Magicwave 190

/ Perfect Charging / Perfect Welding / Solar Energy
Operating Instructions
MagicWave 190
MagicWave 230i EN
TIG Power source
TransTig 230i
42,0426,0250,EN 003-05032018
Fronius prints
Downloaded from www.Manualslib.com on search
manuals elemental
enginechlorine free paper (ECF) sourced from certified sustainable forests (FSC).
2
Downloaded from www.Manualslib.com manuals search engine
Dear reader,
EN
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
safety symbols
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury

may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not

avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
3
4
Contents
EN
Safety rules ................................................................................................................................................ 9
General information 21
General ...................................................................................................................................................... 23
Device concept ..................................................................................................................................... 23
Functional principle ............................................................................................................................... 23
Application areas .................................................................................................................................. 23
FCC / RSS Compliance ........................................................................................................................ 24
Warning notices on the device.............................................................................................................. 25
System components .................................................................................................................................. 26
General ................................................................................................................................................. 26
Overview ............................................................................................................................................... 26
Options.................................................................................................................................................. 26
Control elements and connections 27
Control panel.............................................................................................................................................. 29
General ................................................................................................................................................. 29
Safety.................................................................................................................................................... 29
Control panel......................................................................................................................................... 29
The favourites button ................................................................................................................................. 31
Assigning the Favourites button............................................................................................................ 31
Retrieving favourites ............................................................................................................................. 31
Deleting favourites ................................................................................................................................ 32
Assigning EasyJobs to the Favourites button ....................................................................................... 32
Connections, switches and mechanical components ................................................................................ 34
Connections, switches and mechanical components ........................................................................... 34
Installation and commissioning 37
Minimum equipment needed for welding task............................................................................................ 39

General ................................................................................................................................................. 39
TIG AC welding..................................................................................................................................... 39
TIG DC welding..................................................................................................................................... 39
MMA welding ........................................................................................................................................ 39
Before installation and commissioning....................................................................................................... 40
Safety.................................................................................................................................................... 40
Utilisation for intended purpose ............................................................................................................ 40
Setup regulations .................................................................................................................................. 40
Mains connection .................................................................................................................................. 40
Generator-powered operation............................................................................................................... 41
Information on system components ...................................................................................................... 41
Connecting the mains cable....................................................................................................................... 42
General ................................................................................................................................................. 42
Safety.................................................................................................................................................... 42
Connecting the mains cable.................................................................................................................. 42
Start-up ...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
Remarks on the cooling unit ................................................................................................................. 43
General ................................................................................................................................................. 43
Assembling the system components (overview)................................................................................... 44
Connecting the gas cylinder.................................................................................................................. 45
Connecting the welding torch to the power source and the cooling unit............................................... 46
Establishing a ground earth connection to the workpiece..................................................................... 46
Locking and unlocking the power source using the NFC key .................................................................... 47
General remarks ................................................................................................................................... 47
Restrictions ........................................................................................................................................... 47
5
Welding 49
TIG modes ................................................................................................................................................. 51

Safety.................................................................................................................................................... 51
Symbols and their explanations ............................................................................................................ 51
2-step mode .......................................................................................................................................... 52
4-step mode .......................................................................................................................................... 52
Spot welding ......................................................................................................................................... 53
TIG welding................................................................................................................................................ 54
Safety.................................................................................................................................................... 54
Preparations.......................................................................................................................................... 54
TIG welding........................................................................................................................................... 54
Welding parameters for TIG DC welding .............................................................................................. 55
Welding parameters for TIG AC welding .............................................................................................. 58
Igniting the arc ........................................................................................................................................... 63
General ................................................................................................................................................. 63
Igniting the arc using high frequency(HF ignition)................................................................................. 63
Touchdown ignition ............................................................................................................................... 64
End of welding ...................................................................................................................................... 65
Ignition time out, TIG pulsing and tacking function .................................................................................... 66
Ignition timeout function ........................................................................................................................ 66
TIG pulsing............................................................................................................................................ 66
Tacking function.................................................................................................................................... 67
MMA welding ............................................................................................................................................. 68
Safety.................................................................................................................................................... 68
Preparations.......................................................................................................................................... 68
MMA welding ........................................................................................................................................ 69
Welding parameters for manual metal arc welding............................................................................... 70
Starting current >100% (HotStart) ........................................................................................................ 72
Starting current <100% (SoftStart)........................................................................................................ 73
Anti-stick function.................................................................................................................................. 73
EasyJob mode ........................................................................................................................................... 74
Storing EasyJob operating points ......................................................................................................... 74
Retrieving EasyJob operating points .................................................................................................... 75
Deleting EasyJob operating points ....................................................................................................... 75
Welding job ................................................................................................................................................ 76
Safety.................................................................................................................................................... 76
Preparatory work................................................................................................................................... 76
Welding a job ........................................................................................................................................ 76
Setup settings 77
The Setup menu ........................................................................................................................................ 79

General ................................................................................................................................................. 79
Accessing the Setup menu ................................................................................................................... 79
Overview ............................................................................................................................................... 80
Changing menus and parameters......................................................................................................... 81
The TIG menu............................................................................................................................................ 83
Parameters in the TIG DC menu .......................................................................................................... 83
Parameters in the TIG AC menu........................................................................................................... 84
The MMA menu ......................................................................................................................................... 88
Parameters in the rod electrode menu.................................................................................................. 88
Ignition settings .......................................................................................................................................... 91
Ignition setting parameters.................................................................................................................... 91
The gas menu ............................................................................................................................................ 93
Parameters in the Gas menu ................................................................................................................ 93
The components menu .............................................................................................................................. 94
Parameters in the Components menu .................................................................................................. 94
The Job menu ............................................................................................................................................ 95
Save job ................................................................................................................................................ 95
Loading a job ........................................................................................................................................ 96
Deleting a job ........................................................................................................................................ 96
Defaults...................................................................................................................................................... 97
6
Overview ............................................................................................................................................... 97
Display - backlighting ............................................................................................................................ 97
Display - languages .............................................................................................................................. 97
EN
Display - Time & Date ........................................................................................................................... 97
Display - Display additional parameters................................................................................................ 98
System - Reset to factory settings ........................................................................................................ 98
Reset website password ....................................................................................................................... 99
Performing R/L alignment ..................................................................................................................... 99
System informations .................................................................................................................................. 101
Device information ................................................................................................................................ 101
SmartManager - The power source website 103
SmartManager - The power source website .............................................................................................. 105

General ................................................................................................................................................. 105
Calling up the power source SmartManager......................................................................................... 105
Fronius .................................................................................................................................................. 105
Changing password / logging off........................................................................................................... 105
Language .............................................................................................................................................. 106
Current system data................................................................................................................................... 107
Current system data.............................................................................................................................. 107
Job-Data .................................................................................................................................................... 108
Job data ................................................................................................................................................ 108
Job overview ......................................................................................................................................... 108
Editing a job .......................................................................................................................................... 108
Importing a job ...................................................................................................................................... 109
Exporting a job ...................................................................................................................................... 109
Exporting job(s) as… ............................................................................................................................ 109
Backup & Restore ...................................................................................................................................... 110
General ................................................................................................................................................. 110
Backup & Restore ................................................................................................................................. 110
Overview .................................................................................................................................................... 111
Overview ............................................................................................................................................... 111
Expanding / reducing all groups............................................................................................................ 111
Export component overview as ............................................................................................................ 111
Update ....................................................................................................................................................... 112
Update .................................................................................................................................................. 112
Function Packages .................................................................................................................................... 113
Function packages................................................................................................................................ 113
Installing a function package................................................................................................................. 113
Screenshot................................................................................................................................................. 114
Screenshot............................................................................................................................................ 114
Troubleshooting and maintenance 115
Troubleshooting ......................................................................................................................................... 117

General ................................................................................................................................................. 117
Safety.................................................................................................................................................... 117
Power source - troubleshooting ............................................................................................................ 117
Care, maintenance and disposal ............................................................................................................... 120
General ................................................................................................................................................. 120
Safety.................................................................................................................................................... 120
At every start-up.................................................................................................................................... 120
Every 2 months ..................................................................................................................................... 120
Every 6 months ..................................................................................................................................... 120
Disposal ................................................................................................................................................ 121
Appendix 123
Technical data............................................................................................................................................ 125

Special voltages, MagicWave 190 ........................................................................................................ 125
MagicWave 230i ................................................................................................................................... 127
TransTig 230i ........................................................................................................................................ 128
Explanation of footnotes ....................................................................................................................... 129
7
8
Safety rules
EN
General
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operat-
ing company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- have sufficient knowledge of automated welding, and
- read and carefully follow these operating instructions as well as the oper-
ating instructions for all system components.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed "General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise
safety.
This is for your personal safety!
Proper use
The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating
plate.
Any use above and beyond this purpose is deemed improper. The manufac-
turer shall not be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating
instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect re-
sults.
9
Environmental
Operation or storage of the device outside the stipulated area will be deemed
conditions
as not in accordance with the intended purpose. The manufacturer shall not
be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or sub-
stances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
The operator must only allow persons to work with the device who:
operator
- are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the
section "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
Before using the device, all persons instructed to do so undertake:
personnel
- to observe the basic instructions regarding safety at work and accident
prevention
- to read these operating instructions, especially the "Safety rules" section
and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to
any harm in your absence.
Mains connection
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to the maximum permissible mains impedance *)
- criteria with regard to the minimum short-circuit power requirement *)
*)
at the interface with the public grid
see Technical Data
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the
matter with the power supply company.
NOTE! Ensure that the mains connection is earthed properly
10
Protecting your-
EN
Anyone working with the device exposes themselves to numerous risks, e.g.
self and others
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those

using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective
visor and regulation filter
- Wear regulation protective goggles with side protection behind the protec-
tive visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing
protection against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent
injury
Keep all persons, especially children, out of the working area while any devic-
es are in operation or welding is in progress. If, however, there are people in
the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury
from flying sparks, harmful welding fumes, noise, possible risks from
mains current and welding current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
Danger from toxic

The fumes produced during welding contain harmful gases and vapours.
gases and va-
pours Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.

Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/
hour.
11
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is tak-
ing place.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
Amongst others, the following components are responsible for the degree of
toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's
radiation area.
Danger from fly-

Flying sparks may cause fires or explosions.
ing sparks
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the
arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of in-
jury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in ac-
cordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
Risks from mains

An electric shock is potentially life threatening and can be fatal.
current and weld-
ing current Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool,
the feed rollers and all pieces of metal that are in contact with the welding wire
are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suit-
able, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
12
All cables and leads must be secured, undamaged, insulated and adequately
dimensioned. Replace loose connections and scorched, damaged or inade-
EN
quately dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the
welding electrodes of two power sources. Touching the potentials of both elec-
trodes at the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician
to ensure the ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
Operating the device on a grid without a ground conductor and in a socket
without a ground conductor contact will be deemed gross negligence. The
manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on
again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
Meandering weld-
If the following instructions are ignored, meandering welding currents can de-
ing currents
velop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be weld-
ed.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the follow-
ing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.
13
EMC Device Clas-
Devices in emission class A:
sifications
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas.
This is also true for residential areas in which the energy is sup-
plied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
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 rec-
tify the situation.
Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may be
susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connec-
tion, additional measures are necessary (e.g. use a suitable line fil-
ter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids
- wearers of pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body
14
Specific hazards
EN
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened/removed while maintenance or
repair work is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with
wire-feed unit) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment
must therefore also be worn when reworking workpieces, and steps must be
taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling cool-
ant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when

transporting devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the
load-carrying equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use
a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG de-
vices).
15
If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, coun-
terbalanced lift truck or other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter
is used for the shielding gas connection. Prior to assembly, seal the device-
side thread of the adapter for the shielding gas connection using suitable Tef-
lon tape.
Factors affecting
The following requirements with regard to shielding gas quality must be met if
welding results
the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
Danger from
Shielding gas cylinders contain gas under pressure and can explode if dam-
shielding gas cyl-
aged. As the shielding gas cylinders are part of the welding equipment, they
inders
must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instruc-
tions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical
circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only
use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on
the cylinder.
The manufacturer's instructions must be observed as well as applicable na-
tional and international regulations for shielding gas cylinders and accesso-
ries.
16
Danger from es-
EN
Risk of suffocation from the uncontrolled escape of shielding gas
caping shielding
gas Shielding gas is colourless and odourless and, in the event of a leak, can dis-
place the oxygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least
20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylin-
der or the main gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is
taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before every start-up.
Safety measures
A device toppling over could easily kill someone. Place the device on a solid,
at the installation
level surface such that it remains stable
location and dur-
- The maximum permissible tilt angle is 10°.
ing transport
Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protec-
tion shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport
or lifting.
Before transporting the device, allow coolant to drain completely and detach
the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Safety measures
Only operate the device when all safety devices are fully functional. If the safe-
in normal opera-
ty devices are not fully functional, there is a risk of
tion
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper func-
tioning of safety devices.
17
Always fasten the shielding gas cylinder securely and remove it beforehand if
the device is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices
due to its properties (electrical conductibility, anti-freeze agent, material com-
patibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other
system components or a different coolant. In addition, all warranty claims will
be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ig-
nite under certain conditions. Transport the coolant only in its original, sealed
containers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant na-
tional and international regulations. The coolant safety data sheet may be ob-
tained from your service centre or downloaded from the manufacturer's
website.
Check the coolant level before starting to weld, while the system is still cool.
Noise emission
The device generates a maximum sound power level of > 80 dB(A) (ref. 1pW)
values
when idling and in the cooling phase following operation at the maximum per-
missible operating point under maximum rated load conditions according to
EN 60974-1.
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.
Commissioning,
It is impossible to guarantee that bought-in parts are designed and manufac-
maintenance and
tured to meet the demands made of them, or that they satisfy safety require-
repair
ments.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immedi-
ately.
- When ordering, please give the exact designation and part number as
shown in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the
specified torque.
18
Safety inspection
EN
The manufacturer recommends that a safety inspection of the device is per-
formed 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 stand-
ards 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 on Waste Electrical and Electronic Equipment and its im-
plementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling fa-
cility. Any device that you no longer require must either be returned to your
dealer or given to one of the approved collection and recycling facilities in your
area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
Safety symbols
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards
of the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with
Directive 2014/53/EU. The full text on the EU Declaration of Conformity can
be found at the following address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the rele-
vant standards for Canada and the USA.
Data protection
The user is responsible for the safekeeping of any changes made to the fac-
tory settings. The manufacturer accepts no liability for any deleted personal
settings.
19
Copyright
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.
20
General information

General
EN
Device concept The TransTig (TT) 230i, MagicWave (MW)
190 and MagicWave (MW) 230i TIG power
sources are fully digitised, microprocessor-
controlled inverter power sources.
Their modular design and potential for sys-

tem add-ons ensure a high degree of flexi-
bility. The devices can be adapted to any
situation.
The power sources are generator-compa-

tible. They are exceptionally sturdy in day-
to-day operation thanks to the protected
control elements and their powder-coated
housings.
The TIG pulsed arc function, with its wide frequency range, is available on both the Mag-
icWave 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.
Functional princi- The central control and regulation unit of the power sources is coupled with a digital signal
ple 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 device re-
sponds immediately to any changes. Control algorithms ensure that the desired target
state is maintained.
This results in:

- a precise welding process,
- exact reproducibility of all results
- excellent weld properties.
Application areas The devices are used in workshops and industry for manual TIG applications with unal-
loyed and low-alloy steel and high-alloy chrome-nickel steels.
The MagicWave power sources perform exceptionally well when it comes to welding alu-
minium, aluminium alloys and magnesium due to the variable AC frequency.
23
FCC / RSS Com-
FCC
pliance
This equipment complies with the limit values for a EMC device class A dig-
ital device pursuant to Part 15 of the FCC Rules. These limit values are in-
tended to provide an adequate level of protection against harmful emissions
when the device is used in an industrial environment. This device generates
and uses high frequency energy and can cause interference in radio com-
munications if it is not installed and used according to the Operating Instruc-
tions.
The use of this device in residential areas will probably cause hazardous in-
terference, in which case the user will be obliged to make good any damage
at his own expense.
Industry Canada RSS
This device complies with the Industry Canada licence-exempt RSS stand-
ards. Its use is subject to the following conditions:
(1) The device must not cause any hazardous interference.
(2) The device must be able to cope with any interference, including that
which could adversely affect its operation.
FCC ID: QKWSPBBCU1
IC: 12270A-SPBBCU1
24
Warning notices
EN
Warning notices and safety symbols are affixed to power sources with the CSA test mark
on the device
for use in North America (USA and Canada). These warning notices and safety symbols
must not be removed or painted over. They warn against incorrect operation, as this may
result in serious injury and damage.
* MV power sources: 1 ~ 100 - 230 V
Safety symbols on the rating plate:
Welding is dangerous. The following basic requirements must be met:

- Welders must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved in the welding process must be kept at a safe distance
Do not use the functions described here until you have fully read and understood the
following documents:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the safety
rules
25
System components
General The TransTig and MagicWave power sources can be used with a wide variety of system
add-ons and options.
Overview (1) TIG welding torch

(2) Power sources
(3) Cooling unit (only for TT / MW 230i)
(4) Trolley with gas cylinder holder
Not illustrated:
- Remote controls
- Pedal remote controls
- Electrode cable
- Grounding cable
(4)
Options
OPT/i TIG Ethernet
(only for TT / MW 230i)
Option for a permanent network connection

Carrying strap option
FP Pulse Pro
function package for the extended pulse function (the Base current and Duty cycle pa-
rameters can be set, extended pulse frequency range)
FP Job
Function package for Job mode (EasyJobs, save and edit jobs)
26
Control elements and connections

Control panel
EN
General NOTE! Due to software updates, you may find that your device has certain func-
tions that are not described in these operating instructions or vice versa. Individ-
ual illustrations may also differ slightly from the actual controls on your device, but
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 until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe-
ty rules
Control panel
(7) (8) (9) (10)
(6) (5) (4) (3) (2) (1)
29
No. Function
(1) Welding process / Mode button
to select the welding process and operating mode
(2) Gas-test button
to set the required shielding gas flow rate on the gas pressure regulator
After pressing this button, gas flows for 30 seconds. Press the button again to stop
the gas flow prematurely.
(3) Reading zone for NFC keys
MW / TT 230i only and only in certified countries
to lock/unlock the power source using NFC keys
NFC key = NFC card or NFC key ring

(4) Adjusting dial with turn/press function
- To select elements, set values and scroll through lists
- To save jobs when the FP Job function package is present:
if the adjusting dial is pressed for more than 3 seconds, the selected welding
parameters are saved as a job.
An overview of the most important parameters will be displayed.
For more about how to save a job, see Setup settings / the Job menu / Save
job starting on page 95
(5) Menu button
to open the Setup menu
(6) Favourites button
to save / retrieve preferred settings
(7) Display
(8) Hold indicator - welding current
At the end of each welding operation, the actual values for the welding current and
voltage are stored - HOLD lights up.
(9) Status bar
The status bar displays the following information:
- Current welding process
- Current operating mode
- Selected current type
- Active functions (e.g. high frequency ignition, tacking, pulsing, etc.)
- Status of the power source (locked / unlocked)
- Time
- Date
The information shown in the status bar varies according to which welding process
has been selected.
(10) Hold indicator - welding voltage
At the end of each welding operation, the actual values for the welding current and
voltage are stored - HOLD lights up.
30
The favourites button
EN
Assigning the Fa- The Favourites button can be assigned a parameter from the following Setup menus:
vourites button
This parameter can then be called up and changed directly on the control panel.
1 Select the desired parameter in the Setup menu
More information about the Setup menu can be found from page 77 onwards
2 To assign the selected parameter to the Favourites button, press the Favourites but-
ton for approx. 5 seconds
A confirmation message is displayed.
3 Press the adjusting dial to confirm
The selected parameter is now assigned to the Favourites button.
IMPORTANT! Saving a favourite overwrites the previously saved favourite without warn-
ing.
Retrieving favour- 1 Press the Favourites button briefly

ites
The assigned parameter is displayed:
xxxx
* xxx xxx *
The retrieved parameter can be changed by turning the adjusting dial (blue background).
The new value takes effect immediately.
Press and turn the adjusting dial to choose from the available welding parameters.
31
Deleting favour- 1 Press the Favourites button for longer than 5 seconds
ites
The assigned parameter is deleted and a message is displayed.
2 Press the adjusting dial to confirm
Assigning Easy- If the FP Job function package is present on the power source, EasyJobs can be assigned
Jobs to the Fa- to the Favourites button.
vourites button
IMPORTANT! If EasyJobs is assigned to the Favourites button, any previously saved fa-
vourite parameter will no longer be accessible using that button.
1 Select the Job menu from the Setup menu
More information about the Setup menu can be found from page 95 onwards
2 In the Job menu, set the "EasyJobs to Favourites button" parameter to "on"
3 Press the Menu key
Five EasyJob buttons for the welding parameters are displayed as icons.
50 A
* *
4 Press the Favourites button
32
The 5 EasyJob buttons are displayed and can be selected by turning and pressing the
adjusting dial.
EN
50 A
* 1 2 3 4 5 *
More information about using EasyJobs can be found in the "EasyJob mode" section start-
ing on page 74.
33
Connections, switches and mechanical components
Connections,
switches and me-
chanical compo-
nents
Front Rear
No. Function
(1) (-) current socket with integrated gas connection
to connect:
- the TIG welding torch
- the electrode cable for manual metal arc welding
Symbols on TransTig power sources:
Symbols on MagicWave power sources:
(2) TMC connection (TIG Multi Connector)

- to connect the TIG welding torch control plug
- to connect pedal remote controls
- to connect the remote control during MMA welding
(3) USB port
To connect USB flash drives (such as service dongles, licence keys, etc.).
IMPORTANT! The USB port is not electrically isolated from the welding circuit.
This means that devices that establish an electrical connection with another device
must not be connected to the USB port.
34
No. Function
(4) (+) current socket
EN
to connect the grounding cable
Symbols on TransTig power sources:
Symbols on MagicWave power sources:
(5) Mains switch

To switch the power source on and off
Mains switch for MV devices:
(6) Mains cable with strain relief device
for MV devices:
mains cable connection socket
(7) Shielding gas connection

