Fronius MagicWave 190 Operating Instructions Manual
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Fronius MagicWave 190 Operating Instructions Manual

Tig power source
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/ Perfect Charging /
Perfect Welding
MagicWave 190
MagicWave 230i
TransTig 230i
42,0426,0250,EN 003-05032018
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Solar Energy
Operating Instructions
TIG Power source

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Summary of Contents for Fronius MagicWave 190

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions MagicWave 190 MagicWave 230i TIG Power source TransTig 230i 42,0426,0250,EN 003-05032018 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
  • Page 3 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.

  • Page 5: Table Of Contents

    Contents Safety rules ..............................General information General ..............................Device concept ............................. Functional principle ..........................Application areas ..........................FCC / RSS Compliance ........................Warning notices on the device......................System components ..........................General ..............................Overview ............................... Options..............................Control elements and connections Control panel.............................. General ..............................
  • Page 6 Welding TIG modes ..............................Safety..............................Symbols and their explanations ......................2-step mode ............................4-step mode ............................Spot welding ............................TIG welding..............................Safety..............................Preparations............................TIG welding............................Welding parameters for TIG DC welding ....................Welding parameters for TIG AC welding ....................Igniting the arc ............................General ..............................
  • Page 7 At every start-up............................ 120 Every 2 months ............................. 120 Every 6 months ............................. 120 Disposal ..............................121 Appendix Technical data............................125 Special voltages, MagicWave 190 ......................125 MagicWave 230i ........................... 127 TransTig 230i ............................128 Explanation of footnotes ........................129...

  • Page 9: Safety Rules

    Safety rules 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 operat- ing company, inefficient operation of the device.
  • Page 10 Environmental Operation or storage of the device outside the stipulated area will be deemed conditions 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:...
  • Page 11 Protecting your- Anyone working with the device exposes themselves to numerous risks, e.g. self and others 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...
  • Page 12 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 tak- ing place. 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.
  • Page 13 All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged or inade- quately 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°...
  • Page 14 EMC Device Clas- Devices in emission class A: sifications 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 sup- plied from the public low-voltage mains.
  • Page 15 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 com- ponents. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.
  • Page 16 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, coun- terbalanced 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.
  • Page 17 Danger from es- Risk of suffocation from the uncontrolled escape of shielding gas caping shielding Shielding gas is colourless and odourless and, in the event of a leak, can dis- place the oxygen in the ambient air. Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
  • Page 18 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 com- patibility, flammability, etc.).
  • Page 19 (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 rele- vant standards for Canada and the USA.
  • Page 20 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 pur- chaser.

  • Page 21: General Information

    General information...

  • Page 23: General

    General Device concept The TransTig (TT) 230i, MagicWave (MW) 190 and MagicWave (MW) 230i TIG power sources are fully digitised, microprocessor- controlled inverter power sources. Their modular design and potential for sys- tem add-ons ensure a high degree of flexi- bility.

  • Page 24: Fcc / Rss Compliance

    FCC / RSS Com- pliance This equipment complies with the limit values for a EMC device class A dig- ital device pursuant to Part 15 of the FCC Rules. These limit values are in- tended to provide an adequate level of protection against harmful emissions when the device is used in an industrial environment.

  • Page 25: Warning Notices On The Device

    Warning notices Warning notices and safety symbols are affixed to power sources with the CSA test mark on the device for use in North America (USA and Canada). These warning notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and damage.

  • Page 26: System Components

    System components General The TransTig and MagicWave power sources can be used with a wide variety of system add-ons and options. Overview TIG welding torch Power sources Cooling unit (only for TT / MW 230i) Trolley with gas cylinder holder Not illustrated: Remote controls Pedal remote controls...

  • Page 27: Control Elements And Connections

    Control elements and connections...

  • Page 29: Control Panel

    Control panel General 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. Individ- ual illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.
  • Page 30 No. Function Welding process / Mode button to select the welding process and operating mode Gas-test button to set 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.

  • Page 31: The Favourites Button

    The favourites button Assigning the Fa- The Favourites button can be assigned a parameter from the following Setup menus: vourites button This parameter can then be called up and changed directly on the control panel. Select the desired parameter in the Setup menu More information about the Setup menu can be found from page 77 onwards To assign the selected parameter to the Favourites button, press the Favourites but- ton for approx.

