used to filter the displayed data by a specific time period. This is entered with date (yyyy MM dd) and time (hh mm), each from - to.
An empty filter reloads the most recent welding operations.
The display of welding operations, errors, warnings, notifications, and events can be deactivated.
The following data is displayed:
(1) | Number of the weld |
(2) | Start time (date and time) |
(3) | Duration of welding in s |
(4) | Welding current in A (average) |
(5) | Welding voltage in V (average) |
(6) | Wire speed in m/min |
(7) | IP - arc power in W (based on real-time values according to ISO/TR 18491) |
(8) | IE - arc energy in kJ (as the total throughout the entire welding process according to ISO/TR 18491) |
If present in the system, robot speed and jobs are also displayed.
Clicking on a logbook entry will display the details for that entry.
Details for welds:
Section No.
(9) | Duration of the welding section in s |
(10) | Welding current in A (average) |
(11) | Welding voltage in V (average) |
(12) | Wire speed in m/min |
(13) | Welding speed (cm/min) |
(14) | Arc power from instantaneous values in W (for details see page (→)) |
(15) | Arc energy in kJ (for details see page (→)) |
(16) | Job No. |
(17) | Process |
Additional values can be also displayed by clicking on the "Insert column" button:
If the OPT/i Documentation option is present on the power source, individual sections of welds can also be displayed.
The documentation can be exported in the desired format using the "PDF" and "CSV" buttons.
For CSV exports, the OPT/i documentation option must be present on the power source.
If the OPT/i Jobs option is available on the power source, the following can be carried out under the Job data entry:
* | Viewing and exporting as a PDF also works if the OPT/i Jobs option is not available on the power source. |
If the OPT/i Jobs option is available on the power source, the following can be carried out under the Job data entry:
* | Viewing and exporting as a PDF also works if the OPT/i Jobs option is not available on the power source. |
The job overview lists all jobs stored in the welding system.
After clicking on a job, the data and parameters stored for this job are displayed.
Job data and parameters can only be viewed in the job overview. The column width for parameters and values can be easily adjusted by dragging with the mouse pointer.
Further jobs can be easily added to the list with the displayed data by clicking on the "Add job" button.
All added jobs are compared with the selected job.
Existing jobs in the welding system can be optimized, provided the OPT/i Jobs option is available on the power source.
To help when editing the job, further jobs can be easily added to the list with the displayed data by clicking on "Add job".
Creating a new job
This function allows externally stored jobs to be transferred into the welding system, provided the OPT/i Jobs option is available on the power source.
This function allows the power source to store jobs externally, provided the OPT/i Jobs option is available on the power source.
The jobs are exported as an XML file to the computer's download folder.
Under Job overview and Edit job, existing jobs in the welding system can be exported as PDF or CSV files.
For CSV export, the OPT/i Jobs option must be available on the power source.
The PDF settings or CSV settings are displayed.
A PDF or CSV file of the selected jobs is created and saved depending on the settings for the browser used.
Under Process parameters, you can view and modify general process parameters and process parameters for components & monitoring of a power source.
Changing process parameters
Under Process parameters, you can view and modify general process parameters and process parameters for components & monitoring of a power source.
Changing process parameters
The power source configuration can be viewed and modified under Designation & location.
Under the Save and restore entry
Under the Save and restore entry
Starting a backup
Finding a recovery file
If you have any questions about configuration, contact your network administrator.
Under the User administration entry
User management is created on one power source and can then be saved with the export/import function and transferred to other power sources.
Under the User administration entry
User management is created on one power source and can then be saved with the export/import function and transferred to other power sources.
Existing users can be viewed, changed and deleted, new users can be created.
Viewing/changing a user:
Deleting a user:
Creating a user:
Existing user roles can be viewed, changed and deleted, new user roles can be created.
Viewing/changing a user role:
The "Administrator" role cannot be changed.
Deleting a user role:
The "Administrator" and "locked" roles cannot be deleted.
Creating a user role:
Exporting users and user roles from a power source
User management for the power source is stored in the computer's download folder.
