Fronius TransTig 2200-5000 Comfort, MagicWave 2200-5000 Comfort Operating Instruction [EN]

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TransTig 2200 / 2500 Comfort TransTig 3000 / 4000 Comfort TransTig 5000 Comfort MagicWave 2200 / 2500 Comfort MagicWave 3000 / 4000 Comfort MagicWave 5000 Comfort

Operating instructions

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

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

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

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

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

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

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

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.

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

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.

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

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

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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

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.

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.

System components

FRONIUS

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(3)

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(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

Control elements and connections

Description of the control panels

(3)

(12)

(6)

(9)

(1)

(11)

(10)

(4)

(14)

(13)

)5()2(

(8)

(7)

(15)

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

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

(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

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

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

Connections, switches and mechanical compon-

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(2)

(3)

(4) (5)

(6)

(7)

(8)

ents

MagicWave 2200 Comfort

MagicWave 2200 Comfort - front

No.Function

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

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

MagicWave

MagicWave 4000

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

4000 / 5000 Comfort

MagicWave 4000 / 5000 Comfort - front

No.Function

(1) Mains switch

to switch the power source on and off

(2) Welding torch connection

for connecting the TIG welding torch

(3) Electrode holder connection

for connecting the electrode cable for manual metal arc welding

(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

(5) LocalNet connection

coupler is connected

standardised connection socket for system add-ons (e.g. remote control, JobMaster TIG welding torch, etc.)

(6) Grounding cable connection

for connecting the grounding cable

(7) Blanking covers

reserved for LocalNet connection

MagicWave 4000 / 5000 Comfort - rear

(8) Mains cable with strain relief device

(9) Shielding gas connection

TransTig

(1)

(2)

(3)

(4) (5)

(6)

(7)

(8)

2200 Comfort

TransTig 2200 Comfort - front

No.Function

(1) (+) current socket with bayonet latch

for connecting

- the grounding (earthing) cable when TIG welding

- the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode)

(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) (-) current socket with bayonet latch

for connecting

- the TIG welding torch

- the electrode cable or grounding (earthing) cable during MMA welding (depending on electrode type)

TransTig 2200 Comfort - rear

(6) Shielding gas connection

(7) Mains switch

for switching the power source on and off

(8) Mains cable with strain relief device

TransTig

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

2500 / 3000 Comfort

TransTig 2500 / 3000 Comfort - front

No.Function

(1) (+) current socket with bayonet latch

for connecting

- the grounding (earthing) cable when TIG welding

- the electrode cable or grounding (earthing) cable during MMA welding (depending on electrode type)

(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) (-) current socket with bayonet latch

for connecting

- the TIG welding torch

- the electrode cable or grounding (earthing) cable during MMA welding (depending on electrode type)

TransTig 2500 / 3000 Comfort - rear

(6) Shielding gas connection

(7) Mains cable with strain relief device

(8) Mains switch

for switching the power source on and off

TransTig

TransTig 4000

(1)

(2)

(3)

(4)

(7)

(6)

(5)

(8)

(6)

4000 / 5000 Comfort

TransTig 4000 / 5000 Comfort - front

No.Function

(1) (+) current socket with bayonet latch

for connecting

- the grounding cable when TIG welding

- the electrode cable or grounding cable during MMA welding (depending on the type of electrode)

(2) LocalNet connection

standardised connection socket for system add-ons (e.g. remote control, JobMaster TIG welding torch, etc.)

(3) 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

(4) (-) current socket with bayonet latch

for connecting

- the TIG welding torch

- the electrode cable or grounding cable during MMA welding (depending on the type of electrode)

(5) Mains switch

for switching the power source on and off OFF = - O ON = - I -

TransTig 4000 / 5000 Comfort - rear

(6) Blanking covers

reserved for LocalNet connection

(7) Mains cable with strain relief device

(8) Shielding gas connection

Installation and commissioning

Minimum equipment needed for welding task

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

level 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 cable

- TIG welding torch

- Shielding gas supply with pressure regulator

- Filler metals (as required by the application)

Automated TIG welding

MMA welding - Power source

- Power source

- Robot interface or field bus connection

- Grounding (earthing) cable

- TIG machine welding torch or TIG robot welding torch (a cooling unit is also required with water-cooled machine or robot welding torches)

- Gas connection (shielding gas supply)

- Cold wire-feed unit and filler metals (as required by the application)

- Grounding (earthing) cable

- Electrode holder

- Rod electrodes (as required by the application)

Before installation and commissioning

Safety

Utilisation for intended purpose

WARNING!

Danger due to incorrect operation and incorrectly performed work.

This can result in severe personal injury and damage to property.

All the work and functions described in this document must only be carried out and

▶

used by trained and qualified personnel. Fully read and understand this document.

