Fronius MTG/MTW/MTB/MHP 250i-700i ML /G/W Operating Instruction

Operating Instructions

MTG 250i, 320i, 400i, 550i MTW 250i, 400i, 500i, 700i MTB 250i, 320i, 330i, 400i, 550i G ML MTB 250i, 330i, 400i, 500i W ML MTB 700i W ML MHP 250i, 400i, 550i G ML MHP 500i, 700i W ML

Operating Instructions

Kasutusjuhend

Upute za upotrebu

Kezelési útmutató

Istruzioni per l'uso

操作手順

42,0410,2067 022-17012023

Contents

General 4

Safety 4 General 5 Proper use 5

Options 6

Pistol grip 6 Heat shield 6 Potentiometer 6 Additional torch trigger on the top 7 ExtractionFumeEx 7 Torch trigger extension 7

Description of available functions 8

Up/Down-function 8 JobMaster-function 8 Functions of the two-stage torch trigger 8 Special functions 9

Installation and commissioning 10

MTG d, MTW d - Fitting wearing parts to the torch body 10 Assembling Multilock welding torches 11 Note regarding the inner liner with gascooled welding torches 11 Fitting the inner liner inside the torch hosepack 13 Connecting the welding torch to the wirefeeder 14 Connecting the welding torch to the power source and the cooling unit 15 Twisting the Multilock welding torch body 16 Changing the torch body on a Multilock welding torch 17

Care and maintenance 18

General 18 Recognising faulty wearing parts 18 Maintenance at every start-up 18 Maintenance every time the wirespool/basket-type spool is changed 19

Troubleshooting 21

Technical data 26

General 26 Gas-cooled welding torch - MTG 250i, 320i, 400i, 550i 26 Gas-cooled hosepack - MHP 250i, 400i, 550i G ML 27 Gas-cooled torch body - MTB 250i, 320i, 330i, 400i, 550i G ML 27 Water-cooled welding torch - MTW 250i, 400i, 500i, 700i 28 Water-cooled hosepack - MHP 500i, 700i W ML 28 Water-cooled torch body - MTB 250i, 330i, 400i, 500i, 700i W ML 29

General

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 device

▶

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 devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on.

WARNING!

Danger from electric current due to defective system components and incorrect operation.

This can result in serious personal injury and damage to property.

All cables, leads and hosepacks must always be securely connected, undam-

▶

aged and correctly insulated. Only use adequately dimensioned cables, leads and hosepacks.

▶

WARNING!

Risk of coolant escaping.

This can result in serious personal injury and damage to property.

When disconnecting a welding torch from the cooling unit or other system

▶

components, always seal the coolant hoses using the plastic seal attached to the torch.

WARNING!

Danger due to hot system components and/or equipment.

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.

This can result in serious personal injuries.

Always extract welding fumes.

▶

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate

▶

of at least 20 m³ (169070.1 US gi) per hour at all times. If in doubt, a safety engineer should be commissioned to check the pollution

▶

level in the workplace.

CAUTION!

Danger from operation without coolant.

This can result in damage to property.

Never operate water-cooled welding torches without coolant.

▶

During welding, ensure that the coolant is circulating correctly – this will be

▶

the case for Fronius cooling units if a regular return ﬂow of coolant can be seen in the coolant container of the cooling unit. The manufacturer will not be liable for any damages due to non-observance

▶

of the above mentioned points. All claims against the warranty are void.

General These MIG/MAG welding torches are exceptionally robust and reliable. The ergo-

nomic grip, ball joint and optimal weight distribution combine to enable fatiguefree working. The welding torches are available as gas-cooled and water-cooled versions in different power categories and sizes, so no weld seam is out of reach. The welding torches can be adapted to deal with a huge variety of different tasks, and are ideal for use in manual series and one-off fabrication, as well as in the workshop sector.

Proper use The MIG/MAG manual welding torch is intended solely for MIG/MAG welding in

manual applications. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

Proper use includes:

Carefully reading and following all the instructions given in the operating in-

structions Performing all stipulated inspection and maintenance work.

