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

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 electric current.

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

Before starting work, switch off all the devices and components involved and disconnect them from the grid.

Secure all the devices and components involved to prevent unintentional restarting.

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, undamaged and correctly insulated.

Only use adequately dimensioned cables, leads and hosepacks.

WARNING!

Danger due to contact with toxic welding fume.

This can result in serious personal injury.

Always extract welding fume.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³/h (11.77 cfm) at all times.

If in doubt, a safety engineer should be commissioned to check the pollution level in the workplace.

CAUTION!

Danger due to hot system components and/or equipment.

This can result in 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 if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

CAUTION!

Danger due to operation without coolant.

This can result in damage to property.

Never operate water-cooled devices without coolant.

During welding, ensure that there is a proper coolant flow. When using Fronius cooling units, this is the case if a proper coolant return flow can be seen in the coolant container of the cooling unit.

CAUTION!

Risk of coolant escaping.

This can result in 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 other system components.

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 electric current.

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

Before starting work, switch off all the devices and components involved and disconnect them from the grid.

Secure all the devices and components involved to prevent unintentional restarting.

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, undamaged and correctly insulated.

Only use adequately dimensioned cables, leads and hosepacks.

WARNING!

Danger due to contact with toxic welding fume.

This can result in serious personal injury.

Always extract welding fume.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³/h (11.77 cfm) at all times.

If in doubt, a safety engineer should be commissioned to check the pollution level in the workplace.

CAUTION!

Danger due to hot system components and/or equipment.

This can result in 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 if cooling down is not possible (e.g., heat-resistant gloves, safety goggles, etc.).

CAUTION!

Danger due to operation without coolant.

This can result in damage to property.

Never operate water-cooled devices without coolant.

During welding, ensure that there is a proper coolant flow. When using Fronius cooling units, this is the case if a proper coolant return flow can be seen in the coolant container of the cooling unit.

CAUTION!

Risk of coolant escaping.

This can result in 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 other system components.

These MIG/MAG welding torches are exceptionally robust and reliable. The ergonomic 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.

The MIG/MAG manual welding torch is intended exclusively for MIG/MAG welding in manual applications.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended use.

Intended use also includes:

Following all the instructions contained in the operating instructions
Performing all stipulated inspection and maintenance work

OPT/i T-Handle SET for W6
44,0350,5298

Heat shield
42,0405,0753

OPT/i Userinterface Poti W6
4,001,796

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

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

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

OPT/i Exento MTG400i TD/45°
44,0350,1536

Torch trigger extension
44,0350,5229

The Up/Down torch has the following functions:

Changes the welding power in Synergic 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

The Up/Down torch has the following functions:

Changes the welding power in Synergic 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

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

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.

Various special functions can be stored for the torch trigger and for function keys.
For details on the special functions, please refer to the operating instructions for the welding machine.

TT-SH torch trigger, top - straight torch handle

TT-SH with straight torch handle and torch trigger at top

1

2

3

**	Screw on and tighten the gas nozzle as far as it will go

1

2

3

**	Screw on and tighten the gas nozzle as far as it will go

Variant MTB 200i G / MTB 220i W:
44,0350,4527

1

2

3

**	Screw on and tighten the gas nozzle as far as it will go

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.

1

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.

2

3

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

NOTE!

Risk due to incorrect inner liner insert.

This can result in poor weld properties.

If a gas-cooled welding torch is used with a plastic inner liner and bronze inner liner insert instead of a steel inner liner, the performance data of the welding torch specified in the technical data is reduced by 30%.

To operate gas-cooled welding torches at maximum power, replace the 40 mm (1.575 in.) inner liner insert with the 320 mm (12,598 in.) inner liner insert.

1

Left: Brass clamping nipple with sealing disc. Right: Silver clamping nipple without sealing disc.

*	IMPORTANT! Check the clamping nipple before commissioning and every time the inner liner is changed.

* Carry out a visual inspection for this purpose:

Left: Brass clamping nipple with sealing disc. You cannot see through the sealing disc.
Right: Silver clamping nipple with visible hole.

NOTE!

Incorrect or defective clamping nipple for push applications

Gas loss and poor weld properties will result.

Use brass clamping nipples to minimise gas loss.

Check that the sealing disc is intact.

NOTE!

Incorrect clamping nipple for push-pull applications

Wire winder and increased abrasion in the inner liner when using a clamping nipple with sealing disc.