▶

Fully read and understand 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

Setup regulations The device is tested to IP 23 protection, meaning:

- 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.

Mains connection The devices are designed for the mains voltage specified on the rating plate. If your ver-

sion of the appliance 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.

CAUTION!

An inadequately dimensioned electrical installation can cause serious damage.

The mains lead and its fuse must be dimensioned to suit the local power supply. The

▶

technical data shown on the rating plate applies.

Start-up

Safety

Remarks on the cooling unit

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

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supply.

WARNING!

Danger of electrical current due to electrically conductive dust in the device.

This can result in severe personal injury and damage to property.

Only operate the device if an air filter is fitted. The air filter is a very important safety

▶

device for achieving IP 23 protection.

We recommend using a cooling unit for the following applications and situations:

- JobMaster TIG welding torch

- Robot welding

- Hosepacks over 5 m long

- TIG AC welding

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

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

General This section describes how to commission the power source:

- for the main TIG welding application

- with reference to a standard configuration for a TIG welding system

The standard configuration consists of the following system components:

- Power source

- TIG manual welding torch

- Pressure regulator

- Gas cylinder

Connecting the gas cylinder

If gas cylinders topple over, there is a risk of very serious injury and damage.

▶ ▶

▶

WARNING!

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

Follow the gas cylinder manufacturer's safety instructions.

Secure the gas cylinder

Take the protective cap off the gas cylinder

Briefly open the gas cylinder valve to remove any dust or dirt

Check the seal on the pressure regulator

Screw the pressure regulator onto the gas cylinder and tighten it

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

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 connector:

Connect the TIG welding torch gas hose to the pressure regulator

Establishing a ground (earth) connection to the workpiece

Connecting the welding torch

Move the mains switch to the O position

Plug the grounding (earthing) cable in and latch it

- for MagicWave: in the grounding (earthing) cable connection

- for TransTig: in the (+) current socket

Use the other end of the grounding (earthing) cable to establish a connection to the

workpiece

CAUTION!

Risk of damage from high frequencies.

Do not use the JobMaster TIG welding torch with a LocalNet distributor.

▶

Move the mains switch to the "O" position

Plug in the TIG welding torch welding power-lead and latch it by turning it clockwise:

- for MagicWave: in the welding torch connection

- for TransTig: in the (-) current socket

Plug the welding torch control plug into the torch control connection and latch it

or connect the control line of the JobMaster TIG welding torch to the LocalNet connection

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

Only when using a water-cooled torch and cooling unit:

Plug in the welding torch water connections to the water flow (black) and return (red) connections on the cooling unit.

Welding

TIG modes

Safety

Symbols and their explanations

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!

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

Pull back and hold the torch trigger / Release the torch trigger / Briefly pull back the torch trigger (< 0.5 s)

Push forward and hold the torch trigger / Release the torch trigger

GPr

Gas pre-flow time

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

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

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

G-H

Gas post-flow time at maximum welding current

SPt

Spot welding time

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 continuously lowered until it reaches the end-crater current.

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

G-L

Gas post-flow time at minimum welding current

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

G-L / G-HGPr t

down

GPr t

G-L G-H

- End of welding: Release the torch trigger

NOTE!

To work in 2-step mode after it has been selected, the SPt setup parameter must be set to "OFF" and the spot welding indicator on the control panel must not light up.

2-step mode

... Manual application ... Automatic application

Spot welding If a value has been set for the SPt set-up parameter, 2-step mode will have the spot

welding mode function. The special spot welding indicator on the control panel will light up.

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

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

When using a pedal remote control, the spot welding time starts when the pedal remote control is operated. The power cannot be controlled using the pedal remote control.

GPr t

down

SPt

G-L G-H

Spot welding

GPr

down

G-L

G-H

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

- Welding with main current I1: Release the torch trigger

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

- End of welding: Release the torch trigger

NOTE!

For 4-step mode, the special 4‑step (SFS) setup parameter must be set to "OFF".

4-step mode

*) Intermediate lowering

Intermediate lowering during the main current phase reduces the welding current to the specified reduced current I2.

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

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

Special 4-step mode: variant 1

Variant 1 of special 4-step mode is activated, when the special 4-step (SFS) set-up parameter‑is set to "1".

Briefly pull back the torch trigger to start intermediate lowering to the specified reduced

GPr

down

G-L

G-H

GPr

down

G-L

G-H

current I2. Briefly pull back the torch trigger a second time, to restore the main current I1.

