Fronius TransTig 800-5000, MagicWave 1700-500 Operating Instruction [EN]

Operating
Instructions

TransTig 800
TransTig 2200
TransTig 2500 / 3000
TransTig 4000 / 5000
MagicWave 1700 / 2200
MagicWave 2500 / 3000
MagicWave 4000 / 5000

Operating instructions

EN

42,0426,0027,EN 023-21092022

Contents

Safety rules 7

Explanation of safety notices 7
General 7
Proper use 8
Environmental conditions 8
Obligations of the operator 8
Obligations of personnel 8
Mains connection 9
Protecting yourself and others 9
Noise emission values 10
Danger from toxic gases and vapours 10
Danger from flying sparks 10
Risks from mains current and welding current 11
Meandering welding currents 12
EMC Device Classifications 12
EMC measures 12
EMF measures 13
Specific hazards 13
Requirement for the shielding gas 14
Danger from shielding gas cylinders 14
Danger from escaping shielding gas 15
Safety measures at the installation location and during transport 15
Safety measures in normal operation 16
Commissioning, maintenance and repair 16
Safety inspection 17
Disposal 17
Safety symbols 17
Data protection 17
Copyright 18

EN

General information 19

General 21

Device concept 21
Functional principle 22
Application areas 22
Warning notices on the device 23

System components 24

General 24
Overview 24

Control elements and connections 25

Description of the control panels 27

General 27
Safety 27
Overview 28

MagicWave control panel 29

MagicWave control panel 29

TransTig control panel 34

TransTig control panel 34

Key combinations - special functions 38

General 38
Displaying the software version, operating time and coolant flow 38

Connections, switches and mechanical components 39

MagicWave1700 / 2200 39
MagicWave2500 / 3000 40
MagicWave4000 / 5000 41
TransTig 2200 42
TransTig2500 / 3000 43
TransTig4000 / 5000 44

3

Installation and commissioning 45

Minimum equipment needed for welding task 47

General 47
TIG AC welding 47
TIG DC welding 47
MMA welding 47

Before installation and commissioning 48

Safety 48
Utilisation for intended purpose 48
Setup regulations 48
Mains connection 48
Generator-powered operation (MW 1700 / 2200, TT 2200) 49

Connecting up the mains cable on US power sources 50

General 50
Stipulated mains cables and strain-relief devices 50
Safety 50
Connecting the mains cable 50
Replacing the strain-relief device 52

Start-up 53

Safety 53
Remarks on the cooling unit 53
General 53
Connecting the gas cylinder 53
Establishing a ground (earth) connection to the workpiece 54
Connecting the welding torch 54

Welding 55

TIG modes 57

Safety 57
Symbols and their explanations 57
2-step mode 58
4-step mode 58
Special 4-step mode: variant 4 59

Cap shaping and cap overloading 60

Cap-shaping 60

TIG welding 61

Safety 61
Welding parameters 61
Preparation 62
TIG welding 62

Igniting the arc 64

General 64
Igniting the arc using high frequency(HF ignition) 64
Touchdown ignition 65
End of welding 66

Special functions and options 67

Arc break watchdog function 67
Ignition time-out function 67
Tacking function 67

MMA welding 69

Safety 69
Preparation 69
MMA welding 69
Hotstart function 71
Anti-stick function 71

Setup settings 73

The Setup menu 75

General 75
Overview 75

4

Shielding gas setup menu 76

General 76
Opening the Protective gas shield set-up menu 76
Changing welding parameters 76
Exiting the set-up menu 76
Welding parameters in the Protective gas shield set-up menu 76

TIG setup menu 78

Opening the TIG set-up menu 78
Changing welding parameters 78
Exiting the set-up menu 78
Welding parameters in the TIG setup menu 78

Rod electrode setup menu 82

Open the rod electrode set-up menu 82
Changing welding parameters 82
Exiting the set-up menu 82
Welding parameters in the rod electrode set-up menu 82

Rod electrode setup menu: level 2 84

Opening the rod electrode set-up menu level 2 84
Changing welding parameters 84
Exiting the rod electrode set-up menu - level 2 84
Welding parameters in the rod electrode setup menu - level 2 84

