Fronius MagicWave 5000 is a digital, microprocessor TIG AC/DC power source of industrial class with an MMA mode. You set the TIG current from 3 to 500 A, the MMA current from 10 to 440 A, and at a 40% duty cycle the machine gives 500 A and 350 A in continuous work. We sell this unit in its original configuration: with an FK 4000 R cooler, a trolley, a torch 8 m and a foot pedal.
What this machine is for
This power source is built above all for aluminium and its alloys welded with alternating current. The digital control shapes the course of the wave, so you break up the oxide layer and keep deep penetration without a compromise between one and the other. You set the AC frequency from 40 to 250 Hz, and the balance on a scale from minus 5 to plus 5, so you match the process to the state of the material surface. A higher frequency narrows the arc and helps in corners and on thin edges, a lower one spreads the heat wider. A reserve of 500 A opens up work on vessels, tankers and structural parts made of thick aluminium, where at a 40% duty cycle you join material thicker than 10 to 15 mm without preheating.
In TIG DC mode the machine works on high alloy and stainless steels and on copper. The digital control holds the parameters from 3 A up, which lets you weld very thin metal foils, and the upper limit handles thick walled pipes and plate in the chemical and power industry. Adjustable slope up and slope down of the current closes the crater at the end of the weld, which matters on pressure installations and process pipelines, where the tightness of the joint counts. On such work root shielding with inert gas from the inside of the pipe usually comes on top of that, and it has to be arranged separately, because it is a matter of the equipment at the station and not of the power source itself.
The third mode is the covered electrode up to 440 A. You will pull basic and cellulose electrodes of large diameters with it, so the machine also suits repair work in the field and air carbon gouging. You set the MMA arc dynamics from soft, for thin sheet, to hard, for deep penetration in thick material, and the Anti-Stick function corrects the parameters when the electrode short circuits and makes it easier to break it free. The manufacturer aimed this set at makers of aluminium structures, at welding of pipelines and heat exchangers, at the aircraft and railway industry and at series production, where repeatability and foot control count.
Features and equipment
- TIG current range from 3 to 500 A and MMA from 10 to 440 A: one power source handles metal foils and thick structural sections.
- ActiveWave: digital shaping of the wave course softens the changes of polarity, so at 300 A the noise of the arc drops below 80 dBA without a loss of focus.
- Cap-shaping: the machine forms the ball on the tip of the tungsten electrode itself for the set diameter, so the arc is steady from the first second.
- AC balance control from minus 5 to plus 5: you set the ratio of the cleaning phase to the melting one for the degree of contamination of the aluminium.
- AC frequency control from 40 to 250 Hz: you narrow or widen the arc column and control the width of the face.
- HF ignition: a start without contact, without contaminating the electrode and without excess disturbance around the station.
- RPI ignition: a short reversal of the polarity in the starting phase of TIG DC prepares the starting point and protects the electrode against sticking.
- TAC function: tacking with a modulated pulse runs the edges together without adding filler, the points are flat and heat the material less.
- Slope up and slope down of the current: the slope settings close the crater at the end of a pass.
- Anti-Stick in MMA mode: the circuit reacts to a short circuit of the electrode and protects it against annealing.
- FK 4000 R cooler with a rating of 1000 W: at a flow of 1 litre per minute it takes the heat off the torch even at 500 A, and the tank holds 5.5 litres of coolant.
- Control of the cooler pump from the power source: the system runs when the process needs it, which limits noise and energy use.
- TIG torch 8 m long: reach around large parts without moving the power source, useful on vehicle frames and tanks.
- Foot pedal: you correct the current while welding, both hands stay on the torch and the filler.
- Transport trolley with space for a cylinder: you roll the whole station across the hall in one piece.
- Power source efficiency 86%: smaller energy losses when welding thick sections.
Technical data
| Brand | Fronius |
|---|---|
| Type | digital TIG AC/DC power source with an MMA mode |
| Type of current | AC/DC |
| TIG welding current range | from 3 to 500 A |
| MMA welding current range | from 10 to 440 A |
| Duty cycle 40% at 40 degrees C | 500 A |
| Duty cycle 100% at 40 degrees C | 350 A |
| Supply | 3 x 400 V (tolerance 15%) |
| Mains fuse | 35 A time delay |
| AC frequency | from 40 to 250 Hz |
| Protection rating | IP23 |
| Efficiency | 86% |
| Power source weight | 58.2 kg |
| Weight of the set with coolant and accessories | over 65 kg |
| Torch cooling | liquid |
What you get
- Fronius MagicWave 5000 power source
- FK 4000 R liquid cooler
- transport trolley
- TIG torch 8 m long
- foot pedal for remote current control
What to watch out for
The supply is 3 x 400 V with a tolerance of 15% and a 35 A time delay fuse, so the machine needs a proper power connection, not a workshop socket. The duty cycle at 40 degrees C is 500 A at 40% and 350 A at 100%, which at the full current gives four minutes of welding in every ten. The FK 4000 R cooler works at a rating of 1000 W with a flow of 1 litre per minute, and the tank holds 5.5 litres, so before the start check the coolant level and the flow in the circuit. You will destroy a liquid cooled torch in a few seconds with a dry system.
The power source alone weighs 58.2 kg, and the whole set with coolant and accessories goes over 65 kg, so it stands on the trolley and you move it on a pallet. Protection rating IP23 allows work in a hall and under a roof. The torch 8 m long gives reach, but it needs space for routing the bundle and a regular check of the state of the insulation along the whole length. The foot pedal is not needed for work, but it makes it easier to control the heat in difficult positions. When welding aluminium reckon with a higher use of argon and with a separate set of tungsten electrodes than on steel.
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.
