Fronius TransTig 2200 Comfort, TransTig 2500 Comfort, TransTig 3000 Comfort, TransTig 4000 Comfort, MagicWave 2200 Comfort Operating Instructions Manual
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/ Perfect Charging / Perfect Welding / Solar Energy
TransTig 2200 / 2500 / 3000 / 4000
Comfort
MagicWave 2200 / 2500 / 3000 / 4000
Comfort
Operating Instructions
Spare parts list
EN
TIG Power source
42,0426,0063,EN 017-28062016
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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN
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Contents
Safety rules ................................................................................................................................................ 11
Explanation of safety symbols .............................................................................................................. 11
General ................................................................................................................................................. 11
Proper use ............................................................................................................................................ 12
Environmental conditions...................................................................................................................... 12
Obligations of the operator.................................................................................................................... 12
Obligations of personnel ....................................................................................................................... 13
Mains connection .................................................................................................................................. 13
Protecting yourself and others .............................................................................................................. 13
Noise emission values .......................................................................................................................... 14
Danger from toxic gases and vapours .................................................................................................. 14
Danger from flying sparks ..................................................................................................................... 15
Risks from mains current and welding current...................................................................................... 15
Meandering welding currents................................................................................................................ 16
EMC Device Classifications .................................................................................................................. 16
EMC measures ..................................................................................................................................... 17
EMF measures...................................................................................................................................... 17
Specific hazards.................................................................................................................................... 17
Factors affecting welding results........................................................................................................... 19
Danger from shielding gas cylinders..................................................................................................... 19
Safety measures at the installation location and during transport ........................................................ 19
Safety measures in normal operation ................................................................................................... 20
Commissioning, maintenance and repair.............................................................................................. 21
Safety inspection................................................................................................................................... 21
Disposal ................................................................................................................................................ 21
Safety symbols...................................................................................................................................... 22
Data protection...................................................................................................................................... 22
Copyright............................................................................................................................................... 22
EN
General information 23
General ...................................................................................................................................................... 25
Device concept ..................................................................................................................................... 25
Functional principle ............................................................................................................................... 25
Field of application ................................................................................................................................ 25
System components .................................................................................................................................. 26
General ................................................................................................................................................. 26
Overview ............................................................................................................................................... 26
Control elements and connections 27
Description of the control panels................................................................................................................ 29
General ................................................................................................................................................. 29
Safety.................................................................................................................................................... 29
MagicWave Comfort control panel........................................................................................................ 29
TransTig Comfort control panel ............................................................................................................ 31
Connections, switches and mechanical components ................................................................................ 33
MagicWave2200 Comfort ..................................................................................................................... 33
MagicWave2500 / 3000 Comfort .......................................................................................................... 34
MagicWave4000 Comfort ..................................................................................................................... 35
TransTig2200 Comfort .......................................................................................................................... 36
TransTig2500 / 3000 Comfort ............................................................................................................... 37
TransTig4000 Comfort .......................................................................................................................... 38
Installation and commissioning 39
Minimum equipment needed for welding task............................................................................................ 41
General ................................................................................................................................................. 41
TIG AC welding..................................................................................................................................... 41
TIG DC welding..................................................................................................................................... 41
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Automated TIG welding ........................................................................................................................ 41
MMA welding ........................................................................................................................................ 41
Before installation and commissioning....................................................................................................... 42
Safety.................................................................................................................................................... 42
Utilisation for intended purpose ............................................................................................................ 42
Setup regulations .................................................................................................................................. 42
Mains connection .................................................................................................................................. 42
Start-up ...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
Remarks on the cooling unit ................................................................................................................. 43
General ................................................................................................................................................. 43
Connecting the gas cylinder.................................................................................................................. 43
Establishing a ground (earth) connection to the workpiece .................................................................. 44
Connecting the welding torch................................................................................................................ 44
Welding 45
TIG modes ................................................................................................................................................. 47
Safety.................................................................................................................................................... 47
Symbols and their explanations ............................................................................................................ 47
2-step mode .......................................................................................................................................... 48
Spot welding ......................................................................................................................................... 48
4-step mode .......................................................................................................................................... 49
Special 4-step mode: variant 1 ............................................................................................................. 49
Special 4-step mode: variant 2 ............................................................................................................. 50
Special 4-step mode: variant 3 ............................................................................................................. 50
Special 4-step mode: variant 4 ............................................................................................................. 51
Cap shaping and cap overloading ............................................................................................................. 52
Cap shaping.......................................................................................................................................... 52
Cap overloading.................................................................................................................................... 52
TIG welding................................................................................................................................................ 53
Safety.................................................................................................................................................... 53
Welding parameters: display and navigation ........................................................................................ 53
Welding parameters for TIG.................................................................................................................. 53
Preparation ........................................................................................................................................... 56
TIG welding........................................................................................................................................... 57
Igniting the arc ........................................................................................................................................... 59
General ................................................................................................................................................. 59
Igniting the arc using high frequency(HF ignition)................................................................................. 59
Touchdown ignition ............................................................................................................................... 60
End of welding ...................................................................................................................................... 61
Special functions and options .................................................................................................................... 62
Arc break watchdog function................................................................................................................. 62
Ignition time-out function....................................................................................................................... 62
TIG pulsing............................................................................................................................................ 63
Tacking function.................................................................................................................................... 64
TIG cold-wire welding ........................................................................................................................... 65
