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EN
Operating Instructions
MagicWave 190
MagicWave 230i
TIG Power source
TransTig 230i
42,0426,0250,EN 007-28012019
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Dear reader,
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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 notices
DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If 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.
This does not indicate a potentially hazardous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.
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Contents
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Safety rules ........................................................................................................................................................9
General .........................................................................................................................................................9
Proper use ....................................................................................................................................................9
Environmental conditions .............................................................................................................................9
Obligations of the operator ........................................................................................................................ 10
Obligations of personnel ............................................................................................................................ 10
Mains connection ....................................................................................................................................... 10
Protecting yourself and others ................................................................................................................... 10
Danger from toxic gases and vapours ....................................................................................................... 11
Danger from flying sparks.......................................................................................................................... 11
Risks from mains current and welding current .......................................................................................... 12
Meandering welding currents .................................................................................................................... 13
EMC Device Classifications....................................................................................................................... 13
EMC measures .......................................................................................................................................... 13
EMF measures .......................................................................................................................................... 14
Specific hazards ........................................................................................................................................ 14
Factors affecting welding results ............................................................................................................... 15
Danger from shielding gas cylinders ......................................................................................................... 15
Danger from escaping shielding gas ......................................................................................................... 16
Safety measures at the installation location and during transport ............................................................. 16
Safety measures in normal operation ........................................................................................................ 17
Noise emission values ............................................................................................................................... 17
Commissioning, maintenance and repair .................................................................................................. 17
Safety inspection ....................................................................................................................................... 18
Disposal ..................................................................................................................................................... 18
Safety symbols .......................................................................................................................................... 18
Data protection .......................................................................................................................................... 18
Copyright ................................................................................................................................................... 18
General information 19
General ........................................................................................................................................................... 21
Device concept .......................................................................................................................................... 21
Functional principle .................................................................................................................................... 21
Application areas ....................................................................................................................................... 21
FCC / RSS Compliance ............................................................................................................................. 22
Warning notices on the device .................................................................................................................. 23
System components ....................................................................................................................................... 24
General ...................................................................................................................................................... 24
Overview .................................................................................................................................................... 24
Options ...................................................................................................................................................... 24
Control elements and connections 25
Control panel .................................................................................................................................................. 27
General ...................................................................................................................................................... 27
Safety......................................................................................................................................................... 27
Control panel ............................................................................................................................................. 27
The favourites button ...................................................................................................................................... 29
Assigning the Favourites button ................................................................................................................ 29
Retrieving favourites .................................................................................................................................. 29
Deleting favourites ..................................................................................................................................... 30
Assigning EasyJobs to the Favourites button ........................................................................................... 30
Connections, switches and mechanical components ..................................................................................... 32
Connections, switches and mechanical components ................................................................................ 32
Installation and commissioning 35
Minimum equipment needed for welding task ................................................................................................ 37
General ...................................................................................................................................................... 37
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TIG AC welding ......................................................................................................................................... 37
TIG DC welding ......................................................................................................................................... 37
MMA welding ............................................................................................................................................. 37
Before installation and commissioning ........................................................................................................... 38
Safety......................................................................................................................................................... 38
Utilisation for intended purpose ................................................................................................................. 38
Setup regulations ....................................................................................................................................... 38
Mains connection ....................................................................................................................................... 39
Generator-powered operation ................................................................................................................... 39
Information on system components .......................................................................................................... 39
Connecting the mains cable ........................................................................................................................... 40
General ...................................................................................................................................................... 40
Safety......................................................................................................................................................... 40
Connecting the mains cable ...................................................................................................................... 40
Start-up ........................................................................................................................................................... 41
Safety......................................................................................................................................................... 41
Remarks on the cooling unit ...................................................................................................................... 41
General ...................................................................................................................................................... 41
Assembling the system components (overview) ....................................................................................... 42
Connecting the gas cylinder ...................................................................................................................... 43
Connecting the welding torch to the power source and the cooling unit ................................................... 44
Establishing a ground earth connection to the workpiece ......................................................................... 44
Locking and unlocking the power source using the NFC key ......................................................................... 45
General remarks ........................................................................................................................................ 45
Restrictions ................................................................................................................................................ 45
Welding 47
TIG modes ...................................................................................................................................................... 49
