Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
MagicWave 2600
MagicWave 2600 Cel
MagicWave 3000
TransTig 2600
TransTig 2600 Cel
TransTig 3000
Operating instructions
TIG power source
EN-US
42,0426,0022,EA 003-22032021
Inhaltsverzeichnis
Safety Instructions 6
Explanation of Safety Instructions 6
General 6
Intended Use 6
Environmental Conditions 7
Obligations of the Operating Company 7
Obligations of Personnel 7
Grid Connection 7
Personal Protection and Protection of Others 8
Data regarding Noise Emission Values 8
Danger from toxic gases and vapors 9
Danger from Flying Sparks 9
Risks from grid current and welding current 10
Stray welding currents 11
EMC Device Classifications 11
EMC Measures 11
EMF measures 12
Particular Hazard Areas 12
Undesired welding results 13
Danger from Shielding Gas Cylinders 13
Safety Measures at the Setup Location and During Transport 14
Safety Measures in Normal Operation 14
Maintenance and repair 15
Safety Inspection 15
Disposal 15
Safety Symbols 16
Data backup 16
Copyright 16
General 17
Principle 17
Device concept 17
Field of application 17
Warning notice on the device 18
Minimum equipment for welding operations 19
General 19
TIG AC welding 19
TIG DC welding 19
Manual metal arc welding 19
System components 20
General 20
Overview 20
Control Panel 21
General 21
Overview 21
MagicWave control panel 22
Control panel for TransTig 24
Connections, switches and system extensions 27
MagicWave / TransTig connections with Fronius welding torch central connector F 27
MagicWave / TransTig connections with welding torch central connector GWZ 28
MagicWave / TransTig connections with welding torch central connector GWZ 29
Before installation 30
Safety 30
Intended use 30
Setup regulations 30
Mains operation 30
Generator-powered operation 31
Commissioning 32
General 32
Notes on the cooling unit 32
Connecting the shielding gas cylinder 32
EN-US
3
Establish a connection with the workpiece 33
Connect the welding torch 33
TIG Operating Modes 34
General 34
Symbols and explanations 34
2-step 35
Special 2-step 35
4-step 36
4-step with intermediate lowering 36
Special 4-step: Version 1 37
Special 4-step: Version 2-4 38
Special 4-step: Version 5 39
TIG welding 40
Safety 40
Preparation 40
Select operating mode 41
Select process 41
Cap-shaping (MagicWave) 42
Welding parameter setting 42
Adjust the shielding gas quantity 42
Ignition of the arc - general 42
TIG synchronous welding AC (MagicWave) 42
HF ignition 43
Contact ignition 44
Ignition monitoring 45
Manual Metal Arc Welding 46
Safety 46
Preparation 46
Select operating mode 47
Select process (MagicWave) 47
Welding parameter setting 47
Remote control 49
Safety 49
General 49
AC remote control TR 53mc 49
TIG pulse remote control TR 50mc 50
TIG foot remote control TR 52mc 51
TIG spot welding remote control TR 51mc 52
Remote control TP MC / TP MC-CEL 53
Working with program levels 56
Overview 56
"Program level preferences” 57
Access 57
Select and change setup parameters 57
Available TIG parameters 57
Program levels P1 - P3 61
Access 61
Select and change setup parameters 61
Program level service menu P1 61
Program level code lock P2 61
Program level AC parameters P3 (MagicWave) 62
Fault diagnosis and correction 63
Safety 63
Displayed service codes 63
Power Source 64
Service, maintenance and disposal 67
General 67
At every start-up 67
Every 2 months 67
Every 6 months 67
Disposal 67
Spare parts 67
Technical data 68
Special voltage 68
4
MagicWave 2600/2600CEL 68
MagicWave 3000 69
TransTig 2600/2600CEL 69
TransTig 3000 70
EN-US
5
Safety Instructions
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
Death or serious injury may result if appropriate precautions are not taken.
▶
WARNING!
Indicates a possibly dangerous situation.
Death or serious injury may result if appropriate precautions are not taken.
▶
CAUTION!
Indicates a situation where damage or injury could occur.
