Fronius MagicWave 190, MagicWave 230i, TransTig 230i Operating Instructions Manual

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42,0426,0250,EN 003-05032018

MagicWave 190
MagicWave 230i
TransTig 230i

Operating Instructions

TIG Power source

EN

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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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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.

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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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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.

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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.

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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.

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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

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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.

20

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.

31

EN

The favourites button

Assigning the Fa­vourites button

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

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

Select the desired parameter in the Setup menu

More information about the Setup menu can be found from page 77 onwards

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

A confirmation message is displayed.

Press the adjusting dial to confirm

The selected parameter is now assigned to the Favourites button.

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

Retrieving favour­ites

Press the Favourites button briefly

The assigned parameter is displayed:

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

The new value takes effect immediately.

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

1

2

3

1

xxxx

**

xxx xxx

32

Deleting favour­ites

Press the Favourites button for longer than 5 seconds

The assigned parameter is deleted and a message is displayed.

Press the adjusting dial to confirm

Assigning Easy­Jobs to the Fa­vourites button

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

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

Select the Job menu from the Setup menu

More information about the Setup menu can be found from page 95 onwards

In the Job menu, set the "EasyJobs to Favourites button" parameter to "on"

Press the Menu key

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

Press the Favourites button

1

2

1

2

3

50 A

**

4

33

EN

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

More information about using EasyJobs can be found in the "EasyJob mode" section start­ing on page 74.

50 A

**

12345

34

Connections, switches and mechanical components

Connections,
switches and me­chanical compo­nents

Front Rear

No. Function

(1) (-) current socket with integrated gas connection

to connect:

- the TIG welding torch

- the electrode cable for manual metal arc welding

Symbols on TransTig power sources:

Symbols on MagicWave power sources:

(2) TMC connection (TIG Multi Connector)

- to connect the TIG welding torch control plug

- to connect pedal remote controls

- to connect the remote control during MMA welding

(3) USB port

To connect USB flash drives (such as service dongles, licence keys, etc.).

IMPORTANT! The USB port is not electrically isolated from the welding circuit.
This means that devices that establish an electrical connection with another device
must not be connected to the USB port.

35

EN

(4) (+) current socket

to connect the grounding cable

Symbols on TransTig power sources:

Symbols on MagicWave power sources:

(5) Mains switch

To switch the power source on and off

Mains switch for MV devices:

(6) Mains cable with strain relief device

for MV devices:
mains cable connection socket

(7) Shielding gas connection

(8) Blanking cover

for Ethernet option

No. Function

36

Installation and commissioning

39

EN

Minimum equipment needed for welding task

General Depending on which welding process you intend to use, a certain minimum equipment lev-

el will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for the welding task
are then described.

TIG AC welding - MagicWave power source

- Grounding (earthing) cable

- TIG welding torch with rocker switch

- Gas connection (shielding gas supply), with pressure regulator

- Filler metals (as required by the application)

TIG DC welding - Power source

- Grounding (earthing) cable

- TIG welding torch with rocker switch

- Gas connection (shielding gas supply)

- Filler metals (as required by the application)

MMA welding - Power source

- Grounding (earthing) cable

- Electrode holder

- Rod electrodes (as required by the application)

40

Before installation and commissioning

Safety

Utilisation for in­tended purpose

The power source is intended exclusively for TIG and MMA welding.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in ac­cordance with the intended purpose.
The manufacturer shall not be liable for any damage resulting from such improper use.

Proper use also includes:

- following all the information in the operating instructions

- carrying out all the specified inspection and servicing work

Setup regulations The device is tested to "Degree of protection IP23", meaning:

- protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49
in.)

- protection against direct sprays of water up to 60° from the vertical

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

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

Mains connection The devices are designed to run on the mains voltage shown on the respective rating

plates. If your version of the device does not come with mains cables and plugs ready-fit­ted, these must be fitted in accordance with national regulations and standards. For details
of fuse protection of the mains lead, please see the Technical Data.

WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All work described in this document must only be carried out by
trained and qualified personnel. All functions described in this document must
only be used by trained and qualified personnel. Do not carry out any of the work
or use any of the functions described until you have fully read and understood the
following documents:

- this document

- all the operating instructions for the system components, especially the safe­ty rules

WARNING! If one of these machines topples over or falls it could cause serious
or even fatal injury. Place device on a solid, level surface in such a way that it re­mains stable.

NOTE! Inadequately dimensioned electrical installations can cause serious dam­age. The incoming mains lead and its fuse must be dimensioned to suit the local
power supply. The technical data shown on the rating plate applies.

41

EN

Generator-pow­ered operation

The power source is generator-compatible.

In order to dimension the required generator output, the maximum apparent power S

1max

of the power source is required.

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

IMPORTANT! The generator apparent power S

GEN

must always be higher than the maxi-

mum apparent power S

1max

of the power source.

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

Information on
system compo­nents

The steps and activities described below include references to various system compo­nents, including:

- Trolley

- Cooling units

- Welding torches, etc.

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

The maximum apparent power S

1max

of the power source can be calculated as follows:

S

1max

= I

1max

x U

1

See device rating plate or technical data for I

1max

and U1 values

The generator apparent power S

GEN

needed is calculated using the following rule of

thumb:

S

GEN

= S

1max

x 1.35

NOTE! The voltage delivered by the generator must never exceed the upper or
lower limits of the mains voltage tolerance range. Details of the mains voltage tol­erance can be found in the "Technical data" section.

42

Connecting the mains cable

General If power sources are delivered without a mains cable fitted, a mains cable that is suitable

for the connection voltage must be connected to the power source before commissioning.
The mains cable in included in the scope of supply of the power source.

