Magicwave 190

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Dear reader,
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,
safety symbols
death or serious 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
required.
4
Contents
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
EN
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
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
EN
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

Overview............................................................................................................................................... 97
Display - backlighting............................................................................................................................ 97
Display - languages .............................................................................................................................. 97
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
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 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 automated welding, and
- read and carefully follow these operating instructions as well as the
operating instructions for all system components.
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 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 manufacturer
accepts no responsibility for any damage caused through use in a domestic
setting.

The manufacturer likewise accepts no liability for inadequate or incorrect
results.
Environmental
EN
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
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
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 personnel
Before using the device, all persons instructed to do so undertake:
- 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

- 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 protective 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 devices 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.
- 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.
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 taking place.
10

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values
EN
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.
y-
Flying sparks may cause fires or explosions.
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 injury 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 accordance 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.
ins
An electric shock is potentially life threatening and can be fatal.
eld-
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.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose
connections and scorched, damaged or inadequately 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
11

- 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 electrodes 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.
weld-
If the following instructions are ignored, meandering welding currents can de-
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 welded.
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 following: 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.
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:
12

- Satisfy the emissions criteria for residential and industrial areas.
EN
This is also true for residential areas in which the energy is
supplied 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
rectify 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
connection, additional measures are necessary (e.g. use a suitable
line filter).
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
EMF measures
installation Electromagnetic fields may pose as yet unknown risks to health
- effects on the health of others in the vicinity, e.g. wearers of
and hearing aids
-
wearers of pacemakers must seek advice from their doctor before

approaching 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
13

Specific hazards
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
components.
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
allowed 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
disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling
coolant. 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.
14

EN
- 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
devices).
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas
cylinders are part of the welding equipment, they 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 instructions 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.
15

Danger from Risk of suffocation from the uncontrolled escape of shielding gas
escaping shielding Shielding gas is colourless and odourless and, in the event of a leak, can
gas displace 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
cylinder 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.
The manufacturer's instructions must be observed as well as applicable national and international regulations
for shielding gas cylinders and accessories.
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
protection 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
guidelines 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
damage 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 operaty 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
16

EN
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
functioning of safety devices.
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
compatibility, 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
ignite 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

national and international regulations. The coolant safety data sheet may be
obtained 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 permissible operating point
under maximum rated load conditions according to EN 60974-1.
It is not possible to provide a workplace-related emission value during
welding (or cutting) as this is influenced by both the process and the
environment. All manner of different welding parameters come into play,
including the welding process (MIG/MAG, TIG welding), the type of power
selected (DC or AC), the power range, the type of weld metal, the
resonance characteristics of the workpiece, the workplace environment, etc.
17

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
immediately.
- 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.
Safety inspection
The manufacturer recommends that a safety inspection of the device is
performed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during
the same 12-month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions -
after repair, care and maintenance has been carried out - at
least every twelve months.
For safety inspections, follow the appropriate national and international

standards and directives.
Further details on safety inspection and calibration can be obtained from

your service centre. They will provide you on request with any documents
you may require.
Disposal
Do not dispose of this device with normal domestic waste! To comply with
the European Directive on Waste Electrical and Electronic Equipment and
its implementation as national law, electrical equipment that has reached
the end of its life must be collected separately and returned to an approved
recycling facility. Any device that you no longer require must 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).
18

EN
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
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.
Devices marked with the CSA test mark satisfy the requirements of the
relevant standards for Canada and the USA.
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 purchaser. 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.
19

General information
The TIG pulsed arc function, with its wide frequency range, is available on both the MagicWave and TransTig.
To optimise the ignition sequence in TIG AC welding, the MagicWave takes account not only of the diameter of the electrode,
but also of its temperature, calculated with reference to the preceding welding and welding off-times.
The central control and regulation unit of the power sources is coupled with a digital
signal processor. The central control and regulation unit and signal processor control
the entire welding process.
During the welding process, the actual data is measured continuously and the device
responds 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.
The devices are used in workshops and industry for manual TIG applications with
unalloyed and low-alloy steel and high-alloy chrome-nickel steels.
The MagicWave power sources perform exceptionally well when it comes to welding aluminium, aluminium alloys and
magnesium due to the variable AC frequency.

