Fronius MagicWave 2200 Comfort Operating Instructions Manual Download Page 26

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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

(1)

TIG robot welding torch
Cold wire feeders with wire drive

(2)

Power sources

(3)

Cooling units

(4)

Trolley with gas cylinder holder

(5)

Pedal remote control unit

(6)

Cold wire-feed unit

(7)

TIG welding torch Standard / Up/Down

(8)

JobMaster TIG welding torch

(9)

Remote control units and robot accessories

(10)

Grounding (earthing) cable

(11)

Electrode cable

FRONIUS

(6)

(1)

(2)

(8)

(9)

(3)

(4)

(11)

(10)

(7)

(5)

Summary of Contents for MagicWave 2200 Comfort

Page 1: ...ect Charging Perfect Welding Solar Energy 42 0426 0063 EN 017 28062016 TransTig 2200 2500 3000 4000 Comfort MagicWave 2200 2500 3000 4000 Comfort Operating Instructions Spare parts list TIG Power sour...

Page 2: ...2...

Page 3: ...h the product Reading the instructions carefully will enable you to learn about the many different features it has to offer This will allow you to make full use of its advantages Please also note the...

Page 4: ...4...

Page 5: ...transport 19 Safety measures in normal operation 20 Commissioning maintenance and repair 21 Safety inspection 21 Disposal 21 Safety symbols 22 Data protection 22 Copyright 22 General information 23 Ge...

Page 6: ...52 Cap overloading 52 TIG welding 53 Safety 53 Welding parameters display and navigation 53 Welding parameters for TIG 53 Preparation 56 TIG welding 57 Igniting the arc 59 General 59 Igniting the arc...

Page 7: ...2nd 110 Gas setup 111 General 111 Opening the gas setup 111 Changing welding parameters 112 Exiting gas setup 113 Gas setup parameters 114 Cold wire setup 116 General 116 Opening the AC setup 116 Cha...

Page 8: ...setting the welding machine 166 General 166 Factory for resetting the welding machine 166 L R alignment 167 Abbreviations 167 General information on welding circuit inductivity L 167 General informati...

Page 9: ...are parts list TransTig MagicWave 2500 3000 198 Spare parts list TransTig 4000 200 Spare parts list MagicWave 4000 202 Circuit diagrams MagicWave 2200 Comfort 205 Circuit diagrams MagicWave 2500 Comfo...

Page 10: ...10...

Page 11: ...sused 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 All p...

Page 12: ...ility for inadequate or incorrect re sults Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose The manufacturer shall not be he...

Page 13: ...hort 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...

Page 14: ...g point under maximum rated load conditions according to EN 60974 1 It is not possible to provide a workplace related emission value during welding or cutting as this is influenced by both the process...

Page 15: ...side the device During MIG MAG welding and TIG welding the welding wire the wirespool the feed rollers and all pieces of metal that are in contact with the welding wire are live Always set the wire fe...

Page 16: ...ed to the workpiece Irreparable damage to ground conductors Damage to device and other electrical equipment Ensure that the workpiece is held securely by the workpiece clamp Attach the workpiece clamp...

Page 17: ...e fil ter 2 Welding power leads must be kept as short as possible must run close together to avoid EMF problems must be kept well apart from other leads 3 Equipotential bonding 4 Earthing of the workp...

Page 18: ...data sheet when handling cool ant The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer s website Use only suitable load carrying equipment supplie...

Page 19: ...for the application in hand along with the correct and appropriate accessories regulator hoses and fittings Only use shielding gas cylinders and accessories that are in good condition Turn your face t...

Page 20: ...once a week for obvious damage and proper func tioning of safety devices Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane Only the...

Page 21: ...e power source be calibrated during the same 12 month period A safety inspection should be carried out by a qualified electrician after any changes are made after any additional parts are installed or...

Page 22: ...the relevant stand ards in Canada and the USA The user is responsible for the safekeeping of any changes made to the fac tory settings The manufacturer accepts no liability for any deleted personal s...

Page 23: ...General information...

Page 24: ......

Page 25: ...nce to the preceding welding and welding off times RPI Reverse Polarity Ignition ensures an excellent ignition response during TIG DC weld ing Functional princi ple The central control and regulation...

