Fronius TransTig 800 Job Operating Instructions Manual
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Fronius TransTig 800 Job Operating Instructions Manual

Fronius TransTig 800 Job Operating Instructions Manual

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Perfect Welding
/ Perfect Charging /
TransTig 800 Job
TransTig 2200 Job
TransTig 2500 / 3000 Job
TransTig 4000 / 5000 Job
MagicWave 1700 / 2200 Job
MagicWave 2500 / 3000 Job
MagicWave 4000 / 5000 Job
42,0426,0025,EN 020-11052020
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Operating Instructions
TIG Power source
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  • Page 1 TransTig 2500 / 3000 Job TransTig 4000 / 5000 Job MagicWave 1700 / 2200 Job MagicWave 2500 / 3000 Job MagicWave 4000 / 5000 Job 42,0426,0025,EN 020-11052020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

  • Page 3: Table Of Contents

    Contents Safety rules ..............................Explanation of safety notices ........................ General ..............................Proper use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Mains connection ..........................Protecting yourself and others ......................Noise emission values .......................... Danger from toxic gases and vapours ....................Danger from flying sparks ........................
  • Page 4 TransTig2500 / 3000 Job ........................TransTig4000 / 5000 Job ........................Installation and commissioning Minimum equipment needed for welding task.................... General ..............................TIG AC welding............................. TIG DC welding............................. Automated TIG welding ........................MMA welding ............................Before installation and commissioning....................... Safety..............................Utilisation for intended purpose ......................Setup regulations ..........................
  • Page 5 MMA welding ............................. Safety..............................Preparation ............................MMA welding ............................Hotstart function............................ Anti-stick function..........................Job mode ..............................General ..............................Abbreviations ............................Saving a job ............................Retrieving a job ............................. Retrieving jobs on the JobMaster TIG ....................Copying/overwriting a job........................Deleting a job ............................Setup settings Job correction ............................
  • Page 6 Exiting from the DC set-up menu - level 2 .................... 112 Welding parameters in the DC set-up menu - level 2 ................112 Rod electrode setup menu......................... 113 Opening the rod electrode set-up menu ....................113 Changing welding parameters ......................113 Exiting the set-up menu ........................

  • Page 7: Safety Rules

    Safety rules Explanation of DANGER! safety notices 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. ►...

  • Page 8: Environmental Conditions

    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.

  • Page 9: Protecting Yourself And Others

    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 sup- ply company.

  • Page 10: Danger From Toxic Gases And Vapours

    Danger from toxic The fumes produced during welding contain harmful gases and vapours. gases and va- Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the pours 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.

  • Page 11: Risks From Mains Current And Welding Current

    Risks from mains An electric shock is potentially life threatening and can be fatal. current and weld- Do not touch live parts either inside or outside the device. ing current 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.

  • Page 12: Meandering Welding Currents

    Meandering weld- If the following instructions are ignored, meandering welding currents can develop with the ing currents 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.

  • Page 13: Emf Measures

    Supporting measures for avoidance of EMC problems: Mains supply If electromagnetic interference arises despite correct mains connection, addition- al measures are necessary (e.g. use a suitable line filter). 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 Equipotential bonding Earthing of the workpiece...

  • Page 14: Requirement For The Shielding Gas

    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 cool- ant flow or return lines.

  • Page 15: Danger From Escaping Shielding Gas

    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 cylin- ders 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.

  • Page 16: Safety Measures In Normal Operation

    Safety measures Only operate the device when all safety devices are fully functional. If the safety devices in normal opera- are not fully functional, there is a risk of tion 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...

  • Page 17: Disposal

    (e.g. relevant product standards of the EN 60 974 se- ries). 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...

  • Page 19: General Information

    General information...

  • Page 21: General

    General Device concept The MagicWave (MW)1700 / 2200 / 2500 / 3000 / 4000 / 5000 and TransTig (TT) 800 / 2200 / 2500 / 3000 / 4000 / 5000 TIG power sources are completely digitised, micropro- cessor controlled inverter power sources. Their modular design and potential for sys- tem add-ons ensure a high degree of flexi- bility.

  • Page 22: Functional Principle

    Functional princi- 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 re- sponds immediately to any changes.

  • Page 23: Warning Notices On The Device

    Warning notices US power sources come with extra warning notices affixed to the device. The warning no- on the device tices must NOT be removed or painted over. US version of power source with additional warning notices, e.g. MagicWave 2200...

  • Page 24: 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 (10) (11) System add-ons and options Item Description TIG robot welding torch Cold wire feeders with wire drive Power sources Cooling units Trolley with gas cylinder holder...