23
FCC / RSS Com-
FCC
pliance
This equipment complies with the limit values for a EMC device class A
digital device pursuant to Part 15 of the FCC Rules. These limit values are
intended 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 communications if it is not installed and used
according to the Operating Instructions.
The use of this device in residential areas will probably cause hazardous
interference, 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

standards. 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
Warning notices and safety symbols are affixed to power sources with the CSA test mark EN
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.
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.
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
parameters 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
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. Individual 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
safety rules
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.
The favourites button

Assigning the Favourites button
The Favourites button can be assigned a parameter from the following Setup menus:
1 This parameter can then be called up and changed directly on the control panel.
Select the desired parameter in the Setup menu
More information about the Setup menu can be found from page 77 onwards
28

To assign the 2 selected parameter to the Favourites button, press the Favourites button for approx. 5 seconds
EN
A confirmation message is displayed.
Press the adjusting 3 dial to confirm
The selected parameter is now assigned to the Favourites button.
IMPORTANT! Saving a favourite overwrites the previously saved favourite without warning.
1
Retrieving favour- 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.
1
Deleting favour- Press the Favourites button for longer than 5 seconds ites
Assigning If the FP Job function package is present on the power source, EasyJobs can be assigned to the
EasyJobs to the Favourites button.
Favourites button
The assigned IMPORTANT! If EasyJobs is assigned to the Favourites button, any previously saved favourite
parameter is parameter will no longer be accessible using that button.
deleted and a
message is 1 Select the Job menu from the Setup menu
displayed.
More information about the Setup menu can be found from page 95 onwards
2 Press the
adjusting dial to 2 In the Job menu, set the "EasyJobs to Favourites button" parameter to "on"
confirm
29

Press the Menu key
Five EasyJob buttons for the welding parameters are displayed as

icons.
3
50
A
* *
4 Press the Favourites button

The 5 EasyJob buttons are displayed and can be selected by turning and pressing the adjusting dial.
50 A
* 1 2 3 4 5 *
More information about using EasyJobs can be found in the "EasyJob mode" section starting on page 74.
30

Connections, switches and mechanical components EN
Function No.
(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.
No. Function
(4) (+) current socket to connect the grounding cable
31

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:
32

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
level 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)
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
safety rules
Utilisation for The power source is intended exclusively for TIG and MMA welding.
intended purpose Utilisation for any other purpose, or in any other manner, shall be deemed to be not in
accordance with the intended purpose.
The manufacturer shall not be liable for any damage resulting from such improper use.
Proper use also includes:

- following all the information in the operating instructions
- carrying out all the specified inspection and servicing work
35

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 remains stable.
The venting duct is a very important safety feature. When choosing the location for the
device, 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-
fitted, 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 damage. 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.
erator-powered The power source is generator-compatible.

ration
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
and U
See device rating plate or technical data for I1max 1 values
The generator apparent power SGEN needed is calculated using the following rule of
thumb:
36

SGEN = S1max x 1.35 EN
A smaller generator may be used when not welding at full power.
IMPORTANT! The generator apparent power SGEN must always be higher than the
maximum apparent power S1max of the power source.
When using single-phase devices with a 3-phase generator, note that the specified
generator apparent power is often only available as a whole across all three phases of
the generator. If necessary, obtain further information on the single-phase power of the
generator from the generator manufacturer.
erance can be found in the "Technical data" section.
The steps and activities described below include references to various system
Information on components, including:
system components - Trolley
- Cooling units
- Welding torches, etc.
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-
For more detailed information about installing and connecting the system components, please refer to the
appropriate
operating instructions.
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.
37

Safety
WARNING! Work that is carried out incorrectly can cause serious
injury and damage. The following activities must only be carried out by
trained and qualified personnel. Pay particular attention to the "Safety rules"
sections in the power source and system component operating instructions.
Start-up
Remarks on the The TT / MW 230i power sources can be operated with a cooling unit.
WARNING! An electric shock can be fatal. If the machine is plugged
cooling unit A cooling unit is recommended for the following applications:
into the mains electricity supply during installation, there is a high risk
- Hosepacks over 5 m long
of very serious injury and damage. Do not carry out any work on the device
- TIGunless
AC welding
- the mains switch is in the "O" position,
- In general,
- where welding
the device is performed
is unplugged from theinmains.
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
cooling unit.
This section describes how to commission the power source:

General
- for the main TIG welding application
- with reference to a standard configuration for a TIG welding device.
Safety
The standard configuration consists of the following system components:

- power source
- cooling unit
38

- TIG manual welding torch
EN
- 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
instructions for the system components.
39

40

EN
WARNING! There is a high risk of very serious injury and damage if a
gas cylinder falls over.
Connecting the - Place them on a solid, level surface in such a way that they remain stable
gas cylinder - 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.
When using a TIG welding torch with an integral gas connection:
Use the gas hose to 5 connect the pressure regulator to the shielding gas connection on the rear of the
power source
Tighten the union nut 6 on the gas hose
41

When using a TIG welding torch with no integral gas connection:
Connect the TIG 5 welding torch gas hose to the pressure regulator
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 Set up the welding torch in accordance with the welding torch operating
instructions unit 1
Establishing a Turn 1 the mains switch to the "O" position

ground earth connection to the workpiece
7
Locking and unlocking the

power source using the
NFC key
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
unlocked.
The power source must be switched on before it can be locked or unlocked.
Locking and unlocking of the power source is only possible with the TT/MW 230i and is
Restrictions only permitted in certified countries.
42