File format: userbackup_SNxxxxxxxx_YYYY_MM_DD_hhmmss.user
SN = serial number, YYYY = year, MM = month, DD = day
hh = hour, mm = minute, ss = second
Importing users and user roles into a power source
User management is stored on the power source.
To activate a CENTRUM server
(CENTRUM = Central User Management)
The Overview entry displays the components and options in the welding system with all the available information, e.g. firmware version, item number, serial number, production date, etc.
The Overview entry displays the components and options in the welding system with all the available information, e.g. firmware version, item number, serial number, production date, etc.
Click on the "Expand all groups" button to see further details about the individual system components.
Example power source:
Click on the "Collapse all groups" button to hide the details of the system components.
Click on the "Save as xml file" button to create an XML file from the details of the system components. This XML file can either be opened or saved.
Under the Update entry, the firmware of the power source can be updated.
The current firmware version on the power source is displayed.
Update the power source firmware:
The update file can be downloaded, for example, from the following link:
http://tps-i.com/index.php/firmware
After the update has been completed, the power source may need to be restarted.
After the update has been successfully completed, a confirmation message is displayed.
Under the Update entry, the firmware of the power source can be updated.
The current firmware version on the power source is displayed.
Update the power source firmware:
The update file can be downloaded, for example, from the following link:
http://tps-i.com/index.php/firmware
After the update has been completed, the power source may need to be restarted.
After the update has been successfully completed, a confirmation message is displayed.
The SmartManager is not available during the restart.
After the restart, the SmartManager may no longer be available.
If you select No, the new software functions will be activated the next time the power is turned on/off.
Under the Update entry, the Fronius WeldConnect mobile application can also be called up. Fronius WeldConnect supports welders, designers and work planners in estimating various welding parameters.
Fronius WeldConnect
Fronius WeldConnect is available as follows:
The parameters found for the mobile application can be transferred to the power source via WLAN connection as a welding job (IP address input required).
The function packages, special characteristics, options, etc. that are available on the power source can be displayed under the Function packages entry.
New function packages can also be loaded.
The function packages, special characteristics, options, etc. that are available on the power source can be displayed under the Function packages entry.
New function packages can also be loaded.
Under Welding Packages, the welding packages available on the power source are displayed with the respective item numbers, e.g.:
Possible extensions:
Under Options, the options available on the power source are displayed with the respective item numbers and possible extensions, e.g.:
Options
Possible extensions
Under the Screenshot entry, a digital image of the power source display can be created at any time, regardless of navigation or set values.
Depending on the browser you are using, different functions are available for saving the screenshot, and the display may vary.
Under the Screenshot entry, a digital image of the power source display can be created at any time, regardless of navigation or set values.
Depending on the browser you are using, different functions are available for saving the screenshot, and the display may vary.
The power sources are equipped with an intelligent safety system, meaning it has been possible to dispense with nearly all fuses. After a possible malfunction has been remedied, the power source can be used again as normal.
Possible malfunctions, warning notices or status codes are shown on the display as plain text dialogues.
The power sources are equipped with an intelligent safety system, meaning it has been possible to dispense with nearly all fuses. After a possible malfunction has been remedied, the power source can be used again as normal.
Possible malfunctions, warning notices or status codes are shown on the display as plain text dialogues.
The power sources are equipped with an intelligent safety system, meaning it has been possible to dispense with nearly all fuses. After a possible malfunction has been remedied, the power source can be used again as normal.
Possible malfunctions, warning notices or status codes are shown on the display as plain text dialogues.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Danger due to insufficient ground conductor connection.
This can result in serious personal injury and damage to property.
The housing screws provide a suitable ground conductor connection for grounding the housing.
The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.
