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42,0426,0250,EN 003-05032018
MagicWave 190
MagicWave 230i
TransTig 230i
Operating Instructions
TIG Power source
EN
2
3
EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.
DANGER! Indicates immediate and real danger. If it is not avoided, death or serious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
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Contents
Safety rules ................................................................................................................................................ 9
General information 21
General ...................................................................................................................................................... 23
Device concept ..................................................................................................................................... 23
Functional principle ............................................................................................................................... 23
Application areas .................................................................................................................................. 23
FCC / RSS Compliance ........................................................................................................................ 24
Warning notices on the device.............................................................................................................. 25
System components .................................................................................................................................. 26
General ................................................................................................................................................. 26
Overview ............................................................................................................................................... 26
Options.................................................................................................................................................. 26
Control elements and connections 27
Control panel.............................................................................................................................................. 29
General ................................................................................................................................................. 29
Safety.................................................................................................................................................... 29
Control panel......................................................................................................................................... 29
The favourites button ................................................................................................................................. 31
Assigning the Favourites button............................................................................................................ 31
Retrieving favourites ............................................................................................................................. 31
Deleting favourites ................................................................................................................................ 32
Assigning EasyJobs to the Favourites button ....................................................................................... 32
Connections, switches and mechanical components ................................................................................ 34
Connections, switches and mechanical components ........................................................................... 34
Installation and commissioning 37
Minimum equipment needed for welding task............................................................................................ 39
General ................................................................................................................................................. 39
TIG AC welding..................................................................................................................................... 39
TIG DC welding..................................................................................................................................... 39
MMA welding ........................................................................................................................................ 39
Before installation and commissioning....................................................................................................... 40
Safety.................................................................................................................................................... 40
Utilisation for intended purpose ............................................................................................................ 40
Setup regulations .................................................................................................................................. 40
Mains connection .................................................................................................................................. 40
Generator-powered operation............................................................................................................... 41
Information on system components ...................................................................................................... 41
Connecting the mains cable....................................................................................................................... 42
General ................................................................................................................................................. 42
Safety.................................................................................................................................................... 42
Connecting the mains cable.................................................................................................................. 42
Start-up ...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
Remarks on the cooling unit ................................................................................................................. 43
General ................................................................................................................................................. 43
Assembling the system components (overview)................................................................................... 44
Connecting the gas cylinder.................................................................................................................. 45
Connecting the welding torch to the power source and the cooling unit............................................... 46
Establishing a ground earth connection to the workpiece..................................................................... 46
Locking and unlocking the power source using the NFC key .................................................................... 47
General remarks ................................................................................................................................... 47
Restrictions ........................................................................................................................................... 47
6
Welding 49
TIG modes ................................................................................................................................................. 51
Safety.................................................................................................................................................... 51
Symbols and their explanations ............................................................................................................ 51
2-step mode .......................................................................................................................................... 52
4-step mode .......................................................................................................................................... 52
Spot welding ......................................................................................................................................... 53
TIG welding................................................................................................................................................ 54
Safety.................................................................................................................................................... 54
Preparations.......................................................................................................................................... 54
TIG welding........................................................................................................................................... 54
Welding parameters for TIG DC welding .............................................................................................. 55
Welding parameters for TIG AC welding .............................................................................................. 58
Igniting the arc ........................................................................................................................................... 63
General ................................................................................................................................................. 63
Igniting the arc using high frequency(HF ignition)................................................................................. 63
Touchdown ignition ............................................................................................................................... 64
End of welding ...................................................................................................................................... 65
Ignition time out, TIG pulsing and tacking function .................................................................................... 66
Ignition timeout function ........................................................................................................................ 66
TIG pulsing............................................................................................................................................ 66
Tacking function.................................................................................................................................... 67
MMA welding ............................................................................................................................................. 68
Safety.................................................................................................................................................... 68
Preparations.......................................................................................................................................... 68
MMA welding ........................................................................................................................................ 69
Welding parameters for manual metal arc welding............................................................................... 70
Starting current >100% (HotStart) ........................................................................................................ 72
Starting current <100% (SoftStart)........................................................................................................ 73
Anti-stick function.................................................................................................................................. 73
EasyJob mode ........................................................................................................................................... 74
Storing EasyJob operating points ......................................................................................................... 74
Retrieving EasyJob operating points .................................................................................................... 75
Deleting EasyJob operating points ....................................................................................................... 75
Welding job ................................................................................................................................................ 76