  • Page 32: Deleting Favourites

    Deleting favour- Press the Favourites button for longer than 5 seconds ites The assigned parameter is deleted and a message is displayed. Press the adjusting dial to confirm Assigning Easy- If the FP Job function package is present on the power source, EasyJobs can be assigned Jobs to the Fa- to the Favourites button.
  • Page 33 The 5 EasyJob buttons are displayed and can be selected by turning and pressing the adjusting dial. 50 A More information about using EasyJobs can be found in the "EasyJob mode" section start- ing on page 74.

  • Page 34: Connections, Switches And Mechanical Components

    Connections, switches and mechanical components Connections, switches and me- chanical compo- nents Front Rear No. Function (-) current socket with integrated gas connection to connect: the TIG welding torch the electrode cable for manual metal arc welding Symbols on TransTig power sources: Symbols on MagicWave power sources: TMC connection (TIG Multi Connector) to connect the TIG welding torch control plug...
  • Page 35 No. Function (+) current socket to connect the grounding cable Symbols on TransTig power sources: Symbols on MagicWave power sources: Mains switch To switch the power source on and off Mains switch for MV devices: Mains cable with strain relief device for MV devices: mains cable connection socket Shielding gas connection...

  • Page 37: Installation And Commissioning

    Installation and commissioning...

  • Page 39: Minimum Equipment Needed For Welding Task

    Minimum equipment needed for welding task General Depending on which welding process you intend to use, a certain minimum equipment lev- el will be needed in order to work with the power source. The welding processes and the minimum equipment levels required for the welding task are then described.

  • Page 40: Before Installation And Commissioning

    Before installation and commissioning Safety WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All work described in this document must only be carried out by trained and qualified personnel. All functions described in this document must only be used by trained and qualified personnel.

  • Page 41: Generator-Powered Operation

    Generator-pow- The power source is generator-compatible. ered operation In order to dimension the required generator output, the maximum apparent power S 1max of the power source is required. The maximum apparent power S of the power source can be calculated as follows: 1max 1max 1max...

  • Page 42: Connecting The Mains Cable

    Connecting the mains cable General If power sources are delivered without a mains cable fitted, a mains cable that is suitable for the connection voltage must be connected to the power source before commissioning. The mains cable in included in the scope of supply of the power source. Safety WARNING! Work that is carried out incorrectly can cause serious injury and dam- age.

  • Page 43: Start-Up

    Start-up Safety WARNING! An electric shock can be fatal. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious in- jury and damage. Do not carry out any work on the device unless the mains switch is in the "O"...

  • Page 44: Assembling The System Components (Overview)

    Assembling the system compo- nents (overview)

  • Page 45: Connecting The Gas Cylinder

    Connecting the WARNING! There is a high risk of very serious injury and damage if a gas cylin- gas cylinder der falls over. Place them on a solid, level surface in such a way that they remain stable Secure gas cylinders to prevent them from toppling over: fix the safety strap at the same height as the top part of the cylinder Never fix the safety strap around the neck of the cylinder Follow the gas cylinder manufacturer's safety rules.

  • Page 46: Connecting The Welding Torch To The Power Source And The Cooling Unit

    Connecting the NOTE! Do not use pure tungsten electrodes (colour-coded green) on TransTig welding torch to power sources. the power source and the cooling Set up the welding torch in accordance with the welding torch operating instructions unit NOTE! Always check the follow- ing before switching on: Sealing ring on welding torch connection...

  • Page 47: Locking And Unlocking The Power Source Using The Nfc Key

    Locking and unlocking the power source using the NFC key General remarks NFC key = NFC card or NFC key ring The power source can be locked using an NFC key, e.g. to prevent unauthorised access or welding parameters being changed without permission. A contactless system on the control panel allows the power source to be locked and un- locked.

  • Page 49: Welding

    Welding...

  • Page 51: Tig Modes

    TIG modes Safety 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 safe- ty rules See the "The Setup menu"...

  • Page 52: 2-Step Mode

    2-step mode Welding: Pull back and hold the torch trigger End of welding: Release the torch trigger DOWN 2-step mode 4-step mode Start of welding with starting current I : Pull back and hold the torch trigger Welding with main current I : Release the torch trigger Lowering to final current I : Pull back and hold the torch trigger...