MMA welding ............................................................................................................................................. 66
Safety.................................................................................................................................................... 66
Welding parameters: display and navigation ........................................................................................ 66
Welding parameters for rod electrodes................................................................................................. 66
Preparation ........................................................................................................................................... 68
Manual metal arc welding ..................................................................................................................... 69
Hotstart function.................................................................................................................................... 70
SoftStart function .................................................................................................................................. 71
Anti-stick function.................................................................................................................................. 71
Welding job ................................................................................................................................................ 72
Safety.................................................................................................................................................... 72
Welding parameters: display and navigation ........................................................................................ 72
Welding parameters for TIG.................................................................................................................. 72
Welding parameters for rod electrodes................................................................................................. 75
Preparation ........................................................................................................................................... 77
Welding job ........................................................................................................................................... 78
Finishing the welding job....................................................................................................................... 80
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Saving settings as a job ............................................................................................................................. 82
General ................................................................................................................................................. 82
Preparation ........................................................................................................................................... 82
Saving settings as a job ........................................................................................................................ 83
Finish saving job ................................................................................................................................... 87
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 ............................................................................................................................................ 97
Opening the TIG setup 2nd................................................................................................................... 97
Changing welding parameters .............................................................................................................. 97
Exiting TIG setup 2nd ........................................................................................................................... 98
Welding parameters in the TIG setup 2nd ............................................................................................ 100
AC setup .................................................................................................................................................... 103
General ................................................................................................................................................. 103
Open the AC setup ............................................................................................................................... 103
Changing welding parameters .............................................................................................................. 104
Exiting AC setup ................................................................................................................................... 105
Welding parameters in AC setup .......................................................................................................... 106
AC setup 2nd ............................................................................................................................................. 107
General ................................................................................................................................................. 107
Opening the AC setup 2nd.................................................................................................................... 107
Changing welding parameters .............................................................................................................. 107
Exiting AC setup 2nd ............................................................................................................................ 108
Welding parameters in AC setup 2nd ................................................................................................... 110
Gas setup................................................................................................................................................... 111
General ................................................................................................................................................. 111
Opening the gas setup.......................................................................................................................... 111
Changing welding parameters .............................................................................................................. 112
Exiting gas setup................................................................................................................................... 113
Gas setup parameters .......................................................................................................................... 114
Cold wire setup .......................................................................................................................................... 116
General ................................................................................................................................................. 116
Opening the AC setup........................................................................................................................... 116
Changing welding parameters .............................................................................................................. 117
Exiting the cold wire setup .................................................................................................................... 118
Welding parameters in the cold wire setup ........................................................................................... 119
Calibrating push-pull unit ........................................................................................................................... 120
General ................................................................................................................................................. 120
Calibrating the push-pull unit ................................................................................................................ 120
General ................................................................................................................................................. 122
Service codes during calibration of the push-pull unit........................................................................... 122
Rod elec. setup (rod electrode setup)........................................................................................................ 126
Open the rod electrode setup ............................................................................................................... 126
Changing welding parameters ....................................................................................................
Exiting rod electrode-setup ................................................................................................................... 128
Rod electrode setup parameters:.......................................................................................................... 129
Rod elec. setup 2nd (rod electrode setup 2nd).......................................................................................... 130
Opening the rod electrode setup 2nd.................................................................................................... 130
Changing welding parameters .............................................................................................................. 130
Exiting rod electrode setup 2nd ............................................................................................................ 131
Rod electrode setup 2nd parameters.................................................................................................... 133
AC setup (for rod electrodes)..................................................................................................................... 136
General ................................................................................................................................................. 136
Opening the AC setup........................................................................................................................... 136
Changing welding parameters .............................................................................................................. 137
.......... 127
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Exiting AC setup ................................................................................................................................... 137
Welding parameters in AC setup .......................................................................................................... 138
Job ............................................................................................................................................................. 139
General ................................................................................................................................................. 139
Opening the Job set-up menu............................................................................................................... 139
Save / retrieve....................................................................................................................................... 139
Overview ............................................................................................................................................... 139
Optimising a job ......................................................................................................................................... 140
Optimising a job .................................................................................................................................... 140
Renaming a job..................................................................................................................................... 142
Finish optimising job ............................................................................................................................. 144
Adjustable TIG parameters ................................................................................................................... 145
Adjustable rod electrode parameters .................................................................................................... 150
Deleting a job ............................................................................................................................................. 154
Deleting a job ........................................................................................................................................ 154
Basic setting............................................................................................................................................... 157
General ................................................................................................................................................. 157
Opening the basic settings.................................................................................................................... 157
Changing welding parameters .............................................................................................................. 158
Exiting basic settings ............................................................................................................................ 159
Basic setting parameters ...................................................................................................................... 160
Info ............................................................................................................................................................. 161
General ................................................................................................................................................. 161
Calling up the info screen ..................................................................................................................... 161
Exiting the info screen........................................................................................................................... 162
Entries on the info screen ..................................................................................................................... 163
