Operating
manuals.fronius.com/
html/4204260459
e-Manual
Instructions
MTG Exento
MTW Exento
EN-US
Operating instructions
42,0426,0459,EA 005-21092022
Table of contents
Safety, information on correct use 5
Safety 7
Safety 7
Intended use, requirements for the extraction system 8
Intended use 8
Requirements for the extraction system 8
Extraction information on the rating plate 10
Available interfaces, functions of the torch trigger 11
Available interfaces 13
Up/Down-function 13
JobMaster-function 13
Functions of the torch trigger 14
Functions of the two-staged torch trigger 14
Commissioning 15
Commissioning procedure 17
Procedure for commissioning welding torches with Fronius System Connector 17
Procedure for commissioning welding torches with Euro connection 17
Fitting inner liner in welding torch with Fronius System Connector 18
Note on inner liner in gascooled welding torches 18
Fitting the inner liner 19
Fitting steel inner liner in welding torch with Euro connection 23
Fitting the steel inner liner 23
Fitting plastic inner liner in welding torch with Euro connection 27
Note on inner liner in gascooled welding torches 27
Fitting the plastic inner liner 28
Connecting welding torches to devices with Fronius System Connector 31
Connecting the welding torch to the power source 31
Connecting the welding torch to the wirefeeder 32
Connecting welding torches to devices with Euro connection 33
Connecting the welding torch 33
Connecting welding torch to extraction system and measuring extraction capacity 34
Connecting the welding torch to the extraction system 34
Measuring the extraction capacity (extraction volumetric flow) with the Exentometer 34
Adjusting the extraction capacity 37
Setting the extraction capacity on the welding torch 37
Setting extraction capacity with external air flow regulator 39
EN-US
Fault diagnosis, troubleshooting, maintenance 41
Troubleshooting 43
Troubleshooting 43
Maintenance 49
Detecting defective wear parts 49
Maintenance at the beginning of each working day 50
Maintenance every 48 hours 51
Maintenance at every wirespool/basket-type spool replacement 52
Technical data 55
Technical data of water-cooled welding torches 57
General 57
MTW Exento welding torch technical data 57
Technical data of gascooled welding torches 61
General 61
MTG Exento welding torch technical data 61
3
4
Safety, information on correct use
5
6
Safety
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equip-
▶
ment and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
Before starting work, switch off all the devices and components involved and
▶
disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back
▶
on.
WARNING!
Danger due to emerging wire electrode.
Serious personal injuries may result.
Hold the welding torch so that the tip of the welding torch points away from
▶
the face and body.
Wear suitable protective goggles.
▶
Do not point the welding torch at people.
▶
Ensure that the wire electrode can only intentionally make contact with elec-
▶
trically conductive objects.
WARNING!
Danger due to hot system components and/or equipment.
This can result in serious burns or scalding.
Before starting work, allow all hot system components and/or equipment to
▶
cool to +25°C/+77°F (e.g., coolant, water-cooled system components,
wirefeeder drive motor, etc.).
Wear suitable protective equipment (e.g., heat-resistant gloves, safety
▶
goggles, etc.) if cooling down is not possible.
WARNING!
Danger from contact with toxic welding fumes.
Serious personal injuries may result.
Welding is not permitted without an extraction unit being switched on.
▶
It may not be sufficient to only use a fume extraction torch to reduce the
▶
concentration of noxious substances at the work station. In this case, install
an additional extraction system to properly reduce the concentration of noxious substances at the work station.
In case of doubt, the concentration of noxious substances at the work sta-
▶
tion should be assessed by a safety engineer.
7
Intended use, requirements for the extraction
system
Intended use The MIG/MAG manual welding torch is intended exclusively for MIG/MAG weld-
ing in conjunction with a sufficiently powerful extraction system (see section Re-
quirements for the extraction system from page 8). Any other use is deemed
to be "not in accordance with the intended purpose." The manufacturer accepts
no liability for any damage resulting from improper use.
Intended use also means:
Reading these Operating Instructions in their entirety
-
Following all instructions and safety rules in this document
-
Carrying out all the specified inspection and maintenance work
-
Requirements
for the extraction system
Only operate Schweißbrenner with extraction systems that meet the following
requirements:
-
Extraction capacity (extraction volumetric flow) of at least 70 - 110 m3/h
(2472 - 3885 cfh); depending on the welding torch used
if the value is lower, there is a risk that the welding fumes will not be ad-
-
equately extracted
a higher value means there is a risk that shielding gas will be unintention-
-
ally sucked off the weld seam
Depending on the length of the extraction hose and the welding torch used, a
-
negative pressure of at least 10 - 18 kPa (100 - 180 mbar) must be generated
the shorter and thicker the extraction hose, the smaller the extraction
-
unit can be dimensioned / the less extraction capacity must be provided
to ensure that the welding fumes are optimally extracted
When the altitude increases, the extraction capacity must be reduced ac-
-
cording to the altitude due to the changing environmental conditions (lower
air pressure, etc.), for example by opening the air flow regulator of the welding torch or reducing the extraction capacity
in any case, the requirements for extraction must be met
-
use the Exentometer to determine the current extraction volumetric flow
-
of the welding torch - for this, see section Measuring the extraction ca-
pacity (extraction volumetric flow) with the Exentometer from page 34
The exact requirements for extraction can be found on the rating plate of the respective welding torch (see section Extraction information on the rating plate on
page 10) and in the technical data.