  • Page 53: Spot Welding

    Spot welding When the spot welding operating mode is selected, the symbol for spot welding appears on the status display next to the welding process symbol: Welding: briefly pull back the torch trigger The welding time corresponds to the value set for the spot welding time setup param- eter.

  • Page 54: Tig Welding

    Make sure that the tungsten electrode does not touch any persons or electrically conductive or earthed parts (e.g. housing, etc.). Move the mains switch to the "I" position The Fronius logo appears on the display. TIG welding Press the Welding process / Mode button The welding process and operating mode are displayed.

  • Page 55: Welding Parameters For Tig Dc Welding

    Turn the adjusting dial to select the required parameter Press the adjusting dial The value of the parameter is highlighted in blue and can now be changed. Turn the adjusting dial to change the value of the parameter Press the adjusting dial If required, set further parameters in the Setup menu (For details, see the "Setup parameters"...
  • Page 56 UpSlope 0.5 s 0.5 s UpSlope, 2-step mode and spot welding UpSlope, 4-step mode Unit Setting range off; 0.1 - 30.0 Factory setting IMPORTANT! The UpSlope is saved separately for 2-step and 4-step modes. Main current 50 A 50 A Main current, 2-step mode and spot welding Main current, 4-step mode Unit...
  • Page 57 DownSlope 0.5 s 0.5 s DownSlope, 2-step mode and spot welding DownSlope, 4-step mode Unit Setting range off; 0.1 - 30.0 Factory setting IMPORTANT! The DownSlope is saved separately for 2-step and 4-step modes. Final current Final current, 2-step mode and spot welding Final current, 4-step mode Unit % (of main current)

  • Page 58: Welding Parameters For Tig Ac Welding

    Polarity Unit Setting range DC- / AC Factory setting Welding parame- The polarity welding parameter is only available on MagicWave power sources. ters for TIG AC If the polarity welding parameter is set to AC, the following welding parameters are availa- welding ble: xxA = actual current value depending on the specified main current...
  • Page 59 UpSlope 0.5 s 0.5 s UpSlope, 2-step mode and spot welding UpSlope, 4-step mode Unit Setting range off; 0.1 - 30.0 Factory setting IMPORTANT! The UpSlope is saved separately for 2-step and 4-step modes. Main current 50 A 50 A Main current, 2-step mode and spot welding Main current, 4-step mode Unit...
  • Page 60 DownSlope 0.5 s 0.5 s DownSlope, 2-step mode and spot welding DownSlope, 4-step mode Unit Setting range off; 0.1 - 30.0 Factory setting IMPORTANT! The DownSlope is saved separately for 2-step and 4-step modes. Final current Final current, 4-step mode Final current, 2-step mode and spot welding Unit % (of main current)
  • Page 61 Effect of the balance on the waveshape: I (A) t (s) Electrode diameter 2.4mm Unit Setting range off; 1.0 - 4.0 Factory setting Cap mode on MagicWave only Unit Setting range off / on Factory setting Automatic cap-shaping function is deactivated The ideal cap for the specified diameter of the tungsten electrode is formed during welding start-up.
  • Page 62 Afterwards, the automatic cap-shaping function is reset and deacti- vated. (1) ... before ignition (2) ... after ignition Cap mode must be activated separately for each tungsten elec- trode. NOTE! The automatic cap-shaping function is not necessary if a sufficiently large cap has already formed at the tip of the tungsten electrode.

  • Page 63: Igniting The Arc

    Igniting the arc General To ensure the best ignition sequence in the TIG AC welding process, the MagicWave pow- er sources take account of: the diameter of the tungsten electrode the current temperature of the tungsten electrode with reference to the preceding welding and weld-off times Igniting the arc HF ignition is activated when a time value has been set for the ignition timeout setup pa-...

  • Page 64: Touchdown Ignition

    Tilt the torch back into the normal posi- tion Carry out welding Touchdown igni- If the ignition timeout setup parameter is set to off, HF ignition is deactivated. The welding tion arc is ignited by touching the workpiece with the tungsten electrode. Procedure for igniting the arc using touchdown ignition: Place the gas nozzle down on the igni- tion location, ensuring there is a gap of...