  • Page 25: Control Elements And Connections

    Control elements and connections...

  • Page 27: Description Of The Control Panels

    Description of the control panels General The key feature of the control panel is the logical way in which the control elements 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.

  • Page 28: Overview

    Overview "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: MW 1700 / 2200 TT 800 / 2200 MW 2500 / 3000 TT 2500 / 3000 MW 4000 / 5000 TT 4000 / 5000...

  • Page 29: Magicwave Control Panel

    MagicWave control panel MagicWave con- trol panel (16) (15) (14) (13) (12) (11) (10) No. Function Special indicators Pulse indicator lights up when the F-P setup parameter has been set to a pulse frequency Spot welding indicator lights up when the SPt setup parameter has been set to a spot welding time Tacking indicator lights up when the tAC setup parameter has been set to a period of time Electrode overload indicator...
  • Page 30 No. Function 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 I .
  • Page 31 No. Function mm indicator lights up when the Fdb setup parameter has been selected 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 Job mode:...
  • Page 32 No. Function (11) Welding parameters overview The welding parameters overview contains the most important welding parameters to be used when welding. The sequence of welding parameters follows a clothes- line structure. Use the left and right welding parameter selection buttons to navigate within the welding parameters overview.
  • Page 33 No. Function Job N In Job mode for retrieving welding parameter records stored under job numbers. Electrode diameter used in TIG welding to enter the diameter of the tungsten electrode (12) Adjusting dial for altering welding parameters. If the indicator on the adjusting dial lights up, then the selected welding parameter can be altered.

  • Page 34: Transtig Control Panel

    TransTig control panel TransTig control panel (15) (14) (13) (12) (11) (10) No. Function Special indicators Pulse indicator lights up when the F-P setup parameter has been set to a pulse frequency Spot welding indicator lights up when the SPt setup parameter has been set to a spot welding time Tacking indicator lights up when the tAC setup parameter has been set to a period of time Electrode overload indicator...
  • Page 35 No. Function 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 I .
  • Page 36 No. Function mm indicator lights up when the Fdb setup parameter has been selected Mode button for selecting the mode 2-step mode 4-step mode Job mode MMA welding When a mode is selected, the LED on the relevant symbol lights up. Right parameter selection button for selecting welding parameters within the welding parameters overview (10) When a welding parameter is selected, the LED on the relevant parameter symbol...
  • Page 37 No. Function Reduced current I for TIG 4-step mode and TIG special 4-step mode DownSlope t down when TIG welding, the period over which the current is decreased from the specified main current I to the final current I The DownSlope t is saved separately for 2-step and 4-step modes.
  • Page 38 No. Function (16) Keylock switch (option for TT 2500 / 3000 / 4000 / 5000) When the key is in the horizontal position, all parameters and functions are disabled with the exception of the currently selected parameter or function. (16) Keylock switch position IMPORTANT! The functions available on the control panel of system components are restricted in the same way as those on the control panel of the power source.

  • Page 39: Key Combinations - Special Functions

    Key combinations - special functions General The following functions can be called up by pressing buttons simultaneously or repeatedly on the MagicWave and TransTig control panels. Keylock To activate the keylock: while pressing and holding the Store button, press the right param- eter selection button The lockout message "CLo|SEd"...

  • Page 40: Connections, Switches And Mechanical Components

    Connections, switches and mechanical components MagicWave 1700 / 2200 Job MagicWave 1700 / 2200 Job - front MagicWave 1700 / 2200 Job - rear No. Function Welding torch connection for connecting: the TIG welding torch the electrode cable for manual metal arc welding LocalNet connection standardised connection socket for system add-ons (e.g.

  • Page 41: Magicwave2500 / 3000 Job

    MagicWave 2500 / 3000 Job MagicWave 2500 / 3000 Job - front MagicWave 2500 / 3000 Job - rear No. Function Grounding (earthing) cable connection for connecting the grounding (earthing) cable LocalNet connection standardised connection socket for system add-ons (e.g. remote control, JobMas- ter TIG welding torch, etc.) Handle Torch control connection...

  • Page 42: Magicwave4000 / 5000 Job

    MagicWave 4000 / 5000 Job (5) (4) (3) MagicWave 4000 / 5000 Job - front MagicWave 4000 / 5000 Job - rear No. Function Mains switch for switching the power source on and off Welding torch connection for connecting the TIG welding torch Electrode holder connection for connecting the electrode cable for manual metal arc welding Torch control connection...

  • Page 43: Transtig800 / 2200 Job

    TransTig 800 / 2200 Job TransTig 800 / 2200 Job - front TransTig 800 / 2200 Job - rear No. Function (+) current socket with bayonet latch for connecting the grounding (earthing) cable when TIG welding the electrode cable or grounding (earthing) cable during MMA welding (de- pending on the type of electrode) LocalNet connection standardised connection socket for system add-ons (e.g.

