FRO­NIUS MTG 250i User manual

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
42,0410,2067 022-17012023
EN Operating Instructions
ET Kasutusjuhend
HR Upute za upotrebu
HU Kezelési útmutató
IT Istruzioni per l'uso
JA 操作手順

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
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
3
EN

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 incor-
rect 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.
4

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 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 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.
5
EN

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
6

Additional torch
trigger on the
top
Additional torch trigger on the top
42,0405,0671
4,070,958,Z
43,0004,4062
Extrac-
tionFumeEx
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 ex-
tension
Torch trigger extension
44,0350,5229
7
EN

Description of available functions
Up/Down-func-
tion
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
JobMaster-func-
tion
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 +/- but-
tons
-The display shows the current
welding parameter and value
Functions of the
two-stage torch
trigger
Function of the torch trigger in switch-
ing position 1 (torch trigger half
pressed):
-LED lights up.
8

Function of the torch trigger in switch-
ing 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 func-
tions
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.
9
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
10

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 hosep-
ack 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 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.
11
EN

1 2
12

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
13
EN

***
6*** Screw the clamping nipple onto
the inner liner as far as it will
go. The inner liner must be vis-
ible through the hole in the cap.
7
Connecting the
welding torch to
the wirefeeder
3
48
5
7
6
9
10
1* 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.
14

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
15
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 temperature (+25 °C, +77 °F).
1 2
3 4
* Ensure that the union nut is tightened as far as it will go.
16

Changing the
torch body on a
Multilock weld-
ing 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 en-
gages in the locating hole (2) in the torch body.
3 4
* Ensure that the union nut is tightened as far as it will go.
17
EN

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 mainten-
ance than other components in the welding system.
CAUTION!
Risk of damage from improper hand-
ling 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
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
18

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
1234
5
1
19
EN

2
3Fitting 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.
20