Lock keys ................................................................................................................................................... 164
General ................................................................................................................................................. 164
Lock keys .............................................................................................................................................. 164
Unlock keys again................................................................................................................................. 165
Factory - for resetting the welding machine ............................................................................................... 166
General ................................................................................................................................................. 166
Factory - for resetting the welding machine .......................................................................................... 166
L/R alignment............................................................................................................................................. 167
Abbreviations ........................................................................................................................................ 167
General information on welding circuit inductivity L .............................................................................. 167
General information on welding circuit resistance R............................................................................. 167
L/R alignment........................................................................................................................................ 168
Troubleshooting and maintenance 171
Troubleshooting ......................................................................................................................................... 173
General ................................................................................................................................................. 173
Safety.................................................................................................................................................... 173
Displayed service codes ....................................................................................................................... 173
Service codes displayed in conjunction with the digital gas control option ........................................... 179
Displayed Service codes in conjunction with cold wire-feed unit .......................................................... 179
Power source - troubleshooting ............................................................................................................ 180
Care, maintenance and disposal ............................................................................................................... 182
General ................................................................................................................................................. 182
Safety.................................................................................................................................................... 182
At every start-up.................................................................................................................................... 182
Every 2 months ..................................................................................................................................... 182
Every 6 months ..................................................................................................................................... 182
Disposal ................................................................................................................................................ 183
Appendix 185
Technical data............................................................................................................................................ 187
Special voltages.................................................................................................................................... 187
MagicWave2200 Comfort ..................................................................................................................... 187
MagicWave2500 / 3000 Comfort .......................................................................................................... 188
MagicWave 2500 / 3000 Comfort MV ................................................................................................... 189
MagicWave 4000 Comfort, MagicWave 4000 Comfort MV .................................................................. 190
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TransTig 2200 Comfort ......................................................................................................................... 191
TransTig2500 / 3000 Comfort ............................................................................................................... 192
TransTig 2500 / 3000 Comfort MV........................................................................................................ 193
TransTig 4000 Comfort, TransTig 4000 Comfort MV............................................................................ 194
Explanation of footnotes ....................................................................................................................... 194
Spare parts and circuit diagrams 195
Spare parts list: TransTig / MagicWave 2200 Comfort .............................................................................. 196
Spare parts list: TransTig / MagicWave 2500 / 3000 ................................................................................. 198
Spare parts list: TransTig 4000.................................................................................................................. 200
Spare parts list: MagicWave 4000 ............................................................................................................. 202
Circuit diagrams: MagicWave 2200 Comfort ............................................................................................. 205
Circuit diagrams: MagicWave 2500 Comfort ............................................................................................. 206
Circuit diagrams: MagicWave 3000 Comfort ............................................................................................. 207
Circuit diagrams: MagicWave 4000 Comfort ............................................................................................. 208
Circuit diagrams: TransTig 2200 Comfort .................................................................................................. 210
Circuit diagrams: TransTig 2500 Comfort .................................................................................................. 211
Circuit diagrams: TransTig 3000 Comfort .................................................................................................. 212
Circuit diagrams: TransTig 4000 Comfort .................................................................................................. 213
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Safety rules
EN
Explanation of
safety symbols
General
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- have sufficient knowledge of 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!
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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.
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Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident
prevention
- to read these operating instructions, especially the "Safety rules" section
and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to
any harm in your absence.
EN
Mains connection
Protecting yourself and others
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to the maximum permissible mains impedance
- criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
*)
*)
see Technical Data
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the
matter with the power supply company.
NOTE! Ensure that the mains connection is earthed properly
Persons involved with welding expose 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
Anyone working on the workpiece while welding is in progress must wear suitable protective clothing with 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
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Protective clothing refers to a variety of different items. Operators should:
- protect eyes and face from UV rays, heat and sparks using a protective
visor and regulation filter.
- wear regulation protective goggles with side protection behind the protective visor.
- wear stout footwear that provides insulation even in wet conditions.
- protect the hands with suitable gloves (electrically insulated and providing
protection against heat).
- wear ear protection to reduce the harmful effects of noise and to prevent
injury.
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in
the vicinity,
- make them aware of all the dangers (risk of dazzling by the arc, injury
from flying sparks, harmful welding fumes, noise, possible risks from
mains current and welding current, etc.),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
Noise emission
values
Danger from toxic
gases and vapours
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.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air.
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
If there is any doubt about whether the extraction system is powerful enough,
then 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.
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The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's
radiation area.
EN
Danger from flying sparks
Risks from mains
current and welding current
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the
arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool,
the feed rollers and all pieces of metal that are in contact with the welding wire
are live.
Always set the wire-feed unit up on a sufficiently insulated surface or use a
suitable, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately
dimensioned. Loose connections, scorched, damaged or inadequately dimensioned cables and leads must be repaired/replaced immediately.
Do not sling 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 be touched when the power source is switched on.
Double the open circuit voltage of a power source can occur between the
welding electrodes of two power sources. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician
to ensure the ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
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If the device is operated on a mains supply without a ground conductor and
using a socket without a ground conductor contact, this will be deemed gross
negligence. The manufacturer shall not be held liable for any damage arising
from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on
again.
After opening the device:
- discharge all live components
- ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
Meandering welding currents
EMC Device Classifications
If the following instructions are ignored, meandering welding currents can develop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.
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.
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EMC measures
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may be
susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, additional measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EN
EMF measures
Specific hazards
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
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.
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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 deviceside thread of the adapter for the shielding gas connection using suitable Teflon tape.
18
Page 19
Factors affecting
welding results
The following requirements with regard to shielding gas quality must be met if
the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
EN
Danger from
shielding gas cylinders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they
must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical
circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
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.
Safety measures
at the installation
location and during transport
A device toppling over could easily kill someone. Place the device on a solid,
level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and escape unhindered.
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.
19
Page 20
Before transporting the device, allow coolant to drain completely and detach
the following components:
- Wire-feed unit
- 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.
Safety measures
in normal operation
Only operate the device if 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.
The manufacturer accepts no liability for damage resulting from use of a different coolant. In addition, all warranty claims will be forfeited.
The 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 and while the system is still
cool.
20
Page 21
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as
shown in the spare parts list, as well as the serial number of your device.
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.
EN
Safety inspection
Disposal
The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the
same 12-month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may
require.
Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your
dealer or given to one of the approved collection and recycling facilities in your
area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
21
Page 22
Safety symbols
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (e.g. relevant product standards
from the EN 60 974 series).
Fronius International GmbH declares that the device complies with directive
2014/53/EU. The full text of the EU Declaration of Conformity is available from
the following website: http://www.fronius.com
Devices with the CSA test mark satisfy the requirements of the relevant standards in Canada and the USA.
Data protection
Copyright
The user is responsible for the safekeeping of any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal
settings.
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.