Options

Pistol grip OPT/i T-Handle SET for W6

44,0350,5298

Heat shield Heat shield

42,0405,0753

Potentiometer OPT/i Userinterface Poti W6

4,001,796

Additional torch trigger on the top

Additional torch trigger on the top 42,0405,0671 4,070,958,Z 43,0004,4062

ExtractionFumeEx

Torch trigger extension

OPT/i FumeEx Small /5m 44,0350,4078

OPT/i FumeEx Medium /5m 44,0350,4077

OPT/i FumeEx MTG400i US/45° 44,0350,1536

Torch trigger extension 44,0350,5229

Description of available functions

Up/Down-function

JobMaster-function

The Up/Down torch has the following functions:

Changes the welding power in Syn-

ergic operation via the Up/Down buttons Error display:

all the LEDs light up red if

there is a system fault all the LEDs ﬂash red if there

is a data communication fault

Self-test during the run-up se-

quence:

all LEDs light up brieﬂy one

after the other

The JobMaster welding torch has the following functions:

The desired welding parameter on

the power source can be selected using the arrow buttons The selected welding parameter

can be changed using the +/- buttons The display shows the current

welding parameter and value

Functions of the two-stage torch trigger

Function of the torch trigger in switching position 1 (torch trigger half pressed):

LED lights up.

Function of the torch trigger in switching position 2 (torch trigger fully pressed):

LED goes out

Welding starts.

NOTE!

An LED on welding torches with an optional torch trigger on the top will not work.

Special functions

Various special functions can be stored for the torch trigger and for function keys. For details on the special functions, see the operating instructions for the power source.

Installation and commissioning

MTG d, MTW d Fitting wearing parts to the torch body

1 2

** Screw on and tighten the gas

nozzle as far as it will go

Assembling Multilock welding torches

NOTE!

Risk from incorrect assembly of the welding torch.

This can result in damage to the welding torch.

Before fitting a torch body, ensure that the interface between the torch body

▶

and the hosepack is clean and undamaged. In the case of water-cooled welding torches, increased resistance may arise

▶

when tightening the union nut due to the construction of the welding torch. Always tighten the union nut on the torch body as far as it will go.

▶

2 3

The torch body is in the 0° position when the dowel pin (1) on the hosepack engages in the locating hole (2) in the torch body.

Note regarding the inner liner with gascooled welding torches

* Ensure that the union nut is tightened as far as it will go.

NOTE!

Risk from incorrect inner liner insert.

This can result in poor weld properties.

If a gascooled welding torch is used with a plastic inner liner and bronze in-

▶

ner liner insert instead of a steel inner liner, the performance data specified in the technical data is reduced by 30%. To operate gascooled welding torches at maximum power, replace the 40 mm

▶

(1.575 in.) inner liner insert with the 300 mm (11.81 in.) inner liner insert.

1 2

Fitting the inner

liner inside the torch hosepack

NOTE!

Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner might not be inserted correctly.

1 2

* Steel inner liner ** Plastic inner liner

***

*** Screw the clamping nipple onto

the inner liner as far as it will go. The inner liner must be visible through the hole in the cap.

Connecting the welding torch to the wirefeeder

* Only if the optional coolant

connections are fitted in the wirefeeder and when using a water-cooled welding torch.

Always connect the coolant hoses according to their colour coding.

Connecting the

welding torch to the power source and the cooling unit

1 2

* Only if the optional coolant connections are fitted in the cooling unit and

when using a water-cooled welding torch. Always connect the coolant hoses according to their colour coding.

Twisting the Multilock welding torch body

CAUTION!

Risk of burns from hot coolant and hot torch body.

This can result in severe scalds.

Before carrying out any work, allow the coolant and torch body to cool to

▶

room temperature (+25 °C, +77 °F).

1 2

3 4

* Ensure that the union nut is tightened as far as it will go.

Changing the torch body on a Multilock welding torch

CAUTION!

Risk of burns from hot coolant and hot torch body.

This can result in severe scalds.