  • Page 65: End Of Welding

    Raise the welding torch and rotate it into its normal position The arc ignites. Carry out welding End of welding Depending on the set mode, finish welding by releasing the torch trigger Wait for the set gas post-flow and hold welding torch in position over the end of the weld seam...

  • Page 66: Ignition Time Out, Tig Pulsing And Tacking Function

    Ignition time out, TIG pulsing and tacking function Ignition timeout The power source has an ignition timeout function. function Once the torch trigger is pressed, gas pre-flow begins immediately. Ignition then begins. If an arc does not appear within the time specified in the Setup menu, the power source cuts out automatically.

  • Page 67: Tacking Function

    Tacking function The tacking function is available for the TIG DC welding process. When a time period is specified for the tacking setup parameter (4), the tacking function is assigned to 2-step mode and 4-step mode. The operating sequence of the modes remains unchanged.

  • Page 68: Mma Welding

    "I" position, the rod electrode in the electrode holder is live. Make sure that the rod electrode does not touch any persons or electrically conducting or earthed parts (e.g. the housing, etc.). Move the mains switch to the "I" position The Fronius logo appears on the display.

  • Page 69: Mma Welding

    MMA welding Press the Mode button The welding process and operating mode are displayed. Select MMA (rod electrode) welding process (turn adjusting dial and press) Turn the adjusting dial to select the Polarity parameter Press the adjusting dial Set the polarity for the rod electrode to be used by turning the adjusting dial Confirm the selection by pressing the adjusting dial Turn the adjusting dial to select further welding parameters Press the adjusting dial...

  • Page 70: Welding Parameters For Manual Metal Arc Welding

    Welding parame- Depending on the selected current type, (+), (-) or the alternating current symbol ters for manual is displayed here. metal arc welding xxA = actual current value depending on the specified main current Starting current 100% Starting current: starting current < main current Starting current: starting current = main current ("SoftStart") 150%...
  • Page 71 Main current 130 A 130 A Main current: starting current < main current Main current: starting current = main current ("SoftStart") 130 A Main current: starting current > main current ("Hot- Start") Unit Setting range 0 - 190 ... MW 190 0 - 230 ...

  • Page 72: Starting Current >100% (Hotstart)

    Polarity Polarity, set to DC- Polarity, set to DC+ Polarity, set to AC Unit Setting range DC- / DC+ / AC Factory setting Starting current Benefits > 100 % (Hot- Improved ignition properties, even when using electrodes with poor ignition properties Start) Better fusion of the base material in the start-up phase, meaning fewer cold-shut de- fects...

  • Page 73: Starting Current <100% (Softstart)

    Starting current A starting current < 100% (SoftStart) is intended for basic electrodes. Ignition takes place < 100 % at a low welding current. Once the arc is stable, the welding current continues to rise until (SoftStart) it reaches the welding current command value. Benefits: Improved ignition properties for elec- trodes that ignite at low welding cur-...

  • Page 74: Easyjob Mode

    EasyJob mode Storing EasyJob NOTE! EasyJobs are saved under job numbers 1 - 5 and can also be called up in operating points the Job menu. Storing an EasyJob overwrites any other job saved under the same number! Prerequisite: EasyJobs must be assigned to the Favourites button (see "Assigning EasyJobs to the Fa- vourites button", starting on page 32.

  • Page 75: Retrieving Easyjob Operating Points

    Retrieving Easy- Press the Favourites button Job operating points The 5 EasyJob buttons are opened. Turn the adjusting dial and select the desired storage location To retrieve a saved EasyJob operating point, press the adjusting dial briefly (< 3 sec- onds) The size and colour of the button changes.

  • Page 76: Welding Job

    Welding job Safety 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 safe- ty rules WARNING! An electric shock can be fatal.

  • Page 77: Setup Settings

    Setup settings...

  • Page 79: The Setup Menu

    The Setup menu General The Setup menu provides easy access to the knowledge base in the power source and to additional functions. The Setup menu can be used to make simple adjustments to the weld- ing parameters to suit the various job settings. The following can be found in the Setup menu: all setup parameters that have an immediate effect on the welding process, all setup parameters needed for making the preliminary settings on the welding sys-...

  • Page 80: Overview

    Overview (13) (12) (11) (10) Item Designation TIG menu to set the TIG parameters for TIG DC and TIG AC Rod electrode menu to set the rod electrode parameters Ignition settings to set the TIG arc ignition parameters Gas menu to set the shielding gas parameters Component settings to set the cooling unit operating mode...

  • Page 81: Changing Menus And Parameters

    Item Designation Defaults Display: set display backlighting, languages, date & time, display addition- al parameters System: restore factory settings, reset website password, perform R/L alignment System information to display device information such as software version or IP address (assuming the power source is on a network) Scroll bar (for multiple parameters) (10)
  • Page 82 Setting parameters Press the adjusting dial in the selected menu The first parameter in the menu is selected. Turn the adjusting dial and select the desired parameter Press the adjusting dial to change the parameter The background of the parameter value becomes blue. Turn the adjusting dial and set the value of the parameter The change in the parameter value takes effect immediately Press the adjusting dial to select other parameters...

  • Page 83: The Tig Menu

    The TIG menu Parameters in the Tacking TIG DC menu Tacking function – duration of the pulsed welding current at the start of tacking Unit Setting range Off / 0.1 - 9.9 / On Factory setting The pulsed welding current remains in effect until the end of the tacking operation 0.1 - 9.9 s The set time begins with the UpSlope phase.

  • Page 84: Parameters In The Tig Ac Menu

    Duty cycle Ratio of pulse duration to base current duration in cases where a pulse frequency has been set Unit Setting range 10 - 90 Factory setting Starting current time The starting current time specifies the duration of the starting-current phase. Unit Setting range Off / 0.01 - 30.0...
  • Page 85 FP Pulse Pro to set the Base current and Duty cycle parameters Base current Unit % (of main current I Setting range 0 - 100 Factory setting Duty cycle Ratio of pulse duration to base current duration in cases where a pulse frequency has been set Unit Setting range...
  • Page 86 Effect of the AC frequency on the waveshape: I (A) t (s) 60 Hz 120 Hz AC current offset Unit Setting range -70 to +70 Factory setting distant arc with shallow heat input narrow arc, deep heat input, faster welding speed Effect of the AC current offset on the waveshape: I (A) t (s)
  • Page 87 Negative half-wave waveform Unit Setting range Hard rectangle / Soft rectangle / Triangle / Sine Factory setting Hard rectangle Hard rectangle 100% rectangular waveform (stable but loud arc) Soft rectangle Rectangular waveform with decreased edge steepness, for re- ducing noise levels compared to those that occur with the 100% rectangular waveform Triangle Triangular waveform...

  • Page 88: The Mma Menu

    The MMA menu Parameters in the Starting current time rod electrode HotStart menu Unit Setting range 0.0 - 2.0 Factory setting To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart function. Benefits: Improved ignition properties, even when using electrodes with poor ignition proper- ties Better fusion of the base material in the start-up phase, meaning fewer cold-shut de- fects...
  • Page 89 0.1 - 20.0 (drooping characteristic with adjustable slope) Setting 0.1 - 20.0 is used to set a drooping characteristic (5). The setting range ex- tends from 0.1 A / V (very steep) to 20 A / V (very flat). Setting a flat characteristic (5) is only advisable for cellulose electrodes. NOTE! When setting a flat characteristic (5), set the arc-force dynamic to a higher value.
  • Page 90 For characteristics (5) and (6), if a constant value is set for I , the welding current (I) will also become smaller or larger depending on the welding voltage. Break-voltage Welding voltage limitation Unit Setting range 20 - 90 Factory setting The arc length depends on the welding voltage.

  • Page 91: Ignition Settings

    Ignition settings Ignition setting HF ignition parameters Unit Setting range On / Off / External Factory setting High frequency ignition at start of welding is activated No high frequency ignition at start of welding. In this case, welding starts with touchdown ignition. External Start with external arc starters, e.g.
  • Page 92 Arc break time Time until safety cut-out following an arc break If, following an arc break, there is no current flow within the time specified here, the power source cuts out automatically. To start the welding process again, press any key on the control panel or the torch trigger. Unit Setting range 0.00 - 2.00...