  • Page 44: Transtig2500 / 3000 Job

    TransTig 2500 / 3000 Job TransTig 2500 / 3000 Job - front TransTig 2500 / 3000 Job - rear No. Function (+) current socket with bayonet latch for connecting the grounding (earthing) cable when TIG welding the electrode cable or grounding (earthing) cable during MMA welding (de- pending on electrode type) LocalNet connection standardised connection socket for system add-ons (e.g.

  • Page 45: Transtig4000 / 5000 Job

    TransTig 4000 / 5000 Job TransTig 4000 / 5000 Job - front TransTig 4000 / 5000 Job - rear No. Function (+) current socket with bayonet latch for connecting the grounding (earthing) cable when TIG welding the electrode cable or grounding (earthing) cable during MMA welding (de- pending on the type of electrode) LocalNet connection standardised connection socket for system add-ons (e.g.

  • Page 47: Installation And Commissioning

    Installation and commissioning...

  • Page 49: 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 50: Before Installation And Commissioning

    Before installation and commissioning Safety WARNING! Danger due to incorrect operation and incorrectly performed work. This can result in severe personal injury and damage to property. ► All the work and functions described in this document must only be carried out and used by trained and qualified personnel.

  • Page 51: Generator-Powered Operation (Mw 1700 / 2200, Tt 800 / 2200)

    CAUTION! An inadequately dimensioned electrical installation can cause serious damage. ► The mains lead and its fuse must be dimensioned to suit the local power supply. The technical data shown on the rating plate applies. Generator-pow- The MW 1700 / 2200 and TT 800 / 2200 power sources are generator-compatible, provid- ered operation ed that the maximum apparent power delivered by the generator is at least 10 kVA.

  • Page 52: Connecting Up The Mains Cable On Us Power Sources

    Connecting up the mains cable on US power sourc- General The US power sources are supplied without a mains cable. A mains cable appropriate for the connection voltage must be fitted prior to commissioning. A strain-relief device for a cable cross-section AWG 10 is installed on the power source. Strain-relief devices for larger cable cross-sections must be designed accordingly.

  • Page 53: Replacing The Strain-Relief Device

    Undo the screws (2 x) and clamping nut (size 30) on the strain-relief device Insert the mains cable into the strain- relief device NOTE! Push the mains cable in far enough to make it possible to connect the ground conductor and the phase conductors to the block terminal properly.
  • Page 54 Insert the hexagon nut (size 50 mm) into the holding plate NOTE! To ensure a reliable earth connection to the housing of the power source, the points on the hexagon nut must be fa- cing the holding plate. Screw the front of the large strain-relief device into the hexagon nut (size 50 mm).

  • Page 55: Start-Up

    Start-up Safety WARNING! An electric shock can be fatal. If the device is plugged into the mains during installation, there is a high risk of very serious injury and damage. ► Only carry out work on the device if the mains switch is in the "O" position. ►...

  • Page 56: Establishing A Ground (Earth) Connection To The Workpiece

    Secure the gas cylinder Take the protective cap off the gas cylinder Briefly open the gas cylinder valve to remove any dust or dirt Check the seal on the pressure regulator Screw the pressure regulator onto the gas cylinder and tighten it When using a TIG welding torch with an integral gas connector: Use the gas hose to connect the pressure regulator to the shielding gas connection on the rear of the power source...

  • Page 57: Welding

    Welding...

  • Page 59: Tig Modes

    TIG modes 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 under- stood these Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules! See the "The Setup menu"...

  • Page 60: 2-Step Mode

    Main current phase (welding-current Reduced current phase: intermediate low- phase): uniform thermal input into the ering of the welding current in order to pre- base material, whose temperature is vent any local overheating of the base raised by the advancing heat material Gas post-flow time at maximum welding Gas post-flow time at minimum welding...

  • Page 61: Spot Welding

    Spot welding If a value has been set for the SPt set-up parameter, 2-step mode will have the spot weld- ing mode function. The special spot welding indicator on the control panel will light up. Welding: briefly pull back the torch trigger The welding time corresponds to the value set for the SPt set-up parameter.

  • Page 62: 4-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 End of welding: Release the torch trigger NOTE! For 4-step mode, the special 4-step (SFS) setup parameter must be set to "OFF".

  • Page 63: Special 4-Step Mode: Variant 1

    Special 4-step Variant 1 of special 4-step mode is activated, when the special 4-step (SFS) set-up param- mode: eter-is set to "1". variant 1 Briefly pull back the torch trigger to start intermediate lowering to the specified reduced cur- rent I .