Special 4-step mode: Variant 1

Special 4-step mode: variant 2

Variant 2 of the special 4-step mode is activated when the special 4-step SFS set-up parameter ‑is set to "2“. Intermediate lowering takes place in variant 2 on the basis of the selected slope values downslope t

and upslope tup:

down

- Push forward and hold the torch trigger: the welding current continuously drops at the set downslope value until it reaches the specified reduced current I2. It remains

at the reduced current value I2 until the torch trigger is released.

- When the torch trigger is released: the welding current rises at the specified upslope value until it reaches the main current value I1.

Special 4-step mode: Variant 2

Special 4-step mode: variant 3

Variant 3 of special 4-step mode is activated when the special 4-step mode (SFS) set-up parameter ‑is set to "3".

In variant 3, push forward and hold the torch trigger to start intermediate lowering. Release the torch trigger to resume the main current I1.

When the torch trigger is pulled back, welding ends immediately without downslope and

GPr

G-L / G-H

GPr

down

G-L

G-H

final current.

Special 4-step mode: Variant 3

Special 4-step mode: variant 4

Variant 4 of the special 4-step mode is activated when the SFS set-up parameter is set to "4".

- Welding start-up and welding: briefly pull back and release the torch trigger - the welding current will rise at the specified upslope value from the starting current I

until it reaches the main current value I1.

- Push forward and hold the torch trigger for intermediate lowering

- Release the torch trigger to resume the main current I

- End of welding: briefly pull back and release the torch trigger

Special 4-step mode: variant 4

Cap shaping and cap overloading

(2)(1)

Cap-shaping

(1) Before ignition (2) After ignition

NOTE!

On MagicWave power sources, an

automatic cap-shaping function is available for the TIG AC welding process:

- When the TIG AC welding process is selected, activate automatic cap-shaping

- 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.

- The automatic cap-shaping function is then reset and deactivated. The automatic cap-shaping function has to be activated separately for each tungsten electrode.

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

Cap overloading If the cap is overloaded, there is a risk of an excessively large cap forming on the tung-

sten electrode. This will negatively affect the ignition properties.

If the cap is overloaded, the "Electrode overload" indicator will light up on the control panel.

Possible causes of cap overloading:

- tungsten electrode diameter is too small

- main current value I1 set too high

- the balance has been set too far towards "+"

Remedy:

- use a tungsten electrode with a larger diameter

- reduce the main current and/or set the balance further towards "-"

NOTE!

The "Electrode overload" indicator is fine-tuned to work with the following tungsten electrodes:

TIG AC welding: pure tungsten electrodes TIG DC welding: ceriated electrodes

For all other electrodes, the "Electrode overload" indicator must be treated as a reference value.

TIG welding

Safety

Welding parameters: display and navigation

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!

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

▶

unplugged from the mains

The TIG welding parameters are shown as soon as the 2-step or 4-step mode is selected.

Welding parameters for TIG

Use the left and right arrow keys to navigate within the welding parameters.

Starting current, 2-step mode

Unit % (of main current)

Setting range 30 - 200 AC, 0 - 200 DC

Factory setting 35 AC, 50 DC

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

Starting current, 4-step mode

UpSlope, 2-step mode

UpSlope, 4-step mode

Unit s

Setting range 0.0 - 9.9

Factory setting 0.1

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

Main current, 2-step mode

Main current, 4-step mode

Unit A

Setting range MW 2200 Comfort 3-220

MW 2500 Comfort 3-250 MW 3000 Comfort 3-300 MW 4000 Comfort 3-400 MW 5000 Comfort 3-500

TT 2200 Comfort 3 - 220

TT 2500 Comfort 3 - 250 TT 3000 Comfort 3 - 300 TT 4000 Comfort 3 - 400 TT 5000 Comfort 3 - 500

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.

In the case of 4-step mode

Unit % (of main current)

Setting range 0 - 100

Factory setting 50

DownSlope, 2-step mode

DownSlope, 4-step mode

Unit s

Setting range 0.0 - 9.9

Factory setting 1.0

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

Final current, 2-step mode

Final current, 4-step mode

Unit % (of main current)

Setting range 0 - 100

Factory setting 30

only with MagicWave for the TIG AC welding process

Unit 1

Setting range -5 - +5

Factory setting 0

-5: highest fusing power, lowest cleaning action

+5: highest cleaning action, lowest fusing power

If cold wirefeeder option is available

Unit m/min ipm

Setting range OFF / 0.1 - max. OFF / 3.9 - max.

Factory setting OFF

Unit mm in.

Setting range OFF - max. OFF - max.

Factory setting 2.4 0.1

Preparation

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 con-

▶

ductive or earthed parts (e.g. housing, etc.).

