Magic Wave 2600 PDF

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Operating Instructions
MagicWave 2600 EN Spare Parts List
MagicWave 2600 Cel TIG power source
MagicWave 3000
TransTig 2600
TransTig 2600 Cel
TransTig 3000
42,0426,0022,EN 004-15112013
Dear Reader
Introduction Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
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machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
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Safety rules
DANGER!
“DANGER!” indicates an imminently hazardous situation which, if not
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avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.
WARNING!
“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.
CAUTION!
“CAUTION!” indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to
alert against unsafe practices that may cause property damage.
NOTE! “NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.
Important! “Important!” indicates practical hints and other useful special-information. It is no

signal word for a harmful or dangerous situation.
Whenever you see any of the symbols shown above, you must pay even closer
attention to the contents of the manual!
General remarks This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for
- the life and well-being of the operator or of third parties,
- the equipment and other tangible assets belonging to the owner/
operator,
- efficient working with the equipment.
All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must
- be suitably qualified
- know about welding and
- read and follow exactly the instructions given in this manual.
The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must
be kept on hand, and of course observed in practice.
All the safety instructions and danger warnings on the machine itself:
- must be kept in a legible condition
- must not be damaged, must not be removed
- must not be covered, pasted or painted over
For information about where the safety instructions and danger warnings
are located on the machine, please see the section of your machine’s
instruction manual headed “General remarks”.
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General remarks Any malfunctions which might impair machine safety must be eliminated
(continued) immediately - meaning before the equipment is next switched on.
It’s your safety that’s at stake!
Utilisation for The machine may only be used for jobs as defined by the “Intended purpose”.
intended purpose
only The machine may ONLY be used for the welding processes stated on the
rating plate.
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.
Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual
- complete reading and following of all the safety instructions and danger
warnings
- performing all stipulated inspection and servicing work.
The appliance must never be used for the following:

- Thawing pipes
- Charging batteries/accumulators
- Starting engines
The machine is designed to be used in industrial and workshop

environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.
ikewise the manufacturer will accept no liability for defective or faulty work
results.
Ambient Operation or storage of the power source outside the stipulated range is
conditions deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.
Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)
- when being transported or stored: - 20 °C to + 55 °C (-4 °F to 131 °F)
Relative atmospheric 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.
Elevation above sea level: Up to 2000 m (6500 ft)
Obligations of The owner/operator undertakes to ensure that the only persons allowed to
owner/operator work with the machine are persons who
- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine
- have read and understood this operating manual particulary the sections
on “Safety rules”, and have confirmed as much with their signatures
- be trained in such a way that meets with the requirements of the work
results
Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.
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Obligations of Before starting work, all persons to be entrusted with carrying out work with
personnel (or on) the machine shall undertake
- to observe the basic regulations on workplace safety and accident
prevention
- to read this operating manual particulary the sections on “Safety rules”
and to sign to confirm that they have understood these and will comply
with them.
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Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.
Mains connec- High-performance devices can affect the quality of the mains power due to
tion their current-input.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to maximum permissible mains impedance *)
- criteria with regard to minimum short-circuit power requirement *)
*)
at the interface with the public mains network
see Technical Data
In this case, the plant 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.
NOTE! Ensure that the mains connection is earthed properly.
Protection for When welding, you are exposed to many different hazards such as:
yourself and - flying sparks and hot metal particles
other persons - arc radiation which could damage your eyes and skin
- harmful electromagnetic fields which may put the lives of cardiac pace-
maker users at risk
- electrical hazards from mains and welding current
- increased exposure to noise
- noxious welding fumes and gases.
Anybody working on the workpiece during welding must wear suitable

protective clothing with the following characteristics:
- flame-retardant
- isolating and dry
- must cover whole body, be undamaged and in good condition
- protective helmet
- trousers with no turn-ups
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Protection for “Protective clothing” also includes:
yourself and - protecting your eyes and face from UV rays, heat and flying sparks with
other persons an appropriate safety shield containing appropriate regulation filter glass
(continued) - wearing a pair of appropriate regulation goggles (with sideguards)
behind the safety shield
- wearing stout footwear that will also insulate even in wet conditions
- protecting your hands by wearing appropriate gloves (electrically insula-
ting, heat-proof)
- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!
Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must
- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)
- provide them with suitable protective equipment and/or
- erect suitable protective partitions or curtains.
Information on The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
noise emission when idling and in the cooling phase following operation at the maximum
values 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 wel-

ding (or cutting) as this is influenced by both the process and the environ-
ment. 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.
Hazards from The fumes given off during welding contain gases and vapors that are
noxious gases harmful to health.
and vapours
Welding fumes contain substances which may cause birth defects and
cancers.
Keep your head away from discharges of welding fumes and gases.
Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable
means.
Ensure a sufficient supply of fresh air.
Where insufficient ventilation is available, use a respirator mask with an

independent air supply.
If you are not sure whether your fume-extraction system is sufficiently

powerful, compare the measured pollutant emission values with the
permitted threshold limit values.
Close the shielding gas cylinder valve or central gas supply if no welding is
taking place.
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Hazards from The harmfulness of the welding fumes will depend on e.g. the following
noxious gases components:
and vapours - the metals used in and for the workpiece
(continued) - the electrodes
- coatings
- cleaning and degreasing agents and the like
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For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.
Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.
Hazards from Flying sparks can cause fires and explosions!

flying sparks
Never perform welding anywhere near combustible materials.
Combustible materials must be at least 11 meters (36 ft. 1.07 in.) away from
the arc, or else must be covered over with approved coverings.
Have a suitable, approved fire extinguisher at the ready.
Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that
there is no risk of injury or fire.
Do not perform welding in locations that are at risk from fire and/or
explosion, or in enclosed tanks, barrels or pipes, unless these latter have
been prepared for welding in accordance with the relevant national and
international standards.
Welding must NEVER be performed on containers that have had gases,

fuels, mineral oils etc. stored in them. Even small traces of these
substances left in the containers are a major explosion hazard.
Hazards from An electric shock is potentially life-threatening, and can be fatal.

mains and weld-
ing current Do not touch any live parts, either inside or outside the machine.
In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.
Always place the wirefeeder on an adequately insulated floor or base, or

else use a suitable insulating wirefeeder holder.
Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/
frame potential. The base or cover must completely cover the entire area
between your body and the ground/frame potential.
All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.
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Hazards from Do not loop any cables or other leads around your body or any part of your
mains and weld- body.
ing current
(continued) Never immerse the welding electrode (rod electrode, tungsten electrode,
welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.
Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.
Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.
Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.
If the machine is run on a mains network without a PE conductor and

plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.
Wherever necessary, use suitable measures to ensure that the workpiece is

sufficiently grounded (earthed).
Switch off any appliances that are not in use.
Wear a safety harness if working at height.
Before doing any work on the machine, switch it off and unplug it from the
mains.
Put up a clearly legible and easy-to-understand warning sign to stop

anybody inadvertently plugging the machine back into the mains and
switching it back on again.
After opening up the machine:

- discharge any components that may be storing an electrical charge
- ensure that all machine components are electrically dead.
If work needs to be performed on any live parts, there must be a second

person on hand to immediately switch off the machine at the main switch in
an emergency.
Stray welding If the following instructions are ignored, stray welding currents may occur.
currents These can cause:
- fires
- overheating of components that are connected to the workpiece
- destruction of PE conductors
- damage to the machine and other electrical equipment
Ensure that the workpiece clamp is tightly connected to the workpiece.
Attach the workpiece clamp as close as possible to the area to be welded.
On electrically conductive floors, the machine must be set up in such a way

that it is sufficiently insulated from the floor.
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Stray welding When using current supply distributors, twin head wire feeder fixtures etc.,
currents please note the following: The electrode on the unused welding torch/
(continued) welding tongs is also current carrying. Please ensure that there is sufficient
insulating storage for the unused welding torch/tongs.
In the case of automated MIG/MAG applications, ensure that only insulated

filler wire is routed from the welding wire drum, large wirefeeder spool or
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wirespool to the wirefeeder.
EMC device Devices with emission class A:

classifications - are only designed for use in an industrial setting
- can cause conducted and emitted interference in other areas.
Devices with emission class B:

- satisfy the emissions criteria for residential and industrial areas. This
also applies to residential areas in which power is supplied from the
public low-voltage grid.
EMC device classification as per the rating plate or technical specifications
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.
Examine and evaluate any possible electromagnetic problems that may

occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:
- safety features
- mains, signal and data-transmission leads
- IT and telecoms equipment
- measurement and calibration devices
Ancillary measures for preventing EMC problems:
a) Mains supply
- If electromagnetic interference still occurs, despite the fact that the
mains connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).
b) Welding cables
- Keep these as short as possible
- Arrange them so that they run close together (to prevent EMI problems
as well)
- Lay them well away from other leads.
c) Equipotential bonding
d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable
capacitors.
e) Shielding, where necessary

- Shield other equipment in the vicinity
- Shield the entire welding installation.
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EMI Precautions Electromagnetic fields may cause as yet unknown damage to health.
- Effects on the health of persons in the vicinity, e.g. users of heart pace-
makers and hearing aids
- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces
- Keep as much space as possible between welding cables and head/
body of welder for safety reasons
- Do not carrywelding cables and hose pack over shoulder and do not
loop around body or or any part of body
Particular danger Keep your hands, hair, clothing and tools well away from all moving parts,
spots e.g.:
- fans
- toothed wheels, rollers, shafts
- wire-spools and welding wires
Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.
Covers and sideguards may only be opened or removed for as long as is

absolutely necessary to carry out maintenance and repair work.
While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are
properly mounted ...
- ... and that all covers and sideguards are kept closed.
When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...).
For this reason, when feeder-inching etc., always hold the torch so that it is
pointing away from your body (machines with wirefeeder) and wear suitable
protective goggles.
Do not touch the workpiece during and after welding - risk of injury from
burning!
Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.
Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.
Special regulations apply to rooms at risk from fire and/or explosion.