22
Page 23
General information
Page 24
Page 25
General
EN
Device concept
The MagicWave (MW) 2200 / 2500 / 3000 /
4000 Comfort and Trans-Tig (TT) 2200 /
2500 / 3000 / 4000 Comfort TIG power
sources are completely digitised, microprocessor-controlled inverter power sources.
The modular design and potential for system add-ons ensure a high degree of flexibility. The devices can be adapted to any
situation.
The power sources are generator-compatible. They are exceptionally sturdy in dayto-day operation thanks to the protected
control elements and their powder-coated
housings.
The TIG pulsed arc function, with its wide frequency range, is available on both the MagicWave and TransTig.
To optimise the ignition sequence in TIG AC welding, the MagicWave takes account not
only of the diameter of the electrode, but also of its temperature, calculated with reference
to the preceding welding and welding off-times.
RPI (Reverse Polarity Ignition) ensures an excellent ignition response during TIG DC weld-
ing.
Functional principle
Field of application
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.
The devices are used in workshops and industry for manual and automated TIG applications 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.
25
Page 26
System components
General The TransTig and MagicWave power sources can be used with a wide variety of system
add-ons and options.
Overview
(1)
(2)
(3)
(6)
(7)
A
V
(8)
FRONIUS
(9)
(4)
(5)
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
(10)
(11)
26
Page 27
Control elements and connections
Page 28
Page 29
Description of the control panels
EN
General
Safety
MagicWave
Comfort control
panel
NOTE! Due to software updates, you may find that your device has certain func-
tions that are not described in these operating instructions or vice versa. Individual illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
(15)
(1)
(3)
(4)
)5()2(
(6)
(7)
(8)
(14)
(13)
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
(12)
(11)
(9)
(10)
29
Page 30
No. Function
(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
(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
30
Page 31
TransTig
Comfort control
panel
(14)
(1)
(3)
(4)
(6)
)7()5()2(
EN
(13)
(12)
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
(11)
(10)
(8)
(9)
4-step mode
Manual metal arc welding
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
31
Page 32
No. Function
(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
32
Page 33
Connections, switches and mechanical components
MagicWave
2200 Comfort
(3)
EN
(6)
(2)
(1)
MagicWave 2200 Comfort - front MagicWave 2200 Comfort - rear
No. Function
(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
(4)
(5)
(7)
(8)
33
Page 34
MagicWave
2500 / 3000 Comfort
(3)
(7)
(6)
(2)
(1)
MagicWave 2500 / 3000 Comfort - front MagicWave 2500 / 3000 Comfort - rear
(4)
(5)
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
(8) Mains switch
for switching the power source on and off
(8)
34
Page 35
MagicWave
4000 Comfort
MagicWave 4000
(7)
EN
(7)
(8)
(1)
(4)
(5)
(6)
MagicWave 4000 Comfort - front MagicWave 4000 Comfort - rear
(3)
(2)
No. Function
(1) Mains switch
for switching 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 coupler is connected
(5) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster TIG welding torch, etc.)
(6) Grounding (earthing) cable connection
for connecting the grounding (earthing) cable
(7) Blanking cover
reserved for LocalNet connection
(8) Mains cable with strain relief device
(9) Shielding gas connection
(9)
35
Page 36
TransTig
2200 Comfort
(3)
(6)
(2)
(1)
TransTig 2200 Comfort - front TransTig 2200 Comfort - rear
(4)
(5)
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)
(6) Shielding gas connection
(7) Mains switch
for switching the power source on and off
(8) Mains cable with strain relief device
(7)
(8)
36
Page 37
TransTig
2500 / 3000 Comfort
(3)
EN
(7)
(6)
(2)
(1)
TransTig 2500 / 3000 Comfort - front TransTig 2500 / 3000 Comfort - rear
(4)
(5)
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)
(6) Shielding gas connection
(7) Mains cable with strain relief device
(8) Mains switch
for switching the power source on and off
(8)
37
Page 38
TransTig
4000 Comfort
TransTig 4000
(2)
(3)
(6)
(6)
(7)
(1)
TransTig 4000 Comfort - front TransTig 4000 Comfort - rear
(4)
(5)
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) 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 (earthing) 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 -
(6) Blanking cover
reserved for LocalNet connection
(7) Mains cable with strain relief device
(8) Shielding gas connection
(8)
38
Page 39
Installation and commissioning
Page 40
Page 41
Minimum equipment needed for welding task
General Depending on which welding process you intend to use, a certain minimum equipment lev-
el will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for the welding task
are then described.
TIG AC welding - MagicWave power source
- Grounding (earthing) cable
- TIG welding torch with rocker switch
- Gas connection (shielding gas supply), with pressure regulator
- Filler metals (as required by the application)
TIG DC welding - Power source
- Grounding (earthing) cable
- TIG welding torch with rocker switch
- Gas connection (shielding gas supply)
- Filler metals (as required by the application)
EN
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)
41
Page 42
Before installation and commissioning
Safety
Utilisation for intended purpose
Setup regulations The device is tested to "Degree of protection IP23", meaning:
The power source is intended exclusively for TIG and MMA welding.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose.
The manufacturer shall not be liable for any damage resulting from such improper use.
Proper use also includes:
- following all the information in the operating instructions
- carrying out all the specified inspection and servicing work
- protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49
- protection against direct sprays of water up to 60° from the vertical
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All work described in this document must only be carried out by
trained and qualified personnel. All functions described in this document must
only be used by trained and qualified personnel. Do not carry out any of the work
or use any of the functions described until you have fully read and understood the
following documents:
- this document
- all the operating instructions for the system components, especially the safety rules
in.)
The device can be set up and operated outdoors in accordance with IP23.
Avoid direct wetting (e.g. from rain).
WARNING! If one of these machines topples over or falls it could cause serious
or even fatal injury. Place device on a solid, level surface in such a way that it remains stable.