  • Page 64: Special 4-Step Mode: Variant 3

    Special 4-step Variant 3 of special 4-step mode is activated when the special 4-step mode (SFS) set-up mode: parameter -is set to "3". variant 3 In variant 3, push forward and hold the torch trigger to start intermediate lowering. Release the torch trigger to resume the main current I When the torch trigger is pulled back, welding ends immediately without downslope and final current.

  • Page 65: Special 4-Step Mode: Variant 5

    Special 4-step Variant 5 of the special 4-step mode is activated when the SFS set-up parameter is set to mode: "5". variant 5 Variant 5 allows the welding current to be increased and reduced without an up/down weld- ing torch. The longer the torch trigger is held in the forward position during welding, the more the welding current increases (up to the maximum).
  • Page 66 < 0,5 s < 0,5 s > 0,5 s < 0,5 s < 0,5 s down Special 4-step mode: variant 6...

  • Page 67: Cap Shaping And Cap Overloading

    Cap shaping and cap overloading Cap-shaping On MagicWave power sources, an auto- matic cap-shaping function is available for the TIG AC welding process: When the TIG AC welding process is selected, activate automatic cap- shaping The ideal cap for the specified diame- ter of the tungsten electrode is formed during welding start-up.

  • Page 68: Tig Welding

    TIG welding 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 under- stood these Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules! WARNING! An electric shock can be fatal.
  • Page 69 Main current I Unit Setting range MW 1700 Job..3 - 170 TT 800 Job ..0.5 - 80.0 MW 2200 Job..3 - 220 TT 2200 Job ... 3 - 220 MW 2500 Job..3 - 250 TT 2500 Job ... 3 - 250 MW 3000 Job..

  • Page 70: Preparation

    Preparation Plug in the mains plug CAUTION! Risk of injury and damage from electric shock. As soon as the mains switch is in the "I" position, the tungsten electrode of the welding torch is live. ► Ensure that the tungsten electrode does not touch any persons or electrically conduc- tive or earthed parts (e.g.
  • Page 71 Press the Gas-test button The test gas flow lasts for a maximum of 30 seconds. Press the button again to stop the gas flow prematurely. Turn the adjusting screw on the underside of the pressure regulator until the ma- nometer indicates the desired shielding gas flow rate For long hosepacks and if condensation forms when the device is left unused in a cold environment: pre-purge shielding gas - set the GPU setup parameter to a time value...

  • Page 72: Igniting The Arc

    Risk of injury due to shock caused by electric shock (HF ignition) Although Fronius devices comply with all relevant standards, high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances. ► Use prescribed protective clothing, especially gloves! ►...

  • Page 73: Touchdown Ignition

    Increase the tilt angle of the torch and actuate the torch trigger according to the mode you have selected The arc ignites without the electrode tou- ching down on the workpiece. Tilt the torch back into the normal posi- tion Carry out welding Touchdown igni- If the HFt setup parameter is set to OFF, HF ignition is deactivated.

  • Page 74: End Of Welding

    Actuate the torch trigger Shielding gas flows. Gradually tilt the welding torch up until the tungsten electrode touches the workpiece Raise the welding torch and move it into its normal position The arc ignites. Carry out welding End of welding Depending on the set mode, finish welding by releasing the torch trigger Wait for the set gas post-flow and hold welding torch in position over the end of the weld seam...

  • Page 75: Special Functions And Options

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

  • Page 76: Tacking Function

    Mode of operation of TIG pulsing when TIG DC welding is selected: 1/F-P down TIG pulsing - welding current curve Legend: Starting current Pulse frequency *) Final current Duty cycle Upslope Ground current Downslope Main current Down *) (1/F-P = time interval between two pulses) Tacking function The tacking function is available for the TIG DC welding process.

  • Page 77: Tig Cold-Wire Welding

    Legend: Duration of pulsed welding current for the tacking process Starting current Final current UpSlope DownSlope Down Main current NOTE! The following points apply to the pulsed welding current: ► The power source automatically regulates the pulsing parameters as a function of the specified main current I ►...
  • Page 78 1/F-P down Legend: Starting current Duty cycle Final current Ground current Upslope Main current Downslope Pulse frequency Down Fd.1 Wire feed speed 1 Fd.2 Wire feed speed 2 Delay in the start of wirefeeding Delay in the end of wirefeeding from the beginning of main current from the end of main current phase I...

  • Page 79: Mma Welding

    MMA welding 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 under- stood these Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules! WARNING! An electric shock can be fatal.