Observe all relevant national and international regulations.
Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.
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Particular danger Risk of scalding from accidental discharge of hot coolant. Before unplugging
spots the connectors for coolant forward flow and return flow, switch off the coo-
(continued) ling unit.
Observe the information on the coolant safety data sheet when handling
coolant. The coolant safety data sheet may be obtained from your service
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centre or downloaded from the manufacturer’s website.
When hoisting the machines by crane, only use suitable manufacturer-

supplied lifting devices.
- Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.
- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.
- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).
When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).
If a machine is fitted with a carrying strap or carrying handle, remember that

this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable natio-
nal standards and directives as a minimum.
Danger of colourless and odourless inert gas escaping unnoticed, when

using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.
Factors affecting The following requirements with regard to shielding gas quality must be met
welding results if the welding system is to operate in a correct and safe manner:
- Size of solid matter particles <40µm
- Pressure dew point <-20°C
- Max. oil content <25mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being

used
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Danger from Shielding-gas cylinders contain pressurized gas and may explode if they are
shielding-gas damaged. As shielding-gas cylinders are an integral part of the overall
cylinders welding outfit, they also have to be treated with great care.
Protect shielding-gas cylinders containing compressed gas from excessive

heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).
Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).
Never hang a welding torch on a shielding-gas cylinder.
Never touch a shielding-gas cylinder with a welding electrode.
Explosion hazard - never perform welding on a pressurized shielding-gas

cylinder.
Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories
that are in good condition.
When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.
Close the shielding-gas cylinder valve when no welding is being carried out.
When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.
Observe the manufacturer’s instructions and all relevant national and

international rules applying to shielding-gas cylinders and accessories.
Safety precauti- A machine that topples over can easily kill someone! For this reason, always
ons at the instal- place the machine on an even, firm floor in such a way that it stands firmly.
lation site and - An angle of inclination of up to 10° is permissible.
when being
transported
Special regulations apply to rooms at risk from fire and/or explosion.
Observe all relevant national and international regulations.
By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.
The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.
When installing the appliance, please ensure a clearance radius of 0.5 m

(1.6ft.) , so that cool air can circulate freely.
When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportati-
on and carriage.
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Safety precauti- Before transportation, completely drain any coolant and dismantle the
ons at the instal- following components:
lation site and - Wire feed
when being - Wire wound coil
transported - Gas bottle
(continued)
Before commissioning and after transportation, a visual check for damage
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must be carried out. Any damage must be repaired by trained service
personnel before commissioning.
Safety precau- Only operate the machine if all of its protective features are fully functional. If
tions in normal any of the protective features are not fully functional, this endangers:
operation - the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/operator
- efficient working with the equipment.
Any safety devices that are not fully functional must be put right before you
switch on the machine.
Never evade safety features and never put safety features out of order.
Before switching on the machine, ensure that nobody can be endangered by

your doing so.
- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.
- Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.
- Owing to its special properties (in terms of electrical conductivity, frost-
proofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.
- Only use suitable original coolant of the manufacturer.
- Do not mix original coolant of the manufacturer with other coolants.
- If any damage occurs in cases where other coolants have been used,
the manufacturer shall not be liable for any such damage, and all
warranty claims shall be null and void.
- Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.
- Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.
- Before starting welding - while the machine is still cool - check the
coolant level.
XI ud_fr_st_sv_00467 022013
Preventive and With parts sourced from other suppliers, there is no certainty that these
corrective main- parts will have been designed and manufactured to cope with the stressing
tenance and safety requirements that will be made of them. Use only original spares
and wearing parts (this also applies to standard parts).
Do not make any alterations, installations or modifications to the machine

without getting permission from the manufacturer first.
Replace immediately any components that are not in perfect condition.
When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.
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 2002/96/EC 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 be returned to our agent, or find out about 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 markings Equipment with CE-markings fulfils the basic requirements of the Low-
Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .
Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.
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Data security The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.
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Copyright Copyright to this instruction manual remains the property of the
manufacturer.
The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the
instruction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.
XIII ud_fr_st_sv_00467 022013

ud_fr_st_sv_00467 022013 XIV
Contents
General remarks ........................................................................................................................................... 3
Basic system principle ............................................................................................................................. 3
Machine concept ...................................................................................................................................... 3
Areas of utilisation ................................................................................................................................... 3
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Warning notices affixed to the machine ................................................................................................... 5
Minimum equipment needed for welding ...................................................................................................... 6
General remarks ...................................................................................................................................... 6
TIG-AC welding........................................................................................................................................ 6
TIG-DC welding ....................................................................................................................................... 6
Rod electrode (MMA) welding ................................................................................................................. 6
System components ..................................................................................................................................... 7
General remarks ...................................................................................................................................... 7
Overview .................................................................................................................................................. 7
Control panel ................................................................................................................................................. 8
General remarks ...................................................................................................................................... 8
Overview .................................................................................................................................................. 8
Magic Wave control panel ........................................................................................................................ 9
Trans Tig control panel ............................................................................................................................ 9
Description of functions ......................................................................................................................... 10
Connections, switches and system add-ons .............................................................................................. 13
Magic Wave/Trans Tig connections with Fronius central torch connector F ......................................... 13
Magic Wave/Trans Tig connections with central torch connector GWZ ................................................ 14
Connections and switches on the rear of the machine .......................................................................... 15
Before commissioning ................................................................................................................................ 16
Safety ..................................................................................................................................................... 16
Utilisation in accordance with „intended purpose“ ................................................................................. 16
Set-up regulations .................................................................................................................................. 16
Mains connection ................................................................................................................................... 16
Generator-powered operation ............................................................................................................... 17
Connecting up the gas cylinder ............................................................................................................. 18
Commissioning ........................................................................................................................................... 18
General remarks .................................................................................................................................... 18
Remarks on the cooling unit .................................................................................................................. 18
Establishing a connection to the workpiece ........................................................................................... 19
Connecting the welding torch ................................................................................................................ 19
TIG operating modes .................................................................................................................................. 20
General remarks .................................................................................................................................... 20
Symbols and their explanations ............................................................................................................. 20
2-step ..................................................................................................................................................... 21
Special 2-step ........................................................................................................................................ 22
4-step ..................................................................................................................................................... 23
4-step with intermediate lowering .......................................................................................................... 24
Special 4-step: Variant 1 ........................................................................................................................ 25
Special 4-step: Variant 2 - 4 ................................................................................................................... 26
Special 4-step: Variant 5 ........................................................................................................................ 27
TIG welding ................................................................................................................................................. 28
Safety ..................................................................................................................................................... 28
Tooling up .............................................................................................................................................. 28
Selecting the operating mode ................................................................................................................ 29
Selecting the process (MagicWave) ...................................................................................................... 29
Cap-shaping (MagicWave) .................................................................................................................... 30
Setting the parameters .......................................................................................................................... 30
Setting the shielding gas flow rate ......................................................................................................... 30
Arc ignition - general remarks ................................................................................................................ 30
1
TIG synchronous welding AC (Magic Wave) ......................................................................................... 30
HF ignition .............................................................................................................................................. 31
Touchdown ignition ................................................................................................................................ 33
Ignition monitoring ................................................................................................................................. 33
Rod electrode (MMA) welding .................................................................................................................... 34
Safety ..................................................................................................................................................... 34
Tooling up .............................................................................................................................................. 34
Selecting the operating mode ................................................................................................................ 35
Selecting the process (MagicWave) ...................................................................................................... 35
Setting the parameters .......................................................................................................................... 35
Remote control mode ................................................................................................................................. 36
Safety ..................................................................................................................................................... 36
Remote control mode - general remarks ............................................................................................... 36
AC Remote control TR 53mc ................................................................................................................. 36
TIG pulse remote control TR 50mc ........................................................................................................ 37
TIG pedal remote control TR 52mc ....................................................................................................... 39
TIG spot welding remote control TR 51MC ........................................................................................... 40
TP MC/TP MC-CEL remote control ....................................................................................................... 41
Working with program levels ....................................................................................................................... 43
Overview ................................................................................................................................................ 43
Preliminary settings program level .............................................................................................................. 44
Accessing .............................................................................................................................................. 44
Selecting and altering the set-up parameter .......................................................................................... 44
Available parameters ............................................................................................................................. 44
Program levels P1 - P3 ............................................................................................................................... 48
Accessing .............................................................................................................................................. 48
Selecting and altering the set-up parameter .......................................................................................... 48
Service menu program level P1 ............................................................................................................. 48
Code lock program level P2 ................................................................................................................... 48
AC parameters program level P3 .......................................................................................................... 49
(Magic Wave) ......................................................................................................................................... 49
Troubleshooting .......................................................................................................................................... 50
Safety ..................................................................................................................................................... 50
Displayed service codes ........................................................................................................................ 50
Power source ......................................................................................................................................... 52
Care, maintenance and disposal ................................................................................................................ 54
General remarks .................................................................................................................................... 54
Every start-up ......................................................................................................................................... 54
Every 2 months ...................................................................................................................................... 54
Every 6 months ...................................................................................................................................... 54
Disposal ................................................................................................................................................. 54
Technical data ............................................................................................................................................. 55
Special voltages ..................................................................................................................................... 55
MagicWave 2600/2600CEL ................................................................................................................... 55
MagicWave 3000 ................................................................................................................................... 56
TransTig 2600/2600CEL ........................................................................................................................ 57
TransTig 3000 ........................................................................................................................................ 58
Spare parts list
Fronius Worldwide
2
General remarks
Basic system The TIG power sources MW 2600/2600 CEL/3000 (AC/DC), TT 2600/2600 CEL/3000
EN
principle (DC), designed as primary switched mode welding machines, are the successors to
transistor-controlled welding machines. The supply voltage is rectified and chopped by
a fast transistor switch at 80 kHz. An electronic adjuster adapts the power source
characteristic to the selected weld process.
Another interesting feature is the automatic cap-shaping function for AC welding using
the Magic Wave power sources. This function takes the diameter of the tungsten
electrode into account to help produce optimum results.
Fig.1 MW 2600, TransTig 3000 and MagicWave 3000 power sources with cooling unit and trolley
Machine concept Among the typical features of the power sources are their extreme flexibility and adap-
tability to many types of task. The reasons for these welcome characteristics may be
found not only in the modular product design, but also in the scope that the system
gives for troublefree system add-ons.
You can adapt your power source to practically any specific situation. For example, the
welding current can be adjusted continuously via the torch trigger. In addition, there is a
comprehensive selection of remote control systems for the most varied areas of appli-
cation.
Areas of utilisati- In the workshop and industry, the MagicWave and TransTig can be used for numerous
on applications. They are the ideal power sources for manual welding as well as automa-
ted and robotic tasks. As regards their suitability for welding different materials, they are
just as much “at home” welding unalloyed and low-alloy steel as they are welding high-
alloy, chrome-nickel steels.
These “all-rounder” qualities are enhanced by the machines’ optimised ignition se-
3
Areas of utilisati- quence. For TIG-AC welding, the MagicWave takes account not only of the diameter of
on the electrode, but also of its temperature, calculated with reference to the preceding
(continued) welding and weld-off times.
Moreover, the MagicWave does sterling service when it comes to welding aluminium,
aluminium alloys and magnesium. The AC frequency can be adjusted over a very wide
range, permitting optimum adaptation to your particular requirements.
All power sources are generator-compatible and are exceptionally sturdy in day-to-day
operation, thanks to the protected controls and their powder coated housings. The
wealth of different operating modes and special functions available makes these power
sources just as good at rod electrode welding as they are at TIG welding.
4
Warning notices US power sources come with extra warning labels affixed to the unit. The warning
affixed to the labels must NOT be removed or painted over.
machine
EN
Fig.3 US power source with additional warning signs
5
Minimum equipment needed for welding
General remarks Depending on which weld process you intend to use, a certain minimum level of equip-
ment will be needed in order to work with the power source.
In the section below, you will find lists of what equipment is needed (as a minimum) for
welding with each of the weld processes.
TIG-AC welding - MagicWave power source