  • Page 93: The Gas Menu

    The gas menu Parameters in the Gas pre-flow Gas menu Duration of gas pre-flow Unit Setting range 0.0 - 9.9 Factory setting Gas post-flow Duration of gas post-flow Unit Setting range 0 - 60 Factory setting...

  • Page 94: The Components Menu

    The components menu Parameters in the Cooling unit operating mode Components for controlling a cooling unit menu Unit Setting range eco / auto / on / off Factory setting auto auto Cooling unit is switched off 2 minutes after the end of welding Cooling unit is ON all the time Cooling unit is OFF all the time The coolant pump starts to run when welding starts and is elec-...

  • Page 95: The Job Menu

    The Job menu Save job When jobs are saved, the welding process and all the settings in the welding parameters and the respective set-up menus are saved. When creating jobs you MUST therefore also take into account the welding parameters in the set-up menus.

  • Page 96: Loading A Job

    Loading a job The Load job function can be used to load the data for a saved job or an EasyJob into the welding parameters. The relevant data from the job can be changed, saved as a new job or EasyJob, or used to start welding.

  • Page 97: Defaults

    Defaults Overview Display Backlighting Languages Time & Date Display additional parameters System Reset to factory settings ... Reset website password ... Perform R/L alignment Display - back- Backlighting lighting to set the brightness of the display Unit Setting range 0 - 10 Factory setting Adjust backlighting: Defaults / Display / Backlighting...

  • Page 98: Display - Display Additional Parameters

    Setting the date & time: Defaults / Display / Time & Date Select the desired parameter (turn adjusting dial and press) Modify parameter by turning the adjusting dial Confirm the modified parameter by pressing the adjusting dial Press the menu key to exit the date and time settings Display - Display In the case of welding parameters 1 - 3, this function enables additional parameters or set- additional param-...

  • Page 99: Reset Website Password

    Reset website Defaults / System / Reset website password password Press the adjusting dial A confirmation prompt asking whether you really want to reset the website password is dis- played. Select yes by turning the adjusting dial Press the adjusting dial to reset the website password The website password is reset to the factory setting: User name = admin Password = admin...
  • Page 100 Performing R/L alignment Defaults / System / Perform R/L alignment Press the adjusting dial The current values are displayed Select "More" (turn and press adjusting dial) The second R/L alignment screen is displayed. Follow the instructions displayed on the screen Select "More"...

  • Page 101: System Informations

    System informations Device informa- The following data is displayed in device information: tion Image version Software version Hardware version IP address(es) System run time in h Arc time in h Open source licences Turn the adjusting dial to select open source licences Press the adjusting dial The open source licences used are displayed.

  • Page 103: Smartmanager - The Power Source Website

    SmartManager - The power source website...

  • Page 105: Smartmanager - The Power Source Website

    Factory setting: User name = admin Password = admin The power source SmartManager is displayed. Fronius Click on the Fronius logo to open the Fronius homepage: www.fronius.com Changing pass- By clicking this symbol word / logging off the user password can be changed...

  • Page 106: Language

    Language The languages available for SmartManager can be displayed by clicking on this symbol. The current language selection is displayed next to the symbol. To change the language, click on the one you would like.

  • Page 107: Current System Data

    Current system data Current system The welding system's current data is displayed, e.g. data Welding process ACTUAL or HOLD Welding current Welding voltage Current arc power Current arc energy Shielding gas flow rate Arc time Total operating hours Set values are displayed, as well as actual values and hold values for the welding current and welding voltage.

  • Page 108: Job-Data

    Job-Data Job data The Job data entry is only displayed if the FP Job function package is present in the power source. In the "Job data" entry, existing welding system jobs can be viewed existing welding system jobs can be optimised jobs stored externally can be transferred to the welding system existing jobs in the welding system can be exported as a PDF * or CSV file Job overview...

  • Page 109: Importing A Job

    Creating a new job Click on "Create new job" Enter job data Click on "OK" to apply the new job Importing a job This function enables previously exported jobs to be transferred into the welding system. Click on "Search Job-file" Select desired job file Individual jobs can be selected and new job numbers assigned in the preview of the job import list.

  • Page 110: Backup & Restore

    Backup & Restore General In the backup & restore entry all welding system data can be saved as a backup (e.g. current parameter settings, jobs, defaults, etc.), any existing backups can be restored to the welding system Backup & Restore Starting backup Click on "Start backup"...