Page 26: ...tion 1 TIG robot welding torch Cold wire feeders with wire drive 2 Power sources 3 Cooling units 4 Trolley with gas cylinder holder 5 Pedal remote control unit 6 Cold wire feed unit 7 TIG welding torc...

Page 27: ...Control elements and connections...

Page 28: ......

Page 29: ...ing instructions all the operating instructions for the system components especially the safe ty rules No Function 1 Pulse indicator lights up when the F P set up parameter has been set to a pulse fre...

Page 30: ...ode Manual metal arc welding When a mode is selected the LED on the relevant symbol lights up 11 Gas test button for setting the required shielding gas flow rate on the gas pressure regulator After pr...

Page 31: ...for more information on the electrode overload indicator 7 Keylock indicator lights up when the keylock is activated 8 Right arrow key for navigating in the menu 9 Mode button for selecting the mode...

Page 32: ...13 Left arrow key for navigating in the menu 14 HF high frequency ignition indicator lights up when the HF ignition welding parameter has been set to an interval for the high frequency pulses No Funct...

Page 33: ...rdised connection socket for system add ons e g remote control JobMas ter TIG welding torch etc 3 Handle 4 Torch control connection for connecting the control plug of a conventional welding torch inpu...

Page 34: ...remote control JobMas ter TIG welding torch etc 3 Handle 4 Torch control connection for connecting the control plug of a conventional welding torch input for the collision protection signal when a rob...

Page 35: ...etal arc welding 4 Torch control connection for connecting the control plug of a conventional welding torch input for the collision protection signal when a robot interface or field bus cou pler is co...

Page 36: ...or system add ons e g remote control JobMas ter TIG welding torch etc 3 Handle 4 Torch control connection for connecting the control plug of a conventional welding torch input for the collision protec...

Page 37: ...cket for system add ons e g remote control JobMas ter TIG welding torch etc 3 Handle 4 Torch control connection for connecting the control plug of a conventional welding torch input for the collision...

Page 38: ...remote control JobMas ter TIG welding torch etc 3 Torch control connection for connecting the control plug of a conventional welding torch input for the collision protection signal when a robot interf...

Page 39: ...Installation and commissioning...

Page 40: ......

Page 41: ...er metals as required by the application TIG DC welding Power source Grounding earthing cable TIG welding torch with rocker switch Gas connection shielding gas supply Filler metals as required by the...

Page 42: ...st not be allowed to get sucked into the device Mains connection The devices are designed to run on the mains voltage shown on the respective rating plates If your version of the device does not come...

Page 43: ...provide an overview of how to commission the power source For detailed information about the individual steps please refer to the operating instruc tions for the system components Connecting the gas c...

Page 44: ...ish a connection to the workpiece Connecting the welding torch Move the mains switch to the O position Plug in the TIG welding torch cable and latch it by turning it clockwise for MagicWave in the wel...

Page 45: ...Welding...

Page 46: ......

Page 47: ...S Starting current phase the temperature is raised gently at low welding current so that the filler metal can be positioned cor rectly IE Final current phase to prevent any local overheating of the ba...

Page 48: ...set up parameter to end the welding process prematurely pull the torch trigger back again When using a pedal remote control the spot welding time starts when the pedal remote control is operated The...

Page 49: ...rmediate lowering push forward and hold the torch trigger To revert to the main current release the torch trigger Special 4 step mode variant 1 Variant 1 of special 4 step mode is activated when the s...

Page 50: ...torch trigger is released When the torch trigger is released the welding current rises at the specified upslope value until it reaches the main current value I1 Special 4 step mode Variant 2 Special 4...

Page 51: ...gger the weld ing current will rise at the specified upslope value from the starting current IS until it reaches the main current value I1 Push forward and hold the torch trigger for intermediate lowe...

Page 52: ...on 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...

Page 53: ...ctions all the operating instructions for the system components especially the safe ty rules WARNING An electric shock can be fatal If the power source is connected to the mains electricity supply dur...

Page 54: ...mode Unit A Setting range MW 2500 Comfort 3 250 MW 3000 Comfort 3 300 TT 2500 Comfort 3 250 TT 3000 Comfort 3 300 Factory setting IMPORTANT On welding torches with the Up Down function the entire sett...

Page 55: ...parately for 2 step and 4 step modes Final current 2 step mode Final current 4 step mode Unit of main current Setting range 0 100 Factory setting 30 only with MagicWave for the TIG AC welding process...