8
Rating plate on the welding torch
EN-US
9
Extraction in-
∆
p
c
[kPa]
Check
Qv,c [m³/h] Qv,n [m³/h]
11,0 94 57
MIXED
CO2
I2
X (40°C)
EN IEC 60974-7/-10 Cl.A
EN ISO 21904-1
Charge No.
Art.No.
Type
www.fronius.com
Q
v,n
Q
v,c
pc
pc
formation on the
rating plate
Example of a rating plate
Extraction information on the rating plate
Extraction volumetric flow at the front end of the welding torch ( =
the extraction volumetric flow provided by the welding torch)
Extraction volumetric flow at the extraction connection of the welding torch ( = the extraction volumetric flow that the extraction system must provide)
Required negative pressure at the extraction connection of the welding torch (= the negative pressure that the extraction system must
generate)
10
Available interfaces, functions of
the torch trigger
11
12
Available interfaces
EN-US
Up/Down-function
JobMaster-function
The Up/Down torch has the following
functions:
Changing the welding power in
-
synergic operation by means of up/
down buttons
Error display:
-
in the event of a system error,
-
all the LEDs turn red
in the event of a data commu-
-
nication error, all the LEDs
flash red.
Self-testing in the start-up se-
-
quence:
all the LEDs briefly light up in
-
succession.
The JobMaster welding torch has the
following functions:
The desired parameters are chosen
-
via arrow keys at the power source
Use the +/- keys to change the se-
-
lected parameters
The display shows the current
-
parameters and value
13
Functions of the torch trigger
Functions of the
two-staged
torch trigger
Function of the torch trigger at switch position 1 (torch trigger pushed halfway down) = LED lights up
NOTE!
An LED on the welding torch does not work for welding torches with optional
top torch trigger.
14
Function of the torch trigger in switch position 2 (torch trigger pressed all the way down) = LED goes
out, welding process starts
Commissioning
15
16
Commissioning procedure
EN-US
Procedure for
commissioning
welding torches
with Fronius
System Connector
Procedure for
commissioning
welding torches
with Euro connection
Perform the following activities for the correct commissioning of the welding
torch:
Fit the inner liner - Description from page 18
1
Connect the welding torch
2
Description of power source from page 31
-
Description of wirefeeder from page 32
-
Connect the welding torch to the extraction system - Description from page
3
34
Measure extraction capacity - Description from page 34
4
If necessary, adjust the extraction capacity:
Set the extraction capacity directly on the welding torch - Description from
5
page 37
Set the extraction capacity with external air flow regulator - Description
6
from page 39
Perform the following activities for the correct commissioning of the welding
torch:
Fit the inner liner
1
Description of steel inner liner from page 23
-
Description of plastic inner liner from page 27
-
Connect the welding torch to the power source - Description from page 33
2
Connect the welding torch to the extraction system - Description from page
3
34
Measure extraction capacity - Description from page 34
4
If necessary, adjust the extraction capacity:
Set the extraction capacity directly on the welding torch - Description from
5
page 37
Set the extraction capacity with external air flow regulator - Description
6
from page 39
17
Fitting inner liner in welding torch with Fronius
System Connector
Note on inner
liner in gascooled welding
torches
NOTE!
Risk due to incorrect wire-guide insert.
This can result in poor-quality weld properties.
If a plastic inner liner with a bronze wire-guide insert is used in gascooled
▶
welding torches instead of a steel inner liner, the power data stated in the
technical data of the welding torch must be reduced by 30%.
In order to operate gascooled welding torches at maximum power, replace
▶
the 40 mm (1.575 in.) wire-guide insert with a 320 mm (12.598 in.) wire-guide
insert.
1
18
Fitting the inner
liner
1
EN-US
Lay out the welding torch straight
2
Lay out the inner liner straight; make sure that no burr protrudes into or out of the inner liner
19
3
If the extraction nozzle, gas nozzle, and contact tip are already mounted, remove them
4
20
Push the inner liner into the welding torch (*this can be done from both sides) until it protrudes from
the front and rear of the welding torch; make sure that the inner liner is not kinked or snapped
5
Push the inner liner with the contact tip back into the torch body; mount the contact tip, gas nozzle,
and extraction nozzle; mark the inner liner at the end of the Schweißbrenners
6
EN-US
Pull inner liner 10 cm (3.94 in.) out of the welding torch
21
Loading...