  • Page 80: Hotstart Function

    NOTE! If the MMA welding mode is selected, the welding voltage will only be available after a 3-second delay. Only for MagicWave: press the process button to select the required welding process: MMA AC welding process MMA DC- welding process MMA DC+ welding process NOTE! The TransTig power source has no switchover facility between the MMA DC- and...

  • Page 81: Anti-Stick Function

    Legend I (A) Hot-current time, 0-2 s, factory setting: 0.5 s HotStart current, 0-200%, factory setting 150% Main current = set welding current Function: during the specified hot-current time (Hti), the welding current I is increased to the HotStart current HCU. t (s) To activate the hotstart function, the HotS- tart current HCU must be >...

  • Page 82: Job Mode

    Job mode General Job mode enhances the quality of welding engineering fabrication, both in manual and au- tomated welding. Up to 100 common jobs (operating points) can be reproduced in Job mode, avoiding the need to document welding parameters by hand. Another advantage is that the power source is immediately ready for welding with the de- sired parameters.

  • Page 83: Retrieving A Job

    NOTE! If the selected program location already has a job stored in it, the existing job will be overwritten by the new one. This action cannot be undone. The left-hand digital display reads “Pro” - the job is stored in the program location you have just selected.

  • Page 84: Copying/Overwriting A Job

    Only program locations that have already been programmed can be selected using the JobMaster TIG welding torch. Thus related jobs can be grouped when they are saved by leaving a vacant program location after every job group. When retrieving jobs using the JobMaster TIG welding torch, the Mode button (1) allows you to switch between the jobs in a group.

  • Page 85: Deleting A Job

    Press and hold the Store button NOTE! If the selected program location already has a job stored in it, the existing job will be overwritten by the new one. This action cannot be undone. The left-hand digital display reads "Pro" - the job is copied to the program location you have just selected.

  • Page 87: Setup Settings

    Setup settings...

  • Page 89: Job Correction

    Job correction General In the Job correction menu, setup parameters can be adapted to the specific requirements of individual jobs. Opening the Job Using the Mode button, select "Job mode". correction menu Press and hold the Store button Press the Mode button The power source is now in the Job correction menu.
  • Page 90 I (current)-Starting - Starting current I Unit % (of main current I Setting range 0 - 200 Factory setting UpSlope t - time for the transition from the starting current I to the main current I Unit Setting range 0,0 - 9,9 Factory setting I (current)-1 - main current I Unit...
  • Page 91 NOTE! Switching over from one job to the next without interrupting welding is only possible with a JobMaster TIG welding torch, robot interface or field bus. Gas pre-flow time Unit Setting range 0 - 9,9 Factory setting Gas-Low - gas post-flow time at minimum welding current (minimum gas post-flow time) Unit Setting range...
  • Page 92 I (current)-Ground - Ground current Unit % (of main current I Setting range 0 - 100 Factory setting trigger - Mode selection Unit Setting range 2t / 4t 2t = 2-step mode 4t = 4-step mode Spot welding time Unit Setting range OFF / 0.01 - 9.9 Factory setting...
  • Page 93 AC current offset Unit Setting range -70 to +70 Factory setting For further information on the Io parameter, see the AC / polarity reversal set-up menu. Balance - Relationship between fusing power and cleaning action Unit Setting range -5 to +5 Factory setting = highest fusing power, lowest cleaning action = highest cleaning action, lowest fusing power...
  • Page 94 dynamic - arc force dynamic correction Unit Setting range 0 - 100 Factory setting For further information on the dYn parameter, see the rod electrode set-up menu. Hot-Start current Unit Setting range 0 - 200 Factory setting delay time 1 - time by which the start of wirefeeding is delayed after the beginning of main current phase I (cold wire-feed unit option) Unit...

  • Page 95: The Setup Menu

    The Setup menu General The set-up menu provides easy access to the knowledge base in the power source and to additional functions. The set-up menu can be used to make simple adjustments of the welding parameters to suit the various job settings. The Set-up menu contains all the set-up parameters that have an immediate effect on the welding process.

  • Page 96: Shielding Gas Setup Menu

    Shielding gas setup menu General The Protective gas shield set-up menu provides easy access to the protective gas shield settings. Opening the Pro- Press and hold the Store button tective gas shield set-up menu Press the Gas test button The power source is now in the Protective gas shield set-up menu. The last welding parameter selected is displayed.
  • Page 97 The value set for G-H only applies if the maximum welding current actually has been set. The actual value is derived from the present welding current. For a medium welding cur- rent, for example, the actual value will be half of the value set for G-H. IMPORTANT! The values set for the G-L and G-H set-up parameters are added together.