Page 56: ...on is available Unit m min ipm Setting range OFF 0 1 max OFF 3 9 max Factory setting OFF Unit mm in Setting range OFF max OFF max Factory setting 2 4 0 1 CAUTION Risk of injury and damage from electri...

Page 57: ...menu by pressing the adjusting dial Use the adjusting dial to select the welding parameter To change the welding parameter press the adjusting dial Change the welding parameter value using the adjusti...

Page 58: ...r long hosepacks and if condensation forms when the device is left unused in a cold environment purge protective gas shield and set the GPU set up parameter to a time value Start welding ignite the ar...

Page 59: ...de This results in the tungsten electrode heating up rapidly which is an essential prerequisite for optimum ignition properties Further information on the RPI function can be found in the Chapter Set...

Page 60: ...i tion Carry out welding Touchdown igni tion If the HFt setup parameter is set to OFF HF ignition is deactivated The welding arc is ig nited by touching the workpiece with the tungsten electrode Proce...

Page 61: ...de 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 t...

Page 62: ...ameter Arc are described in TIG set up 2nd section Ignition time out function The power source has an ignition time out function Once the torch trigger is pressed gas pre flow begins immediately Ignit...

Page 63: ...ections of the welding location melt quickly and then solidify again quickly In manual applications using TIG pulsing the welding wire is applied in the maximum cur rent phase only possible in the low...

Page 64: ...ng on what tAC time has been set the pulsed welding current may continue up to and including the final current phase IE tAC set up parameter set to ON After the tAC time has elapsed welding continues...

Page 65: ...1 1 F P time interval between 2 pulses Legend IS Starting current dcY Duty cycle IE Final current I G Ground current tup Upslope I1 Main current tDown Downslope F P Pulse frequency 1 Fd 1 Wire feed sp...

Page 66: ...uments these operating instructions all the operating instructions for the system components especially the safe ty rules WARNING An electric shock can be fatal If the power source is connected to the...

Page 67: ...e arc force dynamic Unit of main current Setting range 0 100 Factory setting 20 0 soft low spatter arc 100 harder more stable arc Functional principle at the instant of droplet transfer or when a shor...

Page 68: ...tion for TransTig in the current socket Plug in the mains plug Move the mains switch to the I position The starting sequence with the Fronius logo current firmware version and Fronius in ternet addres...

Page 69: ...the mains switch to the I position The starting sequence with the Fronius logo current firmware version and Froni us internet address is displayed for approx 1 second Use the right arrow key to select...

Page 70: ...ition properties Better fusion of the base material in the start up phase meaning fewer cold shut de fects Largely prevents slag inclusions For details on setting the available welding parameters plea...

Page 71: ...atter 1 Main current 2 Starting current Anti stick func tion As the arc becomes shorter the welding voltage may drop so far that the rod electrode will tend to stick This may also cause the rod electr...

Page 72: ...derstood 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 If the power...

Page 73: ...p mode Unit A Setting range MW 2500 Comfort 3 250 MW 3000 Comfort 3 300 TT 2500 Comfort 3 250 TT 3000 Comfort 3 300 Factory setting IMPORTANT On welding torches with the Up Down function the entire se...

Page 74: ...rately for 2 step and 4 step modes Final current 2 step mode Final current 4 step mode Unit of main current Setting range 0 100 Factory setting 30 only with MagicWave for the TIG AC welding process Un...

Page 75: ...1 max OFF 3 9 max Factory setting OFF Unit mm in Setting range OFF max OFF max Factory setting 2 4 0 1 Starting current starting current main current SoftStart Starting current starting current main c...

Page 76: ...arc force dynamic Unit of main current Setting range 0 100 Factory setting 20 0 soft low spatter arc 100 harder more stable arc Functional principle at the instant of droplet transfer or when a short...

Page 77: ...only with MagicWave for the manual metal arc AC welding process Unit 1 Setting range 5 5 Factory setting 0 5 highest fusing power lowest cleaning action 5 highest cleaning action lowest fusing power C...

Page 78: ...relevant main menu appears e g Use the adjusting dial to select job turn the adjusting dial Press the adjusting dial The menu items for the job will now appear Use the adjusting dial to select Retriev...