Safety

Connecting the
mains cable

Connect the mains cable:

- Plug in the mains cable

- Turn the mains cable 45° to the

right until you hear it latch into pla­ce

WARNING! Work that is carried out incorrectly can cause serious injury and dam­age. The following activities must only be carried out by trained and qualified per­sonnel. Pay particular attention to the "Safety rules" sections in the power source
and system component operating instructions.

1

43

EN

Start-up

Safety

Remarks on the
cooling unit

The TT / MW 230i power sources can be operated with a cooling unit.
A cooling unit is recommended for the following applications:

- Hosepacks over 5 m long

- TIG AC welding

- In general, where welding is performed in higher power ranges

The cooling unit is powered from the power source. The cooling unit is ready for operation
when the mains switch of the power source is in the "I" position.
More information on the cooling unit can be found in the Operating Instructions for the cool­ing unit.

General This section describes how to commission the power source:

- for the main TIG welding application

- with reference to a standard configuration for a TIG welding device.

The standard configuration consists of the following system components:

- power source

- cooling unit

- TIG manual welding torch

- pressure regulator

- gas cylinder

- gas cylinder holder

- trolley

The steps set out below provide an overview of how to commission the power source.
For detailed information about the individual steps, please refer to the operating instruc­tions for the system components.

WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious in­jury and damage. Do not carry out any work on the device unless

- the mains switch is in the "O" position,

- the device is unplugged from the mains.

44

Assembling the
system compo­nents (overview)

45

EN

Connecting the
gas cylinder

1 2

3 4

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

Use the gas hose to connect the pressure regulator to the shielding gas connection on
the rear of the power source

Tighten the union nut on the gas hose

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

Connect the TIG welding torch gas hose to the pressure regulator

WARNING! There is a high risk of very serious injury and damage if a gas cylin­der falls over.

- Place them on a solid, level surface in such a way that they remain stable

- Secure gas cylinders to prevent them from toppling over: fix the safety strap
at the same height as the top part of the cylinder

- Never fix the safety strap around the neck of the cylinder

Follow the gas cylinder manufacturer's safety rules.

1

2

3 4

5

6

5

46

Connecting the
welding torch to
the power source
and the cooling
unit

Set up the welding torch in accordance with the welding torch operating instructions

5

6

During welding, check at regular intervals
that the coolant is flowing properly.

Establishing a
ground earth con­nection to the
workpiece

Turn the mains switch to the "O" position

7

NOTE! Do not use pure tungsten electrodes (colour-coded green) on TransTig
power sources.

1













2

NOTE! Always check the follow­ing before switching on:

- Sealing ring on welding torch
connection

- Coolant level

1

2

47

EN

Locking and unlocking the power source using the
NFC key

General remarks NFC key = NFC card or NFC key ring

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

A contactless system on the control panel allows the power source to be locked and un­locked.

The power source must be switched on before it can be locked or unlocked.

Restrictions Locking and unlocking of the power source is only possible with the TT/MW 230i and is

only permitted in certified countries.

48

Welding

51

EN

TIG modes

Safety

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

Symbols and
their explanations

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 safe­ty rules

Pull back and hold the torch trig­ger

Release the torch trigger Briefly pull back the torch trigger

(< 0.5 s)

Push forward and hold the torch
trigger

Release the torch trigger

GPr

Gas pre-flow time

SPt

Spot welding time

I

S

Starting-current phase: the temperature is
raised gently at a low welding current so
that the filler metal can be positioned cor­rectly

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.

UP

Upslope phase: the starting current is
steadily increased until it reaches the
main current (welding current) I

1

DOWN

DownSlope phase: the welding current is
steadily lowered until it reaches the final
current

I

1

Main current phase (welding-current
phase): uniform thermal input into the
base material, whose temperature is
raised by the advancing heat

I

2

Reduced current phase: intermediate low­ering of the welding current in order to pre­vent any local overheating of the base
material

GPo

Gas post-flow time

52

2-step mode - Welding: Pull back and hold the torch trigger

- End of welding: Release the torch trigger

2-step mode

4-step mode - Start of welding with starting current IS: Pull back and hold the torch trigger

- Welding with main current I1: Release the torch trigger

- Lowering to final current IE: Pull back and hold the torch trigger

- End of welding: Release the torch trigger

4-step mode

*) Intermediate lowering

Intermediate lowering during the main current phase reduces the welding current to the
specified reduced current I-2.

- To activate intermediate lowering, push forward and hold the torch trigger

- To revert to the main current, release the torch trigger

I

t

I

1

GPo

GPr DOWNUP

I

t

I

1

GPr

I

S

DOWNUP

I

E

I-2

GPo

I

1

*)

53

EN

Spot welding When the spot welding operating mode is selected, the symbol for spot welding appears

on the status display next to the welding process symbol:

- Welding: briefly pull back the torch trigger
The welding time corresponds to the value set for the spot welding time setup param­eter.

- to end the welding process prematurely: pull the torch trigger back again

I

t

I

1

GPr UP DOWN

SPt

GPo

54

TIG welding

Safety

Preparations Plug in the mains plug

Move the mains switch to the "I" position

The Fronius logo appears on the display.

TIG welding Press the Welding process / Mode button

The welding process and operating mode are displayed.

Select the desired welding process by turning the adjusting dial

Confirm the selection by pressing the adjusting dial

Select the desired operating mode by turning the adjusting dial

Confirm the selection by pressing the adjusting dial

The available TIG welding parameters are displayed after a short time or after press­ing the Welding process / Mode button.

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 safe­ty rules

WARNING! An electric shock can be fatal. If the power source is connected to the
mains electricity supply during installation, there is a high risk of very serious in­jury and damage. Before carrying out any work on the device make sure that:

- the power source mains switch is in the "O" position

- the power source is unplugged from the mains

CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the tungsten electrode of the welding torch is live.
Make sure that the tungsten electrode does not touch any persons or electrically
conductive or earthed parts (e.g. housing, etc.).