Safety.................................................................................................................................................... 76
Preparatory work................................................................................................................................... 76
Welding a job ........................................................................................................................................ 76
Setup settings 77
The Setup menu ........................................................................................................................................ 79
General ................................................................................................................................................. 79
Accessing the Setup menu ................................................................................................................... 79
Overview ............................................................................................................................................... 80
Changing menus and parameters......................................................................................................... 81
The TIG menu............................................................................................................................................ 83
Parameters in the TIG DC menu .......................................................................................................... 83
Parameters in the TIG AC menu........................................................................................................... 84
The MMA menu ......................................................................................................................................... 88
Parameters in the rod electrode menu.................................................................................................. 88
Ignition settings .......................................................................................................................................... 91
Ignition setting parameters.................................................................................................................... 91
The gas menu ............................................................................................................................................ 93
Parameters in the Gas menu ................................................................................................................ 93
The components menu .............................................................................................................................. 94
Parameters in the Components menu .................................................................................................. 94
The Job menu ............................................................................................................................................ 95
Save job ................................................................................................................................................ 95
Loading a job ........................................................................................................................................ 96
Deleting a job ........................................................................................................................................ 96
Defaults...................................................................................................................................................... 97
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Overview ............................................................................................................................................... 97
Display - backlighting ............................................................................................................................ 97
Display - languages .............................................................................................................................. 97
Display - Time & Date ........................................................................................................................... 97
Display - Display additional parameters................................................................................................ 98
System - Reset to factory settings ........................................................................................................ 98
Reset website password ....................................................................................................................... 99
Performing R/L alignment ..................................................................................................................... 99
System informations .................................................................................................................................. 101
Device information ................................................................................................................................ 101
SmartManager - The power source website 103
SmartManager - The power source website .............................................................................................. 105
General ................................................................................................................................................. 105
Calling up the power source SmartManager......................................................................................... 105
Fronius .................................................................................................................................................. 105
Changing password / logging off........................................................................................................... 105
Language .............................................................................................................................................. 106
Current system data................................................................................................................................... 107
Current system data.............................................................................................................................. 107
Job-Data .................................................................................................................................................... 108
Job data ................................................................................................................................................ 108
Job overview ......................................................................................................................................... 108
Editing a job .......................................................................................................................................... 108
Importing a job ...................................................................................................................................... 109
Exporting a job ...................................................................................................................................... 109
Exporting job(s) as… ............................................................................................................................ 109
Backup & Restore ...................................................................................................................................... 110
General ................................................................................................................................................. 110
Backup & Restore ................................................................................................................................. 110
Overview .................................................................................................................................................... 111
Overview ............................................................................................................................................... 111
Expanding / reducing all groups............................................................................................................ 111
Export component overview as ............................................................................................................ 111
Update ....................................................................................................................................................... 112
Update .................................................................................................................................................. 112
Function Packages .................................................................................................................................... 113
Function packages................................................................................................................................ 113
Installing a function package................................................................................................................. 113
Screenshot................................................................................................................................................. 114
Screenshot............................................................................................................................................ 114
Troubleshooting and maintenance 115
Troubleshooting ......................................................................................................................................... 117
General ................................................................................................................................................. 117
Safety.................................................................................................................................................... 117
Power source - troubleshooting ............................................................................................................ 117
Care, maintenance and disposal ............................................................................................................... 120
General ................................................................................................................................................. 120
Safety.................................................................................................................................................... 120
At every start-up.................................................................................................................................... 120
Every 2 months ..................................................................................................................................... 120
Every 6 months ..................................................................................................................................... 120
Disposal ................................................................................................................................................ 121
Appendix 123
Technical data
............................................................................................................................................ 125
Special voltages, MagicWave 190 ........................................................................................................ 125
MagicWave 230i ................................................................................................................................... 127
TransTig 230i ........................................................................................................................................ 128
Explanation of footnotes ....................................................................................................................... 129
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9
EN
Safety rules
General
Proper use
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- have sufficient knowledge of automated welding, and
- read and carefully follow these operating instructions as well as the operating instructions for all system components.
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed "General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise
safety.