Page 79: ...select the desired job turn the adjusting dial To change welding parameters according to the job correction stored in the job Use left and right arrow keys to select welding parameters Press the adju...

Page 80: ...is applied Start welding 8 Finish welding Press Menu key The main menu for the welding job appears Use the adjusting dial to select job turn the adjusting dial Press the adjusting dial The menu items...

Page 81: ...81 EN Press the adjusting dial The welding parameters are shown for the most recently selected method e g Starting current 2 step mode 6...

Page 82: ...process TIG AC welding process manual metal arc AC welding TIG AC welding process with automatic cap shaping function man ual metal arc DC welding TIG DC welding process manual metal arc DC welding U...

Page 83: ...ng parameters as well as in the relevant set up menus in a job When creating jobs you MUST therefore also take into account the welding parameters in the set up menus Select the job from the relevant...

Page 84: ...the settings will be stored under the selected job number If all the memory is occupied then a warning prompt will appear Free memory The second Save job screen appears briefly The Name job screen ap...

Page 85: ...nd select Del Press the adjusting dial to delete the last character Press the button on the right OK in order to accept the name The settings will be stored and the third Save job screen will appear P...

Page 86: ...ob return to job numbers overview Right button Yes Store settings under the chosen job number The Name job screen appears If necessary delete the existing job name Turn the adjusting dial and select D...

Page 87: ...ters numbers Press the button on the right OK in order to accept the name The settings will be stored and the Job saved screen will appear Press the button on the right OK The job numbers overview app...

Page 88: ...w symbol by turning the adjusting dial Press the adjusting dial The current set up menu is displayed Press Menu key or Select the arrow symbol by turning the adjusting dial The current welding paramet...

Page 89: ...Setup settings...

Page 90: ......

Page 91: ...ss The 2nd level of the set up menu contains all the set up parameters needed for mak ing the preliminary settings on the welding device The welding parameters are arranged in logical groups Overview...

Page 92: ...parameter is shown on the display TIG welding parameters for 2 step mode TIG welding parameters for 4 step mode Press Menu key The main menu appears Use the adjusting dial to select TIG setup turn the...

Page 93: ...rning the adjusting dial To set the welding parameter press the adjusting dial The value of the selected welding parameter can now be changed Change the welding parameter value by turning the adjustin...

Page 94: ...ing dial Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for the TIG welding parameter is show...

Page 95: ...pre set time period welding continues with a constant welding current any pulsing parameters that have been set are available OFF The tacking function is deactivated The tacking indicator remains lit...

Page 96: ...the starting current phase Is is controlled using the torch trigger Final current time Unit s Setting range OFF 0 01 9 9 Factory setting OFF The final current time t E specifies the duration of the f...

Page 97: ...up 2nd parameter Press the adjusting dial The TIG setup 2nd parameters are shown The power source is now in TIG setup 2nd 1 2 3 Select the desired welding parameter by turning the adjusting dial To se...

Page 98: ...arameter value by turning the adjusting dial To apply the welding parameter value press the adjusting dial 3 4 Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusti...

Page 99: ...l Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for the TIG welding parameter is shown TIG w...

Page 100: ...ed continuously If the return temperature is less than 50 C the cooling unit is switched off automatically Cunit wtchdog Cooling unit watchdog Time from when the flow watchdog is triggered until the n...

Page 101: ...elding circuit inductivity in microhenry R resistance welding circuit resistance in mOhm See the L R alignment section for further details Ignition time out Time until safety cut out is triggered afte...

Page 102: ...peration Fd 1 Wire feed speed 1 cold wire feed unit option The number of user defined welding parameters depends on the configuration and the mode that has been selected Special 2 step Special 2 step...

Page 103: ...s the Mode button to select 2 step mode or 4 step mode The image for the TIG welding parameter is shown on the display TIG welding parameters for 2 step mode TIG welding parameters for 4 step mode Pre...

Page 104: ...tup 4 Select the desired welding parameter by turning the adjusting dial To set the welding parameter press the adjusting dial The value of the selected welding parameter can now be changed Change the...

Page 105: ...sting dial Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for the TIG welding parameter is sh...

Page 106: ...ting 60 Syn for mains synchronisation of two power sources for simultaneous AC welding IMPORTANT If using the Syn setting remember to check the Phase sync parameter in AC setup 2nd Low frequency soft...

