TransTig 800 Job

TransTig 2200 Job

TransTig 2500 / 3000 Job
TransTig 4000 / 5000 Job
MagicWave 1700 / 2200 Job
MagicWave 2500 / 3000 Job
Operating Instructions
MagicWave 4000 / 5000 Job GB
Spare Parts List
TIG power source

42,0426,0025,EN 022011
Dear Reader

Introduction Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.

ud_fr_st_et_00493 012004
Safety rules

DANGER!
“DANGER!” indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.

WARNING!
“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.

CAUTION!
“CAUTION!” indicates a potentially hazardous situation which, if not avo-
ided, may result in minor or moderate injury. It may also be used to alert
against unsafe practices that may cause property damage.

NOTE! “NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.

Important! “Important!” indicates practical hints and other useful special-information. It

is no signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay even
closer attention to the contents of the manual!

General remarks This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for
- the life and well-being of the operator or of third parties,
- the equipment and other tangible assets belonging to the owner/operator,
- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must
- be suitably qualified
- know about welding and
- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must be
kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:
- must be kept in a legible condition
- must not be damaged, must not be removed
- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings are
located on the machine, please see the section of your machine’s instruction
manual headed “General remarks”.

I ud_fr_st_sv_00467 012010
General remarks Any malfunctions which might impair machine safety must be eliminated
(continued) immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

Utilisation for The machine may only be used for jobs as defined by the “Intended
intended purpose purpose”.
only
The machine may ONLY be used for the welding processes stated on the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall not
be liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual
- complete reading and following of all the safety instructions and danger
warnings
- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes
- Charging batteries/accumulators
- Starting engines

The machine is designed to be used in industrial and workshop

environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty work
results.

Ambient Operation or storage of the power source outside the stipulated range is
conditions deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.

Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)
- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric humidity:

- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

Obligations of The owner/operator undertakes to ensure that the only persons allowed to
owner/operator work with the machine are persons who
- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine
- have read and understood the sections on “safety rules” and the “war-
nings“ contained in this manual, and have confirmed as much with their
signatures
- be trained in such a way that meets with the requirements of the work
results

Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.

ud_fr_st_sv_00467 012010 II
Obligations of Before starting work, all persons to be entrusted with carrying out work with
personnel (or on) the machine shall undertake
- to observe the basic regulations on workplace safety and accident
prevention
- to read the sections on “safety rules” and the “warnings” contained in this
manual, and to sign to confirm that they have understood these and will
comply with them.

Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.

Mains connection High-performance devices can affect the quality of the mains power due to
their current-input.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to maximum permissible mains impedance *)
- criteria with regard to minimum short-circuit power requirement *)

*)
at the interface with the public mains network

see Technical Data

In this case, the plant operator or the person using the device should check
whether or not the device is allowed to be connected, where appropriate
through discussion with the power supply company.

Protection for When welding, you are exposed to many different hazards such as:
yourself and - flying sparks and hot metal particles
other persons - arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pace-
maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable pro-
tective clothing with the following characteristics:
- flame-retardant
- isolating and dry
- must cover whole body, be undamaged and in good condition
- protective helmet
- trousers with no turn-ups

III ud_fr_st_sv_00467 012010

Protection for “Protective clothing” also includes:
yourself and - protecting your eyes and face from UV rays, heat and flying sparks with
other persons an appropriate safety shield containing appropriate regulation filter glass
(continued) - wearing a pair of appropriate regulation goggles (with sideguards) behind
the safety shield
- wearing stout footwear that will also insulate even in wet conditions
- protecting your hands by wearing appropriate gloves (electrically insula-
ting, heat-proof)
- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!

Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must
- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)
- provide them with suitable protective equipment and/or
- erect suitable protective partitions or curtains.

Information on The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
noise emission when idling and in the cooling phase following operation at the maximum
values permissible 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
workpiece, the workplace environment, etc.

Hazards from The fumes given off during welding contain gases and vapors that are
noxious gases harmful to health.
and vapours
Welding fumes contain substances which may cause birth defects and
cancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable means.

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an

independent air supply.

If you are not sure whether your fume-extraction system is sufficiently power-
ful, compare the measured pollutant emission values with the permitted
threshold limit values.

ud_fr_st_sv_00467 012010 IV
Hazards from The harmfulness of the welding fumes will depend on e.g. the following
noxious gases components:
and vapours - the metals used in and for the workpiece
(continued) - the electrodes
- coatings
- cleaning and degreasing agents and the like

For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.

Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.

Hazards from Flying sparks can cause fires and explosions!

flying sparks
Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (35 feet) away from the
arc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that there
is no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or explosion,
or in enclosed tanks, barrels or pipes, unless these latter have been
prepared for welding in accordance with the relevant national and
international standards.

Welding must NEVER be performed on containers that have had gases,

fuels, mineral oils etc. stored in them. Even small traces of these substances
left in the containers are a major explosion hazard.

Hazards from An electric shock is potentially life-threatening, and can be fatal.

mains and weld-
ing current Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or else

use a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/frame
potential. The base or cover must completely cover the entire area between
your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.

V ud_fr_st_sv_00467 012010
Hazards from Do not loop any cables or other leads around your body or any part of your
mains and weld- body.
ing current
(continued) Never immerse the welding electrode (rod electrode, tungsten electrode,
welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.

Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor and

plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is

sufficiently grounded (earthed).

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from the
mains.

Put up a clearly legible and easy-to-understand warning sign to stop anybody

inadvertently plugging the machine back into the mains and switching it back
on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge
- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second

person on hand to immediately switch off the machine at the main switch in
an emergency.

Stray welding If the following instructions are ignored, stray welding currents may occur.
currents These can cause:
- fires
- overheating of components that are connected to the workpiece
- destruction of PE conductors
- damage to the machine and other electrical equipment

Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a way

that it is sufficiently insulated from the floor.

ud_fr_st_sv_00467 012010 VI
Stray welding When using current supply distributors, twin head wire feeder fixtures etc.,
currents please note the following: The electrode on the unused welding torch/welding
(continued) tongs is also current carrying. Please ensure that there is sufficient insula-
ting storage for the unused welding torch/tongs.

In the case of automated MIG/MAG applications, ensure that only insulated

filler wire is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wirefeeder.

EMC device Devices with emission class A:

classifications - are only designed for use in an industrial setting
- can cause conducted and emitted interference in other areas.

Devices with emission class B:

- satisfy the emissions criteria for residential and industrial areas. This
also applies to residential areas in which power is supplied from the
public low-voltage grid.

EMC device classification as per the rating plate or technical specifications

EMC measures In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to
rectify the situation.

Examine and evaluate any possible electromagnetic problems that may

occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:
- safety features
- mains, signal and data-transmission leads
- IT and telecoms equipment
- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply
- If electromagnetic interference still occurs, despite the fact that the mains
connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).

b) Welding cables
- Keep these as short as possible
- Arrange them so that they run close together (to prevent EMI problems
as well)
- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable
capacitors.

e) Shielding, where necessary

- Shield other equipment in the vicinity
- Shield the entire welding installation.

VII ud_fr_st_sv_00467 012010

EMI Precautions Electromagnetic fields may cause as yet unknown damage to health.
- Effects on the health of persons in the vicinity, e.g. users of heart pace-
makers and hearing aids
- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces
- Keep as much space as possible between welding cables and head/body
of welder for safety reasons
- Do not carrywelding cables and hose pack over shoulder and do not loop
around body or or any part of body

Particular danger Keep your hands, hair, clothing and tools well away from all moving parts,
spots e.g.:
- fans
- toothed wheels, rollers, shafts
- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.0

Covers and sideguards may only be opened or removed for as long as is

absolutely necessary to carry out maintenance and repair work.

While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are
properly mounted ...
- ... and that all covers and sideguards are kept closed.

When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...). For this
reason, when feeder-inching etc., always hold the torch so that it is pointing
away from your body (machines with wirefeeder).

Do not touch the workpiece during and after welding - risk of injury from
burning!

Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.

Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.

Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.

Risk of scalding from accidental discharge of hot coolant. Before unplugging

the connectors for coolant forward flow and return flow, switch off the cooling
unit.

ud_fr_st_sv_00467 012010 VIII

Particular danger When hoisting the machines by crane, only use suitable manufacturer-
spots supplied lifting devices.
(continued) - Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.
- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.
- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).

When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember that

this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.

Danger of colourless and odourless inert gas escaping unnoticed, when

using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.

Danger from Shielding-gas cylinders contain pressurized gas and may explode if they are
shielding-gas damaged. As shielding-gas cylinders are an integral part of the overall
cylinders welding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessive

heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas

cylinder.

Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories that
are in good condition.

When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national and

international rules applying to shielding-gas cylinders and accessories.

IX ud_fr_st_sv_00467 012010
Safety precauti- A machine that topples over can easily kill someone! For this reason, always
ons at the instal- place the machine on an even, firm floor in such a way that it stands firmly.
lation site and - An angle of inclination of up to 10° is permissible.
when being
transported
Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m

(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportation
and carriage.

Before transportation, completely drain any coolant and dismantle the follo-
wing components:
- Wire feed
- Wire wound coil
- Gas bottle

Before commissioning and after transportation, a visual check for damage

must be carried out. Any damage must be repaired by trained service per-
sonnel before commissioning.

Safety precau- Only operate the machine if all of its protective features are fully functional. If
tions in normal any of the protective features are not fully functional, this endangers:
operation - the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/operator
- efficient working with the equipment.

Any safety features that are not fully functional must be put right before you
switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by

your doing so.

- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.
- Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.
- Owing to its special properties (in terms of electrical conductivity, frost-
proofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.
- Only use suitable original coolant of the manufacturer.
- Do not mix original coolant of the manufacturer with other coolants.

ud_fr_st_sv_00467 012010 X
Safety precauti- - If any damage occurs in cases where other coolants have been used, the
ons in normal manufacturer shall not be liable for any such damage, and all warranty
operation claims shall be null and void.
(continued) - Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.
- Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.
- Before starting welding - while the machine is still cool - check the
coolant level.

Preventive and With parts sourced from other suppliers, there is no certainty that these parts
corrective main- will have been designed and manufactured to cope with the stressing and
tenance safety requirements that will be made of them. Use only original spares and
wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine

without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.

Safety inspection The manufacturer recommends that a safety inspection of the device is
performed at least once every 12 months.

The manufacturer recommends that the 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 after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.

For safety inspections, follow the appropriate national and international

standards and directives.

Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may
require.

Disposal Do not dispose of this device with normal domestic waste!

To comply with the European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation as national law, electrical
equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility Any device that you no longer
require must be returned to our agent, or find out about the approved collec-
tion and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!

XI ud_fr_st_sv_00467 012010
Safety markings Equipment with CE-markings fulfils the basic requirements of the Low-
Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .

Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.

Data security The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.

Copyright Copyright to this instruction manual remains the property of the

manufacturer.

The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the in-
struction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.

ud_fr_st_sv_00467 012010 XII

Contents

General information 5

General remarks ............................................................................................................................................ 7

Machine concept ....................................................................................................................................... 7
Functional principle .................................................................................................................................... 8
Areas of utilisation ..................................................................................................................................... 8
Warning notices affixed to the machine ..................................................................................................... 9
System components ..................................................................................................................................... 10
General remarks ..................................................................................................................................... 10
Overview ................................................................................................................................................. 10

Controls and connections 11

Description of the control panels .................................................................................................................. 13

General remarks ..................................................................................................................................... 13
Safety ...................................................................................................................................................... 13
Overview ................................................................................................................................................. 13
MagicWave control panel ............................................................................................................................. 14
MagicWave control panel ........................................................................................................................ 14
TransTig control panel .................................................................................................................................. 19
TransTig control panel ............................................................................................................................. 19
Key combinations - special functions ............................................................................................................ 24
General remarks ..................................................................................................................................... 24
Keylock .................................................................................................................................................... 24
Displaying the software version, operating time and coolant flow ............................................................ 24
Connections, switches and mechanical components .................................................................................... 25
MagicWave 1700/2200 Job ..................................................................................................................... 25
MagicWave 2500/3000 Job ..................................................................................................................... 26
MagicWave 4000/5000 Job ..................................................................................................................... 27
TransTig 800/2200 Job ............................................................................................................................ 28
TransTig 2500/3000 Job .......................................................................................................................... 29
TransTig 4000/5000 Job .......................................................................................................................... 30

Installation 31

Minimum equipment needed for welding ...................................................................................................... 33

General remarks ..................................................................................................................................... 33
TIG AC welding ....................................................................................................................................... 33
TIG DC welding ....................................................................................................................................... 33
Automated TIG welding ........................................................................................................................... 33
Rod electrode (MMA) welding ................................................................................................................. 33
Before installation and commissioning .......................................................................................................... 34
Safety ...................................................................................................................................................... 34
Utilisation for intended purpose only ........................................................................................................ 34
Set-up guidelines ..................................................................................................................................... 34
Mains connection .................................................................................................................................... 34
Generator-powered operation (MW 1700/2200, TT 800/2200) ................................................................ 35
Connecting up the mains cable on US power sources ................................................................................. 36
General remarks ..................................................................................................................................... 36
Stipulated mains cables and strain relief devices ..................................................................................... 36
Safety ...................................................................................................................................................... 36
Connecting up the mains cable ............................................................................................................... 36
Replacing the strain relief device ............................................................................................................. 37

1
 Commissioning ............................................................................................................................................. 39
Safety ...................................................................................................................................................... 39
Remarks on the cooling unit .................................................................................................................... 39
General remarks ..................................................................................................................................... 39
Connecting up the gas cylinder ............................................................................................................... 39
Establishing an earth (ground) connection to the workpiece .................................................................... 40
Connecting the welding torch .................................................................................................................. 40

Welding 41

TIG modes ................................................................................................................................................... 43

Safety ...................................................................................................................................................... 43
Symbols and their explanations ............................................................................................................... 43
2-step mode ............................................................................................................................................ 44
Spot welding ............................................................................................................................................ 44
4-step mode ............................................................................................................................................ 45
Special 4-step mode: variant 1 ................................................................................................................ 45
Special 4-step mode: variant 2 ................................................................................................................ 46
Special 4-step mode: variant 3 ................................................................................................................ 46
Special 4-step mode: Variant 4 ................................................................................................................ 47
Sonder 4-Takt Betrieb: Variante 4 ............................................................................................................ 47
Special 4-step mode: Variant 5 ................................................................................................................ 47
Sonder 4-Takt Betrieb: Variante 5 ............................................................................................................ 47
Special 4-step mode: Variant 6 ................................................................................................................ 48
Cap shaping and cap overloading ................................................................................................................ 49
Cap shaping ............................................................................................................................................ 49
Cap overloading ...................................................................................................................................... 49
TIG welding .................................................................................................................................................. 50
Safety ...................................................................................................................................................... 50
Welding parameters ................................................................................................................................ 50
Preparations ............................................................................................................................................ 51
TIG welding ............................................................................................................................................. 51
Igniting the arc .............................................................................................................................................. 53
General remarks ..................................................................................................................................... 53
Igniting the arc using high frequency (HF ignition) ................................................................................... 53
Touchdown ignition .................................................................................................................................. 54
Finishing welding ..................................................................................................................................... 55
Special functions and options ....................................................................................................................... 56
Arc break watchdog function ................................................................................................................... 56
Ignition time-out function ......................................................................................................................... 56
TIG pulsing .............................................................................................................................................. 56
Tacking function ...................................................................................................................................... 57
TIG cold-wire welding .............................................................................................................................. 58
Rod electrode (MMA) welding ...................................................................................................................... 60
Safety ...................................................................................................................................................... 60
Preparations ............................................................................................................................................ 60
Rod electrode (MMA) welding ................................................................................................................. 60
Hot-Start function ..................................................................................................................................... 61
Anti-Stick function .................................................................................................................................... 62
Job mode ..................................................................................................................................................... 63
General remarks ..................................................................................................................................... 63
Abbreviations ........................................................................................................................................... 63
Saving a job ............................................................................................................................................. 63
Retrieving a job ....................................................................................................................................... 64
Retrieving jobs on the JobMaster TIG ..................................................................................................... 65
Copying/overwriting a job ........................................................................................................................ 65
Deleting a job .......................................................................................................................................... 66

2
Set-up settings 69

Job correction ............................................................................................................................................... 71

General remarks ..................................................................................................................................... 71
Opening the Job correction menu ............................................................................................................ 71
Changing a parameter ............................................................................................................................. 71
Exiting the Job correction menu .............................................................................................................. 71
Parameters that can be corrected in the Job correction menu ................................................................ 71
The Set-up menu .......................................................................................................................................... 76
General remarks ..................................................................................................................................... 76
Overview ................................................................................................................................................. 76
Shielding gas set-up menu ........................................................................................................................... 77
General remarks ..................................................................................................................................... 77
Opening the Shielding gas set-up menu .................................................................................................. 77
Changing a parameter ............................................................................................................................. 77
Exiting from the Shielding gas set-up menu ............................................................................................ 77
Parameters in the Shielding gas set-up menu ......................................................................................... 77
TIG set-up menu .......................................................................................................................................... 79
Opening the TIG set-up menu ................................................................................................................. 79
Changing a parameter ............................................................................................................................. 79
Exiting from the TIG set-up menu ............................................................................................................ 79
Parameters in the TIG set-up menu ........................................................................................................ 79
TIG set-up menu - level 2 ............................................................................................................................. 83
Opening TIG set-up menu - level 2 .......................................................................................................... 83
Changing a parameter ............................................................................................................................. 83
Exiting from the TIG set-up menu - level 2 .............................................................................................. 83
Parameters in TIG set-up menu - level 2 ................................................................................................. 83
AC/polarity reversal set-up menu .................................................................................................................. 87
General remarks ..................................................................................................................................... 87
Opening the AC/polarity reversal set-up menu ........................................................................................ 87
Changing a parameter ............................................................................................................................. 87
Exiting from the AC/polarity reversal set-up menu ................................................................................... 87
Parameters in the AC/polarity reversal set-up menu ................................................................................ 87
AC/polarity reversal set-up menu - level 2 .................................................................................................... 89
General remarks ..................................................................................................................................... 89
Opening the AC/polarity reversal set-up menu - level 2 ........................................................................... 89
Changing a parameter ............................................................................................................................. 89
Exiting from the AC/polarity reversal set-up menu - level 2 ...................................................................... 89
Parameters in the AC/polarity reversal set-up menu - level 2 .................................................................. 89
DC setup menu ............................................................................................................................................ 91
General ................................................................................................................................................... 91
Open the DC setup menu ........................................................................................................................ 91
Changing a parameter ............................................................................................................................. 91
Exiting from the DC set-up menu ............................................................................................................ 91
Parameters in the DC set-up menu ......................................................................................................... 91
DC set-up menu - level 2 .............................................................................................................................. 92
General ................................................................................................................................................... 92
Opening the DC set-up menu - level 2 ..................................................................................................... 92
Changing a parameter ............................................................................................................................. 92
Exiting from the DC set-up menu - level 2 ............................................................................................... 92
Parameters in the DC set-up menu - level 2 ............................................................................................ 92
Rod electrode set-up menu .......................................................................................................................... 93
Opening the Rod electrode set-up menu ................................................................................................. 93
Changing a parameter ............................................................................................................................. 93
Exiting from the Rod electrode set-up menu ........................................................................................... 93
Parameters in the Rod electrode set-up menu ........................................................................................ 93

3
 Rod electrode set-up menu - level 2 ............................................................................................................. 95
Opening Rod electrode set-up menu - level 2.......................................................................................... 95
Changing a parameter ............................................................................................................................. 95
Exiting from the Rod electrode set-up menu - level 2 .............................................................................. 95
Parameters in the Rod electrode set-up menu - level 2 ........................................................................... 95
Displaying welding circuit resistance r .......................................................................................................... 99
General remarks ..................................................................................................................................... 99
Measuring the welding circuit resistance r ............................................................................................... 99
Displaying welding circuit inductivity L ........................................................................................................ 100
General remarks ................................................................................................................................... 100
Measuring welding circuit inductivity L ................................................................................................... 100

Troubleshooting and maintenance 101

Troubleshooting .......................................................................................................................................... 103

General remarks ................................................................................................................................... 103
Displayed service codes ........................................................................................................................ 103
Power source ........................................................................................................................................ 105
Care, maintenance and disposal ................................................................................................................ 107
General remarks ................................................................................................................................... 107
Safety .................................................................................................................................................... 107
Every start-up ........................................................................................................................................ 107
Every 2 months ..................................................................................................................................... 107
Every 6 months ..................................................................................................................................... 107
Disposal ................................................................................................................................................ 107

Annex 109

Technical Data ............................................................................................................................................. 111

Special voltages ...................................................................................................................................... 111
MagicWave 1700/2200 Job .................................................................................................................... 111
MagicWave 2500/3000 Job .................................................................................................................... 112
MagicWave 2500/3000 Job MV .............................................................................................................. 112
MagicWave 4000/5000 Job .................................................................................................................... 113
MagicWave 4000/5000 Job MV .............................................................................................................. 114
TransTig 800/2200 Job .......................................................................................................................... 115
TransTig 2500/3000 Job ......................................................................................................................... 116
TransTig 2500/3000 Job MV .................................................................................................................. 116
TransTig 4000/5000 Job ......................................................................................................................... 117
TransTig 4000 MV / 5000 Job MV .......................................................................................................... 118
TransTig 4000 MV / 5000 Job MV .......................................................................................................... 119
Explanation of footnotes ......................................................................................................................... 119
Terms and abbreviations used .................................................................................................................... 120
General remarks ................................................................................................................................... 120
Terms and abbreviations A - C ............................................................................................................... 120
Terms and abbreviations D - E .............................................................................................................. 120
Terms and abbreviations F .................................................................................................................... 121
Terms and abbreviations G - H .............................................................................................................. 121
Terms and abbreviations I - P ................................................................................................................ 122
Terms and abbreviations R - 2nd ........................................................................................................... 122

4
General information

5
6
General remarks

Machine concept The MagicWave (MW) 1700 / 2200 / 2500 /

3000 / 4000 / 5000 and TransTig (TT) 800 /
2200 / 2500 / 3000 / 4000 / 5000 TIG power
sources are completely digitised, micropro-
cessor controlled inverter power sources.