Move the mains switch to the "I" position

The starting sequence with the Fronius logo, current firmware version and Fronius internet address is displayed for approx. 1 second:

TIG welding

Press the Mode button to select the required TIG mode:

2-step mode

4-step mode

The image for the TIG welding parameter is shown on the display:

TIG welding parameters for 2-step mode (main cur-

rent welding parameter selected)

TIG welding parameters for 4-step mode (main cur-

rent welding parameter selected)

Only with MagicWave: Press the Mode button to select the required TIG mode:

AC welding process

AC welding process with automatic cap-shaping function

DC welding process

Use the right arrow key to select the relevant welding parameters

Use the adjusting dial to set the selected welding parameter to the required value

If necessary, additional welding parameters can be set in the Setup menu:

- Press the Menu key The relevant menu is displayed:

- Use the adjusting dial to select the desired Setup menu

- Open the selected Setup menu by pressing the adjusting dial

- Use the adjusting dial to select the welding parameter

- To change the welding parameter press the adjusting dial

- Change the welding parameter value using the adjusting dial

- Press the adjusting dial

- Exit the Setup menu

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 was switched off and on again in the interim.

Open the gas cylinder valve

Set the shielding gas flow rate:

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

- Turn the adjusting screw on the underside of the pressure regulator until the

manometer indicates the desired shielding gas flow rate

For long hosepacks and if condensation forms when the device is left unused in a

cold environment: pre-purge shielding gas - set the GPU setup parameter to a time value

Start welding (ignite the arc)

Igniting the arc

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

power 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

To ensure the ideal ignition sequence in TIG DC welding, MagicWave power sources are equipped with RPI (Reverse Polarity Ignition). At the start of welding, the polarity is briefly reversed. Electrons emerge from the workpiece and strike the tungsten electrode. This results in the tungsten electrode heating up rapidly which is an essential prerequisite for optimum ignition properties. Further information on the RPI function can be found in the Chapter Set-up parameters, Section "TIG set-up 2nd".

Igniting the arc using high frequency (HF ignition)

CAUTION!

Risk of injury due to shock caused by electric shock

Although Fronius devices comply with all relevant standards, high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances.

Use prescribed protective clothing, especially gloves!

▶

Only use suitable, completely intact and undamaged TIG hosepacks!

▶

Do not work in damp or wet environments!

▶

Take special care when working on scaffolding, work platforms, in forced positions

▶

(out-of-position welding), in tight, difficult to access or exposed areas!

HF ignition is activated when a time value has been set for the HFt setup parameter. The HF ignition indicator lights up on the control panel.

Compared with 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 igni-

tion location so that there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece

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.

Tilt the torch back into the normal pos-

ition

Carry out welding

Touchdown ignition

If the HFt 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 igni-

tion location so that there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece

Actuate the torch trigger

Shielding gas flows.

Gradually tilt the welding torch up until

the tungsten electrode touches the workpiece

Raise the welding torch and move it

into its normal position

The arc ignites.

Carry out welding

End of welding

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

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

weld seam

Special functions and options

Arc break watchdog function

Ignition time-out function

If the arc breaks and the current does not start to flow again within the time specified in the set-up menu, the power source cuts out automatically. The service code "no | Arc" appears on the control panel.

To start the welding process again, press any key on the control panel or the torch trigger.

The settings for the arc break watchdog set-up parameter (Arc) are described in "TIG set-up 2nd" section.

The power source has an ignition time-out 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 set-up menu, the power source cuts out automatically. The service code "no | IGn" appears on the control panel.

"E55" is displayed on the JobMaster TIG welding torch. To try again, press any key on the control panel or press the torch trigger.

The settings for the ignition time-out parameter (ito) are described in the "TIG set-up 2nd" section.

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

as a whole:

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

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

The TIG pulsing function (TIG welding with pulsing welding current) offers a remedy: a low ground current I-G rises steeply to the significantly higher pulse current I1 and, depending on the set dcY (duty cycle) time, drops back to the ground current I-G. 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:

1/F-P

I-G

down

dcY

tAC

down

TIG pulsing - welding current curve

Legend:

Down

Starting current F-P Pulse frequency *)

Final current dcY Duty cycle

Upslope I-G Ground current

Downslope I

Main current

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

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

When a time period is specified for the tAC (tacking) setup parameter, the tacking function is assigned to 2-step mode and 4-step mode. The operating sequence of the modes remains unchanged. During this period, a pulsed welding current is present that makes the weld pool run together better when two parts are being tacked.

Mode of operation of tacking function when the TIG DC welding process is selected:

Tacking function - welding current curve

Legend:

tAC Duration of pulsed welding current for the tacking process

Down

NOTE!

The following points apply to the pulsed welding current:

▶ ▶

The pulsed welding current begins

- after the end of the starting-current phase I

- With the UpSlope phase t

Depending on what tAC time has been set, the pulsed welding current may continue up to and including the final current phase IE (tAC setup parameter set to "ON").

