Castolin Castotig 2202 AC/DC (Fronius MagicWave 2200 ac/dc), used TIG welder

Castolin CastoTig 2202 AC/DC is a single phase TIG AC/DC inverter with an MMA mode, described in the data sheet also as Fronius MagicWave 2200 AC/DC. You set the TIG current from 5 to 220 A, the MMA current from 10 to 180 A, the supply is 230 V. It weighs from about 12 to 15 kg and the housing is rated IP23S.

What this machine is for

This is a portable TIG power source for the workshop, for service work and for light production. With alternating current you weld aluminium and magnesium, with direct current stainless steels, carbon steels, copper and titanium. The MMA mode works on direct and on alternating current, so you handle rutile and basic electrodes and electrodes for stainless steel.

The TIG duty cycle at 40°C is 35% at 220 A, 60% at 170 A and 100% at 150 A. In MMA it is 35% at 180 A, 60% at 140 A and 100% at 120 A. At 150 A in TIG you weld without a time limit, so on typical workshop thicknesses you do not have to plan breaks.

The machine draws about 6.0 kVA in TIG mode and 7.2 kVA in MMA mode at a power factor of 0.99, which points to a power factor correction circuit. In practice this means less current drawn from the mains and work on a typical 230 V installation fuse, also on a longer extension lead and on a generator supply.

Aluminium needs alternating current. In one half cycle the arc breaks up the oxide layer, which melts much higher than the metal itself, in the other comes the penetration. The balance sets the proportion between these half cycles, so on dirty or oxidised material you shift it towards cleaning, and on a thicker section towards penetration. A frequency up to 250 Hz narrows the arc, which helps on corner welds and on thin sheet, where a wide track burns through the material at once.

The wave shape changes the character of the work. The square wave gives sharp transitions and strong cleaning, the sine wave runs quieter, the triangular wave concentrates the energy and limits the amount of heat in the material. The pulse adds another level of control: at a low frequency you see the rhythm of the pool and it is easier to run a weld in position, at a high one the arc narrows and gets stiffer. You adjust the base current, the peak current and the duty ratio at the same time, so you set the average energy and the way it is delivered.

In MMA mode the machine gives current up to 180 A and a 100% duty cycle at 120 A, which covers typical assembly and repair work. Hot Start adjustable from 0 to 100% makes it easier to strike a cold electrode, Arc Force in the same range steadies the arc with basic electrodes, and Anti-Stick protects against burning when the electrode sticks to the material. MMA work on alternating current is useful with electrodes that need it and on materials prone to arc blow.

Features and equipment

• TIG AC with balance control within the range from 15 to 50%, which changes the proportion between oxide cleaning and penetration.
• Alternating current frequency control from 20 to 250 Hz, a higher frequency concentrates the arc.
• Choice of the alternating current wave shape: square, sine and triangular, matched to the alloy and the thickness.
• Pulse on direct and alternating current with frequency control from 0.5 to 200 Hz and control of the base current, the peak current and the duty ratio.
• HF ignition without contact or Lift Arc ignition by contact.
• MMA with adjustable Hot Start from 0 to 100%, adjustable Arc Force from 0 to 100% and an Anti-Stick function.
• VRD circuit, which drops the open circuit voltage from 65 V to 15 V and raises operator safety.
• Digital panel with a display and program memory, the description gives 9 channels or more, depending on the panel version.
• Works with gas cooled TIG torches, for example SR26, and with liquid cooled ones, for example SR18, once a cooler is added.
• Option to connect a foot pedal and hand held remote controls for adjusting the current while welding.

Technical data

What to watch out for

The supply is 230 V from one phase at 50/60 Hz, with a tolerance given from 10 to 15%. The power draw reaches 7.2 kVA in MMA mode, so when you work at the top settings the state of the installation and the cross section of the extension lead matter. Cooling is by air, the liquid cooler was an option, the description points to CoolTig 22, and the choice of torch depends on it, because SR26 runs on gas and SR18 on liquid.

The balance and frequency controls of the alternating current are the most important knobs on aluminium. The balance shifted towards cleaning picks up the oxides, shifted towards penetration it gives a deeper fusion, and a higher frequency narrows the arc on thin sheet and on corner welds. The VRD circuit drops the open circuit voltage from 65 V to 15 V, which matters when you work in damp and in tight spaces.

The manufacturer description gives a current of 220 A, and the shop filter classifies the machine in the range up to 300 A, so go by the value of 220 A. The data sheet does not list a torch or cables, ask about the content of the set. The program memory depends on the panel version, confirm the configuration before you buy. A weight from about 12 to 15 kg with dimensions of about 460 x 170 x 320 mm makes it portable equipment, but a cylinder with argon comes on top of that. For work on aluminium also prepare a separate brush for stainless steel and space for clean material, because a dirty or greasy surface spoils the pool at once.

How we sell used machines

This unit was checked in our service workshop in Krotoszyn with measurements to PN-EN 60974-4 and a load test. The price includes the first year of the basic service package: an inspection with cleaning of the machine and a validation measurement. Further years can be added. We ship across the European Union, collection in person by appointment.