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TransTig 4000 Comfort

Fronius TransTig 2200 Comfort, TransTig 2500 Comfort, TransTig 3000 Comfort, TransTig 4000 Comfort, MagicWave 2200 Comfort Operating Instructions Manual

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TransTig 2200 / 2500 / 3000 / 4000 Comfort MagicWave 2200 / 2500 / 3000 / 4000 Comfort
Operating Instructions Spare parts list
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.
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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
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
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.
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.
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
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.
17
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.
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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
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
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
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.
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
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
General information
General
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
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
Control elements and connections
Description of the control panels
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
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
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