Before carrying out any work, allow the coolant and torch body to cool to

▶

room temperature (+25 °C, +77 °F). Some coolant will always remain in the torch body. Only remove the torch

▶

body with the gas nozzle pointing downwards

CAUTION!

Risk from incorrect assembly of the welding torch.

This can result in serious damage to property.

Before fitting a torch body, ensure that the interface between the torch body

▶

and the hosepack is clean and undamaged.

1 2

The torch body is in the 0° position when the dowel pin (1) on the hosepack engages in the locating hole (2) in the torch body.

3 4

* Ensure that the union nut is tightened as far as it will go.

Care and maintenance

General Regular preventive maintenance of the welding torch is essential if trouble-free

operation is to be ensured. The welding torch is subjected to high temperatures and heavy soiling. The welding torch therefore requires more frequent maintenance than other components in the welding system.

CAUTION!

Risk of damage from improper handling of the welding torch.

This can result in severe damage to property.

Do not strike the welding torch on

▶

hard objects. Avoid scoring and scratches on the

▶

contact tip. Do not bend the torch body under

▶

any circumstances.

Recognising faulty wearing parts

Insulating parts

1. Burned-off outside edges, notches

Nozzle fittings

2. Burned-off outside edges, notches

Heavily covered in welding spatter

Spatter guard

3. Burned-off outside edges, notches

Contact tips

4. Worn-out (oval) wire entry and wire exit holes

Heavily covered in welding spatter

Penetration on the tip of the contact tip

Gas nozzles

5. Heavily covered in welding spatter

Burned-off outside edges

Notches

Maintenance at every start-up

Check wearing parts

replace faulty wearing parts

Remove welding spatter from gas nozzle

1 2

* Check the gas nozzle, spatter guard and insulation for damage and re-

place any damaged components.

Also at every start-up when using water-cooled welding torches:

check all coolant connections for tightness (no leaks)

check that the coolant can ﬂow unhindered

Maintenance every time the wirespool/ basket-type spool is changed

Clean wirefeeding hose with reduced compressed air

Recommended: replace the inner liner. Clean the wearing parts before fitting

the new inner liner

Fitting wearing parts

For details on fitting the wearing parts, refer to the section MTG d, MTW

d - Fitting wearing parts to the torch body from page 10.

Troubleshooting

No welding current

Power source mains switch is on, indicators on the power source are lit up, shielding gas available

Cause: Remedy:

Nothing happens when the torch trigger is pressed

Power source mains switch is on, indicators on the power source are lit up

Cause:

Remedy:

Cause: Remedy:

Grounding (earthing) connection is incorrect Establish a proper grounding (earthing) connection

There is a break in the current cable in the welding torch Replace welding torch

The FSC ('Fronius System Connector' central connector) is not plugged in properly

Push on the FSC as far as it will go

Welding torch or welding torch control line is faulty Replace welding torch

Interconnecting hosepack faulty or not connected properly Connect interconnecting hosepack properly

Replace faulty interconnecting hosepack

Cause: Remedy:

No shielding gas

All other functions are OK

Cause: Remedy:

Faulty power source Contact After-Sales Service

Gas cylinder is empty Change the gas cylinder

Gas pressure regulator is faulty Replace gas pressure regulator

The gas hose is not connected, or is damaged or kinked Fit gas hose, lay out straight Replace faulty gas hose

Welding torch is faulty Replace welding torch

Gas solenoid valve is faulty Contact After-Sales Service (arrange for gas solenoid valve to be re-

placed)

Poor weld properties

Cause: Remedy:

Incorrect welding parameters Correct settings

Cause: Remedy:

Poor grounding (earthing) connection Ensure good contact to workpiece

Inadequate or no protective gas shield Check the pressure regulator, gas hose, gas solenoid valve and weld-

ing torch shielding gas connection. On gas-cooled welding torches, inspect the gas seals, use a suitable inner liner

Welding torch is leaking Replace welding torch

Contact tip is too large or worn out Replace the contact tip

Wrong wire alloy or wrong wire diameter Check wirespool/basket-type spool in use

Wrong wire alloy or wrong wire diameter Check weldability of the base material

The shielding gas is not suitable for this wire alloy Use the correct shielding gas