1

2

1

2

3

4

5

55

EN

Turn the adjusting dial to select the required parameter

Press the adjusting dial

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

Turn the adjusting dial to change the value of the parameter

Press the adjusting dial

If required, set further parameters in the Setup menu
(For details, see the "Setup parameters" chapter, starting on page 77)

Open the gas cylinder valve

To set the shielding gas flow rate:

- Press the Gas-test button

The test gas flow lasts for a maximum of 30 seconds. Press the button again to
stop the gas flow prematurely.

- Turn the adjusting-screw on the underside of the pressure regulator until the ma­nometer indicates the desired shielding gas flow-rate

Start welding (ignite the arc)

Welding parame­ters for TIG DC
welding

The polarity welding parameter is only available on MagicWave power sources.
If the polarity welding parameter is set to DC, the following welding parameters are avail­able:

xxA = actual current value depending on the specified main current

NOTE! All welding parameter set values that have been set using the adjusting
dial remain stored until the next time they are changed. This applies even if the
power source is switched off and on again.

6

7

8

9

10

11

12

13

Starting current

Starting current, 2-step mode and spot welding Starting current, 4-step mode

Unit % (of main current)

Setting range 0 - 200

Factory setting 50

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

50%

+

-

xxA

+

-

50%

xxA

56

UpSlope

UpSlope, 2-step mode and spot welding UpSlope, 4-step mode

Unit s

Setting range off; 0.1 - 30.0

Factory setting 0.5

IMPORTANT! The UpSlope is saved separately for 2-step and 4-step modes.

Main current

Main current, 2-step mode and spot welding Main current, 4-step mode

Unit A

Setting range 3 - 190 ... MW 190

3 - 230 ... MW / TT 230

Factory setting -

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

Reduced current

Reduced current (only in 4-step mode)

Unit % (of main current)

Setting range 0 - 100

Factory setting 50

0.5 s

+

-

0.5 s

+

-

50 A

+

-

50 A

+

-

+

-

50%

xxA

57

EN

DownSlope

DownSlope, 2-step mode and spot welding DownSlope, 4-step mode

Unit s

Setting range off; 0.1 - 30.0

Factory setting 1.0

IMPORTANT! The DownSlope is saved separately for 2-step and 4-step modes.

Final current

Final current, 2-step mode and spot welding Final current, 4-step mode

Unit % (of main current)

Setting range 0 - 100

Factory setting 30

Electrode diameter

Unit mm

Setting range off; 1.0 - 4.0

Factory setting 2.4

0.5 s

+

-

0.5 s

+

-

+

-

30%

xxA

+

-

30%

xxA

2.4mm

+

-

58

Welding parame­ters for TIG AC
welding

The polarity welding parameter is only available on MagicWave power sources.
If the polarity welding parameter is set to AC, the following welding parameters are availa­ble:

xxA = actual current value depending on the specified main current

Polarity

Unit -

Setting range DC- / AC

Factory setting DC-

DC-

+

-

Starting current

Starting current, 2-step mode and spot welding

Starting current, 4-step mode

Unit % (of main current)

Setting range 0 - 200

Factory setting 50

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

50%

xxA

50%

xxA

59

EN

UpSlope

UpSlope, 2-step mode and spot welding UpSlope, 4-step mode

Unit s

Setting range off; 0.1 - 30.0

Factory setting 0.5

IMPORTANT! The UpSlope is saved separately for 2-step and 4-step modes.

Main current

Main current, 2-step mode and spot welding Main current, 4-step mode

Unit A

Setting range 3 - 190 ... MW 190

3 - 230 ... MW / TT 230

Factory setting -

IMPORTANT! On welding torches with the Up/Down function, the entire setting range
can be selected while the device is idling. During welding, the main current can be cor­rected in steps of +/-20 A.

Reduced current

Reduced current (only in 4-step mode)

Unit % (of main current)

Setting range 0 - 100

Factory setting 50

0.5 s 0.5 s

50 A

50 A

50%

xxA

60

DownSlope

DownSlope, 2-step mode and spot welding

DownSlope, 4-step mode

Unit s

Setting range off; 0.1 - 30.0

Factory setting 1.0

IMPORTANT! The DownSlope is saved separately for 2-step and 4-step modes.

Final current

Final current, 2-step mode and spot welding

Final current, 4-step mode

Unit % (of main current)

Setting range 0 - 100

Factory setting 30

Balance

on MagicWave only

Unit %

Setting range 15 - 50

Factory setting 35

15: highest fusing power, lowest cleaning action

50: highest cleaning action, lowest fusing power

0.5 s 0.5 s

30%

xxA

30%

xxA

35%

+

-

61

EN

Effect of the balance on the waveshape:

Electrode diameter

Unit mm

Setting range off; 1.0 - 4.0

Factory setting 2.4

Cap mode

on MagicWave only

Unit -

Setting range off / on

Factory setting off

off Automatic cap-shaping function is deactivated

on The ideal cap for the specified diameter of the tungsten electrode is

formed during welding start-up.
A separate cap-shaping operation on a test workpiece is not neces­sary.

+

-

t (s)

I (A)

35% 50% 15%

2.4mm

off

62

Afterwards, the automatic cap-shaping function is reset and deacti­vated.

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

Cap mode must be activated separately for each tungsten elec­trode.

NOTE! The automatic cap-shaping function is not necessary if a
sufficiently large cap has already formed at the tip of the tungsten
electrode.

