FRO­NIUS MTG 250i User manual

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/ Perfect Charging / Perfect Welding / Solar Energy
42,0410,2067 012-29052020
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
MIG/MAG manual welding torch
Kasutusjuhend
Manuaalne MIG/MAG-keevituspõ-
leti
Uputstvo za upotrebu
Ručni gorionik za zavarivanje za
MIG/MAG
Kezelési útmutató
MIG/MAG kézi hegesztőpisztoly
Istruzioni per l'uso
Torcia per saldatura manuale MIG/
MAG
操作手順
MIG/MAG 手動溶接トーチ
ENETHRHUITJA

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EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

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Contents
Safety......................................................................................................................................................... 7
Proper use ............................................................................................................................................ 7
Safety.................................................................................................................................................... 7
General ...................................................................................................................................................... 9
General ................................................................................................................................................. 9
Up/Down function.................................................................................................................................. 9
JobMaster function................................................................................................................................ 9
Functions of the torch trigger ..................................................................................................................... 10
Functions of the two-stage torch trigger................................................................................................ 10
Installation and commissioning .................................................................................................................. 11
Fitting wearing parts to the torch body.................................................................................................. 11
Assembling Multilock welding torches .................................................................................................. 12
Note regarding the inner liner with gas-cooled welding torches ........................................................... 13
Fitting the inner liner inside the torch hosepack.................................................................................... 13
Connecting the welding torch to the wire-feed unit............................................................................... 15
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, maintenance and disposal ............................................................................................................... 18
General ................................................................................................................................................. 18
Recognising faulty wearing parts.......................................................................................................... 18
Maintenance at every start-up .............................................................................................................. 19
Maintenance every time the wirespool/basket-type spool is changed:................................................. 19
Troubleshooting ......................................................................................................................................... 20
Troubleshooting .................................................................................................................................... 20
Technical data............................................................................................................................................ 25
General ................................................................................................................................................. 25
Gas-cooled welding torch - MTG 250i, 320i, 400i, 550i........................................................................ 25
Gas-cooled hosepack - MHP 250i, 400i, 550i G ML............................................................................. 26
Gas-cooled torch neck - MTB 250i, 320i, 330i, 400i, 550i G ML .......................................................... 26
Water-cooled welding torch - MTW 250i, 400i, 500i, 700i .................................................................... 27
Water-cooled hosepack - MHP 500i, 700i W ML.................................................................................. 27
Water-cooled torch neck - MTB 250i, 330i, 400i, 500i, 700i W ML....................................................... 28

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Safety
Proper use The MIG/MAG manual welding torch is intended solely for MIG/MAG welding in manual ap-
plications.
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 instructions
- Performing all stipulated inspection and maintenance work.
Safety WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in serious injury and damage to property.
► All the work and functions described in this document must only be carried out by
trained and qualified personnel.
► Read and understand this document.
► Read and understand all the Operating Instructions for the system components, espe-
cially the safety rules.
WARNING!
Danger from electric current and risk of injury from the emerging wire electrode.
This can result in serious injury and damage to property.
► Turn the power source mains switch to the "O" position.
► Disconnect the power source from the mains.
► Ensure that the power source remains disconnected from the mains until all work has
been completed.
WARNING!
Danger from electric current.
This can result in serious injury and damage to property.
► All cables, lines and hosepacks must be properly connected, undamaged, correctly in-
sulated and adequately dimensioned at all times.
CAUTION!
Risk of burns from hot welding torch components and hot coolant.
This can result in severe scalds.
► Before commencing any of the work described in these Operating Instructions, allow
all welding torch components and the coolant to cool to room temperature (+25 °C, +77
°F).

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CAUTION!
Risk of damage due to operation without coolant.
This can result in serious damage to property.
► Never operate a water-cooled welding torch without coolant.
► Fronius shall not be liable for any damage resulting from such action. In addition, no
warranty claims will be entertained.
CAUTION!
Danger from coolant leakage.
This can result in serious injury and damage to property.
► Seal the coolant hoses on water-cooled welding torches with the plastic stoppers fitted
to them if the hoses are detached from the cooling unit or the wirefeeder.

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General
General MIG/MAG welding torches are particularly robust and reliable, with an ergonomic grip, ball
joint and perfect weight distribution for fatigue-free working. The welding torches are avail-
able 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 used in an extremely wide range
of applications. They are ideal for manual batch and single-piece production as well as jobs
in the workshop.
Up/Down function The Up/Down torch has the following func-
tions:
- Changes the welding power in Syner-
gic 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 sequence:
- all LEDs light up briefly one after
the other
JobMaster func-
tion The JobMaster welding torch has the follo-
wing functions:
- The desired welding parameter on the
power source can be selected using
the arrow buttons
- The parameter can be changed using
the +/- buttons
- The display shows the current parame-
ter and value

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Functions of the torch trigger
Functions of the
two-stage torch
trigger
Function of the torch trigger in switching po-
sition 1 (torch trigger half pressed):
- LED lights up.
Function of the torch trigger in switching po-
sition 2 (torch trigger fully pressed):
- LED goes out
- Welding starts.