The venting duct is a very important safety feature. When choosing the location for the device, ensure that the cooling air can enter and exit unhindered through the air ducts on the
front and back of the device. Electrically conductive dust (e.g. from grinding work) must not
be allowed to get sucked into the device.
Mains connection The devices are designed to run on the mains voltage shown on the respective rating
plates. If your version of the device does not come with mains cables and plugs ready-fitted, these must be fitted in accordance with national regulations and standards. For details
of fuse protection of the mains lead, please see the Technical Data.
NOTE! Inadequately dimensioned electrical installations can cause serious damage. The incoming mains lead and its fuse must be dimensioned to suit the local
power supply. The technical data shown on the rating plate applies.
42
Page 43
Start-up
EN
Safety
Remarks on the
cooling unit
General This section describes how to commission the power source:
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.
- for the main TIG welding application
- with reference to a standard configuration for a TIG welding device.
WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious injury and damage. Do not carry out any work on the device unless
- the mains switch is in the "O" position,
- the device is unplugged from the mains.
Connecting the
gas cylinder
The standard configuration consists of the following system components:
- power source
- cooling unit
- TIG manual welding torch
- pressure regulator
- gas cylinder
- gas cylinder holder
- trolley
The steps set out below provide an overview of how to commission the power source.
For detailed information about the individual steps, please refer to the operating instructions for the system components.
WARNING! If gas cylinders topple over, there is a risk of very serious injury and
damage.
- 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
1
Take the protective cap off the gas cylinder
2
Briefly open the gas cylinder valve to remove any dust or dirt
3
Check the seal on the pressure regulator
4
43
Page 44
Screw the pressure regulator onto the gas cylinder and tighten it
5
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
6
the rear of the power source
Tighten the union nut on the gas hose
7
When using a TIG welding torch with no integral gas connector:
Connect the TIG welding torch gas hose to the pressure regulator
6
Establishing a
ground (earth)
connection to the
workpiece
Connecting the
welding torch
Move the mains switch to the O position
1
Plug the grounding (earthing) cable in and latch it
2
- 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
3
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
1
Plug in the TIG welding torch cable and latch it by turning it clockwise:
2
- 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
3
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.
44
Equip the welding torch in accordance with the welding torch operating instructions
4
Only when using a water-cooled torch and cooling unit:
5
Plug in the welding torch water connections to the water flow (black) and return (red)
connections on the cooling unit.
Page 45
Welding
Page 46
Page 47
TIG modes
EN
Safety
Symbols and
their explanations
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
See the "The Setup menu" section for information on the settings, setting range and units
of measurement of the available welding parameters.
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
I
S
Starting-current phase: the temperature is
raised gently at low welding current, so
that the filler metal can be positioned correctly
t
up
Upslope phase: the starting current is continuously increased until it reaches the
main current (welding current) I
I
1
1
Main current phase (welding-current
phase): uniform thermal input into the
base material, whose temperature is
raised by the advancing heat
G-H
Gas post-flow time at maximum welding
current
SPt
Spot welding time
I
E
Final current phase: to prevent any local
overheating of the base material due to
heat build-up towards the end of welding.
This eliminates any risk of weld seam
drop-through.
t
down
Downslope phase: the welding current is
continuously lowered until it reaches the
end-crater current.
I
2
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
47
Page 48
2-step mode - Welding: Pull back and hold the torch trigger
- End of welding: Release the torch trigger
NOTE! To work in 2-step mode after it has been selected, the SPt set-up parameter must be set to "OFF" and the spot welding indicator on the control panel must
not light up.
I
I
S
I
1
I
E
t
GPr t
t
S
E
G-L
G-H
up
t
down
G-L / G-HGPr t
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 weld-
ing 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
48
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.
I
1
I
I
E
t
G-L
E
G-H
GPr t
Spot welding
I
S
t
S
up
t
down
SPt
t
Page 49
4-step mode - Welding start-up 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) set-up parameter must be set
to "OFF".
EN
Special 4-step
mode:
variant 1
I
I
S
GPr
t
up
I
1
I
2
*)
I
1
I
E
t
t
down
G-L
G-H
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
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 current I2. Briefly pull back the torch trigger a second time, to restore the main current I1.
I
I
S
GPr
Special 4-step mode: Variant 1
I
1
I
2
t
up
I
1
I
E
t
t
down
G-L
G-H
49
Page 50
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 3
I
I
S
GPr
Special 4-step mode: Variant 2
t
up
I
1
I
2
I
1
I
E
t
t
down
G-L
G-H
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
final current.
50
I
I
S
GPr
Special 4-step mode: Variant 3
I
1
I
2
I
1
t
t
up
G-L / G-H
Page 51
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 IS 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
1
- End of welding: briefly pull back and release the torch trigger
EN
I
I
S
GPr
t
S
Special 4-step mode: variant 4
I
1
I
2
I
1
I
E
t
t
up
t
down
G-L
t
E
G-H
51
Page 52
Cap shaping and cap overloading
Cap shaping
(1) Before ignition
(2) After ignition
NOTE! The automatic cap-shaping function is not necessary if a sufficiently large
cap has already formed at the tip of the tungsten electrode.
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 capshaping
- 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
(2)(1)
has to be activated separately for
each tungsten electrode.
Cap overloading If the cap is overloaded, there is a risk of an excessively large cap forming on the tungsten
electrode. This will 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.
52
Page 53
TIG welding
EN
Safety
Welding parameters: display and
navigation
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
WARNING! An electric shock can be fatal. If the power source is connected to the
mains electricity supply during installation, there is a high risk of very serious injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
The TIG welding parameters are shown as soon as the 2-step or 4-step mode is selected.