EN
48
Welding
43

44

TIG modes EN
Safety
safety 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 Final current phase: to prevent any local
is raised gently at a low welding current overheating of the base material due to
so that the filler metal can be positioned heat build-up towards the end of welding.
correctly 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
phase): uniform thermal input into the lowering of the welding current in order
base material, whose temperature is to prevent any local overheating of the
raised by the advancing heat base material
45

Gas post-flow time
GPo
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
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
46

- To revert to the main current, release the torch trigger
EN
Spot welding When the spot welding operating mode is selected, the symbol for spot welding appears
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
parameter.
- to end the welding process prematurely: pull the torch trigger back again
I1
I
t
GPr UP DOWN GPo
SPt
47

TIG welding
Safety
safety rules
WARNING! An electric shock can be fatal. If the power source is
connected to the mains electricity supply during installation, there is a
high risk of very serious injury 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
PreparationsPlug in 1 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.).
Move the mains 2 switch to the "I" position
The Fronius logo appears on the display.
TIG weldingPress 1 the Welding process / Mode button
The welding process and operating mode are displayed.
Select thedesired 2 welding process by turning the adjusting dial

Confirm the selection by
3 pressing the adjusting dial
Select the desired operating
4 mode by turning the adjusting dial
Confirm the selection by
5 pressing the adjusting dial
The available TIG welding parameters are displayed after a short time or after pressing the Welding process /
Mode button.
Welding parameters for TIG DC
48

6
welding maximum of 30 seconds. Press the button again to stop the gas flow
EN
Turn the prematurely.
adjusting dial to - Turn the adjusting-screw on the underside of the pressure regulator until the
select the manometer indicates the desired shielding gas flow-rate
required
parameter NOTE! All welding parameter set values that have been set using the
7 Press the adjusting dial remain stored until the next time they are changed. This applies
adjusting dial even if the power source is switched off and on again.
The value of the 13 Start welding (ignite the arc)
parameter is The polarity welding parameter is only available on MagicWave power sources. If the
highlighted in
polarity welding parameter is set to DC, the following welding parameters are available:
blue and can now
be changed. xxA = actual current value depending on the specified main current
8 Starting current
Turn the
adjusting dial to
change the value
9
of
parameter
the 50% xxA
50% xxA
Press the
1
adjusting dial
0
If required, set - + - +
further
Starting current, 2-step mode and spot welding Starting current, 4-step mode
parameters in the
Setup menu
(For details, see Unit % (of main
the "Setup current)
parameters" Setting range 0 - 200
chapter,
1 Factory setting 50
starting on
1 IMPORTANT! The starting current is saved separately for TIG AC welding and TIG DC
page 77)
1 welding.
Open the gas
2
cylinder valve
To set the
shielding gas flow
rate:
- Press the
Gas-test
button
The test
gas flow
lasts for
a
49

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
Unit % (of main

current)
Setting range 0 - 100
Factory setting 50
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)
Unit s
.Manualslib.com manuals search engine

DownSlope
EN
0.5 s 0.5 s
- + - +
DownSlope, 2-step mode and spot welding DownSlope, 4-step mode
Setting range off; 0.1 - 30.0 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
Unit % (of main

current)
Factory setting 30
Electrode diameter
2.4mm
- +
Unit mm
Setting range off; 1.0 - 4.0
Factory setting 2.4
Welding Polarity
parameters
for TIG AC
welding
51

ory setting
DC- DC-
The polarity welding parameter is only available on MagicWave

- +
power sources. If the polarity welding parameter is set to AC, the
Unit -
following welding parameters are available: xxA = actual current
S value depending on the specified main current
e Starting current
t
t
i 50% xxA
50% xxA
n
g
r
Starting current, 2-step mode and spot welding Starting current, 4-step mode
a
n
g
e
A
C
F
a
c Unit % (of main
current)
t
Factory setting 50
IMPORTANT! The starting current is saved separately for TIG AC
welding and TIG DC welding.

UpSlope
EN
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
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 corrected in steps of +/-20 A.
Reduced current
50% xxA
Reduced current (only in 4-step mode)
Unit % (of main

current)
53

DownSlope
0.5 s 0.5 s
DownSlope, 2-step mode and spot welding DownSlope, 4-step mode

Factory setting 50
Unit s
Setting range off; 0.1 - 30.0 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
Unit % (of main

current)
Factory setting 30
Balance
on MagicWave only
35%
+
-
Unit %
Setting range 15 -
50

EN
Factory setting 35
15: highest fusing power, lowest cleaning action
50: highest cleaning action, lowest fusing power
55