(8) Blanking cover
for Ethernet option
35
36
Installation and commissioning

Minimum equipment needed for welding task
EN
General Depending on which welding process you intend to use, a certain minimum equipment lev-
el will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for the welding task
are then described.
TIG AC welding - MagicWave power source

- Grounding (earthing) cable
- TIG welding torch with rocker switch
- Gas connection (shielding gas supply), with pressure regulator
- Filler metals (as required by the application)
TIG DC welding - Power source

- TIG welding torch with rocker switch
- Gas connection (shielding gas supply)
- Filler metals (as required by the application)
MMA welding - Power source

- Electrode holder
- Rod electrodes (as required by the application)
39
Before installation and commissioning
Safety
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All work described in this document must only be carried out by
trained and qualified personnel. All functions described in this document must
only be used by trained and qualified personnel. Do not carry out any of the work
or use any of the functions described until you have fully read and understood the
following documents:
- this document
ty rules
Utilisation for in- The power source is intended exclusively for TIG and MMA welding.
tended purpose Utilisation for any other purpose, or in any other manner, shall be deemed to be not in ac-
cordance with the intended purpose.
The manufacturer shall not be liable for any damage resulting from such improper use.
Proper use also includes:

- following all the information in the operating instructions
- carrying out all the specified inspection and servicing work
Setup regulations The device is tested to "Degree of protection IP23", meaning:

- protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49
in.)
- protection against direct sprays of water up to 60° from the vertical
The device can be set up and operated outdoors in accordance with IP23.
Avoid direct wetting (e.g. from rain).
WARNING! If one of these machines topples over or falls it could cause serious
or even fatal injury. Place device on a solid, level surface in such a way that it re-
mains stable.
The venting duct is a very important safety feature. When choosing the location for the de-
vice, ensure that the cooling air can enter and exit unhindered through the air ducts on the
front and back of the device. Electrically conductive dust (e.g. from grinding work) must not
be allowed to get sucked into the device.
Mains connection The devices are designed to run on the mains voltage shown on the respective rating
plates. If your version of the device does not come with mains cables and plugs ready-fit-
ted, these must be fitted in accordance with national regulations and standards. For details
of fuse protection of the mains lead, please see the Technical Data.
NOTE! Inadequately dimensioned electrical installations can cause serious dam-

age. The incoming mains lead and its fuse must be dimensioned to suit the local
power supply. The technical data shown on the rating plate applies.
40
Generator-pow- The power source is generator-compatible.
EN
ered operation
In order to dimension the required generator output, the maximum apparent power S1max
of the power source is required.
The maximum apparent power S1max of the power source can be calculated as follows:
S1max = I1max x U1
See device rating plate or technical data for I1max and U1 values
The generator apparent power SGEN needed is calculated using the following rule of
thumb:
SGEN = S1max x 1.35
A smaller generator may be used when not welding at full power.
IMPORTANT! The generator apparent power SGEN must always be higher than the maxi-
mum apparent power S1max of the power source.
When using single-phase devices with a 3-phase generator, note that the specified gener-
ator apparent power is often only available as a whole across all three phases of the gen-
erator. If necessary, obtain further information on the single-phase power of the generator
from the generator manufacturer.
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 tol-
erance can be found in the "Technical data" section.
Information on The steps and activities described below include references to various system compo-
system components, including:
nents - Trolley
- Cooling units
- Welding torches, etc.
For more detailed information about installing and connecting the system components,
please refer to the appropriate operating instructions.
41
Connecting the mains cable
General If power sources are delivered without a mains cable fitted, a mains cable that is suitable
for the connection voltage must be connected to the power source before commissioning.
The mains cable in included in the scope of supply of the power source.
Safety
WARNING! Work that is carried out incorrectly can cause serious injury and dam-
age. The following activities must only be carried out by trained and qualified per-
sonnel. Pay particular attention to the "Safety rules" sections in the power source
and system component operating instructions.
Connecting the Connect the mains cable:

1
mains cable - Plug in the mains cable
- Turn the mains cable 45° to the
right until you hear it latch into pla-
ce
42
Start-up
EN
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 in-
jury and damage. Do not carry out any work on the device unless
- the mains switch is in the "O" position,
- the device is unplugged from the mains.
Remarks on the The TT / MW 230i power sources can be operated with a cooling unit.
cooling unit A cooling unit is recommended for the following applications:
- 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 operation
when the mains switch of the power source is in the "I" position.
More information on the cooling unit can be found in the Operating Instructions for the cool-
ing unit.
General This section describes how to commission the power source:

- for the main TIG welding application
- with reference to a standard configuration for a TIG welding device.
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 commission the power source.
For detailed information about the individual steps, please refer to the operating instruc-
tions for the system components.
43
Assembling the
system compo-
nents (overview)
44
Connecting the
EN
WARNING! There is a high risk of very serious injury and damage if a gas cylin-
gas cylinder
der falls over.
- Place them on a solid, level surface in such a way that they remain stable
- Secure gas cylinders to prevent them from toppling over: fix the safety strap
at the same height as the top part of the cylinder
- Never fix the safety strap around the neck of the cylinder
Follow the gas cylinder manufacturer's safety rules.

1 2
1 2
3 4
3 4
When using a TIG welding torch with an integral gas connection:
5 Use the gas hose to connect the pressure regulator to the shielding gas connection on
the rear of the power source
6 Tighten the union nut on the gas hose
When using a TIG welding torch with no integral gas connection:
5 Connect the TIG welding torch gas hose to the pressure regulator
45
Connecting the NOTE! Do not use pure tungsten electrodes (colour-coded green) on TransTig
welding torch to power sources.
the power source
and the cooling 1 Set up the welding torch in accordance with the welding torch operating instructions
unit
5
2
6
NOTE! Always check the follow-

ing before switching on:
- Sealing ring on welding torch
connection
- Coolant level
During welding, check at regular intervals

that the coolant is flowing properly.

Establishing a 1 Turn the mains switch to the "O" position

ground earth con-
nection to the
7
2
workpiece
46
Locking and unlocking the power source using the
NFC key
EN
General remarks NFC key = NFC card or NFC key ring
The power source can be locked using an NFC key, e.g. to prevent unauthorised access
or welding parameters being changed without permission.
A contactless system on the control panel allows the power source to be locked and un-
locked.
The power source must be switched on before it can be locked or unlocked.
Restrictions Locking and unlocking of the power source is only possible with the TT/MW 230i and is
only permitted in certified countries.
47
48
Welding

TIG modes
EN
Safety
ty rules
See the "The Setup menu" section for information on the settings, setting range and units
of measurement of the available welding parameters.
Symbols and
their explanations
Pull back and hold the torch trig- Release the torch trigger Briefly pull back the torch trigger
ger (< 0.5 s)
Push forward and hold the torch Release the torch trigger
trigger
GPr SPt
Gas pre-flow time Spot welding time
IS IE
Starting-current phase: the temperature is Final current phase: to prevent any local
raised gently at a low welding current so overheating of the base material due to
that the filler metal can be positioned cor- heat build-up towards the end of welding.
rectly This eliminates any risk of weld seam
drop-through.
UP DOWN
Upslope phase: the starting current is DownSlope phase: the welding current is
steadily increased until it reaches the steadily lowered until it reaches the final
main current (welding current) I1 current
I1 I2
Main current phase (welding-current Reduced current phase: intermediate low-
phase): uniform thermal input into the ering of the welding current in order to pre-
base material, whose temperature is vent any local overheating of the base
raised by the advancing heat material
GPo
Gas post-flow time
51
2-step mode - Welding: Pull back and hold the torch trigger
- End of welding: Release the torch trigger
I I1
GPr UP DOWN GPo
2-step mode
4-step mode - Start of welding 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
I I1 I1
I-2
*)
IE
IS
GPr UP DOWN GPo
4-step mode
*) Intermediate lowering
Intermediate lowering during the main current phase reduces the welding current to the
specified reduced current I-2.
- To activate intermediate lowering, push forward and hold the torch trigger
- To revert to the main current, release the torch trigger
52
Spot welding When the spot welding operating mode is selected, the symbol for spot welding appears
EN
on the status display next to the welding process symbol:
- Welding: briefly pull back the torch trigger

The welding time corresponds to the value set for the spot welding time setup param-
eter.
- to end the welding process prematurely: pull the torch trigger back again
I1
I
t
GPr UP DOWN GPo
SPt
53
TIG welding
Safety
ty rules
WARNING! An electric shock can be fatal. If the power source is connected to the
jury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
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 "I" position, the tungsten electrode of the welding torch is live.
Make sure that the tungsten electrode does not touch any persons or electrically
conductive or earthed parts (e.g. housing, etc.).
2 Move the mains switch to the "I" position
The Fronius logo appears on the display.
TIG welding 1 Press the Welding process / Mode button
The welding process and operating mode are displayed.
2 Select the desired welding process by turning the adjusting dial

3 Confirm the selection by pressing the adjusting dial
4 Select the desired operating mode by turning the adjusting dial
The available TIG welding parameters are displayed after a short time or after press-
ing the Welding process / Mode button.
54
6 Turn the adjusting dial to select the required parameter
7 Press the adjusting dial
EN
The value of the parameter is highlighted in blue and can now be changed.
8 Turn the adjusting dial to change the value of the parameter

10 If required, set further parameters in the Setup menu
(For details, see the "Setup parameters" chapter, starting on page 77)
11 Open the gas cylinder valve
12 To 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 gas flow prematurely.
- Turn the adjusting-screw on the underside of the pressure regulator until the ma-
nometer indicates the desired shielding gas flow-rate
NOTE! All welding parameter set values that have been set using the adjusting
dial remain stored until the next time they are changed. This applies even if the
power source is switched off and on again.
13 Start welding (ignite the arc)
Welding parame- The polarity welding parameter is only available on MagicWave power sources.
ters for TIG DC If the polarity welding parameter is set to DC, the following welding parameters are avail-
welding able:
xxA = actual current value depending on the specified main current
Starting current
50% xxA
50% xxA
- + - +
Starting current, 2-step mode and spot welding Starting current, 4-step mode
Unit % (of main current)

Setting range 0 - 200
Factory setting 50
IMPORTANT! The starting current is saved separately for TIG AC welding and TIG DC
welding.
55
UpSlope
0.5 s 0.5 s
- + - +
UpSlope, 2-step mode and spot welding UpSlope, 4-step mode
Unit s
Setting range off; 0.1 - 30.0
Factory setting 0.5
IMPORTANT! The UpSlope is saved separately for 2-step and 4-step modes.
Main current
50 A 50 A
- + - +
Main current, 2-step mode and spot welding Main current, 4-step mode
Unit A
Setting range 3 - 190 ... MW 190
3 - 230 ... MW / TT 230
Factory setting -
IMPORTANT! On welding torches with the Up/Down function, the entire setting range
can be selected while the device is idling.
Reduced current
50% xxA
- +
Reduced current (only in 4-step mode)

Factory setting 50
56
DownSlope
EN
0.5 s 0.5 s
- + - +
DownSlope, 2-step mode and spot welding DownSlope, 4-step mode
Unit s
Factory setting 1.0
IMPORTANT! The DownSlope is saved separately for 2-step and 4-step modes.
Final current
30% xxA
30% xxA
- + - +
Final current, 2-step mode and spot welding Final current, 4-step mode