Cause: | Mains lead damaged or broken, mains plug not inserted |
Remedy: | Check mains lead, if necessary insert mains plug |
Cause: | Mains socket or mains plug faulty |
Remedy: | Replace faulty parts |
Cause: | Mains fuse protection |
Remedy: | Replace mains fuse |
Cause: | Short circuit on the 24 V power supply of the SpeedNet connection or external sensor |
Remedy: | Disconnect connected components |
Cause: | Overload; the duty cycle has been exceeded |
Remedy: | Check duty cycle |
Cause: | Thermostatic automatic circuit breaker has been tripped |
Remedy: | Wait until the power source automatically comes back on after the end of the cooling phase |
Cause: | Limited supply of cooling air |
Remedy: | Ensure accessibility to cooling air ducts |
Cause: | The fan in the power source is faulty |
Remedy: | Contact After-Sales Service |
Cause: | Incorrect ground connection |
Remedy: | Check ground connection and terminal for polarity |
Cause: | Power cable in welding torch damaged or broken. |
Remedy: | Replace the welding torch |
Cause: | Control plug not plugged in |
Remedy: | Plug in control plug |
Cause: | Welding torch or welding torch control line faulty |
Remedy: | Replace the welding torch |
Cause: | Interconnecting hosepack defective or not correctly connected (not in the case of power sources with integrated wire drive) |
Remedy: | Check interconnecting hosepack |
Cause: | Gas cylinder empty |
Remedy: | Change gas cylinder |
Cause: | Gas pressure regulator faulty |
Remedy: | Replace the gas pressure regulator |
Cause: | Gas hose is not fitted or is damaged |
Remedy: | Fit or change gas hose |
Cause: | Welding torch faulty |
Remedy: | Change welding torch |
Cause: | Gas solenoid valve faulty |
Remedy: | Contact After-Sales Service |
Cause: | Wrong welding parameters, wrong correction parameters |
Remedy: | Check settings |
Cause: | Poor ground earth connection |
Remedy: | Establish good contact with workpiece |
Cause: | Several power sources welding one part |
Remedy: | Increase distance between hosepacks and grounding cables; Do not use a common ground. |
Cause: | Too little or no shielding gas |
Remedy: | Check pressure regulator, gas hose, gas solenoid valve, welding torch gas connection, etc. |
Cause: | Welding torch leaks |
Remedy: | Change welding torch |
Cause: | Incorrect or heavily worn contact tip |
Remedy: | Change contact tip |
Cause: | Incorrect wire alloy or incorrect wire diameter |
Remedy: | Check wire electrode in use |
Cause: | Incorrect wire alloy or incorrect wire diameter |
Remedy: | Check the weldability of the parent material |
Cause: | Shielding gas not suitable for wire alloy |
Remedy: | Use correct shielding gas |
Cause: | Shielding gas, wirefeeder, welding torch or workpiece contaminated or magnetically charged |
Remedy: | Perform R/L alignment; Adjust arc length; Check shielding gas, wirefeeder, welding torch position or workpiece for contamination or magnetic charge |
Cause: | Incorrect arrangement of welding torch hosepack |
Remedy: | Arrange the welding torch hosepack in as straight a line as possible, avoiding tight bends |
Cause: | Braking force has been set too high |
Remedy: | Loosen the brake |
Cause: | Contact tip hole too narrow |
Remedy: | Use suitable contact tip |
Cause: | Inner liner in the welding torch faulty |
Remedy: | Check the inner liner for kinks, dirt, etc. and replace if necessary |
Cause: | Feed rollers not suitable for wire electrode used |
Remedy: | Use suitable feed rollers |
Cause: | Feed rollers have the wrong contact pressure |
Remedy: | Optimize contact pressure |
Cause: | Welding torch is inadequately sized |
Remedy: | Observe duty cycle and load limits |
Cause: | For water-cooled systems only: Coolant flow too low |
Remedy: | Check coolant level, coolant flow rate, coolant contamination, etc.; coolant pump blocked: Switch on the shaft of the coolant pump at the gland using a screwdriver |
Cause: | For water-cooled systems only: The "Cooling unit operating mode" setup parameter is set to "off". |
Remedy: | In the Setup menu, set the "Cooling unit operating mode" parameter to "eco", "on" or "auto" in the component settings. |
Under normal operating conditions, the power source requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.
Under normal operating conditions, the power source requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all devices and components involved, and disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.
Air inlets and outlets must never be covered, not even partially.
Danger due to the effect of compressed air.
This can result in damage to property.
Do not clean electronic components with compressed air from a short distance.