Page 107: ...the AC setup Select the AC setup 2nd parameter Press the adjusting dial The AC setup 2nd parameters are shown The power source is now in AC setup 2nd 1 2 3 Select the desired welding parameter by tur...

Page 108: ...parameter value by turning the adjusting dial To apply the welding parameter value press the adjusting dial 3 4 Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjust...

Page 109: ...l Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for the TIG welding parameter is shown TIG w...

Page 110: ...Tri Sin Rec Off Factory setting OFF Tri Triangular waveform Sin Sine sinusoidal waveform standard setting for a low noise stable arc Rec Rectangular waveform with decreased edge steepness for re duci...

Page 111: ...tup Press the Mode button to select 2 step mode or 4 step mode The image for the TIG welding parameter is shown on the display TIG welding parameters for 2 step mode TIG welding parameters for 4 step...

Page 112: ...etup 4 Select the desired welding parameter by turning the adjusting dial To set the welding parameter press the adjusting dial The value of the selected welding parameter can now be changed Change th...

Page 113: ...sting dial Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for the TIG welding parameter is sh...

Page 114: ...e set for post flow lmax only applies if the maximum welding current actually has been set The actual value is derived from the present welding current With a medi um welding current for example the a...

Page 115: ...ital Gas Control option Unit Setting range AUT 1 0 10 0 Factory setting AUT IMPORTANT Please refer to Digital Gas Control operating instructions for more de tailed explanations of the gas correction w...

Page 116: ...the AC setup Press the Mode button to select 2 step mode or 4 step mode The image for the TIG welding parameter is shown on the display TIG welding parameters for 2 step mode TIG welding parameters fo...

Page 117: ...e cold wire setup 4 Select the desired welding parameter by turning the adjusting dial To set the welding parameter press the adjusting dial The value of the selected welding parameter can now be chan...

Page 118: ...adjusting dial Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for the TIG welding parameter i...

Page 119: ...Factory setting OFF End delay Delay in the start of wirefeeding from end of the main current phase Unit s Setting range OFF 0 1 9 9 Factory setting OFF Wire threading Wire threading speed Unit m min...

Page 120: ...unit For an overview of the service codes used during calibration of the push pull unit please refer to Service codes for push pull calibration In cold wire setup select the push pull parameter Press...

Page 121: ...pull calibration screen is shown Follow the instructions shown CAUTION Risk of injury from welding wire emerging at speed and from rotating cogs and drive parts Hold the welding torch so that it point...

Page 122: ...aser KD Drive 5 m min or 197 ipm 19 Fronius KD 4010 10 m min or 394 ipm 21 Binzel Torch Drive IWG 8 m min or 315 ipm 25 Fronius KD 7000 Fronius VR 1530 KD 10 m min or 394 ipm The following abbreviatio...

Page 123: ...e error message re appears Contact After Sales Service Cause Push pull calibration was inter rupted Quick stop was activated by pressing the torch trigger Remedy Repeat push pull calibration Service c...

Page 124: ...roller drive of the push pull unit Repeat the push pull calibration If the error message re appears Contact After Sales Service Cause At maximum wire feed speed the wire feed motor does not deliver a...

Page 125: ...e appears Con tact After Sales Service Cause At maximum wire feed speed the motor current of the push pull unit is outside the permitted range Possible reasons are disengaged wire feed unit motors or...

Page 126: ...de The image for the rod electrode welding parameter is shown on the display e g Press Menu key The main menu appears Use the adjusting dial to select Rod elec setup turn the adjusting dial Press the...

Page 127: ...urning the adjusting dial To set the welding parameter press the adjusting dial The value of the selected welding parameter can now be changed Change the welding parameter value by turning the adjusti...

Page 128: ...t the arrow symbol by turning the adjusting dial Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The ima...

Page 129: ...e 0 2 0 Factory setting 0 5 To obtain optimum welding results it will sometimes be necessary to adjust the hotstart function Advantages Improved ignition even when using electrodes with poor ignition...

Page 130: ...d electrode setup 2nd parameter Press the adjusting dial The parameters for rod electrode setup 2nd are shown The power source is now in rod electrode setup 2nd 1 2 3 Select the desired welding parame...

Page 131: ...g parameter value by turning the adjusting dial To apply the welding parameter value press the adjusting dial 3 4 Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adju...