Cause:

Remedy:

Cause: Remedy:

Cause:

Remedy:

Unfavourable welding conditions: shielding gas is contaminated (by moisture, air), inadequate gas shield (weld pool "boiling", draughts), contaminants in the workpiece (rust, paint, grease)

Optimise the welding conditions

Welding spatter in the gas nozzle Remove welding spatter

Turbulence caused by too high a rate of shielding gas ﬂow Reduce shielding gas ﬂow rate, recommended:

shielding gas ﬂow rate (l/min) = wire diameter (mm) x 10 (e.g. 16 l/min for 1.6 mm wire electrode)

Too large a distance between the welding torch and the workpiece Reduce the distance between the welding torch and the workpiece

(approx. 10 - 15 mm / 0.39 - 0.59 in.)

Tilt angle of the welding torch is too great Reduce the tilt angle of the welding torch

Wirefeed components do not match the diameter of the wire electrode / the wire electrode material

Use the correct wirefeed components

Poor wirefeed

Cause:

Remedy:

Depending on the system, brake force in wire-feed unit or power source set too high

Reduce the braking force

Cause: Remedy:

Cause:

Remedy:

Cause: Remedy:

Hole in the contact tip is displaced Replace the contact tip

The inner liner or wire-guide insert is defective Check the inner liner and wire-guide insert for kinks, dirt, etc.

Change the faulty inner liner or wire-guide insert

The wirefeeder rollers are not suitable for the wire electrode being used

Use suitable wirefeeder rollers

Wirefeeder rollers have the wrong contact pressure Optimise the contact pressure

The wirefeeder rollers are soiled or damaged Clean the wirefeeder rollers or replace them by new ones

Inner liner wrongly laid or kinked Replace inner liner

The inner liner has been cut too short Replace the inner liner and cut the new inner liner to the correct

length

Cause:

Remedy:

Cause: Remedy:

The gas nozzle becomes very hot

Cause: Remedy:

Wire electrode worn due to excessive contact pressure on the wirefeeder rollers

Reduce contact pressure on the wirefeeder rollers

Wire electrode contains impurities or is corroded Use high-quality wire electrode with no impurities

For steel inner liners: use of uncoated inner liner Use a coated inner liner

No thermal dissipation as the gas nozzle is too loose Screw on the gas nozzle as far as it will go

The welding torch becomes very hot

Cause: Remedy:

Only on Multilock welding torches: torch neck union nut is loose Tighten the union nut

Cause: Remedy:

Contact tip has a short service life

Cause: Remedy:

Cause:

Remedy:

Cause: Remedy:

Welding torch operated above the maximum welding current Reduce welding power or use a more powerful welding torch

The specification of the welding torch is inadequate Observe the duty cycle and loading limits

Only on water-cooled systems: Inadequate coolant ﬂow Check coolant level, coolant ﬂow, coolant contamination, the routing

of the hosepack, etc.

The tip of the welding torch is too close to the arc Increase stick-out

Incorrect wirefeeder rollers Use correct wirefeeder rollers

Wire electrode worn due to excessive contact pressure on the wirefeeder rollers

Reduce contact pressure on the wirefeeder rollers

Wire electrode contains impurities/is corroded Use high-quality wire electrode with no impurities

Cause: Remedy:

Cause:

Remedy:

NOTE!

When using CrNi, the contact tip may be subject to a higher degree of wear due to the nature of the surface of the CrNi wire electrode.

