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Summary of Contents for Fronius TransTig 800
- Page 1 Operating Instructions TransTig 800 TransTig 2200 TransTig 2500 / 3000 TransTig 4000 / 5000 MagicWave 1700 / 2200 MagicWave 2500 / 3000 MagicWave 4000 / 5000 Operating instructions 42,0426,0027,EN 023-21092022...
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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 Risks from mains current and welding current Meandering welding currents EMC Device Classifications EMC measures... -
Page 4: Special 4-Step Mode: Variant
Installation and commissioning Minimum equipment needed for welding task General TIG AC welding TIG DC welding MMA welding Before installation and commissioning Safety Utilisation for intended purpose Setup regulations Mains connection Generator-powered operation (MW 1700 / 2200, TT 2200) Connecting up the mains cable on US power sources General Stipulated mains cables and strain-relief devices Safety... - Page 5 MagicWave 1700 MagicWave 2200 MagicWave 2500 MagicWave 3000 MagicWave 2500 MV MagicWave 3000 MV MagicWave 4000 MagicWave 5000 MagicWave 4000 MV MagicWave 5000 MV TransTig 800 TransTig 2200 TransTig 2500 TransTig 3000 TransTig 2500 MV TransTig 3000 MV TransTig 4000...
- Page 6 TransTig 5000 TransTig 4000 MV TransTig 5000 MV Explanation of footnotes Terms and abbreviations used General Terms and abbreviations A - F Terms and abbreviations G - H Terms and abbreviations I - U...
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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: Proper Use
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... -
Page 9: Mains Connection
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence. Mains connec- Devices with a higher rating may affect the energy quality of the mains due to tion 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... -
Page 10: Noise Emission Values
Noise emission The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) values when idling and in the cooling phase following operation at the maximum per- missible operating point under maximum rated load conditions according to EN 60974-1. -
Page 11: Risks From Mains Current And Welding Current
Never weld close to flammable materials. Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover. A suitable, tested fire extinguisher must be available and ready for use. Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. -
Page 12: Meandering Welding Currents
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. -
Page 13: Emf Measures
If this is the case, then the operator is obliged to take appropriate action to recti- fy the situation. Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be sus- ceptible to interference from the device include: Safety devices Power, signal and data transfer lines... -
Page 14: Requirement For The Shielding Gas
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 al- lowed to cool down before handling. -
Page 15: Danger From Escaping Shielding Gas
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. -
Page 16: Safety Measures In Normal Operation
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. -
Page 17: Safety Inspection
(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. -
Page 18: Copyright
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 19: General Information
General information... -
Page 21: General
General Device concept The MagicWave (MW)1700 / 2200 / 2500 / 3000 / 4000 / 5000 and Tran- sTig (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. -
Page 22: Functional Principle
Functional prin- The central control and regulation unit of the power sources is coupled with a di- ciple gital signal processor. The central control and regulation unit and signal pro- cessor control the entire welding process. During the welding process, the actual data is measured continuously and the device responds 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 on the device warning notices 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 System add-ons and options Item Description Power sources Cooling units Trolley with gas cylinder holder Pedal remote control unit TIG welding torch Standard / Up/Down JobMaster TIG welding torch JobMaster TIG welding torch functions in conjunction with power sources:... -
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 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. -
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 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 (15) (14) (13) (12) (11) (10) Function Left digital display 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 . - Page 30 Function 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;...
- Page 31 Function MMA welding Right parameter selection button for selecting welding parameters within the welding parameters over- view (11) When a welding parameter is selected, the LED on the relevant para- meter symbol lights up. Gas-test button to set the required shielding gas flow rate on the pressure regulator After pressing this button, shielding gas flows for 30 seconds.
- Page 32 Function Final current I for TIG welding Balance used to set the fusing power/cleaning action for TIG AC welding Electrode diameter used in TIG welding to enter the diameter of the tungsten elec- trode (11) Adjusting dial for altering welding parameters. If the indicator on the adjusting dial lights up, then the selected welding parameter can be altered.
- Page 33 Function IMPORTANT! The functions available on the control panel of system components are restricted in the same way as those on the control pan- el of the power source.