This is for your personal safety!
The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating
plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating
instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
10
Environmental
conditions
Obligations of the
operator
Obligations of
personnel
Mains connection
Operation or storage of the device outside the stipulated area will be deemed
as not in accordance with the intended purpose. The manufacturer shall not
be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the
section "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident
prevention
- to read these operating instructions, especially the "Safety rules" section
and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to
any harm in your absence.
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to the maximum permissible mains impedance
*)
- criteria with regard to the minimum short-circuit power requirement
*)
*)
at the interface with the public grid
see Technical Data
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the
matter with the power supply company.
NOTE! Ensure that the mains connection is earthed properly
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EN
Protecting yourself and others
Danger from toxic
gases and vapours
Anyone working with the device exposes themselves to numerous risks, e.g.
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those
using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective
visor and regulation filter
- Wear regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing
protection against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent
injury
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in
the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury
from flying sparks, harmful welding fumes, noise, possible risks from
mains current and welding current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/
hour.
12
Danger from flying sparks
Risks from mains
current and welding current
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
Amongst others, the following components are responsible for the degree of
toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's
radiation area.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the
arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool,
the feed rollers and all pieces of metal that are in contact with the welding wire
are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
13
EN
Meandering welding currents
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.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the
welding electrodes of two power sources. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician
to ensure the ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
Operating the device on a grid without a ground conductor and in a socket
without a ground conductor contact will be deemed gross negligence. The
manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on
again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
If the following instructions are ignored, meandering welding currents can develop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.
14
EMC Device Classifications
EMC measures
EMF measures
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas.
This is also true for residential areas in which the energy is supplied from the public low-voltage mains.
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 operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may be
susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, additional measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body
15
EN
Specific hazards
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or
repair work is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with
wire-feed unit) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment
must therefore also be worn when reworking workpieces, and steps must be
taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the
load-carrying equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use
a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
16
Factors affecting
welding results
Danger from
shielding gas cylinders
If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter
is used for the shielding gas connection. Prior to assembly, seal the deviceside thread of the adapter for the shielding gas connection using suitable Teflon tape.
The following requirements with regard to shielding gas quality must be met if
the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they
must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any 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 attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only
use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on
the cylinder.
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.
17
EN
Danger from escaping shielding
gas
Safety measures
at the installation
location and during transport
Safety measures
in normal operation
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least
20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is
taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before every start-up.
A device toppling over could easily kill someone. Place the device on a solid,
level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport
or lifting.
Before transporting the device, allow coolant to drain completely and detach
the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
18
Noise emission
values
Commissioning,
maintenance and
repair
Always fasten the shielding gas cylinder securely and remove it beforehand if
the device is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices
due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other
system components or a different coolant. In addition, all warranty claims will
be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed
containers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's
website.
Check the coolant level before starting to weld, while the system is still cool.
The device generates a maximum sound power level of > 80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to
EN 60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as
shown in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the
specified torque.
19
EN
Safety inspection
Disposal
Safety symbols
Data protection
The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the
same 12-month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may
require.
Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your
dealer or given to one of the approved collection and recycling facilities in your
area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards
of the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with
Directive 2014/53/EU. The full text on the EU Declaration of Conformity can
be found at the following address: 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 the safekeeping of any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal
settings.
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Copyright
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve 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 instructions, we will be most grateful for
your comments.
General information
23
EN
General
Device concept
The TransTig (TT) 230i, MagicWave (MW)
190 and MagicWave (MW) 230i TIG power
sources are fully digitised, microprocessorcontrolled inverter power sources.
Their modular design and potential for system add-ons ensure a high degree of flexibility. The devices can be adapted to any
situation.
The power sources are generator-compatible. They are exceptionally sturdy in dayto-day operation thanks to the protected
control elements and their powder-coated
housings.
The TIG pulsed arc function, with its wide frequency range, is available on both the MagicWave and TransTig.
To optimise the ignition sequence in TIG AC welding, the MagicWave takes account not
only of the diameter of the electrode, but also of its temperature, calculated with reference
to the preceding welding and welding off-times.
Functional principle
The central control and regulation unit of the power sources is coupled with a digital signal
processor. The central control and regulation unit and signal processor control the entire
welding process.