Use the left and right arrow keys to navigate within the welding parameters.
Welding parameters for TIG
Starting current 2-step mode Starting current 4-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.
53
Page 54
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 2500 Comfort 3 - 250
MW 3000 Comfort 3 - 300
TT 2500 Comfort 3 - 250
TT 3000 Comfort 3 - 300
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.
54
In the case of 4-step mode
Unit % (of main current)
Setting range 0 - 100
Factory setting 50
Page 55
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
EN
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
55
Page 56
If cold wire-feed unit 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
1
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the tungsten electrode of the welding torch is live.
Make sure that the tungsten electrode does not touch any persons or electrically
conductive or earthed parts (e.g. housing, etc.).
Move the mains switch to the I position
2
The starting sequence with the Fronius logo, current firmware version and Fronius internet address is displayed for approx. 1 second:
56
Page 57
TIG welding Press the Mode button to select the required TIG mode:
1
2-step mode
4-step mode
The image for the TIG welding parameter is shown on the display:
EN
TIG welding parameters for 2-step mode (main current
welding parameter selected)
Only with MagicWave: Press the Mode button to select the required TIG mode:
2
TIG welding parameters for 4-step mode (main current
welding parameter selected)
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
3
Use the adjusting dial to set the selected welding parameter to the required value
4
If necessary, additional welding parameters can be set in the set-up menu:
5
- Press the menu key
The relevant menu is displayed:
- 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 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 set-up 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 is switched off and on again in the meantime.
Open the gas cylinder valve
6
Set the shielding gas flow rate:
7
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 pressure gauge shows the required gas flow rate
57
Page 58
For long hosepacks and if condensation forms when the device is left unused in a cold
8
environment:
purge protective gas shield and set the GPU set-up parameter to a time value
Start welding (ignite the arc)
9
58
Page 59
Igniting the arc
General To ensure the best ignition sequence in the TIG AC welding process, the MagicWave pow-
er sources take account of:
- the diameter of the tungsten electrode
- the current temperature of the tungsten electrode with reference to the preceding
welding and weld-off times
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".
EN
Igniting the arc
using high frequency
(HF ignition)
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-
1
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
59
Page 60
Increase the tilt angle of the torch and
2
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 posi-
3
tion
Carry out welding
4
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-
1
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
60
Page 61
Actuate the torch trigger
2
Shielding gas flows.
Gradually tilt the welding torch up until
3
the tungsten electrode touches the
workpiece
Raise the welding torch and move it
4
into its normal position
The arc ignites.
Carry out welding
5
EN
End of welding Depending on the set mode, finish welding by releasing the torch trigger
1
Wait for the set gas post-flow and hold welding torch in position over the end of the
2
weld seam
61
Page 62
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 setup 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.
62
Page 63
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:
EN
I
I
1
I
I-G
TIG pulsing - welding current curve
S
t
up
1/F-P
Legend:
I
S
I
E
t
up
t
Down
Starting current F-P Pulse frequency *)
Final current dcY Duty cycle
Upslope I-G Ground current
Downslope I
*) (1/F-P = time interval between two pulses)
dcY
I
E
t
down
1
Main current
t
63
Page 64
Tacking function The tacking function is available for the TIG DC welding process.
When a time period is specified for the tAC (tacking) set-up 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 TIG DC welding is selected:
I
I
1
I
S
Tacking function - welding current curve
tAC
t
up
Legend:
tAC Duration of pulsed welding current for the tacking process
I
S
I
E
t
up
t
Down
I
1
Starting current
Final current
Upslope
Downslope
Main current
t
down
I
E
t
64
NOTE! The following points apply to the pulsed welding current:
- The power source automatically regulates the pulsing parameters as a function of the specified main current I
1
- There is no need to set any pulsing parameters
The pulsed welding current begins:
- after the end of the starting-current phase I
- With the upslope phase t
up
S
Depending on what tAC time has been set, the pulsed welding current may continue up to
and including the final current phase IE (tAC set-up parameter set to "ON").
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 set-up parameter can be combined with the SPt set-up parameter (spot welding time).
Page 65
TIG cold-wire
welding
TIG cold-wire welding is only possible in conjunction with a cold wire- feed unit.
EN
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
dcY
dt2
I
1
Fd.1
I-G
Fd.2
I
I
S
t
up
v
D
dt1
Legend:
I
S
I
E
t
up
t
Down
Starting current dcY Duty cycle
Final current I-G Ground current
Upslope I
1
Main current
Downslope F-P 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)
(1/F-P = time interval between 2 pulses)
1
dt2 Delay in the end of wirefeeding
from the end of main current
phase I
1
t
down
a)
I
E
t
b)
t
1)
65
Page 66
MMA welding
Safety
Welding parameters: display and
navigation
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
WARNING! An electric shock can be fatal. If the power source is connected to the
mains electricity supply during installation, there is a high risk of very serious injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
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
("SoftStart")
Starting current: starting current > main current ("HotStart")
Unit % (of main current)
Setting range 0 - 200
Factory setting 150
Starting current: starting current = main current
66
Page 67
Main current: starting current < main current ("SoftStart") Main current: starting current = main current
Main current: starting current > main current ("HotStart")
Unit A
Setting range MW 2500 Comfort 3 - 250
MW 3000 Comfort 3 - 300
TT 2500 Comfort 3 - 250
TT 3000 Comfort 3 - 300
Factory setting -
EN
To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force
dynamic.
Unit % (of main current)
Setting range 0 - 100
Factory setting 20
0 soft, low-spatter arc
100 harder, more stable arc
Functional principle:
at the instant of droplet transfer or when a short circuit occurs, 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.