Polarity

Unit -

Setting range DC- / AC

Factory setting DC-

(2)(1)

AC

63

EN

Igniting the arc

General To ensure the best ignition sequence in the TIG AC welding process, the MagicWave pow-

er sources take account of:

- the diameter of the tungsten electrode

- the current temperature of the tungsten electrode with reference to the preceding
welding and weld-off times

Igniting the arc
using high fre­quency
(HF ignition)

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

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

Procedure for HF ignition:

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

Increase the tilt angle of the torch and
actuate the torch trigger according to
the mode you have selected

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

1

2

64

Tilt the torch back into the normal posi­tion

Carry out welding

Touchdown igni­tion

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

Procedure for igniting the arc using touchdown ignition:

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

Actuate the torch trigger

Shielding gas flows

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

3

4

1

2

3

65

EN

Raise the welding torch and rotate it
into its normal position

The arc ignites.

Carry out welding

End of welding Depending on the set mode, finish welding by releasing the torch trigger

Wait for the set gas post-flow and hold welding torch in position over the end of the
weld seam

4

5

1

2

66

Ignition time out, TIG pulsing and tacking function

Ignition timeout
function

The power source has an ignition timeout function.

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

The settings for the parameter Ignition timeout are described in the section "The HF menu"
from page 91 onwards.

TIG pulsing The welding current set at the start of welding is not always ideal for the welding process

as a whole:

- if the amperage is too low, the base material will not melt sufficiently

- if overheating occurs, the liquid weld pool may drip.

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

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

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

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

TIG pulsing - welding current curve

Legend:

(1) Main current (5) Pulse frequency *)

(2) Base current (6) Duty cycle

(3) Starting current (7) DownSlope

(4) UpSlope (8) Final current

(1)

I [A]

t [s]

(2)

(3)

(4)

(5)

(6)

(7)

(8)

67

EN

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

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

During this period, there is a pulsed welding current that makes the weld pool run together
better when two parts are being tack-joined.

Mode of operation of tacking function for TIG DC welding:

Tacking function - welding current curve

The pulsed welding current begins

- after the end of the starting-current phase (2)

- with the UpSlope phase (3)

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

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

Legend:

(1) Main current

(2) Starting current

(3) UpSlope

(4) Duration of pulsed welding current for the tacking process

(5) DownSlope

(6) Final current

NOTE! The following points apply to the pulsed welding current:

- The power source automatically regulates the pulsing parameters depending
on the specified main current (1).

- There is no need to set any pulsing parameters.

I [A]

t [s]

(1)

(2)

(3)

(4)

(5)

(6)

68

MMA welding

Safety

Preparations Switch off cooling units (in the components menu, set the cooling unit control setup

parameter to OFF)

Move the mains switch to the O position

Disconnect the mains plug

Remove the TIG welding torch

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

Plug in and latch the grounding cable:
in the (+) current socket ... for DC- welding (=/-)
in the (-) current socket ... for DC+ welding (=/+)

Use the other end of the grounding cable to establish a connection to the workpiece

Plug in the electrode cable and turn it clockwise to latch it in place:
in the (-) current socket ... for DC- welding (=/-)
in the (+) current socket ... for DC+ welding (=/+)

Plug in the mains plug

Move the mains switch to the "I" position

The Fronius logo appears on the display.

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 safe­ty rules

WARNING! An electric shock can be fatal. If the power source is connected to the
mains electricity supply during installation, there is a high risk of very serious in­jury and damage. Before carrying out any work on the device make sure that:

- the power source mains switch is in the "O" position

- the power source is unplugged from the mains

CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the rod electrode in the electrode holder is live. Make
sure that the rod electrode does not touch any persons or electrically conducting
or earthed parts (e.g. the housing, etc.).

1

2

3

4

5

6

7

8

9

69

EN

MMA welding Press the Mode button

The welding process and operating mode are displayed.

Select MMA (rod electrode) welding process (turn adjusting dial and press)

Turn the adjusting dial to select the Polarity parameter

Press the adjusting dial

Set the polarity for the rod electrode to be used by turning the adjusting dial

Confirm the selection by pressing the adjusting dial

Turn the adjusting dial to select further welding parameters

Press the adjusting dial

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

Turn the adjusting dial to change the value of the parameter

Press the adjusting dial

If required, set further parameters in the Setup menu
(For details, see the "Setup parameters" chapter, starting on page 77)

Start welding

NOTE! All welding parameter set values that have been set using the adjusting
dial remain stored until the next time they are changed. This applies even if the
power source is switched off and on again.

1

2

3

4

5

6

8

9

10

11

12

13

70

Welding parame­ters for manual
metal arc welding

* Depending on the selected current type, (+), (-) or the alternating current symbol

is displayed here.

xxA = actual current value depending on the specified main current

Starting current

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

Starting current: starting current = main current

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

Unit % (of main current)

Setting range 0 - 200

Factory setting 150

**

50%

xxA

**

100%

xxA

**

150%

xxA

71

EN

Main current

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

Main current: starting current = main current

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

Unit A

Setting range 0 - 190 ... MW 190

0 - 230 ... MW / TT 230

Factory setting -

Arc-force dynamic

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

Unit % (of main current)

Setting range 0 - 100

Factory setting 20

0 soft, low-spatter arc

100 harder, more stable arc

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

130 A

**

130 A

**

130 A

**

20

**

72

Starting current
> 100 % (Hot­Start)

Benefits

- Improved ignition properties, even when using electrodes with poor ignition properties

- Better fusion of the base material in the start-up phase, meaning fewer cold-shut de­fects

- Largely prevents slag inclusions

Example with a starting current > 100% (HotStart)

Mode of operation

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

The starting current time is set in the Setup
menu.

Polarity

Polarity, set to DC- Polarity, set to DC+

Polarity, set to AC

Unit -

Setting range DC- / DC+ / AC

Factory setting DC-

DC-

+

-

DC+

+

-

AC

I (A)

t (s)

0,5 1 1,5

(1)

(3)

(2)

100

150

Legend

(1) Starting current time

0-2 s, factory setting 0.5 s

(2) Starting current

0-200%, factory setting 150%

(3) Main current = pre-set welding

current I

1

73

EN

Starting current
< 100 %
(SoftStart)

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

Example with a starting current < 100% (SoftStart)

Benefits:

- Improved ignition properties for elec­trodes that ignite at low welding cur­rents

- Largely prevents slag inclusions

- Reduces welding spatter

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

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

Anti-stick func­tion

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will
tend to stick. 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. After the rod
electrode has been detached from the workpiece, the welding process can be continued
without any problems.

