Fronius MagicWave 4000 User Manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0027,EN 018-23022017
TransTig 2200
TransTig 2500 / 3000
TransTig 4000 / 5000
MagicWave 1700 / 2200
MagicWave 2500 / 3000
MagicWave 4000 / 5000
Operating Instructions
Spare parts list
TIG Power source
EN

Fronius MagicWave 4000 Specifications

General

Input Voltage	3 x 400 V
Output Current Range MMA	10 - 400 A
Duty Cycle at 400 A	60 %
Duty Cycle at 315 A	100 %
Protection Class	IP 23
No-load Voltage	80 V
Welding Process	TIG, MMA
Rated Input Frequency	50/60 Hz
Open Circuit Voltage	80 V
Output Current Range TIG	5 - 400 A
Welding Current Range	5 A - 400 A
Cooling	Air-cooled

Summary

Safety Rules and Precautions

Explanation of Safety Symbols

Defines safety symbols like DANGER, WARNING, CAUTION, NOTE, and IMPORTANT.

General Safety Precautions

Outlines general safety standards, operator obligations, and device handling requirements.

Proper Use Guidelines

Specifies the intended purpose of the device and lists improper uses.

Operator and Personnel Obligations

Defines responsibilities for personnel operating the welding device, including qualifications and training.

Personal Protection and Hazard Awareness

Lists risks like sparks, arc radiation, EMF, electrocution, noise, fumes, and required protective clothing.

Toxic Gases and Vapour Safety

Warns about welding fumes causing health issues and details ventilation and mask requirements.

Flying Sparks and Fire Hazard Prevention

Details risks from flying sparks, fire hazards, and necessary precautions like fire extinguishers.

Electrical Shock and Cable Safety

Explains risks of electric shock from mains/welding current and precautions for cables and connections.

EMC Mitigation and EMF Hazard Awareness

Lists measures to avoid EMC issues and discusses potential health risks from electromagnetic fields.

Operational Safety and Coolant Handling

Details safety checks during operation, handling hot parts, and risks associated with coolant.

Shielding Gas and Installation Safety

Covers shielding gas cylinder safety, installation stability, and workplace safety measures.

Normal Operation Safety Checks

Emphasizes operating only with functional safety devices, avoiding bypass, and checking for damage.

Maintenance, Repair, and Disposal Safety

Stresses using original parts, avoiding modifications, and proper grounding screw usage.

General Information on Welding Equipment

Device Concept and Modularity

Describes the power sources as digitized, microprocessor-controlled inverters with modular design and flexible add-ons.

Mandatory Device Warning Labels

Emphasizes that warning notices on the device must not be removed or painted over.

System Components Overview

System Components Identification

Illustrates and lists power sources, cooling units, trolleys, torches, remote controls, and cables.

Control Elements and Connections

MagicWave Control Panel Details

Identifies and describes components like digital displays, HOLD indicator, and their functions for MagicWave.

MagicWave Control Panel Functions

Explains indicators (voltage, unit), process buttons, mode buttons, and parameter selection buttons.

TransTig Control Panel Details

Identifies and describes components like digital displays, HOLD indicator, and their functions for TransTig.

TransTig Control Panel Functions

Explains voltage indicator, unit indicators, mode buttons, parameter selection, and gas test button.

Connections, Switches, and Mechanical Components

MagicWave 1700/2200 Connections

Details front and rear connections for MagicWave 1700/2200, including torch, LocalNet, grounding, gas, and mains.

MagicWave 2500/3000 Connections

Details front and rear connections for MagicWave 2500/3000, including grounding, LocalNet, torch, gas, and mains.

MagicWave 4000/5000 Connections

TransTig 2200 Connections

TransTig 2500/3000 Connections

TransTig 4000/5000 Connections

Installation and Commissioning Procedures

Pre-Installation and Commissioning Safety

Emphasizes that all work must be done by trained personnel and highlights risks of incorrect operation or toppling.