IMPORTANT! To update the firmware you need a PC or laptop that is connected to the power source via an Ethernet network.
Materials should be disposed of according to valid local and national regulations.
Gas nozzle size | 4 | 5 | 6 | 7 | 8 | 10 |
Average consumption | 6 l/min | 8 l/min | 10 l/min | 12 l/min | 12 l/min | 15 l/min |
Gas nozzle size | 4 | 5 | 6 | 7 | 8 | 10 |
Average consumption | 6 l/min | 8 l/min | 10 l/min | 12 l/min | 12 l/min | 15 l/min |
Gas nozzle size | 4 | 5 | 6 | 7 | 8 | 10 |
Average consumption | 6 l/min | 8 l/min | 10 l/min | 12 l/min | 12 l/min | 15 l/min |
Wire electrode diameter | 1.0 mm | 1.2 mm | 1.6 mm | 2.0 mm | 2 x 1.2 mm (TWIN) |
Average consumption | 10 l/min | 12 l/min | 16 l/min | 20 l/min | 24 l/min |
Average wire electrode consumption at a wire speed of 5 m/min | |||
| 1.0 mm wire electrode diameter | 1.2 mm wire electrode diameter | 1.6 mm wire electrode diameter |
Steel wire electrode | 1.8 kg/h | 2.7 kg/h | 4.7 kg/h |
Aluminum wire electrode | 0.6 kg/h | 0.9 kg/h | 1.6 kg/h |
CrNi wire electrode | 1.9 kg/h | 2.8 kg/h | 4.8 kg/h |
Average wire electrode consumption at a wire speed of 10 m/min | |||
| 1.0 mm wire electrode diameter | 1.2 mm wire electrode diameter | 1.6 mm wire electrode diameter |
Steel wire electrode | 3.7 kg/h | 5.3 kg/h | 9.5 kg/h |
Aluminum wire electrode | 1.3 kg/h | 1.8 kg/h | 3.2 kg/h |
CrNi wire electrode | 3.8 kg/h | 5.4 kg/h | 9.6 kg/h |
The duty cycle (ED) is the period of a ten minute cycle in which the device may be operated at the stated power without overheating.
The ED values cited on the rating plate relate to an ambient temperature of 40 °C.
If the ambient temperature is higher, the ED or power must be lowered accordingly.
Example: Welding with 150 A at 60% ED
To use the device without interruptions:
The duty cycle (ED) is the period of a ten minute cycle in which the device may be operated at the stated power without overheating.
The ED values cited on the rating plate relate to an ambient temperature of 40 °C.
If the ambient temperature is higher, the ED or power must be lowered accordingly.
Example: Welding with 150 A at 60% ED
To use the device without interruptions:
For devices designed for special voltages, the technical data on the rating plate applies.
The following applies for all devices with a permitted grid voltage of up to 460 V: The standard mains plug allows the user to operate with a grid voltage of up to 400 V. For grid voltages up to 460 V fit a mains plug permitted for such use or install the mains supply directly.