Effect of the balance on the waveshape:
I (A)
35% 50% 15%

+ t (s)
-
Electrode diameter
2.4mm
Unit mm
Setting range off; 1.0 - 4.0
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
necessary.
Afterwards, the automatic cap-shaping function is reset and deactivated.
56

EN
(1) (2)
(1) ... before ignition

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

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

using high HF ignition is activated when a time value has been set for the ignition timeout setup
frequency parameter in the HF menu.
(HF ignition) The HF ignition indicator lights up in the status bar on the control panel.
Igniting the arc
57

Unlike touchdown ignition, HF ignition eliminates the risk of contamination of the
tungsten electrode and the workpiece.
Place the gas nozzle down on the ignition

location, ensuring there is a gap of
approx. 2 to 3 mm (5/64 to 1/8 in.)
between the tungsten electrode and the
workpiece Gap exists.
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.
3 Tilt the torch back into the normal posi-
tion
4 Carry out welding
58

Touchdown igni- If the ignition timeout setup parameter is set to off, HF ignition is deactivated. The welding
EN
tion arc is ignited by touching the workpiece with the tungsten electrode.
Procedure for igniting the arc using touchdown ignition:
Place the gas nozzle down on the ignition

location, ensuring there is a gap of
approx. 2 to 3 mm (5/64 to 1/8 in.)
between the tungsten electrode and the
workpiece Gap exists
Actuate the torch trigger

3 Shielding gas flows
Gradually tilt the welding torch up until the

tungsten electrode touches the workpiece
4 Raise the welding torch and rotate it
into its normal position
The arc ignites.
5 Carry out welding
End of 1 weldingDepending on the set mode, finish welding by releasing the torch trigger
Wait for the set gas 2 post-flow and hold welding torch in position over the end of the weld seam
59

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
current phase (only possible in the low frequency range: 0.25 - 5 Hz). Higher pulse
frequencies are mainly used in automatic mode to stabilise the arc.
TIG pulsing is used for out-of-position welding of steel pipes or when welding thin
sheets.
Mode of operation of TIG pulsing when TIG DC welding is selected:
Ignition time out, TIG pulsing and tacking function
60

EN
(5)
I [A] (6)
(1)
(2) (8)
(3)
(4) (7) t [s]
TIG pulsing - welding current curve
Legend:
(1) Main current (5)
(2) Base current Pulse frequency
(6)
*)
(3) Starting current (7)
Duty cycle
(4) UpSlope (8)
DownSlope
*) (1/F-P = time interval between two pulses) Final current
Tacking function The tacking function is available for the TIG DC welding process.
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:
61

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.
MMA welding
Safety
safety rules
62

the device make sure that: EN
PreparationsSwitch 1 off cooling units (in the components menu, set the cooling unit control setup
parameter to OFF)
Move the mains 2 switch to the O position
Disconnect the mains 3
plug
Remove the TIG welding
4 torch
IMPORTANT! Observe the instructions on the packaging of the rod electrode when selecting the appropriate
type of current and for correctly connecting the electrode cable.
Plug in and latch the 5 grounding cable:

in the (+) current socket ... for DC- welding (=/-) in the (-) current
socket ... for DC+ welding (=/+)
Use the other end of 6 the grounding cable to establish a connection to the workpiece
Plug in the electrode cable
7 and turn it clockwise to latch it in place:
in the (-) current socket ... for DC- welding (=/-) in the (+) current
socket ... for DC+ welding (=/+)
Plug in the mains 8 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.).
Move the mains 9 switch to the "I" position The Fronius logo
appears on the display.
MMA weldingPress 1 the Mode button
Select MMA (rod 2 electrode) welding process (turn adjusting dial and press)
Turn theadjusting 3 dial to select the Polarity parameter

Press the adjusting dial
4
Set the polarity for the5rod electrode to be used by turning the adjusting dial
63

Confirm the selection 6 by pressing the adjusting dial
Turn the adjusting dial8to select further welding parameters

9
The value of the parameter is highlighted in blue and can now be changed.
Turn the adjusting 1 dial to change the value of the parameter

Press the adjusting 0 1 dial
1
If required, set further 1
parameters in the Setup menu
(For details, see the "Setup
2 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.
Start welding 1
3
Welding parameters * Depending on the selected current type, (+), (-) or the alternating current symbol is
for manual metal arc displayed here.
welding
xxA = actual current value depending on the specified main current
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"
)
Unit % (of main

current)
Factory setting 150
64

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.
Unit % (of main current)

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.
65

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-
I (A)
(1)
150
66
Downloaded from www.Manualslib.com manuals search

100 engine
0-2 s, (3) Main current = pre-set welding
EN
factory current I1
setting
0.5 s Mode of operation
(2) during the specified starting current time (1), the welding current I 1 (3) is increased to
the starting current (2).
The starting current time is set in the Setup menu.