Connecting Mains Cable on US Power Sources

Mains Cable Strain-Relief Device Installation

Equipment Start-up Procedures

Start-up Safety Precautions

Warns about severe injury/damage from electric shock during installation and emphasizes unplugging the device.

Gas Cylinder Connection Safety

Warns about injury/damage from toppling gas cylinders and stresses secure mounting and manufacturer's instructions.

Establishing Workpiece Ground Connection

Connecting the Welding Torch

TIG Welding Operations

TIG Welding Mode Safety

Warns about injury/damage from incorrect operation and requirement to read all instructions.

TIG 2-Step and 4-Step Mode Sequences

Automatic Cap Shaping for TIG AC Welding

TIG Welding Parameters and Setup

TIG Welding Safety and Preparation

Warns about injury/damage from incorrect operation and electric shock if the power source is connected.

TIG Main Current (I1) and Downslope (tdown)

TIG Welding Preparation Steps

TIG Welding Ignition and Parameter Adjustment

Arc Ignition Techniques

High Frequency (HF) Ignition Procedure

Explains HF ignition activation, indicator, benefits, and the procedure for placing the nozzle and actuating the trigger.

Touchdown Ignition Procedure

MMA Welding Procedures

MMA Welding Safety and Preparation

Warns about injury/damage from incorrect operation and electric shock during installation.

MMA Mode and Process Selection

Anti-Stick Functionality

Setup Settings Configuration

Troubleshooting and Maintenance

Troubleshooting Safety Precautions

Warns about injury/damage from incorrect work and electric shock, emphasizing safety rules and device disconnection.

Troubleshooting Service Codes (tP1-tSt)

Details service codes for overtemperature in primary/secondary circuits and control circuits.

Troubleshooting Error Codes (Err 051, Err 052)

Troubleshooting Faults (no|IGn, Err|PE, Err|IP)

Troubleshooting: Power Source Not Functioning

Addresses issues where indicators are not lit, including mains lead, plug, or socket faults.

Troubleshooting: No Welding Current

Covers issues with no welding current, including overload, thermostatic cut-out, fan faults, and grounding connection errors.

Troubleshooting: No Torch Trigger Response

Care, Maintenance, and Disposal

Care and Maintenance Safety Precautions

Reiterates safety warnings for work on the device, including electric shock and ground connection integrity.

Appendix Information

Technical Data Specifications

MagicWave 1700/2200 Technical Data

Lists mains voltage, frequency, fuse protection, current ranges, open circuit voltage, and dimensions.

MagicWave 2500/3000 Technical Data

Provides technical specifications for MW 2500/3000, including mains voltage, current ranges, and weight.

MagicWave 2500/3000 MV Technical Data

Lists technical data for MW 2500/3000 MV, covering mains voltage, frequency, and continuous power.

MagicWave 4000/5000 Technical Data

Details technical specifications for MW 4000/5000, including welding current ranges and insulation class.

MagicWave 4000/5000 MV Technical Data

Covers technical data for MW 4000/5000 MV, including mains voltage tolerance and EMC emission class.

MagicWave 4000/5000 MV Data Continued

Continues technical data for MW 4000/5000 MV, detailing dimensions and weight.

TransTig 2200 Technical Data

Lists technical specifications for TT 2200, including mains voltage, current ranges, and working voltage.

TransTig 2500/3000 Technical Data

Provides technical data for TT 2500/3000, including mains connection impedance and primary continuous power.

TransTig 2500/3000 MV Technical Data

Details technical specifications for TT 2500/3000 MV, including mains voltage tolerance and welding current at specific duty cycles.

TransTig 4000/5000 Technical Data

Lists technical data for TT 4000/5000, including current ranges and degree of protection.

TransTig 4000/5000 MV Technical Data

Covers technical data for TT 4000/5000 MV, including mains voltage tolerance and insulation class.