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Page 34: Transtig Control Panel
TransTig control panel TransTig control panel (14) (13) (12) (11) (10) Function Left digital display 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 . - Page 35 Function 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;...
- Page 36 Function Welding parameters overview The welding parameters overview contains the most important welding parameters to be used when welding. The sequence of welding para- meters follows a clothesline structure. Use the left and right welding parameter selection buttons to navigate within the welding parameters overview.
- Page 37 Function (11) Welding current indicator for indicating the welding current for the welding parameters Starting current I Welding current I Final current I Before welding commences, the left-hand digital display shows the set value. For I and I , the right-hand digital display also shows the re- spective percentage of the welding current I After welding begins, the welding parameter I is automatically selec-...
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Page 38: 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. Displaying the Display software version: software version, while pressing and holding the Mode button, press the left operating time parameter selection button. -
Page 39: Connections, Switches And Mechanical Components
Connections, switches and mechanical compon- ents MagicWave 1700 / 2200 MagicWave 1700 / 2200 - front MagicWave 1700 / 2200 - rear 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 40: Magicwave2500 / 3000
MagicWave 2500 / 3000 MagicWave 2500 / 3000 - front MagicWave 2500 / 3000 - rear Function Grounding (earthing) cable connection for connecting the grounding (earthing) cable LocalNet connection standardised connection socket for system add-ons (e.g. remote control, JobMaster TIG welding torch, etc.) Handle Torch control connection for connecting the control plug of a conventional welding torch... -
Page 41: Magicwave4000 / 5000
MagicWave 4000 / 5000 (5) (4) (3) MagicWave 4000 / 5000 - front MagicWave 4000 / 5000 - rear 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 for connecting the control plug of a conventional welding torch... -
Page 42: Transtig 2200
TransTig 2200 TransTig 800 / 2200 - front TransTig 800 / 2200 - rear Function (+) current socket with bayonet latch for connecting the grounding (earthing) cable when TIG welding the electrode cable or grounding (earthing) cable during MMA weld-... -
Page 43: Transtig2500 / 3000
TransTig 2500 / 3000 TransTig 2500 / 3000 - front TransTig 2500 / 3000 - rear Function (+) current socket with bayonet latch for connecting the grounding (earthing) cable when TIG welding the electrode cable or grounding (earthing) cable during MMA weld- ing (depending on the type of electrode) LocalNet connection standardised connection socket for system add-ons (e.g. -
Page 44: Transtig4000 / 5000
TransTig 4000 / 5000 TransTig 4000 / 5000 - front TransTig 4000 / 5000 - rear Function (+) current socket with bayonet latch for connecting the grounding (earthing) cable when TIG welding the electrode cable or grounding (earthing) cable during MMA weld- ing (depending on the type of electrode) LocalNet connection standardised connection socket for system add-ons (e.g. -
Page 45: Installation And Commissioning
Installation and commissioning... -
Page 47: 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 equip- ment level will be needed in order to work with the power source. The welding processes and the minimum equipment levels required for the weld- ing task are then described. -
Page 48: 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 49: Generator-Powered Operation (Mw 1700 / 2200, Tt 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 sup- ply. The technical data shown on the rating plate applies. Generator- The MW 1700/2200 and TT 2200 power sources are generator-compatible, powered opera- provided that the maximum apparent power delivered by the generator is at least tion (MW 1700 /... -
Page 50: Connecting Up The Mains Cable On Us Power Sources
Connecting up the mains cable on US power sources General The US power sources are supplied without a mains cable. A mains cable appro- priate 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. - Page 51 Fit ferrules to phase conductors and the ground conductor of the mains cable; crimp ferrules with pliers CAUTION! Risk of short circuits! If ferrules are not used, there is a risk of short circuits between the phase conductors or between phase conductors and the ground conductor. ▶...