Uncoated wire electrode Use wire electrode with suitable coating

Wrong dimension of contact tip Use a contact tip of the correct dimension

Duty cycle of welding torch has been exceeded Shorten the duty cycle or use a more powerful welding torch

Contact tip has overheated. No thermal dissipation as the contact tip is too loose

Tighten the contact tip

Torch trigger malfunction

Cause: Remedy:

Defective plug connection between welding torch and power source Establish proper plug connections / have power source or welding

torch serviced

Cause: Remedy:

Weld seam porosity

Cause:

Remedy:

Cause: Remedy:

Build up of dirt between torch trigger and torch trigger housing Clean away the dirt

Control line is faulty Contact After-Sales Service

Spatter build-up in the gas nozzle causing inadequate gas shield for weld seam

Remove welding spatter

Holes in gas hose or hose is not connected properly Replace gas hose

O-ring on central connector has been cut or is faulty Replace O-ring

Moisture/condensation in the gas line Dry gas line

Gas ﬂow is either too high or too low Correct gas ﬂow

Cause: Remedy:

Cause:

Remedy:

Cause: Remedy:

Insufficient gas ﬂow at start or end of welding Increase gas pre-ﬂow and gas post-ﬂow

Rusty or poor quality wire electrode Use high-quality wire electrode with no impurities

For gas-cooled welding torches: gas is escaping through a non-insulated inner liner

Use only insulated inner liners with gas-cooled welding torches

Too much parting agent applied Remove excess parting agent/apply less parting agent

Technical data

General Voltage measurement (V-Peak):

for manually-operated welding torches: 113 V

for mechanically-driven welding torches: 141 V

Torch trigger technical data:

U I

max

= 5 V

= 10 mA

The torch trigger may only be operated in accordance with the technical data.

The product conforms to the requirements of IEC 60974-7 / - 10 Class A.

Gas-cooled welding torch MTG 250i, 320i, 400i, 550i

I (ampere) 10 min/ 40°C M21+C1 (EN 439)

[mm (in.)] 0.8-1.2

[m (ft.)] 3.5 / 4.5 (12 /

* ED = Duty cycle

MTG 550i

I (ampere) 10 min/ 40°C C1 (EN 439)

I (ampere) 10 min/ 40°C M21 (EN 439)

I (ampere) 10 min/ 40°C M21+C1 (EN 439)

MTG 250i MTG 320i MTG 400i

40 % ED* 250 60 % ED* 200 100 % ED* 170

(0.032-0.047)

15)

30 % ED* 550

30% ED* 520

60 % ED* 420 100 % ED* 360

40 % ED* 320 60 % ED* 260 100 % ED* 210

0.8-1.6 (0.032-0.063)

3.5 / 4.5 (12 /

15)

40 % ED* 400 60 % ED* 320 100 % ED* 260

0.8-1.6 (0.032-0.063)

3.5 / 4.5 (12 /

15)

[mm (in.)] 1.2-1.6 (0.047-0.063)

[m (ft.)] 3.5 / 4.5 (12 / 15)

* ED = Duty cycle

Gas-cooled

hosepack - MHP 250i, 400i, 550i G ML

MHP 250i G ML MHP 400i G ML

I (ampere) 10 min/40°C M21+C1 (EN 439)

[mm (in.)] 0.8-1.2 (0.032-0.047) 0.8-1.6 (0.032-0.063)

[m (ft.)] 3.35 / 4.35 (11 / 14) 3.35 / 4.35 (11 / 14)

* ED = Duty cycle

40 % ED* 250 60 % ED* 200 100 % ED* 170

MHP 550i G ML

40 % ED* 400 60 % ED* 300 100 % ED* 260

Gas-cooled torch body MTB 250i, 320i, 330i, 400i, 550i G ML

I (ampere) 10 min/40°C C1 (EN 439)

I (ampere) 10 min/40°C M21 (EN 439)

I (ampere) 10 min/40°C M21+C1 (EN 439)

[mm (in.)] 1.2-1.6 (0.047-0.063)

[m (ft.)] 3.35 / 4.35 (11 / 14)

* ED = Duty cycle

MTB 250i G ML MTB 320i G ML MTB 330i G ML

I (ampere) 10 min/ 40°C M21+C1 (EN 439)

[mm (in.)] 0.8-1.2

30 % ED* 550

30% ED* 520

60 % ED* 420 100 % ED* 360

40 % ED* 250 60 % ED* 200 100 % ED* 170

(0.032-0.047)

40 % ED* 320 60 % ED* 260 100 % ED* 210

0.8-1.6 (0.032-0.063)