- Grounding (earthing) cable
- TIG welding torch with rocker switch
- Gas connection (for supplying the machine with shielding gas), with pressure
regulator
- Filler metal (depending on the application)
TIG-DC welding - TransTig or MagicWave power source

- Grounding (earthing) cable
- TIG welding torch with rocker switch
- Gas connection (for supplying the machine with shielding gas)
- Filler metal (depending on the application)
Rod electrode - TransTig or MagicWave power source

(MMA) welding - Grounding (earthing) cable
- Electrode holders
- Rod electrodes (as required by the application)
6
System components
General remarks The TransTig and MagicWave power sources can be used with a wide variety of system
add-ons and options.
EN
Overview
TIG welding torch

Standard/Up/Down
Remote control unit
Power source
Electrode cable
Grounding (earthing) cable
Cooling unit Trolley with

gas cylinder holder
Fig.4 System add-ons and options
7
Control panel
General remarks
Warning! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have read and
completely understood all of the following documents:
- these Operating Instructions
- all “Operating Instructions” for the system components, especially the
“Safety rules”
The key feature of the control panel is the logical way in which the controls are arran-
ged. All the main parameters needed for day-to-day working can easily be
- selected with the buttons
- altered with the potentiometer
- shown on the display during welding.
Note! Owing to firmware updates, you may find that your machine has certain
functions that are not described in these Operating Instructions, or vice-versa.
Also, certain illustrations may be slightly different from the actual controls on
your machine. However, these controls function in exactly the same way.
Overview The illustration below shows an overview of the main settings needed for day-to-day
working, using the MagicWave control panel as an example. You will find a detailed
description of these settings in the following „Description of Functions“ section.
1. Selecting the operating mode:
2-step mode
4-step mode
3. Downslope
Touchdown ignition
Rod electrode (MMA)
1. Balance controller
(MagicWave only)
2. Adjuster for
tungsten electrode
(MagicWave only)
4. Main current controller

2. Choose the process:
(only with MagicWave)
5. Final (i.e. “end”) current
AC welding
DC- welding
DC+ welding
(only with rod electrode)
8
Magic Wave
control panel (1) (13) (2)
(7)
(6)
EN
(19) (5)
(20)
(11) (4)
(9) (3)
(8)
(12)
(10)
(16)
(17)
(14) (15) (18)
Fig.5 MagicWave 2600/2600 CEL/3000 control panel
Trans Tig control

panel (1) (13) (2)
(7)
(6)
(19) (5)
(20)
(11) (4)
(9) (3)
(8)
(12)
(10)
(14) (15)
Fig.6 TransTig 2600/2600 CEL/3000 control panel
9
Description of
functions
“Safety rules”
(1) Welding current display ... for indicating the main current IH
- Command value ... desired welding current
- Actual value ... actual welding current
(2) Welding voltage display

- for displaying the actual welding voltage
(3) Mode button

(7) 2-step mode ... TIG welding with high frequency ignition
(6) 4-step mode ... TIG welding with high frequency ignition
+ (7) + (5) TIG - 2-step mode with touchdown ignition
+ (6) + (5) TIG - 4-step mode with touchdown ignition
- Arc-force dynamic and hot start are disabled

- remote controllers TR 50mc, TR 51mc and TR 52mc switch to the appropri-
ate mode automatically
(4) Rod electrode (MMA) welding
- Open circuit voltage is displayed

- LED indicator IH only lights up during the welding process
- preset values for arc-force dynamic and hot start apply
- the parameters can be altered using TPmc remote control and internal
menu
(8) Starting current LED indicator IS ... lights up when the starting current IS is active
(9) Main current LED indicator IH ... lights up when the main current IH is active
(10) Downslope adjuster ... continuously adjustable current reduction speed from main
current to final current IE. Using the adjuster displays the set value for 3 s.
(11) Final current LED indicator IE ... lights up when the final current IE is active
(12) TIG pulse welding LED indicator ... flashes when the TIG pulse remote control
TR50mc is connected.
10
Description of (13) HOLD indicator ... every time you finish a welding operation, the actual values for
functions welding current and voltage are stored, and the “Hold” indicator lights up.
(continued)
The “Hold” indicator refers to the last value reached by the main current IH.
The “Hold” indicator is cancelled whenever:

- a new welding operation is started
EN
- the main current IH is adjusted
- the operating mode is changed
- the process is changed
- the power source is switched off and on again
Important! If the main current phase was never reached, a pedal remote control
unit was being used, or TIG pulse welding was carried out below 20 Hz, no “Hold”
values are output.
(14) Main current adjuster IH ... continuous adjustment in the 3-260/300 A range.
The main current LED indicator IH lights up when the „Rod electrode (MMA) wel-
ding“ mode is selected.
Before welding begins, the welding current display shows the command value for
IH. After welding begins, the actual welding current value is displayed.
(15) Final current adjuster IE ... for adjusting final current as a percentage of the main
current.
Can only be adjusted in 4-step mode. Reduction takes place using the torch trigger.
(16) Balance controller (MagicWave only) ... function only possible in AC range.
Altering the positive and negative half wave.
-5: highest fusing power, lowest cleaning action.

+5: highest cleaning action, lowest fusing power.
(17) Adjuster for tungsten electrode diameter (Magic Wave only) ... setting range 0-4
mm (0-0.16 in.)
AC mode:
- for automatic cap shaping (see section „TIG Welding“)
- for adjusting the ignition current according to the diameter of the tungsten
electrode.
DC mode:
- for adjusting the ignition current according to the diameter of the tungsten
electrode.
Important! In electrode mode, the adjuster is deactivated.
11
Description of (18) Process button ... for selecting the process, depending on which operating
functions mode has been selected.
(continued)
If 2-step/4-step mode has been selected:
TIG DC-welding
TIG AC-welding
If “Rod electrode (MMA) welding mode” has been selected:
Rod electrode DC+ welding

Rod electrode DC-welding
Rod electrode AC-welding
(19) Overtemperature indicator ... lights up if the power source overheats (e.g. becau-
se the duty cycle has been exceeded). For more information on this, see the
“Troubleshooting” section.
(20) „S“ indicator ... lights up when the monitor function is active.
12
Connections, switches and system add-ons
Magic Wave/ (21) (22) (23) (21) (22) (23)
EN
Trans Tig con-
nections with
Fronius central
torch connector
F
(27) (26) (25) (24) (27) (26) (25) (24)

Fig.7 Magic Wave connections on the front of the Fig.8 Trans Tig connections on the front of the
machine machine
(21) Remote control connection socket ... standardised connection socket for system
add-ons
(22) Torch control connection socket ... for connecting the welding torch control plug
(23) Magic Wave: Grounding (earthing) cable connection socket ... for connecting
the grounding (earthing) cable
TransTig: (+) - current socket with bayonet latch ... for connecting
- the grounding (earthing) cable when TIG welding
- the electrode (or grounding/earthing) cable in rod electrode (MMA) welding,
depending on the type of electrode being used
(24) Magic Wave: welding torch connection socket ... for connecting the electrode
cable for rod electrode (MMA) welding
TransTig: (-) - current socket with bayonet latch ... for connecting
(25) TIG welding torch connection socket ... for connecting the TIG welding torch
(26) Water flow connection socket ... for connecting a water-cooled welding torch
(27) Water return connection socket ... for connecting a water-cooled welding torch
13
Magic Wave/ (21) (22) (23) (21) (22) (23)
Trans Tig con-
nections with
central torch
connector GWZ
(28) (26) (25) (24) (28) (26) (25) (24)

Fig.9 Magic Wave connections on the front of the Fig.10 Trans Tig connections on the front of the
machine machine
(21) Remote control connection socket ... standardised connection socket for system
add-ons
(22) Torch control connection socket ... for connecting the welding torch control plug
(23) Magic Wave: grounding (earthing) cable connection socket ... for connecting
the grounding (earthing) cable
TransTig: (+) - current socket with bayonet latch ... for connecting
- the grounding (earthing) cable when TIG welding
(24) Magic Wave: welding torch connection socket ... for connecting the electrode
cable for rod electrode (MMA) welding
TransTig: (-) - current socket with bayonet latch ... for connecting
(25) TIG welding torch connection socket ... for connecting

- the TIG welding torch
- the water supply (water return) of a water-cooled TIG welding torch
(26) Water flow connection socket ... for connecting a water-cooled welding torch
(28) Shielding gas connection socket
14
Connections and
switches on the
rear of the machi-
ne (29)
(30)
EN
(31)
(32)
Fig.11 Connections and switches on the rear of the

machine
(29) Mains switch ... for switching the power source on and off
(30) Shielding gas connection socket
(31) Gas-test button ... for setting the required gas-flow rate on the pressure regulator.
When the gas-test button is pressed, shielding gas flows out.
(32) Mains cable with strain relief device
15
Before commissioning
Safety
“Safety rules”
Utilisation in The power source may ONLY be used for TIG welding and rod electrode (MMA) wel-
accordance with ding.
„intended purpo- Utilisation for any other purpose, or in any other manner, shall be deemed to be „not in
se“ accordance with the intended purpose“. The manufacturer shall not be liable for any
damage resulting from such improper use.
Utilisation in accordance with the “intended purpose” also comprises