The anti-stick function can be activated and deactivated in the rod electrodes menu.

I (A)

t

90A

30A

(1)

(3)

(2)

74

EasyJob mode

Storing EasyJob
operating points

Prerequisite:
EasyJobs must be assigned to the Favourites button (see "Assigning EasyJobs to the Fa­vourites button", starting on page 32.

Set the welding process, mode and welding parameters

Press the Favourites button

The 5 EasyJob buttons are opened.

Turn the adjusting dial and select the desired storage location

To save the current welding settings, press and hold the adjusting dial for about 3 sec­onds

The size and colour of the button changes.

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

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

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

NOTE! EasyJobs are saved under job numbers 1 - 5 and can also be called up in
the Job menu.
Storing an EasyJob overwrites any other job saved under the same number!

1

2

3

4

75

EN

Retrieving Easy­Job operating
points

Press the Favourites button

The 5 EasyJob buttons are opened.

Turn the adjusting dial and select the desired storage location

To retrieve a saved EasyJob operating point, press the adjusting dial briefly (< 3 sec­onds)

The size and colour of the button changes.

The EasyJob buttons are then minimised and the active EasyJob is indicated by a flag.

Deleting EasyJob
operating points

Press the Favourites button

The 5 EasyJob buttons are opened.

Turn the adjusting dial and select the storage location to be deleted

To delete an EasyJob operating point, press and hold the adjusting dial for about 5
seconds

The button

- first changes its size and colour;

- it changes to a green colour after about 3 seconds;

The saved operating point is overwritten with the current settings.

- is highlighted in red (= delete) after a total of 5 seconds.

The EasyJob operating point has been deleted.

1

2

3

1

2

3

76

Welding job

Safety

Preparatory work Set up and install the power source in accordance with the welding job

Plug in the mains plug

Move the mains switch to the "I" position

Welding a job Press the Mode button

The welding process and operating mode are displayed.

Select "JOB" (turn adjusting dial and press)

The welding parameters of the previously opened job are displayed after a short time. The
job number is selected.

Press the adjusting dial
The job number can now be modified.

Select the job number of the welding job (turn adjusting dial and press)
The welding parameters of the selected job are displayed and the job can now be
welded.

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 safe­ty rules

WARNING! An electric shock can be fatal. If the power source is connected to the
mains electricity supply during installation, there is a high risk of very serious in­jury and damage. Before carrying out any work on the device make sure that:

- the power source mains switch is in the "O" position

- the power source is unplugged from the mains

CAUTION! Risk of injury and damage from an electric shock.
As soon as the mains switch is in the "I" position, the tungsten electrode in the
welding torch is live. Ensure that the tungsten electrode does not touch any per­sons or electrically conductive or earthed parts (e.g. housing, etc.).

1

2

3

1

2

2

3

Setup settings

79

EN

The Setup menu

General The Setup menu provides easy access to the knowledge base in the power source and to

additional functions. The Setup menu can be used to make simple adjustments to the weld­ing parameters to suit the various job settings.

The following can be found in the Setup menu:

- all setup parameters that have an immediate effect on the welding process,

- all setup parameters needed for making the preliminary settings on the welding sys­tem.

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

Accessing the
Setup menu

Press Menu key

The Setup menu appears.

To leave the Setup menu, press the Menu key again

The current welding parameters will be displayed.

1

1

2

80

Overview

Item Designation

(1) TIG menu

to set the TIG parameters for TIG DC and TIG AC

(2) Rod electrode menu

to set the rod electrode parameters

(3) Ignition settings

to set the TIG arc ignition parameters

(4) Gas menu

to set the shielding gas parameters

(5) Component settings

to set the cooling unit operating mode

(6) Job menu

(only if FP Job function package is present)

- to save, load and delete jobs

- to assign EasyJobs to the Favourites button

(1) (2) (3) (4) (5) (6)

(10)

(7)

(13) (12) (11)

(8)

(9)

**

*

81

EN

Changing menus
and parameters

Selecting a menu

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

Turn the adjusting dial until the parameter's higher-level menu is selected

Press the adjusting dial

The background of the selected menu becomes blue.

Turn the adjusting dial and select the desired menu (blue background)

(7) Defaults

to

- Display:
set display backlighting, languages, date & time, display addition­al parameters

- System:
restore factory settings, reset website password, perform R/L
alignment

(8) System information

to display device information such as software version or IP address
(assuming the power source is on a network)

(9) Scroll bar

(for multiple parameters)

(10) Available menus

the number of available menus can vary depending on the firmware
version and available options.

(11) Value, unit

(12) Setup parameters

depending on the selected menu and the current settings for the weld­ing process and operating mode, parameters that are not relevant are
greyed out and cannot be selected.

(13) Display of the currently selected menu

taking into account the current settings for welding process and oper­ating mode

* Menu currently being adjusted (blue background)

** Position of the currently selected menu

Item Designation

Selected menu Selected parameter

Change the menu Set the parameter

1

2

3

82

Setting parameters

Press the adjusting dial in the selected menu

The first parameter in the menu is selected.

Turn the adjusting dial and select the desired parameter

Press the adjusting dial to change the parameter

The background of the parameter value becomes blue.