Troubleshooting and maintenance 87

Troubleshooting 89

General 89
Safety 89
Displayed service codes 89
Power source - troubleshooting 92

Care, maintenance and disposal 94

General 94
Safety 94
At every start-up 94
Every 2 months 94
Every 6 months 95
Disposal 95

EN

Appendix 97

Average consumption values during welding 99

Average wire electrode consumption during MIG/MAG welding 99
Average shielding gas consumption during MIG/MAG welding 99
Average shielding gas consumption during TIG welding 99

Technical data 100

Special voltages 100
Overview with critical raw materials, year of production of the device 100
MagicWave 1700 100
MagicWave 2200 101
MagicWave 2500 102
MagicWave 3000 103
MagicWave 2500 MV 104
MagicWave 3000 MV 105
MagicWave 4000 106
MagicWave 5000 107
MagicWave 4000 MV 108
MagicWave 5000 MV 109
TransTig 800 110
TransTig 2200 111
TransTig 2500 112
TransTig 3000 113
TransTig 2500 MV 114
TransTig 3000 MV 116
TransTig 4000 117

5

TransTig 5000 118
TransTig 4000 MV 119
TransTig 5000 MV 120
Explanation of footnotes 121

Terms and abbreviations used 122

General 122
Terms and abbreviations A - F 122
Terms and abbreviations G - H 122
Terms and abbreviations I - U 123

6

Safety rules

EN

Explanation of
safety notices

DANGER!

Indicates immediate danger.

If not avoided, death or serious injury will result.

▶

WARNING!

Indicates a potentially hazardous situation.

If not avoided, death or serious injury may result.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

If not avoided, minor injury and/or damage to property may result.

▶

NOTE!

Indicates a risk of flawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to

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!

7

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 in-

-

structions
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 sec-

-

tion "safety rules", and have confirmed as much with their signatures
are trained to produce the required results.

-

Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.

Obligations of
personnel

8

Before using the device, all persons instructed to do so undertake:

to observe the basic instructions regarding safety at work and accident pre-

-

vention
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 device types in terms of:

Connection restrictions

-

-

Criteria with regard to the maximum permissible mains impedance

-

Criteria with regard to the minimum short-circuit power requirement

*)

at the interface with the public grid

*)

*)

see "Technical data"

In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the mat­ter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Anyone working with the device exposes themselves to numerous risks, e.g.

flying sparks and hot pieces of metal

-

Arc radiation, which can damage eyes and skin

-

Hazardous electromagnetic fields, which can endanger the lives of those us-

-

ing cardiac pacemakers
Risk of electrocution from mains current and welding current

-

Greater noise pollution

-

Harmful welding fumes and gases

-

Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:

Flame-resistant

-

Insulating and dry

-

Covers the whole body, is undamaged and in good condition

-

Safety helmet

-

Trousers with no turn-ups

-

Protective clothing refers to a variety of different items. Operators should:

Protect eyes and face from UV rays, heat and sparks using a protective visor

-

and regulation filter
Wear regulation protective goggles with side protection behind the protect-

-

ive 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 in-

-

jury

Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vi­cinity:

Make them aware of all the dangers (risk of dazzling by the arc, injury from

-

flying sparks, harmful welding fumes, noise, possible risks from mains cur­rent and welding current, etc.)
Provide suitable protective equipment

-

Alternatively, erect suitable safety screens/curtains.

-

9

Noise emission
values

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum per­missible operating point under maximum rated load conditions according to EN
60974-1.

It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the work­piece, the workplace environment, etc.

Danger from tox­ic gases and va­pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph
118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

must not be breathed in

-

must be extracted from the working area using appropriate methods.

-

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of
at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.

The following components are responsible, amongst other things, for the degree
of toxicity of welding fumes:

Metals used for the workpiece

-

Electrodes

-

Coatings

-

Cleaners, degreasers, etc.

-

Welding process used

-

Danger from fly­ing sparks

10

The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for
identifying working conditions can be found on the European Welding Associ­ation website under Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi­ation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Risks from mains
current and
welding current

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.

EN

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable,
insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry
base or cover for the earth or ground potential. This base or cover must extend
over the entire area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately di­mensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must

never be immersed in liquid for cooling

-

Never touch the electrode when the power source is switched on.