Starting current

Final current

UpSlope

DownSlope

Main current

The power source automatically regulates the pulsing parameters as a function of the specified main current I1.

There is no need to set any pulsing parameters.

TIG cold-wire welding

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

NOTE!

To set a specified tacking time, the tAC setup parameter can be combined with the SPt setup parameter (spot welding time).

TIG cold-wire welding is only possible in conjunction with a cold wire- feed unit.

Mode of operation of TIG cold-wire welding at a set pulse frequency when DC welding is selected: a) Current waveshape b) Wire feed speed curve

1/F-P

I-G

dt2

dt1

down

Fd.2

Fd.1

dcY

Legend:

Down

Starting current dcY Duty cycle

Final current I-G Ground current

Upslope I

Downslope F-P

Main current

Pulse frequency

Fd.1 Wire feed speed 1 Fd.2 Wire feed speed 2

dt1 Delay in the start of wirefeeding

from the beginning of main current phase I

(1/F-P = time interval between 2 pulses)

dt2 Delay in the end of wirefeeding

from the end of main current phase I

MMA welding

Safety

Welding parameters: display and navigation

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!

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

▶

unplugged from the mains

The welding parameters for manual metal arc welding are shown as soon as the manual metal arc welding mode is selected.

Use the left and right arrow keys to navigate within the welding parameters.

Welding parameters for rod electrodes

Starting current: starting current < main current ("Soft-

Start")

Starting current: starting current > main current ("Hot-

Start")

Starting current: starting current = main current

Unit % (of main current)

Setting range 0 - 200

Factory setting 150

Main current: starting current < main current ("Soft-

Start")

Main current: starting current = main current

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

Unit A

Setting range MW 2200 Comfort 10 - 180

MW 2500 Comfort 10 - 250 MW 3000 Comfort 10 - 300 MW 4000 Comfort 10 - 400 MW 5000 Comfort 10 - 500

Factory setting -

TT 2200 Comfort 10 - 180 TT 2500 Comfort 10 - 250 TT 3000 Comfort 10 - 300 TT 4000 Comfort 10 - 400 TT 5000 Comfort 10 - 500

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

Preparation

only with MagicWave for the manual metal arc AC welding process

Unit 1

Setting range -5 - +5

Factory setting 0

-5: highest fusing power, lowest cleaning action

+5: highest cleaning action, lowest fusing power

Switch off cooling units (set setup parameter C-C to OFF)

Move the mains switch to the "O" position

Disconnect the mains plug

Remove the TIG welding torch

Plug the grounding cable in and latch it into place:

- for MagicWave: in the grounding cable connection

- for TransTig: in the (+) current socket

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

Plug in the electrode cable and twist it clockwise to latch it into place:

- for MagicWave: in the welding torch connection

- for TransTig: in the (-) current socket

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 conduct-

▶

ive or earthed parts (e.g. the housing, etc.).

Move the mains switch to the "I" position

The starting sequence with the Fronius logo, current firmware version and Fronius internet address is displayed for approx. 1 second:

MMA welding

Press the Mode button to select:

NOTE!

If the MMA welding mode is selected, the welding voltage will only be available after a 3-second delay.

The image for the rod electrode welding parameter is shown on the display:

Only for MagicWave: press the process button to select the required welding pro-

cess:

Manual metal arc welding mode

Verfahren Stabelektroden AC Schweißen

Verfahren Stabelektroden DC- Schweißen

Verfahren Stabelektroden DC+ Schweißen

NOTE!

The TransTig power source has no switchover facility between the MMA DC- and MMA DC+ welding processes.

Procedure with TransTig power source for switching from MMA DC- welding to MMA DC + welding: a) Move the mains switch to the "O" position b) Disconnect the mains plug c) Reconnect the electrode holder and the grounding cable to the opposite current

sockets (i.e. swap them over)

d) 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 con-

▶

ductive or earthed parts (e.g. the housing, etc.)

e) Move the mains switch to the "I" position

The starting sequence with the Fronius logo, current firmware version and Fronius internet address is displayed for approx. 1 second:

Use the right arrow key to select the relevant welding parameters

Use the adjusting dial to set the selected welding parameter to the required value

If necessary, additional welding parameters can be set in the Setup menu:

- Press the Menu key The relevant menu is displayed:

- Use the adjusting dial to select the desired Setup menu

- Open the selected Setup menu by pressing the adjusting dial

- Use the adjusting dial to select the welding parameter

- To change the welding parameter press the adjusting dial

- Change the welding parameter value using the adjusting dial

- Press the adjusting dial

- Exit the Setup menu

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 was switched off and on again in the interim.

