FRONIUS MagicWave 2600 Manual de usuario
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
MagicWave 2600
MagicWave 2600 Cel
MagicWave 3000
TransTig 2600
TransTig 2600 Cel
TransTig 3000
EN-US
Operating instructions
TIG power source
42,0426,0022,EA 003-22032021
Inhaltsverzeichnis
Safety Instructions 6
Explanation of Safety Instructions 6
General 6
Intended Use 6
Environmental Conditions 7
Obligations of the Operating Company 7
Obligations of Personnel 7
Grid Connection 7
Personal Protection and Protection of Others 8
Data regarding Noise Emission Values 8
Danger from toxic gases and vapors 9
Danger from Flying Sparks 9
Risks from grid current and welding current 10
Stray welding currents 11
EMC Device Classifications 11
EMC Measures 11
EMF measures 12
Particular Hazard Areas 12
Undesired welding results 13
Danger from Shielding Gas Cylinders 13
Safety Measures at the Setup Location and During Transport 14
Safety Measures in Normal Operation 14
Maintenance and repair 15
Safety Inspection 15
Disposal 15
Safety Symbols 16
Data backup 16
Copyright 16
General 17
Principle 17
Device concept 17
Field of application 17
Warning notice on the device 18
Minimum equipment for welding operations 19
General 19
TIG AC welding 19
TIG DC welding 19
Manual metal arc welding 19
System components 20
General 20
Overview 20
Control Panel 21
General 21
Overview 21
MagicWave control panel 22
Control panel for TransTig 24
Connections, switches and system extensions 27
MagicWave / TransTig connections with Fronius welding torch central connector F 27
MagicWave / TransTig connections with welding torch central connector GWZ 28
MagicWave / TransTig connections with welding torch central connector GWZ 29
Before installation 30
Safety 30
Intended use 30
Setup regulations 30
Mains operation 30
Generator-powered operation 31
Commissioning 32
General 32
Notes on the cooling unit 32
Connecting the shielding gas cylinder 32
3
EN-US
Establish a connection with the workpiece 33
Connect the welding torch 33
TIG Operating Modes 34
General 34
Symbols and explanations 34
2-step 35
Special 2-step 35
4-step 36
4-step with intermediate lowering 36
Special 4-step: Version 1 37
Special 4-step: Version 2-4 38
Special 4-step: Version 5 39
TIG welding 40
Safety 40
Preparation 40
Select operating mode 41
Select process 41
Cap-shaping (MagicWave) 42
Welding parameter setting 42
Adjust the shielding gas quantity 42
Ignition of the arc - general 42
TIG synchronous welding AC (MagicWave) 42
HF ignition 43
Contact ignition 44
Ignition monitoring 45
Manual Metal Arc Welding 46
Safety 46
Preparation 46
Select operating mode 47
Select process (MagicWave) 47
Welding parameter setting 47
Remote control 49
Safety 49
General 49
AC remote control TR 53mc 49
TIG pulse remote control TR 50mc 50
TIG foot remote control TR 52mc 51
TIG spot welding remote control TR 51mc 52
Remote control TP MC / TP MC-CEL 53
Working with program levels 56
Overview 56
"Program level preferences” 57
Access 57
Select and change setup parameters 57
Available TIG parameters 57
Program levels P1 - P3 61
Access 61
Select and change setup parameters 61
Program level service menu P1 61
Program level code lock P2 61
Program level AC parameters P3 (MagicWave) 62
Fault diagnosis and correction 63
Safety 63
Displayed service codes 63
Power Source 64
Service, maintenance and disposal 67
General 67
At every start-up 67
Every 2 months 67
Every 6 months 67
Disposal 67
Spare parts 67
Technical data 68
Special voltage 68
4
Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
▶Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
▶Minor injury or damage to property may result if appropriate precautions are not
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to
recognized safety standards. If used incorrectly or misused, however, it can cause
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- Not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section
headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
6
The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in
accordance with the intended purpose." The manufacturer is not responsible for any
damage resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not
be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer accepts no liability for any
damage resulting from improper use.
Temperature range of the ambient air:
- During operation: -10°C to +40°C (14°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
Operating Com-
pany
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section
"Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following before begin-
ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and con-
firm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can
occur in one's absence.
Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-
rent consumption.
7
EN-US
This may affect a number of device types in terms of:
- connection restrictions
-criteria regarding maximum permissible grid impedance *)
-criteria regarding the minimum required short-circuit power *)
*) both at the interface with the public grid
See technical data
In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Personal Protec-
tion and Protec-
tion of Others
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pace-
makers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face
guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)
- Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and during
the welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
Data regarding
Noise Emission
Values
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in
the cooling phase following operation in relation to the maximum permitted operating
point at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be specified
because this value depends on the welding process and the environmental conditions. It
is influenced by a wide range of parameters, such as the welding process itself (MIG/
MAG, TIG welding), the selected current type (direct current, alternating current), the
8
power range, the type of weld metal, the resonance properties of the workpiece, the
workplace environment, and many other factors.
Danger from
toxic gases and
vapors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph 118 from
the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow
rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the
measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
- The welding process used
Consult the corresponding material safety data sheets and manufacturer's instructions
for the components listed above.
Recommendations for exposure scenarios, risk management measures and identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
Danger from Fly-
ing Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro-
tected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks,
drums, or pipes if these have not been prepared in accordance with corresponding
national and international standards.
9
EN-US
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like
are/were stored. Residues pose a risk of explosion.
Risks from grid
current and weld-
ing current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed
rollers, as well as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating
wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with sufficient
insulation against the ground potential. The temporary backing or cover must completely
cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimen-
sioned. Replace loose connections and scorched, damaged, or inadequately dimen-
sioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least
180° around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
- Never immerse it in liquids to cool it
- Never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between the elec-
trodes of two welding systems. Touching the potentials of both electrodes at the same
time may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that
the ground conductor is functioning properly.
Protection class I devices require a grid with a ground conductor and a connector system
with ground conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket without a
ground conductor contact is only permitted if all national regulations for protective separ-
ation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no liability for
any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if neces-
sary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched on again
by applying a clearly legible and understandable warning sign.
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will switch off
the main switch at the correct time.
10
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