Page 132: ...ow symbol by turning the adjusting dial Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for th...

Page 133: ...ode will tend to stick This may also cause the rod electrode to burn out Electrode burn out is prevented by activating the anti stick function If the rod electrode begins to stick the power source imm...

Page 134: ...cts with the load line 2 NOTE When setting a flat characteristic 5 set the arc force dynamic to a higher value NOTE If there are problems with a rod electrode tending to stick set the arc force dynami...

Page 135: ...piece With the Uco parameter the welding voltage can be limited to a value that makes it possible to end the welding operation simply by slightly lifting the rod electrode NOTE If the welding process...

Page 136: ...Mode button to select the MMA welding mode The image for the rod electrode welding parameter is shown on the display e g Press Menu key The main menu appears Use the adjusting dial to select AC setup...

Page 137: ...set the welding parameter press the adjusting dial The value of the selected welding parameter can now be changed Change the welding parameter value by turning the adjusting dial To apply the welding...

Page 138: ...etc Press the adjusting dial The main menu appears Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The image for the rod electrode welding parameter is...

Page 139: ...lete a job The following actions can be performed in the Job set up menu Save Save settings as a job Retrieve Retrieve jobs for the welding job Retrieve Adjust and modify stored jobs Delete Delete sto...

Page 140: ...dial to select optimise turn the adjusting dial Press the adjusting dial The first Optimise job screen or the last job to be selected or saved ap pears Example job Press the adjusting dial to select t...

Page 141: ...turn the adjusting dial Press the adjusting dial The welding parameters for the job to be optimised appear Turn the adjusting dial to select the welding parameters to be modified e g Press the adjusti...

Page 142: ...ing dial To apply the welding parameter value press the adjusting dial 8 9 In the Optimise job menu item turn the adjusting dial to select Job name Press the adjusting dial The Name job screen appears...

Page 143: ...Turn the adjusting dial to select the desired letters numbers Then press the adjusting dial in order to enter these letters numbers Press the button on the right OK in order to accept the name The ne...

Page 144: ...ect the arrow symbol by turning the adjusting dial Press the adjusting dial The menu items for the job appear Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjustin...

Page 145: ...ing parameter selected 3 Electrode diam Electrode diameter Unit mm Setting range Off 0 1 4 8 Starting current Unit of main current Setting range 30 200 AC 0 200 DC UpSlope Unit s Setting range 0 0 9 9...

Page 146: ...Unit s Setting range 0 25 Factory setting 5 Post flow lmax Post flow at Imax Increase in gas post flow time at maximum welding current Unit s Setting range 0 40 Aut Factory setting Aut The value set...

Page 147: ...urrent any pulsing parameters that have been set are available OFF The tacking function is deactivated Pulse frequency Unit Hz kHz Setting range OFF 0 20 Hz 2 00 kHz The selected pulse frequency is al...

Page 148: ...70 highest fusing power lowest cleaning action 70 narrow arc deep heat input faster welding speed Balance only on MagicWave for TIG AC welding process Unit Setting range 5 5 5 distant arc with shallo...

Page 149: ...parameter current crrctn has been set to 30 The welding current I1 can then be decreased or increased by up to 30 IMPORTANT Every subsequent correction of the main current I1 is reset i e cancelled w...

Page 150: ...c function Unit of main current Setting range 0 100 0 soft low spatter arc 100 harder more stable arc Functional principle at the instant of droplet transfer or when a short circuit occurs there is a...

Page 151: ...tarting curr time Unit s Setting range OFF 0 01 9 9 The starting current time t S specifies the duration of the starting current phase Is Char For selecting characteristics Unit Setting range con or 0...

Page 152: ...epending upon the welding voltage arc length the welding current I will also become either smaller or larger even though the value set for I1 remains the same 1 Load line for rod electrode 2 Load line...

Page 153: ...us AC welding IMPORTANT If using the Syn setting remember to check the Phase sync parameter in AC setup 2nd Low frequency soft distant arc with shallow heat input High frequency focused arc with deep...

Page 154: ...t Delete job screen is displayed Turn the adjusting dial to select the job for deletion Press the right button The second Delete job screen is displayed Press the button on the left or right Left butt...

Page 155: ...te job screen is displayed Press the right button The menu items for the job appear Press Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The current set up...