The modular design and potential for

system add-ons ensure a high degree of
flexibility. The machines can be adapted to
any specific situation.

The straightforward operating concept

means the welder can see the key functions
„at a glance“ and adjust them accordingly.
The „Job Mode“ feature allows welding
data (programmed welding sequences) to
Fig.1 TransTig 2200 Job, MagicWave 1700 Job be stored. This can then be recalled at any
and MagicWave 2200 Job with cooling unit time and used again for welding the
relevant type of seam.

A standardised LocalNet interface makes

it easy to connect up digital system add-
ons (e.g. JobMaster TIG welding torches,
robot welding torches, remote control
units, etc.).

Automatic cap shaping for AC welding with

MagicWave power sources takes the
diameter of the tungsten electrode into
account to help produce optimum results.

All power sources are generator-compatible

and are exceptionally sturdy in day-to-day
operation, thanks to the protected controls
and to their powder-coated housings.
Fig.2 MagicWave 3000 Job with cooling unit and
MagicWave 2200 Job
The TIG pulsed arc function, with its wide
frequency range, is available on both the
MagicWave and TransTig.

To optimise the ignition sequence in TIG

AC welding, the MagicWave takes account
not only of the diameter of the electrode,
but also of its temperature, calculated with
reference to the preceding welding and
welding off-times.
RPI (Reverse Polarity Ignition) ensures an
excellent ignition response during TIG DC
welding.

Fig.3 TransTig 5000 Job and MagicWave 5000

Job, both with cooling unit and trolley

7
Functional prin- The central control and regulation unit of the power sources is coupled with a digital
ciple signal processor. The central control and regulation unit and signal processor control the
entire welding process.
During the welding process, the actual data is measured continuously and the machine
responds immediately to any changes. Control algorithms ensure that the specified
target status is maintained.

This results in:

- a precise welding process,
- exact reproducibility of all results
- excellent welding properties.

Areas of utilisati- The machines are used in workshops and industry for manual and automated TIG
on applications with unalloyed and low-alloy steel and high-alloy chrome-nickel steels.

The MagicWave power sources perform exceptionally well when it comes to welding
aluminium, aluminium alloys and magnesium due to the variable AC frequency.

8
Warning notices US power sources come with extra warning labels affixed to the unit. The warning
affixed to the labels must NOT be removed or painted over.
machine

Fig.4 US version of power source with additional warning notices, e.g. MagicWave 2200

9
System components

General remarks The TransTig and MagicWave power sources can be used with a wide variety of system
add-ons and options.

Overview

Cold wire feeders

TIG welding torch
Standard / Up/Down

TIG welding torch

JobMaster TIG

TIG robot welding torch

Cold wire feeders with wire drive
Remote control unit

FR
O
NI
US
Pedal remote control units

Robot accessories

Electrode cable
Power source
A

Earthing (grounding) cable

Trolley with
Cooling units Gas cylinder holder

Fig.5 System add-ons and options

10
Controls and connections

11
12
Description of the control panels

General remarks The key feature of the control panel is the logical way in which the controls are arranged.
All the main parameters needed for day-to-day working can easily be
- selected using the buttons
- altered with the adjusting dial
- displayed during welding on the digital display

NOTE! Owing to software updates, you may find that your machine has certain
functions that are not described in these Operating Instructions, or vice versa.
Also, certain illustrations may differ slightly from the actual controls on your
machine. However, these controls function in exactly the same way.

Safety
WARNING! Operating the equipment incorrectly can cause serious injury
and damage. Do not use the functions described here until you have read
and completely understood all of the following documents:
- these operating instructions
- all operating instructions for the system components, especially the
„Safety rules“

Overview „Description of the control panels“ is composed of the following sections:

- MagicWave control panel
- TransTig control panel
- Special functions

a) a)

b) b)

c) c)

Fig.6 MagicWave control panels: Fig.7 TransTig control panels

a) MW 1700 / 2200 a) TT 800 / 2200
b) MW 2500 / 3000 b) TT 2500 / 3000
c) MW 4000 / 5000 c) TT 4000 / 5000

13
MagicWave control panel

MagicWave
control panel (1) (2) (3) (4) (5) (6)

(16)
(7)

(15)

(14) (13) (12) (11) (10) (9) (8)

Fig.8 MagicWave control panel

No. Function
(1) Special indicators

Pulse indicator
lights up when the F-P set-up parameter has been set to a certain pulsing
frequency

Spot welding indicator

lights up when the SPt set-up parameter has been set to a certain spot-
welding time

Tacking indicator
lights up when the tAC set-up parameter has been set to a certain length of
time

Electrode overload indicator

lights up when the cap at the tip of the tungsten electrode is overloaded
See section on TIG welding under Welding for more information on the
Electrode overload indicator.

Keylock indicator
lights up when keylock is enabled

Inch indicator (only on MagicWave 2500/3000/4000/5000)

lights up when the SEt set-up parameter has been set to US

HF (high-frequency) ignition indicator

lights up when the HFt set-up parameter has been set to a certain interval for
the high-frequency pulses

Cold wire feeder indicator

lights up when a cold wire feeder has been connected up

14
MagicWave No. Function
control panel
(2) Left digital display
(continued)
(3) HOLD indicator
every time you finish a welding operation, the actual values for welding current and
welding voltage are stored, and the „Hold“ indicator lights up.

The „Hold“ indicator refers to the last value reached by the main current I1. As soon
as any other parameter is selected, the „Hold“ indicator goes out. The „Hold“ values
will continue to be available, however, if parameter I1 is selected again.

The „Hold“ indicator goes out whenever:

- a new welding operation is started
- the welding current I1 is adjusted
- the mode is changed
- the process is changed

Important! A Hold value is not output if

- the main current phase has not been reached,
or
- a pedal remote control was used.
(4) Right digital display
(5) Welding voltage indicator
lights up when parameter I1 is selected
The actual welding voltage value is shown on the right digital display during welding.

Before welding, the following appears on the right digital display

- 0.0 if a TIG welding mode is selected
- 50 V if rod electrode welding mode is selected (after a delay of 3 seconds; 50 V
is the average value for the pulsed open-circuit voltage)
(6) Unit indicators

m/min indicator
lights up when parameter Fd.1 or set-up parameter Fd.2 has been selected

Job No indicator
lights up in Job mode

kHz indicator
lights up when set-up parameter F-P is selected if the value entered for the
pulsing frequency >/= 1000 Hz

Hz indicator
lights up when
- set-up parameter F-P is selected if the value entered for the pulsing
frequency < 1000 Hz
- set-up parameter ACF has been selected

A indicator

% indicator
lights up when the parameters IS, I2 and IE plus set-up parameters dcY, I-G
and HCU have been selected

15
MagicWave No. Function
control panel
(6) Unit indicators
(continued)
s indicator
lights up when the tup and tdown parameters plus the following set-up parame-
ters have been selected:
- GPr - tAC - dt2 - Ito
- G-L - t-S - Hti - Arc
- G-H - t-E - Ct
- SPt - dt1 - HFt

mm indicator
lights up when the Fdb set-up parameter has been selected
(7) Process button
used to select the process depending on the mode that has been chosen

2-step mode/4-step mode:

automatic cap shaping;
only available in conjunction with TIG AC welding

TIG AC welding

TIG DC- welding

Job mode:
The process stored for the current job is displayed.

Rod electrode (MMA) welding mode:

Rod electrode AC welding

Rod electrode DC- welding

Rod electrode DC+ welding

When a process is selected, the LED on the relevant symbol lights up.
(8) Mode button
used to select the mode
2-step mode
4-step mode
Job mode
Rod electrode (MMA) welding

When a mode is selected, the LED on the relevant symbol lights up.
(9) Parameter Selection button (right)
used to select the welding parameters in the welding parameters overview (11)

When a parameter is selected, the LED on the relevant parameter symbol lights up.
(10) Gas-test button
used to set the required amount of shielding gas at the pressure regulator. After you
press this button, gas will flow out for 30 s. Press the button again to stop the test
gas flow before the 30 seconds are up.

16
MagicWave No. Function
control panel
(11) Welding parameters overview
(continued)
The welding parameters overview contains the most important welding parameters
for the welding mode. The sequence of welding parameters follows a clothesline
structure. Use the left and right Parameter Selection buttons to navigate within the
welding parameters overview.

Fig.9 Welding parameters overview

The welding parameters overview contains the following welding parameters:

Starting current IS
for TIG welding

Important! The starting current IS is saved separately for the TIG AC welding
and TIG DC- welding modes.

Upslope tup
period in TIG welding during which the starting current IS is increased to the
specified main current I1

Important! The upslope tup is saved separately for 2-step and 4-step modes.

Main current I1 (welding current)

- for TIG welding
- for rod electrode (MMA) welding

Reduced current I2
for TIG 4-step mode and TIG special 4-step mode

Downslope tdown
period in TIG welding during which the specified main current I1 is lowered to
the final current IE

Important! The downslope tdown is saved separately for 2-step and 4-step
modes.

Final current IE
for TIG welding

Balance
used to set the fusing power/cleaning action for TIG AC welding

17
MagicWave No. Function
control panel
(11) Welding parameters overview
(continued)
Wirefeed speed (only on MagicWave 4000/5000)
used to set the Fd.1 parameter if the cold-wire feeder option is available

Job No
used in Job mode to retrieve stored parameter records (using job numbers).

Electrode diameter
used in TIG welding to enter the diameter of the tungsten electrode

(12) Adjusting dial

used to change parameters. If the indicator on the adjusting dial lights up, then the
selected parameter can be altered.
(13) Welding current indicator
used to indicate the welding current for the following parameters
- starting current IS
- welding current I1
- reduced current I2
- final current IE

Before the start of welding, the left-hand digital display shows the command value.
For IS, I2 and IE the right-hand digital display also shows the respective percentage of
the welding current I1.

After the start of welding, the parameter I1 is automatically selected. The left-hand
digital display shows the actual welding current value.

In the welding parameters overview (11), LEDs for the various parameters (IS, tup,
etc.) light up to show the current position in the welding process.
(14) Store button
used to store jobs and access the Set-up menu
(15) Parameter Selection button (left)
used to select the welding parameters in the welding parameters overview (11)

When a parameter is selected, the LED on the relevant parameter symbol lights up.
(16) Overtemperature indicator
lights up if the power source overheats (e.g. because the duty cycle has been
exceeded). For more information on this, see the „Troubleshooting“ section.
(17) Keylock switch (option for MW 2500 / 3000 / 4000 / 5000)
When the key is in the horizontal position, all parameters and functions are disabled
with the exception of the currently selected parameter or function.

Important! The functions available on

the control panel of system compon-
ents are then restricted in the same (17)
way as those of the control panel on
the power source. Keylock switch position

18
TransTig control panel

TransTig control
panel (1) (2) (3) (4) (5) (6)

(15)

(14)

(13) (12) (11) (10) (9) (8) (7)

Fig.10 TransTig control panel

No. Function
(1) Special indicators

Pulse indicator
lights up when the F-P set-up parameter has been set to a certain pulsing
frequency

Spot welding indicator

lights up when the SPt set-up parameter has been set to a certain spot-
welding time

Tacking indicator
lights up when the tAC set-up parameter has been set to a certain length of time

Electrode overload indicator

lights up when the cap at the tip of the tungsten electrode is overloaded
See section on TIG welding under Welding for more information on the
Electrode overload indicator.

Keylock indicator
lights up when keylock is enabled

Inch indicator (only on TransTig 2500/3000/4000/5000)

lights up when the SEt set-up parameter has been set to US

HF (high-frequency) ignition indicator

lights up when the HFt set-up parameter has been set to a certain interval for
the high-frequency pulses

Cold wire feeder indicator

lights up when a cold wire feeder has been connected up

19
TransTig control No. Function
panel
(2) Left digital display
(continued)
(3) HOLD indicator
every time you finish a welding operation, the actual values for welding current and
welding voltage are stored, and the „Hold“ indicator lights up.

The „Hold“ indicator refers to the last value reached by the main current I1. As soon
as any other parameter is selected, the „Hold“ indicator goes out. The „Hold“ values
will continue to be available, however, if parameter I1 is selected again.

The „Hold“ indicator goes out whenever:

- a new welding operation is started
- the welding current I1 is adjusted
- the mode is changed
- the process is changed

Important! A Hold value is not output if

- the main current phase has not been reached,
or
- a pedal remote control was used.
(4) Right digital display
(5) Welding voltage display
lights up when parameter I1 is selected
The actual welding voltage value is shown on the right digital display during welding.

Before welding, the following appears on the right digital display

- 0.0 if a TIG welding mode is selected
- 50 V if a rod electrode welding mode is selected (after a delay of 3 seconds; 50
V is the average value for the pulsed open-circuit voltage)
(6) Unit indicators

m/min indicator
lights up when parameter Fd.1 or set-up parameter Fd.2 has been selected

Job No indicator
lights up in Job mode

kHz indicator
lights up when set-up parameter F-P is selected if the value entered for the
pulsing frequency >/= 1000 Hz

Hz indicator
lights up when
- set-up parameter F-P is selected if the value entered for the pulsing
frequency < 1000 Hz
- set-up parameter ACF has been selected

A indicator

% indicator
lights up when the parameters IS, I2 and IE plus set-up parameters dcY, I-G
and HCU have been selected.

20
TransTig control No. Function
panel
(6) Unit indicators
(continued)
s indicator
lights up when the tup and tdown parameters plus the following set-up parame-
ters have been selected:
- GPr - tAC - dt2 - Ito
- G-L - t-S - Hti - Arc
- G-H - t-E - Ct
- SPt - dt1 - HFt

mm indicator
lights up when the Fdb set-up parameter has been selected
(7) Mode button
used to select the mode
2-step mode
4-step mode
Job mode
Rod electrode (MMA) welding

When a mode is selected, the LED on the relevant symbol lights up.
(8) Parameter Selection button (right)
used to select the welding parameters in the welding parameters overview (10)

When a parameter is selected, the LED on the relevant parameter symbol lights up.
(9) Gas-test button
used to set the required amount of shielding gas at the pressure regulator. After you
press this button, gas will flow out for 30 s. Press the button again to stop the test
gas flow before the 30 seconds are up.
(10) Welding parameters overview
The welding parameters overview contains the most important welding parameters
for the welding mode. The sequence of the welding parameters follows a clothesline
structure. Use the left and right Parameter Selection buttons to navigate within the
welding parameters overview.

Fig.11 Welding parameters overview

The welding parameters overview contains the following welding parameters:

Starting current IS
for TIG welding

Important! The starting current IS is saved separately for the TIG AC welding
and TIG DC- welding modes.

21
TransTig control No. Function
panel
(10) Welding parameters overview
(continued)
Upslope tup
period in TIG welding during which the starting current IS is increased to the
specified main current I1

Important! The upslope tup is saved separately for 2-step and 4-step modes.

Main current I1 (welding current)

- for TIG welding
- for rod electrode (MMA) welding

Reduced current I2
for TIG 4-step mode and TIG special 4-step mode

Downslope tdown
period in TIG welding during which the specified main current I1 is lowered to
the final current IE

Important! The downslope tdown is saved separately for 2-step and 4-step
modes.

Final current IE
for TIG welding

Wirefeed speed (only for TransTig 4000/5000)

used to set the Fd.1 parameter if the cold-wire feeder option is available

Job No
used in Job mode to retrieve stored parameter records (using job numbers).

Electrode diameter
used for entering the tungsten electrode diameter for TIG welding

(11) Adjusting dial

used to change parameters. If the indicator on the adjusting dial lights up, then the
selected parameter can be altered.
(12) Welding current indicator
used to indicate the welding current for the following parameters
- starting current IS
- welding current I1
- reduced current I2
- final current IE

Before the start of welding, the left-hand digital display shows the command value.
For IS, I2 and IE the right-hand digital display also shows the respective percentage of
the welding current I1.

After the start of welding, the parameter I1 is automatically selected. The left-hand
digital display shows the actual welding current value.

In the welding parameters overview (10), LEDs for the various parameters (IS, tup,
etc.) light up to show the current position in the welding process.
(13) Store button
used to store jobs and access the Set-up menu

22
TransTig control No. Function
panel
(14) Parameter Selection button (left)
(continued)
used to select the welding parameters in the welding parameters overview (10)

When a parameter is selected, the LED on the relevant parameter symbol lights up.
(15) Overtemperature indicator
lights up if the power source overheats (e.g. because the duty cycle has been
exceeded). For more information on this, see the „Troubleshooting“ section.
(16) Keylock switch (option for TT 2500 / 3000 / 4000 / 5000)
When the key is in the horizontal position, all parameters and functions are disabled
with the exception of the currently selected parameter or function.

Important! The functions available on

the control panel of system compon-
ents are then restricted in the same (17)
way as those of the control panel on
the power source. Keylock switch position

23
Key combinations - special functions

General remarks The following functions can be called up by pressing buttons simultaneously or repeated-
ly on the MagicWave and TransTig control panels.

Keylock To activate the keylock:

+
While pressing and holding the Store button, press the right Parameter
Selection button

The lockout message „CLo|SEd“ briefly appears on the display.

On the control panel, the special keylock indicator lights up

If you press any of the buttons, the lockout message „CLo|SEd“ will now
appear on the digital display. The adjusting dial can only be used to change
the parameter that had been selected when the keylock was activated.

Important! The keylock remains enabled even if the power source is

switched off and then on again.

To deactivate the keylock:

+
While pressing and holding the Store button, press the right Paramet
Selection button

The unlocking message „-OP|En-“ briefly appears on the digital display

The special keylock indicator goes out

Displaying the + To display the software version:

software version, While pressing and holding the Store button, press the left Parameter
operating time Selection button.
and coolant flow
The software version is now shown on the digital display.

Display operating time:

Press the left Parameter Selection button again

The operating time records the actual arc burning time since the initial
start-up.
Example: „654 | 32.1“ = 65,432.1 h = 65,432 h | 6 min

Important! The operating time display is not suitable as a basis for

calculating hiring fees, guarantee, etc.

Display coolant flow (only in conjunction with a cooling unit with the flow
watchdog option):
Press the left Parameter Selection button again

The present coolant flow of the cooling unit is shown in l/min (CFL =
Coolant Flow)
If the coolant flow is less than 0.7 l/min, the power source switches off
after the end of the time specified in Parameter C-t and the error
message „no | H2O“ is shown.

To exit, press the Store button.