  • Page 111: Overview

    Overview Overview In the overview entry, welding system components and options are displayed with all avail- able information, e.g. firmware version, item number, serial number, production date, etc. Expanding / re- Clicking on the button "Expand all groups" displays further details for the indi- ducing all groups vidual system components.

  • Page 112: Update

    To restart the power source, click on "Yes" The power source restarts; the display goes black for a short time. The Fronius logo is shown on the power source display during the restart. Once the update has been completed successfully, a confirmation and the current firmware version are displayed.

  • Page 113: Function Packages

    Function Packages Function packag- In the Function Packages entry, the function packages present on the power source are displayed. New function packages can be uploaded. Installing a func- Organise and save a function package tion package Click on "Search function package file" Select the desired function package file (*.xml) Click on "Open"...

  • Page 114: Screenshot

    Screenshot Screenshot In the Screenshot entry, a digital image of the power source display can be created at any time, irrespective of the navigation or set values. Click on "Create screenshot" to capture a screenshot of the display A screenshot of the currently displayed settings is created. Different functions are available for saving the screenshot depending on the browser used;...

  • Page 115: Troubleshooting And Maintenance

    Troubleshooting and maintenance...

  • Page 117: Troubleshooting

    Troubleshooting General The digital power sources are equipped with an intelligent safety system. This means that apart from the fuse for the coolant pump, it has been possible to dispense with fuses en- tirely. After a possible malfunction or error has been remedied, the power source can be put back into normal operation again without any fuses having to be replaced.
  • Page 118 No welding current Mains switch is ON, overtemperature indicator is lit up Cause: Overload Remedy: Check duty cycle Cause: Thermostatic safety cut-out has tripped Remedy: Wait until the power source automatically comes back on after the end of the cooling phase Cause: The fan in the power source is faulty Remedy:...
  • Page 119 Poor weld properties Cause: Incorrect welding parameters Remedy: Check the settings Cause: Grounding (earthing) connection is incorrect Remedy: Check the grounding (earthing) connection and terminal for correct polarity The welding torch becomes very hot Cause: The dimensions of the welding torch are inadequate Remedy: Observe the duty cycle and loading limits Cause:...

  • Page 120: Care, Maintenance And Disposal

    Care, maintenance and disposal General Under normal operating conditions, the power source requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure it remains in a usable condition for many years. Safety WARNING! Work that is carried out incorrectly can cause serious injury or dam- age.

  • Page 121: Disposal

    Disposal Dispose of in accordance with the applicable national and local regulations.

  • Page 123: Appendix

    Appendix...

  • Page 125: Technical Data

    Special voltages NOTE! An inadequately dimensioned electrical installation can cause serious damage. The mains cable and its fuse must be dimensioned accordingly. The technical data shown on the rating plate applies. MagicWave 190 MW 190 MW 190 MV Mains voltage U...
  • Page 126 MW 190 MW 190 MV Marks of conformity S, CE S, CE Max. shielding gas pressure 6 bar 6 bar 87.02 psi 87.02 psi Noise emission (L 68 dB(A) 68 dB(A)

  • Page 127: Magicwave 230I

    MagicWave 230i MW 230i MW 230i MV Mains voltage U 1 x 230 V 1 x 120 / 230 V Mains voltage tolerance ± 15 % ± 15 % Mains frequency 50 / 60 Hz 50 / 60 Hz Mains fuse protection (slow-blow) 16 A 16 A (U = 230 V)

  • Page 128: Transtig 230I

    TransTig 230i TT 230i TT 230i MV Mains voltage U 1 x 230 V 1 x 120 / 230 V Mains voltage tolerance ± 15 % ± 15 % Mains frequency 50 / 60 Hz 50 / 60 Hz Mains fuse protection (slow-blow) 16 A 16 A (U = 230 V)

  • Page 129: Explanation Of Footnotes

    Explanation of connected to public mains supply with 230 / 400 V and 50 Hz footnotes D.C. = Duty cycle PCC = interface to the public grid TIG welding MMA welding An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
  • Page 132 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...

This manual is also suitable for:

Magicwave 230iTranstig 230i

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