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

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 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.

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.

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

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

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.

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.

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

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