- following all the instructions given in this manual
- performing all stipulated inspection and servicing work.
Machine set-up The power source is tested to IP 23, meaning:

regulations - protection against penetration by solid foreign bodies with diameters Ø 12.5 mm
(.49 in.)
- protection against spraywater up to an angle of 60° to the upright
Warning! A machine that topples over or falls from its stand can easily kill
someone. Place equipment on an even, firm floor in such a way that it stands
firmly.
The venting duct is a very important safety feature. When choosing the machine locati-
on, ensure that the cooling air can enter and exit unhindered through the air ducts on
the front and back of the machine. Any electroconductive metallic dust (e.g. from grin-
ding work) must not be allowed to get sucked into the power source.
Mains connec- The equipment is designed to run on the mains voltage given on the respective rating
tion plates. If your version of the machine does not come with the mains cables and plugs
ready-mounted, these must be mounted in accordance with your national regulations
and Standards. For details of fuse protection of the mains supply lead, please see the
Technical Data.
Note! Inadequately dimensioned electrical installations can lead to serious

damage. The mains lead, and its fuse protection, must be dimensioned accor-
dingly. The technical data shown on the rating plate shall apply.
16
Generator- The power sources are generator-compatible, provided that the maximum apparent
powered operati- power delivered by the generator is at least:
on - MW 2600/TT 2600: 18 kVA
- MW 2600 CEL/TT 2600 CEL: 20 kVA
- MW 3000/TT 3000: 22 kVA
Note! The voltage delivered by the generator must NEVER fall below or ex-
EN
ceed the mains voltage tolerance range. Details of the mains voltage tolerance
are given in the section headed “Technical data”.
17
Commissioning
General remarks
Warning! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the machine when
- the mains switch is in the “O” position,
- the machine is unplugged from the mains.
This section describes how to put the power source into service:
- for the principal application (TIG welding)
- with reference to a standard configuration for a TIG welding installation.
The standard configuration consists of the following components:

- Power source
- Cooling unit
- TIG manual welding torch
- Pressure regulator
- Gas cylinder
- Gas cylinder holder
- Trolley
The steps set out below will give you an overview of how to put the power source into
service.
For detailed information on each of these steps, please refer to the instruction manuals
for the appliances in question.
Remarks on the We recommend using a cooling unit for the following applications and situations:
cooling unit - Robot welding
- Hosepacks over 5 m long
- TIG-AC welding
- In general, where welding is performed in higher power ranges
The cooling unit is powered from the power source. The cooling unit is ready for opera-
tion when the mains switch of the power source is in the “I” position.
Connecting the
Caution! Risk of injury from gas cylinder toppling over.
gas cylinder
- Always use a safety strap
- 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
- Fix the gas cylinder to the trolley

- Connect up the gas cylinder:
- Take the protective cap off the gas cylinder
- Briefly turn the gas cylinder valve anticlockwise to blow off any dust and dirt
- Inspect the seal on the pressure regulator
- Screw the pressure regulator onto the gas cylinder and tighten it
18
Connecting the When using a TIG welding torch with an integral gas connector:
gas cylinder - On the rear of the power source, connect the pressure regulator to the shielding
(continued) gas connection socket using the gas hose
- Tighten the swivel nut
When using a TIG welding torch with no integral gas connector:

- Connect the gas hose to the pressure regulator
EN
Establishing a - Move the mains switch to the “O” position
connection to the - Plug the grounding (earthing) cable into the “plus” current socket and twist it to
workpiece fasten it
- With the other end of the grounding (earthing) cable, establish a connection to the
workpiece
Connecting the - Move the mains switch to the “O” position

welding torch - Plug the welding cable of the TIG torch into the “minus” current socket and twist it
clockwise to latch it into place
- Plug the control plug of the welding torch into the torch control connection and twist
it to fasten it
- Tool up the welding torch (see the instruction manual for the torch)
When using a TIG welding torch with an integral gas connector:

- On the rear of the power source, connect the pressure regulator to the shielding
gas connection socket using the gas hose
Only when using a water-cooled torch:

- Plug the welding torch water connectors into the water flow and return connections
on the cooling unit.
19
TIG operating modes
General remarks
“Safety rules”
Please see the section headed “Preliminary settings program level” for information on
the settings, setting range and units of measurement of the available parameters.
Symbols and
their explanati-
ons
Pull back and hold the Release the torch trigger Briefly pull back the
torch trigger torch trigger (< 0.5 s)
Briefly push the torch Push forward and hold the Release the torch trigger
trigger forwards (< 0.5 s) torch trigger
Symbol Explanation
GAS Gas pre-flow time
IS Starting current phase: the temperature is raised gently, at low welding
current, so that the filler metal can be positioned correctly
tup Upslope phase: the starting current is continuously increased until it
reaches the welding current
IH Welding current phase: uniform thermal input into the base metal, whose
temperature is raised by the advancing heat
tdown Downslope phase: the welding current is continuously lowered until it
reaches the final current.
IE Crater-fill phase: to prevent any local overheating of the base metal due to
heat build-up towards the end of welding. This eliminates any risk of weld
drop-through.
SPt Spot-welding time
G-H / G-L Gas post-flow time
20
2-step Select 2-step mode (2)
Important! The Sts parameter must be set to „OFF“ (see section „Preliminary
settings program level“). The factory setting (i.e. in which the power source is
delivered) is: parameter StS “OFF”.
- Welding: pull back and hold the torch trigger
EN
- End of welding: release trigger
I IH
GAS tup tdown G-H

G-L
Fig.12 2-step mode
21
Special 2-step Select 2-step mode (2)
Important! The Sts parameter must be set to “ON” (see section “Preliminary
settings program level”). The factory setting (i.e. in which the power source is
delivered) is: parameter StS “OFF”.
- Welding: pull back and hold the torch trigger

I IH
GAS G-L
G-H
Fig.13 Special 2-step mode
22
4-step Select 4-step mode
Important! The SFS parameter must be set to „OFF“ (see section „Prelimina-
ry settings program level“). The factory setting (i.e. in which the power source
is delivered) is: Parameter SFS = “OFF”.
- Welding start-up with starting current IS: Pull back and hold the torch trigger
EN
- Welding with main current IH: Release the torch trigger
- Lowering to final current IE: Pull back and hold the torch trigger
I I1
IE
IS
t
GAS tup tdown G-L
G-H
Fig.14 4-step mode
23
4-step with In the variant of the 4-step mode illustrated below, an “intermediate lowering” of the
intermediate welding current to IE takes place. This is initiated by pushing forward and holding the
lowering trigger.
- Select 4-step mode
Important! The SFS parameter must be set to „OFF“ (see section „Preliminary settings
program level“). The factory setting (i.e. in which the power source is delivered) is:
Parameter SFS = “OFF”.
- For intermediate lowering of the welding current to the pre-set reduced current IE
during the main current phase: Push forward and hold the torch trigger
- To return to the main current:release the torch trigger
I IH IH
IE IE
IS
t
GAS tup tdown G-L

G-H
Fig.15 4-step mode with intermediate lowering
24
Special 4-step: The variant of the special 4-step mode illustrated below enables intermediate lowering
variant 1 to the pre-set reduced current I3. This is done by briefly pushing the torch trigger for-
wards on TIG torches without the double pushbutton function. When the torch trigger is
briefly pushed forward a second time, the voltage returns to the main current IH.

- Set the SFS set-up parameter to “1”
EN
(see: “Preliminary settings program level”)
I IH IH
I3
IE
IS
t
GAS tup tdown G-L
G-H
Fig.16 Special 4-step mode: Variant 1
25
Special 4-step: The variants of the special 4-step mode illustrated below enable intermediate lowering
variant 2-4 to the pre-set reduced current using TIG torches with double pushbutton function.

- Set the SFS set-up parameter to “2, 3, 4 or 5” for the desired variant
(see: “Preliminary settings program level”)
I IH IH
IE IE
IS
t
GAS tup tdown tup tdown G-L
G-H
Fig.17 Special 4-step mode: variant 2
I IH IH
IE IE
IS
t
GAS tup tdown tup tdown G-L

G-H
26
Special 4-step:
variant 2-4
(continued)
EN
I IH IH
IE
IS
t
GAS tup tdown tup G-L

G-L
Special 4-step: The variant of the special 4-step mode illustrated below allows the welding current to be
variant 5 increased or decreased without an up/down torch.
The longer the torch button is held in the forward position during welding, the more the
welding current increases (up to the maximum).
The welding current remains constant when the torch button is released. The longer the
torch button is pushed forward again, the more the welding current decreases.
IH >
I
IH
IH <
IE
IS
GAS tup tdown G-L

G-H
27
TIG welding
Safety
- all operating instructions for the system components, especially the
“Safety rules”
Tooling up - Unplug the machine from the mains

- Move the mains switch to the “O” position
- Plug the grounding (earthing) cable into the “plus” current socket and twist it to
fasten it
- Use the other end of the grounding (earthing) cable to establish a connection to the
workpiece
- Plug the welding cable of the TIG torch into the “minus” current socket and twist it
clockwise to latch it into place
- Plug the control plug of the welding torch into the torch control connection and twist
it to fasten it
- Tool up the welding torch (see the instruction manual for the torch)
- Screw the pressure regulator onto the gas cylinder and tighten it
When using a TIG welding torch with an integral gas connector:

- On the rear of the power source, connect the pressure regulator to the shielding
gas connection socket using the gas hose
Only when using a water-cooled torch and cooling unit:

- Plug the welding torch water connectors into the water flow and return connections
on the cooling unit.
- Plug in the mains plug
Only when using a remote control:

- Connect remote control to the remote control connection socket
28
Selecting the
Caution! Risk of injury and damage from electric shock. As soon as the mains
operating mode
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 electri-
cally conducting or earthed parts (e.g. housing etc.)
- Move the mains switch to the “I” position
EN
(7)
(6)
(3)
(7+5)
(6+5)
(3)
Press the “Mode” button (3) to select either:

- 2-step mode (7) with high frequency ignition
- 4-step mode (6) with high frequency ignition
- 2-step mode (7+5) with touchdown ignition
- 4-step mode (6+5) with touchdown ignition
Note! Do not use pure tungsten electrodes (colour-coded green) on TransTig

power sources.
Selecting the - Press the “Process” button to select:

process (Magic-
Wave) AC welding process or
DC welding process
29
Cap-shaping Where the AC welding process has been selected, automatic cap-shaping is available
(MagicWave) on the MagicWave power sources. This function takes account of the pre-set electrode
diameter in order to achieve the best results.
The automatic cap-shaping function

ensures that the optimum electrode tip
shape is formed automatically during the
welding start-up. A separate cap-shaping
operation on a test piece is no longer
necessary.
Before ignition After ignition

Fig.21 Cap-shaping
Note! The “AC welding process with activated cap-shaping function” is not
necessary if there is already a sufficiently large cap at the tip of the tungsten
electrode.
Using the tungsten electrode adjuster, set the electrode diameter.