-

Double the open circuit voltage of a power source can occur between the welding
electrodes of two power sources. Touching the potentials of both electrodes at
the same time may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician to
ensure the ground conductor is functioning properly.

Protection class I devices require a mains supply with ground conductor and a
connector system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a
socket without ground conductor contact is only permitted if all national regula­tions for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be
held liable for any damage arising from such usage.

11

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on again.

After opening the device:

Discharge all live components

-

Ensure that all components in the device are de-energised.

-

If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.

Meandering
welding currents

If the following instructions are ignored, meandering welding currents can devel­op with the following consequences:

Fire hazard

-

Overheating of parts connected to the workpiece

-

Damage to ground conductors

-

Damage to device and other electrical equipment

-

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive envir­onments, such as insulation against conductive floor or insulation to conductive
racks.

If power distribution boards, twin-head mounts, etc., are being used, note the fol­lowing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used is
kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wirefeeder.

EMC Device
Classifications

EMC measures In certain cases, even though a device complies with the standard limit values for

12

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 low­voltage mains.

EMC device classification as per the rating plate or technical data.

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:

Mains supply

1.
If electromagnetic interference arises despite correct mains connection,

-

additional measures are necessary (e.g. use a suitable line filter).

Welding power leads

2.
must be kept as short as possible

-

must run close together (to avoid EMF problems)

-

must be kept well apart from other leads

-

Equipotential bonding

3.

Earthing of the workpiece

4.
If necessary, establish an earth connection using suitable capacitors.

-

Shielding, if necessary

5.
Shield off other nearby devices

-

Shield off entire welding installation

-

EN

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

Effects on the health of persons in the vicinity, e.g. those with pacemakers

-

and hearing aids
Individuals with pacemakers must seek advice from their doctor before ap-

-

proaching the device or any welding that is in progress
For safety reasons, maintain as large a distance as possible between the

-

welding power-leads and the head/torso of the welder
Do not carry welding power-leads and hosepacks over the shoulders or wind

-

them around any part of the body

Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:

Fans

-

Cogs

-

Rollers

-

Shafts

-

Wirespools and welding wires

-

Do not reach into the rotating cogs of the wire drive or into rotating drive com­ponents.

Covers and side panels may only be opened/removed while maintenance or repair
work is being carried out.

During operation

Ensure that all covers are closed and all side panels are fitted properly.

-

Keep all covers and side panels closed.

-

The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).

Therefore, always keep the welding torch away from the body (devices with
wirefeeder) and wear suitable protective goggles.

13

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 or ropes onto all suspension points provided on the load-carry-

-

ing equipment.
Chains and ropes must be at the smallest angle possible to the vertical.

-

Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

-

Requirement for
the shielding gas

If the wirefeeder 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 tackle (straps, handles, chains, etc.) used in connection with the device
or its components must be tested regularly (e.g. for mechanical damage, corro­sion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is
used for the shielding gas connection. Prior to assembly, seal the device-side
thread of the adapter for the shielding gas connection using suitable Teflon tape.

Especially with ring lines, contaminated shielding gas can cause damage to
equipment and reduce welding quality.
Meet the following requirements regarding shielding gas quality:

Solid particle size < 40 µm

-

Pressure condensation point < -20 °C

-

Max. oil content < 25 mg/m³

-

Danger from
shielding gas cyl­inders

14

Use filters if necessary.

Shielding gas cylinders contain gas under pressure and can explode if damaged.
As the shielding gas cylinders are part of the welding equipment, they must be
handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat,
mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions
to prevent them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical
circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only use
shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

If the shielding gas cylinder is not connected, leave the valve cap in place on the
cylinder.

The manufacturer's instructions must be observed as well as applicable national
and international regulations for shielding gas cylinders and accessories.

EN

Danger from es­caping shielding
gas

Safety measures
at the installa­tion location and
during transport

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace
the oxygen in the ambient air.

Ensure an adequate supply of fresh air with a ventilation rate of at least

-

20 m³/hour.
Observe safety and maintenance instructions on the shielding gas cylinder or

-

the main gas supply.
Close the shielding gas cylinder valve or main gas supply if no welding is tak-

-

ing place.
Check the shielding gas cylinder or main gas supply for uncontrolled gas

-

leakage before every start-up.

