Fronius MagicWave 4000 is a digital TIG AC/DC power source for a 3 x 400 V supply, cooled by liquid. The maximum welding current is 400 A, and at a continuous 100% load the machine holds from 310 A to 380 A. The current is run by a DSP signal processor, and the Active Wave technology keeps the noise level below 80 dBA.
What this machine is for
This is a power source for plants that weld aluminium in production, not now and then. A reserve of 400 A is enough for engine blocks, thick pipes and heavy duty structures, where the part draws off so much heat that a smaller source would not hold the pool. Continuous work in the range from 310 A to 380 A means the machine welds through a whole shift, without breaks for cooling, so it suits a production line and not only single repairs.
The control is digital. The signal processor analyses the course of the arc many thousands of times per second and corrects the current on the fly, so the parameters do not drift when the arc length changes, with mains swings or when you work on a long cable. An open circuit voltage of 90 V gives a sure strike also on material that is not very clean and with longer welding cables.
You take alternating current for aluminium and its alloys, because the positive half wave tears the aluminium oxide layer off the pool. Direct current serves black steel, acid resistant steels, copper, nickel and titanium, with a concentrated arc and a narrow heat affected zone. The manufacturer aimed this model at plants building tankers and railway wagons, that is where thick plates are welded from both sides and the stability of the arc on both sides of the joint counts.
Features and equipment
- Active Wave: digital modulation smooths the passage of the current through zero, so the alternating current arc does not squeal and the noise level at full load drops below 80 dBA. The welder hears the pool and the surroundings, so it is easier to correct the technique during a pass.
- DSP signal processor: the system measures the arc parameters thousands of times per second and corrects the output current on the fly, which gives an even arc with a changing electrode stick out.
- TAC function, that is vibration tacking: the arc sets both edges vibrating, the pools go into resonance and run together into one flat point, on thin sheet without adding filler. The tacks are flat, without temper colours, and the source description gives a 50% cut in tacking time.
- Automatic cap forming: the machine picks the current itself and forms a symmetrical cap on the tungsten electrode, without striking on a piece of copper. The cap comes out smaller than one formed by hand, so the arc is narrower and gives deeper penetration in fillets.
- RPI Ignition, that is ignition with reversed polarity: the arc starts at once also with a slightly oxidised electrode and material that is not fully clean, without tapping the electrode against the part.
- Synchronisation mode: two machines joined by a cable agree the passages of the current through zero, so two welders work on both sides of a thick plate without magnetic arc blow.
- Tunnel cooling of the electronics: the control boards are separated from the duct with the cooling air, so metal dust does not settle on the circuits.
Technical data
| Brand | Fronius |
|---|---|
| Model | MagicWave 4000 |
| Type | digital TIG power source |
| Type of current | AC/DC |
| Maximum welding current | 400 A |
| Duty cycle 100% | from 310 A to 380 A |
| Welding current given in the data sheet | up to 400 A |
| Supply voltage | 3 x 400 V, tolerance from -20% to +15% |
| Open circuit voltage | 90 V |
| Control processor | DSP |
| Noise level at full load | below 80 dBA, Active Wave technology |
| Protection rating | IP23 |
| Cooling | liquid, electronics cooled by tunnel |
| Functions | Active Wave, TAC, automatic cap, RPI Ignition, synchronisation of two power sources |
What to watch out for
The supply is a 3 x 400 V mains with a tolerance from -20% to +15%, so the machine takes a weaker circuit and a long extension lead, but size the power circuit for work at 400 A and settle it with an electrician. The duty cycle drops with the current: you work without breaks in the range from 310 A to 380 A, and 400 A is the maximum value, which you plan for short stretches. Protection rating IP23 allows work under a roof and in a hall, not in the rain.
The data sheet does not list a torch, an earth cable or a cooler in the set, so confirm the content with us before you buy. For work at 400 A you need a liquid cooled TIG torch of the right rating, and check the liquid circuit before the first strike: the fluid level, the flow and the tightness of the quick couplings. On alternating current the tungsten electrode wears faster than on direct current, so keep a stock of electrodes and collets, and for the synchronisation mode a second machine and a connecting cable. Count in an argon cylinder with a regulator too, because at such currents the gas goes down fast. The data sheet gives no weight and no dimensions, settle the transport with us in advance.
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.