Safety......................................................................................................................................................... 49
Symbols and their explanations ................................................................................................................ 49
2-step mode ............................................................................................................................................... 50
4- step mode ............................................................................................................................................... 50
Spot welding .............................................................................................................................................. 51
TIG welding ..................................................................................................................................................... 52
Safety......................................................................................................................................................... 52
Preparatory work ....................................................................................................................................... 52
TIG welding ............................................................................................................................................... 53
Welding parameters for TIG DC welding ................................................................................................... 54
Welding parameters for TIG AC welding ................................................................................................... 57
Igniting the arc ................................................................................................................................................ 63
General ...................................................................................................................................................... 63
Igniting the arc using high frequency(HF ignition) ..................................................................................... 63
Touchdown ignition .................................................................................................................................... 64
Electrode overload ..................................................................................................................................... 65
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 .................................................................................................................................................. 69
Safety......................................................................................................................................................... 69
Preparatory work ....................................................................................................................................... 69
MMA welding ............................................................................................................................................. 70
Welding parameters for manual metal arc welding ................................................................................... 71
Welding parameters for MMA welding with cellulose electrodes .............................................................. 74
Starting current >100% (HotStart) ............................................................................................................. 76
Starting current <100% (SoftStart) ............................................................................................................ 77
Anti-stick function ...................................................................................................................................... 77
EasyJob mode ................................................................................................................................................ 78
Storing EasyJob operating points .............................................................................................................. 78
Retrieving EasyJob operating points ......................................................................................................... 79
Deleting EasyJob operating points ............................................................................................................ 79
Welding job ..................................................................................................................................................... 80
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Safety......................................................................................................................................................... 80
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Preparatory work ....................................................................................................................................... 80
Welding a job ............................................................................................................................................. 81
Setup settings 83
The Setup menu ............................................................................................................................................. 85
General ...................................................................................................................................................... 85
Accessing the Setup menu ........................................................................................................................ 85
Overview .................................................................................................................................................... 86
Changing menus and parameters ............................................................................................................. 87
The TIG menu ................................................................................................................................................. 89
Parameters in the TIG DC menu ............................................................................................................... 89
Parameters in the TIG AC menu ............................................................................................................... 92
The MMA menu .............................................................................................................................................. 96
Parameters in the rod electrode menu ...................................................................................................... 96
The CEL menu ................................................................................................................................................ 99
Parameters in the CEL menu .................................................................................................................... 99
Ignition settings ............................................................................................................................................. 100
Ignition setting parameters ...................................................................................................................... 100
The gas menu ............................................................................................................................................... 102
Parameters in the Gas menu................................................................................................................... 102
The components menu ................................................................................................................................. 103
Parameters in the Components menu ..................................................................................................... 103
Emptying the torch hosepack .................................................................................................................. 104
Filling the torch hosepack ........................................................................................................................ 105
The Job menu ............................................................................................................................................... 106
Save job ................................................................................................................................................... 106
Loading a job ........................................................................................................................................... 107
Deleting a job ........................................................................................................................................... 107
Defaults ......................................................................................................................................................... 108
Overview .................................................................................................................................................. 108
Display .......................................................................................................................................................... 109
Backlighting ............................................................................................................................................. 109
Languages ............................................................................................................................................... 109
Time & Date ............................................................................................................................................. 109
Show system data ................................................................................................................................... 110
Display additional parameters ................................................................................................................. 110
System .......................................................................................................................................................... 112
Restoring the factory settings .................................................................................................................. 112
Reset website password .......................................................................................................................... 112
Performing R/L alignment ........................................................................................................................ 112
Network ......................................................................................................................................................... 114
General .................................................................................................................................................... 114
Bluetooth on ............................................................................................................................................ 114
Configuring Bluetooth devices ................................................................................................................. 115
System informations ..................................................................................................................................... 116
Device information ................................................................................................................................... 116
SmartManager - The power source website 117
SmartManager - The power source website ................................................................................................ 119
General .................................................................................................................................................... 119
Calling up the power source SmartManager ........................................................................................... 119
Fronius ..................................................................................................................................................... 119
Changing password / logging off ............................................................................................................. 119