24
Connections, switches and mechanical components

MagicWave
1700/2200 Job (3)

(6) (7)

(8)

(2) (4)
(1) (5)

Fig.12 MagicWave 1700/2200 - front Fig.13 MagicWave 1700 / 2200 - rear

No. Function
(1) Welding torch connection
used to connect
- the TIG welding torch
- the electrode cable for rod electrode (MMA) welding
(2) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster
TIG torch, etc.)
(3) Handle (only on MagicWave 2200)
MagicWave 1700 has carrying strap
(4) Torch control connection
- for connecting a conventional torch control plug
- Input for collision protection signal when a robot interface or field bus coupler is
connected
(5) Earthing (grounding) cable connection
for connecting the earthing (grounding) cable
(6) Shielding gas connection
(7) Mains switch
for switching the power source on and off
(8) Mains cable with strain-relief device

25
MagicWave
2500/3000 Job (3)
(7)

(6)
(8)

(2) (4)
(1) (5)

Fig.14 MagicWave 2500/3000 - front Fig.15 MagicWave 2500/3000 - rear

No. Function
(1) Earthing (grounding) cable connection
for connecting the earthing (grounding) cable
(2) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster
TIG torch, etc.)
(3) Handle
(4) Torch control connection
- for connecting a conventional torch control plug
- Input for collision protection signal when a robot interface or field bus coupler is
connected
(5) Welding torch connection
used to connect
- the TIG welding torch
- the electrode cable for rod electrode (MMA) welding
(6) Shielding gas connection
(7) Mains cable with strain-relief device
(8) Mains switch
for switching the power source on and off

26
MagicWave
4000/5000 Job

(7)
(7)

(8)

(1) (9)

(6) (5) (4) (3) (2)

Fig.16 MagicWave 4000/5000 Job - front Fig.17 MagicWave 4000/5000 Job - rear

No. Function
(1) Mains switch
for switching the power source on and off
(2) Welding torch connection
for connecting a TIG torch
(3) Electrode holder connection
for connecting the electrode cable for rod electrode (MMA) welding
(4) Torch control connection
- for connecting a conventional torch control plug
- Input for collision protection signal when a robot interface or field bus coupler is
connected
(5) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster
TIG torch, etc.)
(6) Earthing (grounding) cable connection
for connecting the earthing (grounding) cable.
(7) Blanking covers
reserved for a LocalNet connection
(8) Mains cable with strain-relief device
(9) Shielding gas connection

27
TransTig
800/2200 Job (3)

(6) (7)

(8)

(2) (4)
(1) (5)

Fig.18 TransTig 800 / 2200 - front Fig.19 TransTig 800 / 2200 - rear

No. Function
(1) (+)-current socket with bayonet latch
used to connect
- the earthing (grounding) cable in TIG welding
- the electrode (or earthing/grounding) cable in rod electrode (MMA) welding,
depending on the type of electrode being used
(2) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster
TIG torch, etc.)
(3) Handle (TransTig 2200 only)
TransTig 800 has carrying strap
(4) Torch control connection
- for connecting a conventional torch control plug
- Input for collision protection signal when a robot interface or field bus coupler is
connected
(5) (-)-current socket with bayonet latch
used to connect
- the TIG welding torch
- the electrode (or earthing/grounding) cable in rod electrode (MMA) welding,
depending on the type of electrode being used
(6) Shielding gas connection
(7) Mains switch
for switching the power source on and off
(8) Mains cable with strain-relief device

28
TransTig
2500/3000 Job (3)
(7)

(6)
(8)

(2) (4)
(1) (5)

Fig.20 TransTig 2500/3000 - front Fig.21 TransTig 2500/3000 - rear

No. Function
(1) (+)-current socket with bayonet latch
used to connect
- the earthing (grounding) cable in TIG welding
- the electrode (or earthing/grounding) cable in rod electrode (MMA) welding,
depending on the type of electrode being used
(2) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster
TIG torch, etc.)
(3) Handle
(4) Torch control connection
- for connecting a conventional torch control plug
- Input for collision protection signal when a robot interface or field bus coupler is
connected
(5) (-)-current socket with bayonet latch
used to connect
- the TIG welding torch
- the electrode (or earthing/grounding) cable in rod electrode (MMA) welding,
depending on the type of electrode being used
(6) Shielding gas connection
(7) Mains cable with strain-relief device
(8) Mains switch
for switching the power source on and off

29
TransTig 4000/
5000 Job

(2) (6)
(6)
(3)
(7)

(4) (5) (8)

(1)

Fig.22 TransTig 4000/5000 - front Fig.23 TransTig 4000/5000 - rear

No. Function
(1) (+)-current socket with bayonet latch
used to connect
- the earthing (grounding) cable in TIG welding
- the electrode (or earthing/grounding) cable in rod electrode (MMA) welding,
depending on the type of electrode being used
(2) LocalNet connection
standardised connection socket for system add-ons (e.g. remote control, JobMaster
TIG torch, etc.)
(3) Torch control connection
- for connecting a conventional torch control plug
- Input for collision protection signal when a robot interface or field bus coupler is
connected
(4) (-)-current socket with bayonet latch
used to connect
- the TIG welding torch
- the electrode (or earthing/grounding) cable in rod electrode (MMA) welding,
depending on the type of electrode being used
(5) Mains switch
for switching the power source on and off
(6) Blanking covers
reserved for a LocalNet connection
(7) Mains cable with strain-relief device
(8) Shielding gas connection

30
Installation

31
32
Minimum equipment needed for welding

General remarks Depending on which weld process you intend to use, a certain minimum level of equip-
ment will be needed in order to work with the power source.
The minimum equipment required for welding in each of the welding processes is listed
below.

TIG AC welding - MagicWave power source

- Earthing (grounding) cable
- TIG welding torch with rocker switch
- Gas connection (for supplying the machine with shielding gas), with pressure
regulator
- Filler metals (as required by the application)

TIG DC welding - TransTig or MagicWave power source

- Earthing (grounding) cable
- TIG welding torch with rocker switch
- Gas connection (for supplying the machine with shielding gas)
- Filler metals (as required by the application)

Automated TIG - TransTig or MagicWave power source

welding - Robot interface or field bus connection
- Earthing (grounding) cable
- TIG machine welding torch or TIG robot welding torch
(with water-cooled machines or robot welding torches a cooling unit is also required)
- Gas connection (for supplying the machine with shielding gas)
- Cold-wire feeder and filler metals (as required by the application)

Rod electrode - TransTig or MagicWave power source

(MMA) welding - Earthing (grounding) cable
- Electrode holders
- Rod electrodes (as required by the application)

33
Before installation and commissioning

Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have read and
completely understood all of the following documents:
- these operating instructions
- all operating instructions for the system components, especially the
„Safety rules“

Utilisation for The power source may ONLY be used for TIG welding and rod electrode (MMA) welding.
intended purpose Utilisation for any other purpose, or in any other manner, shall be deemed to be „not in
only accordance with the intended purpose“. The manufacturer shall not be liable for any
damage resulting from such improper use.

Utilisation in accordance with the „intended purpose“ also comprises

- following all the instructions given in this manual
- performing all stipulated inspection and servicing work.

Set-up guidelines The power source is tested to IP23, meaning:

- Protection against penetration by solid foreign bodies with diameters Ø 12.5 mm
(.49 in.)
- Protection against direct sprays of water up to 60° from the vertical

The machine can be set up and operated outdoors in accordance with IP23.
Direct wetting (e.g. from rain) should be avoided.

WARNING! A machine that topples over or falls from its stand can easily kill
someone. Place equipment on a solid, level floor in such a way that it stands
securely.

The venting duct is a very important safety feature. When choosing the machine locati-
on, ensure that the cooling air can enter and exit unhindered through the air ducts on the
front and back of the machine. Prevent any electroconductive metallic dust (e.g. from
grinding work) from being drawn into the machine.

Mains connection The equipment is designed to run on the mains voltage given on the respective rating
plates. If your version of the machine does not come with mains cables and plugs ready-
fitted, these must be fitted in accordance with national regulations and standards. For
details of fuse protection of the mains supply lead, please see the Technical Data.

NOTE! Inadequately dimensioned electrical installations can lead to serious

damage. The mains lead and its fuse protection must be rated accordingly. The
technical data shown on the rating plate shall apply.

34
Generator- The MW 1700/2200 and TT 800/2200 power sources are suitable for being run on
powered operati- generator power, provided that the maximum apparent power delivered by the generator
on (MW 1700/ is at least 10 kVA.
2200, TT 800/
2200) NOTE! The voltage delivered by the generator must never exceed the upper or
lower limits of the mains voltage tolerance range. Details of the mains voltage
tolerance are given in the “Technical data” section.

35
Connecting up the mains cable on US power sources

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

Stipulated mains Power source Mains voltage Cable cross-section

cables and strain
TT 4000/5000 MV Job, MW 4000/5000 MV Job 3 x 380 - 460 V AWG 10
relief devices
3 x 200 - 240 V AWG 6

AWG ... American wire gauge

Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. The following activities must only be carried out by trained and
qualified personnel! Pay particular attention to the „Safety rules“ section.

Connecting up 1. Remove the left side panel of the power source

the mains cable 2. Strip approx 100 mm (4 in.) off the end of the mains cable.

Important! The PE conductor (green, or green with yellow stripes) should be approx.
10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

3. Fit wire-end ferrules to phase conductors and the PE conductor of the mains cable;
crimp ferrules with pliers

NOTE! If wire end ferrules are not used, there is a risk of short circuits between
the phase conductors or between phase conductors and the PE conductor. Fit
wire-end ferrules to all phase conductors and the PE conductor of the stripped
mains cable.

4. Undo the screws (2 x) and clamping

nut (width-across flats 30mm) on the
strain relief device

Fig.24 Undoing the screws and clamping nut

36
Connecting up 5. Insert the mains cable into the strain
the mains cable relief device
(continued)
Important! Push the mains cable in
far enough to make it possible to
connect the PE conductor and the
phase conductors to the block termi-
PE
W1
V1
nal properly.
U1
8
6. Tighten the clamping nut (width-
7 across flats 30 mm)

6
7. Tighten the screws (2 x)
8. Connect the mains cable to the block
5 terminal properly:
- PE conductor (green, or green with
yellow stripes) to the PE
Fig.25 Connecting up the mains cable connection
- Phase conductors to connections L1 -
L3
9. Replace the left side panel of the
power source

Replacing the 1. Remove the left side panel of the

strain relief power source
device 2. Remove the screws (2 x) from the old
strain relief device
3. Pull the old strain relief device for-
wards to detach it
4. Remove the screws for the adapter
2
4 plate, and remove the adapter plate
2

3 4

Fig.26 Removing an existing strain relief device

5. Assembling the large strain relief

device:
- Insert the hexagon nut (width-across
flats 50 mm) into the holding plate

Important! The points of the hexagon

nut must point towards the holding
plate for a reliable earth (ground)
connection to the power source
housing.

- Screw the front of the large strain

relief device into the hexagon nut
(width-across flats 50 mm).
The hexagon nut (width-across
flats 50 mm) now bites into the
Fig.27 Assembling the large strain relief device holding plate

37
Replacing the 6. Slot the large strain relief device into
strain relief the housing and fasten it with 2
device screws
(continued) 7. Connecting up the mains cable
8. Replace the left side panel of the
power source

7 6
7

Fig.28 Fitting a large strain relief device

38
Commissioning

Safety
WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the machine when
- the mains switch is in the „OFF“ position,
- the machine is unplugged from the mains.

Remarks on the We recommend using a cooling unit for the following applications and situations:
cooling unit - JobMaster TIG welding torch
- Robot welding
- Hosepacks over 5 m long
- TIG AC welding
- In general, where welding is performed in higher power ranges

The cooling unit is powered from the power source. The cooling unit is ready for operati-
on when the mains switch of the power source is in the „On“ position.

More information on the cooling unit can be found in the operating instructions for the
cooling unit.

General remarks This section describes how to put the power source into service
- for the main TIG welding application
- with reference to a standard configuration for a TIG welding system.

The standard configuration consists of the following system components:

- Power source
- Cooling unit
- TIG manual welding torch
- Pressure regulator
- Gas cylinder
- Gas cylinder holder
- Trolley

The steps set out below provide an overview of how to put the power source into service.
For detailed information about the individual steps, please refer to the operating instruc-
tions for the system components.

Connecting up
WARNING! There is a high risk of very serious injury and damage from
the gas cylinder
toppling gas cylinders.
- Place gas cylinders on a solid, level surface.
- Secure gas cylinders to prevent them from toppling over: fix the safety
strap level with the top part of the cylinder
- Never fix the safety strap around the neck of the cylinder

Follow the gas cylinder manufacturer’s safety instructions

39
Connecting up 1. Fix the gas cylinder to the trolley
the gas cylinder 2. Take the protective cap off the gas cylinder
(continued) 3. Briefly open the gas cylinder valve to blow off any dust or dirt
4. Inspect the seal on the pressure regulator
5. Screw the pressure regulator onto the gas cylinder and tighten it

When using a TIG welding torch with an integral gas connector:

6. Using the gas hose, connect the pressure regulator to the shielding gas connection
on the rear of the power source
7. Tighten union nut on the gas hose

When using a TIG welding torch without integral gas connector:

6. Connect the TIG welding torch gas hose to the pressure regulator

Establishing an 1. Switch the mains switch „OFF“

earth (ground) 2. Plug the earthing (grounding) cable in and latch it in securely:
connection to the - MagicWave: in the earthing (grounding) cable connection
workpiece - TransTig: in the (+)-current socket
3. With the other end of the earthing (grounding) cable, establish a connection to the
workpiece

Connecting the
CAUTION! Risk of damage from high frequencies. Do not use the JobMaster
welding torch
TIG welding torch with a LocalNet distributor.

1. Switch the mains switch „OFF“

2. Plug in the TIG welding torch cable and twist it clockwise to latch it into place:
- MagicWave: in the welding torch connection
- TransTig: in the (-)-current socket
3. Plug the control plug of the welding torch into the torch control connection and twist
it to fasten it
or
Connect the JobMaster TIG welding torch control line to the LocalNet connection

NOTE! Do not use pure tungsten electrodes (colour-coded green) on TransTig

power sources.

4. Fit the welding torch in accordance with the welding torch operating instructions

5. Only when using a water-cooled torch and cooling unit:

Plug in the welding torch water connectors to the water flow (black) and return (red)
connections on the cooling unit.

40
Welding

41
42
TIG modes

Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have read and
completely understood all of the following documents:
- these operating instructions
- all operating instructions for the system components, especially the
„Safety rules“

For information on settings, setting range and units of measurement, please see the
section headed „Set-up menu“.

Symbols and
their explanati-
ons

Pull back and hold the torch Release the torch trigger Briefly pull back the torch
trigger trigger (< 0.5 s)

Push forward and hold the torch Release the torch trigger
trigger

GPr tdown
Gas pre-flow time Downslope phase: The welding current is
IS continuously lowered until it reaches the
Starting current phase: the temperature is final current.
raised gently, at low welding current, so IE
that the filler metal can be positioned Final current phase: To prevent any local
correctly overheating of the base metal due to heat
tS build-ups towards the end of welding. This
Starting current time eliminates any risk of weld drop-through.
tup tE
Upslope phase: the starting current is Final current time
continuously increased until it reaches the SPt
main current (welding current) I1 Spot-welding time
I1 G-H
Main current phase (welding current Gas post-flow time at maximum welding
phase): Uniform thermal input into the current
base metal, whose temperature is raised G-L
by the advancing heat Gas post-flow time at minimum welding
I2 current
Reduced current phase: Intermediate
lowering of the welding current in order to
prevent any local overheating of the base
metal

43
2-step mode - Welding: Pull back and hold the torch trigger
- End of welding: Release the torch trigger

Important! To work in 2-step mode after 2-step mode has been selected, the set-up
parameter SPt must be set to „OFF“ and the special spot welding indicator on the control
panel must not light up.

I I1

... Manual application

... Automatic application
IE
IS

t
GPr tS tCF G-L
G-H

GPr tup tdown G-L/G-H

Fig. 29 2-step mode

Spot welding If a value has been set for the SPt set-up parameter, 2-step mode will will have the
function of spot welding mode. The special spot welding indicator on the control panel
will light up.

- Welding: Briefly pull back the torch trigger

The welding time corresponds to the value set for the SPt set-up parameter.
- to end welding before the end of the welding process: pull the torch trigger back
again

When using a pedal remote control unit, the spot welding time starts when the pedal remote
control is operated. The power cannot be controlled using the pedal remote control unit.

I I1

IE
IS
t

GPr tS tup tdown tCF G-L

G-H

SPt

Fig. 30 Spot welding

44
4-step mode - Welding start-up with starting current IS: Pull back and hold the torch trigger
- Welding with main current I1: Release the torch trigger
- Lowering to final current IE: Pull back and hold the torch trigger
- End of welding: Release the torch trigger

Important! For 4-step mode, the set-up parameter SFS must be set to „OFF“.

I I1 I1

I2

Intermediate lowering
IE
IS

GPr tup tdown G-L

G-H
Fig.31 4-step mode

Intermediate lowering - during the main current phase the welding current is reduced to
the specified reduced current I2.

- to activate intermediate lowering push forward and hold the torch trigger
- to revert to the main current, release the torch trigger

Special 4-step Variant 1 of special 4-step mode is activated when set-up parameter SFS is set to „1“.
mode: Briefly pull back the torch trigger to start intermediate lowering to the specified reduced
variant 1 current I2 When the torch trigger is briefly pulled back a second time, the current returns
to the Main current I1.

I
I1 I1

I2

IE
IS

GPr tup tdown G-L

G-H
Fig.32 Special 4-step mode: variant 1

45
Special 4-step Variant 2 of special 4-step mode is activated when set-up parameter SFS is set to „2“.
mode: In variant 2, intermediate lowering takes place on the basis of the selected slope values -
variant 2 downslope tdown and upslope tup:
- Push forward and hold the torch trigger: the welding current continuously drops at
the set downslope value until it reaches the specified reduced current I2. It remains
at the reduced current value I2 until the torch trigger is released.
- When the torch trigger is released: the welding current rises at the specified upslo-
pe value until it reaches the main current value I1.

I I1 I1

I2

IE
IS

GPr tS tup tdown tE G-L

G-H
Fig.33 Special 4-step mode: variant 2

Special 4-step Variant 3 of special 4-step mode is activated when set-up parameter SFS is set to „3“.
mode:
variant 3 In variant 4, push forward and hold the torch trigger to start intermediate lowering. When
the torch trigger is briefly pulled back a second time, the main current I1 resumes.

When the torch trigger is pulled back, welding ends immediately without downslope and
final current.

I I1 I1

I2

IS

GPr tup G-L/G-H

Fig.34 Special 4-step mode: variant 3

46
Special 4-step Variant 4 of the special 4-step mode is activated when the SFS set-up parameter is set
mode: to „4“.
Variant 4 - Welding start-up and welding: briefly pull back and release the torch trigger - the
welding current will rise at the specified upslope value from the starting current IS
until it reaches the main current value I1.
- Push forward and hold the torch trigger for intermediate lowering
- When the torch trigger is released, the main current I1 resumes
- End of welding: briefly pull back and release the torch trigger

I I1 I1

I2

IE
IS

GPr tS tup tdown tE G-L

G-H
Fig.34a Special 4-step mode: Variant 4

Special 4-step Variant 5 of the special 4-step mode is activated when the SFS set-up parameter is set
mode: to „5“.
Variant 5
Variant 5 allows the welding current to be increased and reduced without an up/down
welding torch.
- The longer the torch trigger is held in the forward position during welding, the more
the welding current increases (up to the maximum).
- The welding current remains constant when the torch trigger is released.
- The longer the torch trigger is pushed forward again, the more the welding current
decreases.

I1 >
I

I1

I1 <

IE
IS

GPr tS tup tdown tE G-L

G-H
Fig.34b Special 4-step mode: Variant 5

47
Special 4-step Variant 6 of the special 4-step mode is activated when the SFS set-up parameter is set
mode: to „6“.
Variant 6
- Welding start-up with starting current IS and upslope: pull back and hold the torch
trigger
- Intermediate lowering to I2 and changing from I2 back to the main current I1: briefly
press (< 0.5 s) and release the torch trigger
- End the welding process: press the torch trigger for longer (> 0.5 s) and release.

The process is automatically ended after the downslope phase and the final current
phase.

If the torch trigger is pressed briefly (< 0.5 s) and released during either the downs-
lope phase or the final current phase, then an upslope will take effect until it reaches
the main current and the welding process will continue.

