FRO­NIUS MTG 250i User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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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
EN
Operating instructions
MIG/MAG manual welding torch
ET
Kasutusjuhend
Manuaalne MIG/MAG-keevituspõleti
HR
Upute za upotrebu
Ručni gorionik za zavarivanje za
MIG/MAG
HU
Kezelési útmutató
MIG/MAG kézi hegesztőpisztoly
IT
Istruzioni per l'uso
Torcia per saldatura manuale
MIG/MAG
JA
操作手順
MIG/MAG 手動溶接トーチ
42,0410,2067 013-28062021

Contents
Safety 4
Proper use 4
Safety 4
General 6
General 6
Up/Down function 6
JobMaster function 6
Functions of the torch trigger 7
Functions of the two-stage torch trigger 7
Installation and commissioning 8
MTG d, MTW d - Fitting wearing parts to the torch body 8
Assembling Multilock welding torches 9
Note regarding the inner liner with gascooled welding torches 9
Fitting the inner liner inside the torch hosepack 11
Connecting the welding torch to the wirefeeder 12
Connecting the welding torch to the power source and the cooling unit 13
Twisting the Multilock welding torch body 14
Changing the torch body on a Multilock welding torch 15
Care, maintenance and disposal 16
General 16
Recognising faulty wearing parts 16
Maintenance at every start-up 16
Maintenance every time the wirespool/basket-type spool is changed: 17
Troubleshooting 19
Troubleshooting 19
Technical data 24
General 24
Gas-cooled welding torch - MTG 250i, 320i, 400i, 550i 24
Gas-cooled hosepack - MHP 250i, 400i, 550i G ML 25
Gas-cooled torch neck - MTB 250i, 320i, 330i, 400i, 550i G ML 25
Water-cooled welding torch - MTW 250i, 400i, 500i, 700i 26
Water-cooled hosepack - MHP 500i, 700i W ML 26
Water-cooled torch neck - MTB 250i, 330i, 400i, 500i, 700i W ML 27
3
EN

Safety
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 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,
especially 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
insulated 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).
4

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 fit-
ted to them if the hoses are detached from the cooling unit or the wirefeeder.
5
EN

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
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 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 func-
tion
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 fol-
lowing 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 para-
meter and value
6

Functions of the torch trigger
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.
7
EN

Installation and commissioning
MTG d, MTW d -
Fitting wearing
parts to the torch
body
1 2
3** Screw on and tighten the gas
nozzle as far as it will go
8

Assembling Mul-
tilock 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.
1The 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.
2 3
* Ensure that the union nut is tightened as far as it will go.
Note regarding
the inner liner
with gascooled
welding torches
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 inner 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.
9
EN

1 2
10

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
1 2
3
*
**
4
5* Steel inner liner
** Plastic inner liner
11
EN

***
6*** 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.
7
Connecting the
welding torch to
the wirefeeder
*
4
4
3
5
1
* only if the optionally available coolant connections are installed in the wirefeeder
and with water-cooled welding torch.
Always connect the coolant hoses according to their colour marking.
12

Connecting the
welding torch to
the power source
and the cooling
unit
33
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.
3
13
EN

Twisting the Mul-
tilock 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 tem-
perature (+25 °C, +77 °F).
1 2
3 4
* Ensure that the union nut is tightened as far as it will go.
14

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 tem-
perature (+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.
15
EN

Care, maintenance and disposal
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 serious damage.
▶Do not strike the welding torch on
hard objects.
▶Avoid scoring and scratches in the
contact tip in which welding spatter
may become firmly lodged.
▶Do not bend the torch body under any
circumstances!
Recognising
faulty wearing
parts
1. 2. 3. 4. 5.
1. Insulating parts
- Burned-off outside edges, notches
2. Nozzle fittings
- Burned-off outside edges, notches
- Heavily covered in welding spatter
3. Spatter guard
- Burned-off outside edges, notches
4. Contact tips
- Worn-out (oval) wire entry and wire exit holes
- Heavily covered in welding spatter
- Penetration on the tip of the contact tip
5. Gas nozzles
- 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
16

1 2
* Check the gas nozzle, spatter guard and insulation for damage and replace 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
1
17
EN

2
18

Troubleshooting
Troubleshooting No welding current
Power source mains switch is on, indicators on the power source are lit up, shielding gas
available
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
Cause:
Remedy:
Cause:
Remedy:
Nothing happens when the torch trigger is pressed
Power source mains switch is on, indicators on the power source are lit up
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
Faulty power source
Contact After-Sales Service
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
No shielding gas
All other functions are OK
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 replaced)
Cause:
Remedy:
Cause:
Remedy:
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19
EN

Poor weld properties
Incorrect welding parameters
Correct settings
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 welding
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
Unfavourable welding conditions: shielding gas is contaminated (by mois-
ture, air), inadequate gas shield (weld pool "boiling", draughts), contamin-
ants 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
Cause:
Remedy:
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20