Use the silver clamping nipple to facilitate wire feeding.

1

Lay the welding torch out straight

2

Lay the inner liner out straight

3

Push the inner liner into the welding torch until it protrudes from the front of the welding torch

4

Mark the end of the torch connector on the inner liner

5

Cut off the inner liner at the marking and deburr; left inner liner made of steel, right inner liner made of plastic

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

Fit the extraction nozzle

Push the extraction nozzle on as far as it will go.

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

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.

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.

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.

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.

Insulating parts
- Burned-off outside edges, notches
Nozzle fittings
- Burned-off outside edges, notches
- Heavily covered in welding spatter
Spatter guard
- Burned-off outside edges, notches
Contact tips
- Worn-out (oval) wire entry and wire exit holes
- Heavily covered in welding spatter
- Penetration on the tip of the contact tip
Gas nozzles
- Heavily covered in welding spatter
- Burned-off outside edges
- Notches

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 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

Clean wirefeeding hose with reduced compressed air
Recommended: replace the inner liner. Clean the wearing parts before fitting the new inner liner

1

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 (→).

No welding current

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

Cause:	Grounding (earthing) connection is incorrect
Remedy:	Establish a proper grounding (earthing) connection
Cause:	There is a break in the current cable in the welding torch
Remedy:	Replace welding torch

Nothing happens when the torch trigger is pressed

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

Cause:	The FSC ('Fronius System Connector' central connector) is not plugged in properly
Remedy:	Push on the FSC as far as it will go
Cause:	Welding torch or welding torch control line is faulty
Remedy:	Replace welding torch
Cause:	Interconnecting hosepack faulty or not connected properly
Remedy:	Connect interconnecting hosepack properly Replace faulty interconnecting hosepack
Cause:	Faulty power source
Remedy:	Contact After-Sales Service

No shielding gas

All other functions are OK

Cause:	Gas cylinder is empty
Remedy:	Change the gas cylinder
Cause:	Gas pressure regulator is faulty
Remedy:	Replace gas pressure regulator
Cause:	The gas hose is not connected, or is damaged or kinked
Remedy:	Fit gas hose, lay out straight Replace faulty gas hose
Cause:	Welding torch is faulty
Remedy:	Replace welding torch
Cause:	Gas solenoid valve is faulty
Remedy:	Contact After-Sales Service (arrange for gas solenoid valve to be replaced)

Poor weld properties

Cause:	Incorrect welding parameters
Remedy:	Correct settings
Cause:	Poor ground earth connection
Remedy:	Ensure good contact to workpiece
Cause:	Inadequate or no shielding gas
Remedy:	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
Cause:	Welding torch is leaking
Remedy:	Replace welding torch
Cause:	Contact tip is too large or worn out
Remedy:	Replace contact tip
Cause:	Wrong wire alloy or wrong wire diameter
Remedy:	Check wirespool/basket-type spool in use
Cause:	Wrong wire alloy or wrong wire diameter
Remedy:	Check weldability of the base material
Cause:	The shielding gas is not suitable for this wire alloy
Remedy:	Use the correct shielding gas
Cause:	- Contaminated shielding gas (e.g. due to moisture or air) - Inadequate gas shield (e.g. due to draughts) - Unsteady, oxidising weld pool - Contamination in the workpiece (e.g. rust, paint, grease, coatings) - Arc length too short - Irregularities in the wire feeding (e.g. due to clogged inner liner)
Remedy:	Optimise the welding conditions
Cause:	Shielding gas loss at the clamping nipple
Remedy:	Use the correct clamping nipple
Cause:	Clamping nipple sealing disc defective, shielding gas loss at the clamping nipple
Remedy:	Replace clamping nipple to ensure gas tightness
Cause:	Welding spatter in the gas nozzle
Remedy:	Remove welding spatter
Cause:	Turbulence caused by too high a rate of shielding gas flow
Remedy:	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)
Cause:	Too large a distance between the welding torch and the workpiece
Remedy:	Reduce the distance between the welding torch and the workpiece (approx. 10 - 15 mm / 0.39 - 0.59 in.)
Cause:	Tilt angle of the welding torch is too great
Remedy:	Reduce the tilt angle of the welding torch
Cause:	Wirefeed components do not match the diameter of the wire electrode / the wire electrode material
Remedy:	Use the correct wirefeed components