< 0.5 s < 0.5 s

> 0.5 s

< 0.5 s < 0.5 s

I
I1 I1 I1

I2

IE
IS
t

GPr tS tup tdown tE G-L

G-H
Fig.34c Special 4-step mode: Variant 6

48
Cap shaping and cap overloading

Cap shaping On MagicWave power sources, an auto-

matic cap-shaping function is available for
the TIG AC welding process:
- when the TIG AC welding process is
selected, activate automatic cap-
shaping
- the ideal electrode tip for the specified
diameter of the tungsten electrode is
formed during welding start-up.
A separate cap-shaping operation on
a test workpiece is no longer neces-
sary.
- The automatic cap-shaping function is
then reset and deactivated.
Before ignition After ignition The automatic cap-shaping function
has to be activated separately for
Fig.35 Cap shaping each tungsten electrode.

Important! The automatic cap-shaping function is not necessary if a sufficiently large

cap has already formed at the tip of the electrode.

Cap overloading If the cap is overloaded, there is a risk of an excessively large cap forming on the tungs-
ten electrode. This will affect the ignition properties.

If the cap is overloaded, the „Electrode overload“ indicator will light up on the
control panel.

Possible causes of cap overloading:

- tungsten electrode diameter is too small
- main current value I1 set too high
- „balance“ has been set too far towards „+“

Remedy:
- use a tungsten electrode with a larger diameter
- reduce the main current and/or set „Balance“ further towards „-“

Important! The „Electrode overload“ indicator is fine-tuned to work with the following
tungsten electrodes:
- TIG AC welding: Pure tungsten electrodes
- TIG DC welding: Ceriated electrodes

For all other electrodes, the „Electrode overload“ indicator must be taken as a guideline
only.

49
TIG welding

Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have read and
completely understood all of the following documents:
- these operating instructions
- all operating instructions for the system components, especially the
„Safety rules“

WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the machine when
- the mains switch is in the „OFF“ position,
- the machine is unplugged from the mains.

Welding parame- Starting current IS

ters
Unit %
Setting range 0 - 200 % of main current I1
Factory setting 35 AC, 50 DC

Important! The starting current IS is saved separately for the TIG AC welding and TIG
DC welding modes.
Upslope tup
Unit s
Setting range 0.0 - 9.9
Factory setting 0.1

Important! The upslope tup is saved separately for 2-step and 4-step modes.

Main current I1
Unit A
Setting range MW 1700 Job ...... 3 - 170 TT 800 Job ..... 0,5 - 80,0
MW 2200 Job ...... 3 - 220 TT 2200 Job ... 3 - 220
MW 2500 Job ...... 3 - 250 TT 2500 Job ... 3 - 250
MW 3000 Job ...... 3 - 300 TT 3000 Job ... 3 - 300
MW 4000 Job ...... 3 - 400 TT 4000 Job ... 3 - 400
MW 5000 Job ...... 3 - 500 TT 5000 Job ... 3 - 500
Factory setting -

Important! On welding torches with Up/Down functionality, the entire setting range can
be selected while the machine is idling. During welding, the main current can be cor-
rected in steps of +/-20 A.
Reduced current I2 (4-step mode)
Unit % (of main current I1)
Setting range 0 - 100
Factory setting 50

50
Welding parame- Downslope tdown
ters
(continued) Unit s
Setting range 0.0 - 9.9
Factory setting 1.0

Important! The downslope tdown is saved separately for 2-step and 4-step modes.
Final current IE
Unit % (of main current I1)
Setting range 0 - 100
Factory setting 30
Balance (only on MagicWave for TIG 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
Wirefeed speed (only on MW 4000/5000 and TT 4000/5000)
when cold-wire feeder option is available
Unit m/min ipm
Setting range OFF / 0.1 - max. OFF/3.9 - max.
Factory setting OFF
Electrode diameter
Unit mm in.
Setting range OFF - max. OFF - max.
Factory setting 2.4 0.095

Preparations 1. Plug in the mains plug

CAUTION! Risk of injury and damage from electric shock. As soon as the
mains switch is in the „ON“ position, the tungsten electrode of the welding
torch is LIVE. Make sure that the tungsten electrode does not touch any
persons or electrically conducting or earthed parts (e.g. housing etc.)

2. Switch the mains switch „ON“

all the indicators on the control panel light up briefly

TIG welding 1. press the Mode button to select the required TIG mode:
2-step mode
4-step mode
2. Only with Magic Wave: press the Process button to select the required welding
process
AC welding process
AC welding process with automatic cap-shaping function
DC welding process
3. Use the left or right Parameter Selection button to select the relevant parameter in
the welding parameters overview
4. Use the adjusting dial to set the selected parameter to the required value

51
TIG welding Important! The wirefeed speed parameter is available even though is not shown on the
(continued) welding parameters overview for the MW 1700/2200/2500/3000 and TT 2200/2500/3000
power sources.

Setting the wirefeed speed parameter on MW 1700/2200/2500/3000 and on TT 2200/

2500/3000
a) Press the left Parameter Selection button until all the LEDs in the welding parame-
ters overview go out

The m/min indicator on the units indicator lights up

b) Use the adjusting dial to set the wirefeed speed parameter to the required value

The value for the wirefeed speed is displayed in the right-hand digital display.

All parameter command values that have been set by means of the adjusting dial
will remain stored until the next time they are changed. This is true even if the power
source is switched off and on again in the meantime.

5. Open the gas cylinder valve

6. Set the shielding gas flow rate:
Press the Gas-test button
The test gas flow lasts for a maximum of 30 seconds. Press the button again to
stop the test gas flow before the 30 seconds are up.
- Turn the adjusting screw on the underside of the pressure regulator until the
manometer indicates the required shielding gas flow rate
7. For longer hosepacks and when condensation has formed after the device has been
left unused in a cold environment for a prolonged period:
purge shielding gas - set the GPU set-up parameter to a time value
8. Start welding (ignite the arc)

52
Igniting the arc

General remarks To ensure the best ignition sequence in the TIG AC welding process, the MagicWave
power sources take account of:
- the diameter of the tungsten electrode
- the current temperature of the tungsten electrode showing the preceding welding
and weld-off times

To ensure the ideal ignition sequence in TIG DC welding, MagicWave power sources are
equipped with RPI (Reverse Polarity Ignition).
At the start of welding, the polarity is briefly reversed. Electrons emerge from the workpi-
ece and impact upon the tungsten electrode. This results in rapid heating-up of the
tungsten electrode - which in itself is an essential precondition for optimum ignition
performance.
For further information on the RPI function, please refer to the section on Set-up para-
meters under „Set-up menu: level 2“.

Igniting the arc HF ignition is activated when a time value has been set for the HFt set-up parameter.
using high fre- On the control panel, the special HF ignition indicator lights up.
quency (HF
ignition)

Compared with touchdown ignition, HF ignition eliminates the risk of contamination of the
tungsten electrode and the workpiece.

Procedure for HF ignition:

1. Place the gas nozzle down on the

ignition location in such a way that
there is a gap of approx. 2 to 3 mm
(0.08 to 0.12 in.) between the tungs-
ten electrode and the workpiece.

Fig.36 Placing the gas nozzle down

53
Igniting the arc 2. Increase the tilt angle of the torch,
using high fre- and actuate the torch trigger in the
quency (HF sequence required for the mode you
ignition) have selected3.
(continued) The arc ignites without the electrode
touching down on the workpiece

Fig.37 Non-contact HF ignition

4. Tilt the torch back into the normal

position
5. Start welding

Fig.38 Welding

Touchdown When the HFt set-up parameter is set to OFF, HF ignition is deactivated. The welding
ignition arc is ignited by touching the workpiece with the tungsten electrode.

Procedure for igniting the arc using touchdown ignition:

1. Place the gas nozzle down on the

ignition location in such a way that
there is a gap of approx. 2 to 3 mm
(0.08 to 0.12 in.) between the tungs-
ten electrode and the workpiece.

Fig.39 Placing the gas nozzle down

54
Touchdown 2. Actuate the torch trigger - the shiel-
ignition ding gas starts to flow
(continued) 3. Gradually tilt the torch up until the
tungsten electrode touches the
workpiece

Fig.37 Arc ignition by touching the workpiece

4. Raise the torch and tilt it into the

normal position; the arc now ignites
5. Start welding

Fig.38 Welding

Finishing welding 1. Depending on the selected mode, finish welding by releasing the torch trigger
2. Wait for the set gas post-flow, hold welding torch in position over the end of the weld
seam.

55
Special functions and options

Arc break watch- If the arc breaks and no current starts to flow again within a time defined in the Set-up
dog function menu, the power source cuts out automatically. The service code „no | Arc“ appears on
the control panel.

To start welding again, press any key on the control panel or press the torch trigger.

The settings for the arc break watchdog set-up parameter (Arc) are described in „Set-up
menu - level 2“.

Ignition time-out The power source has an „Ignition time-out“ function.

function
Once the torch trigger is pressed, gas pre-flow begins immediately. Ignition then begins.
If no arc appears within the time specified in the Set-up menu, the power source cuts
out automatically. The service code „no | IGn“ appears on the control panel.

„E55“ is displayed on the JobMaster TIG torch.

To make another attempt to achieve ignition, press any key on the control panel or press
the torch trigger.

The settings for the ignition time-out parameter (ito) are described in „Set-up menu -
level 2“.

TIG pulsing The welding current set at the start of the welding procedure is not necessarily ideal for
the welding process as a whole:
- if the current is too low, the base material will not melt sufficiently,
- if overheating occurs, the liquid weld pool may drip.

The TIG pulsing function offers a remedy (TIG welding with pulsing welding current):
a low base current I-G rises steeply to the significantly higher pulsing current I1 and,
depending on the set dcY (duty cycle) time, drops back to the base current I-G.
In TIG pulsing, small sections of the welding location melt quickly and then solidify again
quickly.
In manual applications using TIG pulsing, the filler wire is applied in the maximum
current phase (only possible in the low frequency range: 0.25 - 5 Hz). Higher pulsing
frequencies are mainly used in automatic mode to stabilise the arc.

TIG pulsing is used for out-of-position welding of steel pipes or when welding thin sheet.

56
TIG pulsing Mode of operation of TIG pulsing when TIG DC welding is selected:
(continued)

1/F-P
I
dcY

I1
IE
IS
I-G

tup tdown t

Fig.39 TIG pulsing - welding current curve

Legend:
- IS Starting current - dcY Duty cycle
- IE Final current - I-G Base current
- tUp Upslope - I1 Main current
- tDown Downslope
- F-P Pulsing frequency
(1/F-P = time interval between 2
pulses)

Tacking function The tacking function is available for the TIG DC welding process.

When a time period is specified for the tAC (tacking) set-up parameter, the tacking
function is assigned to the modes „2-step mode“ and „4-step mode“. The operating
sequence of each of these modes remains unchanged.
During this period, there is a pulsed welding current that makes the weld pool run toge-
ther better when two parts are being tack-joined.

Mode of operation of tacking function when TIG DC welding is selected:

I tAC

I1
IE
IS

tup tdown t

Fig.40 Tacking function - welding current curve

57
Tacking function Legend:
(continued) - tAC Duration of pulsed current for the tacking operation
- IS Starting current
- IE Final current
- tUp Upslope
- tDown Downslope
- I1 Main current

Important! The following points apply to the pulsed welding current:

- The power source automatically regulates the pulsing parameters as a function of
the specified main current I1.
- There is no need to set any pulsing parameters.

The pulsed welding current begins

- at the end of the starting current phase IS
- with the upslope phase tup

Depending 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 at constant welding current, and any
pulsing parameters that may have been set continue to be available.

Important! To set a defined tacking time, the tAC set-up parameter can be combined
with the SPt set-up parameter (spot-welding time).

TIG cold-wire TIG cold-wire welding is only possible in conjunction with a cold-wire feeder.
welding
Mode of operation of TIG cold-wire welding at a set pulsing frequency when DC welding
is selected:

1/F-P
I
dcY

I1
IE
IS
I-G

tup tdown t
dt1 dt2
Wire speed
Fd.1

Fd.2

t
Fig.41 TIG cold-wire welding - welding current and wirefeed speed curves

58
TIG cold-wire Legend:
welding - IS Starting current - Fd.1 Wirefeed speed 1
(continued) - IE Final current - Fd.2 Wirefeed speed 2
- tUp Upslope - dt1 Time by which the start of
- tDown Downslope wirefeeding is delayed after
- F-P Pulsing frequency the beginning of main current
(1/F-P = time interval between 2 phase I1
pulses) - dt2 Time by which the end of
- dcY Duty cycle wirefeeding is delayed after
- I-G Base current the end of main current
- I1 Main current phase I1

59
Rod electrode (MMA) welding

Safety
WARNING! Operating the equipment incorrectly can cause serious injury
and damage. Do not use the functions described here until you have read
and completely understood all of the following documents:
- these operating instructions
- all operating instructions for the system components, especially the
„Safety rules“

WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the machine when
- the mains switch is in the „OFF“ position,
- the machine is unplugged from the mains.

Preparations 1. Switch off cooling units (set-up parameter C-C to OFF)

2. Switch the mains switch „OFF“
3. Unplug the machine from the mains
4. Disconnect the TIG welding torch
5. Plug the earthing (grounding) cable in and latch it in securely:
- Magic Wave: in the earthing (grounding) cable connection
- Trans Tig: in the (+)-current socket
6. With the other end of the earthing (grounding) cable, establish a connection to the
workpiece
7. Plug in the electrode cable and twist it clockwise to latch it into place:
- MagicWave: in the welding torch connection
- TransTig: in the (-)-current socket
8. Plug in the mains plug

CAUTION! Risk of injury and damage from electric shock. As soon as the
mains switch is in the „ON“ position, the rod electrode in the electrode holder
is LIVE. Make sure that the rod electrode does not touch any persons or
electrically conducting or earthed parts (e.g. the housing etc.)

9. Switch the mains switch „ON“

all the indicators on the control panel light up briefly

Rod electrode 1. Press the Mode button to select:

(MMA) welding Rod electrode (MMA) welding mode

Important!If you select „Rod electrode (MMA) welding“ mode, the welding voltage
will only be available after a 3-second time lag.

2. Only with MagicWave: press the Process button to select the required welding
process:
Rod electrode AC welding
Rod electrode DC- welding
Rod electrode DC+ welding

60
Rod electrode Important! The TransTig power source has no switchover facility between the rod
(MMA) welding electrode DC- and rod electrode DC+ welding processes.
(continued)
Procedure with TransTig power source for switching from rod electrode DC- welding
to rod electrode DC+ welding:
a) Switch the mains switch „OFF“
b) Unplug the machine from the mains
c) Reconnect the electrode holder and the earthing (grounding) cable to the
opposite current sockets (i.e. swap them over)
d) Plug in the mains plug

CAUTION! Risk of injury and damage from electric shock. As soon as the
mains switch is in the „ON“ position, the rod electrode in the electrode
holder is LIVE. Make sure that the rod electrode does not touch any
persons or electrically conducting or earthed parts (e.g. the housing etc.)

e) Switch the mains switch „ON“

all the indicators on the control panel light up briefly

3. Use the adjusting dial to set the required welding current

The welding current value is displayed in the left-hand digital display.

Important! All parameter command values that have been set by means of the
adjusting dial will remain stored until the next time they are changed. This is true
even if the power source is switched off and on again in the meantime.

4. Start welding.

Hot-Start func- In order to obtain optimum welding results, it will sometimes be necessary to set or
tion adjust the Hot-Start function:

Advantages:
- Improved ignition, even when using electrodes with poor ignition properties
- Better fusion of the base metal in the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions

For details on setting the available parameters, please refer to „Set-up menu - level 2“.

Legend
I (A) Hti ....... Hot-current time,
Hti
0-2 s, factory setting 0.5 s
HCU ... Hot start current, 0 -100 %,
150
factory setting 50 %
HCU I1 ......... Main current = specified welding
current
100
Mode of operation
During the specified hot-current time (Hti),
I1 the welding current is increased to a certain
value. This value (HCU) is 0-100% higher
t (s) than the specified welding current (I1).

0,5 1 1,5

Fig.42 Example of „Hot-Start“ function

61
Anti-Stick func- As the arc becomes shorter, the welding voltage may drop so far that the rod electrode
tion will tend to „stick“. This may also cause „burn-out“ of the rod electrode.

Electrode burn-out is prevented if the anti-stick function has been activated. If the rod
electrode begins to stick, the power source immediately switches the welding current off.
After the rod electrode has been detached from the workpiece, the welding operation
can be continued without any difficulty.

The anti-stick function can be activated and deactivated in the „Set-up menu: level 2“.

62
Job mode

General remarks Job mode enhances the quality of welding-engineering fabrication, both in manual
welding and also in semi-automatic and fully automated operation.

Up to 100 common jobs (operating points) can be reproduced in Job mode, avoiding the
need to document parameters by hand.

Another advantage is that the power source is immediately ready for welding with the
desired parameters. You can also arrange jobs in the order required by the production
sequence. „Grouping“ of jobs is also supported (e.g. by different components).

The result is to minimise downtimes while ensuring 100% reproducible quality.

Abbreviations The following messages may be displayed while working with jobs:

—- No job in this program location (when you attempt to retrieve a job)

nPG No job in this program location (when saving a job)
PrG There is a job in this program location
Pro Job is being copied to this program location
dEL Job is being deleted from this program location

Saving a job Important! Jobs are not created in the Job mode process. Jobs can be created in the
TIG AC welding, TIG DC welding and rod electrode (MMA) welding processes.

The machine comes with no jobs pre-programmed. To create a job, proceed as follows:

1. Set the desired welding parameters that you want to store as a „Job“.

Important! All the settings that are active at that instant will be stored. Exception:
Power source specific settings in Set-up menu - level 2

2. Briefly press the Store button to switch to the Job menu.

The first vacant program location for the job is indicated.

3. Select the desired program location with the adjusting dial, or else leave the sugges-
ted program location unchanged.

63
Saving a job 4. Press and hold the Store button
(continued)
Important! If the selected program location already has a job stored in it, then this
existing job will be overwritten with the new job. This action cannot be undone.

The left-hand digital display reads „Pro“ - the job is stored in the program location
you have just selected.

„PrG“ appears on the left-hand digital display to indicate that the job is now stored.

5. Release the Store button

6. Briefly press the Store button to exit from the job menu.

The power source switches to the setting selected before the job was stored.

Retrieving a job NOTE! Before retrieving a job, make sure that the welding machine has been
installed and set up for the job.

1. Using the Mode button, select Job mode.

The display shows the last job to be used.

2. Use the adjusting dial to select the desired job

- To view the settings for this job, use the left and right Parameter Selection
buttons. The settings cannot be modified.
- The mode and process (MagicWave) of the stored job are displayed.
- When you retrieve a job directly from the power source, you can also select
vacant program locations (symbolised by „- - -“).

3. Start welding
Welding takes place with the welding parameters stored in the job.
During welding you can switch to another job without stopping (e.g. in robot operation).

When you change to another process, Job mode is ended.

64
Retrieving jobs When in Job mode, TIG jobs can also be selected using the JobMaster TIG welding torch.
on the JobMaster
TIG Only program locations that have already been programmed can be selected using the
JobMaster TIG torch. This allows related jobs to be grouped when they are saved since
a vacant program location is left after every job group.

When retrieving jobs using the JobMaster TIG torch, the Mode button (1) allows you to
switch between the jobs in a group.

-
+

(1) (1) (1)

nPG (10)

Job (11)

Job (12)

Job (13)
nPG (5)

nPG (9)
Job (1)

Job (3)

Job (4)

Job (6)

Job (7)

Job (8)
Job (2)

(1)

Group 1 Group 2 Group 3

Fig.43 Example of job retrieval with the JobMaster TIG welding torch

To switch to another group of jobs on the JobMaster TIG welding torch:

- Press the Parameter Settings button (1) for longer than 2 s
- This changes over to the next group up (or down)

Important! It is not possible to change a group while welding is in progress.

Copying/overwri- In Job mode you can copy a job that has already been saved to one program location to
ting a job any other program location. To copy a job, proceed as follows:

1. Using the Mode button, select Job mode.

The display shows the last job to be used.