Start welding

Hotstart function To obtain optimum welding results, it will sometimes be necessary to adjust the hotstart

I (A)

t (s)

0,5 1 1,5

Hti

HCU

100

150

I (A)

90A

30A

(1)

(3)

(2)

function.

Benefits

- Improved ignition, 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

For details on setting the available welding parameters, please refer to the "Rod elect. setup 2nd" section.

Legend

Hti Hot-current time, 0-2 s, factory

setting: 0.5 s

HCU HotStart current, 0-200%,

factory setting 150%

Starting current < 100 % (SoftStart)

Main current = set welding current

Function:

during the specified hot-current time (Hti), the welding current I1 is increased to the

HotStart current HCU.

To activate the hotstart function, the Hot-

Example of hotstart function

Start current HCU must be > 100.

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

Anti-stick function

(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)

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 elect. setup 2nd" menu.

Welding job

Safety

Welding parameters: display and navigation

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!

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

▶

unplugged from the mains

The welding parameters for the welding job are displayed as soon as a job has been selected. LEDs on the relevant symbols are illuminated according to the method and operating mode of the chosen job.

Welding parameters for TIG

Use the left and right arrow keys to navigate within the welding parameters.

Starting current, 2-step mode

Unit % (of main current)

Setting range 30 - 200 AC, 0 - 200 DC

Factory setting 35 AC, 50 DC

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

Starting current, 4-step mode

UpSlope, 2-step mode

UpSlope, 4-step mode

Unit s

Setting range 0.0 - 9.9

Factory setting 0.1

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

Main current, 2-step mode

Main current, 4-step mode

Unit A

Setting range MW 2200 Comfort 3-220

MW 2500 Comfort 3-250 MW 3000 Comfort 3-300 MW 4000 Comfort 3-400 MW 5000 Comfort 3-500

TT 2200 Comfort 3 - 220

TT 2500 Comfort 3 - 250 TT 3000 Comfort 3 - 300 TT 4000 Comfort 3 - 400 TT 5000 Comfort 3 - 500

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.

In the case of 4-step mode

Unit % (of main current)

Setting range 0 - 100

Factory setting 50

DownSlope, 2-step mode

DownSlope, 4-step mode

Unit s

Setting range 0.0 - 9.9

Factory setting 1.0

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

Final current, 2-step mode

Final current, 4-step mode

Unit % (of main current)

Setting range 0 - 100

Factory setting 30

only with MagicWave for the TIG AC welding process

Unit 1

Setting range -5 - +5

Factory setting 0

-5: highest fusing power, lowest cleaning action

+5: highest cleaning action, lowest fusing power

If cold wirefeeder option is available

Unit m/min ipm

Setting range OFF / 0.1 - max. OFF / 3.9 - max.

Factory setting OFF

Unit mm in.

Setting range OFF - max. OFF - max.

Factory setting 2.4 0.1

Welding parameters for rod electrodes

Starting current: starting current < main current ("Soft-

Start")

Starting current: starting current > main current ("Hot-

Start")

Starting current: starting current = main current

Unit % (of main current)

Setting range 0 - 200

Factory setting 150

Main current: starting current < main current ("Soft-

Start")

Main current: starting current = main current

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

Unit A

Setting range MW 2200 Comfort 10 - 180

MW 2500 Comfort 10 - 250 MW 3000 Comfort 10 - 300 MW 4000 Comfort 10 - 400 MW 5000 Comfort 10 - 500

Factory setting -

TT 2200 Comfort 10 - 180 TT 2500 Comfort 10 - 250 TT 3000 Comfort 10 - 300 TT 4000 Comfort 10 - 400 TT 5000 Comfort 10 - 500

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

Unit % (of main current)

Setting range 0 - 100

Factory setting 20

0 soft, low-spatter arc

100 harder, more stable arc

only with MagicWave for the manual metal arc AC welding process

Unit 1

Setting range -5 - +5

Factory setting 0

-5: highest fusing power, lowest cleaning action

+5: highest cleaning action, lowest fusing power

Preparation

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

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 con-

▶

ductive or earthed parts (e.g. housing, etc.).