0-200%, Starting current < 100 % (SoftStart)
factory A starting current < 100% (SoftStart) is intended for basic electrodes. Ignition takes
setting place at a low welding current. Once the arc is stable, the welding current continues to
150% rise until it reaches the welding current command value.
Benefits:
- Improved ignition properties for electrodes that ignite at
I (A)
low welding currents
- Largely prevents slag inclusions - Reduces welding
spatter
(3)
90A
(1) Starting current
(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)
As the arc becomes shorter, the welding voltage may drop so far that the rod electrode
-stick function 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 continued without any problems.
The anti-stick function can be activated and deactivated in the rod electrodes menu.
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
Favourites button", starting on page 32.
Set the welding 1 process, mode and welding parameters

Press the Favourites 2 button
The 5 EasyJob buttons are opened.
Turn the adjusting 3 dial and select the desired storage location
67

To save the current 4 welding settings, press and hold the adjusting dial for about 3 seconds
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
Retrieving Easy- 1 Press the Favourites button Job

operating
points The 5 EasyJob buttons are opened.
Turn the adjusting 2 dial and select the desired storage location
To retrieve a saved 3 EasyJob operating point, press the adjusting dial briefly (< 3 seconds)
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.
Turn the adjusting 2 dial and select the storage location to be deleted
68

EN
To delete an 3 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.
Welding job
Safety
safety rules
the device make sure that:
Preparatory 1 workSet up and install the power source in accordance with the welding job
Plug in the mains 2 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 persons or electrically conductive or earthed parts (e.g. housing,
etc.).
Move the mains 3 switch to the "I" position
Welding a jobPress 1 the Mode button
69

Select "JOB" (turn 2 adjusting dial and press)
The welding parameters of the previously opened job are displayed after a short time.
The job number is selected.
Press the adjusting 2 dial

The job number can now be modified.
Select the job 3 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.
70

Setup settings

The Setup menu
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 welding 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 system.
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 selected.
The Setup menu appears.
To leave the Setup 2 menu, press the Menu key again
The current welding parameters will be displayed.

EN
(1) (2) (3) (4) (5) (6) (7) (8)
**
(13) (12) (11) (10) (9)
Overview
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
73

Item Designation
(7) Defaults
to
- Display:
set display backlighting, languages, date &
time, display additional 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
(9) source is on a network)
Scroll bar
(10) (for multiple parameters)
Available menus
the number of available menus can vary depending
(11) on the firmware version and available options.
(12) Value, unit
Setup parameters
depending on the selected menu and the
current settings for the welding process and
(13)
operating mode, parameters that are not
relevant are greyed out and cannot be
selected.
Display of the currently selected menu
* taking into account the current settings for welding
process and operating 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):
Turn the adjusting 1 dial until the parameter's higher-level menu is selected
The background of the selected menu becomes blue.
Turn the adjusting 3 dial and select the desired menu (blue background)
74

Setting parameters
EN
4 Press the adjusting dial in the selected menu The first parameter in the menu is selected.
Turn the adjusting dial and select the desired parameter

5
Press the adjusting dial to change the parameter
6
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
75

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 deactivated
The TIG menu
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
parameters 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)

76

Factory setting 50
EN
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
trigger.
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
4step 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
TIG AC menu Pulse frequency
Duty cycle
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 parameters cannot be
selected.
The set pulse frequency is also used for the reduced current.
77

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
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 trigger.
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 4step 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
soft, distant arc with shallow heat

Low frequency input
High frequency focused arc with deep heat input
Effect of the AC frequency on the waveshape: I (A)
78

EN
+
- 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
reducing 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)
Negative 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
79

reducing 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)
80

Parameters in the Starting current time
EN
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
properties
- Better fusion of the base material in the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions
Char
To select characteristics
Unit - / A/V / -
Setting range I-constant / 0.1 - 20.0 / P-constant
Factory setting I-constant
The MMA menu
81

(1) Load line for rod electrode
con - 20 A / V (2) Load line for rod electrode where arc length is in-
U (V)
(4) creased
(6) (3) Load line for rod electrode where arc length is re-
(2)
duced
(1)
(5)
(3) (4) Characteristic for parameter setting I-constant
(constant welding current
)
(7) (8) (5) Characteristic for parameter setting 0.1 - 20.0

(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
(8) Example of pre-set arc-force dynamic where

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,
irrespective 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).
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 extends from 0.1 A / V
(very steep) to 20 A / V (very flat).
- Setting a flat characteristic (5) is only advisable for cellulose electrodes.
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.
82

EN
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 operating point provides
information on the current welding voltage and the current welding current.
Where the welding current (I 1) 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).
83

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 parameter, the welding voltage can be limited to a value that makes it possible to
end the welding operation simply by slightly lifting the rod electrode.
NOTE! If, during welding, you often find that the welding operation is ended
unintentionally, 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
continued without any problems.
AC frequency
only for MMA AC welding (welding parameter polarity = AC)
Unit Hz
Setting range 40 -
250
Factory setting 60