Turn the adjusting dial and set the value of the parameter

The change in the parameter value takes effect immediately

Press the adjusting dial to select other parameters

4

5

6

7

8

83

EN

The TIG menu

Parameters in the
TIG DC menu

Tacking

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

Unit s

Setting range Off / 0.1 - 9.9 / On

Factory setting Off

On The pulsed welding current remains in effect until the end of the

tacking operation

0.1 - 9.9 s The set time begins with the UpSlope phase. After the end of the
pre-set time period, welding continues with a constant welding
current; any pulsing parameters that have been set are available.

Off The tacking function is de-

activated

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

Pulse frequency

Unit Hz

Setting range Off / 0.20 - 2000 (10000 with FP Pulse Pro option)

Factory setting Off

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

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

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

FP Pulse Pro

to set the Base current and Duty cycle parameters

Base current

Unit % (of main current I1)

Setting range 0 - 100

Factory setting 50

84

Parameters in the
TIG AC menu

Duty cycle

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

Unit %

Setting range 10 - 90

Factory setting 50

Starting current time

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

Unit s

Setting range Off / 0.01 - 30.0

Factory setting Off

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

Final current time

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

Unit s

Setting range Off / 0.01 - 30

Factory setting Off

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

Spot-welding time

Unit s

Setting range 0.02 - 120

Factory setting 5.0

Pulse frequency

Unit Hz

Setting range Off / 0.20 - 2000 (10000 with FP Pulse Pro option)

Factory setting Off

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

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

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

85

EN

FP Pulse Pro

to set the Base current and Duty cycle parameters

Base current

Unit % (of main current I

1

)

Setting range 0 - 100

Factory setting 50

Duty cycle

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

Unit %

Setting range 10 - 90

Factory setting 50

Starting current time

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

Unit s

Setting range Off / 0.01 - 30.0

Factory setting Off

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

Final current time

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

Unit s

Setting range Off / 0.01 - 30

Factory setting Off

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

AC frequency

Unit Hz

Setting range 40 - 250

Factory setting 60

Low frequency soft, distant arc with shallow heat input

High frequency focused arc with deep heat input

86

Effect of the AC frequency on the waveshape:

AC current offset

Unit %

Setting range -70 to +70

Factory setting 0

+70 distant arc with shallow heat input

-70 narrow arc, deep heat input, faster welding speed

Effect of the AC current offset on the waveshape:

* Factory setting: 20% shift to the negative

Positive half-wave waveform

Unit -

Setting range Hard rectangle / Soft rectangle / Triangle / Sine

Factory setting Hard rectangle

Hard rectangle 100% rectangular waveform (stable but loud arc)

Soft rectangle Rectangular waveform with decreased edge steepness, for re-

ducing noise levels compared to those that occur with the 100%
rectangular waveform

Triangle Triangular waveform

Sine Sinusoidal waveform (standard setting for a low-noise, stable

arc)

+

­t (s)

I (A)

60 Hz 120 Hz

I (A)

t (s)

-70%+70%

+

-

0

*

87

EN

Negative half-wave waveform

Unit -

Setting range Hard rectangle / Soft rectangle / Triangle / Sine

Factory setting Hard rectangle

Hard rectangle 100% rectangular waveform (stable but loud arc)

Soft rectangle Rectangular waveform with decreased edge steepness, for re-

ducing noise levels compared to those that occur with the 100%
rectangular waveform

Triangle Triangular waveform

Sine Sinusoidal waveform (standard setting for a low-noise, stable

arc)

88

The MMA menu

Parameters in the
rod electrode
menu

I-constant (constant welding current)

- If the I-constant characteristic is set, the welding current will be kept constant, irre­spective of the welding voltage. This results in a vertical characteristic (4).

- This setting is particularly suited to
rutile electrodes,
basic electrodes,
arc air gouging (set the arc-force dynamic to 100 for arc air gouging).

Starting current time

HotStart

Unit s

Setting range 0.0 - 2.0

Factory setting 0.5

To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart
function.

Benefits:

- Improved ignition properties, even when using electrodes with poor ignition proper­ties

- Better fusion of the base material in the start-up phase, meaning fewer cold-shut de­fects

- Largely prevents slag inclusions

Char

To select characteristics

Unit - / A/V / -

Setting range I-constant / 0.1 - 20.0 / P-constant

Factory setting I-constant

(1) Load line for rod electrode

(2) Load line for rod electrode where arc length is in-

creased

(3) Load line for rod electrode where arc length is re-

duced

(4) Characteristic for parameter setting I-constant

(constant welding current)

(5) Characteristic for parameter setting 0.1 - 20.0

(drooping characteristic with adjustable slope)

(6) Characteristic for parameter setting P-constant

(constant welding power)

(7) Example of pre-set arc-force dynamic where

characteristic (4) is selected

(8) Example of pre-set arc-force dynamic where

characteristic (5) or (6) is selected

Adjustable characteristics

0040 200100 300 I (A)

U (V)

con - 20 A / V

(4)

(5)

(6)

(7) (8)

(1)

(2)

(3)

89

EN

0.1 - 20.0 (drooping characteristic with adjustable slope)

- Setting 0.1 - 20.0 is used to set a drooping characteristic (5). The setting range ex­tends from 0.1 A / V (very steep) to 20 A / V (very flat).

- Setting a flat characteristic (5) is only advisable for cellulose electrodes.

P-constant (constant welding power)

- If the P-constant characteristic is set, the welding power is kept constant, irrespective
of the welding voltage and welding current. This results in a hyperbolic characteristic
(6).

- This setting is particularly suitable for cellulose electrodes.

The characteristics (4), (5) and (6) shown here apply when using a rod electrode whose
characteristic corresponds to the load line (1) at a given arc length.

Depending on what welding current (I) has been set, the point of intersection (operating
point) of characteristics (4), (5) and (6) will be displaced along the load line (1). The oper­ating point provides information on the current welding voltage and the current welding cur­rent.