Minor injury or damage to property may result if appropriate precautions are not
▶
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to
recognized 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 equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- Not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section
headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
6
The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in
accordance with the intended purpose." The manufacturer is not responsible for any
damage resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not
be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
EN-US
Environmental
Conditions
Obligations of the
Operating Company
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer accepts no liability for any
damage resulting from improper use.
Temperature range of the ambient air:
- 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)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section
"Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-
All persons who are assigned to work with the device must do the following before beginning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can
occur in one's absence.
rent consumption.
7
This may affect a number of device types in terms of:
- connection restrictions
-
criteria regarding maximum permissible grid impedance
-
criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
*)
*)
See technical data
In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Personal Protection and Protection of Others
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face
guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)
- Wearing ear protection to reduce noise exposure and protect against injury
Data regarding
Noise Emission
Values
8
Keep persons, especially children, away during the operation of the devices and during
the welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in
the cooling phase following operation in relation to the maximum permitted operating
point at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be specified
because this value depends on the welding process and the environmental conditions. It
is influenced by a wide range of parameters, such as the welding process itself (MIG/
MAG, TIG welding), the selected current type (direct current, alternating current), the
power range, the type of weld metal, the resonance properties of the workpiece, the
workplace environment, and many other factors.
EN-US
Danger from
toxic gases and
vapors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph 118 from
the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow
rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the
measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
- The welding process used
Danger from Flying Sparks
Consult the corresponding material safety data sheets and manufacturer's instructions
for the components listed above.
Recommendations for exposure scenarios, risk management measures and identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks,
drums, or pipes if these have not been prepared in accordance with corresponding
national and international standards.
9
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like
are/were stored. Residues pose a risk of explosion.
Risks from grid
current and welding current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed
rollers, as well as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating
wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with sufficient
insulation against the ground potential. The temporary backing or cover must completely
cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least
180° around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
- Never immerse it in liquids to cool it
- Never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between the electrodes of two welding systems. Touching the potentials of both electrodes at the same
time may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that
the ground conductor is functioning properly.
Protection class I devices require a grid with a ground conductor and a connector system
with ground conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket without a
ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no liability for
any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched on again
by applying a clearly legible and understandable warning sign.
10
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will switch off
the main switch at the correct time.
Stray welding
currents
If the following instructions are not observed, stray welding currents may occur, which
pose a risk of the following:
- Fire
- Overheating of components connected to the workpiece
- Destruction of ground conductors
- Damage to the device and other electrical equipment
Ensure that the workpiece terminal is securely connected to the workpiece.
Secure the workpiece terminal as close to the spot to be welded as possible.
Position the device with sufficient insulation against electrically conductive environments,
e.g., insulation against electrically conductive floors or electrically conductive mounts.
Observe the following when using electrical distributors, double-headed retainers, etc.:
Even the electrode of the welding torch/electrode holder not in use carries electric potential. Ensure that there is sufficient insulation when the unused welding torch/electrode
holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the welding wire
drum, large spool or wirespool to the wirefeeder with insulation.
EN-US
EMC Device Classifications
EMC Measures In certain cases, even though a device complies with the standard limit values for emis-
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 grid.
EMC device classification as per the rating plate or technical data.
sions, it may affect the application area for which it was designed (e.g., when there is
sensitive equipment at the same location, or if the site where the device is installed is
close to either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to
rectify the situation.
Test and assess the immunity of equipment in the vicinity of the device in accordance
with national and international provisions. Examples of interference-prone equipment
that could be affected by the device:
- Safety devices
- Grid power lines, signal lines and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
- If necessary, establish grounding using suitable capacitors
11
5. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing
aids
- Persons with pacemakers must seek advice from their doctor before staying in the
immediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large
as possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them
around one's body or body parts
Particular Hazard
Areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- fans
- gears
- rollers
- shafts
- wirespools and welding wires.
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side parts must only be opened/removed during maintenance and repair
work.
During operation:
- Ensure that all covers are closed, and all side parts have been mounted properly.
- Keep all covers and side parts closed.
The protrusion of welding wire from the welding torch represents a high risk of injury
(cuts to the hand, facial and eye injuries, etc.)
Therefore always hold the welding torch away from the body (devices with wirefeeder)
and use suitable protective goggles.