Mains voltage (U1) | 3 x 400 V |
Max. effective primary current (I1eff) | 12.7 A |
Max. primary current (I1max) | 16.9 A |
Mains fuse | 16 A slow-blow |
Mains voltage tolerance | +/- 15 % |
Mains frequency | 50/60 Hz |
Cos phi (1) | 0.99 |
Max. permitted grid impedance Zmax on PCC1) | 156 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 300 A |
MIG/MAG | 3 - 300 A |
MMA | 10 - 300 A |
Welding current | 40% / 300 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 29.0 V |
MMA | 20.4 - 32.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 99 V |
Striking voltage (UP) | 10 kV |
Protection class | IP 23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 700 x 300 x 510 mm |
Weight | 46.4 kg / 102.29 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 39.7 W |
Power source efficiency at | 87 % |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400-V and 50-Hz public grid |
2) | A device in emissions class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 380 / 400 / 460 V |
Max. effective primary current (I1eff) |
|
3 x 380 V | 13.57 A |
3 x 400 V | 12.7 A |
3 x 460 V | 11.2 A |
Max. primary current (I1max) |
|
3 x 380 V | 18.1 A |
3 x 400 V | 16.9 A |
3 x 460 V | 14.8 A |
Mains fuse protection | 16 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 156 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 300 A |
MIG/MAG | 3 - 300 A |
MMA | 10 - 300 A |
Welding current | 40% / 300 A |
Output voltage range according to standard characteristic (U2) | |
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 29.0 V |
MMA | 20.4 - 32.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 99 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 700 x 300 x 510 mm |
Weight | 45.1 kg / 99.43 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 39.7 W |
Power source efficiency at | 87% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 200/230/240/380/400/460/600 V |
Max. effective primary current (I1eff) |
|
3 x 200 V | 26.1 A |
3 x 230 V | 22.5 A |
3 x 240 V | 20.9 A |
3 x 380 V | 13.5 A |
3 x 400 V | 12.7 A |
3 x 460 V | 11.2 A |
3 x 600 V | 11.6 A |
Max. primary current (I1max) |
|
3 x 200 V | 35.2 A |
3 x 230 V | 30.2 A |
3 x 240 V | 28.2 A |
3 x 380 V | 18.1 A |
3 x 400 V | 16.9 A |
3 x 460 V | 14.8 A |
3 x 600 V | 14.8 A |
Mains fuse |
|
Mains voltage tolerance | -10 / +6 % |
Mains frequency | 50/60 Hz |
Cos phi (1) | 0.99 |
Max. permitted grid impedance Zmax on PCC1) | 172 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 300 A |
MIG/MAG | 3 - 300 A |
MMA | 10 - 300 A |
Welding current | 40% / 300 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 29.0 V |
MMA | 20.4 - 32.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 104 V |
Striking voltage (UP) | 10 kV |
Protection class | IP 23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE, CSA |
Dimensions l x w x h | 700 x 300 x 510 mm |
Weight | 46.5 kg / 102.52 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 39.7 W |
Power source efficiency at | 87 % |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400-V and 50-Hz public grid |
2) | A device in emissions class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 400 V |
Max. effective primary current (I1eff) | 18.4 A |
Max. primary current (I1max) | 24.9 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | ~ 92 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 400 A |
MIG/MAG | 3 - 400 A |
MMA | 10 - 400 A |
Welding current | 40% / 400 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 34.0 V |
MMA | 20.4 - 36.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 99 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 510 mm |
Weight | 49.9 kg / 110.01 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 40.9 W |
Power source efficiency at | 87% |
Max. shielding gas pressure | 7 bar / 5 dB (A) |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 380 / 400 / 460 V |
Max. effective primary current (I1eff) |
|
3 x 380 V | 19.3 A |
3 x 400 V | 18.4 A |
3 x 460 V | 16.1 A |
Max. primary current (I1max) |
|
3 x 380 V | 26.2 A |
3 x 400 V | 24.9 A |
3 x 460 V | 21.7 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | ~ 92 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 400 A |
MIG/MAG | 3 - 400 A |
MMA | 10 - 400 A |
Welding current | 40% / 400 A |
Output voltage range according to standard characteristic (U2) | |
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 34.0 V |