Activate cap-shaping by briefly pushing the torch trigger forward.
Setting the Set the desired parameters using the potentiometer on the control panel.
parameters
A list of the parameters available in the program levels can be found in “Preliminary
settings program level”.
Setting the - Press the “Gas test” button

shielding gas - Set the desired shielding gas flow rate
flow rate
Arc ignition - For an optimised ignition sequence when the TIG-AC welding process has been se-
general remarks lected, the MagicWave power sources take account of the diameter of the electrode.
They also take account of the electrode’s actual temperature, calculated with reference
to the preceding welding and weld-off times.
TIG synchronous For mains synchronisation of two power sources for simultaneous AC welding.
welding AC
(Magic Wave) For details of setting the SYn parameter, see „Program levels P1-P3“, subsection „AC
parameters program level P3“.
Note! The phase sequence must be the same on both machines.
30
HF ignition For details of how to adjust the set-up parameter “HFt”, please refer to the section
headed “Preliminary settings program level”.
Use the HFt parameter to set the time interval of the HF pulses to 0.01 s. The factory
setting (i.e. in which the power source is delivered) for the HFt parameter is 0.01s.
Note! If there are problems with sensitive equipment in the immediate vicinity,
EN
increase the HFt parameter to a maximum of 0.4 s.
Compared with touchdown ignition, HF ignition eliminates the risk of contamination of

the electrode and of the workpiece.
31
HF ignition To ignite the arc, proceed as follows:
(continued)
- Place the gas nozzle down on the
ignition location in such a way that
there is a gap of approx. 2 to 3 mm
(0.08 to 0.12 in.) between the tungs-
ten electrode and the workpiece.
Fig.22 Placing the gas nozzle down
- Increase the tilt angle of the torch,

and actuate the torch trigger in the
sequence required for the operating
mode you have selected
(see the section headed “TIG opera-
ting modes”)
- The arc ignites, without the electrode
touching down on the workpiece
Fig.23 Non-contact HF ignition
- Tilt the torch back into the normal

position
Fig.24 Welding
32
Touchdown To ignite the arc, proceed as follows:
ignition
- Place the gas nozzle down on the
ignition location in such a way that
there is a gap of approx. 2 to 3 mm
(0.08 to 0.12 in.) between the tungs-
ten electrode and the workpiece.
EN
Fig.25 Placing the gas nozzle down
- Actuate the torch trigger - the shiel-

ding gas starts to flow
- Gradually tilt the torch up until the
tungsten electrode touches the
workpiece
Fig.26 Arc ignites when electrode touches down on

workpiece
- Raise the torch and tilt it into the
normal position; the arc now ignites
Fig.27 Welding
Ignition monito- If no arc appears within 5 seconds, the power source cuts out automatically. To make
ring another attempt to achieve ignition, press the torch trigger again.
33
Rod electrode (MMA) welding
Safety
“Safety rules”
Switch off any cooling units at hand (see “Preliminary settings program level”, subsec-
tion “TIG parameters”, C-C ... Cooling unit control)
Tooling up - Unplug the machine from the mains

- Move the mains switch to the “O” position
- Disconnect the TIG welding torch
Important! The TransTig power source has no switchover facility between the rod
electrode DC- and rod electrode DC+ welding processes.
To change over from the rod electrode DC- welding process to the rod electrode DC+
welding process on the TransTig power source, reconnect the electrode holder and the
grounding (earthing) cable to the opposite welding sockets (i.e. swap them over).
- Plug the grounding (earthing) cable into the “plus” current socket and twist it to
fasten it
- With the other end of the grounding (earthing) cable, establish a connection to the
workpiece
- Plug the welding cable into the “minus” current socket and twist it clockwise to latch
it into place
- Plug in the mains plug
Only when using a remote control:

- Connect remote control to the remote control connection socket
34
Selecting the
Caution! Risk of injury and damage from electric shock. As soon as the mains
operating mode
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 switch to the “I” position
EN
Press the “Mode” button (3) to select
either:
- Rod electrode (MMA) welding mode
(5)
(5)
(3)
Selecting the - Press the “Process” button to select:

process (Magic-
Wave) AC welding process or
DC- welding process
DC+ welding process
Setting the A list of all the available parameters can be found in the section headed: “Preliminary
parameters settings program level”.
- Welding voltage display shows open-circuit voltage

- Connect TPmc remote control, if applicable (set arc-force dynamic and hot start)
- Preselect welding current IH
- Start welding.
35
Remote control mode
Safety
“Safety rules”
Remote control A remote control system is advisable if the settings are to be made directly from the
mode - general welding location. The remote control is connected to the power source using special
remarks remote control cables in 5 or 10 m (197 or 394 in.) lengths.
The following types of remote control are available:

- TIG and manual electrode remote control (AC) TR53mc
- Manual electrode and TIG remote control (DC) TPmc
- TIG pulse remote control (AC/DC) TR50mc
- TIG spot welding remote control (DC) TR51mc
- TIG pedal remote control (AC/DC) TR52mc
AC Remote The AC-remote control TR 53mc is especially suited to TIG-AC welding. The following
control TR 53mc parameters can be set using the remote control:
- Main welding current IH
- AC Balance
- AC frequency
(33)
(34)
(35)
Fig.28 AC-remote control TR53 mc
36
AC Remote (33) Main current adjuster IH ... for continuous adjustment of the welding current
control TR 53mc
(continued) (34) AC arc frequency adjuster ... for altering the arc concentration
(35) Balance adjuster ... for changing the positive and negative half wave in manual
electrode and TIG-AC welding.
EN
Important! When using the remote control for manual electrode welding in the AC or
DC range, the values set in the machine for hot start current, hot start time and arc
force apply. (See „Preliminary settings program level“)
TIG pulse remote Connect TIG pulse remote control to the connection socket.
control TR 50mc
(12)
- TIG pulse welding indicator (12) flashes as soon as the remote control is con-
nected.
Two modes are available on the pulse remote control TR 50mc:

- Impulse current adjustment I1 on remote control TR 50mc
- Impulse current adjustment I1 with pedal remote control TR 52mc
(36) (38)
(39)
(37) (40)
(41)
(42)
Fig.29 TIG pulse remote control TR 50mc
(36) Pulse current adjuster I1 ... for continuous adjustment of the pulse main current
(37) Pulse frequency adjuster f ... for continuous adjustment of pulse frequency
depending on the preselected frequency range (40)
(38) Background current adjuster I2 ... for setting the background current as a percen-
tage of the set value of the pulse current I1 (36)
(39) Duty cycle adjuster dcY ... for setting the pulse current phase and background
current phase ratio as a percentage.
Setting example for low heat insertion:

Duty cycle adjuster in position „10“
- short pulse current phase of 10%
- long background current phase of 90%
37
TIG pulse remote (40) Frequency range adjuster ... for preselecting the desired frequency in stages
control TR 50mc
(continued) Setting ranges:
- 0.2-2 Hz
- 2-20 Hz
- 20-200 Hz
- 200-2000 Hz
The diagram below illustrates TIG pulsing in cases where the DC welding process has
been selected.
1/F-P dcY
I
I1
IE
I2 IS
tup tdown t
Fig.30 TIG pulsing - welding current curve
Legend:
- IS ......... Starting current - dcY ..... Duty cycle
- IE ......... Final (i.e. “end”) current - I2 ......... Background current
- tUp ....... Upslope - I1 ......... Main current
- tDown .... Downslope
- F-P ..... Pulsing frequency
(1/F-P = time interval between 2
pulses)
(41) Power source connection socket ... for connecting the remote control to the
power source
(42) Pedal remote control connection socket ... for connecting the pedal remote
control TR 52mc. Especially useful for TIG manual welding. The pulse welding
current can be altered during the welding process (e.g. variable material strength).
38
TIG pedal remote The TIG pedal remote control TR 52mc is especially suited to welding complex workpi-
control TR 52mc ece shapes.
EN
Fig.31 TIG pedal remote control TR 52mc
Function:
- 2-step mode indicator lights up once the remote control is connected (automatic
switchover)
- Set main current adjuster IH to desired maximum current
- Set gas pre-flow and post-flow time directly at the power source (see “Preliminary
settings program level”)
- Start ignition by pressing down lightly on the pedal
- Starting current IS, main current IH and final current can be controlled using the
pedal
Important! When pressing down on the pedal, the welding current does not ex-
ceed the preselected value.
- Take your foot off the pedal to turn off the welding current
- The welding process is interrupted, the gas post-flow time expires
I IH
GAS G-H
G-L
Fig.32 Function sequence using pedal remote control TR 52mc
39
TIG spot welding Welding stainless light-gauge sheet is often not possible due to severe warping of the
remote control material. Similarly, joints that are only accessible on one side can be managed without
TR 51MC any problems using the TIG spot welding process.
Important! With TIG spot welding, aluminium materials can usually only be joined
badly, if at all. The layer of oxide between the plates cannot be removed.
(43) Spot welding current adjuster I1
(44) Remote control connection socket
(45) Spot welding time adjuster SPt (0.1-8

s)
(43)
(45)
(44)
Fig.33 TIG spot welding remote control TR 51MC
Function sequence:
- 2-step mode indicator lights up once the remote control is connected (automatic
switchover)
- Set downslope on the power source
- Use special spot-welding nozzle (insulated on cone)
- Fit the tungsten electrode back from the edge of the nozzle (approx. 2-3 mm (0.10
in.) depending on spot size)
- Place welding torch onto sheet and apply light pressure to the base metal
- Begin spot-welding (avoid air gap)
I I1
GAS tup tdown G-L
SPt G-H
Fig.34 Spot welding
40
Remote control The TP MC/TP MC-Cel remote control is especially suited to manual electrode and TIG-
TP MC/TP MC- DC welding.
CEL
EN
(46)
(46)
(47)
(48)
5
40 60
3 7
20 80
1 9 0 100
DYNAMIC HOT START
(49) (47) (48) (50)