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Page 52: Replacing The Strain-Relief Device
Replacing the Remove the left side panel of the strain-relief power source device Remove the screws (2 x) from the existing strain-relief device Pull the existing strain-relief device forwards to detach it Remove the screws for the adapter plate, and remove the adapter plate Insert the hexagon nut (size 50 mm) into the holding plate... -
Page 53: 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 54: 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 con- nection on the rear of the power source... -
Page 55: Welding
Welding... -
Page 57: 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 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 partic- ular the safety rules! See the "The Setup menu"... -
Page 58: 2-Step Mode
Gas post-flow time at maximum Gas post-flow time at minimum welding current welding current 2-step mode Welding: Pull back and hold the torch trigger End of welding: Release the torch trigger G-L / G-H down 2-step mode 4-step mode Welding start-up with starting current I : Pull back and hold the torch trig- Welding with main current I : Release the torch trigger... - Page 59 Special 4-step Variant 4 of the special 4-step mode is activated when the SFS set-up parameter mode: is set to "4". variant 4 Welding start-up and welding: briefly pull back and release the torch trigger - the welding current will rise at the specified upslope value from the starting current I until it reaches the main current value I Push forward and hold the torch trigger for intermediate lowering...
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Page 60: Cap Shaping And Cap Overloading
Cap shaping and cap overloading Cap-shaping On MagicWave power sources, an automatic cap-shaping function is available for the TIG AC welding process: When the TIG AC welding pro- cess is selected, activate auto- matic cap-shaping The ideal cap for the specified diameter of the tungsten elec- trode is formed during welding start-up. -
Page 61: 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 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 partic- ular the safety rules! WARNING! -
Page 62: Preparation
DownSlope t down Unit Setting range 0.0 - 9.9 Factory setting The DownSlope t is saved separately for 2-step and 4-step modes. down Final current I Unit % (of main current I Setting range 0 - 100 Factory setting Balance (only on MagicWave for TIG AC welding process) Unit Setting range -5 to +5... - Page 63 Only with MagicWave: Press the Mode button to select the required TIG mode: AC welding process AC welding process with automatic cap-shaping function DC welding process Use the left or right parameter selection button to select the relevant weld- ing parameters in the welding parameters overview Use the adjusting dial to set the selected welding parameter to the required value All welding parameter set values that have been set using the adjusting dial...
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Page 64: 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 ig- nition can transmit a harmless but noticeable electric shock under certain cir- cumstances. ▶... -
Page 65: Touchdown Ignition
Increase the tilt angle of the torch and actuate the torch trigger ac- cording to the mode you have se- lected The arc ignites without the electrode touching down on the workpiece. Tilt the torch back into the normal position Carry out welding Touchdown igni- If the HFt setup parameter is set to OFF, HF ignition is deactivated. -
Page 66: 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 67: 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 spe- dog function cified in the set-up menu, the power source cuts out automatically. The service code "no | Arc" appears on the control panel. To start the welding process again, press any key on the control panel or the torch trigger. - Page 68 Legend: Duration of pulsed welding current for the tacking process Starting current Final current Upslope Downslope Down Main current IMPORTANT The following points apply to the pulsed welding current: The power source automatically regulates the pulsing parameters as a function of the pre-set main current I The pulsed welding current begins: after the end of the starting-current phase I...
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Page 69: 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 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 partic- ular the safety rules! WARNING! - Page 70 Manual metal arc welding mode 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!
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Page 71: Hotstart Function
Hotstart func- To obtain optimum welding results, it will sometimes be necessary to adjust the tion hotstart function. Benefits Improved ignition, even when using electrodes with poor ignition properties Better fusion of the base material in the start-up phase, meaning fewer cold- shut defects Largely prevents slag inclusions See the "Set-up menu: level 2"... -
Page 73: Setup Settings
Setup settings... -
Page 75: 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 adjust- ments of the welding parameters to suit the various job settings. The following can be found in the set-up menu: Set-up parameters that have an immediate effect on the welding process Set-up parameters needed for making the preliminary settings on the weld-... -
Page 76: 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 "Mode" button tective gas Press the Gas test button shield set-up menu The power source is now in the Protective gas shield set-up menu. The last welding parameter selected is displayed. - Page 77 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 current, for example, the actual value will be half of the value set for G-H.