A device toppling over could easily kill someone. Place the device on a solid, level
surface such that it remains stable

The maximum permissible tilt angle is 10°.

-

Special regulations apply in rooms at risk of fire or explosion

Observe relevant national and international regulations.

-

Use internal directives and checks to ensure that the workplace environment is
always clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection
shown on the rating plate.

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.

7.69 in.) to ensure that cooling air can flow in and out freely.

When transporting the device, observe the relevant national and local guidelines
and accident prevention regulations. This applies especially to guidelines regard­ing the risks arising during transport.

15

Do not lift or transport operational devices. Switch off devices before transport
or lifting.

Before transporting the device, allow coolant to drain completely and detach the
following components:

Wirefeeder

-

Wirespool

-

Shielding gas cylinder

-

After transporting the device, the device must be visually inspected for damage
before commissioning. Any damage must be repaired by trained service techni­cians before commissioning the device.

Safety measures
in normal opera­tion

Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a risk of

injury or death to the operator or a third party

-

damage to the device and other material assets belonging to the operator

-

inefficient operation of the device

-

Any safety devices that are not functioning properly must be repaired before
switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper function­ing of safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the
device is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due
to its 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.

Commissioning,
maintenance and
repair

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other sys­tem components or a different coolant. In addition, all warranty claims will be
forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite
under certain conditions. Transport the coolant only in its original, sealed con­tainers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant na­tional and international regulations. The coolant safety data sheet may be ob­tained from your service centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

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.

16

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 Do not dispose of this device with normal domestic waste! To comply with the

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.

European Directive on Waste Electrical and Electronic Equipment and its imple­mentation as national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an approved recycling facility.
Any device that you no longer require must either be returned to your dealer or
given to one of the approved collection and recycling facilities in your area. Ig­noring this European Directive may have potentially adverse affects on the envir­onment and your health!

Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage

and electromagnetic compatibility directives (e.g. relevant product standards of
the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with
Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be
found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.

Data protection The user is responsible for the safekeeping of any changes made to the factory

settings. The manufacturer accepts no liability for any deleted personal settings.

17

Copyright Copyright of these operating instructions remains with the manufacturer.

The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur­chaser. If you have any suggestions for improvement, or can point out any mis­takes that you have found in the instructions, we will be most grateful for your
comments.

18

General information

19

20

General

EN

Device concept

TransTig 2200 Job, MagicWave 1700 Job and
MagicWave 2200 Job with cooling unit

The MagicWave (MW)1700 / 2200 /
2500 / 3000 / 4000 / 5000 and Tran­sTig (TT) 800 / 2200 / 2500 / 3000 /
4000 / 5000 TIG power sources are
completely digitised, microprocessor
controlled inverter power sources.

Their modular design and potential for
system add-ons ensure a high degree
of flexibility. The devices can be adap-
ted to any situation.

The straightforward operating
concept means that essential func­tions can be seen at a glance and ad­justed as required.

A standardised LocalNet interface
makes it easy to connect digital sys­tem add-ons (e.g. JobMaster TIG
welding torches, robot welding
torches, remote control units, etc.).

Automatic cap-shaping for AC weld­ing with MagicWave power sources
takes the diameter of the tungsten
electrode into account to help pro­duce optimum results.

MagicWave 3000 Job with cooling unit and
MagicWave 2500 Job

TransTig 5000 Job and MagicWave 5000 Job,
both with cooling unit and trolley

The power sources are generator­compatible. They are exceptionally
sturdy in day-to-day operation thanks
to the protected control elements and
their powder-coated housings.

To optimise the ignition sequence in
TIG AC welding, the MagicWave takes
into account not only the diameter of
the electrode, but also its current
temperature, calculated with refer­ence to the preceding welding time
and welding off-time.

21

Functional prin­ciple

The central control and regulation unit of the power sources is coupled with a di­gital signal processor. The central control and regulation unit and signal pro­cessor control the entire welding process.
During the welding process, the actual data is measured continuously and the
device responds immediately to any changes. Control algorithms ensure that the
desired target state is maintained.