Fig.35 Remote control TP mc Fig.36 Remote control TP mc-CEL
(46) Welding current adjuster ... for continuous adjustment of the welding current
(47) Arc-force dynamic adjuster ... dYn - dynamic - arc force dynamic correction
In order to obtain optimum welding results, it will sometimes be necessary to adjust

the arc-force dynamic. For details on setting the “dYn” parameter, please see the
section headed “Preliminary settings program level”, sub-section “Rod electrode
set-up parameters”.
Functional principle
At the instant of droplet transfer, or when a short circuit occurs, there is a momenta-
ry rise in the current. In order to obtain a stable arc, the welding current is tempora-
rily 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”.
Setting range of the dYn parameter

0 ........ soft, low-spatter arc
10 ....... harder, more stable arc
(48) Hot start adjuster ... In order to obtain optimum welding results, it will sometimes
be necessary to set or adjust the hot start function.
Advantages:
- Improved ignition, even when using electrodes with poor ignition properties
- Better fusion of the base metal in the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions
41
Remote control For details on setting the available parameters, please see the section headed „Prelimi-
TP MC/TP MC- nary settings program level“.
CEL
(continued) Legend
I (A)
Hti HTI ...... Hot current time,
0-2 s, factory setting: 0.5 s
150 HCU .... Hot start current, 0-100%
I1 .......... Main current = pre-set welding
HCU current
100
Mode of functioning
During the pre-set hot current time (Hti),
I1 the welding current is increased to a
certain value. This value (HCU) is 0-100%
higher than the pre-set welding current
t (s) (I1).
0,5 1 1,5
Fig.37 Example of “Hot-Start” function
(49) Polarity switch ... for switching between electrode polarities
Important! Manual electrode cable must be connected to the connection socket (24).
(24)
(50) Range switch for TIG/electrode
42
Working with program levels
Overview The illustration below shows an overview of the parameter settings in the preliminary
EN
settings program level, using the MagicWave control panel as an example. A detailed
description of these settings can be found in the following sections.
Rod electrode set-up parameters:

Hti ......
hot-current time
HCU .. hot start current
dYn .... arc force dynamic correction
PRO .. store program
FAC ... reset welding machine
“Mode” button (3)
“Process” button (18)
TIG parameters:
GAS ... gas pre-flow
G-L .... gas post-flow at minimum welding
current
G-L .... gas post-flow at maximum welding
current
UPS ... upslope
SCU ... start current - as % of IH
I3 ....... reduced current
HFt .... high frequency
SCU ... start current rel/abs
StS ..... special 2-step mode
SFS ... special 4-step mode
C-C .... cooling unit control
E-S .... power source switch-off
PRO .. store program
FAC ... reset
WIG AC:
as WIG DC mode
43
Preliminary settings program level
Accessing 1. Select desired mode: TIG or electrode

2. Switch off power source
3. Switch on the power source with the mode button (3) or process button (18)
pressed. „—“ appears for preliminary settings level.
4. Release mode button (3) or process button (18)
Selecting and - Select desired parameter using mode button (3) or process button (18)
altering the set- - Alter the parameter value using the torch trigger
up parameter
Available para- Parameters available in TIG mode

meters
GAS - gas pre-flow
unit s
setting range 0 - 20
factory setting 0,4
G-L
Gas-Low - gas post-flow at minimum welding current (minimum gas post-flow time)
unit s
factory setting 5
G-H
Gas-High - gas post-flow time at maximum welding current
unit s
factory setting 15
The value set for G-H only applies if the maximum welding current really has been set.
The actual value is derived from the instantaneous welding current. With a medium
welding current, for example, the actual value will be one-half of the value set for G-H.
UPS
Upslope - time it takes for transition from starting current IS to welding current IH
unit s
setting range 0.1 - 7
factory setting 1.0
44
Available para-
SCU
meters
Start current
(continued)
unit %
setting range DC: 0 - 100/AC: 30 - 100 of the main current IH
factory setting DC: 29/AC: 50
EN
I3 - reduced current
unit %
setting range 0 - 100 of the main current IH
factory setting 50
HFt
High frequency time - High-frequency ignition: time interval between the HF pulses
unit s
setting range 0.01 - 0.4
factory setting 0.01
Note! If there are problems with sensitive equipment in the immediate vicinity,
increase the HFt parameter to a maximum of 0.4 s.
SCU
Start current
unit -
setting range rel/abs
factory setting rel
StS
Special two-step mode
unit -
setting range ON/OFF
factory setting OFF
SFS
Special four-step mode
unit -
setting range OFF/1 -5
factory setting OFF
The special 4-step mode variants are described in the section headed “Operating
modes”.
C-C
Cooling unit control (optional)
unit -
setting range Aut/ON/OFF
factory setting Aut
“Aut” position ........ Cooling unit is switched off 2 minutes after the end of welding
“ON” position ........ Cooling unit is ON all the time

“OFF” position ...... Cooling unit is OFF all the time
45
Available para-
E-S
meters
Emergency stop - for stopping the power source via the robot
(continued)
unit -
factory setting OFF
PRO
Program - store the set parameters by pressing the torch trigger
FAC
Factory - reset welding machine by pressing the torch trigger
Available parameters where the “Rod electrode (MMA) welding” mode has been se-
lected:
Hti
Hot current time
unit s
setting range 0,2 - 2,0
factory setting 0,5
HCU
Hot start current
unit %
factory setting 50
In order to obtain optimum welding results, it will sometimes be necessary to adjust the
hot start function.
Advantages
- Improved ignition, even when using electrodes with poor ignition properties
- Better fusion of the base metal in the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions
46
Available para- Legend
I (A)
meters Hti HTI ...... Hot current time,
(continued) 0-2 s, factory setting: 0.5 s
150 HCU .... Hot start current, 0-100%, factory
setting 50 %
HCU I1 .......... Main current = pre-set welding
current
EN
100
Mode of functioning
I1 During the pre-set hot current time (Hti),
the welding current is increased to a
certain value. This value (HCU) is 0-100%
t (s) higher than the pre-set welding current
(I1).
0.5 1 1.5
Fig.38 Example of “Hot-Start” function
dyn
dYn - dynamic - arc-force dynamic correction
unit A
factory setting 40
In order to obtain optimum welding results, it will sometimes be necessary to adjust the
arc-force dynamic.
Functional principle
At the instant of droplet transfer, or when a short circuit occurs, there is a momentary
rise in the current. 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 pre-
vents the weld pool solidifying, as well as preventing more prolonged short-circuiting of
the arc. This largely prevents the rod electrode from “sticking”.
Setting range of the dYn parameter

0 ........ soft, low-spatter arc
100 .... harder, more stable arc
PRO
FAC
Factory - reset welding machine by pressing the torch trigger
47
Program levels P1 - P3
Accessing 1. Switch on the power source with the mode button (3) or process button (18)
pressed. „—“ appears for preliminary settings level.
2. Press and hold torch trigger until

1. — appears .... preliminary settings program level
2. P1 appears ... service menu program level
3. P2 appears ... code lock program level
4. P3 appears ... AC parameters program level
3. Release mode button (3) or process button (18)
Selecting and - Select desired parameter using mode button (3) or process button (18)
altering the set- - Alter the parameter value using the torch trigger
up parameter
Service menu Service menu with various test programs

program level P1
Code lock pro- The code lock is deactivated when the power source leaves the factory.
gram level P2 A three-character code can be entered.
factory setting 321
Important! It is imperative to make a note of any changes to the number combination.
Changing and activating the code:

1. Select program level P2
2. Enter current code (on new machines: 321)
- Set digit using main current adjuster IH (14)
- Confirm digit with „Mode“ button (3)
- Repeat procedure twice until „Cod OFF“ appears on the display.
3. Switch to „Cod ON“ using torch trigger
4. Change to „CYC__?“ using „Mode“ button (3)
5. CYC ... cycle indicates how often the machine can be switched on without having
to enter a code.
6. Set the number of cycles using the torch trigger and confirm using the „Mode“
button (3)
Entering a new code:

1. Using the torch trigger, select 0-9/A-H
2. Confirm input with „Mode“ button (3)
3. Repeat procedure twice until code is entered
4. Press the torch trigger
5. Confirm new code by entering it again
6. On the third acknowledgement, the code is automatically stored
48
Code lock pro- Note! If the code is entered incorrectly three times (ERR), the power source
gram level P2 automatically switches to „LOC“. The process must be repeated by switching
(continued) off and on again.
7. Power source is ready for welding
Deactivating the code:
EN
1. Access program level P2
2. Enter current code
- set digit using adjuster IH
- confirm digit with „Mode“ button (3)
- repeat procedure twice until „Cod ON“ appears on the display.
3. Press torch trigger, „Cod OFF“ appears.
4. Change to „PRO“ using „Mode“ button (3) or „Process“ button (18)
5. Press the torch trigger
6. The current code is deactivated and the power source is ready for welding
Important! The code is now 321 again.
If the power source is started up with the code lock activated, select the digits using
adjuster IH and confirm with „Mode“ button (3).
AC parameters Select parameters using the „Mode“ button (3) or „Process“ button (18) and then
program level P3 change their values using the torch trigger.
(Magic Wave)
Available parameters:
ACF
AC frequency
unit Hz
factory setting 60
POS
Positive half wave
unit -
setting range tri/SIN/rEC/OFF * (TIG only)
factory setting SIN
nEG
Negative half wave
unit -
setting range tri/SIN/rEC/OFF * (TIG only)
factory setting rEC
PRO
SYn
Synchronous function
unit -
factory setting OFF
* tri (triangle), SIN (sine), rEC (rectangle)
49
Troubleshooting
Safety
Warning! An electric shock can be fatal. Before opening up the machine
- Switch the mains switch to the “O” position
- Unplug the machine from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that electrical-
ly charged components (e.g. capacitors) have been discharged
Caution! Inadequate PE conductor connections can cause serious injury and

damage. The housing screws provide a suitable PE conductor connection for
earthing (grounding) the housing and must NOT be replaced by any other
screws which do not provide a reliable PE conductor connection.
Displayed ser- If any error message that is described here appears on the displays, then the fault is
vice codes one that can only be put right by a service technician. Make a note of the error mes-
sage shown in the display, and of the serial number and configuration of the power
source, and get in touch with our after-sales service, giving them a detailed description
of the error.
Error message from UTI1A PCB:
Err 102
Cause: temperature sensor short circuit
Err 103
Cause: temperature sensor open circuit
Err 107
Cause: RAM access error
Err 109
Cause: secondary overvoltage error
Err 110
Cause: power source switch-off
Err 112
Cause: ADC offset error
Err 113
Cause: ADC gain error
Err 116
Cause: cooling circuit error
Err 117
Cause: primary overcurrent error
Err 118
Cause: supply voltage error (+5V, +15V)
50
Displayed ser-
Err 119
vice codes
(continued) Cause: serial data transfer error
Err 120
Cause: power module error
EN
Err U-P
Cause: primary over/undervoltage
Err 113
Error message from UTMS1 PCB
Err 004
Ursache: timer error (82C54)
Err 006
Cause: Icomm compensation error
Err 007
Cause: RAM access error
Err 008
Cause: SEEPROM access error
Err 010
Cause: external error (robot welding only)
Err 012
Cause: ADC offset error
Err 013
Err 019
Cause: serial data transfer error
Err 021
Cause: stack overflow
51
Power source
Power source does not function
Mains switch is ON, but indicators are not lit up
Cause: there is a fault in the mains lead; the mains plug is not plugged in
Remedy: check the mains lead, make sure that the mains plug is plugged in
Cause: mains fuse is faulty