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Page 78: 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 "Mode" button Press the right parameter selection button The power source is now in the TIG set-up menu. The last welding parameter selected is displayed. - Page 79 Cooling unit control (option) Unit Setting range Aut / ON / OFF Factory setting 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 IMPORTANT! If the cooling unit is provided with the optional "thermostat", the coolant return temperature is checked continuously.
- Page 80 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 81 PhA (only with MW / TT 2500 / 3000 / 4000 / 5000) Phase adjustment of the mains connection of two power sources for simultan- eous AC welding. Unit Setting range 0 - 5 Factory setting IMPORTANT! Before phase adjustment the "ACF" parameter must be set to "Syn"...
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Page 82: Rod Electrode Setup Menu
Rod electrode setup menu Open the rod Press the Mode button to select the MMA welding mode electrode set-up Press and hold the "Mode" button menu Press the right parameter selection button The power source is now in the rod electrode set-up menu. The last welding parameter selected is displayed. - Page 83 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 mo- mentary rise in amperage.
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Page 84: 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 "Mode" button Press the right parameter selection button The power source is now in the rod electrode set-up menu - level 2. - Page 85 con - 20 A / V U (V) Load line for rod electrode Load line for rod electrode where arc length is increased Load line for rod electrode where arc length is reduced Characteristic where "CON" parameter is selected (constant welding current) I (A) Characteristic where "0.1 - 20"...
- Page 86 Load line for rod electrode U (V) Load line for rod electrode where arc length is increased Load line for rod electrode where arc length is reduced Characteristic where "CON" parameter is selected (constant welding current) Characteristic where "0.1 - 20" parameter I (A) is selected (drooping characteristic with adjustable slope)
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Page 87: Troubleshooting And Maintenance
Troubleshooting and maintenance... -
Page 89: 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 dis- pense with fuses entirely. 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 90 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 Note: xxx stands for a temperature value Cause: Overtemperature in the primary circuit of the power source Remedy: Allow power source to cool down tP4 | xxx...
- Page 91 Err | 051 Cause: Mains undervoltage: The mains voltage has dropped below the lower limit of the tolerance range (see section "Technical data") Remedy: Check the mains voltage Err | 052 Cause: Mains overvoltage: The mains voltage has exceeded the upper limit of the tolerance range (see section "Technical data") Remedy: Check the mains voltage...
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Page 92: Power Source - Troubleshooting
no | H2O Cause: Cooling unit flow watchdog has been triggered Remedy: Check the cooling unit; if necessary, top up the coolant or bleed the system as described in "Putting the cooling unit into service" hot | H2O Cause: Thermostat on cooling unit has tripped Remedy: Wait until the end of the cooling phase, i.e. - Page 93 Nothing happens when the torch trigger is pressed Mains switch is on, indicators are lit up Cause: The control plug is not plugged in Remedy: Plug in the control plug Cause: Welding torch or welding torch control line is faulty Remedy: Replace welding torch No protective gas shield...