MMA | 20.4 - 36.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 99 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 510 mm |
Weight | 48.0 kg / 105.82 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 40.9 W |
Power source efficiency at | 87% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 200/230/240/380/400/460/600 V |
Max. effective primary current (I1eff) |
|
3 x 200 V | 37.8 A |
3 x 230 V | 34.1 A |
3 x 240 V | 30.7 A |
3 x 380 V | 19.3 A |
3 x 400 V | 18.4 A |
3 x 460 V | 16.1 A |
3 x 600 V | 15.7 A |
Max. primary current (I1max) |
|
3 x 200 V | 53.3 A |
3 x 230 V | 45.6 A |
3 x 240 V | 41.7 A |
3 x 380 V | 26.2 A |
3 x 400 V | 24.9 A |
3 x 460 V | 21.7 A |
3 x 600 V | 20.8 A |
Mains fuse protection |
|
3 x 200/230/240 V | 63 A slow-blow |
3 x 380/400/460 V | 35 A slow-blow |
3 x 600 V | 16 A slow-blow |
Mains voltage tolerance | -10 / +6% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 97 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 400 A |
MIG/MAG | 3 - 400 A |
MMA | 10 - 400 A |
Welding current | 40% / 400 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 34.0 V |
MMA | 20.4 - 36.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 104 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 510 mm |
Weight | 49.3 kg / 108.69 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 40.9 W |
Power source efficiency at | 87% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 400 V |
Max. effective primary current (I1eff) | 21.9 A |
Max. primary current (I1max) | 34.4 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 55 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 500 A |
MIG/MAG | 3 - 500 A |
MMA | 10 - 500 A |
Welding current | 40% / 500 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 30.0 V |
MIG/MAG | 14.2 - 36.5 V |
MMA | 20.4 - 40.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 99 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 510 mm |
Weight | 51.5 kg / 113.54 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 40.5 W |
Power source efficiency at | 88% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 380 / 400 / 460 V |
Max. effective primary current (I1eff) |
|
3 x 380 V | 22.8 A |
3 x 400 V | 21.9 A |
3 x 460 V | 19.2 A |
Max. primary current (I1max) |
|
3 x 380 V | 36.0 A |
3 x 400 V | 34.4 A |
3 x 460 V | 30.0 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 55 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 500 A |
MIG/MAG | 3 - 500 A |
MMA | 10 - 500 A |
Welding current | 40% / 500 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 30 V |
MIG/MAG | 14.2 - 36.5 V |
MMA | 20.4 - 40.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 99 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 510 mm |
Weight | 49.7 kg / 109.57 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 40.5 W |
Power source efficiency at | 88% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 200/230/240/380/400/460/600 V |
Max. effective primary current (I1eff) |
|
3 x 200 V | 43.1 A |
3 x 230 V | 38.9 A |
3 x 240 V | 36.2 A |
3 x 380 V | 22.8 A |
3 x 400 V | 21.9 A |
3 x 460 V | 19.2 A |
3 x 600 V | 18.4 A |
Max. primary current (I1max) |
|
3 x 200 V | 68.1 A |
3 x 230 V | 62.0 A |
3 x 240 V | 57.3 A |
3 x 380 V | 36.0 A |
3 x 400 V | 34.4 A |
3 x 460 V | 30.0 A |
3 x 600 V | 27.2 A |
Mains fuse protection | |
3 x 200/230/240 V | 63 A slow-blow |
3 x 380/400/460/600 V | 35 A slow-blow |
Mains voltage tolerance | -10 / +6% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 71 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 500 A |
MIG/MAG | 3 - 500 A |
MMA | 10 - 500 A |
Welding current at 10 min/40 °C (104 °F) |
|
U1 = 200 - 240 V |
|
U1 = 200 - 240 V |
|
U1 = 380 - 600 V | 40% / 500 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 30.0 V |
MIG/MAG | 14.2 - 36.5 V |
MMA | 20.4 - 40.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 104 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 510 mm |
Weight | 51.3 kg / 113.10 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 40.5 W |
Power source efficiency at | 88% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 400 V |
Max. effective primary current (I1eff) | 15.5 A |
Max. primary current (I1max) | 18.4 A |
Mains fuse protection | 16 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 143 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 300 A |
MIG/MAG | 3 - 300 A |
MMA | 10 - 300 A |
Welding current | 40% / 300 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 29.0 V |