Do not touch the workpiece during or after welding—burning hazard.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective
equipment when reworking workpieces and ensure that other persons are sufficiently
protected.
12
Leave the welding torch and other parts with a high operating temperature to cool before
working on them.
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g. boilers) must be
labeled with the symbol (Safety). However, the power source may not be located in such
areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting
connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data sheet. The
coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.
Only use suitable load-carrying equipment from the manufacturer when transporting
devices by crane.
- Attach chains or ropes to all designated attachments of the suitable load-carrying
equipment.
- Chains or ropes must be the smallest angle possible from vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
In the event of crane attachment of the wirefeeder during welding, always use a suitable,
insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclusively for
transport by hand. The carrier belt is not suitable for transport by crane, counterbalanced
lift truck or other mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association with the
device or its components, must be checked regularly (e.g. for mechanical damage, corrosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an adapter
is used for the shielding gas connection. Use suitable Teflon tape to seal the thread of
the shielding gas connection adapter on the device side before installation.
EN-US
Undesired welding results
Danger from
Shielding Gas
Cylinders
The following specifications concerning shielding gas quality must be met in order to
ensure the safe and proper function of the welding system:
- Solid particle size <40μm
- Pressure dew point <-20 °C
- Max. oil content <25mg/m³
Use filters if necessary.
NOTE!
Ring lines in particular pose a risk of contamination
Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding
gas cylinders are an integral part of the welding equipment, so they must be handled
very carefully.
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical
impact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with instructions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the correct
matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
13
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.
Follow the manufacturer's instructions and applicable national and international provisions for shielding gas cylinders and accessories.
Safety Measures
at the Setup Location and During
Transport
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.
Only set up and operate the device in accordance with the protection class shown on the
rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and accident
prevention regulations are observed when transporting the device, especially guidelines
concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or lifting.
Before transporting the device, completely drain the coolant and dismantle the following
components:
- wirefeeder
- wirespool
- shielding gas cylinder
Safety Measures
in Normal Operation
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before commissioning. Have any damage repaired by trained service technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a danger of:
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device is switched
on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage
and functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by crane.
Only the original coolant from the manufacturer is suitable for use in our devices due to
its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)
14
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the manufacturer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in
certain conditions. Only transport the coolant in closed original containers and keep
away from sources of ignition.
Properly dispose of used coolant according to national and international regulations. The
coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.
When the system is cool, always check the coolant level before starting welding.
EN-US
Maintenance and
repair
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at
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.
least every 12 months.
The manufacturer recommends calibrating power sources within the same 12-month
interval.
A safety inspection by a certified electrician is recommended:
- After changes
- After alterations
- After repair, care, and maintenance
- At least every 12 months
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection and calibration from your
service center. The service center will provide the necessary documents upon request.
Disposal 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 be returned to your dealer, or you must locate the approved collection and
recycling facilities in your area. Ignoring this European Directive may have potentially
adverse affects on the environment and your health!
15
Safety Symbols Devices with the CE label satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g. relevant product standards of the EN 60974
series).
Fronius International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings. The
manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves the right to
make changes. The contents of the Operating Instructions shall not provide the basis for
any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the Operating
Instructions, we will be most grateful for your comments.
16
General
Principle The TIG power sources MW 2600 / 2600 CEL / 3000 (AC/DC) or TT 2600 / 2600 CEL /
3000 (DC), designed as primary switched welding systems, are a further development of
transistor controlled welding systems. The supply voltage is rectified and chopped by a
fast transistor switch with 80 kHz. An electronic controller adjusts the characteristics of
the power source to the selected welding process.
Another interesting feature is the automatic cap-shaping for AC welding with MagicWave
power sources. For optimum results, this function takes into account the diameter of the
tungsten electrode used.
EN-US
Fig.1 Power source MW 2600, TransTig 3000 and MagicWave 3000 with cooling unit and trolley
Device concept The particular flexibility and the ease of adjustment to different tasks are typical of the
power sources. The reasons for these pleasing features are both the modular product
design and the options available for problem-free system extension.