40 % ED* 330 60 % ED* 270 100 % ED* 220

0.8-1.6 (0.032-0.063)

* ED = Duty cycle

MTB 400i G ML MTB 550i G ML

I (ampere) 10 min/ 40°C C1 (EN 439)

I (ampere) 10 min/ 40°C M21 (EN 439)

I (ampere) 10 min/ 40°C M21+C1 (EN 439)

[mm (in.)] 0.8-1.6 (0.032-0.063) 0.8-1.6 (0.032-0.063)

* ED = Duty cycle

- 30 % ED* 550

- 30 % ED* 520

40 % ED* 400 60 % ED* 320 100 % ED* 260

60 % ED* 420 100 % ED* 360

Water-cooled

welding torch MTW 250i, 400i, 500i, 700i

I (ampere) 10 min/ 40°C M21+C1 (EN 439)

MTW 250i MTW 400i MTW 500i MTW 700i

100 % ED* 250

100 % ED* 400

100 % ED* 500

100 % ED* 700

max

min

[mm (in.)] 0.8-1.2

(0.032-0.04

[m (ft.)] 3.5 / 4.5

(12 / 15)

[W]** 500/600 W 800/950 W 1400 /

[l/min

1 (0.26) 1 (0.26) 1 (0.26) 1 (0.26)

0.8-1.6 (0.032-0.06

3.5 / 4.5 (12 / 15)

(gal./min)]

min

max

[bar (psi.)] 3 bar (43

psi)

[bar (psi.)] 5 bar (72

psi)

3 bar (43 psi)

5 bar (72 psi)

* ED = Duty cycle ** Lowest cooling power according to IEC 60974-2

1.0-1.6 (0.039-0.06

3.5 / 4.5 / 6 (12 / 15 /

20)

1700 / 2000 W

3 bar (43 psi)

5 bar (72 psi)

1.0-1.6 (0.039-0.06

3.5 / 4.5 (12 / 15)

1800 / 2200 W

3 bar (43 psi)

5 bar (72 psi)

Water-cooled hosepack - MHP 500i, 700i W ML

MHP 500i W ML MHP 700i W ML

I (ampere) 10 min/

100 % ED* 500 100 % ED* 700 40°C M21+C1 (EN 439)

[mm (in.)] 0.8-1.6 (0.032-0.063) 1.0-1.6 (0.039-0.063)

[m (ft.)] 3.35 / 4.35 / 5.85

(11/14/19)

max

min

[W]** 1400 / 1700 / 2000 W 1800 / 2200 W

[l/min

1 (0.26) 1 (0.26)

(gal./min)]

min

max

[bar (psi.)] 3 bar (43 psi) 3 bar (43 psi)

[bar (psi.)] 5 bar (72 psi) 5 bar (72 psi)

* ED = Duty cycle ** Lowest cooling power according to IEC 60974-2

3.35 / 4.35 (11 / 14)

Water-cooled

torch body MTB 250i, 330i, 400i, 500i, 700i W ML

I (ampere) 10 min/ 40°C M21+C1 (EN 439)

MTB 250i W ML

100 % ED* 250

MTB 330i W ML

100 % ED* 330

MTB 400i W ML

100 % ED* 400

MTB 500i W ML

100 % ED* 500

[mm (in.)] 0.8-1.2

min

[l/min (gal./min)]

* ED = Duty cycle

I (ampere) 10 min/ 40°C M21+C1 (EN 439)

[mm (in.)] 1.0-1.6

min

[l/min (gal./min)]

* ED = Duty cycle

(0.032-0.04

0.8-1.6 (0.032-0.06

1.0-1.6 (0.039-0.06

1 (0.26) 1 (0.26) 1 (0.26) 1 (0.26)

MTB 700i W ML

100 % ED* 700

(0.039-0.063)

1 (0.26)

+ 142 hidden pages

Fronius MTG/MTW/MTB/MHP 250i-700i ML /G/W Operating Instruction

Specifications and Main Features

Frequently Asked Questions

User Manual