Remedy: change fuse
Cause mains outlet socket or plug is faulty

Remedy: replace faulty components
No welding current
Mains switch is ON, overtemperature indicator is lit up
Cause: overloading, the duty cycle has been exceeded
Remedy: do not exceed the duty cycle
Cause: thermostatic cut-out system has tripped

Remedy: wait until the power source automatically comes back on at the end of the
cooling phase
Cause: the fan in the power source is defective

Remedy: change fan
No welding current
Mains switch is ON and indicators are lit up
Cause: grounding (earthing) connection is wrong
Remedy: check grounding (earthing) connection and clamp for correct polarity
Cause: there is a fault in the current cable in the welding torch

Remedy: change torch
Nothing happens when the torch trigger is pressed

Mains switch is ON and indicators are lit up
Cause: control plug is not plugged in
Remedy: plug in control plug
Cause: remaining power on time not yet expired after switching on

Remedy: wait 10 s after switching on
Cause: welding torch or torch control lead is defective

Remedy: replace torch
No shielding gas
All other functions are OK
Cause: gas cylinder is empty
Remedy: change gas cylinder
Cause: gas pressure regulator is faulty

Remedy: change gas pressure regulator
Cause: gas hose is not fitted, or is damaged

Remedy: fit/change the gas hose
Cause: welding torch is faulty

Remedy: change welding torch
Cause: gas solenoid valve is faulty

Remedy: change gas solenoid valve
52
Power source
Poor welding properties
(continued)
Cause: incorrect welding parameters
Remedy: check settings
Cause: grounding (earthing) connection is wrong

Remedy: check grounding (earthing) connection and clamp for correct polarity
EN
The welding torch becomes very hot
Cause: design dimensions of the torch are not sufficient for this task
Remedy: observe duty cycle and loading limits
Cause: on water-cooled machines only: water through-flow is too low

Remedy: check water level, through-flow rate, cleanliness, etc. If the coolant pump
is blocked: use a screwdriver - placed on the bushing - to turn the shaft of
the coolant pump.
Cause: on water-cooled machines only: parameter C-C is set to “OFF”.

Remedy: in the set-up menu, set parameter C-C to “Aut” or “ON” position.
53
Care, maintenance and disposal
General remarks 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 the
welding machine remains in a usable condition for many years.
Warning! An electric shock can be fatal. Before opening up the machine

- Switch the mains switch to the “O” position
- Unplug the machine from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that electrical-
ly charged components (e.g. capacitors) have been discharged
Every start-up - Check mains plug, mains cable, welding torch, interconnection cable assembly and
bondings for damage
- Check that there is a gap of 0.5 m (1 ft. 7in.) all around the machine to ensure that
cooling air can flow and escape unhindered
Note! Furthermore, air inlets and outlets must in no case be covered, not even
covered partly.
Every 2 months - If present: clean air filter
Every 6 months - Dismantle machine side panels and clean machine inside with dry reduced com-
pressed air
Note! Risk of damage to electronic components. Do not bring the air nozzle
too close to the electronic components.
- If a lot of dust has accumulated, clean the cooling air ducts.
Disposal Dispose of in accordance with the applicable national and local regulations.
54
Technical data
Special voltages Note! Inadequately dimensioned electrical installations can lead to serious
damage. The mains lead, and its fuse protection, must be dimensioned accor-
EN
dingly. The technical data shown on the rating plate shall apply.
MagicWave 2600/ MW 2600 MW 2600CEL

2600CEL
Mains voltage 3x400 V 3x400 V
Mains voltage tolerance -20% / +15% -20% / +15%
Mains fuse protection (slow-blow) 16 A 16 A
Apparent power at
40 % d.c. - 15.7 kVA
50 % d.c. 11.1 kVA -
60 % d.c. 10.6 kVA 10.4 kVA
100 % d.c. 8.1 kVA 8.1 kVA
Cos phi1
150 A 0,99 0,99
260 A 0,99 0,99
Degree of efficiency 86 % 83 %
Welding current range:
DC 3 -260 A 3 -260 A
AC 5 -260 A 5 -260 A
Welding current at 10 min/40°C
40% d.c. - 260 A
50% d.c. 260 A -
60% d.c. 240 A 180 A
100% d.c. 185 A 145 A
Open-circuit voltage 56 V DC 75 V DC
Max. working voltage 40 V 48 V
Striking voltage (Up) 9.5 kV 9.5 kV
The arc striking voltage is designed for manual guided operation.
Protection IP 23 IP 23
Type of cooling AF AF
Insulation class F F
Dimensions l/b/h 625/290/480 mm 625/290/480 mm
24.61/11.42/18.90 in. 24.61/11.42/18.90 in.
Weight (without cooling circuit) 33 kg 30 kg
72.75 lb. 66.14 lb.
Marks of conformity CE, CSA CE, CSA
Safety mark S S
55
MagicWave 3000 MW 3000 MW 3000
Apparent power at
35 % d.c. 9.7 kVA -
60 % d.c. 6.1 kVA -
65 % d.c. - 11.8 kVA
100 % d.c. 4.6 kVA 9.7 kVA
Cos phi1
150 A 0,99 0,99
300 A 0,99 0,99
Welding current range
DC 3 -300 A 3 -300 A
AC 5 -300 A 5 -300 A
35% d.c. 300 A -
60% d.c. 220 A -
65% d.c. - 300 A
100% d.c. 170 A 260 A
24.61/11.42/18.90 in. 24.61/11.42/18.90 in.
74.96 lb. 74.96 lb.
Safety mark S S
56
TransTig 2600/ TT 2600 TT 2600CEL
2600CEL
Apparent power at
EN
60 % d.c. 10.5 kVA 10.7 kVA
100 % d.c. 8.4 kVA 9.2 kVA
Cos phi1
150 A 0,99 0,99
260 A 0,99 0,99
DC 3 -260 A 3 -260 A
AC - -
60% d.c. 260 A 260 A
100% d.c. 220 A 230 A
Standardised working voltage
TIG 10.1 -20.4 V 10.1 -22.0 V
Rod electrode (MMA) 20.1 -30.4 V 20.1 -30.4 V
24.61/9.84/18.90 in. 24.61/11.42/18.90 in.
61.73 lb. 61.73 lb.
Safety mark S S
57
TransTig 3000 TT 3000 TT 3000
Apparent power at
35 % d.c. 9.7 kVA -
60 % d.c. 6.1 kVA -
65 % d.c. - 11.8 kVA
100 % d.c. 4.6 kVA 9.7 kVA
Cos phi1
150 A 0,99 0,99
300 A 0,99 0,99
DC 3 -300 A 3 -300 A
AC - -
35% d.c. 300 A -
60% d.c. 220 A -
65% d.c. - 300 A
100% d.c. 170 A 260 A
Standardised working voltage
TIG 10.1 -22.0 V 10.1 -22.0 V
Rod electrode (MMA) 20.1 -32.0 V 20.1 -32.0 V
24.61/9.84/18.90 in. 24.61/9.84/18.90 in.
61.73 lb. 61.73 lb.
Safety mark S S
58
Ersatzteilliste
DE
Spare Parts List
EN
Liste de pièces de rechange
FR
Lista parti di ricambio
IT
ES
Lista de repuestos
PT-BR
Lista de peças sobresselentes
NL
NO Onderdelenlijst
Reservdelsliste
CS
Seznam náhradních dílù

RU
Ñïèñîê çàïàñíûõ ÷àñòåé

SK
Zoznam náhradných dielov

SV
Reservdelslistan
Parça Listesi
TR
Czyszczenie palnika
PL
ud_fr_st_tb_00150 012012
MagicWave 3000 G/W/Z 4,075,083 TransTig 2600 G/W/Z Cel 4,075,084
MagicWave 3000 G/W/E 4,075,083,001 TransTig 2600 G/W/E Cel 4,075,084,001
MagicWave 2600 Cel G/W/Z 4,075,083,630 TransTig 3000 G/W/Z 4,075,090
MagicWave 2600 Cel G/W/E 4,075,083,631 TransTig 3000 G/W/E 4,075,090,001
MagicWave 3000 G/F 4,075,083,636 TransTig 3000 G/W/Z 3x220/230V 4,075,090,630
MagicWave 3000 G/W/Z/US 4,075,083,800 TransTig 3000 G/F 4,075,090,636
MacicWave 3000 G/F/US 4,075,083,801 TransTig 2600 G/W/Z 4,075,118
MagicWave 3000 G/W/Z 3x220V 4,075,083,980 TransTig 2600 G/W/E 4,075,118,001
MagicWave 2600 G/W/Z 4,075,117 TransTig 2600 G/F 4,075,118,636
MagicWave 2600 G/W/E 4,075,117,001 TransTig 2600 Cel G/F 4,075,118,637
MagicWave 2600 G/F 4,075,117,636
MagicWave 2600 Cel G/F 4,075,117,637
MagicWave 2600 G/W/Z/US 4,075,117,800
MagicWave 2600 G/F/US 4,075,117,801
42,0407,0449
42,0406,0292
42,0200,8860
32,0405,0165 - TT
32,0405,0164 - MW
AM2,0200,8878 - TT
AM2,0200,8819 - MW
45,0200,0918
43,0004,0789
43,0004,0586 - 3x230V
43,0004,2323 - US
12,0405,0162 - TT
12,0405,0161 - MW
42,0300,0648
42,0300,1815 - 3x230V
42,0300,1815 - US
42,0406,0294
42,0406,0137 - 3x230V
43,0002,0238
43,0002,0257 - 3x230V
43,0002,0079
12,0405,0162 - TT
12,0405,0161 - MW 42,0409,2483
BE2,0200,8876 - TT
BE2,0200,8822 - MW
42,0001,3541 - US
43,0013,0015
42,0407,0284
40,0001,0310 - *
42,0409,2538 - MW/TT 3000