Page 156: ...key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The current welding parameters are displayed e g TIG welding parameters for 2 step mode main current welding param...

Page 157: ...metal arc welding mode is selected Opening the ba sic settings Press Menu key The main menu appears TIG main menu Rod electrode main menu Use the adjusting dial to select Basic setting turn the adjus...

Page 158: ...ning the adjusting dial To set the welding parameter press the adjusting dial The value of the selected welding parameter can now be changed Change the welding parameter value by turning the adjusting...

Page 159: ...Menu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The relevant main menu appears TIG main menu Rod electrode main menu Press Menu key or Select the arrow symb...

Page 160: ...ory setting D D German E Spanish NL Dutch GB English CZ Czech PL Polish F French S Swedish I Italian P Brazilian Portuguese Unit Setting determines whether metric or imperial units are shown Unit Sett...

Page 161: ...g mode is selected Calling up the info screen Press Menu key The main menu appears TIG main menu Rod electrode main menu Use the adjusting dial to select Info turn the adjusting dial Press the adjusti...

Page 162: ...enu key or Select the arrow symbol by turning the adjusting dial Press the adjusting dial The relevant main menu appears TIG main menu Rod electrode main menu Press Menu key or Select the arrow symbol...

Page 163: ...elding parameters for 2 step mode Firmware Current display control panel firmware UST Software Current software of the power source control board UST Arc burn time Arc time Actual total arc burn time...

Page 164: ...ally the Lock keys function can be activated on the power source Lock keys Press Menu key The main menu appears TIG main menu Rod electrode main menu Use the adjusting dial to select Lock keys turn th...

Page 165: ...Lock unlock keys screen appears Press the key on the right OK within 3 seconds The keys are unlocked and the image for the currently selected mode is shown e g TIG welding parameters for 2 step mode...

Page 166: ...t Jobs are not deleted when the welding machine is reset these are preserved The parameter settings in the second level of the set up menu are not deleted either Opening the basic settings Select Fact...

Page 167: ...urrent rise is restricted Correct arrangement of the hosepack Changing the way the hosepack is arran ged may help to improve the welding re sults The hosepack must be laid out as shown in the illustra...

Page 168: ...the following L R alignment screens pressing the left button takes you back to the previous screen Press the right button The second L R alignment screen is displayed Follow the instructions shown IM...

Page 169: ...right button After R L alignment a confirmation and the current welding circuit resistance will be shown Press the right button Depending on the mode selected TIG setup 2nd or rod electrode setup 2nd...

Page 170: ...170...

Page 171: ...Troubleshooting and maintenance...

Page 172: ......

Page 173: ...NG Work that is carried out incorrectly can cause serious injury or dam age All the work described below must only be carried out by trained and quali fied personnel Do not carry out any of the work d...

Page 174: ...mperature sensor fault short circuit or break Remedy Contact After Sales Service E17 E20 E21 E29 E35 E36 Cause Fault in central control and regu lation unit Remedy Contact After Sales Service Cause Fa...

Page 175: ...ow watchdog has been triggered Remedy Check the cooling unit if neces sary top up the coolant or bleed the system as described in Put ting the cooling unit into service Cause The software activation c...

Page 176: ...it Cause Ignition time out function is ac tive no current started flowing be fore the end of the time specified in the set up menu The safety cut out of the power source has been triggered Remedy Pres...

Page 177: ...longer displayed ROB 5000 or field bus coupler for robot control Before resuming welding set the Source error reset signal Cause Overtemperature in JobMaster welding torch Remedy Allow the JobMaster w...

Page 178: ...The welding device configuration has been changed Remedy Check LHSB link Cause No connection to power source Remedy Check connection to power source and its software Cause Emergency Stop safety circu...

Page 179: ...unit vDmin minimum wire feed speed vDmax maximum wire feed speed Cause The external supply voltage has dropped below the tolerance limit Remedy Check the external supply volt age Cause Wire feed unit...

Page 180: ...ut 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 Contact After Sales Service No w...

Page 181: ...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...

Page 182: ...rsonnel Do not carry out any of the work described below until you have fully read and understood the following documents this document all documents relating to the system components especially the s...

Page 183: ...183 EN Disposal Dispose of in accordance with the applicable national and local regulations...

Page 184: ...184...