2. Use the adjusting dial to select which job you want to copy

3. Briefly press the Store button to change to the job menu.

The first vacant program location for the job to be copied is suggested

65
Copying/overwri- 4. Select the desired program location with the adjusting dial, or else leave the sugges-
ting a job ted program location unchanged.
(continued)

5. Press and hold the Store button

Important! If the selected program location already has a job stored in it, then this
existing job will be overwritten with the new job. This action cannot be undone.

The left-hand digital display reads „Pro“ - the job is copied to the program location
you have just selected.

„PrG“ appears on the left-hand digital display to indicate that the job has been
copied.

6. Release the Store button

7. Briefly press the Store button to exit from the Job menu

The power source switches to the setting selected before the job was copied.

Deleting a job Stored jobs can also be deleted again. To delete a job, proceed as follows:

1. Briefly press the Store button to switch to the Job menu.

The first vacant program location is shown.

2. Using the adjusting dial, select the job to be deleted (the DEL symbol lights up on
the Gas-test button).

3. Press and hold the Gas-test „DEL“ button.

The left-hand display reads „dEL“ - the job is deleted.

66
Deleting a job „nPG“ appears on the left-hand digital display to indicate that the job has been
(continued) deleted.

4. Release the Gas-test button

5. Briefly press the Store button to exit from the Job menu.

The power source switches to the setting selected before the job was deleted

67
68
Set-up settings

69
70
Job correction

General remarks In the Job correction menu, set-up parameters can be adapted to the specific require-
ments of individual jobs.

Opening the Job 1. Using the Mode button, select „Job mode“.
correction menu
2. Press and hold the Store button

3. Press the Mode button

The power source is now in the Job correction menu. The first parameter,
„Job“, is shown. The „Job“ parameter is used to select the job for which
the parameters are to be adjusted.

Changing a 1. Turn the adjusting dial to select the job whose parameters you want to
parameter change
2. Use the left or right Parameter Selection button to select the parameter
that you want to correct
3. Alter the parameter value using the adjusting dial

Important! Any parameters that you change will be stored immediately and
accepted as the valid parameters for the welding process.

Exiting the Job 1. Press the Store button

correction menu

Parameters that Important! Certain parameters apply specifically to the Job correction menu and relate,
can be corrected for example, to changing settings that were made on the control panel the first time the
in the Job correc- job was stored. There is an explanation of each of these parameters in the following list,
tion menu together with information about the setting ranges.

You can alter the following parameters for any stored job:

Eld
Electrode diameter
Unit mm in.
Setting range OFF - max OFF - max
Factory setting 2.4 0.095
I-S
I (current) - Starting IS
Unit % (of main current I1)
Setting range 0 - 200
Factory setting 35

71
Parameters that UPS
can be corrected Upslope tup - time for the transition from starting current Is to main current I1
in the Job correc-
tion menu Unit s
(continued) Setting range 0.0 - 9.9
Factory setting 0.5
I-1
I (current)-1 - main current I1
Unit A
Setting range MW 1700 Job ...... 3 - 170 TT 800 Job ..... 0,5 - 80,0
MW 2200 Job ...... 3 - 220 TT 2200 Job ... 3 - 220
MW 2500 Job ...... 3 - 250 TT 2500 Job ... 3 - 250
MW 3000 Job ...... 3 - 300 TT 3000 Job ... 3 - 300
MW 4000 Job ...... 3 - 400 TT 4000 Job ... 3 - 400
MW 5000 Job ...... 3 - 500 TT 5000 Job ... 3 - 500
Factory setting -
I-2
I (current)-2 - reduced current I2 (only active in 4-step mode)
Unit % (of main current I1)
Setting range 0 - 100
Factory setting 50
dSL
Downslope tdown - time for the transition from main current I1 to final current IE
Unit s
Setting range 0.0 - 9.9
Factory setting 1.0
I-E
I (current) - End IE
Unit % (of main current I1)
Setting range 0 - 100
Factory setting 30
JSL
Job Slope - For changing to another job during welding. „JSL“ is the time that it takes for
the welding current to adjust seamlessly from the present job to the one that you want to
switch over to.
Unit s
Setting range OFF / 0.1 - 9.9
Factory setting OFF

Important! You can set the job slope „JSL“ separately for each job that is stored.

NOTE! Switching over from one job to the next without interrupting welding is
only possible with a JobMaster TIG torch, a robot interface or a field bus.
GPr
Gas pre-flow time
Unit s
Setting range 0 - 9.9
Factory setting 0.4
G-L
Gas-Low - Gas post-flow time at minimum welding current
Unit s
Setting range 0 - 25
Factory setting 5

72
Parameters that G-H
can be corrected Gas-High - Increase in the gas post-flow time at maximum welding current
in the Job correc-
tion menu Unit s
(continued) Setting range 0 - 40 / Aut
Factory setting Aut

For further information on the G-H parameter, see the Shielding gas set-up menu.
tAC
Tacking function: Duration of the pulsed welding current at the start of tacking
Unit s
Setting range OFF / 0.1 - 9.9 / ON
Factory setting OFF

For further information on the tAC parameter, see the TIG set-up menu.
F-P
Frequency pulsing
Unit Hz / kHz
Setting range OFF / 0.20 Hz - 2.00 kHz
Factory setting OFF

For further information on the F-P parameter, see the TIG set-up menu.
dcY
Duty cycle - The ratio of pulse duration to background-current duration when a pulsing
frequency has been set
Unit %
Setting range 10 - 90
Factory setting 50
I-G
I (current) - Ground
Unit % (of main current I1)
Setting range 0 - 100
Factory setting 50
tri
trigger - mode selection
Unit -
Setting range 2t/4t

2t = 2-step mode
4t = 4-step mode
SPt
Spot-welding time
Unit s
Setting range OFF / 0.01 - 9.9
Factory setting OFF

For further information on the SPt parameter, see the TIG set-up menu.
t-S
time-Starting
Unit s
Setting range OFF / 0.01 - 9.9
Factory setting OFF

For further information on the t-S parameter, see the TIG set-up menu.

73
Parameters that t-E
can be corrected time-End
in the Job correc-
tion menu Unit s
(continued) Setting range OFF / 0.01 - 9.9
Factory setting OFF

For further information on the t-E parameter, see the TIG set-up menu.
POL
Polarity - Welding-current polarity
Unit -
Setting range AC / nEG / POS

AC = AC welding
nEG = DC- welding
POS = DC+ welding
ACF
AC frequency
Unit Hz
Setting range Syn / 40 - 250
Factory setting 60

For further information on the ACF parameter, see the AC/polarity reversal set-up menu.
Io
AC current offset
Unit %
Setting range -70 - +70
Factory setting 0

For further information on the Io parameters, see the AC/polarity reverser set-up menu.
bAL
Balance - relationship between fusing power and cleaning action
Unit 1
Setting range -5 to +5
Factory setting 0

-5 = highest fusing power, lowest cleaning action

+5 = highest cleaning action, lowest fusing power
I-c
I (current) correction - I1 correction range for job retrieval
Unit %
Setting range OFF/1 - 100
Factory setting OFF

Important! The I1 correction range only applies to job retrieval.

In the jobs, all the settings are permanently saved, i.e. cannot be changed. However, the
parameter „I-c“ permits subsequent correction of the main current I1.

Example
The set-up parameter „I-c“ 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)
when the power source is switched off.

74
Parameters that Fd.1
can be corrected Feeder 1 - wirefeed speed 1 (cold-wire feeder option)
in the Job correc-
tion menu Unit m/min ipm
(continued) Setting range OFF / 0.1 - max. OFF / 3.94 - max.
Factory setting OFF OFF
Fd.2
Feeder 2 - wirefeed speed 2 (cold-wire feeder option)
Unit m/min ipm
Setting range OFF / 0.1 - max. OFF / 3.94 - max.
Factory setting OFF OFF

For further information on the Fd.2 parameter, see the TIG set-up menu.
dYn
dynamic - arc force dynamic correction
Unit -
Setting range 0 - 100
Factory setting 20

For further information on the dYn parameter, see the Rod electrode set-up menu.
HCU
Hot-start current
Unit %
Setting range 0 - 100
Factory setting 50
dt1
delay time 1 - time by which the start of wirefeeding is delayed after the beginning of
main current phase I1 (cold-wire feeder option)
Unit s
Setting range OFF / 0.1 - 9.9
Factory setting OFF
dt2
delay time 2 - time by which the start of wirefeeding is delayed after the end of main
current phase I1 (cold-wire feeder option)
Unit s
Setting range OFF / 0.1 - 9.9
Factory setting OFF
Fdi
Feeder inching (cold-wire feeder option)
Unit m/min ipm
Setting range 0.1 - max. 3.94 - max.
Factory setting 5 197
Fdb
Feeder backward - wire withdrawal (cold-wire feeder option)
Unit mm in.
Setting range OFF / 1 -50 OFF / 0.04 -1.97
Factory setting OFF OFF

For further information on the Fdb parameter, see the TIG set-up menu.

75
The Set-up menu

General remarks The Set-up menu provides simple access to expert knowledge in the power source and
to additional functions. The Set-up menu can be used to make simple adjustments of the
parameters to the various job settings.

- The Set-up menu contains all the set-up parameters that have an immediate effect
on the welding process.
- Set-up menu - level 2 contains all the set-up parameters needed for making the
preliminary settings on the welding machine.

The parameters are arranged in logical groups. Each of these groups is called up by
pressing a different combination of buttons.

Overview The set-up menu is composed of the following sections:

- Shielding gas set-up menu
- TIG set-up menu
- TIG set-up menu - level 2
- AC/polarity reversal set-up menu
- AC/polarity reversal set-up menu - level 2
- Rod electrode set-up menu
- Rod electrode set-up menu - level 2
- Displaying welding circuit resistance r
- Displaying welding circuit inductivity L

76
Shielding gas set-up menu

General remarks The Shielding gas set-up menu offers easy access to the shielding gas settings.

Opening the 1. Press and hold the Store button

Shielding gas
set-up menu 2. Press the Gas-test button

The power source is now in the Shielding gas set-up menu. The last
parameter to be selected is displayed.

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the parameter value using the adjusting dial

Exiting from the 1. Press the Store button

Shielding gas
set-up menu

Parameters in the „Min.“ and „max.“ are used for setting ranges that differ according to power source, wire
Shielding gas feed, welding program, etc.
set-up menu
GPr
Gas pre-flow time
Unit s
Setting range 0 - 9.9
Factory setting 0.4
G-L
Gas-Low - Gas post-flow time at minimum welding current
Unit s
Setting range 0 - 25
Factory setting 5
G-H
Gas-High - Increase in the gas post-flow time at maximum welding current
Unit s
Setting range 0 - 40 / Aut
Factory setting Aut

The value set for G-H only applies if the maximum welding current has in fact been set.
The actual value is derived from the welding current at any given time. With a medium
welding current, for example, the actual value will be one-half of the value set for G-H.

77
Parameters in the Important! The values for the set-up parameters G-L and G-H are added together. For
Shielding gas example, if both parameters are on maximum (25 s / 40 s), the gas post-flow will last:
set-up menu - 25 s at minimum welding current
(continued) - 65 s at maximum welding current
- 37,5 s if the welding current is exactly half the maximum, etc.

If Aut is selected, the gas post-flow time G-H is calculated automatically. This takes the
selected process (AC or DC welding) into account.

G-H
Actual
gas post-flow time

G-L

I
Imin Actual welding current Imax

Fig.44 Gas post-flow time as a function of the welding current

GAS
Gasflow - command value for shielding gas flow (digital gas control option)
Unit l/min cfh
Setting range OFF / 5.0 - max. OFF / 10.71 - max.
Factory setting 15.0 32.14

Important! Please refer to „Digital Gas Control“ instructions for more detailed explanati-
ons of „GAS“ parameters.
GPU
Gas purger
Unit min
Setting range OFF/0.1 - 10.0
Factory setting OFF

Purging of the shielding gas begins as soon as GPU is allocated a value.

For safety reasons, purging of the shielding gas cannot be restarted until a new GPU
value is entered.

Important! Purging with shielding gas is necessary if condensation forms when the
device is left unused in a cold environment for a prolonged period. Long hosepacks are
most affected.

78
TIG set-up menu

Opening the TIG 1. Press the Mode button to select either 2-step mode or 4-step mode
set-up menu

2. Press and hold the Store button

3. Press the Mode button

The power source is now in the TIG set-up menu. The last parameter to
be selected is displayed

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change

2. Alter the parameter value using the adjusting dial

Exiting from the 1. Press the Store button

TIG set-up menu

Parameters in the „Min.“ and „max.“ are used for setting ranges that differ according to power source, wire
TIG set-up menu feed, welding program, etc.

SPt
Spot-welding time
Unit s
Setting range OFF / 0.05 -25.0
Factory setting OFF

If a value has been set for the „SPt“ set-up parameter, the operating mode „2-step
mode“ will have the function of the spot-welding mode.

The special spot welding indicator remains lit on the control panel as long as a value
has been specified for the spot welding time.
tAC
Tacking function when TIG DC welding is selected: Duration of the pulsed welding
current at the start of tacking
Unit s
Setting range OFF / 0.1 - 9.9 / ON
Factory setting OFF

„ON“ The pulsed welding current remains in effect until the end of the
tacking operation
0.1 - 9.9 s The pre-set time begins with the upslope phase. After the end of the
pre-set time period, welding continues at constant amperage; any
pulsing parameters that have been set are available.

79
Parameters in the „OFF“ The tacking function is deactivated
TIG set-up menu
(continued) The special tacking indicator remains lit on the control panel as long as a value has
been specified for the tacking time.
F-P
Frequency pulsing
Unit Hz / kHz
Setting range OFF / 0.20 Hz - 2.00 kHz
Factory setting OFF

The selected pulsing frequency is also used for the reduced current I2.

Important! If F-P is set to „OFF“:

- the set-up parameters dcY, I-G and Fd.2 cannot be selected
- the constant wirefeed speed set on the control panel is used for constant wirefeed at
constant welding current.

The special pulsing indicator remains lit on the control panel as long as a value has
been specified for the pulsing frequency.

Selecting the pulsing frequency F-P:

0.2 Hz to 5 Hz Thermal pulsing (out-of-position welding, automated welding)
1 kHz to 2 kHz Arc-stabilising pulsing (for stabilising the arc at low welding currents)

dcY
Duty cycle - The ratio of pulse duration to background-current duration when a pulsing
frequency has been set
Unit %
Setting range 10 - 90
Factory setting 50
I-G
I (current) - Ground
Unit %
Setting range 0 - 100 % of main current I1
Factory setting 50
t-S
time-Starting
Unit s
Setting range OFF / 0.01 - 9.9
Factory setting OFF

The starting current time t-S specifies the duration of the starting current phase Is.

Important! The set-up parameter „t-S“ only applies in 2-step mode. In 4-step mode, the
duration of the starting current phase Is is controlled manually using the torch trigger
t-E
time-End
Unit s
Setting range OFF / 0.01 - 9.9
Factory setting OFF

The final current time t-E specifies the duration of the final current phase IE.

Important! The set-up parameter t-E only applies in 2-step mode. In 4-step mode, the
duration of the final current phase IE is controlled manually from the torch trigger (see:
„TIG operating modes“).

80
Parameters in the
TIG set-up menu I
(continued) I1

IE
IS

t
GPr tS tup tdown tE

Fig.45 2-step mode: Starting and final current time

Legend:
GPr Gas pre-flow time I1 Main current
Is Starting current tdown Downslope
ts Starting current time IE Final current
tup Upslope tE Final current time
Fd.2
Feeder 2 - wirefeed speed 2 (only where an optional cold-wire feeder is connected)
Unit m/min ipm
Setting range OFF/0.1 - max. OFF/3.94 - max.
Factory setting OFF OFF

If a different value is set for each of the set-up parameters Fd.2 and F-P, the wirefeed
speed alternates between the values set for Fd.1 and Fd.2 according to the pulsing
frequency F-P of the welding current.
dt1
delay time 1 - time by which the start of wirefeeding is delayed after the beginning of
main current phase I1 (only where an optional cold-wire feeder is connected)
Unit s
Setting range OFF / 0.1 - 9.9
Factory setting OFF
dt2
delay time 2 - time by which the start of wirefeeding is delayed after the end of main
current phase I1 (only where an optional cold-wire feeder is connected)
Unit s
Setting range OFF / 0.1 - 9.9
Factory setting OFF
Fdb
Feeder backward - wire withdrawal (cold-wire feeder option)
Unit mm in.
Setting range OFF / 1 -50 OFF / 0.04 -1.97
Factory setting OFF OFF

Important! Wire withdrawal prevents the welding wire from burning at the end. Before
the welding current is switched off, the wire is withdrawn to the set value. A prerequisite
for this function is that the arc has ignited.

81
Parameters in the FAC
TIG set-up menu Factory - for resetting the welding machine
(continued) Press and hold the Store button for 2 s to reset the machine to the factory settings.
When the digital display reads „PrG“, the welding machine has been reset.

Important! When the welding machine is reset, all the personal settings in the Set-up
menu are lost. Jobs are not deleted when the welding machine is reset - these are
preserved. Parameter settings in Set-up menu - level 2 are not deleted.
2nd
Setup menu - level 2: second level of the Set-up menu

82
TIG set-up menu - level 2

Opening TIG set- 1. Open the TIG set-up menu

up menu - level 2
2. Select parameter „2nd“

3. Press and hold the Store button

4. Press the Mode button

The power source is now in TIG set-up menu - level 2.

The last parameter to be selected is displayed

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the parameter value using the adjusting dial

Exiting from the 1. Press the Store button

TIG set-up menu
- level 2 The power source is now in the TIG set-up menu

2. To exit from the TIG set-up menu, press the Store button again

Parameters in „Min.“ and „max.“ are used for setting ranges that differ according to power source, wire
TIG set-up menu feed, welding program, etc.
- level 2
SFS
Special four-step mode
Unit -
Setting range OFF / 1 -3
Factory setting OFF

1 Variant 1 4 Variant 4
2 Variant 2 5 Variant 5
3 Variant 3 6 Variant 6
STS
Special Two Step - Special two step mode for HF ignition after touching the workpiece
Unit -
Setting range OFF / 1
Factory setting OFF

Procedure for ignition, when the STS parameter has been set to 1:
- touch the workpiece with the tungsten electrode
- the short circuit detection of the power source responds
- lift away the tungsten electrode from workpiece
- after 300 ms gas pre-flow starts
- the HF ignition starts
- end of welding by breaking the arc

83
Parameters in C-C
TIG set-up menu Cooling unit control (option)
- level 2
(continued) Unit -
Setting range Aut / ON / OFF
Factory setting Aut

Aut Cooling unit is switched off 2 minutes after the end of welding
ON Cooling unit is ON all the time
OFF Cooling unit is OFF all the time

Important! If the coolant unit is provided with the optional „temperature limit controller“,
the coolant return temperature is checked all the time. If the return temperature is less
than 50 °C, the cooling unit is switched off automatically.
C-t
Cooling time - time from when the rate-of-flow watchdog is triggered until the „no | H2O“
service code is output. For example, if air bubbles occur in the cooling system, the
cooling unit will only cut out at the end of this pre-set time.
Unit s
Setting range 5 - 25
Factory setting 10

Important! Every time the power source is switched on, the cooling unit will carry out a
test run for 180 seconds.
HFt
High Frequency time - high-frequency ignition: time interval between the HF pulses
Unit s
Setting range 0.01 - 0.4 / OFF / EHF (Start with external arc starters, e.g. plasma
welding)
Factory setting 0.01

NOTE! If there are problems with sensitive equipment in the immediate vicinity,
increase the HFt parameter to a maximum of 0.4 s.

The special HF ignition indicator remains lit as long as a value has been specified
for the HFt parameter.