67
Page 68
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 Switch off cooling units (set-up parameter C-C to OFF)
1
Move the mains switch to the O position
2
Disconnect the mains plug
3
Disconnect the TIG welding torch
4
Plug the grounding (earthing) cable in and latch it into place:
5
- 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
6
workpiece
Plug in the electrode cable and twist it clockwise to latch it into place:
7
- for MagicWave: in the welding torch connection
- for TransTig: in the (-) current socket
Plug in the mains plug
8
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the rod electrode in the electrode holder is live. Make
sure that the rod electrode does not touch any persons or electrically conducting
or earthed parts (e.g. the housing etc.).
Move the mains switch to the I position
9
The starting sequence with the Fronius logo, current firmware version and Fronius internet address is displayed for approx. 1 second:
68
Page 69
Manual metal arc
welding
Press the Mode button to select:
1
MMA welding mode
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 process:
2
MMA AC welding process
MMA DC- welding process
MMA DC+ welding process
EN
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 earthing (grounding) cable to the oppo-
site 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 conducting 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
3
Use the adjusting dial to set the selected welding parameter to the required value
4
69
Page 70
If necessary, additional welding parameters can be set in the set-up menu:
5
- Press the menu key
The relevant menu is displayed:
- 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 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 set-up 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 is switched off and on again in the meantime.
Start welding
6
Hotstart function To obtain optimum welding results, it will sometimes be necessary to adjust the hotstart
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.
I (A)
Hti
Legend
Hti Hot-current time, 0-2 s, factory
setting: 0.5 s
150
HCU HotStart current, 0-200%,
factory setting 150%
100
HCU
I
1
Function:
during the specified hot-current time (Hti),
I
1
the welding current I1 is increased to the
Main current = set welding current
HotStart current HCU.
t (s)
To activate the hotstart function, the Hot-
0,5 1 1,5
Start current HCU must be > 100.
70
Example of hotstart function
Page 71
SoftStart function The SoftStart function 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.
EN
Anti-stick function
I (A)
- Improved ignition properties for electrodes that ignite at low welding currents
Benefits:
- Largely prevents slag inclusions
- Reduces welding spatter
(1) Main current
(2) Starting current
t
90A
30A
Example of "SoftStart" function
(2)
(1)
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.
71
Page 72
Welding job
Safety
Welding parameters: display and
navigation
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
WARNING! An electric shock can be fatal. If the power source is connected to the
mains electricity supply during installation, there is a high risk of very serious injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
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.
Use the left and right arrow keys to navigate within the welding parameters.
Welding parameters for TIG
Starting current 2-step mode Starting current 4-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.
72
Page 73
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 2500 Comfort 3 - 250
MW 3000 Comfort 3 - 300
TT 2500 Comfort 3 - 250
TT 3000 Comfort 3 - 300
Factory setting -
EN
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
73
Page 74
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
74
Page 75
If cold wire-feed unit 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
EN
Welding parameters for rod electrodes
Starting current: starting current < main current
("SoftStart")
Starting current: starting current > main current ("HotStart")
Unit % (of main current)
Setting range 0 - 200
Factory setting 150
Starting current: starting current = main current
75
Page 76
Main current: starting current < main current ("SoftStart") Main current: starting current = main current
Main current: starting current > main current ("HotStart")
Unit A
Setting range MW 2500 Comfort 3 - 250
MW 3000 Comfort 3 - 300
TT 2500 Comfort 3 - 250
TT 3000 Comfort 3 - 300
Factory setting -
To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force
dynamic.
Unit % (of main current)
Setting range 0 - 100
Factory setting 20
0 soft, low-spatter arc
100 harder, more stable arc
Functional principle:
at the instant of droplet transfer or when a short circuit occurs, 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.
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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
EN
Preparation Set up and install the power source in accordance with the welding job
1
Plug in the mains plug
2
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the tungsten electrode of the welding torch is live.
Make sure that the tungsten electrode does not touch any persons or electrically
conductive or earthed parts (e.g. housing, etc.).
Move the mains switch to the I position
3
The starting sequence with the Fronius logo, current firmware version and Fronius internet address is displayed for approx. 1 second:
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Welding job
Press Menu key
1
The relevant main menu appears, e.g.:
Use the adjusting dial to select "job" (turn the adjusting dial)
2
Press the adjusting dial
3
The menu items for the job will now appear:
Use the adjusting dial to select 'Retrieve' (turn the adjusting dial)
4
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Press the adjusting dial
5
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)
6
EN
To change welding parameters according to the job correction stored in the
7
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)
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- Press the adjusting dial
The adjusted value of the selected welding parameter is applied
Start welding
8
Finishing the
welding job
Finish welding
1
Press Menu key
2
The main menu for the welding job appears:
Use the adjusting dial to select "job" (turn the adjusting dial)
3
Press the adjusting dial
4
The menu items for an active job will now appear:
80
Use the adjusting dial to select "Finish" (turn the adjusting dial)
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Press the adjusting dial
6
The welding parameters are shown for the most recently selected method,
e.g.:
Starting current 2-step mode
EN
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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:
1
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 welding
2
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
3
Change the welding parameter value by turning the adjusting dial
4
Press the Menu key in order to set other welding parameters in the set-up
5
menu
The relevant menu is displayed, e.g.:
Use the adjusting dial to select the desired set-up menu
6
Open the selected set-up menu by pressing the adjusting dial
7
Use the adjusting dial to select a welding parameter
8
To change a welding parameter press the adjusting dial
9
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Change the welding parameter value using the adjusting dial
10
Saving settings
as a job
Press the adjusting dial
11
Press Menu key
12
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
1
dial
EN
Press the adjusting dial
2
The menu items for the job will now appear:
Use the adjusting dial to select "Save" (turn the adjusting dial)
3
Press the adjusting dial
4
The first "Save job" screen will appear:
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Turn the adjusting dial to select the job number under which the settings are
5
to be stored
Press the adjusting dial
6
- 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.