42,0409,2501 - MW/TT 2600
42,0409,2541 - MW/TT 2600 CEL
4,060,070
BP2,0200,8879 - TT 43,0001,3197 - TT
43,0001,3196 - MW
BP2,0200,8837 - MW
42,0406,0322
42,0406,0323
42,0406,0324
Magic Wave / Trans Tig 2600 - 3000

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/3
el_fr_st_wi_00129 012004
4,070,540 - NF316
4,070,529 - NF330-3x230V
43,0004,1491 NF
4,070,589 - UTI2A
4,070,612 - UTI2C-3x230V
U
T
I
2
43,0004,1492
43,0004,1494
43,0004,1716
41,0005,0170
41,0005,0288 - 3x230V
42,0300,1523
42,0400,0132 43,0006,0152 - MW/TT 3000
43,0001,1092 - MW/TT 2600
41,0002,0059 43,0006,0152 - MW/TT 2600CEL
41,0002,0060 - 3x230V
43,0001,1015 - MW/TT 3000

43,0001,1159,Z - MW/TT 2600 41,0009,0066
43,0001,1035 - MW/TT 2600 CEL
43,0001,1066 - MW/TT 3x230V
42,0405,0131
33,0005,4105
33,0005,4106 - CEL
33,0005,4110 - 3x230V
4,070,507 - FU20
F
43,0001,0600
U
20
41,0003,0203
H
4,070,708 - HF66
F
66
4,070,496 - TTS8A
A
S8
33,0010,0206
TT
41,0003,0145
33,0010,0179 - CEL
43,0001,1037
33,0005,0437 43,0001,1038
43,0001,0950 43,0001,0871
43,0001,0599

el_fr_st_wi_00129 012004
F 43,0004,1497
42,0409,2982 - TT
32,0405,0183 42,0409,2983 - MW
42,0401,0867
42,0407,0063
40,0001,0012 - *
42,0407,0063
43,0004,1495
42,0405,0189
42,0407,0273
42,0405,0187 - BLACK
42,0405,0186 - RED
42,0404,0024
44,0001,1145 42,0405,0056
43,0003,0040
4,100,423
Z 43,0004,1497
32,0405,0183 32,0409,2498 - TT
32,0409,2485 - MW
42,0401,0867
42,0407,0063
42,0407,0273 40,0001,0012 - * 43,0004,1495

42,0001,0133
42,0401,0867
42,0001,1281
42,0407,0063
40,0001,0012 - *
42,0404,0024
42,0407,0063
42,0001,2129 42,0405,0056
42,0401,0869 4,001,603 43,0003,0040
E 43,0004,1497
32,0409,2499 - TT
32,0405,0183 32,0409,2500 - MW
43,0004,3748
42,0401,0867
42,0407,0063
40,0001,0012 - *
42,0407,0063
42,0001,0133
44,0001,0348
44,0001,0305
43,0003,0040

el_fr_st_wi_00129 012004
2
6,7,9,11
6,8,10,12 1
13
4
POS. BENENNUNG ARTICLE DENOMINATION

1 GEHÄUSE SW TR20MC CASE BLACK TR20MC CHASSIS NOIR TR20MC BE4.0750.0057
2 GRIFF SW TP3 HANDLE BLACK TP3 POIGNEE NOIRE TP3 BE2.0200.5381
3 DRUCK FRONTPL. TP-MC FRONT PANEL TP-MC PANNEAU FRONTAL TP-MC 42.0409.2292
4 ANBAUGEHÄUSE STIFT STROMQU FR MOUNTING CASE PIN FR ELEMENT RAPPORT BROCHE 32.0405.0160
5 STIFTKONTAKT C 1 CPC PIN CONTACT C 1 CPC CONTACT AIGUILLE C1 CPC 43.0003.0486
6 WIDPOT 2K2 10 ABW 1 RESISTOR 2K2 10 ABW 1 RESISTANCE 2K2 10 ABW 1 41.0001.0509
7 DREHKNOPF 31 schw 6mm ACHSE P TURNING KNOB D=31 BLACK 6MM P BOUTON TOURNANT NOIR 42.0406.0104
8 DREHKNOPF 16 schw 6mm ACHSE P TURNING KNOB D=16 BLACK 6MM P BOUTON TOURNANT NOIR 42.0406.0099
9 PFEILSCH 31 rot P ARROW-DISC FEED UNIT NEW BOUTON CRANTE 42.0406.0173
10 MUTTERABD 16 rot P NUT-COVER 16 RED CAPOT ECROU ROUGE 16 42.0406.0213
11 DECKEL 31 rot P COVER D=31 RED CACHE BOUTON ROUGE 31 42.0406.0113
12 DECKEL 16 grau P COVER D=16 GREY P CACHE BOUTON GRIS 16 P 42.0406.0107
13 HAFTMAGNET 63 M8 MAGNET D=63 MM AIMANT 63MM 44.0001.0192
TP-MC 4.046.048
el_fr_st_fb_00018 001999
TP-MC CEL 4,046,076
BE4,0460,0010
42,0406,0218
42,0406,0322
41,0001,0509
42,0406,0073
43,0002,0152
46,0460,0015
43,0003,0486 41,0001,0509
42,0406,0322
32,0405,0160
4,070,572 - TPCEL
43,0002,0284
BE4,0460,0009
44,0001,0739
TP-MC CEL
el_fr_st_fb_00009 012003
TR 50 MC 4,046,049
42,0406,0242
42,0406,0244
32,0409,2294
43,0003,0486
32,0405,0160
T
R
50
M 4,070,456 - TR50M
32,0405,0159
43,0003,0485
BE2,0200,5381
42,0409,2288 TR
50
-M
C
BE4,0750,0058
42,0300,0501
Remote Control
el_fr_st_fb_00005 012003
TR 51 MC 4,046,052
42,0406,0218
42,0406,0244
42,0409,2317
43,0003,0486
4,070,458 - TR51M
BE2,0200,5381
T
R
51
M
32,0405,0160
42,0409,2318
TR
51
-M
C
BE4,0750,0057
44,0001,0192
Remote Control
el_fr_st_fb_00004 012003
TR 52-MC 4,046,050
42,0300,1145
BE4,0750,0082 BE2,0200,3845
44,0750,0086
43,0002,0004
4,070,459 - TR52M
52
TR 44,0750,0085
42,0404,0152
42,0404,0033
42,0403,0083
42,0408,0035
42,0001,1492 41,0001,0015
32,0405,0160
M C
2-
43,0003,0486
BE4,0750,0081
5
TR
42,0409,2319
BE4,0750,0083
Remote Control
el_fr_st_fb_00002 012003
TR 53 MC 4,046,051
42,0406,0150 42,0406,0218
42,0406,0080
42,0409,2293
41,0001,0509 BE2,0200,5381
43,0003,0486 42,0409,2289
TR
32,0405,0160
53
-M
C
BE4,0750,0057
44,0001,0192
Remote Contol
el_fr_st_fb_00001 012003
FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
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.
ud_fr_st_so_00082 012011

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/ Battery Charging Systems / Welding Technology / Solar Electronics

MagicWave 2600 Cel TIG power source

Important! “Important!” indicates practical hints and other useful special-information. It is no

It’s your safety that’s at stake!

Utilisation in accordance with the “intended purpose” also comprises

The appliance must never be used for the following:

The machine is designed to be used in industrial and workshop

Temperature range of ambient air:

Relative atmospheric humidity:

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

Elevation above sea level: Up to 2000 m (6500 ft)

see Technical Data

NOTE! Ensure that the mains connection is earthed properly.

- electrical hazards from mains and welding current

- increased exposure to noise

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable

III ud_fr_st_sv_00467 022013

It is not possible to provide a workplace-related emission value during wel-

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an

If you are not sure whether your fume-extraction system is sufficiently

Hazards from Flying sparks can cause fires and explosions!

Have a suitable, approved fire extinguisher at the ready.

Welding must NEVER be performed on containers that have had gases,

Hazards from An electric shock is potentially life-threatening, and can be fatal.

Always place the wirefeeder on an adequately insulated floor or base, or

If the machine is run on a mains network without a PE conductor and

Wherever necessary, use suitable measures to ensure that the workpiece is

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Put up a clearly legible and easy-to-understand warning sign to stop

After opening up the machine:

If work needs to be performed on any live parts, there must be a second

Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a way

In the case of automated MIG/MAG applications, ensure that only insulated

EMC device Devices with emission class A:

Devices with emission class B:

EMC device classification as per the rating plate or technical specifications

Examine and evaluate any possible electromagnetic problems that may

Ancillary measures for preventing EMC problems:

d) Workpiece grounding (earthing)

e) Shielding, where necessary

VII ud_fr_st_sv_00467 022013

Covers and sideguards may only be opened or removed for as long as is

While the machine is in use:

Special regulations apply to rooms at risk from fire and/or explosion.

ud_fr_st_sv_00467 022013 VIII

When hoisting the machines by crane, only use suitable manufacturer-

If a machine is fitted with a carrying strap or carrying handle, remember that

Danger of colourless and odourless inert gas escaping unnoticed, when

Filters must be used if necessary.

NOTE! There is an increased risk of soiling if ring mains are being

Protect shielding-gas cylinders containing compressed gas from excessive

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas

Observe the manufacturer’s instructions and all relevant national and

When installing the appliance, please ensure a clearance radius of 0.5 m

Before switching on the machine, ensure that nobody can be endangered by

Do not make any alterations, installations or modifications to the machine