If the „HFt“ set-up parameter is set to „OFF“, no high-frequency ignition takes place at the
start of welding. In this case, the start of welding commences with touchdown ignition.
Pri
Pre Ignition - delayed ignition with immediate high frequency start
Unit s
Setting range OFF / 0,1 - 1
Factory setting OFF

When a time value has been set for the Pri parameter, the ignition of the arc follows
delayed for this time value: push the torch trigger - high frequency is activated for the
time value - ignition of arc
r
r (resistance) - welding circuit resistance (in mOhm)
see „Displaying welding circuit resistance r“
L
L (inductivity) - welding circuit inductivity (in microhenrys)
see „Displaying welding circuit inductivity L“

84
Parameters in Ito
TIG set-up menu Ignition Time-Out - time until safety cut-out following an abortive ignition attempt
- level 2
(continued) Unit s
Setting range 0.1 - 9.9
Factory setting 5

Important! „Ignition Time-Out“ is a safety function so cannot be deactivated. A descripti-

on of the „Ignition Time-Out“ function may be found in the section headed „TIG welding“.
Arc
Arc - arc break watchdog: Time until safety cut-out following an arc break
Unit s
Setting range 0.1 - 9.9
Factory setting 2

Important! The arc break watchdog is a safety function so cannot be deactivated. A

description of the arc break watchdog function may be found in the section headed „TIG
welding“.
SEt
Setting - country-specific setting (Standard / USA) ... Std / US
Unit -
Setting range Std, US (Standard / USA)
Factory setting Standard version: Std (measurements in cm/mm)
USA version: US (measurements in inches)
E-P
External parameter - a user-defined parameter for the JobMaster TIG welding torch or
robot interface (both optional).
A user-defined parameter is available both on the JobMaster TIG welding torch and for
the robot interface. If „E-P“ has been selected, you can use the adjusting dial to choose
between the following possibilities for this freely definable parameter:

- OFF No freely defined parameter has been assigned (factory setting)

- ELd Electrode diameter
- bAL Balance
- SPt Spot-welding time
- I-S Starting current
- UPS Upslope
- I-2 Reduced current
- dsl Downslope
- I-E Final current
- ACF AC frequency
- F-P Pulsing frequency
- dcY Duty cycle
- I-G Base current
- tAC Tacking function: Duration of the tacking operation
- Fd.1 Wirefeed speed 1 (cold-wire feeder option)

The number of user-defined parameters depends on the configuration and the mode that
has been selected.
ACS
Automatic current switch - automatic switchover to main current
Unit -
Setting range ON / OFF
Factory setting ON

ON The parameter I1 (main current) will automatically be selected after

the start of welding
The main current I1 can be set immediately

85
Parameters in OFF The most recently selected parameter remains enabled during
TIG set-up menu welding.
- level 2
The last parameter to be selected can be adjusted immediately.
(continued)
No automatic selection of parameter I1 takes place.
PPU
Select push-pull unit (cold-wire feeder option)
FCO
Feeder control - wirefeeder cut-out (wire-end sensor option)
Unit -
Setting range OFF / ON / noE
Factory setting OFF

OFF The power source halts wire feed when the wire-end sensor is
triggered. „Err|056“ appears on the display.
ON When the wire-end sensor is triggered, the power source only halts
wire feed after the current weld has been completed. „Err|056“
appears on the display.
noE The power source does not halt wire feed when the wire-end sensor
is triggered. The wire-end alarm is not displayed and is only transmit-
ted to the robot control via the field bus.

Important! The „noE“ setting only functions in conjunction with the field bus applications.
Robot interfaces ROB 4000/5000 do not support this function.
COr
Correction - gas correction (digital gas control option)
Unit -
Setting range AUT / 1.0 - 10.0
Factory setting AUT

Important! Please refer to „Digital Gas Control“ instructions for more detailed explanati-
ons of the „COr“ parameter.

86
AC/polarity reversal set-up menu

General remarks The AC/polarity reversal set-up menu is only available with MagicWave power sources.

Opening the AC/

1. Press the Process button to select the AC welding process
polarity reversal
set-up menu
2. Press and hold the Store button

3. Press the Process button

The power source is now in the AC/polarity reversal set-up menu. The
last parameter to be selected is displayed.

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the value of the set-up parameter with the adjusting dial

Exiting from the 1. Press the Store button

AC/polarity
reversal set-up
menu

Parameters in the „Min.“ and „max.“ are used for setting ranges that differ according to power source, wire
AC/polarity feed, welding program, etc.
reversal set-up
menu ACF
AC frequency
Unit Hz
Setting range Syn / 40 - 250
Factory setting 60

Syn For mains synchronisation of two power sources for simultaneous

AC welding.

Important! In addition to the „Syn“ setting, take account of the „PhA“ parameter (phase
adjustment in Set-up menu - level 2 AC/polarity reversal).

Low frequency soft, distant arc with shallow heat input

High frequency focused arc with deep heat input

87
Parameters in the Io
AC/polarity AC current offset
reverser set-up
menu Unit %
(continued) Setting range -70 - +70
Factory setting 0

+70 distant arc with shallow heat input

-70 narrow arc, deep heat input, faster welding speed

2nd
Setup menu - level 2: second level of the set-up menu

I (A) 35% 50% 15% Balance

+
t (s)
-
0 +5 -5
I (A) AC frequency
+
t (s)
-
60 Hz 120 Hz
I (A)
AC current offset
+
*) t (s)
-

0 +70% -70%
Effect of the AC parameters on the waveform

*) Factory setting: 20% shift to the negative

88
AC/polarity reversal set-up menu - level 2

General remarks The AC/polarity reversal set-up menu - level 2 is only available with MagicWave power
sources.

Opening the AC/ 1. Opening the AC/polarity reversal set-up menu

polarity reversal
2. Select parameter „2nd“
set-up menu -
level 2
3. Press and hold the Store button

4. Press the Mode button

The power source is now in the AC/polarity reversal set-up menu -

level 2.
The last parameter to be selected is displayed

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the parameter value using the adjusting dial

Exiting from the 1. Press the Store button

AC/polarity
reversal set-up The power source is now in the AC/polarity reversal set-up menu
menu - level 2
2. To exit from the AC/polarity reversal set-up menu, press the Store button
again

Parameters in the „Min.“ and „max.“ are used for setting ranges that differ according to power source, wire
AC/polarity feed, welding program, etc.
reversal set-up
menu - level 2 PoS
Positive half wave
Unit -
Setting range tri / Sin / rEc / OFF
Factory setting OFF

tri Triangular waveform

Sin Sinusoidal waveform (the standard setting for a low noise, stable
arc)
rEc Rectangular waveform with decreased edge steepness, for reducing
noise levels compared to those that occur with the 100% rectangular
waveform
OFF 100% rectangular waveform (stable but loud arc)

89
Parameters in the nEG
AC/polarity Negative half-wave
reversal set-up
menu - level 2 Unit -
(continued) Setting range tri / Sin / rEc / OFF
Factory setting rEc

tri Triangular waveform

Sin Sinusoidal waveform (the standard setting for a low noise, stable arc)
rEc Rectangular waveform with decreased edge steepness, for reducing
noise levels compared to those that occur with the 100% rectangular
waveform
OFF 100% rectangular waveform (stable but loud arc)
PhA
Phase adjustment of the mains connection of two power sources for simultaneous AC
welding.
Unit -
Setting range 0-5
Factory setting 0

Important! Before phase adjustment the „ACF“ parameter must be set to „Syn“ in the
AC/polarity reversal set-up menu.

Phase synchronisation takes place as follows:

- Prepare a test workpiece for simultaneous AC welding.
- Adjust the PhA value on a power source to between 0 and 5 until the best weld
result is achieved.

90
DC setup menu

General The DC set-up menu is only available with MagicWave power sources.

Open the DC
1. Press the Process button to select the DC welding process
setup menu
2. Press and hold the Store button

3. Press the Process button

The power source is now in the DC setup menu. The last parameter to
be selected is displayed.

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the value of the set-up parameter with the adjusting dial

Exiting from the 1. Press the Store button

DC set-up menu

Parameters in the „Minimum“ and „maximum“ are used for setting ranges that differ according to power
DC set-up menu source, wire feed, welding program, etc.

2nd
Setup menu - level 2: second level of the Set-up menu

91
DC set-up menu - level 2

General The DC set-up menu - level 2 is only available with MagicWave power sources.

Opening the DC 1. Open the DC setup menu

set-up menu -
2. Select parameter „2nd“
level 2
3. Press and hold the Store button

4. Press the Mode button

The power source is now in DC set-up menu - level 2.

The last parameter to be selected is displayed

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the parameter value using the adjusting dial

Exiting from the 1. Press the Store button

DC set-up menu -
level 2 The power source is now in the DC setup menu

2. To exit from the DC setup menu, press the Store button again

Parameters in the „Minimum“ and „maximum“ are used for setting ranges that differ according to power
DC set-up menu - source, wire feed, welding program, etc.
level 2
rPI
Reversed polarity Ignition
Unit -
Setting range ON / OFF
Factory setting OFF

Important! The rPI ignition function

- is only available on the MagicWave power source
- is not recommended for welding light-gauge sheet

92
Rod electrode set-up menu

Opening the Rod 1. Press the Mode button to select Rod electrode (MMA) welding mode
electrode set-up
menu 2. Press and hold the Store button

3. Press the Mode button

The power source is now in the Rod electrode set-up menu. The last
parameter to be selected is displayed.

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the value of the set-up parameter with the adjusting dial

Exiting from the 1. Press the Store button

Rod electrode
set-up menu

Parameters in the „Min.“ and „max.“ are used for setting ranges that differ according to power source, wire
Rod electrode feed, welding program, etc.
set-up menu
HCU
Hot-start current
Unit % (of main current I1)
Setting range 0 - 200
Factory setting 150
Hti
Hot-current time
Unit s
Setting range 0 - 2.0
Factory setting 0.5

In order to obtain optimum welding results, it will sometimes be necessary to set or

adjust the Hot-Start function.

Advantages
- Improved ignition, even when using electrodes with poor ignition properties
- Better fusion of the base metal in the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions
dyn
dYn - arc force dynamic correction
Unit -
Setting range 0 - 100
Factory setting 20

93
Parameters in the 0 soft, low-spatter arc
Rod electrode 100 harder, more stable arc
set-up menu
(continued) In order to obtain optimum welding results, it will sometimes be necessary to adjust the
„Dynamic (arc-force)“ function.

Working principle:
At the instant of droplet transfer or when a short circuit occurs, there is a momentary rise
in the current. In order to obtain a stable arc, the welding current is temporarily increa-
sed. If the rod electrode threatens to sink into the weld pool, this measure prevents the
weld pool solidifying, as well as preventing more prolonged short-circuiting of the arc.
This largely prevents the rod electrode from „sticking“.
FAC
Factory - for resetting the welding machine
Press and hold the Store button for 2 s to reset the machine to the factory settings.
When the digital display reads „PrG“, the welding machine has been reset.

Important! When the welding machine is reset, all the personal settings in the Set-up
menu are lost. Jobs are not deleted when the welding machine is reset - these are
preserved. Parameter settings in Set-up menu - level 2 are not deleted.
2nd
Setup menu - level 2: second level of the Set-up menu

94
Rod electrode set-up menu - level 2

Opening Rod 1. Open the Rod electrode set-up menu

electrode set-up
2. Select parameter „2nd“
menu - level 2
3. Press and hold the Store button

4. Press the Mode button

The power source is now in the Rod electrode set-up menu - level 2.
The last parameter to be selected is displayed

Changing a 1. Use the left or right Parameter Selection button to select the parameter
parameter that you want to change
2. Alter the parameter value using the adjusting dial

Exiting from the 1. Press the Store button

Rod electrode
set-up menu - The power source is now in the Rod electrode set-up menu
level 2
2. To exit from the Rod electrode set-up menu, press the Store button again

Parameters in the „Min.“ and „max.“ are used for setting ranges that differ according to power source, wire
Rod electrode feed, welding program, etc.
set-up menu -
level 2 r
r (resistance) - welding circuit resistance (in mOhm)
see „Displaying welding circuit resistance r“
L
L (inductivity) - welding circuit inductivity (in microhenrys)
see „Displaying welding circuit inductivity L“
ASt
Anti-stick
Unit -
Setting range ON / OFF
Factory setting ON

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode
will tend to „stick“. This may also cause „burn-out“ of the rod electrode.

Electrode burn-out is prevented if the anti-stick function has been activated. If the rod
electrode begins to stick, the power source immediately switches the welding current off.
After the rod electrode has been detached from the workpiece, the welding operation
can be continued without difficulty.

95
Parameters in the ELn
Rod electrode Electrode line - characteristic selection
set-up menu -
level 2 Unit -
(continued) Setting range con / 0.1 - 20 / P
Factory setting con

(1) Load line for rod electrode

con - 20 A / V (2) Load line for rod electrode where arc length is
U (V) increased
(4)
(6) (3) Load line for rod electrode where arc length is
reduced
(2)
(4) Characteristic where „con“ parameter is
(1)
(5) selected (constant welding current)
(3)
(5) Characteristic where „0.1 - 20“ parameter is
selected (falling characteristic with adjustable
(7) slope)
(8)
(6) Characteristic where „P“ parameter is selected
(constant welding power)
(7) Example of pre-set arc force dynamic where
characteristic (4) is selected
0 25 50 75 100 I (A) (8) Example of pre-set arc force dynamic where
characteristic (5) or (6) is selected

Fig.46 Characteristics that can be selected using the Eln function

„con“ parameter (constant welding current)

- If the „con“ parameter has been set, the welding current will be kept constant irres-
pective of the welding voltage. This results in a vertical characteristic (4).
- The „con“ parameter is especially suitable for rutile electrodes and basic electrodes,
as well as for gouging.
- For gouging, set the arc-force dynamic to „100“.

„0.1 - 20“ parameter (falling characteristic with adjustable slope)

- The „0.1 -20“ parameter is used to set a falling characteristic (5). The setting range
extends from 0.1 A / V (very steep) to 20 A / V (very flat).
- Setting a flat characteristic (5) is only advisable for cellulose electrodes.

Important!When setting a flat characteristic (5), set the arc-force dynamic to a

higher value.

„P“ parameter (constant welding power)

- If the „P“ parameter has been set, the welding power is kept constant irrespective of
the welding voltage and welding current. This results in a hyperbolic characteristic
(6).
- The „P“ parameter is particularly suitable for cellulose electrodes.

Important! If there are problems with a rod electrode tending to „stick“, set the arc-
force dynamic to a higher value.

96
Parameters in the
Rod electrode (9)
set-up menu - U (V) (a)
level 2
(continued) 30
(6) (2)
25
(a)
(1)
20 (b)
(5) (c) (3)
15

10 (4) (c)

5
(8)

50 100 150 200 I (A)

I1 - 50 % I1 + arc-force dynamic

(1) Load line for rod electrode (8) Example of pre-set arc force dynamic where
(2) Load line for rod electrode where arc length characteristic (5) or (6) is selected
is increased (9) Possible change in the current where
(3) Load line for rod electrode where arc length characteristic (5) or (6) is selected, as a
is reduced function of the welding voltage (arc length)
(4) Characteristic where „con“ parameter is (a) Operating point where arc length is long
selected (constant welding current) (b) Operating point where welding current I1 is
(5) Characteristic where „0.1 - 20“ parameter is set
selected (falling characteristic with (c) Operating point where arc length is short
adjustable slope)
(6) Characteristic where „P“ parameter is
selected (constant welding power)

Fig. 47 Settings example: I1 = 125 A, arc-force dynamic = 50

The characteristics (4), (5) and (6) shown here apply when using a rod electrode whose
characteristic corresponds - at a given arc length - to the load line (1).

Depending on what welding current (I) has been set, the point of intersection (operating
point) of characteristics (4), (5) and (6) will be displaced along the load line (1). The
operating point provides information on the actual welding voltage and the actual welding
current.

Where the welding current (I1) is permanently set, the operating point may migrate along
the characteristics (4), (5) and (6) depending on the welding voltage at that moment in
time. The welding voltage U is dependent upon the length of the arc.

If the arc length changes (e.g. in accordance with the load line (2)) the resulting opera-
ting point will be the point where the corresponding characteristic (4), (5) or (6) intersects
with the load line (2).

Applies to characteristics (5) and (6): Depending 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.

97
Parameters in the Uco
Rod electrode U (Voltage) cut-off - welding voltage limitation
set-up menu -
level 2 Unit -
(continued) Setting range OFF / 5 - 90 V
Factory setting OFF

The arc length is basically dependent upon the welding voltage. In order to end the
welding operation, it is usually necessary to make a pronounced lifting motion of the rod
electrode away from the workpiece. With the „Uco“ parameter, the welding voltage can
be limited to a value that makes it possible to end the welding operation simply by only
slightly lifting the rod electrode.

NOTE! If, during welding, you often find that the welding operation is ended
unintentionally, set the „Uco“ parameter to a higher value.

98
Displaying welding circuit resistance r

General remarks Measuring the welding circuit resistance „r“ provides information on the overall resis-
tance of the torch hosepack, welding torch, workpiece and earthing (grounding) cable.

If an increased welding circuit resistance is detected, e.g. after changing the torch, this
may mean that one or more of the following components is/are faulty:
- Torch hose pack
- Welding torch
- Earth (ground) connection to the workpiece
- Earthing (grounding) cable

The calculated welding circuit resistance is displayed on the right-hand digital display.

r ... Welding circuit resistance (in mOhm)

Measuring the Important! Make sure that the contact between the earthing (grounding) clamp and the
welding circuit workpiece is on a cleaned section of the workpiece.
resistance r
1. Make an earth (ground) connection to the workpiece
2. Open the TIG set-up menu - level 2, or the Rod electrode set-up menu - level 2
3. Use the left or right Parameter Selection button to select the parameter „r“ that you
want to correct

Important! Make sure that the contact between the electrode and the workpiece is on a
cleaned section of the workpiece. While the measurement is being performed, the
cooling unit and the cold-wire feeder are deactivated.

4. Place the electrode down firmly on the surface of the workpiece

5. Press the torch trigger or the Gas-test button

The welding circuit resistance is now calculated; during the measurement, the right-
hand digital display reads „run“.

6. The measurement is finished when the welding circuit resistance is shown on the
right-hand digital display (e.g. 11.4 milliohms)

99
Displaying welding circuit inductivity L

General remarks The way that the hosepack is arranged has a very significant effect on the welding
properties. Particularly with pulsed-arc welding and AC welding, a high welding circuit
inductivity may occur, depending on the length of the hosepack and on the way that it is
arranged. The result is that the current rise is restricted.

Changing the way the hosepack is arran-

ged may help to improve the welding
results. The hosepack must be laid out as
shown in the illustration.

Fig.48 Correct arrangement of the hosepack

Measuring wel- 1. Measuring welding circuit resistance r

ding circuit 2. Select the set-up parameter „L“ using the left or right Parameter Selection button.
inductivity L
The right-hand digital display shows the welding circuit inductivity (e.g. 5 microhenrys)

100
Troubleshooting and maintenance

101
102
Troubleshooting

General remarks The digital power sources are equipped with an intelligent safety system. This means
that apart from the fuse for the coolant-pump, it has been possible to dispense with
fuses entirely. After a possible malfunction or error has been remedied, the power source
can be put back into normal operation again without any fuses having to be replaced.

WARNING! An electric shock can be fatal. Before opening the machine

- Switch the mains switch „OFF“
- Unplug machine from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertent-
ly switching it back on again
- Using a suitable measuring instrument, check to make sure that electri-
cally charged components (e.g. capacitors) have been discharged

CAUTION! Inadequate PE conductor connections can cause serious injury

and damage. The housing screws provide a suitable PE conductor connec-
tion for earthing (grounding) the housing and must NOT be replaced by any
other screws which do not provide a reliable PE conductor connection.