EN
90
Ignition settings
Ignition setting HF ignition

parameters
Unit -
Setting range On / Off / External
Factory setting On
High frequency ignition at start of welding is

On
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
85

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".
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.
86

EN
The gas menu
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
Setting range 0 -
60
Factory setting 0.5
87

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
electronically 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
temperature.
When these 2 minutes have passed, the fans and coolant
pump are switched off.
The components menu
88

EN
The Job menu
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.
Set welding process, 1 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
Turn the adjusting 3 dial and select the
Job menu
Turn the adjusting dial 5and select "Save Job as ..."
Press the adjusting dial6
An overview of the most important parameters is displayed.
Select "More" (turn 7 adjusting dial and press)

Turn the adjusting dial:8
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.
Select Job number 9 (turn adjusting dial and press) Select "More" (turn
adjusting dial and 10 press)
The keyboard is displayed.
Turn and press the 1 adjusting dial to enter a name for the job. Select "More" (turn
adjusting dial and 1
12 press)
89

A message confirming that the job has been saved is displayed.
Select "Finish" (turn 1 adjusting dial and press)

2
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.
Press the Menu key 1
Turn the adjusting 2 dial and select the Job menu

3
Turn the adjusting dial4and select "Load Job ..." Press the adjusting dial
5
The job list is displayed.
Select the job that 6 you want to load (turn adjusting dial and press)
A message advising that the job is about to be loaded is displayed.
Select "Yes" (turn 7 adjusting dial and press)
The job is loaded into the welding parameters.
Deleting a jobPress 1 the Menu key
Turn theadjusting 2 dial and select the Job menu

3
Turn the adjusting dial4and select "Delete Job ..." Press the adjusting dial
5
The job list is displayed.
Select the job that 6 you want to delete (turn adjusting dial and press)
A warning that the job is about to be deleted is displayed.
Select "Yes" (turn 7 adjusting dial and press)
The job is deleted.
90

EN
Defaults
Overview Display
Display - backlighting Unit -
Setting range Year / Month / Day / Hour / Minute / Time
zone
Factory setting -
- Display additional parameters
System
- Reset to factory settings ...
- Reset website password ...
- Perform R/L alignment
Backlighting to set the brightness of the display

Unit -
Display - languages Setting range 0 -
10
Factory setting 10
Adjust backlighting:
Defaults / Display / Backlighting

1
2 Press the adjusting dial
Select backlighting brightness (turn adjusting dial and press)
3
Language
Unit -
Display - Time & Date Setting range Depends on the version of the software Factory settingEnglish
- Backlighting
- Languages
- Time & Date
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.
91

T & Date to set the time and date Display
Setting the date & time:
Defaults / Display / 1 Time & Date

Select the desired 2 parameter (turn adjusting dial and press)
Modify parameter by turning
3 the adjusting dial
Confirm the modified parameter
4 by pressing the adjusting dial
Press the menu key to5exit the date and time settings
i - Display additional parameters

m In the case of welding parameters 1 - 3, this function enables additional
e parameters or settings to be displayed.
System - Reset to 4 Select parameter location P1 - P3 (turn and press adjusting dial)
factory settings Choose which parameter to display in the selected parameter location (turn adjusting
- Not assigned 5 dial and press)
- Welding process
Select Save (turn adjusting dial and press)
- TIG welding torch mode
- TIG settings
The parameter is displayed in the selected parameter location, where it can now also
Tacking
be modified.
Pulse frequency
Base current 1
Duty cycle Defaults / System / Reset to factory settings Press
2
the adjusting dial
Final current time
Spot welding timeA confirmation prompt asking whether you really want to restore the factory settings is
AC frequency displayed.
AC current offset3
Positive half-wave waveform
Select yes by turning the adjusting dial
4
Negative half-wave waveform
Press the adjusting dial to reset to factory settings
The power source is reset to the factory settings.

Display additional
parameters:
1 Default / Display
/ Display
additional
parameters
2 Press the
adjusting dial
3
92

EN
Reset website 1 Defaults / System / Reset website password

passwordPress the 2 adjusting dial
A confirmation prompt asking whether you really want to reset the website password is displayed.
Select yes by turning 3 the adjusting dial

4 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
The way that the

hosepack is
arranged has a very
significant effect on
the weld properties.
Particularly with
pulsed-arc welding
and AC welding, a
high welding circuit
inductivity may
occur, depending on
the length of the
93

hosepack and on the way that it is arranged. The result is that the current rise is
restricted.
The weld results can be optimised by changing the arrangement of the torch hosepack.
The hosepack must be laid out as shown in the illustration.
Performing R/L alignment
1 Defaults / System / Perform R/L alignment