Where the welding current (I

1

) is permanently set, the operating point may migrate along

the characteristics (4), (5) and (6) depending on the welding voltage at that moment in time.

The welding voltage U is dependent upon the arc length.

If the arc length changes (e.g. in accordance with the load line (2)) the resulting operating
point will be the point where the corresponding characteristic (4), (5) or (6) intersects with
the load line (2).

NOTE! When setting a flat characteristic (5), set the arc-force dynamic to a higher
value.

NOTE! If there are problems with a rod electrode tending to "stick", set the arc­force dynamic to a higher value.

(1) Load line for rod electrode

(2) Load line for rod electrode where arc length is in-

creased

(3) Load line for rod electrode where arc length is re-

duced

(4) Characteristic for parameter setting I-constant

(constant welding current)

(5) Characteristic for parameter setting 0.1 - 20.0

(drooping characteristic with adjustable slope)

(6) Characteristic for parameter setting P-constant

(constant welding power)

(7) Example of pre-set arc-force dynamic where

characteristic (5) or (6) is selected

(8) Possible change in the current where character-

istic (5) or (6) is selected, as a function of the

welding voltage (arc length)

(a) Operating point where arc length is long

(b) Operating point when welding current I1 is set

(c) Operating point where arc length is short

Settings example: I1 = 250 A, arc-force dynamic = 50

10

20

30

40

50

60

U (V)

004003001 200

I (A

)

I1 + DynamikI1 - 50 %

(8)

(2)

(1)

(3)

(7)

(c)

(c)

(b)

(a)

(a)

(6)

(5)

(4)

90

For characteristics (5) and (6), if a constant value is set for I

1

, the welding current (I) will

also become smaller or larger depending on the welding voltage.

Break-voltage

Welding voltage limitation

Unit V

Setting range 20 - 90

Factory setting 20

The arc length depends on the welding voltage. To end the welding process, it is usually
necessary to significantly lift the rod electrode away from the workpiece. With this param­eter, the welding voltage can be limited to a value that makes it possible to end the weld­ing operation simply by slightly lifting the rod electrode.

NOTE! If, during welding, you often find that the welding operation is ended unin­tentionally, increase the value of the break-voltage parameter.

Anti-stick

Unit -

Setting range On / Off

Factory setting On

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode
will tend to stick. 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. After the
rod electrode has been detached from the workpiece, the welding process can be contin­ued without any problems.

AC frequency

only for MMA AC welding (welding parameter polarity = AC)

Unit Hz

Setting range 40 - 250

Factory setting 60

91

EN

Ignition settings

Ignition setting
parameters

HF ignition

Unit -

Setting range On / Off / External

Factory setting On

On High frequency ignition at start of welding is activated

Off No high frequency ignition at start of welding.

In this case, welding starts with touchdown ignition.

External Start with external arc starters, e.g. plasma welding

The HF ignition indicator in the status bar on the display lights up as long as HF ignition
has been set to On.

Reversed polarity ignition

(MagicWave power sources only)

To optimise the ignition sequence in TIG DC welding, the polarity is reversed briefly when
welding starts. Electrons emerge from the workpiece and strike the tungsten electrode.
This results in rapid heating-up of the tungsten electrode - which in itself is an essential
precondition for optimum ignition performance.

Unit -

Setting range Off / On

Factory setting Off

IMPORTANT! Reversed polarity ignition is not recommended when welding light gauge
sheet.

Ignition timeout

Ignition timeout until safety cut-out after abortive ignition attempt.

Unit s

Setting range 0.1 - 9.9

Factory setting 5

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

92

Arc break time

Time until safety cut-out following an arc break

If, following an arc break, there is no current flow within the time specified here, the power
source cuts out automatically.
To start the welding process again, press any key on the control panel or the torch trigger.

Unit s

Setting range 0.00 - 2.00

Factory setting 0.20

Arc break message

Reaction if there is no current flow within the arc break time

Unit -

Setting range Ignore / Error

Factory setting Ignore

Ignore The interruption is ignored.

Error An error message, which has to be acknowledged, is displayed

on the power source.

93

EN

The gas menu

Parameters in the
Gas menu

Gas pre-flow

Duration of gas pre-flow

Unit s

Setting range 0.0 - 9.9

Factory setting 0.1

Gas post-flow

Duration of gas post-flow

Unit s

Setting range 0 - 60

Factory setting 0.5

94

The components menu

Parameters in the
Components
menu

Cooling unit operating mode

for controlling a cooling unit

Unit -

Setting range eco / auto / on / off

Factory setting auto

auto Cooling unit is switched off 2 minutes after the end of welding

On Cooling unit is ON all the time

Off Cooling unit is OFF all the time

eco The coolant pump starts to run when welding starts and is elec-

tronically controlled subject to the coolant return temperature.
The fans start up at a coolant return temperature of 40 °C
(104 °F) and are electronically controlled subject to the coolant
return temperature.
After the end of welding, the coolant pump and fans continue to
run for another 2 minutes subject to the coolant return tempera­ture.
When these 2 minutes have passed, the fans and coolant pump
are switched off.

95

EN

The Job menu

Save job When jobs are saved, the welding process and all the settings in the welding parameters

and the respective set-up menus are saved.
When creating jobs you MUST therefore also take into account the welding parameters in
the set-up menus.

Jobs can be saved in two ways.

An overview of the most important parameters is displayed.

Select "More" (turn adjusting dial and press)

Turn the adjusting dial:
Overwrite existing job
(after pressing the adjusting dial, a confirmation prompt asking whether you really
want to overwrite the job is displayed)

or

Create new job

Press the adjusting dial; the first available job number is displayed.

Select Job number (turn adjusting dial and press)

Select "More" (turn adjusting dial and press)

The keyboard is displayed.

Turn and press the adjusting dial to enter a name for the job.

Select "More" (turn adjusting dial and press)

A message confirming that the job has been saved is displayed.