Displayed service If any error message that is not described here appears on the displays, then the fault is
codes one that can only be put right by a service technician. Make a note of the error message
shown in the display, and of the serial number and configuration of the power source,
and get in touch with our After-Sales Service, giving them a detailed description of the
error.

no | Prg
Cause: No pre-programmed program has been selected
Remedy: Select a pre-programmed program
tP1 | xxx, tP2 | xxx, tP3 | xxx, tP4 | xxx, tP5 | xxx, tP6 | xxx
Cause: Over-temperature in the primary circuit of the power source
Remedy: Allow the power source to cool down
tS1 | xxx, tS2 | xxx, tS3 | xxx
Cause: Over-temperature in the secondary circuit of the power source
Remedy: Allow the power source to cool down
tSt | xxx
Cause: Over-temperature in the control circuit
Remedy: Allow the power source to cool down
Err | 049
Cause: Phase failure in power supply
Remedy: Check the mains fuse, the mains lead and the mains plug
Err | 050
Cause: Indirect symmetry error
Remedy: Contact After-Sales Service
Err | 051
Cause: Mains undervoltage: The mains voltage has dropped below the
tolerance range (see section on „Technical data“)
Remedy: Check the mains voltage

103
Displayed service Err | 052
codes
(continued) Cause: Mains overvoltage: The mains voltage has exceeded the upper limit
of the tolerance range (see section on „Technical data“)
Remedy: Check the mains voltage
no | IGn
Cause: „Ignition time-out“ function is active: No current started flowing
before the end of the time specified in the set-up menu. The safety
cut-out of the power source has been triggered.
Remedy: Press the torch trigger repeatedly; clean the workpiece surface; if
necessary, in Set-up menu - level 2 increase the time until the safety
cut-out is triggered.
Err | PE
Cause: The earth fault current watchdog has triggered the safety cut-out of
the power source.
Remedy: Switch off the power source, wait for 10 seconds and then switch it
on again. If you have tried this several times and the error keeps on
occurring - contact After-Sales Service.
Err | IP
Cause: Primary overcurrent
Remedy: Contact After-Sales Service
Err | bPS
Cause: Fault in power module
Remedy: Contact After-Sales Service
dSP | Axx, dSP | Cxx, dSP | Exx, dSP | Sy, dSP | nSy
Cause: Fault in central control and regulation unit
Remedy: Contact After-Sales Service
r | E30
Cause: r-Alignment: There is no contact with the workpiece.
Remedy: Connect up the earthing (grounding) cable; ensure a tight connection
between the electrode and the workpiece
r | E31
Cause: r-Alignment: Procedure has been interrupted by repeated pressing of
the torch trigger or Gas-test button.
Remedy: Ensure a tight connection between the electrode and the workpiece -
press the torch trigger or Gas-test button once only
r | E33, r | E34
Cause: r-Alignment: Poor contact between the tungsten electrode and the
workpiece
Remedy: Clean the point of contact, check the earthing (grounding) connection
no | Arc
Cause: Arc break
Remedy: Press the torch trigger repeatedly; clean the surface of the workpiece
no | H2O
Cause: Cooling unit flow watchdog has been triggered
Remedy: Check the cooling unit; if necessary, top up the coolant or bleed the
water flow as described in „Putting the cooling unit into service“
hot | H2O
Cause: Thermostat on cooling unit has tripped
Remedy: Wait until the end of the cooling phase, i.e. until „Hot | H2O“ is no
longer displayed. ROB 5000 or field bus coupler for robot control:
Before resuming welding, initialise the „Source error reset“ signal.

104
Displayed service -St | oP- (where the power source is being operated with a robot interface or a
codes field bus)
(continued)
Cause: Robot not ready
Remedy: Initialise „Robot ready“ signal, initialise „Source error reset“ signal
(N.B. „Source error reset“ only available in conjunction with ROB
5000 and field bus coupler for robot control)

Power source Power source does not function

Mains switch is ON, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains supply lead, plug in mains plug if necessary
Cause Mains socket or mains plug faulty
Remedy: Replace faulty components
Power source does not function
Mains switch is ON, but indicators are not lit up
Cause: Mains fuse is faulty
Remedy: Replace the mains fuse
No welding current
Mains switch is ON, overtemperature indicator is lit up
Cause: Overloading; the duty cycle has been exceeded
Remedy: Do not exceed the duty cycle
Cause: Thermostatic cut-out system 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 defective
Remedy: Replace the fan (After-Sales Service)
No welding current
Mains switch is ON and indicators are lit up
Cause: Incorrect earth (ground) connection
Remedy: Check the earth (ground) connection and clamp for correct polarity
Cause: There is a break in the current cable in the welding torch
Remedy: Replace torch
Nothing happens when the torch trigger is pressed
Mains switch is ON and indicators are lit up
Cause: The control plug is not plugged in
Remedy: Plug in the control plug
Cause: The welding torch or torch control lead is defective
Remedy: Replace the torch
No shielding gas
All other functions are OK
Cause: The gas cylinder is empty
Remedy: Change the gas cylinder
Cause: Gas pressure regulator is faulty
Remedy: Replace the gas pressure regulator
Cause: The gas hose is not connected, or is damaged
Remedy: Connect/replace the gas hose
Cause: The welding torch is defective
Remedy: Replace the welding torch
Cause: Gas solenoid valve is defective
Remedy: Replace gas solenoid valve

105
Power source Poor welding properties
(continued)
Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Incorrect earth (ground) connection
Remedy: Check the earth (ground) connection and clamp for correct polarity
The welding torch becomes very hot
Cause: The design dimensions of the torch are not sufficient for this task

Remedy: Observe the duty cycle and loading limits

Cause: Only on water-cooled machines: Water flow rate is insufficient
Remedy: Check the coolant level, flow rate, cleanliness of coolant, etc. If the
coolant pump is blocked: Use a screwdriver - placed on the bushing
- to turn the shaft of the coolant pump.
Cause: Only on water-cooled machines: Parameter C-C is set to „OFF“.
Remedy: In the set-up menu, set parameter C-C to „Aut“ or „ON“ position.

106
Care, maintenance and disposal

General remarks Under normal operating conditions the power source requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the
welding machine remains in a usable condition for many years.

Safety
WARNING! An electric shock can be fatal. Before opening the machine
- Switch the mains switch „OFF“
- Unplug machine from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertent-
ly switching it back on again
- Using a suitable measuring instrument, check to make sure that electri-
cally charged components (e.g. capacitors) have been discharged

Every start-up - Check mains plug, mains cable, welding torch, interconnecting hosepack and earth
(ground) connection for damage
- Check that there is a gap of 0.5 m (1 ft. 8 in.) all around the machine to ensure that
cooling air can flow and escape unhindered

NOTE! Air inlets and outlets must never be covered, not even partly.

Every 2 months - Optional: clean air filter

Every 6 months - Dismantle machine side panels and clean machine inside with dry reduced com-
pressed air

NOTE! Risk of damage to electronic components. Do not bring the air nozzle
too close to the electronic components.

- If a lot of dust has accumulated, clean the cooling air ducts.

Disposal Dispose of in accordance with the applicable national and local regulations.

107
108
Annex

109
110
Technical Data

Special voltages NOTE! Inadequately dimensioned electrical installations can lead to serious
damage. The mains lead and its fuse protection must be rated accordingly. The
technical data shown on the rating plate shall apply.

MagicWave 1700/ MW 1700 Job MW 2200 Job

2200 Job
Mains voltage 230 V 230 V
Mains voltage tolerance -20% / +15% -20% / +15%
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 16 A 16 A
Grid connection 1)
Restrictions No restrictions
possible
Primary continuous power (100% d.c.)3.3 kVA 3.7 kVA
Cos phi 0.99 0.99
Welding current range
TIG 3 - 170 A 3 -220 A
Rod electrode (MMA) 10 -140 A 10 -180 A
Welding current at
10 min/25°C (77°F) 40% d.c.2) 170 A 220 A
10 min/25°C (77°F) 60% d.c.2) 140 A 180 A
10 min/25°C (77°F) 100% d.c.2) 110 A 150 A
10 min/40°C (104°F) 35% d.c.2) 170 A 220 A
10 min/40°C (104°F) 60% d.c.2) 130 A 170 A
10 min/40°C (104°F) 100% d.c.2) 100 A 150 A
Open circuit voltage 88 V 88 V
Working voltage
TIG 10.1 - 16.8 V 10.1 -18.8 V
Rod electrode (MMA) 20.4 -25.6 V 20.4 -27.2 V
Striking voltage (Up) 9.5 kV 9.5 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class B B
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 485/180/344 mm 485/180/390 mm
19.1/7.1/13.6 in. 19.1/7.1/15.4 in.
Weight (without handle) 14.6 kg 17.4 kg
30.8 lb. 38.3 lb.
Weight (with handle) 15 kg 17.8 kg
33 lb. 39.2 lb.
Marks of conformity S, CE S, CE

111
MagicWave 2500/ MW 2500 Job MW 3000 Job
3000 Job
Mains voltage 3 x 400 V 3 x 400 V
Mains voltage tolerance -15% / +15% -15% / +15%
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 16 A 16 A
Grid connection1) Zmax on PCC3) Zmax on PCC3)
= 122 mOhm = 87 mOhm
Primary continuous power (100% d.c.2)) 4.7 kVA 5.5 kVA
Cos phi 0.99 0.99
Welding current range
TIG 3 - 250 A 3 - 300 A
Rod electrode (MMA) 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 10.1 - 20.0 V 10.1 - 22.0 V
Rod electrode (MMA) 20.4 - 30.0 V 20.4 - 32.0 V
Striking voltage (Up) 10 kV 10 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class B B
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 560/250/435 mm 560/250/435 mm
22.0/9.8/17.1 in. 22.0/9.8/17.1 in.
Weight 26.6 kg 28.1 kg
58.64 lb. 61.95 lb.
Marks of conformity S, CE S, CE

MagicWave 2500/ MW 2500 Job MV MW 3000 Job MV

3000 Job MV
Mains voltage 3 x 200 - 240 V 3 x 200 - 240 V
3 x 400 - 460 V 3 x 400 - 460 V
1 x 200 - 240 V 1 x 200 - 240 V
Mains voltage tolerance -10% / +10% -10% / +10%
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow)
3 x 400 - 460 V 16 A 16A
3 x 200 - 240 V 32 A 32 A
1 x 200 - 240 V 32 A 32 A
Grid connection1) Zmax on PCC3) Zmax on PCC3)
= 122 mOhm = 87 mOhm
Primary continuous power (100% d.c.)
3 x 400 - 460 V 4.8 kVA 5.1 kVA
3 x 200 - 240 V 4.4 kVA 4.9 kVA
1 x 200 - 240 V 3.9 kVA 4.3 kVA
Cos phi 0.99 0.99

112
MagicWave 2500/ MW 2500 Job MV MW 3000 Job MV
3000 Job MV
Welding current range (3-phase)
(continued)
TIG 3 - 250 A 3 - 300 A
Electrode 10 - 250 A 10 - 300 A
Welding current range (1-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% d.c.2) 180 A 190 A
Welding current at 3 x 200 - 240 V
10 min/40°C (104°F) 30% d.c.2) - 300 A
10 min/40°C (104°F) 35% d.c.2) 250 A -
10 min/40°C (104°F) 100% d.c.2) 170 A 180 A
Welding current at 1x 200 - 240 V
10 min/40°C (104°F) 40% d.c.2) 220 A -
10 min/40°C (104°F) 50% d.c.2) - 220 A
10 min/40°C (104°F) 100% d.c.2) 150 A 160 A
Open circuit voltage 89 V 89 V
Working voltage
TIG 10.1 - 20.0 V 10.1 - 22.0 V
Rod electrode (MMA) 20.4 - 30.0 V 20.4 - 32.0 V
Striking voltage (Up) 10 kV 10 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class B B
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 560/250/435 mm 560/250/435 mm
22.0/9.8/17.1 in. 22.0/9.8/17.1 in.
Weight 28.2 kg 30 kg
62.17 lb. 66.14 lb.
Marks of conformity S, CE S, CE

MagicWave 4000/ MW 4000 Job MW 5000 Job

5000 Job
Mains voltage 3 x 400 V 3 x 400 V
Mains voltage tolerance +/- 15 % +/- 15 %
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 35 A 35 A
Grid connection1) Restrictions Restrictions
possible possible
Primary continuous power (100% d.c.2)) 15.5 kVA 17.9 kVA
Cos phi 0.99 0.99
Welding current range
TIG 3 - 400 A 3 - 500 A
Rod electrode (MMA) 10 - 400 A 10 - 440 A

113
MagicWave 4000/ MW 4000 Job MW 5000 Job
5000 Job
Welding current at
(continued)
10 min/40°C (104°F) 40% d.c.2) - 500 A
10 min/40°C (104°F) 45% d.c.2) 400 A -
10 min/40°C (104°F) 60% d.c.2) 365 A 440 A
10 min/40°C (104°F) 100% d.c.2) 310 A 350 A
Open circuit voltage 90 V 90 V
Working voltage
TIG 10.1 - 26.0 V 10.1 - 30.0 V
Rod electrode (MMA) 20.4 - 36.0 V 20.4 - 37.6 V
Striking voltage (Up) 9.5 kV 9.5 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class F F
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 625/290/705 mm 625/290/705 mm
24.6/11.4/27.8 in. 24.6/11.4/27.8 in.
Weight 58.2 kg 58.2 kg
128 lb. 128 lb.
Marks of conformity S, CE S, CE

MagicWave 4000/ MW 4000 Job MV MW 5000 Job MV

5000 Job MV
Mains voltage 3 x 200 - 240 V 3 x 200 - 240 V
3 x 380 - 460 V 3 x 380 - 460 V
Mains voltage tolerance +/- 10 % +/- 10 %
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 63 / 35 A 63 / 35 A
Grid connection1) Restrictions Restrictions
possible possible
Primary continuous power (100% d.c.2)) 13.9 kVA 16.5 kV
Cos phi 0.99 0.99
Welding current range
TIG 3 - 400 A 3 - 500 A
Rod electrode (MMA) 10 - 400 A 10 - 440 A
Welding current at
10 min/40°C (104°F) 40% d.c.2) - 500 A
10 min/40°C (104°F) 45% d.c.2) 400 A -
10 min/40°C (104°F) 60% d.c.2) 360 A 440 A
10 min/40°C (104°F) 100% d.c.2) 300 A 350 A
Open-circuit voltage 90 V 90 V
Working voltage
TIG 10.1 - 26.0 V 10.1 - 30.0 V
Rod electrode (MMA) 20.4 - 36.0 V 20.4 - 37.6 V
Striking voltage (Up) 9.5 kV 9.5 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF

114
MagicWave 4000/ MW 4000 Job MV MW 5000 Job MV
5000 Job MV
Insulation class F F
(continued)
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 625/290/705 mm 625/290/705 mm
24.6/11.4/27.8 in. 24.6/11.4/27.8 in.
Weight 60 kg 60 kg
132.30 lb. 132.30 lb.
Marks of conformity S, CE, CSA S, CE, CSA

TransTig 800/ TT 800 Job TT 2200 Job

2200 Job
Mains voltage 230 V 230 V
Mains voltage tolerance -20% / +15% -20% / +15%
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 16 A 16 A
Grid connection 1)
Restrictions No restrictions
possible
Primary continuous power (100% d.c.2)) 2.1 kVA 3.0 kVA
Cos phi 0.99 0.99
Welding current range
TIG 0.5 -80 A 3 -220 A
Rod electrode (MMA) 10 -80 A 10 -180 A
Welding current at
10 min/25°C (77°F) 50% d.c.2) - 220 A
10 min/25°C (77°F) 60% d.c.2) - 200 A
10 min/25°C (77°F) 100% d.c.2) 80 A 170 A
10 min/40°C (104°F) 40% d.c.2) - 220 A
10 min/40°C (104°F) 60% d.c.2) 80 A 180 A
10 min/40°C (104°F) 100% d.c.2) 70 A 150 A
Open-circuit voltage 85 V 84 V
Working voltage
TIG 10.0 - 13.2 V 10.1 -18.8 V
Rod electrode (MMA) 10.4 - 23.2 V 20.4 -27.2 V
Striking voltage (Up) 9.0 kV 9.5 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class B B
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 485/180/344 mm 485/180/390 mm
19.1/7.1/13.5 in. 19.1/7.1/15.4 in.
Weight (without handle) 14.2 kg 16.4 kg
31.3 lb. 37 lb.
Weight (with handle) - 16.8 kg
- 37 lb.
Marks of conformity S, CE S, CE

115
TransTig 2500/ TT 2500 Job TT 3000 Job
3000 Job
Mains voltage 3 x 400 V 3 x 400 V
Mains voltage tolerance -15% / +15% -15% / +15%
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 16 A 16 A
Grid connection1) Zmax on PCC3) Zmax on PCC3)
= 172 mOhm = 97 mOhm
Primary continuous power (100% d.c.2)) 5.1 kVA 5.7 kVA
Cos phi 0.99 0.99
Welding current range
TIG 3 - 250 A 3 - 300 A
Rod electrode (MMA) 10 - 250 A 10 - 300 A
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
Working voltage
TIG 10.1 - 20.0 V 10.1 - 22.0 V
Rod electrode (MMA) 20.4 - 30.0 V 20.1 - 32.0 V
Striking voltage (Up) 10 kV 10 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class B B
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 560/250/435 mm 560/250/435 mm
22.0/9.8/17.1 in. 22.0/9.8/17.1 in.
Weight 24.2 kg 24,2 kg
53.35 lb. 53.35 lb.
Marks of conformity S, CE S, CE

TransTig 2500/ TT 2500 Job MV TT 3000 Job MV

3000 Job MV
Mains voltage 3 x 220 - 240 V 3 x 200 - 240 V
3 x 400 - 460 V 3 x 400 - 460 V
1 x 200 - 240 V 1 x 200 - 240 V
Mains voltage tolerance -10% / +10% -10% / +10%
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow)
3 x 400 - 460 V 16 A 16 A
3 x 200 - 240 V 32 A 32 A
1 x 200 - 240 V 32 A 32 A
Grid connection1) Zmax on PCC3) Zmax on PCC3)
= 172 mOhm = 97 mOhm
Primary continuous power (100% d.c.)
3 x 400 - 460 V 4.7 kVA 5.9 kVA
3 x 200 - 240 V 4.1 kVA 5.0 kVA
1 x 200 - 240 V 4.3 kVA 4.3 kVA

116
TransTig 2500/ TT 2500 Job MV TT 3000 Job MV
3000 Job MV
Cos phi 0.99 0.99
(continued)
Welding current range (3-phase)
TIG 3 - 250 A 3 - 300 A
Electrode 10 - 250 A 10 - 300 A
Welding current range (1-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% d.c.2) 200 A 240 A
Welding current at 3 x 200 - 240 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% d.c.2) 180 A 210 A
Welding current at 1x 200 - 240 V
10 min/40°C (104°F) 50% d.c.2) 220 A -
10 min/40°C (104°F) 55% d.c.2) - 220 A
10 min/40°C (104°F) 100% d.c.2) 190 A 190 A
Open circuit voltage 50 V 50 V
Working voltage
TIG 10.1 - 20.0 V 10.1 - 20.0 V
Rod electrode (MMA) 20.4 - 30.0 V 20.4 - 32.0 V
Striking voltage (Up) 10 kV 10 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class B B
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 560/250/435 mm 560/250/435 mm
22.0/9.8/17.1 in. 22.0/9.8/17.1 in.
Weight 25.9 kg 25,9 kg
57.10 lb. 57.10 lb.
Marks of conformity S, CE S, CE

TransTig 4000/ TT 4000 Job TT 5000 Job

5000 Job
Mains voltage 3 x 400 V 3 x 400 V
Mains voltage tolerance +/- 15 % +/- 15 %
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 35 A 35 A
Grid connection 1)
Restrictions Restrictions
possible possible
Primary continuous power (100% d.c.2)) 11.8 kVA 15.1 kVA
Cos phi 0.99 0.99

117
TransTig 4000/ TT 4000 Job TT 5000 Job
5000 Job
Welding current range
(continued)
TIG 3 - 400 A 3 - 500 A
Rod electrode (MMA) 10 - 400 A 10 - 500 A
Welding current at
10 min/40°C (104°F) 40% d.c.2) - 500 A
10 min/40°C (104°F) 45% d.c.2) 400 A -
10 min/40°C (104°F) 60% d.c.2) 365 A 450 A
10 min/40°C (104°F) 100% d.c.2) 310 A 350 A
Open-circuit voltage 86 V 86 V
Working voltage
TIG 10.1 - 26.0 V 10.1 - 30.0 V
Rod electrode (MMA) 20.4 - 36.0 V 20.4 - 40.0 V
Striking voltage (Up) 9.5 kV 9.5 kV
The arc striking voltage is designed for manual operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class F F
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 625/290/475 mm 625/290/475 mm
24.6/11.4/18.7 in. 24.6/11.4/18.7 in.
Weight 39.8 kg 39.8 kg
87.7 lb. 88 lb.
Marks of conformity S, CE S, CE

TransTig 4000 MV TT 4000 Job MV TT 5000 Job MV

/ 5000 Job MV
Mains voltage 3 x 200 - 240 V 3 x 200 - 240 V
3 x 380 - 460 V 3 x 380 - 460 V
Mains voltage tolerance +/- 10 % +/- 10 %
Mains frequency 50 / 60 Hz 50 / 60 Hz
Mains fuse protection (slow-blow) 63 / 35 A 63 / 35 A
Grid connection 1)
Restrictions Restrictions
possible possible
Primary continuous power (100% d.c.2)) 11.5 kVA 14.2 kVA
Cos phi 0.99 0.99
Welding current range
TIG 3 - 400 A 3 - 500 A
Rod electrode (MMA) 10 - 400 A 10 - 500 A
Welding current at
10 min/40°C (104°F) 40% d.c.2) - 500 A
10 min/40°C (104°F) 45% d.c.2) 400 A -
10 min/40°C (104°F) 60% d.c.2) 360 A 440 A
10 min/40°C (104°F)100% d.c.2) 300 A 350 A
Open-circuit voltage 86 V 86 V
Working voltage
TIG 10.1 - 26.0 V 10.1 - 30.0 V
Rod electrode (MMA) 20.4 - 36.0 V 20.4 - 40.0 V
Striking voltage (Up) 9.5 kV 9.5 kV
The arc striking voltage is designed for manual operation.