They can adapt their power source to virtually any specific circumstance. For example,
welding current control is infinitely variable via the torch trigger. In addition, an extensive
range of remote controls is available for a wide variety of applications.
Field of application
There are numerous commercial applications for the MagicWave and the TransTig. For
manual welding, but also for automation and robot tasks, they are the ideal power
sources. In terms of materials, they are suitable for unalloyed and low-alloyed steel as
well as for high-alloyed chrome/nickel steel.
These all-round properties are supported by an optimum ignition sequence.
For TIG AC welding, the MagicWave takes into account not only the electrode diameter,
but also the current electrode temperature, based on the previous welding time and
pause.
In addition, the MagicWave performs excellently in the field of welding aluminum, aluminum alloys and magnesium. You can optimally adjust the AC frequency to your
requirements within a very wide range.
17
The power sources are all generator-compatible and offer the greatest possible robustness in operation thanks to protected operating elements and powder-coated housing.
The wealth of available operating modes and special functions means the power sources
are just as competent when performing MMA welding as TIG welding.
Warning notice
on the device
US power sources are equipped with additional warning notices on the device. The
warning notices must not be removed or painted over.
18
Fig.3 US power source with additional warning notices
Minimum equipment for welding operations
General Depending on the welding process, certain minimum equipment is required for working
with the power source.
The following description contains the minimum equipment required for the respective
welding procedure.
TIG AC welding - MagicWave power source
- Grounding cable
- TIG welding torch with rocker switch
- Gas connection (shielding gas supply) with gas pressure regulator
- Filler metal, depending on application
TIG DC welding - TransTig or MagicWave power source
- Grounding cable
- TIG welding torch with rocker switch
- Gas connection (shielding gas supply)
- Filler metal, depending on application
EN-US
Manual metal arc
welding
- TransTig or MagicWave power source
- Grounding cable
- Electrode holder
- Rod electrodes, depending on application
19
System components
(1)
(2)
(3)
(4)
(5)
(6)
(7)
General The TransTig and MagicWave power sources can be operated with numerous system
extensions and options.
Overview
Fig.4 System extensions and options
(1) Power source
(2) Cooling unit
(3) Trolley with gas cylinder holder
(4) TIG welding torch Standard / Up/Down
(5) Remote control
(6) Electrode cable
(7) Grounding cable
20
Control Panel
(1) (2)
(3)
(4)
(5)
(6)
(7)
EN-US
General
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
▶
▶
An essential feature of the control panel is the logical arrangement of the operating elements. All welding parameters that are essential for daily work can be simply
- selected with the keys
- changed by means of potentiometer
- shown on the display during welding.
Because of software updates, certain functions may be available for your device but not
described in these Operating Instructions or vice versa. In addition, individual figures
may also differ slightly from the operating controls of your device. These operating elements function in exactly the same way, however.
Overview The following figure shows an overview of the essential settings for daily work, using the
MagicWave control panel as an example. A detailed description of these settings can be
found in the following chapter "Description of the functions".
WARNING!
Read safety instructions
Read all Operating Instructions, including those for the system components
NOTE!
(1) Select the operating mode:
(2) Balance controller (MagicWave only)
(3) Adjuster for tungsten electrode (MagicWave only)
- 2-step mode
- 4-step mode
- Contact ignition
- Rod electrode
21
MagicWave con-
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(23)
(22)
(18)
(17)
(16)
(15)
(14)
(13)
(12)
(11)
(10)
(9)
(8)
(19) (21)
(20)
trol panel
(4) Select the process:
- AC welding
- DC- welding
- DC+ welding (only with rod electrode)
(5) Final current
(6) Main current controller
(7) DownSlope or current lowering time
Fig.5 Control panel for MagicWave 2600 / 2600 CEL / 3000
(1) Welding current indicator ... for displaying the main current I
H
- Set value ... desired welding current
- Actual value ... actual welding current
(2) Welding voltage indicator
- for displaying the current actual value of the welding voltage
(3) Mode button
(4) Manual metal arc welding
Manual metal arc welding symbol
(5) Contact ignition, can only be combined with TIG 2-step mode, or TIG 4-step
mode
Contact ignition symbol
(6) 4-step mode ... TIG welding with HF ignition
22
4-step mode symbol
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