During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired target
state is maintained.
This results in:
- a precise welding process,
- exact reproducibility of all results
- excellent weld properties.
Application areas The devices are used in workshops and industry for manual TIG applications with unal-
loyed and low-alloy steel and high-alloy chrome-nickel steels.
The MagicWave power sources perform exceptionally well when it comes to welding aluminium, aluminium alloys and magnesium due to the variable AC frequency.
24
FCC / RSS Compliance
FCC
This equipment complies with the limit values for a EMC device class A digital device pursuant to Part 15 of the FCC Rules. These limit values are intended to provide an adequate level of protection against harmful emissions
when the device is used in an industrial environment. This device generates
and uses high frequency energy and can cause interference in radio communications if it is not installed and used according to the Operating Instructions.
The use of this device in residential areas will probably cause hazardous interference, in which case the user will be obliged to make good any damage
at his own expense.
Industry Canada RSS
This device complies with the Industry Canada licence-exempt RSS standards. Its use is subject to the following conditions:
(1) The device must not cause any hazardous interference.
(2) The device must be able to cope with any interference, including that
which could adversely affect its operation.
FCC ID: QKWSPBBCU1
IC: 12270A-SPBBCU1
25
EN
Warning notices
on the device
Warning notices and safety symbols are affixed to power sources with the CSA test mark
for use in North America (USA and Canada). These warning notices and safety symbols
must not be removed or painted over. They warn against incorrect operation, as this may
result in serious injury and damage.
* MV power sources: 1 ~ 100 - 230 V
Safety symbols on the rating plate:
Welding is dangerous. The following basic requirements must be met:
- Welders must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved in the welding process must be kept at a safe distance
Do not use the functions described here until you have fully read and understood the
following documents:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the safety
rules
26
System components
General The TransTig and MagicWave power sources can be used with a wide variety of system
add-ons and options.
Overview
(1) TIG welding torch
(2) Power sources
(3) Cooling unit (only for TT / MW 230i)
(4) Trolley with gas cylinder holder
Not illustrated:
- Remote controls
- Pedal remote controls
- Electrode cable
- Grounding cable
Options
(4)
OPT/i TIG Ethernet
(only for TT / MW 230i)
Option for a permanent network connection
Carrying strap option
FP Pulse Pro
function package for the extended pulse function (the Base current and Duty cycle parameters can be set, extended pulse frequency range)
FP Job
Function package for Job mode (EasyJobs, save and edit jobs)
Control elements and connections
29
EN
Control panel
General
Safety
Control panel
NOTE! Due to software updates, you may find that your device has certain func-
tions that are not described in these operating instructions or vice versa. Individual illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.
WARNING! Operating the equipment 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 the operating instructions for the system components, especially the safe-
ty rules
(1)(2)(3)(4)(5)(6)
(7) (8) (10)(9)
30
No. Function
(1) Welding process / Mode button
to select the welding process and operating mode
(2) Gas-test button
to set the required shielding gas flow rate on the gas pressure regulator
After pressing this button, gas flows for 30 seconds. Press the button again to stop
the gas flow prematurely.
(3) Reading zone for NFC keys
MW / TT 230i only and only in certified countries
to lock/unlock the power source using NFC keys
NFC key = NFC card or NFC key ring
(4) Adjusting dial with turn/press function
- To select elements, set values and scroll through lists
- To save jobs when the FP Job function package is present:
if the adjusting dial is pressed for more than 3 seconds, the selected welding
parameters are saved as a job.
An overview of the most important parameters will be displayed.
For more about how to save a job, see Setup settings / the Job menu / Save
job starting on page 95
(5) Menu button
to open the Setup menu
(6) Favourites button
to save / retrieve preferred settings
(7) Display
(8) Hold indicator - welding current
At the end of each welding operation, the actual values for the welding current and
voltage are stored - HOLD lights up.
(9) Status bar
The status bar displays the following information:
- Current welding process
- Current operating mode
- Selected current type
- Active functions (e.g. high frequency ignition, tacking, pulsing, etc.)
- Status of the power source (locked / unlocked)
- Time
- Date
The information shown in the status bar varies according to which welding process
has been selected.
(10) Hold indicator - welding voltage
At the end of each welding operation, the actual values for the welding current and
voltage are stored - HOLD lights up.
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