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Page 94: 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... -
Page 95: 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 compressed air If a lot of dust has accumulated, clean the cooling air ducts WARNING! -
Page 97: Appendix
Appendix... -
Page 99: Average Consumption Values During Welding
Average consumption values during welding Average wire Average wire electrode consumption at a wire speed of 5 m/min electrode con- 1.0 mm wire 1.2 mm wire 1.6 mm wire sumption during electrode dia- electrode dia- electrode dia- MIG/MAG weld- meter meter meter Steel wire electrode... -
Page 100: Technical Data
An overview of which critical raw materials are contained in this device can be terials, year of found at the following Internet address. production of www.fronius.com/en/about-fronius/sustainability. the device To calculate the year of production of the device: Each device is provided with a serial number... -
Page 101: Magicwave 2200
Working voltage 10.1 - 16.8 V Electrode 20.4 -25.6 V Striking voltage (U 9.5 kV The arc striking voltage is suitable for manual operation. Degree of protection IP 23 Type of cooling Insulation class EMC device class (in accordance with EN/IEC 60974-10) Dimensions L/W/H (with handle) 485 / 180 / 344 m 19.1 / 7.1 / 13.6 in. -
Page 102: Magicwave 2500
Striking voltage (U 9.5 kV The arc striking voltage is suitable for manual operation. Degree of protection IP 23 Type of cooling Insulation class EMC device class (in accordance with EN/IEC 60974-10) Dimensions L/W/H (with handle) 485 / 180 / 390 m 19.1 / 7.1 / 15.4 in. -
Page 103: Magicwave 3000
Type of cooling Insulation class EMC device class (in accordance with EN/IEC 60974-10) Dimensions L/W/H (with handle) 560 / 250 / 435 m 22.0 / 9.8 / 17.1 in. Weight 26.6 kg 58.64 lb. Mark of conformity S, CE Idle state power consumption at 400 V 50.0 W Power source efficiency at 250 A / 30.0 V MagicWave 3000... -
Page 104: Magicwave 2500 Mv
Dimensions L/W/H (with handle) 560 / 250 / 435 m 22.0 / 9.8 / 17.1 in. Weight 28.1 kg 61.95 lb. Mark of conformity S, CE Idle state power consumption at 400 V 50.0 W Power source efficiency at 300 A / 32.0 V MagicWave 2500 Mains voltage 3 x 200 - 240 V... -
Page 105: Magicwave 3000 Mv
Welding current at 1 x 200 - 240 V 220 A 10 min/40 °C (104 °F) 40% D.C. 10 min/40 °C (104 °F) 50% D.C. 150 A 10 min/40 °C (104 °F) 100% D.C. Open circuit voltage 89 V Working voltage 10.1 - 20.0 V Electrode 20.4 - 30.0 V... -
Page 106: Magicwave 4000
Welding current range (3-phase) 3 - 300 A Electrode 10 - 300 A Welding current range (single phase) 3 - 220 A Electrode 10 - 180 A Welding current at 3 x 400 - 460 V 300 A 10 min/40 °C (104 °F) 35% D.C. 10 min/40 °C (104 °F) 40% D.C. -
Page 107: Magicwave 5000
Mains voltage tolerance ± 15% Grid frequency 50/60 Hz Mains fuse protection (slow-blow) 35 A Restrictions pos- Mains connection sible 15.5 kVA Primary continuous power (100% D.C. Cos phi 0.99 Welding current range 3 - 400 A Electrode 10 - 400 A Welding current at 10 min/40 °C (104 °F) 40% D.C. -
Page 108: Magicwave 4000 Mv
Restrictions pos- Mains connection sible 17.9 kVA Primary continuous power (100% D.C. Cos phi 0.99 Welding current range 3 - 500 A Electrode 10 - 440 A Welding current at 500 A 10 min/40 °C (104 °F) 40% D.C. 10 min/40 °C (104 °F) 45% D.C. 440 A 10 min/40 °C (104 °F) 60% D.C. -
Page 109: Magicwave 5000 Mv
Cos phi 0.99 Welding current range 3 - 400 A Electrode 10 - 400 A Welding current at 10 min/40 °C (104 °F) 40% D.C. 400 A 10 min/40 °C (104 °F) 45% D.C. 360 A 10 min/40 °C (104 °F) 60% D.C. 300 A 10 min/40 °C (104 °F) 100% D.C. - Page 110 132.30 lb. Mark of conformity S, CE, CSA Idle state power consumption at 400 V 45.5 W Power source efficiency at 440 A / 37.6 V TransTig 800 Mains voltage 230 V Mains voltage tolerance -20% / +15% Grid frequency...