Language ................................................................................................................................................. 120
Current system data ..................................................................................................................................... 121
Current system data ................................................................................................................................ 121
Job-Data ....................................................................................................................................................... 122
Job data ................................................................................................................................................... 122
Job overview ............................................................................................................................................ 122
Editing a job ............................................................................................................................................. 122
Importing a job ......................................................................................................................................... 123
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Exporting a job ......................................................................................................................................... 123
Exporting job(s) as… ............................................................................................................................... 123
Backup & Restore ......................................................................................................................................... 124
General .................................................................................................................................................... 124
Backup & Restore .................................................................................................................................... 124
Overview ....................................................................................................................................................... 125
Overview .................................................................................................................................................. 125
Expanding / reducing all groups .............................................................................................................. 125
Export component overview as ............................................................................................................... 125
Update .......................................................................................................................................................... 126
Update ..................................................................................................................................................... 126
Function Packages ....................................................................................................................................... 127
Function packages .................................................................................................................................. 127
Installing a function package ................................................................................................................... 127
Screenshot .................................................................................................................................................... 128
Screenshot .............................................................................................................................................. 128
Troubleshooting and maintenance 129
Troubleshooting ............................................................................................................................................ 131
General .................................................................................................................................................... 131
Safety....................................................................................................................................................... 131
Power source - troubleshooting ............................................................................................................... 131
Care, maintenance and disposal .................................................................................................................. 134
General .................................................................................................................................................... 134
Safety....................................................................................................................................................... 134
At every start-up ...................................................................................................................................... 134
Every 2 months ........................................................................................................................................ 134
Every 6 months ........................................................................................................................................ 135
Disposal ................................................................................................................................................... 135
Appendix 137
Technical data .............................................................................................................................................. 139
Special voltages ...................................................................................................................................... 139
MagicWave 190 ....................................................................................................................................... 139
MagicWave 230i ...................................................................................................................................... 141
TransTig 230i ........................................................................................................................................... 143
Explanation of footnotes .......................................................................................................................... 144
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Safety rules
EN
General 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!
Proper use 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.
Environmental
conditions
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.
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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.)
Obligations of the
operator
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.
Obligations of
personnel
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.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
consumption.
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance
- Criteria with regard to the minimum short-circuit power requirement
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at the interface with the public grid
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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.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting yourself and others
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
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Suitable protective clothing must be worn when working with the device. The protective
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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.
Danger from toxic
gases and vapours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances, cause birth de-
fects 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.
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.
Danger from fly-
Flying sparks may cause fires or explosions.
ing sparks
Never weld close to flammable materials.
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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.
Risks from mains
An electric shock is potentially life threatening and can be fatal.
current and welding current
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.
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.
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Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
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one 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.
Meandering welding currents
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 ma-
terial to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The elec-
trode 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 wirefeed unit.
EMC Device Classifications
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.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
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 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
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Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al 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
EMF measures 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
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.
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Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
EN
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 cool-
ant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The cool-
ant 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).
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 device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
Factors affecting
welding results
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.
IMPORTANT! There is an increased risk of soiling if ring mains are being used
Danger from
shielding gas cylinders
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.
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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.
Danger from escaping shielding
gas
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 ox-
ygen 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.
Safety measures
at the installation
location and during transport
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.
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EN
Safety measures
in normal operation
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.
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 prop-
erties (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 com-
ponents 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 cer-
tain 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.
Noise emission
values
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.
Commissioning,
maintenance and
repair
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.
18
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.
Safety inspection 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.
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
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!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic 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.
Data protection 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.
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
21
General
EN
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 alu-
minium, aluminium alloys and magnesium due to the variable AC frequency.
22
FCC / RSS Com-
pliance
Einschub
TT/MW
Smart
210mm
43,0001,3533
FCC
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
(1) this device may not cause harmful interference, and
(2) this device must accept any interference received,
including interference that may cause undesired operation.
Changes or modifications not expressly approved by the party responsible
for compliance could void the user's authority to operate the equipment.
FCC ID: QKWSPBBCU1
FCC/ Industry Canada RSS
This device complies with FCC and ISED Canada radiation exposure limits
when the device is operated with a min separation distance of 20 cm
between the front side (control panel)
and any human body during normal operating conditions.