118
TransTig 4000 MV TT 4000 Job MV TT 5000 Job MV
/ 5000 Job MV
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class F F
EMC emission class A A
(according to EN/IEC 60974-10)
Dimensions l/w/h 625/290/475 mm 625/290/475 mm
24.6/11.4/18.7 in. 24.6/11.4/18.7 in.
Weight 42.0 kg 42.0 kg
92.6 lb. 92.6 lb.
Marks of conformity S, CE, CSA S, CE, CSA

Explanation of 1)
To 230/400 V, 50 Hz public supply grids
footnotes 2)
d.c. = Duty cycle
3)
PCC = point of common coupling

119
Terms and abbreviations used

General remarks The terms and abbreviations listed here are used in connection with functions that are
either included in the standard scope of supply or that are available as optional extras.

Terms and ACF

abbreviations AC frequency
A-C AC frequency
ACS
Automatic current switch
for switching over to main current
Arc
Arc
Arc-break watchdog
ASt
Anti-stick
For reducing the effect of a „sticking“ rod electrode (MMA welding)
bAL
Balance
When „bAL“ is selected for the external parameter „E-P“, the balance on the JobMaster
TIG welding torch can be adjusted.
C-C
Cooling unit control
Cooling unit control
COr
Correction
Gas correction; modification of the digital gas control to different shielding gases (digital
gas control option)
C-t
Cooling time
Time from when the rate-of-flow watchdog is triggered until the „no | H2O“ service code
is output

Terms and dcY

abbreviations Duty cycle
D-E Ratio of pulse duration to base current duration (in TIG AC welding)
dt1
Delay time 1
Wirefeed start delay time (only where an optional cold-wire feeder is connected)
dt2
Delay time 2
Wirefeed start delay time (only where an optional cold-wire feeder is connected)
dYn
Dynamic
Arc force dynamic correction for rod electrode (MMA) welding
Eld
Electrode diameter
Electrode diameter; when „Eld“ is selected for the external parameter „E-P“, the electro-
de diameter on the JobMaster TIG welding torch can be adjusted.

120
Terms and ELn
abbreviations Electrode line
D-E Characteristic selection (rod electrode [MMA] welding)
(continued)
E-P
External parameter
User-defined parameter for the JobMaster TIG welding torch

Terms and abbre- FAC

viations F Factory
for resetting the welding machine
FCO
Feeder control
Wirefeeder cut-out („Wire-end sensor“ option)
Fd.1
Feeder1
Wirefeed speed 1 (only where an optional cold-wire feeder is connected)
Fd.2
Feeder2
Wirefeed speed 2 (only where an optional cold-wire feeder is connected)
Fdb
Feeder backward
Withdraws wire to prevent it from being burned at the welding end (cold wire feeder
option).
Fdi
Feeder inching
Feeder inching speed
F-P
Frequency pulse
Pulsing frequency

Terms and GAS

abbreviations Gasflow
G-H Command value for shielding gas flow
G-H
Gas post-flow time high
Gas post-flow time at maximum welding current
G-L
Gas post-flow time low
Gas post-flow time at minimum welding current
GPr
Gas pre-flow time
Gas pre-flow time
GPU
Gas purger
Purging of shielding gas
HCU
Hot-start current
Hot-start current (rod electrode (MMA) welding)
HFt
High frequency time
High-frequency ignition

121
Terms and Hti
abbreviations Hot-current time
I-P Hot-current time (rod electrode (MMA) welding)
I-E
I (current) - End
Final current
I-G
I (current) - Ground
Base current
Io
AC current offset
I-S
I (current) - Starting
Starting current
Ito
Ignition time-out
L
L (inductivity)
for displaying the welding circuit inductivity L
nEG
Negative
Negative half-wave (in TIG AC welding)
PhA
Phase adjustment
Phase synchronisation of mains connection of two power sources for simultaneous AC
welding.
Pos
Positive
Positive half-wave (in TIG AC welding)
Pri
Pre Ignition - delayed high frequency ignition
PPU
Push-pull unit
For selecting and aligning the connected push-pull unit

Terms and r
abbreviations r (resistance)
R - 2nd for measuring the welding circuit resistance
rPi
Reverse polarity ignition
Reverse polarity ignition
SEt
Setting
Country-specific setting (Standard / USA)
SFS
Special four step
Special 4-step mode
SPt
Spot-welding time
Spot-welding time
STS
Special Two Step - Special 2-step mode for HF ignition after touching the workpiece
tAC
Tacking
Tacking function

122
Terms and t-E
abbreviations Time - end current
R - 2nd Final current time
(continued)
t-S
Time - starting current
Starting current time
Uco
U (voltage) cut-off
Limiting the welding voltage in the case of rod-electrode welding. Makes it possible to
stop the welding process by slightly raising the rod electrode.
2nd
Second level of Set-up menu

123
124
 Ersatzteilliste
D
Schaltplan

Spare Parts List

GB
Circuit Diagram

Liste de pièces de rechange

F
Schéma de connexions

Lista parti di ricambio

I
Schema

Lista de repuestos
E
Esquema de cableado

Lista de peças sobresselentes

P
Esquema de conexões

Onderdelenlijst
NL
Bedradingsschema

Reservdelsliste
N
Koblingsplan

Seznam náhradních dílů

CZ
Schéma zapojení

Ñïèñîê çàïàñíûõ ÷àñòåé

RUS
Ýëåêòðè÷åñêàÿ ñõåìà

Zoznam náhradných dielov

SK
Schéma zapojenia

Reservdelslistan
S
Kopplingsschema

Parça Listesi
TR
Baðlantý þemasý

Czyszczenie palnika
PL
Schemat połączeń

ud_fr_st_tb_00149 012010
MagicWave 2200 Job G/F 4,075,119 MagicWave 2200 G/F 4,075,125
MagicWave 2200 Job G/F/US 4,075,119,800 MagicWave 2200 G/F/US 4,075,125,800
TransTig 800 Job G/F 4,075,159 TransTig 2200 G/F 4,075,126
TransTig 2200 Job G/F 4,075,120 TransTig 2200 G/F/US 4,075,126,800
TransTig 2200 Job G/F/US 4,075,120,800 MagicWave 1700 G/F 4,075,127
MagicWave 1700 Job G/F 4,075,121 MagicWave 1700 G/F/US 4,075,127,800
MagicWave 1700 Job G/F/US 4,075,121,800
12,0405,0369

42,0201,1328

42,0406,0320
43,0004,1993 - US
43,0004,0519

AM2,0201,1327

43,0002,0295

42,0300,0648
45,0200,1151
42,0409,2979 - US
42,0409,2911
42,0001,3541 - US

43,0013,0015
42,0407,0273 BE2,0201,1329

40,0001,0310 - *

12,0405,0365

33,0005,4146 - TT800
33,0005,4130 - MW1700
33,0005,4129 - MW/TT2200
43,0006,0152 - MW2200
43,0006,0134 - MW1700/TT800/2200
42,0405,0421

2IS 41,0003,0282,Z - MW 1700/2200

W2
FM

4,070,949 - FMW22IS

41,0003,0279

41,0003,0203
12,0405,0365 33,0010,0326
43,0001,1177 43,0001,0600
43,0001,1176 - TT
43,0001,1178
43,0001,3280 - TT 2200 42,0409,3211 - TT800 43,0001,1273 TT800
43,0001,3279 - MW1700/2200 42,0409,2935 - TT2200
43,0001,3258 - TT800/2200 Job 42,0409,2934 - MW1700
43,0001,3259 - MW1700/2200 Job 42,0409,2882 - MW2200
42,0406,0315 * gewünschte Länge angeben
42,0405,0398 - MW1700/2200 * Specify the length required
42,0406,0093 42,0405,0399 - TT2200 * Indiquer la longueur désirée
* Indicar la longitud deseada
42,0001,1501 43,0004,2328 * Indicare la lunghezza desiderat
* indicar o comprimento desejado
42,0001,5477 43,0004,2330 XYHG
WHSRåDGRYDQRXGpONX

32,0405,0183
42,0404,0024

TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/2

el_fr_st_wi_00545 012007
 4,070,813 - BSV22 TT2200
4,070,798,Z - BPS17 MW 1700/TT 800
4,070,804,Z - TTS22 MW1700/2200
4,070,799,Z - BPS22 TT/MW 2200
41,0001,0627

41,0009,0057

33,0024,0032
2
S2
TT 22 33,0010,0325 - MW/TT2200
V
BS
S
BP 43,0006,0168

43,0001,1191
42,0405,0420

4,070,960,Z - UST2C

T2
2 US
F2
HF

4,070,812 - HFF22
43,0004,1122 - 26pol.

TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/2

el_fr_st_wi_00545 012007
MagicWave 2500 G/F 4,075,155 MagicWave 3000 G/F 4,075,157
MagicWave 2500 G/F US 4,075,155,800 MagicWave 3000 G/F US 4,075,157,800
TransTig 2500 G/F 4,075,151 TransTig 3000 G/F 4,075,153
TransTig 2500 G/F US 4,075,151,800 TransTig 3000 G/F US 4,075,153,800
MagicWave 2500 Job G/F 4,075,156 MagicWave 3000 Job G/F 14,075,158
MagicWave 2500 Job G/F US 4,075,156,800 MagicWave 3000 Job G/F US 4,075,158,800
TransTig 2500 Job G/F 4,075,152 TransTig 3000 Job G/F 4,075,154
TransTig 2500 Job G/F US 4,075,152,800 TransTig 3000 Job G/F US 4,075,154,800
MagicWave 2500 Comfort G/F 4,075,156,631 MagicWave 3000 Comfort G/F 4,075,158,631
MagicWave 2500 Comfort MV G/F 4,075,156,801 MagicWave 3000 Comfort MV G/F 4,075,158,801
TransTig 2500 Comfort G/F 4,075,152,631 TransTig 3000 Comfort G/F 4,075,154,631
TransTig 2500 Comfort G/F MV 4,075,152,801 TransTig 3000 Comfrt G/F MV 4,075,154,801
12,0405,0369

42,0201,2418

42,0406,0320

AM2,0201,2420

45,0200,1270

43,0004,0789

43,0004,2323 - MV
41,0003,0309

41,0003,0308
42,0406,0294

43,0001,0600 43,0002,0417 - MV
43,0002,0405
41,0003,0309 42,0001,3541
43,0013,0015
42,0300,1511
42,0407,0284
43,0001,1171 40,0001,0310 - *
42,0407,0532 - MV
43,0001,0600
42,0409,3197
41,0002,0059
41,0002,0060
41,0002,0060-MV 42,0409,3198 - MV

43,0001,1217
43,0001,1216 - TT2500 42,0405,0597

42,0405,0591
43,0001,1138

43,0006,0223
33,0005,4147 - TT2500
33,0005,4145
43,0001,1274 - MW 3000

42,0405,0591
41,0003,0279 - MW

43,0001,0600
41,0003,0203
41,0003,0291 - MW 3000

33,0005,0503
43,0001,1176 - TT

TT / MW 2500/3000 Job, TT / MW 2500/3000 Comfort

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/2

el_fr_st_wi_01389 012010
 43,0004,3830 - 26pol.

4,070,960,Z - UST2C
4,071,201,Z

T
N
4,071,068,Z
2
T
S
U

43,0001,3320

43,0006,0168
S
4,071,063,Z BP
4,071,064,Z - MV 33,0010,0366
RP
33,0010,0367

4,071,065,Z - MW2500
4,071,066,Z - MW3000

4,071,071 - TT3000

0
2 00
F2 V3
HF BS

42,0409,3196 - MW
42,0409,3195 - TT W
FM

43,0001,3318 - TT 2500/3000

43,0001,3319 - MW 2500/3000 4,070,812,Z - HFF22

33,0010,0377-TT2500
43,0001,3311 - MW
43,0001,3312 - MW JOB
43,0001,3313 - TT
43,0001,3314 - TT JOB

42,0406,0315 42,0405,0596 - MW
42,0405,0600 - TT
42,0406,0093
43,0004,2650
42,0001,1501

42,0001,5477 43,0004,2652

32,0405,0183 42,0404,0024

TT / MW 2500/3000 Job, TT / MW 2500/3000 Comfort

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/2

el_fr_st_wi_01389 012010
MagicWave 4000 G/F 4,075,132
MagicWave 4000 G/F MV 4,075,132,800
MagicWave 4000 G/F MV 4,075,132,630
MagicWave 4000 Job G/F 4,075,133
MagicWave 4000 Job G/F MV 4,075,133,800
MagicWave 4000 Job G/F MV 4,075,133,630
MagicWave 5000 G/F 4,075,134
MagicWave 5000 G/F MV 4,075,134,800
MagicWave 5000 G/F MV 4,075,134,630 42,0200,8860
MagicWave 5000 Job G/F MV 4,075,135
MagicWave 5000 Job G/F MV 4,075,135,800
32,0405,0164
MagicWave 5000 Job G/F MV 4,075,135,630

AM2,0200,8819

45,0200,1204

45,0200,1204

43,0013,0015

12,0405,0208

41,0003,0291
41,0012,0030
40,0009,0043

43,0001,0600
43,0001,1139
41,0003,0291

33,0005,4139
33,0010,0343

43,0006,0152

4,070,946 - SYNC50
41,0009,0187

41,0002,0060

S
BP
40,0009,0043
43,0001,0600

43,0001,1104
12,0405,0208

42,0406,0299 4,070,771,Z - BPS43 TT/MW 4000

43,0002,0358 4,070,772,Z - BPS53 TT/MW 5000

MagicWave 4000/5000
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/3

el_fr_st_wi_00991 012007
 43,0004,0987

43,0004,0664 - MV
43,0004,2324 - US AWG 6
43,0001,1199 - 40A 40,0003,0377 - US AWG 10 *

42,0407,0437 - MV 4G10
42,0407,0533 - MV AWG 6
43,0001,1213 - MV 80A 42,0407,0534 - MV AWG 10

BE2,0201,1355 - MV

BE2,0201,1593 - MV
BE2,0201,1934 - MV 4G10

42,0300,1511

32,0409,2657

42,0400,0132
42,0300,1523
41,0005,0288

42,0409,3092
42,0409,3075

43,0001,3272
43,0001,3273 - Job

42,0406,0336
4,070,685,Z - ASU40 MV
42,0406,0113
U
42,0409,3093 AS
24
NT T2
US
43,0006,0168
* gewünschte Länge angeben
* Specify the length required
* Indiquer la longueur désirée
* Indicar la longitud deseada
* Indicare la lunghezza desiderat 4,070,960,Z - UST2C
* indicar o comprimento desejado
4,070,626,Z - NT24
XYHG
WHSRåDGRYDQRXGpONX

MagicWave 4000/5000
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/3

el_fr_st_wi_00991 012007
 41,0003,0279

4,070,941 - FMW50

43,0001,0600 0
W5 41,0003,0109
FM

41,0001,0664

43,0001,1216 BE2,0201,1788

43,0001,1217 42,0405,0462

43,0006,0134

33,0010,0327

4,070,945 - HQL50

2
0 S2 4,070,804,Z - TTS22
42,0405,0462 FU
5 TT

4,070,942 - FU50 50
HF 4,070,940 - HF50

43,0004,2650

43,0004,2652 * gewünschte Länge angeben

42,0405,0461 * Specify the length required
* Indiquer la longueur désirée
32,0405,0183 40,0001,0418 - * * Indicar la longitud deseada
* Indicare la lunghezza desiderat
42,0405,0056 42,0407,0284 * indicar o comprimento desejado
* uved'te požadovanou délku
42,0404,0024
42,0001,1501
42,0001,5477
42,0400,0039

MagicWave 4000/5000
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 3/3

el_fr_st_wi_00991 012007
TransTig 4000 G/F 4,075,128
TransTig 4000 G/F MV 4,075,128,800
TransTig 4000 G/F MV 4,075,128,630
TransTig 4000 Job G/F 4,075,129
TransTig 4000 Job G/F MV 4,075,129,800
TransTig 4000 Job G/F MV 4,075,129,630
TransTig 5000 G/F 4,075,130 42,0200,8860
TransTig 5000 G/F MV 4,075,130,800
TransTig 5000 G/F MV 4,075,130,630
TransTig 5000 Job G/F 4,075,131
TransTig 5000 Job G/F MV 4,075,131,800
32,0405,0164
TransTig 5000 Job G/F MV 4,075,131,630

AM2,0200,8819

45,0200,0918 45,0200,0918

4,070,948,Z - BSV50
43,0013,0015

41,0003,0203 12,0405,0208
41,0012,0030
40,0009,0043
43,0001,1216
43,0001,1103
43,0001,0600
43,0001,1139
41,0003,0203

33,0005,4139
33,0010,0343

43,0001,1217
42,0406,0299

43,0002,0358

43,0006,0152

41,0009,0187

41,0002,0060

S
BP
40,0009,0043
43,0001,0600

43,0001,1104
12,0405,0208

4,070,771,Z - BPS43 TT/MW 4000

33,0005,0493 4,070,658,Z - BPS50 TT/MW 5000

TransTig 4000/5000
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/2

el_fr_st_wi_00989 012007
 43,0004,0987

43,0004,0664 - MV
43,0004,2324 - US AWG 6
43,0001,1199 - 40A 40,0003,0377 - US AWG 10 *

42,0407,0437 - MV 4G10
42,0407,0533 - MV AWG 6
43,0001,1213 - MV 80A 42,0407,0534 - MV AWG 10

BE2,0201,1355 - MV

BE2,0201,1934 - MV 4G10
BE2,0201,1593 - MV

42,0300,1511

4,070,940 - HF50
50
4,070,787 - VOWI220
WI
HF
VO
32,0409,2657

42,0400,0132
42,0300,1523
41,0005,0288
45,0200,1205
42,0409,3076

4,070,685,Z - ASU40 MV
43,0001,3274
43,0001,3275 - Job

42,0406,0336
U
42,0406,0113
AS
45,0200,1203
24
43,0003,0031
NT T2
US
43,0004,2328
43,0006,0168
40,0001,0418 - *

32,0405,0183
42,0407,0284 4,070,960,Z - UST2C
4,100,423 4,070,626,Z - NT24
4,070,942 - FU50
42,0404,0024
42,0405,0056 * gewünschte Länge angeben
43,0004,2330 * Specify the length required
* Indiquer la longueur désirée
* Indicar la longitud deseada
* Indicare la lunghezza desiderat
* indicar o comprimento desejado
XYHG
WHSRåDGRYDQRXGpONX

TransTig 4000/5000
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/2

el_fr_st_wi_00989 012007
MagicWave 1700 Job
MagicWave 2200 Job
MagicWave 2500 Job / MagicWave 2500 Job MV
MagicWave 3000 Job / MagicWave 3000 Job MV
MagicWave 4000 Job / MagicWave 5000 Job (1)
MagicWave 4000 Job / MagicWave 5000 Job (2)
MagicWave 4000 Job MV / MagicWave 5000 Job MV (1)
MagicWave 4000 Job MV / MagicWave 5000 Job MV (2)
MagicWave 4000 Job MV / MagicWave 5000 Job MV (3)
TransTig 800 Job
TransTIG 2200 Job
TransTIG 2500 Job / TransTig 2500 Job MV
TransTIG 3000 Job / TransTig 3000 Job MV
TransTig 4000 Job / TransTig 5000 Job
TransTig 4000 Job MV / TransTig 5000 Job MV (1)
TransTig 4000 Job MV / TransTig 5000 Job MV (2)
TransTig 4000 Job MV / TransTig 5000 Job MV (3)
 FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: [email protected]
www.fronius.com

www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations.

ud_fr_st_so_00082 012011