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Page 111: Transtig 2200
Welding current at 10 min/25 °C (77 °F) 50% D.C. 10 min/25 °C (77 °F) 60% D.C. 80 A 10 min/25 °C (77 °F) 100% D.C. 10 min/40 °C (104 °F) 40% D.C. 80 A 10 min/40 °C (104 °F) 60% D.C. 70 A 10 min/40 °C (104 °F) 100% D.C. -
Page 112: Transtig 2500
Welding current at 220 A 10 min/25 °C (77 °F) 50% D.C. 200 A 10 min/25 °C (77 °F) 60% D.C. 170 A 10 min/25 °C (77 °F) 100% D.C. 220 A 10 min/40 °C (104 °F) 40% D.C. 180 A 10 min/40 °C (104 °F) 60% D.C. -
Page 113: Transtig 3000
Welding current at 10 min/40 °C (104 °F) 45% D.C. 250 A 10 min/40 °C (104 °F) 50% D.C. 240 A 10 min/40 °C (104 °F) 60% D.C. 210 A 10 min/40 °C (104 °F) 100% D.C. Open circuit voltage 85 V Working voltage 10.1 - 20.0 V... -
Page 114: Transtig 2500 Mv
Welding current at 300 A 10 min/40 °C (104 °F) 45% D.C. 10 min/40 °C (104 °F) 50% D.C. 270 A 10 min/40 °C (104 °F) 60% D.C. 230 A 10 min/40 °C (104 °F) 100% D.C. Open circuit voltage 85 V Working voltage 10.1 - 22.0 V... - Page 115 Welding current range (3-phase) 3 - 250 A Electrode 10 - 250 A Welding current range (single phase) 3 - 220 A Electrode 10 - 180 A Welding current at 3 x 400 - 460 V 10 min/40 °C (104 °F) 45% D.C. 250 A 10 min/40 °C (104 °F) 50% D.C.
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Page 116: Transtig 3000 Mv
TransTig 3000 Mains voltage 3 x 200 - 240 V 3 x 400 - 460 V 1 x 200 - 240 V Mains voltage tolerance ± 10% Grid frequency 50/60 Hz Mains fuse protection (slow-blow) 3 x 400 - 460 V 16 A 3 x 200 - 240 V 32 A... -
Page 117: Transtig 4000
Degree of protection IP 23 Type of cooling Insulation class EMC device class (in accordance with EN/IEC 60974-10) Dimensions L/W/H (with handle) 560 / 250 / 435 m 22.0 / 9.8 / 17.1 in. Weight 25.9 kg 57.10 lb. Mark of conformity S, CE Idle state power consumption at 400 V 43.0 W... -
Page 118: Transtig 5000
EMC device class (in accordance with EN/IEC 60974-10) Dimensions L/W/H (with handle) 625 / 290 / 475 m 24.6 / 11.4 / 18.7 i Weight 39.8 kg 87.7 lb. Mark of conformity S, CE Idle state power consumption at 400 V 35.3 W Power source efficiency at 400 A / 36.0 V TransTig 5000... -
Page 119: Transtig 4000 Mv
Dimensions L/W/H (with handle) 625 / 290 / 475 m 24.6 / 11.4 / 18.7 i Weight 39.8 kg 87.7 lb. Mark of conformity S, CE Idle state power consumption at 400 V 35.3 W Power source efficiency at 500 A / 40.0 V TransTig 4000 Mains voltage 3 x 200 - 240 V... -
Page 120: Transtig 5000 Mv
Dimensions L/W/H (with handle) 625 / 290 / 475 m 24.6 / 11.4 / 18.7 i Weight 42.0 kg 92.6 lb. Mark of conformity S, CE, CSA Idle state power consumption at 400 V 40.5 W Power source efficiency at 400 A / 36.0 V TransTig 5000 Mains voltage 3 x 200 - 240 V... -
Page 121: Explanation Of Footnotes
Dimensions L/W/H (with handle) 625 / 290 / 475 m 24.6 / 11.4 / 18.7 i Weight 42.0 kg 92.6 lb. Mark of conformity S, CE, CSA Idle state power consumption at 400 V 40.5 W Power source efficiency at 500 A / 40.0 V Explanation of connected to public mains supply with 230 / 400 V and 50 Hz footnotes... -
Page 122: Terms And Abbreviations Used
Terms and abbreviations used General The terms and abbreviations listed here are used in connection with functions that are either included in the standard scope of supply or that are available as optional extras. Terms and ab- breviations A - F AC frequency Cooling unit control dynamic... -
Page 123: Terms And Abbreviations I - U
Hot-current time (MMA welding) Terms and ab- breviations I - U Reduced current (4-step mode with intermediate lowering) Phase Adjustment Phase adjustment of the mains connection of two power sources for simultan- eous AC welding Pre Ignition - delayed high frequency ignition Tacking function UpSlope The starting current is continuously increased until it reaches the welding cur-...
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