Page 185: ...Appendix...

Page 186: ......

Page 187: ...e TIG 3 220 A Electrode 10 180 A Welding current at 10 min 25 C 77 F 40 d c 2 220 A 10 min 25 C 77 F 60 d c 2 180 A 10 min 25 C 77 F 100 d c 2 150 A 10 min 40 C 104 F 35 d c 2 220 A 10 min 40 C 104 F...

Page 188: ...de 10 250 A 10 300 A Welding current at 10 min 40 C 104 F 35 d c 2 300 A 10 min 40 C 104 F 40 d c 2 250 A 10 min 40 C 104 F 100 d c 2 180 A 200 A Open circuit voltage 89 V 89 V Working voltage TIG 10...

Page 189: ...ding current range single phase TIG 3 220 A 3 220 A Electrode 10 180 A 10 180 A Welding current at 3 x 400 460 V 10 min 40 C 104 F 35 d c 2 300 A 10 min 40 C 104 F 40 d c 2 250 A 10 min 40 C 104 F 100...

Page 190: ...9 kVA Cos phi 0 99 0 99 Welding current range TIG 3 400 A 3 400 A Electrode 10 400 A 10 400 A Welding current at 10 min 40 C 104 F 40 d c 2 10 min 40 C 104 F 45 d c 2 400 A 400 A 10 min 40 C 104 F 60...

Page 191: ...200 A 10 min 25 C 77 F 100 ED2 170 A 10 min 40 C 104 F 40 ED2 220 A 10 min 40 C 104 F 60 ED2 180 A 10 min 40 C 104 F 100 ED2 150 A Open circuit voltage 84 V Working voltage TIG 10 1 18 8 V Electrode 2...

Page 192: ...Welding current at 10 min 40 C 104 F 45 d c 2 300 A 10 min 40 C 104 F 50 d c 2 250 A 10 min 40 C 104 F 60 d c 2 240 A 270 A 10 min 40 C 104 F 100 d c 2 210 A 230 A Open circuit voltage 85 V 85 V Work...

Page 193: ...ding current range single phase TIG 3 220 A 3 220 A Electrode 10 180 A 10 180 A Welding current at 3 x 400 460 V 10 min 40 C 104 F 45 d c 2 300 A 10 min 40 C 104 F 50 d c 2 250 A 10 min 40 C 104 F 100...

Page 194: ...estrictions possible Primary continuous power 100 d c 2 11 8 kVA 11 5 kVA Cos phi 0 99 0 99 Welding current range TIG 3 400 A 3 400 A Electrode 10 400 A 10 400 A Welding current at 10 min 40 C 104 F 4...

Page 195: ...Spare parts and circuit diagrams...

Page 196: ...196 Spare parts list TransTig MagicWave 2200 Comfort...

Page 197: ...197...

Page 198: ...198 Spare parts list TransTig MagicWave 2500 3000...

Page 199: ...0409 3195 TT 43 0001 3311 MW 43 0001 3312 MW JOB 43 0001 3313 TT 43 0001 3314 TT JOB 42 0406 0315 42 0406 0093 42 0001 1501 42 0001 5477 32 0405 0183 42 0404 0024 43 0004 2652 43 0004 2650 42 0405 05...

Page 200: ...200 Spare parts list TransTig 4000...

Page 201: ...201...

Page 202: ...202 Spare parts list MagicWave 4000...

Page 203: ...203...

Page 204: ...204...

Page 205: ...205 Circuit diagrams MagicWave 2200 Comfort V 12 06 2014...

Page 206: ...206 Circuit diagrams MagicWave 2500 Comfort...

Page 207: ...207 Circuit diagrams MagicWave 3000 Comfort...

Page 208: ...208 Circuit diagrams MagicWave 4000 Comfort V 17 12 2012 1 2...

Page 209: ...209 V 17 12 2012 2 2...

Page 210: ...210 Circuit diagrams TransTig 2200 Comfort V 14 12 2010...

Page 211: ...211 Circuit diagrams TransTig 2500 Comfort...

Page 212: ...212 Circuit diagrams TransTig 3000 Comfort...

Page 213: ...213 Circuit diagrams TransTig 4000 Comfort V 17 12 2012...

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Page 216: ...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...

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Fronius MagicWave 2200 Comfort, Operating Instructions Manual

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