Move the mains switch to the "I" position

The starting sequence with the Fronius logo, current firmware version and Fronius internet address is displayed for approx. 1 second:

Welding job

Press Menu key

The relevant main menu appears, e.g.:

Use the adjusting dial to select "job" (turn the adjusting dial)

Press the adjusting dial

The menu items for the job will now appear:

Use the adjusting dial to select 'Retrieve' (turn the adjusting dial)

Press the adjusting dial

The display now shows the last job that was selected:

A free memory location is indicated as follows:

Use the adjusting dial to select the desired job (turn the adjusting dial)

To change welding parameters according to the job correction stored in the

job:

- Use left and right arrow keys to select welding parameters

- Press the adjusting dial

The value of the selected welding parameter is displayed in a box:

- Use the adjusting dial to set the required value (turn the adjusting dial)

- Press the adjusting dial

The adjusted value of the selected welding parameter is applied

Finishing the welding job

Start welding

Finish welding

Press Menu key

The main menu for the welding job appears:

Use the adjusting dial to select "job" (turn the adjusting dial)

Press the adjusting dial

The menu items for an active job will now appear:

Use the adjusting dial to select "Finish" (turn the adjusting dial)

Press the adjusting dial

The welding parameters are shown for the most recently selected method, e.g.:

Starting current 2-step mode

Saving settings as a job

General In the individual welding processes, settings and welding parameters can be stored in

100 jobs (job numbers 0 to 99).

Preparation

Select the mode to be saved using the Mode button:

TIG 2-step mode

TIG 4-step mode

Manual metal arc welding mode

The relevant image for the welding parameters is displayed, e.g.:

TIG welding parameters for 2-step mode

(main current welding parameter selected)

Only for MagicWave: press the Process button to select the required weld-

ing process

TIG AC welding process / manual metal arc AC welding

TIG AC welding process with automatic cap-shaping function /

manual metal arc DC welding

TIG DC welding process / manual metal arc DC+ welding

Use the right arrow key to select the individual welding parameters

Change the welding parameter value by turning the adjusting dial

Press the Menu key in order to set other welding parameters in the set-up

The relevant menu is displayed, e.g.:

Use the adjusting dial to select the desired set-up menu

Open the selected set-up menu by pressing the adjusting dial

Use the adjusting dial to select a welding parameter

Saving settings as a job

To change a welding parameter press the adjusting dial

Change the welding parameter value using the adjusting dial

Press the adjusting dial

Press Menu key

The latest menu appears, e.g.:

NOTE!

When settings are saved as a job, all the settings are stored in the welding parameters as well as in the relevant set-up menus in a job.

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

Select the job from the relevant set-up menu by turning the 'Job' adjusting

dial

Press the adjusting dial

The menu items for the job will now appear:

Use the adjusting dial to select "Save" (turn the adjusting dial)

Press the adjusting dial

The first "Save job" screen will appear:

Turn the adjusting dial to select the job number under which the settings are

to be stored

Press the adjusting dial

- If there is memory available, then the settings will be stored under the selected job number.

- If all the memory is occupied, then a warning prompt will appear.

The second "Save job" screen appears briefly:

Free memory:

The "Name job" screen appears:

Name job:

- Turn the adjusting dial to select the desired letters / numbers:

- Then press the adjusting dial in order to enter these letters / numbers:

- In order to delete letters / numbers, turn the adjusting dial and select

- Press the adjusting dial to delete the last character:

'Del':

- Press the button on the right (OK) in order to accept the name

The settings will be stored and the third 'Save job' screen will appear:

Press the button on the right (OK)

The job numbers overview appears:

A warning prompt will appear:

Allocated memory:

The "Name job" screen appears:

Press the button on the left or right:

- Left button (No): Do not overwrite job, return to job numbers overview

- Right button (Yes): Store settings under the chosen job number:

- If necessary, delete the existing job name: Turn the adjusting dial and select 'Del'

- Press the adjusting dial to delete the last character:

- Turn the adjusting dial to select the desired letters / numbers:

- Then press the adjusting dial in order to enter these letters / numbers:

- Press the button on the right (OK) in order to accept the name

The settings will be stored and the "Job saved" screen will appear:

Press the button on the right (OK)

The job numbers overview appears:

Finish saving job

Press Menu key

- Select the arrow symbol by turning the adjusting dial

- Press the adjusting dial

The menu items for the job will now appear:

Press Menu key

- Select the arrow symbol by turning the adjusting dial

- Press the adjusting dial

The current set-up menu is displayed:

Press Menu key

- Select the arrow symbol by turning the adjusting dial

The current welding parameters are displayed e.g.:

TIG welding parameters for 2-step mode

(main current welding parameter selected)

Setup settings

The Setup menu

General The set-up menu provides easy access to the knowledge base in the power source and

to additional functions. The set-up menu can be used to make simple adjustments of the welding parameters to suit the various job settings.

- The set-up menu contains all the set-up parameters that have an immediate effect on the welding process.

- The 2nd level of the set-up menu contains all the set-up parameters needed for making the preliminary settings on the welding device.

The welding parameters are arranged in logical groups.

