Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
TransTig 2200 / 2500 Comfort
TransTig 3000 / 4000 Comfort
TransTig 5000 Comfort
MagicWave 2200 / 2500 Comfort
MagicWave 3000 / 4000 Comfort
MagicWave 5000 Comfort
Operating instructions
EN
TIG power source
42,0426,0063,EN 022-18122020
Contents
Safety rules 8
Explanation of safety notices 8
General 8
Proper use 8
Environmental conditions 9
Obligations of the operator 9
Obligations of personnel 9
Mains connection 9
Protecting yourself and others 10
Noise emission values 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
Requirement for the shielding gas 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 16
Commissioning, maintenance and repair 17
Safety inspection 17
Disposal 18
Safety symbols 18
Data protection 18
Copyright 18
EN
General information 19
General 21
Device concept 21
Functional principle 21
Application areas 21
System components 22
General 22
Overview 22
Control elements and connections 23
Description of the control panels 25
General 25
Safety 25
MagicWave Comfort control panel 25
TransTig Comfort control panel 27
Connections, switches and mechanical components 29
MagicWave2200 Comfort 29
MagicWave2500 / 3000 Comfort 30
MagicWave4000 / 5000 Comfort 31
TransTig2200 Comfort 32
TransTig2500 / 3000 Comfort 33
TransTig4000 / 5000 Comfort 34
Installation and commissioning 35
Minimum equipment needed for welding task 37
General 37
TIG AC welding 37
TIG DC welding 37
3
Automated TIG welding 37
MMA welding 37
Before installation and commissioning 38
Safety 38
Utilisation for intended purpose 38
Setup regulations 38
Mains connection 38
Start-up 40
Safety 40
Remarks on the cooling unit 40
General 40
Connecting the gas cylinder 40
Establishing a ground (earth) connection to the workpiece 41
Connecting the welding torch 41
Welding 43
TIG modes 45
Safety 45
Symbols and their explanations 45
2-step mode 46
Spot welding 46
4-step mode 47
Special 4-step mode: variant 1 47
Special 4-step mode: variant 2 48
Special 4-step mode: variant 3 48
Special 4-step mode: variant 4 49
Cap shaping and cap overloading 50
Cap-shaping 50
Cap overloading 50
TIG welding 51
Safety 51
Welding parameters: display and navigation 51
Welding parameters for TIG 51
Preparation 54
TIG welding 54
Igniting the arc 56
General 56
Igniting the arc using high frequency(HF ignition) 56
Touchdown ignition 57
End of welding 58
Special functions and options 59
Arc break watchdog function 59
Ignition time-out function 59
TIG pulsing 59
Tacking function 60
TIG cold-wire welding 61
MMA welding 63
Safety 63
Welding parameters: display and navigation 63
Welding parameters for rod electrodes 64
Preparation 65
MMA welding 66
Hotstart function 68
Starting current < 100 % (SoftStart) 68
Anti-stick function 68
Welding job 70
Safety 70
Welding parameters: display and navigation 70
Welding parameters for TIG 70
Welding parameters for rod electrodes 73
Preparation 75
4
Welding job 76
Finishing the welding job 78
Saving settings as a job 80
General 80
Preparation 80
Saving settings as a job 81
Finish saving job 86
Setup settings 89
The Setup menu 91
General 91
Overview 91
TIG setup 92
Opening the TIG setup 92
Changing welding parameters 93
Exiting TIG setup 94
Welding parameters in the TIG setup 95
TIG setup 2nd 98
Opening the TIG setup 2nd 98
Changing welding parameters 98
Exiting TIG setup 2nd 99
Welding parameters in the TIG setup 2nd 101
AC setup 105
General 105
Open the AC setup 105
Changing welding parameters 106
Exiting AC setup 107
Welding parameters in AC setup 108
AC setup 2nd 110
General 110
Opening the AC setup 2nd 110
Changing welding parameters 110
Exiting AC setup 2nd 112
Welding parameters in AC setup 2nd 113
Gas setup 115
General 115
Opening the gas setup 115
Changing welding parameters 116
Exiting gas setup 117
Gas setup parameters 118
Cold wire setup 121
General 121
Opening the AC setup 121
Changing welding parameters 122
Exiting the cold wire setup 123
Welding parameters in the cold wire setup 124
Calibrating push-pull unit 126
General 126
Calibrating the push-pull unit 126
General 128
Service codes during calibration of the push-pull unit 129
Rod elec. setup (rod electrode setup) 133
Open the rod electrode setup 133
Changing welding parameters 134
Exiting rod electrode-setup 135
Rod electrode setup parameters: 135
Rod elec. setup 2nd (rod electrode setup 2nd) 137
Opening the rod electrode setup 2nd 137
Changing welding parameters 137
Exiting rod electrode setup 2nd 138
Rod electrode setup 2nd welding parameters 140
EN
5
AC setup (for rod electrodes) 143
General 143
Opening the AC setup 143
Changing welding parameters 144
Exiting AC setup 145
Welding parameters in AC setup 145
Job 147
General 147
Opening the Job set-up menu 147
Save / retrieve 147
Overview 148
Optimising a job 149
Optimising a job 149
Renaming a job 151
Finish optimising job 153
Adjustable TIG parameters 154
Adjustable rod electrode parameters 159
Deleting a job 163
Deleting a job 163
Basic setting 166
General 166
Opening the basic settings 166
Changing welding parameters 167
Exiting basic settings 168
Basic setting parameters 169
Info 170
General 170
Calling up the info screen 170
Exiting the info screen 171
Entries on the info screen 172
Lock keys 173
General 173
Lock keys 173
Unlock keys again 174
Factory - for resetting the welding machine 175
General 175
Factory - for resetting the welding machine 175
L/R alignment 177
Abbreviations 177
General information on welding circuit inductivity L 177
General information on welding circuit resistance R 177
L/R alignment 177
Troubleshooting and maintenance 181
Troubleshooting 183
General 183
Safety 183
Displayed service codes 183
Service codes displayed in conjunction with the digital gas control option 189
Displayed Service codes in conjunction with cold wire-feed unit 189
Power source - troubleshooting 190
Care, maintenance and disposal 193
General 193
Safety 193
At every start-up 193
Every 2 months 193
Every 6 months 194
Disposal 194
Appendix 195
Average consumption values during welding 197
6
Average wire electrode consumption during MIG/MAG welding 197
Average shielding gas consumption during MIG/MAG welding 197
Average shielding gas consumption during TIG welding 197
Technical data 198
Special voltages 198
Overview with critical raw materials, year of production of the device 198
MagicWave 2200 Comfort 198
MagicWave 2500 Comfort 199
MagicWave 3000 Comfort 200
MagicWave 2500 Comfort MV 201
MagicWave 3000 Comfort MV 202
MagicWave 4000 Comfort 203
MagicWave 4000 Comfort MV 204
MagicWave 5000 Comfort 205
MagicWave 5000 Comfort MV 206
TransTig2200 Comfort 207
TransTig 2500 Comfort 208
TransTig 3000 Comfort 209
TransTig 2500 Comfort MV 210
TransTig 3000 Comfort MV 211
TransTig 4000 Comfort 213
TransTig 4000 Comfort MV 214
TransTig 5000 Comfort 214
TransTig 5000 Comfort MV 215
Explanation of footnotes 216
EN
7
Safety rules
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.
General The device is manufactured using state-of-the-art technology and according to recog-
nised 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 welding and
- read and follow these operating instructions carefully.
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 switching on 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.
8
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.
EN
Environmental
conditions
Obligations of the
operator
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer shall not be held liable for any
damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section
"safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their cur-
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.
rent consumption.
9
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
*)
at the interface with the public grid
*)
*)
see "Technical data"
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power
supply company.
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
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective visor and
regulation filter
- Wear regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Noise emission
values
10
Keep all persons, especially children, out of the working area while any devices are in
operation or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
The 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.
Danger from
toxic gases and
vapours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
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. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
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.
The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
- Welding process used
EN
Danger from flying sparks
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for identifying working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation
area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or
alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near
sealed tanks, vessels or pipes unless these have been prepared in accordance with the
relevant national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
11
Risks from mains
current and welding current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed
rollers and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry base or
cover for the earth or ground potential. This base 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 pretension.
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.
Protection class I devices require a mains supply with ground conductor and a connector
system with ground conductor contact for proper operation.
Operation of the device on a mains supply without ground conductor and on a socket
without ground conductor contact is only permitted if all national regulations for protective
separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable
for any damage arising from such usage.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent
anyone from plugging the mains plug back in and switching it on again.
12
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.
Position the device with sufficient insulation against electrically conductive environments,
e.g. Insulation against conductive floor or insulation to conductive racks.
If distribution boards, twin-head mounts, etc., are being used, note the following: The
electrode of the welding torch / electrode holder that is not used is also live. Make sure
that the welding torch / electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the
wirefeeder.
EN
EMC Device Classifications
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
sions, it may affect the application area for which it was designed (e.g. when there is
sensitive equipment at the same location, or if the site where the device is installed is
close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the
situation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addi-
tional 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.
13
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.
14
Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting
coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The
coolant safety data sheet may be obtained from your service centre or downloaded from
the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
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.
EN
Requirement for
the shielding gas
Danger from
shielding gas cylinders
Especially with ring lines, contaminated shielding gas can cause damage to equipment
and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas
cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
15
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
Safety measures
at the installation
location and during transport
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the
oxygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the
main gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage
before every start-up.
A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown
on the rating plate.
Safety measures
in normal operation
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69
in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and
accident prevention regulations. This applies especially to guidelines regarding the risks
arising during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before
commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
16
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
properties (electrical conductibility, anti-freeze agent, material compatibility, flammability,
etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other system
components or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under
certain conditions. Transport the coolant only in its original, sealed containers and keep
well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.
EN
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
maintenance and
repair
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
least once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12month 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.
17
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.
18
General information
19
20
General
Device concept The MagicWave (MW) 2200 / 2500 /
3000 / 4000 / 5000 Comfort and TransTig
(TT) 2200 / 2500 / 3000 / 4000 / 5000
Comfort TIG power sources are completely digitised, microprocessor-controlled
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.
EN
To optimise the ignition sequence in TIG AC welding, the MagicWave takes into account
not only the diameter of the electrode, but also its current temperature, calculated with
reference to the preceding welding time and welding off-time.
RPI (Reverse Polarity Ignition) ensures an excellent ignition response during TIG DC
welding.
Functional principle
Application areas The devices are used in workshops and industry for manual and automated TIG applica-
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.
tions with unalloyed and low-alloy steel and high-alloy chrome-nickel steels.
The MagicWave power sources perform exceptionally well when it comes to welding aluminium, aluminium alloys and magnesium due to the variable AC frequency.
21
System components
FRONIUS
A
V
(6)
(1)
(2)
(8)
(9)
(3)
(4)
(11)
(10)
(7)
(5)
General The TransTig and MagicWave power sources can be used with a wide variety of system
add-ons and options.
Overview
System add-ons and options
Item Description
(1) TIG robot welding torch
Cold wire feeders with wire drive
(2) Power sources
(3) Cooling units
(4) Trolley with gas cylinder holder
(5) Pedal remote control unit
(6) Cold wire-feed unit
(7) TIG welding torch Standard / Up/Down
(8) JobMaster TIG welding torch
(9) Remote control units and robot accessories
(10) Grounding (earthing) cable
(11) Electrode cable
22
Control elements and connections
23
24
Description of the control panels
(3)
(12)
(6)
(9)
(1)
(11)
(10)
(4)
(14)
(13)
)5()2(
(8)
(7)
(15)
EN
General
Safety
MagicWave
Comfort 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!
Danger from incorrect operation.
Possible serious injury and damage to property.
Do not use the functions described here until you have read and completely under-
▶
stood these Operating Instructions.
Do not use the functions described here until you have fully read and understood all
▶
of the Operating Instructions for the system components, in particular the safety
rules!
No. Function
(1) Pulse indicator
lights up when the F-P set-up parameter has been set to a pulse frequency
(2) Spot welding indicator
lights up when the SPt set-up parameter has been set to a spot welding
time
(3) Cold wire-feed unit indicator
lights up when a cold wire-feed unit is connected
(4) Display
25
No. Function
(5) Tacking indicator
lights up when the tAC set-up parameter has been set to a period of time
(6) Electrode overload indicator
lights up if the tungsten electrode is overloaded
See section on TIG welding in Chapter "Welding mode" for more information on the electrode overload indicator.
(7) Keylock indicator
lights up when the keylock is activated
(8) Process button
for selecting the welding process depending on the mode that has been chosen
2-step mode/4-step mode:
automatic cap-shaping;
only available in conjunction with TIG AC welding
TIG AC welding process
TIG DC- welding process
Manual metal arc welding mode:
MMA AC welding process
MMA DC- welding process
MMA DC+ welding process
When a process is selected, the LED on the relevant symbol lights up.
(9) Right arrow key
for navigating in the menu
(10) Mode button
for selecting the mode
2-step mode
4-step mode
Manual metal arc welding
When a mode is selected, the LED on the relevant symbol lights up.
(11) Gas test button
for setting the required shielding gas flow rate on the gas pressure regulator
After pressing this button, gas flows for 30 seconds. Press the button again to
stop the gas flow prematurely.
(12) Adjusting dial
- Turn the adjusting dial to: select welding parameter
- Press the adjusting dial to: confirm a selection in a menu, accept values
26
(13) Menu button
for calling up the menu in the selected process
(14) Left arrow key
for navigating in the menu
No. Function
(3)
(11)
(6)
(8)
(1)
(10)
(9)
(4)
(13)
(12)
)7()5()2(
(14)
TransTig
Comfort control
panel
(15) HF (high frequency) ignition indicator
lights up when the HF ignition welding parameter has been set to an interval for the high frequency pulses
EN
No. Function
(1) Pulse indicator
lights up when the F-P set-up parameter has been set to a pulse frequency
(2) Spot welding indicator
lights up when the SPt set-up parameter has been set to a spot welding
time
(3) Cold wire-feed unit indicator
lights up when a cold wire-feed unit is connected
(4) Display
(5) Tacking indicator
lights up when the tAC set-up parameter has been set to a period of time
(6) Electrode overload indicator
lights up if the tungsten electrode is overloaded
See section on TIG welding in Chapter "Welding mode" for more information on the electrode overload indicator.
(7) Keylock indicator
lights up when the keylock is activated
(8) Right arrow key
for navigating in the menu
(9) Mode button
for selecting the mode
2-step mode
4-step mode
Manual metal arc welding
27
No. Function
When a mode is selected, the LED on the relevant symbol lights up.
(10) Gas test button
for setting the required shielding gas flow rate on the gas pressure regulator
After pressing this button, gas flows for 30 seconds. Press the button again to
stop the gas flow prematurely.
(11) Adjusting dial
- Turn the adjusting dial to: select welding parameter
- Press the adjusting dial to: confirm a selection in a menu, accept values
(12) Menu button
for calling up the menu in the selected process
(13) Left arrow key
for navigating in the menu
(14) HF (high frequency) ignition indicator
lights up when the HF ignition welding parameter has been set to an interval for the high frequency pulses
28
Connections, switches and mechanical compon-
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
ents
MagicWave
2200 Comfort
MagicWave 2200 Comfort - front
No.Function
EN
MagicWave 2200 Comfort - rear
(1) Welding torch connection
for connecting:
- the TIG welding torch
- the electrode cable for manual metal arc welding
(2) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster TIG welding torch, etc.)
(3) Handle
(4) Torch control connection
- for connecting the control plug of a conventional welding torch
- input for the collision protection signal when a robot interface or field bus
coupler is connected
(5) Grounding (earthing) cable connection
for connecting the grounding (earthing) cable
(6) Shielding gas connection
(7) Mains switch
for switching the power source on and off
(8) Mains cable with strain relief device
29
MagicWave
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
2500 / 3000 Comfort
MagicWave 2500 / 3000 Comfort - front
No.Function
(1) Grounding (earthing) cable connection
for connecting the grounding (earthing) cable
(2) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster TIG welding torch, etc.)
(3) Handle
(4) Torch control connection
- for connecting the control plug of a conventional welding torch
- input for the collision protection signal when a robot interface or field bus
coupler is connected
(5) Welding torch connection
for connecting:
- the TIG welding torch
- the electrode cable for manual metal arc welding
(6) Shielding gas connection
(7) Mains cable with strain relief device
MagicWave 2500 / 3000 Comfort - rear
(8) Mains switch
for switching the power source on and off
30
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