FRONIUS TransTig 800 User manual

Operating

Instructions

TransTig 800

TransTig 2200

TransTig 2500 / 3000

TransTig 4000 / 5000

MagicWave 1700 / 2200

MagicWave 2500 / 3000

MagicWave 4000 / 5000

42,0426,0027,EN 023-21092022

EN Operating instructions

Contents

Safety rules 7

Explanation of safety notices 7

General 7

Proper use 8

Environmental conditions 8

Obligations of the operator 8

Obligations of personnel 8

Mains connection 9

Protecting yourself and others 9

Noise emission values 10

Danger from toxic gases and vapours 10

Danger from ﬂying sparks 10

Risks from mains current and welding current 11

Meandering welding currents 12

EMC Device Classifications 12

EMC measures 12

EMF measures 13

Specific hazards 13

Requirement for the shielding gas 14

Danger from shielding gas cylinders 14

Danger from escaping shielding gas 15

Safety measures at the installation location and during transport 15

Safety measures in normal operation 16

Commissioning, maintenance and repair 16

Safety inspection 17

Disposal 17

Safety symbols 17

Data protection 17

General information 19

General 21

Device concept 21

Functional principle 22

Application areas 22

Warning notices on the device 23

System components 24

General 24

Overview 24

Control elements and connections 25

Description of the control panels 27

General 27

Safety 27

Overview 28

MagicWave control panel 29

TransTig control panel 34

Key combinations - special functions 38

General 38

Displaying the software version, operating time and coolant ﬂow 38

Connections, switches and mechanical components 39

MagicWave1700 / 2200 39

MagicWave2500 / 3000 40

MagicWave4000 / 5000 41

TransTig 2200 42

TransTig2500 / 3000 43

TransTig4000 / 5000 44

Installation and commissioning 45

Minimum equipment needed for welding task 47

General 47

TIG AC welding 47

TIG DC welding 47

MMA welding 47

Before installation and commissioning 48

Safety 48

Utilisation for intended purpose 48

Setup regulations 48

Mains connection 48

Generator-powered operation (MW 1700 / 2200, TT 2200) 49

Connecting up the mains cable on US power sources 50

General 50

Stipulated mains cables and strain-relief devices 50

Safety 50

Connecting the mains cable 50

Replacing the strain-relief device 52

Start-up 53

Safety 53

Remarks on the cooling unit 53

General 53

Connecting the gas cylinder 53

Establishing a ground (earth) connection to the workpiece 54

Connecting the welding torch 54

Welding 55

TIG modes 57

Safety 57

Symbols and their explanations 57

2-step mode 58

4-step mode 58

Special 4-step mode: variant 4 59

Cap shaping and cap overloading 60

Cap-shaping 60

TIG welding 61

Safety 61

Welding parameters 61

Preparation 62

TIG welding 62

Igniting the arc 64

General 64

Igniting the arc using high frequency(HF ignition) 64

Touchdown ignition 65

End of welding 66

Special functions and options 67

Arc break watchdog function 67

Ignition time-out function 67

Tacking function 67

MMA welding 69

Safety 69

Preparation 69

MMA welding 69

Hotstart function 71

Anti-stick function 71

Setup settings 73

The Setup menu 75

General 75

Overview 75

Shielding gas setup menu 76

General 76

Opening the Protective gas shield set-up menu 76

Changing welding parameters 76

Exiting the set-up menu 76

Welding parameters in the Protective gas shield set-up menu 76

TIG setup menu 78

Opening the TIG set-up menu 78

Changing welding parameters 78

Exiting the set-up menu 78

Welding parameters in the TIG setup menu 78

Rod electrode setup menu 82

Open the rod electrode set-up menu 82

Changing welding parameters 82

Exiting the set-up menu 82

Welding parameters in the rod electrode set-up menu 82

Rod electrode setup menu: level 2 84

Opening the rod electrode set-up menu level 2 84

Changing welding parameters 84

Exiting the rod electrode set-up menu - level 2 84

Welding parameters in the rod electrode setup menu - level 2 84

Troubleshooting and maintenance 87

Troubleshooting 89

General 89

Safety 89

Displayed service codes 89

Power source - troubleshooting 92

Care, maintenance and disposal 94

General 94

Safety 94

At every start-up 94

Every 2 months 94

Every 6 months 95

Disposal 95

Appendix 97

Average consumption values during welding 99

Average wire electrode consumption during MIG/MAG welding 99

Average shielding gas consumption during MIG/MAG welding 99

Average shielding gas consumption during TIG welding 99

Technical data 100

Special voltages 100

Overview with critical raw materials, year of production of the device 100

MagicWave 1700 100

MagicWave 2200 101

MagicWave 2500 102

MagicWave 3000 103

MagicWave 2500 MV 104

MagicWave 3000 MV 105

MagicWave 4000 106

MagicWave 5000 107

MagicWave 4000 MV 108

MagicWave 5000 MV 109

TransTig 800 110

TransTig 2200 111

TransTig 2500 112

TransTig 3000 113

TransTig 2500 MV 114

TransTig 3000 MV 116

TransTig 4000 117

TransTig 5000 118

TransTig 4000 MV 119

TransTig 5000 MV 120

Explanation of footnotes 121

Terms and abbreviations used 122

General 122

Terms and abbreviations A - F 122

Terms and abbreviations G - H 122

Terms and abbreviations I - U 123

Safety rules

Explanation of

safety notices DANGER!