  • Page 98: Tig Setup Menu

    TIG setup menu Opening the TIG Press the Mode button to select 2-step mode or 4-step mode set-up menu Press and hold the Store button Press the Mode button The power source is now in the TIG set-up menu. The last welding param- eter selected is displayed.
  • Page 99 Tacking function when TIG DC welding is selected: 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 100 time-Starting - Starting current duration Unit Setting range OFF / 0.01 - 9.9 Factory setting The starting current time t-S specifies the duration of the starting-current phase I IMPORTANT! The t-S set-up parameter only applies to 2-step mode. In 4-step mode, the duration of the starting-current phase I is controlled using the torch trigger time-End - Final current duration...
  • Page 101 delay time 1 - time by which the start of wirefeeding is delayed after the beginning of main current phase I (only where an optional cold wire-feed unit is connected) Unit Setting range OFF / 0.1 - 9.9 Factory setting delay time 2 - time by which the start of wirefeeding is delayed after the beginning of main current phase I (only where an optional cold wire-feed unit is connected)

  • Page 102: Tig Setup Menu: Level 2

    TIG setup menu: level 2 Opening the TIG Opening the TIG set-up menu set-up menu: lev- Select "2nd" welding parameter el 2 Press and hold the Store button Press the Mode button The power source is now in the TIG set-up menu - level 2. The last weld- ing parameter selected is displayed.
  • Page 103 Special two step - special 2-step mode for HF ignition after touching the workpiece Unit Setting range OFF / 1 Factory setting Ignition sequence, when the STS parameter is set to 1: Touch the workpiece with the tungsten electrode The short circuit detection on the power source is triggered Lift the tungsten electrode off After 300 ms the gas pre-flow time begins HF ignition is initiated...
  • Page 104 In this case, welding starts with touchdown ignition. CAUTION! Risk of injury due to shock caused by electric shock Although Fronius devices comply with all relevant standards, high-frequency ignition can transmit a harmless but noticeable electric shock under certain circumstances. ► Use prescribed protective clothing, especially gloves! ►...
  • Page 105 Setting - Country-specific setting (Standard/USA) ... Std/US Unit Setting range Std, US (Standard/USA) Factory setting Standard version: Std (measurements: cm/mm) USA version: US (measurements: inches) External parameter - a user-defined welding parameter for the JobMaster TIG welding torch or robot interface (both optional). A freely selectable welding parameter is available both on the JobMaster TIG welding torch and for the robot interface.
  • Page 106 Feeder control - Wirefeeder cut-out (wire end sensor option) Unit Setting range OFF/ON/noE Factory setting The power source halts the wirefeeder when the wire end sensor is triggered. "Err|056" appears on the display. When the wire end sensor is triggered, the power source only halts the wirefeeder after the current weld seam has been com- pleted.

  • Page 107: Ac/Polarity Reversal Set-Up Menu

    AC/polarity reversal set-up menu General This set-up menu is only available with MagicWave power sources. Opening the AC/ Press the Process button to select the AC welding process polarity reversal set-up menu Press and hold the Store button Press the Process button The power source is now in the AC/polarity reversal set-up menu.
  • Page 108 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 set-up menu - level 2: second level of the set-up menu Balance I (A) AC frequency AC current offset t (s) Factory setting: 20% shift to the ne-...

  • Page 109: Ac/Polarity Reversal Set-Up Menu - Level 2

    AC/polarity reversal set-up menu - level 2 General This set-up menu is only available with MagicWave power sources. Opening the AC/ Open the AC/polarity reversal set-up menu polarity reversal Select "2nd" welding parameter set-up menu - lev- el 2 Press and hold the Store button Press the Process button The power source is now in the set-up menu - level 2 AC/polarity reversal.
  • Page 110 negative half-wave Unit Setting range tri / Sin / rEc / OFF Factory setting Triangular waveform Sine ... sinusoidal waveform (standard setting for a low-noise, stable arc) Rectangular waveform with decreased edge steepness, for re- ducing noise levels compared to those that occur with the 100% rectangular waveform 100% rectangular waveform (stable but loud arc) Phase adjustment of the mains connection of two power sources for simultaneous AC...

  • Page 111: Dc Set-Up Menu

    DC set-up menu General This set-up menu is only available with MagicWave power sources. Opening the DC Press the Process button to select the DC welding process set-up menu Press and hold the Store button Press the Process button The power source is now in the DC set-up menu. The last welding param- eter selected is displayed.

  • Page 112: Dc Set-Up Menu - Level 2

    DC set-up menu - level 2 General This set-up menu is only available with MagicWave power sources. Opening the DC Open the DC set-up menu set-up menu - lev- Select "2nd" welding parameter el 2 Press and hold the Store button Press the Process button The power source is now in the DC set-up menu - level 2.

