FRO­NIUS TransTig 800 User manual

Operating
Instructions
TransTig 800
TransTig 2200
TransTig 2500 / 3000
TransTig 4000 / 5000
MagicWave 1700 / 2200
MagicWave 2500 / 3000
MagicWave 4000 / 5000
42,0426,0027,EN 023-21092022
EN Operating instructions

Contents
Safety rules 7
Explanation of safety notices 7
General 7
Proper use 8
Environmental conditions 8
Obligations of the operator 8
Obligations of personnel 8
Mains connection 9
Protecting yourself and others 9
Noise emission values 10
Danger from toxic gases and vapours 10
Danger from flying sparks 10
Risks from mains current and welding current 11
Meandering welding currents 12
EMC Device Classifications 12
EMC measures 12
EMF measures 13
Specific hazards 13
Requirement for the shielding gas 14
Danger from shielding gas cylinders 14
Danger from escaping shielding gas 15
Safety measures at the installation location and during transport 15
Safety measures in normal operation 16
Commissioning, maintenance and repair 16
Safety inspection 17
Disposal 17
Safety symbols 17
Data protection 17
Copyright 18
General information 19
General 21
Device concept 21
Functional principle 22
Application areas 22
Warning notices on the device 23
System components 24
General 24
Overview 24
Control elements and connections 25
Description of the control panels 27
General 27
Safety 27
Overview 28
MagicWave control panel 29
MagicWave control panel 29
TransTig control panel 34
TransTig control panel 34
Key combinations - special functions 38
General 38
Displaying the software version, operating time and coolant flow 38
Connections, switches and mechanical components 39
MagicWave1700 / 2200 39
MagicWave2500 / 3000 40
MagicWave4000 / 5000 41
TransTig 2200 42
TransTig2500 / 3000 43
TransTig4000 / 5000 44
3
EN

Installation and commissioning 45
Minimum equipment needed for welding task 47
General 47
TIG AC welding 47
TIG DC welding 47
MMA welding 47
Before installation and commissioning 48
Safety 48
Utilisation for intended purpose 48
Setup regulations 48
Mains connection 48
Generator-powered operation (MW 1700 / 2200, TT 2200) 49
Connecting up the mains cable on US power sources 50
General 50
Stipulated mains cables and strain-relief devices 50
Safety 50
Connecting the mains cable 50
Replacing the strain-relief device 52
Start-up 53
Safety 53
Remarks on the cooling unit 53
General 53
Connecting the gas cylinder 53
Establishing a ground (earth) connection to the workpiece 54
Connecting the welding torch 54
Welding 55
TIG modes 57
Safety 57
Symbols and their explanations 57
2-step mode 58
4-step mode 58
Special 4-step mode: variant 4 59
Cap shaping and cap overloading 60
Cap-shaping 60
TIG welding 61
Safety 61
Welding parameters 61
Preparation 62
TIG welding 62
Igniting the arc 64
General 64
Igniting the arc using high frequency(HF ignition) 64
Touchdown ignition 65
End of welding 66
Special functions and options 67
Arc break watchdog function 67
Ignition time-out function 67
Tacking function 67
MMA welding 69
Safety 69
Preparation 69
MMA welding 69
Hotstart function 71
Anti-stick function 71
Setup settings 73
The Setup menu 75
General 75
Overview 75
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Shielding gas setup menu 76
General 76
Opening the Protective gas shield set-up menu 76
Changing welding parameters 76
Exiting the set-up menu 76
Welding parameters in the Protective gas shield set-up menu 76
TIG setup menu 78
Opening the TIG set-up menu 78
Changing welding parameters 78
Exiting the set-up menu 78
Welding parameters in the TIG setup menu 78
Rod electrode setup menu 82
Open the rod electrode set-up menu 82
Changing welding parameters 82
Exiting the set-up menu 82
Welding parameters in the rod electrode set-up menu 82
Rod electrode setup menu: level 2 84
Opening the rod electrode set-up menu level 2 84
Changing welding parameters 84
Exiting the rod electrode set-up menu - level 2 84
Welding parameters in the rod electrode setup menu - level 2 84
Troubleshooting and maintenance 87
Troubleshooting 89
General 89
Safety 89
Displayed service codes 89
Power source - troubleshooting 92
Care, maintenance and disposal 94
General 94
Safety 94
At every start-up 94
Every 2 months 94
Every 6 months 95
Disposal 95
Appendix 97
Average consumption values during welding 99
Average wire electrode consumption during MIG/MAG welding 99
Average shielding gas consumption during MIG/MAG welding 99
Average shielding gas consumption during TIG welding 99
Technical data 100
Special voltages 100
Overview with critical raw materials, year of production of the device 100
MagicWave 1700 100
MagicWave 2200 101
MagicWave 2500 102
MagicWave 3000 103
MagicWave 2500 MV 104
MagicWave 3000 MV 105
MagicWave 4000 106
MagicWave 5000 107
MagicWave 4000 MV 108
MagicWave 5000 MV 109
TransTig 800 110
TransTig 2200 111
TransTig 2500 112
TransTig 3000 113
TransTig 2500 MV 114
TransTig 3000 MV 116
TransTig 4000 117
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EN

TransTig 5000 118
TransTig 4000 MV 119
TransTig 5000 MV 120
Explanation of footnotes 121
Terms and abbreviations used 122
General 122
Terms and abbreviations A - F 122
Terms and abbreviations G - H 122
Terms and abbreviations I - U 123
6

Safety rules
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can
cause:
-injury or death to the operator or a third party,
-damage to the device and other material assets belonging to the operating
company,
-inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the
device must:
-be suitably qualified,
-have sufficient knowledge of welding and
-read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and en-
vironmental protection.
All safety and danger notices on the device
-must be in a legible state,
-must not be damaged,
-must not be removed,
-must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
7
EN

Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating
plate.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be held liable for any damage arising from such usage.
Proper use includes:
-carefully reading and following all the instructions given in the operating in-
structions
-studying and obeying all safety and danger notices carefully
-performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
-Thawing out pipes
-Charging batteries
-Starting engines
The device is designed for use in industry and the workshop. The manufacturer
accepts no responsibility for any damage caused through use in a domestic set-
ting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer shall not be held
liable for any damage arising from such usage.
Ambient temperature range:
-during operation: -10 °C to + 40 °C (14 °F to 104 °F)
-during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
-up to 50% at 40 °C (104 °F)
-up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of
the operator
The operator must only allow persons to work with the device who:
-are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
-have read and understood these operating instructions, especially the sec-
tion "safety rules", and have confirmed as much with their signatures
-are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
-to observe the basic instructions regarding safety at work and accident pre-
vention
-to read these operating instructions, especially the "Safety rules" section and
sign to confirm that they have understood them and will follow them.
8

Before leaving the workplace, ensure that people or property cannot come to any
harm in your absence.
Mains connec-
tion
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number device types in terms of:
-Connection restrictions
-Criteria with regard to the maximum permissible mains impedance *)
-Criteria with regard to the minimum short-circuit power requirement *)
*) at the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your-
self and others
Anyone working with the device exposes themselves to numerous risks, e.g.
-flying sparks and hot pieces of metal
-Arc radiation, which can damage eyes and skin
-Hazardous electromagnetic fields, which can endanger the lives of those us-
ing cardiac pacemakers
-Risk of electrocution from mains current and welding current
-Greater noise pollution
-Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
-Flame-resistant
-Insulating and dry
-Covers the whole body, is undamaged and in good condition
-Safety helmet
-Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
-Protect eyes and face from UV rays, heat and sparks using a protective visor
and regulation filter
-Wear regulation protective goggles with side protection behind the protect-
ive visor
-Wear stout footwear that provides insulation even in wet conditions
-Protect the hands with suitable gloves (electrically insulated and providing
protection against heat)
-Wear ear protection to reduce the harmful effects of noise and to prevent in-
jury
Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vi-
cinity:
-Make them aware of all the dangers (risk of dazzling by the arc, injury from
flying sparks, harmful welding fumes, noise, possible risks from mains cur-
rent and welding current, etc.)
-Provide suitable protective equipment
-Alternatively, erect suitable safety screens/curtains.
9
EN

Noise emission
values
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum per-
missible operating point under maximum rated load conditions according to EN
60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the work-
piece, the workplace environment, etc.
Danger from tox-
ic gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph
118 of the International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
-must not be breathed in
-must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of
at least 20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
The following components are responsible, amongst other things, for the degree
of toxicity of welding fumes:
-Metals used for the workpiece
-Electrodes
-Coatings
-Cleaners, degreasers, etc.
-Welding process used
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for
identifying working conditions can be found on the European Welding Associ-
ation website under Health & Safety (https://european-welding.org).
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-
ation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
Danger from fly-
ing sparks
Flying sparks may cause fires or explosions.
10