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.

▶If not avoided, minor injury and/or damage to property may result.

NOTE!

Indicates a risk of ﬂawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to

recognised safety standards. If used incorrectly or misused, however, it can

cause:

-injury or death to the operator or a third party,

-damage to the device and other material assets belonging to the operating

company,

-inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the

device must:

-be suitably qualified,

-have sufficient knowledge of welding and

-read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being

used. In addition to the operating instructions, attention must also be paid to any

generally applicable and local regulations regarding accident prevention and en-

vironmental protection.

All safety and danger notices on the device

-must be in a legible state,

-must not be damaged,

-must not be removed,

-must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the sec-

tion headed "General" in the operating instructions for the device.

Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

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

-studying and obeying all safety and danger notices carefully

-performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

-Thawing out pipes

-Charging batteries

-Starting engines

The device is designed for use in industry and the workshop. The manufacturer

accepts no responsibility for any damage caused through use in a domestic set-

ting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental

conditions

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 held

liable for any damage arising from such usage.

Ambient temperature range:

-during operation: -10 °C to + 40 °C (14 °F to 104 °F)

-during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:

-up to 50% at 40 °C (104 °F)

-up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances,

etc.

Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of

the operator

The operator must only allow persons to work with the device who:

-are familiar with the fundamental instructions regarding safety at work and

accident prevention and have been instructed in how to use the device

-have read and understood these operating instructions, especially the sec-

tion "safety rules", and have confirmed as much with their signatures

-are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are

working in a safety-conscious manner.

Obligations of

personnel

Before using the device, all persons instructed to do so undertake:

-to observe the basic instructions regarding safety at work and accident pre-

vention

-to read these operating instructions, especially the "Safety rules" section and

sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any

harm in your absence.

Mains connec-

tion

Devices with a higher rating may affect the energy quality of the mains due to

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 *)

*) at the interface with the public grid

see "Technical data"

In this case, the plant operator or the person using the device should check

whether the device may be connected, where appropriate by discussing the mat-

ter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Protecting your-

self and others

Anyone working with the device exposes themselves to numerous risks, e.g.

-ﬂying sparks and hot pieces of metal

-Arc radiation, which can damage eyes and skin

-Hazardous electromagnetic fields, which can endanger the lives of those us-

ing cardiac pacemakers

-Risk of electrocution from mains current and welding current

-Greater noise pollution

-Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The

protective clothing must have the following properties:

-Flame-resistant

-Insulating and dry

-Covers the whole body, is undamaged and in good condition

-Safety helmet

-Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

-Protect eyes and face from UV rays, heat and sparks using a protective visor

and regulation filter

-Wear regulation protective goggles with side protection behind the protect-

ive visor

-Wear stout footwear that provides insulation even in wet conditions

-Protect the hands with suitable gloves (electrically insulated and providing

protection against heat)

-Wear ear protection to reduce the harmful effects of noise and to prevent in-

jury

Keep all persons, especially children, out of the working area while any devices

are in operation or welding is in progress. If, however, there are people in the vi-

cinity:

-Make them aware of all the dangers (risk of dazzling by the arc, injury from

ﬂying sparks, harmful welding fumes, noise, possible risks from mains cur-

rent and welding current, etc.)

-Provide suitable protective equipment

-Alternatively, erect suitable safety screens/curtains.

Noise emission

values

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)

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.

It is not possible to provide a workplace-related emission value during welding

(or cutting) as this is inﬂuenced by both the process and the environment. All

manner of different welding parameters come into play, including the welding

process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the

power range, the type of weld metal, the resonance characteristics of the work-

piece, the workplace environment, etc.

Danger from tox-

ic gases and va-

pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph

118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.

If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

-must not be breathed in

-must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of

at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the

measured toxic emission values should be compared with the permissible limit

values.

The following components are responsible, amongst other things, for the degree

of toxicity of welding fumes:

-Metals used for the workpiece

-Electrodes

-Coatings

-Cleaners, degreasers, etc.

-Welding process used

The relevant material safety data sheets and manufacturer's specifications for

the listed components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for

identifying working conditions can be found on the European Welding Associ-

ation website under Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-

ation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking

place.

Danger from ﬂy-

ing sparks

Flying sparks may cause fires or explosions.

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