IC: 12270A-SPBBCU1
23
CE
Frequency Range (MHz)
Channels used/ power
Modulation
2412-2462
Channel:1-11 b,g,n
HT20
Channel: 3-9 HT40
<18dBm
802.11b: DSSS (1Mbps
DBPSK, 2Mbps DQPSK,
5.5/11Mbps CCK)
802.11g: OFDM (6/9Mbps
BPSK, 12/18Mbps QPSK,
24/36Mbps 16-QAM,
48/54Mbps 64-QAM)
802.11n: OFDM (6.5Mbps
BPSK, 13/19 Mbps QPSK,
26/39 Mbps16QAM,52/58.5/65Mbps 64QAM)
13,56
-13,5 dBµA/m at 10m
Functions: R/W, Card
Emulation and P2P
Protocol standards: ISO
14443A/B
ISO15693, NFCIP-2,
Data rate: 848kbps
Reader/Writer, card
emulation, Peer to Peer
modes
2402-2482
0-39
<10dBm
GFSK
Compliance
Einschub
TT/MW
Smart
210mm
43,0001,3533
CE
Compliance with 2014/53/EU
Radio Equipment Directive (RED)
In accordance with Article 10.8(a) and 10.8(b) of the RED, the following table provides
information on the frequency bands used and the maximum RF transmit power of Fronius
wireless products for sale in the EU.
24
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
25
System components
General The TransTig and MagicWave power sources can be used with a wide variety of system
add-ons and options.
Overview
Options
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)
(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
26
Control elements and connections
27
Control panel
(1)
(2)
(3)
(4)
(5)
(6)
(10)
(9)
(7) (8)
EN
General
Safety
Control panel
NOTE!
Due to software updates, you may find that your device has certain functions 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
these operating instructions
► Do not use the functions described until you have thoroughly read and understood all
the operating instructions for the system components, especially the safety rules
28
No. Function
(1) Mode/welding process button
For selecting welding processes and mode
(2) Gas-test button
To set the required shielding gas flow rate on the gas pressure regulator
After pressing the gas-test button, shielding gas flows for 30 seconds. Press the
button again to stop the gas flow prematurely.
(3) Key card reader 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 106
(5) Menu key
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
welding 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.)
- Indication of electrode overload
- Status of the power source (locked/unlocked)
- Active Bluetooth connection
- 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
welding voltage are stored - HOLD lights up.
29
The favourites button
xxx xxx
xxxx
EN
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 83 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 warn-
ing.
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.
30
* *
50 A
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 106 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
31
The 5 EasyJob buttons are displayed and can be selected by turning and pressing the
50 A
* 1
2
3
4
5 *
EN
adjusting dial.
More information about using EasyJobs can be found in the "EasyJob mode" section starting on page 78.
32
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
(2) TMC connection (TIG Multi Connector)
(3) USB port
Symbols on TransTig power sources:
Symbols on MagicWave power sources:
- to connect the TIG welding torch control plug
- to connect pedal remote controls
- to connect the remote control during MMA welding
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.
33
EN
No. Function
(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
34
Installation and commissioning
37
Minimum equipment needed for welding task
EN
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)
38
Before installation and commissioning
Safety
Utilisation for intended purpose
Setup regulations The device is tested to IP 23 protection, meaning:
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 per-
sonnel.
► 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
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
- Protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49
in.)
- Protection against spraywater at any angle up to 60° to the vertical
The device can be set up and operated outdoors in accordance with degree of protection
IP 23.
Avoid direct wetting (e.g. from rain).
WARNING!
Toppling or falling devices can cause life-threatening injuries.
► Place devices on a solid, level surface so that they remain stable.
The venting duct is a very important safety device. When choosing the installation location,
ensure that the cooling air can enter and exit unhindered through the air ducts on the front
and back of the device. Electroconductive metallic dust (e.g. from grinding work) must not
be allowed to get sucked into the device.
39
EN
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.
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.
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.
The maximum apparent power S
S
1max
= I
1max
x U
1
See device rating plate or technical data for I
of the power source can be calculated as follows:
1max
and U1 values
1max
The generator apparent power S
thumb:
S
GEN
= S
1max
x 1.35
needed is calculated using the following rule of
GEN
A smaller generator may be used when not welding at full power.
IMPORTANT! The generator apparent power S
mum apparent power S
of the power source.
1max
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.
must always be higher than the maxi-
GEN
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.
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.
40
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
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.
Connect the mains cable:
- Plug in the mains cable
- Turn the mains cable 45° to the
right until you hear it latch into place
41
Start-up
EN
Safety
Remarks on the
cooling unit
General This section describes how to commission the power source:
WARNING!
An electric shock can be fatal.
If the device is plugged into the mains during installation, there is a high risk of very serious
injury and damage.
► Only carry out work on the device if the mains switch is in the "O" position.
► Only carry out work on the charger when it has been disconnected from the mains sup-
ply.
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.
- 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.
42
Assembling the
system components (overview)
43
EN
Connecting the
gas cylinder
WARNING!
There is a high risk of very serious injury and damage if a gas cylinder falls over.
► Place gas cylinders 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.
► Observe the safety rules of the gas cylinder manufacturer.
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
NOTE!
When using a MultiControl (MC) cool unit, please see the Operating Instructions of
the cooling unit for a description of the gas connection.
44
Connecting the
welding torch to
the power source
and the cooling
unit
NOTE!
Do not use pure tungsten electrodes (colour-coded green) on TransTig power
sources.
Set up the welding torch in accordance with the welding torch operating instructions
NOTE!
Before each start-up:
► Check the sealing ring on the welding
torch connection.
Establishing a
ground earth connection to the
workpiece
Turn the mains switch to the "O" position
► Check coolant level.
During welding, check at regular intervals
that the coolant is flowing properly.
45
Locking and unlocking the power source using the
EN
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.
46
Welding
49
Pull back and hold the torch trigger
TIG modes
Push forward and hold the torch
trigger
Release the torch trigger
Release the torch trigger
Briefly pull back the torch trigger
(< 0.5 s)
EN
Safety
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
these operating instructions
► Do not use the functions described until you have thoroughly read and understood all
the operating instructions for the system components, especially the safety rules
See the "The Setup menu" section for information on the settings, setting range and units
of measurement of the available welding parameters.
GPr
Gas pre-flow 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
UP
Upslope phase: the starting current is
steadily increased until it reaches the
main current (welding current) I
I
1
1
Main current phase (welding-current
phase): uniform thermal input into the
base material, whose temperature is
raised by the advancing heat
GPo
Gas post-flow time
SPt
Spot welding time
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.
DOWN
DownSlope phase: the welding current is
steadily lowered until it reaches the final
current
I
2
Reduced current phase: intermediate low-
ering of the welding current in order to prevent any local overheating of the base
material
50
DOWN GPo
GPr UP
t
I
1
I
I
I
1
I
1
I-2
*)
I
S
I
E
t
GPr
UP
DOWN
GPo
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 I
- 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
: Pull back and hold the torch trigger
S
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
51
SPt
GPo
DOWN
UP
GPr
I
1
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
52
TIG welding
Safety
Preparatory work Plug in the mains plug
WARNING!
Operating the equipment incorrectly can cause serious injury and damage.
► Do not use the functions described until you have thoroughly read and understood
these operating instructions
► Do not use the functions described until you have thoroughly read and understood 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
► Before carrying out any work on the device make sure that the power source is un-
plugged 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.
► Ensure that the tungsten electrode does not touch any persons or electrically conduc-
tive or earthed parts (e.g. housing, etc.).
Move the mains switch to the "I" position
The Fronius logo appears on the display.
53
10
11
12
EN
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.
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 83)
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 ma-
nometer indicates the desired shielding gas flow-rate
54
NOTE!
0.5 s
0.5 s
13
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.
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
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.
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 saved UpSlope value applies to both the 2-step and 4-step modes.
55
Ib > 100 %
The values for Slope1 and Slope2 can be
set using the TIG menu.
Slope1
Ib < 100 %
Slope2
50 A
50 A
-
+
150%
EN
Main current (I1)
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 (I2)
only in 4-step mode
xxA
Reduced current I2 < Main current I
1
Reduced current I2 > Main current I
1
Unit % (of main current I1)
Setting range 0 - 200
Factory setting 50
I2 < 100 % Short, adapted reduction of the welding current
(for example when changing the welding wire during the welding
process)
I2 > 100 % Short, adapted increase of the welding current
(for example to weld over tacked spots with higher power)
Slope1
Slope2
56
0.5 s
0.5 s
2.4mm
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 saved DownSlope value applies to both the 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
57
DC-
50%
50%
EN
Polarity
Unit -
Setting range DC- / AC
Factory setting DC-
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
Starting current
xxA
Starting current, 2-step mode and spot welding
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.
Starting current, 4-step mode
xxA
58
150%
0.5 s
0.5 s
50 A
50 A
50%
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 saved UpSlope value applies to both the 2-step and 4-step modes.
Main current (I1)
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 (I2)
only in 4-step mode
Reduced current I2 < Main current I
xxA
1
Reduced current I2 > Main current I
xxA
1
Unit % (of main current I1)
Setting range 0 - 200
Factory setting 50
59
I2 < 100 % Short, adapted reduction of the welding current
Ib > 100 %
The values for Slope1 and Slope2 can be
set using the TIG menu.
Slope1
Ib < 100 %
Slope2
0.5 s
0.5 s
30%
30%
EN
(for example when changing the welding wire during the welding
process)
I2 > 100 % Short, adapted increase of the welding current
(for example to weld over tacked spots with higher power)
Slope1
Slope2
DownSlope
DownSlope, 2-step mode and spot welding
Unit s
Setting range off; 0.1 - 30.0
Factory setting 1.0
DownSlope, 4-step mode
IMPORTANT! The saved DownSlope value applies to both the 2-step and 4-step modes.
Final current
Final current, 2-step mode and spot welding
Unit % (of main current)
Setting range 0 - 100
Factory setting 30
xxA
Final current, 4-step mode
xxA
60
15%
35%
50%
35%
50%
15%
+
t (s)
2.4mm
Balance
on MagicWave only
Balance = 15%
Balance = 50 %
Unit %
Setting range 15 - 50
Factory setting 35
15: highest fusing power, lowest cleaning action
50: highest cleaning action, lowest fusing power
Effect of the balance on the waveshape:
Balance = 35 %
I (A)
Electrode diameter
Unit mm
Setting range off; 1.0 - 4.0
Factory setting 2.4
61
off
EN
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.
Afterwards, the automatic cap-shaping function is reset and deactivated.
(1) (2)
(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.
62
AC
Polarity
Unit -
Setting range DC- / AC
Factory setting DC-
63
Igniting the arc
EN
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.
64
Tilt the welding 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
65
Raise the welding torch and rotate it
EN
into its normal position
The arc ignites.
Carry out welding
Electrode overload
End of welding Depending on the set mode, finish welding by releasing the torch trigger
If the tungsten electrode is overloaded, material can detach from the electrode that then
contaminates the weld pool.
If the tungsten electrode is overloaded, the "Electrode overload" indicator in the
status bar of the control panel lights up.
The "Electrode overload" indicator depends on the electrode diameter and
welding current that have been set.
Wait for the set gas post-flow and hold welding torch in position over the end of the
weld seam
66
Ignition time out, TIG pulsing and tacking function
Legend:
(1)
Main current
(5)
Pulse frequency *)
(2)
Base current
(6)
Duty cycle
(3)
Starting current
(7)
DownSlope
(4)
UpSlope
(8)
Final current
t [s]
(7)
(4)
(8)
(3)
(2)
(1)
(6)
(5)
I [A]
Ignition timeout
function
TIG pulsing The welding current set at the start of welding is not always ideal for the welding process
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 100 onwards.
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.
Mode of operation of TIG pulsing when TIG DC welding is selected:
TIG pulsing - welding current curve
*) (1/F-P = time interval between two pulses)
67
t [s]
(5)
(3)
(2)
(6)
(1)
(4)
I [A]
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 tacked.
Mode of operation of tacking function for TIG DC welding:
Tacking function - welding current curve
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 set
main current (1).
There is no need to set any pulsing parameters.
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").
68
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.
69
MMA welding
EN
Safety
Preparatory work Switch off cooling units (in the components menu, set the cooling unit control setup
WARNING!
Operating the equipment incorrectly can cause serious injury and damage.
► Do not use the functions described until you have thoroughly read and understood
these operating instructions
► Do not use the functions described until you have thoroughly read and understood 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
► Before carrying out any work on the device make sure that the power source is un-
plugged from the mains
parameter to OFF)
Turn 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
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.).
Move the mains switch to the "I" position
The Fronius logo appears on the display.
70
10
11
12
MMA welding Press the Mode button
The welding process and operating mode are displayed.
Select electrode welding processes (Stick / MMA) or CEL (turn and press the adjusting
dial)
Turn the adjusting dial to select the Polarity parameter:
DC- / DC+ / AC ... during MMA welding
DC- / DC+ ... during MMA welding with cellulose electrodes
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 83)
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.
Start welding
71
150%
xxA
*
*
50%
xxA
*
*
100%
xxA
*
*
EN
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
72
130 A
*
*
130 A
*
*
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.
73
-
+
DC-
+
-
DC+
AC
EN
Polarity
Polarity, set to DC- Polarity, set to DC+
Polarity, set to AC
Unit -
Setting range DC- / DC+ / AC
Factory setting DC-
74
150%
xxA
*
*
50%
xxA
*
*
100%
xxA
*
*
Welding parameters for MMA
welding with cellulose electrodes
* Depending on the selected current type, (+) or (-) 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
75
130 A
*
*
130 A
*
*
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.
76
DC-
DC+
1,5 0,5
t (s)
(3)
(2)
100
150
(1)
I (A)
Polarity
Polarity, set to DC- Polarity, set to DC+
Unit -
Setting range DC- / DC +
Factory setting DC-
Starting current
> 100 % (Hot-
Start)
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
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
Mode of operation
during the specified starting current time
(1), the welding current I1 (3) is increased to
the starting current (2).
Example with a starting current > 100% (HotStart)
The starting current time is set in the Setup
menu.
77
t
(2)
(1)
30A
90A
(3)
I (A)
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.
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.
Example with a starting current < 100% (SoftStart)
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.
78
EasyJob mode
Storing EasyJob
operating points
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!
Prerequisite:
EasyJobs must be assigned to the Favourites button (see "Assigning EasyJobs to the Favourites button", starting on page 30.
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
79
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.
Deleting EasyJob
operating points
The EasyJob buttons are then minimised and the active EasyJob is indicated by a flag.
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.
80
Welding job
Safety
Preparatory work Set up and install the power source in accordance with the welding job
WARNING!
Operating the equipment incorrectly can cause serious injury and damage.
► Do not use the functions described until you have thoroughly read and understood
these operating instructions
► Do not use the functions described until you have thoroughly read and understood 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
► Before carrying out any work on the device make sure that the power source is un-
plugged from the mains
Plug in the mains plug
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.
► Ensure that the tungsten electrode does not touch any persons or electrically conduc-
tive or earthed parts (e.g. housing, etc.).
Move the mains switch to the "I" position
81
EN
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.
82
Setup settings
85
The Setup menu
EN
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.
86
(4)
Ignition settings
to set the TIG arc ignition parameters
(5)
Gas menu
to set the shielding gas parameters
(6)
Component settings
to set the cooling unit operating mode
(2)
Rod electrode menu
to set the rod electrode parameters
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(14)
(13)
(12)
(11)
(10)
**
Overview
Item Designation
(1) TIG menu
to set the TIG parameters for TIG DC and TIG AC
(3) CEL menu
(7) Job menu
to set the parameters for MMA welding with CEL electrodes
(only if FP Job function package is present)
- to save, load and delete jobs
- to assign EasyJobs to the Favourites button
87
EN
Item Designation
(8) Defaults
to
- Display:
set display backlighting, languages, date & time, display additional parameters
- System:
restore factory settings, reset website password, perform R/L
alignment
- Network:
Bluetooth on, configure Bluetooth devices
(9) System information
to display device information such as software version or IP address
(assuming the power source is on a network)
(10) Scroll bar
(for multiple parameters)
(11) Available menus
the number of available menus can vary depending on the firmware
version and available options.
(12) Value, unit
(13) 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.
(14) 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
Changing menus
and parameters
Selected menu Selected parameter
Change the menu Set the parameter
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)
88
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
89
The TIG menu
EN
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 (10,000 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
90
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
Base current waveform
To optimise the arc pressure
Unit -
Setting range Hard rectangle / Soft rectangle / 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
Sine Sinusoidal waveform (standard setting for a low-noise, stable
arc)
Pulse current waveform
To optimise the arc pressure
Unit -
Setting range Hard rectangle / Soft rectangle / 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
Sine Sinusoidal waveform (standard setting for a low-noise, stable
arc)
Optimising the arc pressure has the following effects:
- Better wetting of the weld pool (improved welding of butt welds or corner welds)
- Slow current rise or current drop (especially with fillet welds, high-alloy steels or clad-
ding applications, the filler material or the weld pool is not pushed away)
- Quieter welding thanks to smoother waveforms
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.
91
EN
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").
Slope reduced current
To set the Slope1 reduced current and Slope2 reduced current parameters
Slope1 reduced current
Unit s
Setting range off / 0.01 - 30
Factory setting Off
If a time value has been entered for the Slope1 reduced current parameter, the short-term
current reduction or current increase is not abrupt, but rather slow and adapted to the desired current curve.
This reduces negative effects on the weld seam and component, especially for aluminium
applications.