MMA | 20.4 - 32.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 101 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 64.4 kg / 141.98 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 48.5 W |
Power source efficiency at | 83% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 380 / 400 / 460 V |
Max. effective primary current (I1eff) |
|
3 x 380 V | 16.3 A |
3 x 400 V | 15.5 A |
3 x 460 V | 13.6 A |
Max. primary current (I1max) |
|
3 x 380 V | 19.4 A |
3 x 400 V | 18.4 A |
3 x 460 V | 16.2 A |
Mains fuse protection | 16 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 143 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 300 A |
MIG/MAG | 3 - 300 A |
MMA | 10 - 300 A |
Welding current | 40% / 300 A |
Output voltage range according to standard characteristic (U2) | |
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 29.0 V |
MMA | 20.4 - 32.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 101 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 63.1 kg / 139.11 lb. |
Max. noise emission (LWA) | 75 dB (A) |
Idle state power consumption | 48.5 W |
Power source efficiency at | 83% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 200/230/240/380/400/460/600 V |
Max. effective primary current (I1eff) |
|
3 x 200 V | 31.0 A |
3 x 230 V | 26.7 A |
3 x 240 V | 23.5 A |
3 x 380 V | 16.3 A |
3 x 400 V | 15.5 A |
3 x 460 V | 13.6 A |
3 x 600 V | 12.3 A |
Max. primary current (I1max) |
|
3 x 200 V | 37.9 A |
3 x 230 V | 32.5 A |
3 x 240 V | 28.8 A |
3 x 380 V | 19.4 A |
3 x 400 V | 18.4 A |
3 x 460 V | 16.2 A |
3 x 600 V | 14.9 A |
Mains fuse protection | |
3 x 200/230/240 V | 35 A slow-blow |
3 x 380/400/460/600 V | 16 A slow-blow |
Mains voltage tolerance | -10 / +6% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 121 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 300 A |
MIG/MAG | 3 - 300 A |
MMA | 10 - 300 A |
Welding current | 40% / 300 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 29.0 V |
MMA | 20.4 - 32.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 102 V |
Striking voltage (UP ) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 64.5 kg / 142.20 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 48.5 W |
Power source efficiency at | 83% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 400 V |
Max. effective primary current (I1eff) | 22.7 A |
Max. primary current (I1max) | 30.8 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 97 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 400 A |
MIG/MAG | 3 - 400 A |
MMA | 10 - 400 A |
Welding current | 40% / 400 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 34.0 V |
MMA | 20.4 - 36.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 101 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 68.8 kg / 151.68 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 46.7 W |
Power source efficiency at | 84% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 380 / 400 / 460 V |
Max. effective primary current (I1eff) |
|
3 x 380 V | 23.9 A |
3 x 400 V | 22.7 A |
3 x 460 V | 19.8 A |
Max. primary current (I1max) |
|
3 x 380 V | 32.3 A |
3 x 400 V | 30.8 A |
3 x 460 V | 27.1 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 97 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 400 A |
MIG/MAG | 3 - 400 A |
MMA | 10 - 400 A |
Welding current | 40% / 400 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 34.0 V |
MMA | 20.4 - 36.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 101 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 66.9 kg / 147.49 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 46.7 W |
Power source efficiency at | 84% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 200/230/240/380/400/460/600 V |
Max. effective primary current (I1eff) |
|
3 x 200 V | 45.7 A |
3 x 230 V | 39.4 A |
3 x 240 V | 34.6 A |
3 x 380 V | 23.9 A |
3 x 400 V | 22.7 A |
3 x 460 V | 19.8 A |
3 x 600 V | 18.0 A |
Max. primary current (I1max) |
|
3 x 200 V | 63.3 A |
3 x 230 V | 54.5 A |
3 x 240 V | 47.1 A |
3 x 380 V | 32.3 A |
3 x 400 V | 30.8 A |
3 x 460 V | 27.1 A |
3 x 600 V | 25.1 A |
Mains fuse protection | |
3 x 200/230/240 V | 63 A slow-blow |
3 x 380/400/460/600 V | 35 A slow-blow |
Mains voltage tolerance | -10 / +6% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | ~ 90 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 400 A |
MIG/MAG | 3 - 400 A |
MMA | 10 - 400 A |