2 Press the adjusting dial
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

Select "More" (turn and press adjusting dial) The third R/L alignment
5
screen is displayed.
6 Follow the instructions displayed on the screen

Select "More" (turn and press adjusting dial)
7
The current values are calculated.
After R/L alignment has been completed, a confirmation and the current values are displayed.
94

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
95

102
SmartManager - The power source

website

SmartManager - The power source website
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 Note 1 down the IP address for the power source in system information
power source Enter 2 the IP address in the browser search field
SmartManager
Enter user name and 3 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.
Enter the old 1 password
Enter the new 2 password
98

Repeat the new 3 password
EN
Click on "Save" 4
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.
99

Current system data
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.
100

Job-Data EN
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
parameters 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
column" button.
This offers a simple way of comparing the values from various jobs.
Editing a job Existing welding system jobs can be edited.
Click on "Edit job" 1

Click on the job to be 2 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
Amend the values 3 accordingly

Save / Delete adjustments,
4 Save as / Delete job
As an aid when editing a job, other jobs can be easily added to the list with the data
displayed by clicking on "Add column".
Creating a new job
Click on "Create new 1 job"
101

Enter job data 2
Click on "OK" to apply3the new job
Importing a job This function enables previously exported jobs to be transferred into the welding system.
Click on "Search 1 Job-file"

Select desired job 2 file
Individual jobs can be selected and new job numbers assigned in the preview of the job import list.
Click on "Import Job" 3
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.
Select jobs to be 1 exported:

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

numbers
Click on "Save PDF" 3 or "Save CSV"
A PDF or CSV file containing the selected jobs is created and saved according to the settings of the browser
in question.
102

EN
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
Click on "Start 1 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
Click on "Search 1 restore file" to transfer an existing backup to the power source
Select the file and 2 click on "Open"
The selected backup file is displayed on the power source SmartManager under "Restore".
103

3
Click on "Start recovery"
Once the data has been successfully restored, a confirmation to this effect is displayed.
Overview
Overview In the overview entry, welding system components and options are displayed with all
available information, e.g. firmware version, item number, serial number, production
date, etc.
Expanding / Clicking on the button "Expand all groups" displays further details for the
reducing all groups individual 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
components.
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.
...
104

EN
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
Organise and save 1 the update file

Click on "Search 2 update file"
Select and open the update
3 file
The selected update file is displayed on the power source SmartManager under "Update 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.
To restart the power 4 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.
105

Once the update has been completed successfully, a confirmation and the current
firmware version are displayed.
You can now log on 5 to SmartManager again
106

Function Packages
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

packageClick on 2 "Search function package file"
Select the desired function
3 package file (*.xml)
Click on "Open" 4
107

The selected function package file is displayed on the power source SmartManager under "Install function
package".
Click on "Install function

5 package"
Once the function package has been successfully installed, a confirmation to this effect is displayed.
108

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.
Click on "Create 1 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.

Troubleshooting and maintenance
110

Troubleshooting
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 entirely. After a
possible malfunction or error has been remedied, the power source can be put back into normal
operation again without any fuses having to be replaced.
Safety
injury or damage. All the work described below must only be carried
out by trained and qualified 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 below:
- 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
electrically charged components (e.g. capacitors) have been discharged.
WARNING! An inadequate ground conductor connection can cause
serious injury or damage. The housing screws provide a suitable ground
conductor connection for earthing the housing and must NOT be replaced by
any other screws that do not provide a reliable ground conductor connection.
troubleshooting
Power source - Power source does not function Mains switch is
on, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged
in
Remedy: Check the mains 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
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
Gas hose is not fitted or is

Cause: 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
Remedy: Check the settings

Cause: Grounding (earthing) connection is incorrect
EN
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".
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
injury or damage. All the work described below must only be carried
out by trained and qualified 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 below:
- 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
electrically charged components (e.g. capacitors) have been discharged.
113

WARNING! An inadequate ground conductor connection can cause
serious injury or damage. The housing screws provide a suitable
ground conductor connection 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 grounding (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 cooling 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
Dismantle device side panels and clean inside of device with dry reduced
Every 6 months - 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.

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.
MW 190 MW 190 MV
Mains voltage U1 x 230 V x 120 / 230 V
Mains voltage tolerance ± 15% ± 15%

Mains frequency 50/60 Hz 50/60 Hz
Mains fuse protection (slow-blow) A 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 - 190 A - 190 A
Electrode - 170 A - 170 A
Welding current at A 4) A 4) (U1 = 230 V)
min/40 °C (104 °F) 35% DC2) A 5) A 4) (U1 = 120 V)
A 5) (U1 = 230 V)
A 5) (U1 = 120 V)
min/40 °C (104 °F) 60% DC2) A 4) A 4) (U1 = 230 V)