This results in:

a precise welding process,

-

exact reproducibility of all results

-

excellent weld properties.

-

Application
areas

The devices are used in workshops and industry for manual 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.

22

Warning notices
on the device

US power sources come with extra warning notices affixed to the device. The

warning notices must NOT be removed or painted over.

EN

US version of power source with additional warning notices, e.g. MagicWave 2200

23

System components

FRONIUS

A

V

(1)

(6)

(7)

(2)

(3)

(9)

(8)

(5)

(4)

General The TransTig and MagicWave power sources can be used with a wide variety of

system add-ons and options.

Overview

System add-ons and options

Item Description

(1) Power sources
(2) Cooling units
(3) Trolley with gas cylinder holder
(4) Pedal remote control unit
(5) TIG welding torch Standard / Up/Down
(6) JobMaster TIG welding torch

JobMaster TIG welding torch functions in conjunction with power sources:

welding current indicator on the welding torch

-

UP/Down control

-

(7) Remote control units and robot accessories
(8) Grounding (earthing) cable
(9) Electrode cable

24

Control elements and connections

25

26

Description of the control panels

General The key feature of the control panel is the logical way in which the control ele-

ments are arranged. All the main welding parameters needed for day-to-day
working can easily be:

selected using the buttons

-

altered with the adjusting dial

-

shown during welding on the digital display.

-

NOTE!

Due to software updates, you may find that your device has certain functions
that are not described in these operating instructions or vice versa.

Individual illustrations may also differ slightly from the actual controls on your
device, but these controls function in exactly the same way.

EN

Safety

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

Do not use the functions described here until you have read and completely

▶

understood these Operating Instructions.
Do not use the functions described here until you have fully read and under-

▶

stood all of the Operating Instructions for the system components, in partic­ular the safety rules!

27

Overview

(1)

(3)

(2)

(4)

(6)

(5)

"Description of the control panels" is composed of the following sections:

MagicWave control panel

-

TransTig control panel

-

Key combinations - special functions

-

MagicWave control panels: TransTig control panels:

(1) MW 1700 / 2200 (4) TT 2200

(2) MW 2500 / 3000 (5) TT 2500 / 3000

(3) MW 4000 / 5000 (6) TT 4000 / 5000

28

MagicWave control panel

(2)

(11)

(5)

(8)

(10) (9)

(3)

(12)

(1) (4)

(7)

(6)

(13)

(15)

(14)

MagicWave con­trol panel

EN

No. Function

(1) Left digital display

(2) HOLD indicator

at the end of each welding operation, the actual values for the welding
current and voltage are stored and the Hold indicator lights up.

The Hold indicator refers to the last value reached by the main current
I1. As soon as any other welding parameter is selected, the Hold indic-

ator goes off. The Hold values will continue to be available, however, if
welding parameter I1 is selected again.

The Hold indicator is cleared when:

a new welding operation is started

-

the welding current I1 is set

-

the mode is changed

-

the welding process is changed

-

IMPORTANT! Hold values are not output if

the main current phase was never reached,

-

or
a pedal remote control was used.

-

(3) Right digital display

29

No. Function

(4) Welding voltage indicator

lights up when parameter I
is selected. During welding the current actual value for the welding

voltage is shown on the right-hand digital display.

Before welding, the following appears on the right digital display:

0.0 if a TIG welding mode is selected

-

50 V if an MMA welding mode is selected (after a delay of 3

-

seconds; 50 V is approximately the average value for the pulsed
open circuit voltage)

(5) Unit indicators

A indicator

% indicator

lights up when the IS, I2 and IE welding parameters and the dcY,
I-G and HCU setup parameters have been selected

s indicator

lights up when the tup and t
following setup parameters have been selected:

1

welding parameters plus the

down

GPr

-

G-L

-

G-H

-

UPS

-

mm indicator

lights up when the Fdb setup parameter has been selected

(6) 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 process

TIG AC welding process

TIG DC- welding process

Manual metal arc welding mode:

MMA AC welding process

tAC

-

Hti

-

HFt

-

30

MMA DC- welding process

MMA DC+ welding process

When a welding process is selected, the LED on the relevant symbol
lights up.

(7) Mode button

for selecting the mode

2-step mode

4-step mode