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122

General

Service codes
during calibration
of the push-pull
unit

No. Push-pull unit

Wire feed speed

Fronius KD 7000
Fronius VR 1530 KD

22 m/min or 866 ipm

Fronius KD 7000
Fronius VR 1530 KD

30 m/min or 1181 ipm

Fronius Robacta KD Drive
Fronius Robacta Plasma KD Drive
Fronius Robacta Laser KD Drive

10 m/min or 394 ipm

Fronius Robacta KD Drive
Fronius Robacta Plasma KD Drive
Fronius Robacta Laser KD Drive

22 m/min or 866 ipm

Fronius KD 7000
Fronius VR 1530 KD

10 m/min or 394 ipm

Fronius Robacta KD Drive
Fronius Robacta Plasma KD Drive
Fronius Robacta Laser KD Drive

5 m/min or 197 ipm

Fronius KD 4010

10 m/min or 394 ipm

Binzel Torch Drive IWG

8 m/min or 315 ipm

Fronius KD 7000
Fronius VR 1530 KD

10 m/min or 394 ipm

The following abbreviations are used for the service codes shown during calibration of the
push-pull unit:
KD

= Cold wire-feed unit

PPU

= Push-pull unit

vDmin

= minimum wire feed speed

vDmax = maximum wire feed speed

Service codes when the drive units are disengaged (open-circuit calibration)

Cause:

Incorrect measurement during
push-pull calibration

Remedy:

Repeat push-pull calibration

St1 - E1, St1 - E3

Cause:

At minimum wire feed speed, the
wire-feed unit motor does not de-
liver any actual rotational speed
value.

Remedy:

Repeat the push-pull calibration.
If the error message re-appears:
Contact After-Sales Service.

Содержание MagicWave 2200 Comfort

Страница 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...

Страница 2: ...2...

Страница 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...

Страница 4: ...4...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 10: ...10...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 23: ...General information...

Страница 24: ......

Страница 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...

Страница 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...

Страница 27: ...Control elements and connections...

Страница 28: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 39: ...Installation and commissioning...

Страница 40: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 45: ...Welding...

Страница 46: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 89: ...Setup settings...

Страница 90: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 170: ...170...

Страница 171: ...Troubleshooting and maintenance...

Страница 172: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 184: ...184...

Страница 185: ...Appendix...

Страница 186: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 197: ...197...

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

Страница 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...

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

Страница 201: ...201...

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

Страница 203: ...203...

Страница 204: ...204...

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

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

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

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

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

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

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

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

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

Страница 214: ......

Страница 215: ......

Страница 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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