Overview The Setup menu is composed of the following sections:

- TIG-setup

- TIG setup 2nd

- AC-setup

- AC setup 2nd

- Gas-setup

- Coldwire-setup

- Push-pull calibration

- Rod elect. Setup (rod electrode setup)

- Rod elect. Setup 2nd (rod electrode setup 2nd)

- AC-setup (for rod electrodes)

- Job

- Basic setting

- Info

- Lock keys

- Factory - for resetting the welding system

- L/R alignment

TIG setup

Opening the TIG setup

Press the Mode button to select 2-step mode or 4-step mode

The image for the TIG welding parameter is shown on the display:

TIG welding parameters for 2-step mode

TIG welding parameters for 4-step mode

Press Menu key

The main menu appears:

Use the adjusting dial to select "TIG setup" (turn the adjusting dial)

Press the adjusting dial

The TIG setup parameters are shown:

The power source is now in the TIG setup.

Changing welding parameters

Select the desired welding parameter by turning the adjusting dial:

To set the welding parameter, press the adjusting dial

The value of the selected welding parameter can now be changed:

Change the welding parameter value by turning the adjusting dial:

To apply the welding parameter value press the adjusting dial

Exiting TIG setup

Press Menu key

- Select the arrow symbol by turning the adjusting dial

- Press the adjusting dial

The main menu appears:

Press Menu key

- Select the arrow symbol by turning the adjusting dial

- Press the adjusting dial

The image for the TIG welding parameter is shown:

TIG welding parameters for 2-step mode

TIG welding parameters for 4-step mode

Welding parameters in the TIG setup

"Minimum" and "maximum" are used for setting ranges that differ according to power source, wire-feed unit, welding program, etc.

Spot welding time

Unit s

Setting range OFF / 0.05 - 25.0

Factory setting OFF

If a value has been set for the spot welding time, "2‑step mode" will work in the same way as spot welding mode.

The spot welding indicator remains lit on the control panel as long as a value has

been specified for the spot welding time.

Tacking function

for the TIG DC welding process: 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 deactivated

The tacking indicator remains lit on the control panel as long as a value has been

specified for the tacking time.

Pulse frequency

Unit Hz / kHz

Setting range OFF / 0.20 Hz - 2.00 kHz

Factory setting OFF

The selected pulse frequency is also used for the reduced current I2.

IMPORTANT!If the pulse frequency is set to "OFF":

- then the welding parameters Duty Cycle, Ground Current and Wirefeed spd2

(from cold wire setup) are not available

- the wire feed speed set on the control panel is used for constant wirefeed at a

constant welding current.

The pulse indicator remains lit on the control panel as long as a value has been

specified for the pulse frequency.

Setting the pulse frequency:

0.2 Hz to 5 Hz Thermal pulsing (out-of-position welding, automated welding)

1 kHz to 2 kHz Arc-stabilising pulsing (stabilising the arc at a low welding cur-

rent)

Duty Cycle

The ratio of pulse duration to base current duration when a pulse frequency has been set

Unit %

Setting range 10 - 90

Factory setting 50

Ground current

Unit % (of main current I1)

Setting range 0 - 100

Factory setting 50

Starting current time

Unit s

Setting range OFF / 0.01 - 9.9

Factory setting OFF

The starting current time t-S specifies the duration of the starting-current phase Is .

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

Final current time

Unit s

Setting range OFF / 0.01 - 9.9

Factory setting OFF

The final current time t-E specifies the duration of the final current phase IE .

IMPORTANT!The final current time only applies in 2-step mode. In 4-step mode, the duration of the final current phase IE is controlled with the torch trigger (see: "TIG oper-

ating modes").

GPr

down

2-step mode: Starting and final current time

Legend:

GPr Gas pre-flow time I

TIG-Setup 2nd

Starting current

Starting current time

UpSlope

Second level of the TIG setup

down

Main current

Downslope

Final current

Final current time

TIG setup 2nd

Opening the TIG setup 2nd

Opening the TIG setup

Select the 'TIG setup 2nd' parameter

Press the adjusting dial

The TIG setup 2nd parameters are shown:

Changing welding parameters

The power source is now in TIG setup 2nd

Select the desired welding parameter by turning the adjusting dial:

To set the welding parameter, press the adjusting dial

The value of the selected welding parameter can now be changed:

Change the welding parameter value by turning the adjusting dial:

Exiting TIG setup 2nd

To apply the welding parameter value press the adjusting dial

Press Menu key

- Select the arrow symbol by turning the adjusting dial

- Press the adjusting dial

The TIG setup parameters are shown:

Press Menu key

- Select the arrow symbol by turning the adjusting dial

- Press the adjusting dial

The main menu appears:

Press Menu key

- Select the arrow symbol by turning the adjusting dial

- Press the adjusting dial

The image for the TIG welding parameter is shown:

100

Fronius TransTig 2200-5000 Comfort, MagicWave 2200-5000 Comfort Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual