FRONIUS MagicWave 2600 Bedienungsanleitung

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

/ Perfect Charging / Perfect Welding / Solar Energy

MagicWave 2600

MagicWave 2600 Cel

MagicWave 3000

TransTig 2600

TransTig 2600 Cel

TransTig 3000

EN-US

Operating instructions

TIG power source

42,0426,0022,EA 003-22032021

Inhaltsverzeichnis

Safety Instructions 6

Explanation of Safety Instructions 6

General 6

Intended Use 6

Environmental Conditions 7

Obligations of the Operating Company 7

Obligations of Personnel 7

Grid Connection 7

Personal Protection and Protection of Others 8

Data regarding Noise Emission Values 8

Danger from toxic gases and vapors 9

Danger from Flying Sparks 9

Risks from grid current and welding current 10

Stray welding currents 11

EMC Device Classifications 11

EMC Measures 11

EMF measures 12

Particular Hazard Areas 12

Undesired welding results 13

Danger from Shielding Gas Cylinders 13

Safety Measures at the Setup Location and During Transport 14

Safety Measures in Normal Operation 14

Maintenance and repair 15

Safety Inspection 15

Disposal 15

Safety Symbols 16

Data backup 16

General 17

Principle 17

Device concept 17

Field of application 17

Warning notice on the device 18

Minimum equipment for welding operations 19

General 19

TIG AC welding 19

TIG DC welding 19

Manual metal arc welding 19

System components 20

General 20

Overview 20

Control Panel 21

General 21

Overview 21

MagicWave control panel 22

Control panel for TransTig 24

Connections, switches and system extensions 27

MagicWave / TransTig connections with Fronius welding torch central connector F 27

MagicWave / TransTig connections with welding torch central connector GWZ 28

MagicWave / TransTig connections with welding torch central connector GWZ 29

Before installation 30

Safety 30

Intended use 30

Setup regulations 30

Mains operation 30

Generator-powered operation 31

Commissioning 32

General 32

Notes on the cooling unit 32

Connecting the shielding gas cylinder 32

EN-US

Establish a connection with the workpiece 33

Connect the welding torch 33

TIG Operating Modes 34

General 34

Symbols and explanations 34

2-step 35

Special 2-step 35

4-step 36

4-step with intermediate lowering 36

Special 4-step: Version 1 37

Special 4-step: Version 2-4 38

Special 4-step: Version 5 39

TIG welding 40

Safety 40

Preparation 40

Select operating mode 41

Select process 41

Cap-shaping (MagicWave) 42

Welding parameter setting 42

Adjust the shielding gas quantity 42

Ignition of the arc - general 42

TIG synchronous welding AC (MagicWave) 42

HF ignition 43

Contact ignition 44

Ignition monitoring 45

Manual Metal Arc Welding 46

Safety 46

Preparation 46

Select operating mode 47

Select process (MagicWave) 47

Welding parameter setting 47

Remote control 49

Safety 49

General 49

AC remote control TR 53mc 49

TIG pulse remote control TR 50mc 50

TIG foot remote control TR 52mc 51

TIG spot welding remote control TR 51mc 52

Remote control TP MC / TP MC-CEL 53

Working with program levels 56

Overview 56

"Program level preferences” 57

Access 57

Select and change setup parameters 57

Available TIG parameters 57

Program levels P1 - P3 61

Access 61

Select and change setup parameters 61

Program level service menu P1 61

Program level code lock P2 61

Program level AC parameters P3 (MagicWave) 62

Fault diagnosis and correction 63

Safety 63

Displayed service codes 63

Power Source 64

Service, maintenance and disposal 67

General 67

At every start-up 67

Every 2 months 67

Every 6 months 67

Disposal 67

Spare parts 67

Technical data 68

Special voltage 68

MagicWave 2600/2600CEL 68

MagicWave 3000 69

TransTig 2600/2600CEL 69

TransTig 3000 70

EN-US

Safety Instructions

Explanation of

Safety Instruc-

tions

DANGER!

Indicates an immediate danger.

▶Death or serious injury may result if appropriate precautions are not taken.

WARNING!

Indicates a possibly dangerous situation.

▶Death or serious injury may result if appropriate precautions are not taken.

CAUTION!

Indicates a situation where damage or injury could occur.

▶Minor injury or damage to property may result if appropriate precautions are not

taken.

NOTE!

Indicates the possibility of flawed results and damage to the equipment.

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

recognized 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 equipment

All persons involved in the commissioning, operation, maintenance, and servicing of the

device must

- Be suitably qualified

- Have knowledge of welding

- Have completely read and followed these Operating Instructions

The Operating Instructions must always be at hand wherever the device is being used. In

addition to the Operating Instructions, all applicable local rules and regulations regarding

accident prevention and environmental protection must also be followed.

All safety and danger notices on the device must

- Be kept in a legible state

- Not be damaged/marked

- Not be removed

- 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 switching on the device, remove any faults that could compromise safety.

Your personal safety is at stake!

Intended Use The device is to be used exclusively for its intended purpose.

The device is intended exclusively for the welding process specified on the rating plate.

Utilization for any other purpose, or in any other manner, shall be deemed to be "not in

accordance with the intended purpose." The manufacturer is not responsible for any

damage resulting from improper use.

Proper use also means

- Completely reading and obeying all instructions in the Operating Instructions

- Completely reading and obeying all safety instructions and danger notices

- Carrying out all the specified inspection and servicing work

Never use the device for the following applications:

- Thawing pipes

- Charging batteries

- Starting motors

The device is designed for operation in industry and business. The manufacture shall not

be liable for any damage resulting from use in a living area.

The manufacture shall also not be liable for faulty or incorrect work 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 accepts no liability for any

damage resulting from improper use.

Temperature range of the ambient air:

- 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)

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

Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

Obligations of the

Operating Com-

pany

The operating company must only allow persons to work with the device if they

- Are familiar with the basic occupational safety and accident prevention regulations

and are trained in handling the device

- Have read and understood these Operating Instructions, especially the section

"Safety Rules," and have confirmed this with their signature

- Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

Obligations of

Personnel

All persons who are assigned to work with the device must do the following before begin-

ning the work:

- Follow the basic regulations for occupational safety and accident prevention

- Read these Operating Instructions, especially the section "Safety Rules," and con-

firm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can

occur in one's absence.

Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-

rent consumption.

EN-US

This may affect a number of device types in terms of:

- connection restrictions

-criteria regarding maximum permissible grid impedance *)

-criteria regarding the minimum required short-circuit power *)

*) both at the interface with the public grid

See technical data

In this case, the operator or the person using the device should check whether or not the

device is allowed to be connected, where appropriate through discussion with the power

supply company.

IMPORTANT! Ensure secure grounding of the grid connection!

Personal Protec-

tion and Protec-

tion of Others

You are exposed to numerous hazards while handling the device, for example:

- Flying sparks and pieces of hot metal

- Arc radiation that poses a risk of injury to the eyes and skin

- Hazardous electromagnetic fields that pose a risk of death for individuals with pace-

makers

- Electrical risks from grid current and welding current

- Increased noise exposure

- Harmful welding fumes and gases

Wear suitable protective clothing when dealing with the device. The protective clothing

must have the following properties:

- Flame resistant

- Insulating and dry

- Covering the entire body and in good condition with no damage

- Safety helmet

- Cuffless pants

Protective clothing involves the following:

- Protecting the face and eyes from UV radiation, heat and flying sparks with a face

guard featuring a regulation-compliant filter

- Wearing regulation-compliant protective goggles with side protection behind the face

guard

- Wearing rigid, wet-insulating footwear

- Protecting hands with appropriate gloves (featuring electrical insulation and thermal

protection)

- Wearing ear protection to reduce noise exposure and protect against injury

Keep persons, especially children, away during the operation of the devices and during

the welding process. If persons are in the vicinity, however:

- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying

sparks, welding fumes hazardous to health, noise exposure, possible hazard due to

grid current or welding current, etc.)

- Provide suitable protective equipment or

- Construct suitable protective walls and curtains.

Data regarding

Noise Emission

Values

The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in

the cooling phase following operation in relation to the maximum permitted operating

point at standard loading in accordance with EN 60974-1.