Factory setting 30
Electrode diameter
2.4mm
- +
Unit mm
Factory setting 2.4
57
Polarity
DC-
- +
Unit -
Setting range DC- / AC
Factory setting DC-
Welding parame- The polarity welding parameter is only available on MagicWave power sources.
ters for TIG AC If the polarity welding parameter is set to AC, the following welding parameters are availa-
welding ble:
Starting current
50% xxA
50% xxA
Starting current, 2-step mode and spot welding Starting current, 4-step mode

Factory setting 50
IMPORTANT! The starting current is saved separately for TIG AC welding and TIG DC
welding.
58
UpSlope
EN
0.5 s 0.5 s
UpSlope, 2-step mode and spot welding UpSlope, 4-step mode
Unit s
Factory setting 0.5
IMPORTANT! The UpSlope is saved separately for 2-step and 4-step modes.
Main current
50 A 50 A
Main current, 2-step mode and spot welding Main current, 4-step mode
Unit A
3 - 230 ... MW / TT 230
Factory setting -
IMPORTANT! On welding torches with the Up/Down function, the entire setting range
can be selected while the device is idling. During welding, the main current can be cor-
rected in steps of +/-20 A.
Reduced current
50% xxA
Reduced current (only in 4-step mode)

Factory setting 50
59
DownSlope
0.5 s 0.5 s
DownSlope, 2-step mode and spot welding DownSlope, 4-step mode
Unit s
Factory setting 1.0
IMPORTANT! The DownSlope is saved separately for 2-step and 4-step modes.
Final current
30% xxA
30% xxA
Final current, 2-step mode and spot welding Final current, 4-step mode

Factory setting 30
Balance
on MagicWave only
35%
+
-
Unit %
Factory setting 35
15: highest fusing power, lowest cleaning action

50: highest cleaning action, lowest fusing power
60
Effect of the balance on the waveshape:
EN
I (A)
35% 50% 15%

+ t (s)
-
Electrode diameter
2.4mm
Unit mm
Factory setting 2.4
Cap mode
on MagicWave only
off
Unit -
Setting range off / on
Factory setting off
off Automatic cap-shaping function is deactivated
on The ideal cap for the specified diameter of the tungsten electrode is
formed during welding start-up.
A separate cap-shaping operation on a test workpiece is not neces-
sary.
61
Afterwards, the automatic cap-shaping function is reset and deacti-
vated.
(1) (2)
(1) ... before ignition

(2) ... after ignition
Cap mode must be activated separately for each tungsten elec-

trode.
NOTE! The automatic cap-shaping function is not necessary if a

sufficiently large cap has already formed at the tip of the tungsten
electrode.
Polarity
AC
Unit -
Setting range DC- / AC
Factory setting DC-
62
Igniting the arc
EN
General To ensure the best ignition sequence in the TIG AC welding process, the MagicWave pow-
er sources take account of:
- the diameter of the tungsten electrode
- the current temperature of the tungsten electrode with reference to the preceding
welding and weld-off times
Igniting the arc HF ignition is activated when a time value has been set for the ignition timeout setup pa-
using high fre- rameter in the HF menu.
quency The HF ignition indicator lights up in the status bar on the control panel.
(HF ignition)
Unlike 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 igni-

tion location, ensuring there is a gap of
approx. 2 to 3 mm (5/64 to 1/8 in.) bet-
ween the tungsten electrode and the
workpiece Gap exists.
2 Increase the tilt angle of the torch and

actuate the torch trigger according to
the mode you have selected
The arc ignites without the electrode

touching down on the workpiece.
63
3 Tilt the torch back into the normal posi-
tion
4 Carry out welding
Touchdown igni- If the ignition timeout setup parameter is set to off, HF ignition is deactivated. The welding
tion 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 igni-

tion location, ensuring there is a gap of
approx. 2 to 3 mm (5/64 to 1/8 in.) bet-
ween the tungsten electrode and the
workpiece Gap exists
2 Actuate the torch trigger
Shielding gas flows
3 Gradually tilt the welding torch up until

the tungsten electrode touches the
workpiece
64
4 Raise the welding torch and rotate it
into its normal position
EN
The arc ignites.
5 Carry out welding
End of welding 1 Depending on the set mode, finish welding by releasing the torch trigger
2 Wait for the set gas post-flow and hold welding torch in position over the end of the
weld seam
65
Ignition time out, TIG pulsing and tacking function
Ignition timeout The power source has an ignition timeout function.

function
Once the torch trigger is pressed, gas pre-flow begins immediately. Ignition then begins. If
an arc does not appear within the time specified in the Setup menu, the power source cuts
out automatically.
The settings for the parameter Ignition timeout are described in the section "The HF menu"
from page 91 onwards.
TIG pulsing The welding current set at the start of welding is not always ideal for the welding process
as a whole:
- if the amperage is too low, the base material will not melt sufficiently
- if overheating occurs, the liquid weld pool may drip.
The TIG pulsing function (TIG welding with pulsing welding current) offers a remedy:
a low base current (2) rises steeply to the significantly higher pulse current and, depending
on the set duty cycle (5), drops back to the base current (2).
In TIG pulsing, small sections of the welding location melt quickly and then solidify again
quickly.
In manual applications using TIG pulsing, the welding wire is applied in the maximum cur-
rent phase (only possible in the low frequency range: 0.25 - 5 Hz). Higher pulse frequen-
cies 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 sheets.
Mode of operation of TIG pulsing when TIG DC welding is selected:
I [A] (5)
(6)
(1)
(2) (8)
(3)
(4) (7) t [s]
TIG pulsing - welding current curve
Legend:
(1) Main current (5) Pulse frequency *)
(2) Base current (6) Duty cycle
(3) Starting current (7) DownSlope
(4) UpSlope (8) Final current
*) (1/F-P = time interval between two pulses)
66
Tacking function The tacking function is available for the TIG DC welding process.
EN
When a time period is specified for the tacking setup parameter (4), the tacking function is
assigned to 2-step mode and 4-step mode. The operating sequence of the modes remains
unchanged.
The tacking (TAC) indicator lights up in the status bar on the display:
During this period, there is a pulsed welding current that makes the weld pool run together
better when two parts are being tack-joined.
Mode of operation of tacking function for TIG DC welding:
I [A] (4)
(1)
(6)
(2)
(3) (5) t [s]
Tacking function - welding current curve
Legend:
(1) Main current
(2) Starting current
(3) UpSlope
(4) Duration of pulsed welding current for the tacking process
(5) DownSlope
(6) Final current
NOTE! The following points apply to the pulsed welding current:

- The power source automatically regulates the pulsing parameters depending
on the specified main current (1).
- There is no need to set any pulsing parameters.
The pulsed welding current begins
- after the end of the starting-current phase (2)
- with the UpSlope phase (3)
Depending on what tacking period has been set, the pulsed welding current may continue
up to and including the final current phase (6) (tacking setup parameter (4) set to "on").
After the tacking time has elapsed, welding continues at a constant welding current, and
any pulsing parameters that may have been set continue to be available.
67
MMA welding
Safety
ty rules
Preparations 1 Switch off cooling units (in the components menu, set the cooling unit control setup
parameter to OFF)
2 Move the mains switch to the O position
3 Disconnect the mains plug
4 Remove the TIG welding torch
IMPORTANT! Observe the instructions on the packaging of the rod electrode when select-
ing the appropriate type of current and for correctly connecting the electrode cable.
5 Plug in and latch the grounding cable:

in the (+) current socket ... for DC- welding (=/-)
in the (-) current socket ... for DC+ welding (=/+)
6 Use the other end of the grounding cable to establish a connection to the workpiece
7 Plug in the electrode cable and turn it clockwise to latch it in place:
in the (-) current socket ... for DC- welding (=/-)
in the (+) current socket ... for DC+ welding (=/+)
8 Plug in the mains plug
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" 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.).
The Fronius logo appears on the display.
68
MMA welding 1 Press the Mode button
EN
2 Select MMA (rod electrode) welding process (turn adjusting dial and press)
3 Turn the adjusting dial to select the Polarity parameter

5 Set the polarity for the rod electrode to be used by turning the adjusting dial
8 Turn the adjusting dial to select further welding parameters

The value of the parameter is highlighted in blue and can now be changed.
10 Turn the adjusting dial to change the value of the parameter

12 If required, set further parameters in the Setup menu
(For details, see the "Setup parameters" chapter, starting on page 77)
NOTE! All welding parameter set values that have been set using the adjusting
dial remain stored until the next time they are changed. This applies even if the
power source is switched off and on again.
13 Start welding
69
Welding parame-
* Depending on the selected current type, (+), (-) or the alternating current symbol
ters for manual
is displayed here.
metal arc welding
Starting current
50% xxA
100% xxA
* * * *
Starting current: starting current < main current Starting current: starting current = main current
("SoftStart")
150% xxA
* *
Starting current: starting current > main current
("HotStart")

Factory setting 150
70
Main current
EN
130 A 130 A
* * * *
Main current: starting current < main current Main current: starting current = main current
("SoftStart")
130 A
* *
Main current: starting current > main current ("Hot-
Start")
Unit A
0 - 230 ... MW / TT 230
Factory setting -
Arc-force dynamic
20
* *
To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force
dynamic.

Factory setting 20
0 soft, low-spatter arc

100 harder, more stable arc
Functional principle:
at the instant of droplet transfer or in the event of a short circuit, there is a momentary rise
in amperage. In order to obtain a stable arc, the welding current is temporarily increased.
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.
71
Polarity
DC- DC+
- + + -
Polarity, set to DC- Polarity, set to DC+
AC
Polarity, set to AC
Unit -
Setting range DC- / DC+ / AC
Factory setting DC-
Starting current Benefits

> 100 % (Hot- - Improved ignition properties, even when using electrodes with poor ignition properties
Start) - Better fusion of the base material in the start-up phase, meaning fewer cold-shut de-
fects
- Largely prevents slag inclusions
Legend
I (A)
(1) (1) Starting current time
0-2 s, factory setting 0.5 s
150
0-200%, factory setting 150%
(3) Main current = pre-set welding
100
current I1
(2)
Mode of operation
(3) during the specified starting current time
(1), the welding current I1 (3) is increased to
t (s) the starting current (2).
0,5 1 1,5 The starting current time is set in the Setup

menu.
Example with a starting current > 100% (HotStart)
72
Starting current A starting current < 100% (SoftStart) is intended for basic electrodes. Ignition takes place
EN
< 100 % at a low welding current. Once the arc is stable, the welding current continues to rise until
(SoftStart) it reaches the welding current command value.
Benefits:
- Improved ignition properties for elec-
I (A) trodes that ignite at low welding cur-
rents
(3)
- Reduces welding spatter
90A
(2) Starting current time
(1)
30A (3) Main current
The starting current time is set in the rod

electrodes menu.
t
(2)
Example with a starting current < 100% (SoftStart)
Anti-stick func- As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will
tion tend to stick. This may also cause the rod electrode to burn out.
Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode be-
gins to stick, the power source immediately switches the welding current off. After the rod
electrode has been detached from the workpiece, the welding process can be continued
without any problems.
The anti-stick function can be activated and deactivated in the rod electrodes menu.
73
EasyJob mode
Storing EasyJob NOTE! EasyJobs are saved under job numbers 1 - 5 and can also be called up in
operating points the Job menu.
Storing an EasyJob overwrites any other job saved under the same number!
Prerequisite:
EasyJobs must be assigned to the Favourites button (see "Assigning EasyJobs to the Fa-
vourites button", starting on page 32.
1 Set the welding process, mode and welding parameters

2 Press the Favourites button
The 5 EasyJob buttons are opened.
3 Turn the adjusting dial and select the desired storage location
4 To save the current welding settings, press and hold the adjusting dial for about 3 sec-
onds
The size and colour of the button changes.
After about 3 seconds, the button is displayed in green.
The settings have now been stored. The most recently stored settings will be active.
An active EasyJob is indicated by a flag on the EasyJob button.
An occupied storage location is displayed in black, e.g.:

Storage location 1 ... occupied and active
Storage location 2 ... selected
Storage location 3 ... free
74
Retrieving Easy- 1 Press the Favourites button
EN
Job operating
points The 5 EasyJob buttons are opened.
2 Turn the adjusting dial and select the desired storage location
3 To retrieve a saved EasyJob operating point, press the adjusting dial briefly (< 3 sec-
onds)
The size and colour of the button changes.
The EasyJob buttons are then minimised and the active EasyJob is indicated by a flag.
Deleting EasyJob 1 Press the Favourites button

operating points
The 5 EasyJob buttons are opened.
2 Turn the adjusting dial and select the storage location to be deleted
3 To delete an EasyJob operating point, press and hold the adjusting dial for about 5
seconds
The button
- first changes its size and colour;
- it changes to a green colour after about 3 seconds;
The saved operating point is overwritten with the current settings.
- is highlighted in red (= delete) after a total of 5 seconds.
The EasyJob operating point has been deleted.
75
Welding job
Safety
ty rules
Preparatory work 1 Set up and install the power source in accordance with the welding job
2 Plug in the mains plug
CAUTION! Risk of injury and damage from an electric shock.

As soon as the mains switch is in the "I" position, the tungsten electrode in the
welding torch is live. Ensure that the tungsten electrode does not touch any per-
sons or electrically conductive or earthed parts (e.g. housing, etc.).
Welding a job 1 Press the Mode button
2 Select "JOB" (turn adjusting dial and press)
The welding parameters of the previously opened job are displayed after a short time. The
job number is selected.

The job number can now be modified.
3 Select the job number of the welding job (turn adjusting dial and press)
The welding parameters of the selected job are displayed and the job can now be
welded.
76
Setup settings

The Setup menu
EN
General The Setup menu provides easy access to the knowledge base in the power source and to
additional functions. The Setup menu can be used to make simple adjustments to the weld-
ing parameters to suit the various job settings.
The following can be found in the Setup menu:

- all setup parameters that have an immediate effect on the welding process,
- all setup parameters needed for making the preliminary settings on the welding sys-
tem.
The display of the parameters and the ability to change them depends on the selected
menu and the current settings for the welding process and operating mode.
Parameters that are not relevant to the current settings are greyed out and cannot be se-
lected.
Accessing the
Setup menu
1 Press Menu key
The Setup menu appears.
2 To leave the Setup menu, press the Menu key again
The current welding parameters will be displayed.
79
Overview
(1) (2) (3) (4) (5) (6) (7) (8)
**
(13) (12) (11) (10) (9)
Item Designation
(1) TIG menu
to set the TIG parameters for TIG DC and TIG AC
(2) Rod electrode menu

to set the rod electrode parameters
(3) Ignition settings

to set the TIG arc ignition parameters
(4) Gas menu

to set the shielding gas parameters
(5) Component settings

to set the cooling unit operating mode
(6) Job menu

(only if FP Job function package is present)
- to save, load and delete jobs
- to assign EasyJobs to the Favourites button
80
Item Designation
(7) Defaults
EN
to
- Display:
set display backlighting, languages, date & time, display addition-
al parameters
- System:
restore factory settings, reset website password, perform R/L
alignment
(8) System information
to display device information such as software version or IP address
(assuming the power source is on a network)
(9) Scroll bar
(for multiple parameters)
(10) Available menus
the number of available menus can vary depending on the firmware
version and available options.
(11) Value, unit
(12) Setup parameters
depending on the selected menu and the current settings for the weld-
ing process and operating mode, parameters that are not relevant are
greyed out and cannot be selected.
(13) Display of the currently selected menu
taking into account the current settings for welding process and oper-
ating mode
* Menu currently being adjusted (blue background)

** Position of the currently selected menu
Changing menus
and parameters
Selected menu Selected parameter
Change the menu Set the parameter
Selecting a menu
If a parameter is selected (blue frame, white background):
1 Turn the adjusting dial until the parameter's higher-level menu is selected
The background of the selected menu becomes blue.
3 Turn the adjusting dial and select the desired menu (blue background)
81
Setting parameters
4 Press the adjusting dial in the selected menu
The first parameter in the menu is selected.
5 Turn the adjusting dial and select the desired parameter

6 Press the adjusting dial to change the parameter
The background of the parameter value becomes blue.
7 Turn the adjusting dial and set the value of the parameter
The change in the parameter value takes effect immediately
8 Press the adjusting dial to select other parameters
82
The TIG menu
EN
Parameters in the
Tacking
TIG DC menu
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
On The pulsed welding current remains in effect until the end of the
tacking operation
0.1 - 9.9 s The set time begins with the UpSlope phase. After the end of the
pre-set time period, welding continues with a constant welding
current; any pulsing parameters that have been set are available.
Off The tacking function is de-

activated
The tacking indicator (TAC) in the status bar on the display lights up provided that a value
has been set.
Pulse frequency
Unit Hz
Setting range Off / 0.20 - 2000 (10000 with FP Pulse Pro option)
Factory setting Off
IMPORTANT! If the pulse frequency is set to "Off", the Base current and Duty cycle pa-
rameters cannot be selected.
The set pulse frequency is also used for the reduced current.
The pulse indicator in the status bar on the display lights up provided a value has been
specified for the pulse frequency.
FP Pulse Pro
to set the Base current and Duty cycle parameters
Base current
Unit % (of main current I1)

Factory setting 50
83
Duty cycle
Ratio of pulse duration to base current duration in cases where a pulse frequency has
been set
Unit %
Factory setting 50
Starting current time
The starting current time specifies the duration of the starting-current phase.
Unit s
Setting range Off / 0.01 - 30.0
Factory setting Off
IMPORTANT! The starting current time only applies to 2-step mode and spot welding. In
4-step mode, the duration of the starting-current phase is controlled using the torch trig-
ger.
Final current time
The final current time specifies the duration of the final current phase.
Unit s
Setting range Off / 0.01 - 30
Factory setting Off
IMPORTANT! The final current time only applies to 2-step mode and spot welding. In 4-
step mode, the duration of the final current phase is controlled using the torch trigger (see
"TIG operating modes").
Spot-welding time
Unit s
Setting range 0.02 - 120
Factory setting 5.0
Parameters in the
Pulse frequency
TIG AC menu
Unit Hz
Setting range Off / 0.20 - 2000 (10000 with FP Pulse Pro option)
Factory setting Off
IMPORTANT! If the pulse frequency is set to "Off", the Base current and Duty cycle pa-
rameters cannot be selected.
The set pulse frequency is also used for the reduced current.
The pulse indicator in the status bar on the display lights up provided a value has been
specified for the pulse frequency.
84
FP Pulse Pro
to set the Base current and Duty cycle parameters
EN
Base current
Unit % (of main current I1)

Factory setting 50
Duty cycle
Ratio of pulse duration to base current duration in cases where a pulse frequency has
been set
Unit %
Factory setting 50
The starting current time specifies the duration of the starting-current phase.
Unit s
Setting range Off / 0.01 - 30.0
Factory setting Off
IMPORTANT! The starting current time only applies to 2-step mode and spot welding. In
4-step mode, the duration of the starting-current phase is controlled using the torch trig-
ger.
Final current time
The final current time specifies the duration of the final current phase.
Unit s
Setting range Off / 0.01 - 30
Factory setting Off
IMPORTANT! The final current time only applies to 2-step mode and spot welding. In 4-
step mode, the duration of the final current phase is controlled using the torch trigger (see
"TIG operating modes").
AC frequency
Unit Hz
Factory setting 60
Low frequency soft, distant arc with shallow heat input

High frequency focused arc with deep heat input
85
Effect of the AC frequency on the waveshape:
I (A)
+
- t (s)
60 Hz 120 Hz
AC current offset
Unit %
Setting range -70 to +70
Factory setting 0
+70 distant arc with shallow heat input

-70 narrow arc, deep heat input, faster welding speed
Effect of the AC current offset on the waveshape:
I (A)
+ t (s)
-
*
0 +70% -70%
* Factory setting: 20% shift to the negative

Positive half-wave waveform
Unit -
Setting range Hard rectangle / Soft rectangle / Triangle / Sine
Factory setting Hard rectangle
Hard rectangle 100% rectangular waveform (stable but loud arc)

Soft rectangle Rectangular waveform with decreased edge steepness, for re-
ducing noise levels compared to those that occur with the 100%
rectangular waveform
Triangle Triangular waveform
Sine Sinusoidal waveform (standard setting for a low-noise, stable
arc)
86
Negative half-wave waveform
EN
Unit -
Setting range Hard rectangle / Soft rectangle / Triangle / Sine
Factory setting Hard rectangle
Hard rectangle 100% rectangular waveform (stable but loud arc)

Soft rectangle Rectangular waveform with decreased edge steepness, for re-
ducing noise levels compared to those that occur with the 100%
rectangular waveform
Triangle Triangular waveform
Sine Sinusoidal waveform (standard setting for a low-noise, stable
arc)
87
The MMA menu
Parameters in the
rod electrode
HotStart
menu
Unit s
Setting range 0.0 - 2.0
Factory setting 0.5
To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart
function.
Benefits:
- Improved ignition properties, even when using electrodes with poor ignition proper-
ties
- Better fusion of the base material in the start-up phase, meaning fewer cold-shut de-
fects
Char
To select characteristics
Unit - / A/V / -
Setting range I-constant / 0.1 - 20.0 / P-constant
Factory setting I-constant
(1) Load line for rod electrode
con - 20 A / V (2) Load line for rod electrode where arc length is in-
U (V) creased
(4)
(3) Load line for rod electrode where arc length is re-
(6)
(2) duced
(1)
(5)
(3) (4) Characteristic for parameter setting I-constant
(constant welding current)
(5) Characteristic for parameter setting 0.1 - 20.0

(7) (8)
(drooping characteristic with adjustable slope)
(6) Characteristic for parameter setting P-constant
(constant welding power)
0 100 200 300 400 I (A)
(7) Example of pre-set arc-force dynamic where
characteristic (4) is selected
characteristic (5) or (6) is selected
Adjustable characteristics
I-constant (constant welding current)

- If the I-constant characteristic is set, the welding current will be kept constant, irre-
spective of the welding voltage. This results in a vertical characteristic (4).
- This setting is particularly suited to
rutile electrodes,
basic electrodes,
arc air gouging (set the arc-force dynamic to 100 for arc air gouging).
88
0.1 - 20.0 (drooping characteristic with adjustable slope)
- Setting 0.1 - 20.0 is used to set a drooping characteristic (5). The setting range ex-
tends from 0.1 A / V (very steep) to 20 A / V (very flat).
EN
- Setting a flat characteristic (5) is only advisable for cellulose electrodes.
NOTE! When setting a flat characteristic (5), set the arc-force dynamic to a higher
value.
P-constant (constant welding power)

- If the P-constant characteristic is set, the welding power is kept constant, irrespective
of the welding voltage and welding current. This results in a hyperbolic characteristic
(6).
- This setting is particularly suitable for cellulose electrodes.
NOTE! If there are problems with a rod electrode tending to "stick", set the arc-
force dynamic to a higher value.
(1) Load line for rod electrode

(2) Load line for rod electrode where arc length is in-
(8)
U (V) (a) creased
(3) Load line for rod electrode where arc length is re-
60 (6)
duced
(2)
50
(4) Characteristic for parameter setting I-constant
(a)
(1) (constant welding current)
40 (b)
(5) (c) (3)
30 (5) Characteristic for parameter setting 0.1 - 20.0
(drooping characteristic with adjustable slope)
20 (c)
(4) (6) Characteristic for parameter setting P-constant
10
(constant welding power)
(7)
100 200 300 400 I (A)
characteristic (5) or (6) is selected
I1 - 50 % I1 + Dynamik
(8) Possible change in the current where character-
istic (5) or (6) is selected, as a function of the
welding voltage (arc length)
(a) Operating point where arc length is long
(b) Operating point when welding current I1 is set

(c) Operating point where arc length is short
Settings example: I1 = 250 A, arc-force dynamic = 50
The characteristics (4), (5) and (6) shown here apply when using a rod electrode whose
characteristic corresponds to the load line (1) at a given arc length.
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 oper-
ating point provides information on the current welding voltage and the current welding cur-
rent.
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 arc length.
If the arc length changes (e.g. in accordance with the load line (2)) the resulting operating
point will be the point where the corresponding characteristic (4), (5) or (6) intersects with
the load line (2).
89
For characteristics (5) and (6), if a constant value is set for I1, the welding current (I) will
also become smaller or larger depending on the welding voltage.
Break-voltage
Welding voltage limitation
Unit V
Factory setting 20
The arc length depends on the welding voltage. To end the welding process, it is usually
necessary to significantly lift the rod electrode away from the workpiece. With this param-
eter, the welding voltage can be limited to a value that makes it possible to end the weld-
ing operation simply by slightly lifting the rod electrode.
NOTE! If, during welding, you often find that the welding operation is ended unin-
tentionally, increase the value of the break-voltage parameter.
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 the rod electrode to burn out.
Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode
begins to stick, the power source immediately switches the welding current off. After the
rod electrode has been detached from the workpiece, the welding process can be contin-
ued without any problems.
AC frequency
only for MMA AC welding (welding parameter polarity = AC)
Unit Hz
Factory setting 60
90
Ignition settings
EN
Ignition setting
HF ignition
parameters
Unit -
Setting range On / Off / External
Factory setting On
On High frequency ignition at start of welding is activated
Off No high frequency ignition at start of welding.

In this case, welding starts with touchdown ignition.
External Start with external arc starters, e.g. plasma welding
The HF ignition indicator in the status bar on the display lights up as long as HF ignition
has been set to On.
Reversed polarity ignition
(MagicWave power sources only)
To optimise the ignition sequence in TIG DC welding, the polarity is reversed briefly when
welding starts. Electrons emerge from the workpiece and strike the tungsten electrode.
This results in rapid heating-up of the tungsten electrode - which in itself is an essential
precondition for optimum ignition performance.
Unit -
Setting range Off / On
Factory setting Off
IMPORTANT! Reversed polarity ignition is not recommended when welding light gauge
sheet.
Ignition timeout
Ignition timeout until safety cut-out after abortive ignition attempt.
Unit s
Factory setting 5
IMPORTANT! Ignition timeout is a safety function and cannot be deactivated.

The description of the ignition timeout function can be found in the section "TIG welding".
91
Arc break time
Time until safety cut-out following an arc break
If, following an arc break, there is no current flow within the time specified here, the power
source cuts out automatically.
To start the welding process again, press any key on the control panel or the torch trigger.
Unit s
Factory setting 0.20
Arc break message
Reaction if there is no current flow within the arc break time
Unit -
Setting range Ignore / Error
Factory setting Ignore
Ignore The interruption is ignored.
Error An error message, which has to be acknowledged, is displayed

on the power source.
92
The gas menu
EN
Parameters in the
Gas pre-flow
Gas menu
Duration of gas pre-flow
Unit s
Factory setting 0.1
Gas post-flow
Duration of gas post-flow
Unit s
Factory setting 0.5
93
The components menu
Parameters in the
Cooling unit operating mode
Components
for controlling a cooling unit
menu
Unit -
Setting range eco / auto / on / off
Factory setting auto
auto 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
eco The coolant pump starts to run when welding starts and is elec-
tronically controlled subject to the coolant return temperature.
The fans start up at a coolant return temperature of 40 °C
(104 °F) and are electronically controlled subject to the coolant
return temperature.
After the end of welding, the coolant pump and fans continue to
run for another 2 minutes subject to the coolant return tempera-
ture.
When these 2 minutes have passed, the fans and coolant pump
are switched off.
94
The Job menu
EN
Save job When jobs are saved, the welding process and all the settings in the welding parameters
and the respective set-up menus are saved.
When creating jobs you MUST therefore also take into account the welding parameters in
the set-up menus.
Jobs can be saved in two ways.
1 Set welding process, mode, welding parameters and setup parameters
Save job via the Job menu Save job using the adjusting dial
2 Press the Menu key 2 Press the adjusting dial for more than
3 seconds
3 Turn the adjusting dial and select the

Job menu
5 Turn the adjusting dial and select
"Save Job as ..."
An overview of the most important parameters is displayed.
7 Select "More" (turn adjusting dial and press)

8 Turn the adjusting dial:
Overwrite existing job
(after pressing the adjusting dial, a confirmation prompt asking whether you really
want to overwrite the job is displayed)
or
Create new job
Press the adjusting dial; the first available job number is displayed.
9 Select Job number (turn adjusting dial and press)

The keyboard is displayed.
11 Turn and press the adjusting dial to enter a name for the job.
A message confirming that the job has been saved is displayed.
12 Select "Finish" (turn adjusting dial and press)
95
Loading a job The Load job function can be used to load the data for a saved job or an EasyJob into the
welding parameters.
The relevant data from the job can be changed, saved as a new job or EasyJob, or used
to start welding.
1 Press the Menu key
2 Turn the adjusting dial and select the Job menu

4 Turn the adjusting dial and select "Load Job ..."
The job list is displayed.
6 Select the job that you want to load (turn adjusting dial and press)
A message advising that the job is about to be loaded is displayed.
7 Select "Yes" (turn adjusting dial and press)
The job is loaded into the welding parameters.
Deleting a job 1 Press the Menu key
2 Turn the adjusting dial and select the Job menu

4 Turn the adjusting dial and select "Delete Job ..."
The job list is displayed.
6 Select the job that you want to delete (turn adjusting dial and press)
A warning that the job is about to be deleted is displayed.
7 Select "Yes" (turn adjusting dial and press)
The job is deleted.
96
Defaults
EN
Overview Display
- Backlighting
- Languages
- Time & Date
- Display additional parameters
System
- Reset to factory settings ...
- Reset website password ...
- Perform R/L alignment
Display - back-
Backlighting
lighting
to set the brightness of the display
Unit -
Factory setting 10
Adjust backlighting:
1 Defaults / Display / Backlighting

3 Select backlighting brightness (turn adjusting dial and press)
Display - languag-
Language
es
Unit -
Setting range Depends on the version of the software
Factory setting English
Setting the language:
1 Defaults / Display / Language

2 Select the desired language (turn adjusting dial and press)
The Globe symbol appears briefly and the language changes.
Display - Time &

Time & Date
Date
to set the time and date
Unit -
Setting range Year / Month / Day / Hour / Minute / Time zone
Factory setting -
97
Setting the date & time:
1 Defaults / Display / Time & Date

2 Select the desired parameter (turn adjusting dial and press)
3 Modify parameter by turning the adjusting dial
4 Confirm the modified parameter by pressing the adjusting dial
5 Press the menu key to exit the date and time settings
Display - Display In the case of welding parameters 1 - 3, this function enables additional parameters or set-
additional param- tings to be displayed.
eters
- Not assigned - Electrode settings
- Welding process Starting current time
- TIG welding torch mode Characteristic
- TIG settings Break voltage
Tacking Anti-stick
Pulse frequency AC frequency
Base current - Ignition settings
Duty cycle HF ignition
Starting current time Ignition timeout
Final current time Arc break time
Spot welding time Arc break message
AC frequency Reversed polarity ignition
AC current offset - Gas settings
Positive half-wave waveform Gas pre-flow
Negative half-wave waveform Gas post-flow
- Component settings
Cooling unit mode
Display additional parameters:
1 Default / Display / Display additional parameters

3 Select parameter location P1 - P3 (turn and press adjusting dial)
4 Choose which parameter to display in the selected parameter location (turn adjusting
dial and press)
5 Select Save (turn adjusting dial and press)
The parameter is displayed in the selected parameter location, where it can now also be
modified.
System - Reset to 1 Defaults / System / Reset to factory settings

factory settings Press the adjusting dial
2
A confirmation prompt asking whether you really want to restore the factory settings is dis-
played.
3 Select yes by turning the adjusting dial

4 Press the adjusting dial to reset to factory settings
The power source is reset to the factory settings.
98
Reset website 1 Defaults / System / Reset website password
EN
password Press the adjusting dial
2
A confirmation prompt asking whether you really want to reset the website password is dis-
played.
3 Select yes by turning the adjusting dial

4 Press the adjusting dial to reset the website password
The website password is reset to the factory setting:

User name = admin
Password = admin
Performing R/L NOTE! R/L alignment must be carried out separately for each welding process.
alignment
Welding circuit resistance R [mOhm]
Measuring the welding circuit resistance "r" provides information on the overall resistance
of the torch hosepack, welding torch, workpiece and grounding cable.
If an increased welding circuit resistance is detected, e.g. after changing the welding torch,
this may mean that the following components are faulty:
- Torch hosepack
- Welding torch
- Grounding (earthing) connection to the workpiece
- Grounding cable
Welding circuit inductivity L [μH]
The way that the hosepack is arranged has

a very significant effect on the weld proper-
ties.
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 arran-
ged. The result is that the current rise is re-
stricted.
The weld results can be optimised by chan-

ging the arrangement of the torch hose-
pack.
The hosepack must be laid out as shown in
the illustration.
99
Performing R/L alignment
1 Defaults / System / Perform R/L alignment

The current values are displayed
3 Select "More" (turn and press adjusting dial)
The second R/L alignment screen is displayed.
4 Follow the instructions displayed on the screen

The third R/L alignment screen is displayed.
6 Follow the instructions displayed on the screen

The current values are calculated.
After R/L alignment has been completed, a confirmation and the current values are
displayed.
100
System informations
EN
Device informa- The following data is displayed in device information:
tion
Image version
Software version
Hardware version
IP address(es)
System run time in h
Arc time in h
Open source licences

- Turn the adjusting dial to select open source licences
- Press the adjusting dial
The open source licences used are displayed.
- Select close by turning the adjusting dial

- Press the adjusting dial
101
102
SmartManager - The power source
website

SmartManager - The power source website
EN
General The power source has its own website: SmartManager.
As soon as the power source is connected to a computer using a network cable, or is on a
network, the power source's SmartManager can be retrieved using the power source's IP
address.
At least IE 10 or a similar modern browser is required to access SmartManager.
The entries displayed on SmartManager may vary depending on system configuration,

software upgrades and available options.
Examples of entries displayed:
- Current system data - Overview

- Job data (only if the FP Job function - Update
package is present) - Function packages
- Backup & Restore - Screenshot
Calling up the 1 Note down the IP address for the power source in system information
power source Enter the IP address in the browser search field
2
SmartManager
3 Enter user name and password
Factory setting:
User name = admin
Password = admin
The power source SmartManager is displayed.
Fronius
Click on the Fronius logo to open the Fronius homepage:
www.fronius.com
Changing pass-
By clicking this symbol
word / logging off
- the user password can be changed
- you can log out of SmartManager
Changing the password for the SmartManager:
NOTE!
User name = admin (predefined, cannot be edited!)
The password can only be reset on the power source.
1 Enter the old password

2 Enter the new password
3 Repeat the new password
4 Click on "Save"
105
Language
The languages available for SmartManager can be displayed by
clicking on this symbol.
The current language selection is displayed next to the symbol.
To change the language, click on the one you would like.
106
Current system data
EN
Current system The welding system's current data is displayed, e.g.
data
Welding process
ACTUAL or HOLD
Welding current Welding voltage

Current arc power
Current arc energy
Shielding gas flow rate

Arc time Total operating hours
Set values are displayed, as well as actual values and hold values for the welding current
and welding voltage. Miscellaneous other actual values are displayed as well as general
system data.
If a cooling unit is present, the coolant flow and temperature will also be displayed.
107
Job-Data
Job data The Job data entry is only displayed if the FP Job function package is present in the power
source.
In the "Job data" entry,

- existing welding system jobs can be viewed
- existing welding system jobs can be optimised
- jobs stored externally can be transferred to the welding system
- existing jobs in the welding system can be exported as a PDF * or CSV file
Job overview The job overview lists all jobs stored in the welding system.
Clicking on a job displays the data and parameters stored for this job.
Job data and parameters can only be viewed in the job overview. The column width for pa-
rameters and values can be easily dragged and adjusted with the mouse pointer.
Other jobs can easily be added to the list with the data listed by clicking on the "Add col-
umn" button.
This offers a simple way of comparing the values from various jobs.
Editing a job Existing welding system jobs can be edited.
1 Click on "Edit job"

2 Click on the job to be amended in the list of available jobs
The selected job is opened and the following job data is shown:
- Parameter
The parameter currently stored in the job
- Value
The values of the parameter currently stored in the job
- Change value to
To enter the new parameter value
- Setting range
Possible setting range for the new parameter values
3 Amend the values accordingly

4 Save / Delete adjustments, Save as / Delete job
As an aid when editing a job, other jobs can be easily added to the list with the data dis-
played by clicking on "Add column".
108
Creating a new job
Click on "Create new job"
EN
1
2 Enter job data

3 Click on "OK" to apply the new job
Importing a job This function enables previously exported jobs to be transferred into the welding system.
1 Click on "Search Job-file"

2 Select desired job file
Individual jobs can be selected and new job numbers assigned in the preview of the
job import list.
3 Click on "Import Job"
If the import is successful, a corresponding confirmation is displayed and the imported

jobs appear in the list.
Exporting a job This function enabled jobs to be exported from the power source and saved externally.
1 Select jobs to be exported:

- Click on the job and the arrow
or
- Double-click on the job
or
- Drag & drop
2 Click on "Export Job"
The jobs are exported as an XML file into the computer's Download folder.
Exporting job(s) Existing jobs in the welding system can be exported as a PDF or CSV file under Job over-
as… view and Edit job.
1 Click on "Export job(s) as..."
The PDF or CSV settings are displayed.
2 Select the job(s) to be exported:

current job / all jobs / job numbers
3 Click on "Save PDF" or "Save CSV"
A PDF or CSV file containing the selected jobs is created and saved according to the set-
tings of the browser in question.
109
Backup & Restore
General In the backup & restore entry
- all welding system data can be saved as a backup (e.g. current parameter settings,
jobs, defaults, etc.),
- any existing backups can be restored to the welding system
Backup & Restore Starting backup
1 Click on "Start backup" to create a backup of the welding system data
The data is saved in the selected location in the default format

Backup_SNxxxxxxxx_JJJJ_MM_TT_HHmmSS.fbc
.
SNxxxxxxxx = Serial number (8 digits)

YYYY = Year
MM = Month
DD = Day
HH = Hour
mm = Minute
SS = Second
The date and time correspond to the power source settings.
Searching for a restore file
1 Click on "Search restore file" to transfer an existing backup to the power source
2 Select the file and click on "Open"
The selected backup file is displayed on the power source SmartManager under "Re-
store".
3 Click on "Start recovery"
Once the data has been successfully restored, a confirmation to this effect is dis-
played.
110
Overview
EN
Overview In the overview entry, welding system components and options are displayed with all avail-
able information, e.g. firmware version, item number, serial number, production date, etc.
Expanding / re-
Clicking on the button "Expand all groups" displays further details for the indi-
ducing all groups
vidual system components.
Power source example:

- TT/MW Smart: Item number
BCU1-COM: Item number, version, serial number, production date
Bootloader: Version
Image: Version
Licences: ...
- SC2: Item number
Firmware: Version
- etc.
Clicking on the button "Reduce all groups" hides the details for the system com-
ponents.
Export compo-
Click the "XML" button to create an XML file of the system component
nent overview as
details. This XML file can either be opened or saved.
...
111
Update
Update The power source firmware can be updated in the "Update" entry.
The current version of the firmware on your power source is displayed.
The update file can be downloaded via the following link, for example:
http://www.fronius.com/transtig
http://www.fronius.com/magicwave
Updating the power source firmware
1 Organise and save the update file

2 Click on "Search update file"
3 Select and open the update file
The selected update file is displayed on the power source SmartManager under "Up-
date file".
Click on "Update"
A progress bar is displayed above the update process.

When this reaches 100%, you will be prompted to restart the power source.
SmartManager is not available during the restart.

After the restart, SmartManager may not be available any more.
If you select "No", the new software functions are activated when you next
switch the device on/off.
4 To restart the power source, click on "Yes"
The power source restarts; the display goes black for a short time.
The Fronius logo is shown on the power source display during the restart.
Once the update has been completed successfully, a confirmation and the current
firmware version are displayed.
5 You can now log on to SmartManager again
112
Function Packages
EN
Function packag- In the Function Packages entry, the function packages present on the power source are
es displayed.
New function packages can be uploaded.
Installing a func- 1 Organise and save a function package

tion package Click on "Search function package file"
2
3 Select the desired function package file (*.xml)
4 Click on "Open"
The selected function package file is displayed on the power source SmartManager
under "Install function package".
5 Click on "Install function package"
Once the function package has been successfully installed, a confirmation to this ef-
fect is displayed.
113
Screenshot
Screenshot In the Screenshot entry, a digital image of the power source display can be created at any
time, irrespective of the navigation or set values.
1 Click on "Create screenshot" to capture a screenshot of the display
A screenshot of the currently displayed settings is created.
Different functions are available for saving the screenshot depending on the browser used;
the display may vary.
114
Troubleshooting and maintenance

Troubleshooting
EN
General The digital power sources are equipped with an intelligent safety system. This means that
apart from the fuse for the coolant pump, it has been possible to dispense with fuses en-
tirely. 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.
Safety
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. All the work described below must only be carried out by trained and quali-
fied personnel. Do not carry out any of the work described below until you have
fully read and understood the following documents:
- this document
- all documents relating to the system components, especially the safety rules
WARNING! An electric shock can be fatal. Before starting the work described be-
low:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed
After opening the device, use a suitable measuring instrument to check that elec-
trically charged components (e.g. capacitors) have been discharged.
WARNING! An inadequate ground conductor connection can cause serious inju-

ry or damage. The housing screws provide a suitable ground conductor connec-
tion for earthing the housing and must NOT be replaced by any other screws that
do not provide a reliable ground conductor connection.
Power source - Power source does not function

troubleshooting 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 lead, ensure that the mains plug is plugged in
Cause: Mains socket or mains plug faulty

Remedy: Replace faulty parts
Cause: Mains fuse protection

Remedy: Change the mains fuse protection
117
No welding current
Mains switch is ON, overtemperature indicator is lit up
Cause: Overload
Remedy: Check duty cycle
Cause: Thermostatic safety cut-out has tripped

Remedy: Wait until the power source automatically comes back on after the end of the
cooling phase
Cause: The fan in the power source is faulty

Remedy: Contact After-Sales Service
No welding current
Mains switch is on, indicators are lit up
Cause: Grounding (earthing) connection is incorrect

Remedy: Check the grounding (earthing) connection and terminal for correct polarity
Cause: There is a break in the current cable in the welding torch

Remedy: Replace welding torch
Nothing happens when the torch trigger is pressed

Mains switch is on, indicators are lit up
Cause: The control plug is not plugged in

Remedy: Plug in the control plug
Cause: Welding torch or welding torch control line is faulty

Remedy: Replace welding torch
No protective gas shield

All other functions are OK
Cause: Gas cylinder is empty

Remedy: Change the gas cylinder
Cause: Gas pressure regulator is faulty

Remedy: Change the gas pressure regulator
Cause: Gas hose is not fitted or is damaged

Remedy: Fit or change the gas hose
Cause: Welding torch is faulty

Remedy: Change the welding torch
Cause: Gas solenoid valve is faulty

Remedy: Contact After-Sales Service
118
Poor weld properties
Cause: Incorrect welding parameters
EN
Remedy: Check the settings
Cause: Grounding (earthing) connection is incorrect

Remedy: Check the grounding (earthing) connection and terminal for correct polarity
The welding torch becomes very hot

Cause: The dimensions of the welding torch are inadequate
Remedy: Observe the duty cycle and loading limits
Cause: Only on water-cooled machines: water flow rate is insufficient

Remedy: Check the water level, water flow rate, cleanliness, etc. If the coolant pump is
blocked: use a screwdriver - placed on the bushing - to turn the coolant pump
shaft
Cause: Only on water-cooled machines: welding parameter 'Cool. unit ctrl' is set to
"OFF".
Remedy: In the set-up menu, set welding parameter 'Cool. unit ctrl' to "Aut" or "ON".
The welding torch becomes very hot

Cause: The dimensions of the welding torch are inadequate
Remedy: Observe the duty cycle and loading limits
Cause: Only on water-cooled machines: water flow is insufficient

Remedy: Check the water level, water flow rate, cleanliness, etc. If the coolant pump is
blocked: use a screwdriver - placed on the bushing - to turn the coolant pump
shaft
Cause: Only on water-cooled machines: C-C parameter is set to "OFF".

Remedy: In the set-up menu, set the C-C parameter to "Aut" or "ON".
119
Care, maintenance and disposal
General Under normal operating conditions, the power source requires only a minimum of care and
maintenance. However, it is vital to observe some important points to ensure it remains in
a usable condition for many years.
Safety
WARNING! Work that is carried out incorrectly can cause serious injury or dam-
age. All the work described below must only be carried out by trained and quali-
fied personnel. Do not carry out any of the work described below until you have
fully read and understood the following documents:
- this document
- all documents relating to the system components, especially the safety rules
WARNING! An electric shock can be fatal. Before starting the work described be-
low:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed
After opening the device, use a suitable measuring instrument to check that elec-
trically charged components (e.g. capacitors) have been discharged.
WARNING! An inadequate ground conductor connection can cause serious inju-

ry or damage. The housing screws provide a suitable ground conductor connec-
tion for earthing the housing and must NOT be replaced by any other screws that
do not provide a reliable ground conductor connection.
At every start-up - Check mains plug, mains cable, welding torch, interconnecting hosepack and ground-
ing (earthing) connection for damage
- Check that there is a gap of 0.5 m (1 ft. 8 in.) all around the device to ensure that cool-
ing air can flow and escape unhindered
NOTE! Air inlets and outlets must never be covered, not even partially.
Every 2 months - If present: clean air filter
Every 6 months - Dismantle device side panels and clean inside of device with dry reduced compressed
air
NOTE! Risk of damage to electronic components. Do not bring air nozzle too
close to electronic components.
- If a lot of dust has accumulated, clean the cooling air ducts.
120
Disposal Dispose of in accordance with the applicable national and local regulations.
EN
121
122
Appendix

Technical data
EN
Special voltages NOTE! An inadequately dimensioned electrical installation can cause serious
damage. The mains cable and its fuse must be dimensioned accordingly.
The technical data shown on the rating plate applies.
MagicWave 190
MW 190 MW 190 MV
Mains voltage U1 1 x 230 V 1 x 120 / 230 V
Mains voltage tolerance ± 15% ± 15%
Mains frequency 50/60 Hz 50/60 Hz
Mains fuse protection (slow-blow) 16 A 16 A (U1 = 230 V)
20 A (U1 = 120 V)
Mains connection1) Zmax on PCC3) Zmax on PCC3)
= 315 mOhm = 315 mOhm
Cos phi 0.99 0.99
Welding current range
TIG 3 - 190 A 3 - 190 A
Electrode 10 - 170 A 10 - 170 A
Welding current at
10 min/40 °C (104 °F) 35% DC2) 190 A 4) 190 A 4) (U1 = 230 V)
170 A 5) 150 A 4) (U1 = 120 V)
170 A 5) (U1 = 230 V)
100 A 5) (U1 = 120 V)
10 min/40 °C (104 °F) 60% DC2) 160 A 4) 160 A 4) (U1 = 230 V)
140 A 5) 120 A 4) (U1 = 120 V)
140 A 5) (U1 = 230 V)
80 A 5) (U1 = 120 V)
10 min/40 °C (104 °F) 100% DC2) 140 A 4) 140 A 4) (U1 = 230 V)
120 A 5) 100 A 4) (U1 = 120 V)
120 A 5) (U1 = 230 V)
70 A 5) (U1 = 120 V)
Open circuit voltage 100 V 100 V
Working voltage
TIG 10.1 - 17.6 V 10.1 - 17.6 V
Electrode 20.4 - 26.8 V 20.4 - 26.8 V
Striking voltage (Up) 9.6 kV 9.6 kV
The arc striking voltage is suitable for manual operation.
Degree of protection IP 23 IP 23
Type of cooling AF AF
Overvoltage category III III
Pollution degree according to IEC 60664 3 3
EMC Emissions class A 6) A 6)
Insulation class B B
Dimensions L x W x H (with handle) 558 / 210 / 369 mm 558 / 210 / 369 mm
22.0 / 8.3 / 14.5 in. 22.0 / 8.3 / 14.5 in.
Weight 17.0 kg 16.5 kg
37.5 lb. 36.4 lb.
125
MW 190 MW 190 MV
Marks of conformity S, CE S, CE
Max. shielding gas pressure 6 bar 6 bar
87.02 psi 87.02 psi
Noise emission (LWA) 68 dB(A) 68 dB(A)
126
MagicWave 230i
EN
MW 230i MW 230i MV
Mains voltage tolerance ± 15 % ± 15 %
Mains frequency 50 / 60 Hz 50 / 60 Hz
20 A (U1 = 120 V)
Mains connection1) Zmax on PCC3) Zmax on PCC3)
= 273 mOhm = 273 mOhm
Cos phi 0.99 0.99
TIG 3 - 230 A 3 - 230 A
Electrode 10 - 190 A 10 - 190 A
Welding current at
10 min/40 °C (104 °F) 35% DC2) 230 A 4) 230 A 4) (U1 = 230 V)
190 A 5) 170 A 4) (U1 = 120 V)
190 A 5) (U1 = 230 V)
120 A 5) (U1 = 120 V)
10 min/40 °C (104 °F) 60% DC2) 195 A 4) 195 A 4) (U1 = 230 V)
150 A 5) 140 A 4) (U1 = 120 V)
150 A 5) (U1 = 230 V)
105 A 5) (U1 = 120 V)
10 min/40 °C (104 °F) 100% DC2) 165 A 4) 165 A 4) (U1 = 230 V)
120 A 5) 120 A 4) (U1 = 120 V)
120 A 5) (U1 = 230 V)
85 A 5) (U1 = 120 V)
Working voltage
TIG 10.1 - 19.2 V 10.1 - 19.2 V
Electrode 20.4 - 27.6 V 20.4 - 27.6 V
overvoltage category III III
pollution degree according IEC 60664 3 3
EMC emission class A 6) A 6)
22.0 / 8.3 / 14.5 in. 22,0 / 8,3 / 14,5 in.
37.5 lb. 36.4 lb.
maximum shielding gas pressure 6 bar 6 bar
87.02 psi 87.02 psi
sound power level (LWA) 68 dB(A) 68 dB(A)
127
TransTig 230i
TT 230i TT 230i MV
Mains voltage tolerance ± 15 % ± 15 %
Mains frequency 50 / 60 Hz 50 / 60 Hz
20 A (U1 = 123 V)
Mains connection1) Zmax am PCC3) Zmax am PCC3)
= 273 mOhm = 273 mOhm
Cos phi 0,99 0,99
TIG 3 - 230 A 3 - 230 A
Electrode 10 - 190 A 10 - 190 A
Welding current at
10 min/40 °C (104 °F) 35% DC2) 190 A 5) 190 A 5) (U1 = 230 V)
120 A 5) (U1 = 120 V)
10 min/40 °C (104 °F) 45% DC2) 230 A 4) 230 A 4) (U1 = 230 V)
170 A 4) (U1 = 120 V)
10 min/40 °C (104 °F) 60% DC2) 205 A 4) 205 A 4) (U1 = 230 V)
155 A 5) 155 A 4) (U1 = 120 V)
155 A 5) (U1 = 230 V)
105 A 5) (U1 = 120 V)
10 min/40 °C (104 °F) 100% DC2) 170 A 4) 170 A 4) (U1 = 230 V)
125 A 5) 130 A 4) (U1 = 120 V)
125 A 5) (U1 = 230 V)
85 A 5) (U1 = 120 V)
Working voltage
TIG 10.1 - 19.2 V 10.1 - 19.2 V
Electrode 20.4 - 27.6 V 20.4 - 27.6 V
overvoltage category III III
pollution degree according IEC 60664 3 3
EMC emission class A 6) A 6)
22.0 / 8.3 / 14.5 in. 22.0 / 8.3 / 14.5 in.
36.2 lb. 35.1 lb.
maximum shielding gas pressure 6 bar 6 bar
87.02 psi 87.02 psi
sound power level (LWA) 68 dB(A) 68 dB(A)
128
1)
Explanation of connected to public mains supply with 230 / 400 V and 50 Hz
EN
footnotes 2)
D.C. = Duty cycle
3)
PCC = interface to the public grid
4) TIG welding
5) MMA welding
6)
An emission class A device is not designed for use in residential areas supplied
with power from a public low-voltage grid.
The electromagnetic compatibility can be influenced by conducted or radiated ra-
dio frequencies.
129
130
EN
131
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

Magicwave 190

Uploaded by

Magicwave 190

Uploaded by

/ Perfect Charging / Perfect Welding / Solar Energy

WARNING! Indicates a potentially dangerous situation. Death or serious injury

CAUTION! Indicates a situation where damage or injury could occur. If it is not

Control elements and connections 27

Installation and commissioning 37

Minimum equipment needed for welding task............................................................................................ 39

TIG modes ................................................................................................................................................. 51

The Setup menu ........................................................................................................................................ 79

SmartManager - The power source website 103

SmartManager - The power source website .............................................................................................. 105

Troubleshooting and maintenance 115

Troubleshooting ......................................................................................................................................... 117

Technical data............................................................................................................................................ 125

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

- Risk of electrocution from mains current and welding current

- Greater noise pollution

- Harmful welding fumes and gases

Danger from toxic

Keep your face away from welding fumes and gases.

Danger from fly-

Risks from mains

Never touch the workpiece during or after welding - risk of burns.

Use only suitable load-carrying equipment supplied by the manufacturer when

Special regulations apply in rooms at risk of fire or explosion

Downloaded from www.Manualslib.com manuals search engine

Their modular design and potential for sys-

The power sources are generator-compa-

This results in:

Industry Canada RSS

FCC ID: QKWSPBBCU1

* MV power sources: 1 ~ 100 - 230 V

Safety symbols on the rating plate:

Welding is dangerous. The following basic requirements must be met:

Overview (1) TIG welding torch

Option for a permanent network connection

Downloaded from www.Manualslib.com manuals search engine

(7) (8) (9) (10)

(6) (5) (4) (3) (2) (1)

NFC key = NFC card or NFC key ring

1 Select the desired parameter in the Setup menu

A confirmation message is displayed.

3 Press the adjusting dial to confirm

The selected parameter is now assigned to the Favourites button.

Retrieving favour- 1 Press the Favourites button briefly

The assigned parameter is displayed:

The new value takes effect immediately.

The assigned parameter is deleted and a message is displayed.

2 Press the adjusting dial to confirm

1 Select the Job menu from the Setup menu

3 Press the Menu key

4 Press the Favourites button

Symbols on TransTig power sources:

Symbols on MagicWave power sources:

(2) TMC connection (TIG Multi Connector)

Symbols on TransTig power sources:

Symbols on MagicWave power sources:

(5) Mains switch

Mains switch for MV devices:

(6) Mains cable with strain relief device

(7) Shielding gas connection

Downloaded from www.Manualslib.com manuals search engine

TIG AC welding - MagicWave power source

TIG DC welding - Power source

MMA welding - Power source

Proper use also includes:

Setup regulations The device is tested to "Degree of protection IP23", meaning:

NOTE! Inadequately dimensioned electrical installations can cause serious dam-

A smaller generator may be used when not welding at full power.

Connecting the Connect the mains cable:

General This section describes how to commission the power source:

The standard configuration consists of the following system components:

Follow the gas cylinder manufacturer's safety rules.

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

When using a TIG welding torch with no integral gas connection:

NOTE! Always check the follow-

During welding, check at regular intervals