  • Page 113: Rod Electrode Setup Menu

    Rod electrode setup menu Opening the rod Press the Mode button to select the MMA welding mode electrode set-up menu Press and hold the Store button Press the Mode button The power source is now in the rod electrode set-up menu. The last weld- ing parameter selected is displayed.
  • Page 114 dYn - arc force dynamic correction Unit Setting range 0 - 100 Factory setting soft, low-spatter arc harder, more stable arc To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force dynamic. Functional principle: at the instant of droplet transfer or when a short circuit occurs, there is a momentary rise in amperage.

  • Page 115: Rod Electrode Setup Menu: Level 2

    Rod electrode setup menu: level 2 Opening the rod Open the rod electrode set-up menu electrode set-up Select "2nd" welding parameter menu level 2 Press and hold the Store button Press the Mode button The power source is now in the rod electrode set-up menu - level 2. The last welding parameter selected is displayed.
  • Page 116 Electrode line - characteristic selection Unit Setting range con or 0.1 - 20 or P Factory setting Load line for rod electrode Load line for rod electrode where arc length is in- con - 20 A / V U (V) creased Load line for rod electrode where arc length is re- duced...
  • Page 117 Load line for rod electrode Load line for rod electrode where arc length is in- creased U (V) Load line for rod electrode where arc length is re- duced Characteristic where "CON" parameter is select- ed (constant welding current) Characteristic where "0.1 - 20" parameter is se- lected (drooping characteristic with adjustable slope) Characteristic where "P"...
  • Page 118 NOTE! If, during welding, you often find that the welding operation is ended unintentionally, increase the value of the Uco parameter.

  • Page 119: Measuring Welding Circuit Resistance R

    Measuring welding circuit resistance r General Measuring the welding circuit resistance "r" provides information on the overall resistance of the torch hosepack, welding torch, workpiece and grounding (earthing) cable. If an increased welding circuit resistance is detected, e.g. after changing the torch, this may mean that the following components are faulty: Torch hosepack Welding torch...

  • Page 120: Displaying Welding Circuit Inductivity L

    Displaying welding circuit inductivity L General informa- The way that the hosepack is arranged has a very significant effect on the weld properties. tion on welding Particularly with pulsed-arc welding and AC welding, a high welding circuit inductivity may circuit inductivity occur, depending on the length of the hosepack and on the way that it is arranged.

  • Page 121: Troubleshooting And Maintenance

    Troubleshooting and maintenance...

  • Page 123: 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 124 tP1 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the primary circuit of the power source Remedy: Allow power source to cool down tP2 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the primary circuit of the power source Remedy: Allow power source to cool down tP3 | xxx...
  • Page 125 tSt | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the power source control circuit Remedy: Allow power source to cool down Err | 049 Cause: Phase failure in power supply Remedy: Check the mains fuse, the mains lead and the mains plug Err | 050 Cause: Indirect symmetry error...
  • Page 126 dSP | Exx Cause: Fault in the central control and regulation unit Remedy: Contact After-Sales Service dSP | Sy Cause: Fault in the central control and regulation unit Remedy: Contact After-Sales Service dSP | nSy Cause: Fault in the central control and regulation unit Remedy: Contact After-Sales Service r | E30...

  • Page 127: Power Source - Troubleshooting

    Power source - Power source does not function troubleshooting Mains switch is on, but indicators are not lit up Cause: There is a break in the mains lead; the mains plug is not plugged in Remedy: Check the mains lead, ensure that the mains plug is plugged in Cause: Mains socket or mains plug faulty Remedy:...
  • Page 128 No protective gas shield All other functions are OK Cause: Gas cylinder is empty Remedy: Change the gas cylinder Cause: Gas pressure regulator is faulty Remedy: Change the gas pressure regulator Cause: Gas hose is not fitted or is damaged Remedy: Fit or change the gas hose Cause:...

  • Page 129: 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 may result in serious injury or damage to prop-...

  • Page 130: Every 6 Months

    Every 6 months CAUTION! Danger due to the effect of compressed air. This can result in damage to property. ► Do not bring the air nozzle too close to electronic components. Dismantle device side panels and clean inside of device with dry, reduced com- pressed air If a lot of dust has accumulated, clean the cooling air ducts WARNING!

  • Page 131: Appendix

    Appendix...

  • Page 133: Technical Data

    Technical data Special voltages CAUTION! An inadequately dimensioned electrical installation can cause serious damage. ► The mains lead and its fuse must be dimensioned accordingly. The technical data shown on the rating plate applies. MagicWave MW 1700 Job MW 2200 Job 1700 / 2200 Job Mains voltage 230 V...