A 5) A 4) (U1 = 120 V)
A 5) (U1 = 230 V)
A 5) (U1 = 120 V)
min/40 °C (104 °F) 100% DC2) A 4) A 4) (U1 = 230 V)

5)
A A 4) (U1 = 120 V)
A 5) (U1 = 230 V)
A 5) (U1 = 120 V)
Open circuit voltage V 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
117

MagicWave 190
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 36.4
37.5 lb. lb.
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)
MW 230i MW 230i MV
Mains voltage U1 1 x 230 V 1 x 120 / 230 V
Mains voltage tolerance ± 15 % ± 15 %

EN
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)

= 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 230 A 4) 230 A 4) (U1 = 230 V)
10 min/40 °C (104 °F) 35% DC2) 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)

5)
120 A 120 A 4) (U1 = 120 V)
120 A 5) (U1 = 230 V)
85 A 5) (U1 = 120 V)
Open circuit voltage 100 V 100 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
126
119

MagicWave 230i
Striking voltage (Up) 9.6 kV 9.6 kV

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.
Weight 17.0 kg 16.5 kg
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)

TT 230i TT 230i MV EN
Mains voltage U1 x 230 V x 120 / 230 V

TransTig 230i
Mains voltage tolerance ± 15 % ± 15 %
Mains frequency / 60 Hz / 60 Hz
Mains fuse protection (slow-blow) A A (U1 = 230 V) 20 A
(U1 = 123 V)
1) Zmax am PCC3) Zmax am PCC3)
Mains connection
= 273 mOhm = 273 mOhm
Cos phi 0,99 0,99
TIG - 230 A - 230 A
Electrode - 190 A - 190 A
Welding current at
A 5) (U1 = 230 V)
2) A 5)
min/40 °C (104 °F) 35% DC
A 5) (U1 = 120 V)
min/40 °C (104 °F) 45% DC2) A 4) A 4) (U1 = 230 V)

A 4) (U1 = 120 V)
min/40 °C (104 °F) 60% DC2) A 4) A 4) (U1 = 230 V)

A 5) A 4) (U1 = 120 V)
A 5) (U1 = 230 V)
A 5) (U1 = 120 V)
min/40 °C (104 °F) 100% DC2) A 4) A 4) (U1 = 230 V)

5)
A A 4) (U1 = 120 V)
A 5) (U1 = 230 V)
A 5) (U1 = 120 V)
Open circuit voltage V V
Working voltage Striking voltage (Up) 9.6 kV 9.6 kV
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.
Weight 16.4 kg 15.9 kg
36.2 lb. 35.1 lb.
maximum shielding gas pressure 6 bar 6 bar
87.02 psi 87.02 psi
121

sound power level (LWA) 68 dB(A) 68 dB(A)
128
Explanation of 1) connected to public mains supply with 230 / 400 V and 50 Hz

footnotes 2) D.C. = Duty cycle
3) PCC = interface to the public grid
TIG welding
4)
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
radio frequencies.

EN
130
123

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
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Device concept ..................................................................................................................................... 23

Application areas .................................................................................................................................. 23

FCC / RSS Compliance........................................................................................................................ 24

Warning notices on the device.............................................................................................................. 25

System components .................................................................................................................................. 26

Control elements and connections 27

The favourites button ................................................................................................................................. 31

Assigning the Favourites button............................................................................................................ 31

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

MMA welding ........................................................................................................................................ 39

Before installation and commissioning....................................................................................................... 40

Utilisation for intended purpose ............................................................................................................ 40

Information on system components...................................................................................................... 41

Connecting the mains cable....................................................................................................................... 42

Connecting the mains cable.................................................................................................................. 42

Remarks on the cooling unit ................................................................................................................. 43

Assembling the system components (overview)................................................................................... 44

Connecting the gas cylinder.................................................................................................................. 45

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

Symbols and their explanations............................................................................................................ 51

Spot welding ......................................................................................................................................... 53

Welding parameters for TIG DC welding.............................................................................................. 55

Welding parameters for TIG AC welding .............................................................................................. 58

Igniting the arc ........................................................................................................................................... 63

Igniting the arc using high frequency(HF ignition)................................................................................. 63

End of welding ...................................................................................................................................... 65

Ignition time out, TIG pulsing and tacking function .................................................................................... 66

Ignition timeout function........................................................................................................................ 66

MMA welding ............................................................................................................................................. 68

MMA welding ........................................................................................................................................ 69

Welding parameters for manual metal arc welding............................................................................... 70

Starting current >100% (HotStart) ........................................................................................................ 72

Starting current <100% (SoftStart)........................................................................................................ 73

EasyJob mode ........................................................................................................................................... 74

Storing EasyJob operating points......................................................................................................... 74

Retrieving EasyJob operating points .................................................................................................... 75

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

Accessing the Setup menu................................................................................................................... 79

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 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

Loading a job ........................................................................................................................................ 96