A workplace-specific emission value for welding (and cutting) cannot be specified

because this value depends on the welding process and the environmental conditions. It

is influenced by a wide range of parameters, such as the welding process itself (MIG/

MAG, TIG welding), the selected current type (direct current, alternating current), the

power range, the type of weld metal, the resonance properties of the workpiece, the

workplace environment, and many other factors.

Danger from

toxic gases and

vapors

The fumes produced during welding contain toxic gases and vapors.

Welding fumes contain substances that cause cancer, as stated in monograph 118 from

the International Agency for Research on Cancer.

Use at-source extraction source and a room extraction system.

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

Keep your head out of the welding fumes and gases.

Take the following precautionary measures for fumes and harmful gases:

- Do not breathe them in.

- Extract them from the work area using appropriate equipment.

Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow

rate of at least 20 m³ per hour.

Use a welding helmet with air supply if there is insufficient ventilation.

If there is uncertainty as to whether the extraction capacity is sufficient, compare the

measured toxic emission values against the permissible limit values.

The following components are factors that determine how toxic the welding fumes are:

- The metals used for the workpiece

- Electrodes

- Coatings

- Cleaning agents, degreasers, and the like

- The welding process used

Consult the corresponding material safety data sheets and manufacturer's instructions

for the components listed above.

Recommendations for exposure scenarios, risk management measures and identifying

working conditions can be found on the European Welding Association website under

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

Keep flammable vapors (such as solvent vapors) out of the arc radiation range.

When no welding is taking place, close the valve of the shielding gas cylinder or the main

gas supply.

Danger from Fly-

ing Sparks

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro-

tected with a certified cover.

Keep suitable, tested fire extinguishers on hand.

Sparks and pieces of hot metal may also get into surrounding areas through small cracks

and openings. Take appropriate measures to ensure that there is no risk of injury or fire.

Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks,

drums, or pipes if these have not been prepared in accordance with corresponding

national and international standards.

EN-US

Do not undertake welding on containers in which gases, fuels, mineral oils, and the like

are/were stored. Residues pose a risk of explosion.

Risks from grid

current and weld-

ing current

An electric shock can be fatal.

Do not touch voltage-carrying parts inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed

rollers, as well as all pieces of metal that are in contact with the welding wire, are live.

Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating

wirefeeder holder.

Ensure suitable personal protection with dry temporary backing or cover with sufficient

insulation against the ground potential. The temporary backing or cover must completely

cover the entire area between the body and the ground potential.

All cables and leads must be secured, undamaged, insulated, and adequately dimen-

sioned. Replace loose connections and scorched, damaged, or inadequately dimen-

sioned cables and leads immediately.

Before every use, check power connections for secure fit by hand.

In the case of power cables with bayonet connectors, turn the power cable by at least

180° around the longitudinal axis and pretension.

Do not wrap cables or leads around your body or parts of the body.

Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)

- Never immerse it in liquids to cool it

- Never touch it when the power source is switched on.

The open circuit voltage of a welding system may double, for example, between the elec-

trodes of two welding systems. Touching the potentials of both electrodes at the same

time may be life-threatening in some cases.

Have the grid and device supply lead regularly inspected by an electrician to ensure that

the ground conductor is functioning properly.

Protection class I devices require a grid with a ground conductor and a connector system

with ground conductor contact for proper operation.

Operation of the device on a grid without a ground conductor and on a socket without a

ground conductor contact is only permitted if all national regulations for protective separ-

ation are observed.

Otherwise, this is considered gross negligence. The manufacturer accepts no liability for

any damage resulting from improper use.

Use suitable equipment to ensure that the workpiece is sufficiently grounded if neces-

sary.

Switch off unused devices.

When working at elevated heights, wear a safety harness to prevent falls.

Before working on the device, switch off the device and remove the grid plug.

Secure the device to prevent the grid plug from being connected and switched on again

by applying a clearly legible and understandable warning sign.

After opening the device:

- Discharge all electrically charged components

- Ensure that all components are disconnected from the power supply.

If work is needed on voltage-carrying parts, bring in a second person who will switch off

the main switch at the correct time.

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