Welding current | 40% / 400 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 26.0 V |
MIG/MAG | 14.2 - 34.0 V |
MMA | 20.4 - 36.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 1021 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 68.4 kg / 150.80 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 46.7 W |
Power source efficiency at | 84% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 400 V |
Max. effective primary current (I1eff) | 24.8 A |
Max. primary current (I1max) | 39.2 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 50 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 500 A |
MIG/MAG | 3 - 500 A |
MMA | 10 - 500 A |
Welding current | 40% / 500 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 30.0 V |
MIG/MAG | 14.2 - 36.5 V |
MMA | 20.4 - 40.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 101 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 69.6 kg / 153.44 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 48.5 W |
Power source efficiency at | 85% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 380 / 400 / 460 V |
Max. effective primary current (I1eff) |
|
3 x 380 V | 26.0 A |
3 x 400 V | 24.8 A |
3 x 460 V | 21.6 A |
Max. primary current (I1max) |
|
3 x 380 V | 41.0 A |
3 x 400 V | 39.2 A |
3 x 460 V | 34.2 A |
Mains fuse protection | 35 A slow-blow |
Mains voltage tolerance | +/- 15% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 50 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 500 A |
MIG/MAG | 3 - 500 A |
MMA | 10 - 500 A |
Welding current | 40% / 500 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 30.0 V |
MIG/MAG | 14.2 - 36.5 V |
MMA | 20.4 - 40.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 101 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 67.8 kg / 149.470 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 48.5 W |
Power source efficiency at | 85% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Mains voltage (U1) | 3 x 200/230/240/380/400/460/600 V |
Max. effective primary current (I1eff) |
|
3 x 200 V | 44.6 A |
3 x 230 V | 44.0 A |
3 x 240 V | 43.1 A |
3 x 380 V | 26.0 A |
3 x 400 V | 24.8 A |
3 x 460 V | 21.6 A |
3 x 600 V | 18.9 A |
Max. primary current (I1max) |
|
3 x 200 V | 70.5 A |
3 x 230 V | 69.9 A |
3 x 240 V | 65.5 A |
3 x 380 V | 41.0 A |
3 x 400 V | 39.2 A |
3 x 460 V | 34.2 A |
3 x 600 V | 29.8 A |
Mains fuse protection | |
3 x 200/230/240 V | 63 A slow-blow |
3 x 380/400/460/600 V | 35 A slow-blow |
Mains voltage tolerance | -10 / +6% |
Mains frequency | 50 / 60 Hz |
Cos phi (1) | 0.99 |
Max. permitted mains impedance Zmax on PCC1) | 52 mOhm |
Recommended residual-current circuit breaker | Type B |
Welding current range (I2) |
|
TIG | 3 - 500 A |
MIG/MAG | 3 - 500 A |
MMA | 10 - 500 A |
Welding current at 10 min/40 °C (104 °F) |
|
U1 = 200 - 240 V |
|
U1 = 200 -240V |
|
U1 = 380 - 600 V | 40% / 500 A |
Output voltage range according to standard characteristic (U2) |
|
TIG | 10.1 - 30.0 V |
MIG/MAG | 14.2 - 36.5 V |
MMA | 20.4 - 40.0 V |
Open circuit voltage (U0 peak / U0 r.m.s) | 102 V |
Striking voltage (UP) | 10 kV |
Protection class | IP23 |
Type of cooling | AF |
Overvoltage category | III |
Pollution degree according to IEC60664 | 3 |
EMC emission class | A 2) |
Safety symbols | S, CE |
Dimensions l x w x h | 706 x 300 x 720 mm |
Weight | 69.2 kg / 152.56 lb. |
Max. noise emission (LWA) | 77 dB (A) |
Idle state power consumption | 48.5 W |
Power source efficiency at | 85% |
Max. shielding gas pressure | 7 bar/102 psi |
1) | Interface to a 230/400 V and 50 Hz public grid |
2) | A device in emission class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. Electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. |
Compliance with directive 2014/53/EU - Radio Equipment Directive (RED)
The following table provides information on the frequency bands used and the maximum HF transmission power of Fronius wireless radio products sold in the EU, in accordance with Articles 10.8 (a) and 10.8 (b) of the RED.
Frequency range | Modulation |
---|---|
2412 - 2462 MHz | 802.11b: DSSS 802.11 g: OFDM 802.11n: OFDM |
13.56 MHz | Functions: Protocol standards: Data rate: Reader/writer, card emulation, peer to peer modes |
2402 - 2482 MHz | GFSK |
Overview with critical raw materials:
An overview of which critical raw materials are contained in this device can be found at the following Internet address.
www.fronius.com/en/about-fronius/sustainability.