  • Page 134: Magicwave2500 / 3000 Job

    MagicWave MW 2500 Job MW 3000 Job 2500 / 3000 Job Mains voltage 3 x 400 V 3 x 400 V Mains voltage tolerance ± 15 % ± 15 % Mains frequency 50/60 Hz 50/60 Hz Mains fuse protection (slow-blow) 16 A 16 A Mains connection...

  • Page 135: Magicwave4000 / 5000 Job

    MW 2500 Job MV MW 3000 Job MV Primary continuous power (100% d.c. 3 x 400 - 460 V 4.8 kVA 5.1 kVA 3 x 200 - 240 V 4.4 kVA 4.9 kVA 1 x 200 - 240 V 3.9 kVA 4.3 kVA Cos phi 0,99...

  • Page 136: Magicwave 4000 / 5000 Job Mv

    MW 4000 Job MW 5000 Job Mains fuse protection (slow-blow) 35 A 35 A Mains connection Restrictions possible Restrictions possible Primary continuous power (100% d.c. 15.5 kVA 17.9 kVA Cos phi 0,99 0,99 Welding current range 3 - 400 A 3 - 500 A Electrode 10 - 400 A...

  • Page 137: Transtig800 / 2200 Job

    MW 4000 Job MV MW 5000 Job MV Welding current at 10 min/40 °C (104 °F) 40% d.c. 500 A 10 min/40 °C (104 °F) 45% d.c. 400 A 10 min/40 °C (104 °F) 60% d.c. 360 A 440 A 10 min/40 °C (104 °F) 100% d.c.

  • Page 138: Transtig2500 / 3000 Job

    TT 800 Job TT 2200 Job Striking voltage (U 9.0 kV 9.5 kV The arc striking voltage is suitable for manual operation. Degree of protection IP 23 IP 23 Type of cooling Insulation class EMC emission class (in accordance with EN/IEC 60974-10) Dimensions L x W x H (with handle) 485 / 180 / 344 mm 485 / 180 / 390 mm...

  • Page 139: Transtig 2500 / 3000 Job Mv

    TT 2500 Job TT 3000 Job Weight 24.2 kg 24.2 kg 53.35 lb. 53.35 lb. Mark of conformity S, CE S, CE TransTig TT 2500 Job MV TT 3000 Job MV 2500 / 3000 Job Mains voltage 3 x 200 - 240 V 3 x 200 - 240 V 3 x 400 - 460 V 3 x 400 - 460 V...

  • Page 140: Transtig4000 / 5000 Job

    TT 2500 Job MV TT 3000 Job MV Degree of protection IP 23 IP 23 Type of cooling Insulation class EMC emission class (in accordance with EN/IEC 60974-10) Dimensions L x W x H (with handle) 560 / 250 / 435 mm 560 / 250 / 435 mm 22.0 / 9.8 / 17.1 in.

  • Page 141: Transtig 4000 / 5000 Job Mv

    TransTig TT 4000 Job MV TT 5000 Job MV 4000 / 5000 Job Mains voltage 3 x 200 - 240 V 3 x 200 - 240 V 3 x 380 - 460 V 3 x 380 - 460 V Mains voltage tolerance ±...

  • Page 142: Terms And Abbreviations Used

    Terms and abbreviations used General The terms and abbreviations listed here are used in connection with functions that are ei- ther included in the standard scope of supply or that are available as optional extras. Terms and abbre- viations A - C AC frequency Automatic current switch Switchover to main current...

  • Page 143: Terms And Abbreviations F

    Electrode diameter When "Eld" is selected for the external parameter "E-P", the electrode diameter on the JobMaster TIG welding torch can be adjusted. Electrode line Characteristic selection (MMA welding) External parameter Freely selectable welding parameter for the JobMaster TIG welding torch Terms and abbre- viations F Factory...

  • Page 144: Terms And Abbreviations I - P

    Hot-start current (MMA welding) High frequency time High frequency ignition Hot-current time (MMA welding) Terms and abbre- viations I - P I (current) - End Final current I (current) - Ground Ground current AC current offset I (current) - Starting Starting current Ignition time-out L (inductivity)
  • Page 145 Special four-step mode Spot welding time Special Two Step Special 2-step mode for HF ignition after touching the workpiece Tacking function time - End current Final current duration time - Starting current Starting current duration U (Voltage) cut-off Welding voltage limitation during MMA welding Makes it possible to stop the welding pro- cess by slightly raising the rod electrode.
  • Page 148 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations.

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