Select "Finish" (turn adjusting dial and press)

Set welding process, mode, welding parameters and setup parameters

Save job via the Job menu Save job using the adjusting dial

Press the Menu key

Turn the adjusting dial and select the
Job menu

Press the adjusting dial

Turn the adjusting dial and select
"Save Job as ..."

Press the adjusting dial

Press the adjusting dial for more than
3 seconds

1

2

3

4

5

6

2

7

8

9

10

11

12

12

96

Loading a job The Load job function can be used to load the data for a saved job or an EasyJob into the

welding parameters.
The relevant data from the job can be changed, saved as a new job or EasyJob, or used
to start welding.

Press the Menu key

Turn the adjusting dial and select the Job menu

Press the adjusting dial

Turn the adjusting dial and select "Load Job ..."

Press the adjusting dial

The job list is displayed.

Select the job that you want to load (turn adjusting dial and press)

A message advising that the job is about to be loaded is displayed.

Select "Yes" (turn adjusting dial and press)

The job is loaded into the welding parameters.

Deleting a job Press the Menu key

Turn the adjusting dial and select the Job menu

Press the adjusting dial

Turn the adjusting dial and select "Delete Job ..."

Press the adjusting dial

The job list is displayed.

Select the job that you want to delete (turn adjusting dial and press)

A warning that the job is about to be deleted is displayed.

Select "Yes" (turn adjusting dial and press)

The job is deleted.

1

2

3

4

5

6

7

1

2

3

4

5

6

7

97

EN

Defaults

Overview Display

- Backlighting

- Languages

- Time & Date

- Display additional parameters

System

- Reset to factory settings ...

- Reset website password ...

- Perform R/L alignment

Display - back­lighting

Adjust backlighting:

Defaults / Display / Backlighting

Press the adjusting dial

Select backlighting brightness (turn adjusting dial and press)

Display - languag­es

Setting the language:

Defaults / Display / Language

Select the desired language (turn adjusting dial and press)

The Globe symbol appears briefly and the language changes.

Display - Time &
Date

Backlighting

to set the brightness of the display

Unit -

Setting range 0 - 10

Factory setting 10

1

2

3

Language

Unit -

Setting range Depends on the version of the software

Factory setting English

1

2

Time & Date

to set the time and date

Unit -

Setting range Year / Month / Day / Hour / Minute / Time zone

Factory setting -

98

Setting the date & time:

Defaults / Display / Time & Date

Select the desired parameter (turn adjusting dial and press)

Modify parameter by turning the adjusting dial

Confirm the modified parameter by pressing the adjusting dial

Press the menu key to exit the date and time settings

Display - Display
additional param­eters

In the case of welding parameters 1 - 3, this function enables additional parameters or set­tings to be displayed.

Display additional parameters:

Default / Display / Display additional parameters

Press the adjusting dial

Select parameter location P1 - P3 (turn and press adjusting dial)

Choose which parameter to display in the selected parameter location (turn adjusting
dial and press)

Select Save (turn adjusting dial and press)

The parameter is displayed in the selected parameter location, where it can now also be
modified.

System - Reset to
factory settings

Defaults / System / Reset to factory settings

Press the adjusting dial

A confirmation prompt asking whether you really want to restore the factory settings is dis­played.

Select yes by turning the adjusting dial

Press the adjusting dial to reset to factory settings

The power source is reset to the factory settings.

1

2

3

4

5

- Not assigned

- Welding process

- TIG welding torch mode

- TIG settings
Tacking
Pulse frequency
Base current
Duty cycle
Starting current time
Final current time
Spot welding time
AC frequency
AC current offset
Positive half-wave waveform
Negative half-wave waveform

- Electrode settings
Starting current time
Characteristic
Break voltage
Anti-stick
AC frequency

- Ignition settings
HF ignition
Ignition timeout
Arc break time
Arc break message
Reversed polarity ignition

- Gas settings
Gas pre-flow
Gas post-flow

- Component settings
Cooling unit mode

1

2

3

4

5

1

2

3

4

99

EN

Reset website
password

Defaults / System / Reset website password

Press the adjusting dial

A confirmation prompt asking whether you really want to reset the website password is dis­played.

Select yes by turning the adjusting dial

Press the adjusting dial to reset the website password

The website password is reset to the factory setting:
User name = admin
Password = admin

Performing R/L
alignment

Welding circuit resistance R [mOhm]

Measuring the welding circuit resistance "r" provides information on the overall resistance
of the torch hosepack, welding torch, workpiece and grounding cable.

If an increased welding circuit resistance is detected, e.g. after changing the welding torch,
this may mean that the following components are faulty:

- Torch hosepack

- Welding torch

- Grounding (earthing) connection to the workpiece

- Grounding cable

Welding circuit inductivity L [μH]

The way that the hosepack is arranged has
a very significant effect on the weld proper­ties.
Particularly with pulsed-arc welding and AC
welding, a high welding circuit inductivity
may occur, depending on the length of the
hosepack and on the way that it is arran­ged. The result is that the current rise is re­stricted.

The weld results can be optimised by chan­ging the arrangement of the torch hose­pack.
The hosepack must be laid out as shown in
the illustration.

1

2

3

4

NOTE! R/L alignment must be carried out separately for each welding process.

100

Performing R/L alignment

Defaults / System / Perform R/L alignment

Press the adjusting dial

The current values are displayed

Select "More" (turn and press adjusting dial)

The second R/L alignment screen is displayed.

Follow the instructions displayed on the screen

Select "More" (turn and press adjusting dial)

The third R/L alignment screen is displayed.

Follow the instructions displayed on the screen

Select "More" (turn and press adjusting dial)

The current values are calculated.

After R/L alignment has been completed, a confirmation and the current values are
displayed.

1

2

3

4

5

6

7