Slope2 reduced current
Unit s
Setting range off / 0.01 - 30
Factory setting Off
If a time value has been entered for the Slope2 reduced current parameter, the adaptation of the reduced current to the welding current is not abrupt, but rather slow and adapted to the desired current curve.
For example, during a current increase, the weld pool is heated slowly, not abruptly. This
allows the weld pool to outgas and reduces pores during aluminium welding.
Spot welding time
(spot welding mode only)
Unit s
Setting range 0.02 - 120
Factory setting 5.0
92
Parameters in the
TIG AC menu
Pulse frequency
Unit Hz
Setting range Off / 0.20 - 2000 (10,000 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
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").
93
EN
Slope reduced current
To set the Slope1 reduced current and Slope2 reduced current parameters
Slope1 reduced current
Unit s
Setting range off / 0.01 - 30
Factory setting Off
If a time value has been entered for the Slope1 reduced current parameter, the short-term
current reduction or current increase is not abrupt, but rather slow and adapted to the desired current curve.
This reduces negative effects on the weld seam and component, especially for aluminium
applications.
Slope2 reduced current
Unit s
Setting range off / 0.01 - 30
Factory setting Off
If a time value has been entered for the Slope2 reduced current parameter, the adaptation of the reduced current to the welding current is not abrupt, but rather slow and adapted to the desired current curve.
For example, during a current increase, the weld pool is heated slowly, not abruptly. This
allows the weld pool to outgas and reduces pores during aluminium welding.
Spot welding time
(spot welding mode only)
Unit s
Setting range 0.02 - 120
Factory setting 5.0
AC frequency
Unit Hz
Setting range Syn / 40 - 250
Factory setting 60
Syn Setting for synchronous welding (both-side, simultaneous weld-
ing with 2 power sources)
The AC frequency of both power sources must be set to "Syn" to
enable synchronous welding.
Synchronous welding is used on thick materials to achieve a high
deposition rate while minimising inclusions.
IMPORTANT! Owing to the phasing of the input voltage, in some
cases the synchronisation of the two power sources cannot be
carried out properly.
In this case, pull out the mains plug of the power source, turn it
through 180°, and plug it back in again.
Low frequency soft, distant arc with shallow heat input
High frequency focused arc with deep heat input
94
t (s)
Effect of the AC frequency on the waveshape:
+
t (s)
I (A)
60 Hz 120 Hz
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:
I (A)
* Factory setting: 20% shift to the negative
Positive half-wave waveform
0 +70% -70%
Unit -
Setting range Hard rectangle / Soft rectangle / Triangle / Sine
Factory setting Sine
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)
95
EN
Negative half-wave waveform
Unit -
Setting range Hard rectangle / Soft rectangle / Triangle / Sine
Factory setting Soft 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)
96
The MMA menu
Parameters in the
rod electrode
menu
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 proper-
ties
- Better fusion of the base material in the start-up phase, meaning fewer cold-shut de-
fects
- 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
U (V)
0 100
Adjustable characteristics
(5)
(6)
200
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).
(4)
(7) (8)
300
con - 20 A / V
400
(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-
(2)
(1)
(3)
I (A)
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
97
0.1 - 20.0 (drooping characteristic with adjustable slope)
Load line for rod electrode
Load line for rod electrode where arc length is in-
creased
Load line for rod electrode where arc length is re-
duced
Characteristic for parameter setting I-constant
(constant welding current)
Characteristic for parameter setting 0.1 - 20.0
(drooping characteristic with adjustable slope)
Characteristic for parameter setting P-constant
(constant welding power)
Example of pre-set arc-force dynamic where
characteristic (5) or (6) is selected
Possible change in the current where character-
istic (5) or (6) is selected, as a function of the
welding voltage (arc length)
Operating point where arc length is long
Operating point when welding current I1 is set
Operating point where arc length is short
(a)
(b)
(c)
(8)
400
I (A)
(7)
(6)
(5)
(4)
(3)
(2)
(1)
EN
- 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.
NOTE!
When setting a flat characteristic (5), set the arc-force dynamic to a higher value.
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.
NOTE!
If there are problems with a rod electrode tending to "stick", set the arc-force dynamic to a higher value.
Settings example: I1 = 250 A, arc-force dynamic = 50
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 (I1) 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.
98
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).
For characteristics (5) and (6), if a constant value is set for I1, 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
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