Free memory:
The second "Save job" screen appears briefly:
The "Name job" screen appears:
Name job:
7
- Turn the adjusting dial to select the desired letters / numbers:
- Then press the adjusting dial in order to enter these letters / numbers:
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- In order to delete letters / numbers, turn the adjusting dial and select
'Del':
- Press the adjusting dial to delete the last character:
- Press the button on the right (OK) in order to accept the name
EN
The settings will be stored and the third 'Save job' screen will appear:
Press the button on the right (OK)
8
The job numbers overview appears:
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Allocated memory:
A warning prompt will appear:
Press the button on the left or right:
7
- Left button (No): Do not overwrite job, return to job numbers overview
- Right button (Yes): Store settings under the chosen job number:
The "Name job" screen appears:
- 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:
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- 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:
EN
Finish saving job
Press the button on the right (OK)
8
The job numbers overview appears:
Press Menu key
1
or
- Select the arrow symbol by turning the adjusting dial
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- Press the adjusting dial
The menu items for the job will now appear:
Press Menu key
2
or
- Select the arrow symbol by turning the adjusting dial
- Press the adjusting dial
The current set-up menu is displayed:
Press Menu key
3
or
- Select the arrow symbol by turning the adjusting dial
The current welding parameters are displayed e.g.:
88
TIG welding parameters for 2-step mode (main
current welding parameter selected)
Page 89
Setup settings
Page 90
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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 set-up menu" is composed of the following sections:
- TIG setup
- TIG setup 2nd
- AC setup
- AC setup 2nd
- Gas setup
- Cold wire setup
- Calibrating the push-pull unit
- Rod elec. setup (rod electrode setup)
- Rod elec. setup 2nd (rod electrode setup 2nd)
- AC setup (for rod electrodes)
- Job
- Basic setting
- Info
- Lock keys
- Factory - for resetting the welding machine
- L/R alignment
EN
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TIG setup
Opening the TIG
setup
Press the Mode button to select 2-step mode or 4-step mode
1
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
2
The main menu appears:
Use the adjusting dial to select "TIG setup" (turn the adjusting dial)
3
Press the adjusting dial
4
The TIG setup parameters are shown:
The power source is now in the TIG setup.
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Changing welding parameters
Select the desired welding parameter by turning the adjusting dial:
1
To set the welding parameter, press the adjusting dial
2
The value of the selected welding parameter can now be changed:
Change the welding parameter value by turning the adjusting dial:
3
EN
To apply the welding parameter value press the adjusting dial
4
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Exiting TIG setup
Press Menu key
1
or
- Select the arrow symbol by turning the adjusting dial
- Press the adjusting dial
The main menu appears:
Press Menu key
2
or
- 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
94
TIG welding parameters for 4-step mode
Page 95
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
EN
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 con-
stant 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)
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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 I
)
1
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 I
.
s
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 operating
modes").
I
I
S
GPr
2-step mode: Starting and final current time
t
S
t
up
Legend:
GPr Gas pre-flow time
I
S
t
S
t
up
Starting current
Starting current time
UpSlope
TIG-Setup 2nd
Second level of the TIG setup
I
1
I
E
t
t
E
I
1
t
down
I
E
t
E
t
down
Main current
Downslope
Final current
Final current time
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TIG setup 2nd
EN
Opening the TIG
setup 2nd
Opening the TIG setup
1
Select the 'TIG setup 2nd' parameter
2
Press the adjusting dial
3
The TIG setup 2nd parameters are shown:
The power source is now in TIG setup 2nd
Changing welding parameters
Select the desired welding parameter by turning the adjusting dial:
1
To set the welding parameter, press the adjusting dial
2
The value of the selected welding parameter can now be changed:
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Change the welding parameter value by turning the adjusting dial:
3
To apply the welding parameter value press the adjusting dial
4
Exiting TIG setup
2nd
Press Menu key
1
or
- Select the arrow symbol by turning the adjusting dial
- Press the adjusting dial
The TIG setup parameters are shown:
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Press Menu key
2
or
- Select the arrow symbol by turning the adjusting dial
- Press the adjusting dial
The main menu appears:
EN
Press Menu key
3
or
- 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
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Welding parameters in the TIG setup 2nd
"Minimum" and "maximum" are used for setting ranges that differ according to power
source, wire-feed unit, welding program, etc.
Special 4-step
Special 4-step mode
Unit -
Setting range OFF / 1 - 3
Factory setting OFF
1
2
3
Cool. unit ctrl
Cooling unit control (option)
Unit -
Setting range Aut / ON / OFF
Factory setting Aut
Aut Cooling unit is switched off 2 minutes after the end of welding
ON Cooling unit is ON all the time
OFF Cooling unit is OFF all the time
Variant 1
Variant 2
Variant 3
IMPORTANT! If the coolant unit is provided with the optional "thermostat", the coolant return temperature is checked continuously. If the return temperature is less than 50 °C, the
cooling unit is switched off automatically.
Cunit wtchdog
Cooling unit watchdog
Time from when the flow watchdog is triggered until the "no | H2O" service code is output.
For example, if there are air bubbles in the cooling system, the cooling unit will not cut out
until the end of this pre-set time.
Unit s
Setting range 5 - 25
Factory setting 10
IMPORTANT! Each time the power source is switched on, the cooling unit carries out a
test run for 180 seconds.
HF ignition
High frequency ignition: Time interval between the HF pulses
Unit s
Setting range 0.01 - 0.4 / OFF / EHF (Start with external arc starters, e.g. plas-
ma welding)
Factory setting 0,01
100
NOTE! If there are problems with sensitive equipment in the immediate vicinity,
increase the HF ignition parameter to a maximum of 0.4 s.
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