Poor wirefeeding

Cause:	Depending on the system, brake force in wirefeeder or power source set too high
Remedy:	Reduce the brake force
Cause:	Hole in the contact tip is displaced
Remedy:	Change the contact tip
Cause:	The inner liner or wire-guide insert is defective
Remedy:	Check the inner liner and wire-guide insert for kinks, dirt, etc. Change the defective inner liner or wire-guide insert
Cause:	The feed rollers are not suitable for the wire electrode being used
Remedy:	Use suitable wirefeeder rollers
Cause:	Wirefeeder rollers have the wrong contact pressure
Remedy:	Optimise contact pressure
Cause:	The wirefeeder rollers are soiled or damaged
Remedy:	Clean or replace wirefeeder rollers
Cause:	Inner liner wrongly fitted or kinked
Remedy:	Replace inner liner
Cause:	The inner liner has been cut too short
Remedy:	Replace the inner liner and cut the new inner liner to the correct length
Cause:	Wire electrode worn due to excessive contact pressure on the wirefeeder rollers
Remedy:	Reduce contact pressure on the wirefeeder rollers
Cause:	Wire electrode contains impurities or is corroded
Remedy:	Use high-quality wire electrode with no impurities
Cause:	For steel inner liners: use of uncoated inner liner
Remedy:	Use a coated inner liner
Cause:	Clamping nipple in wire entry and wire exit area deformed (oval, knocked out), shielding gas escaping at clamping nipple
Remedy:	Replace clamping nipple to ensure a gas-tight seal

The gas nozzle becomes very hot

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

The welding torch becomes very hot

Cause:	Only on Multilock welding torches: torch neck union nut is loose
Remedy:	Tighten the union nut
Cause:	Welding torch operated above the maximum welding current
Remedy:	Reduce welding power or use a more powerful welding torch
Cause:	The specification of the welding torch is inadequate
Remedy:	Observe the duty cycle and loading limits
Cause:	Only on water-cooled systems: Inadequate coolant flow
Remedy:	Check coolant level, coolant flow, coolant contamination, the routing of the hosepack, etc.
Cause:	The tip of the welding torch is too close to the arc
Remedy:	Increase stick-out

Contact tip has a short service life

Cause:	Incorrect wirefeeder rollers
Remedy:	Use correct wirefeeder rollers
Cause:	Wire electrode worn due to excessive contact pressure on the wirefeeder rollers
Remedy:	Reduce contact pressure on the wirefeeder rollers
Cause:	Wire electrode contains impurities/is corroded
Remedy:	Use high-quality wire electrode with no impurities
Cause:	Uncoated wire electrode
Remedy:	Use wire electrode with suitable coating
Cause:	Wrong dimension of contact tip
Remedy:	Use a contact tip of the correct dimension
Cause:	Duty cycle of welding torch has been exceeded
Remedy:	Shorten the duty cycle or use a more powerful welding torch
Cause:	Contact tip has overheated. No thermal dissipation as the contact tip is too loose
Remedy:	Tighten the contact tip
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.

Torch trigger malfunction

Cause:	Defective plug connection between welding torch and power source
Remedy:	Establish proper plug connections / have power source or welding torch serviced
Cause:	Build up of dirt between torch trigger and torch trigger housing
Remedy:	Clean away the dirt
Cause:	Control line is faulty
Remedy:	Contact After-Sales Service

Weld seam porosity

Cause:	Spatter build-up in the gas nozzle causing inadequate gas shield for weld seam
Remedy:	Remove welding spatter
Cause:	Holes in gas hose or hose is not connected properly
Remedy:	Replace gas hose
Cause:	O-ring on central connector has been cut or is faulty
Remedy:	Replace O-ring
Cause:	Moisture/condensation in the gas line
Remedy:	Dry gas line
Cause:	Gas flow is either too high or too low
Remedy:	Correct gas flow
Cause:	Insufficient gas flow at start or end of welding
Remedy:	Increase gas pre-flow and gas post-flow
Cause:	Rusty or poor quality wire electrode
Remedy:	Use high-quality wire electrode with no impurities
Cause:	For gas-cooled welding torches: gas is escaping through a non-insulated inner liner
Remedy:	Use only insulated inner liners with gas-cooled welding torches
Cause:	Too much parting agent applied
Remedy:	Remove excess parting agent/apply less parting agent

Voltage measurement (V-Peak):

for manually-operated welding torches: 113 V
for mechanically-driven welding torches: 141 V

Torch trigger technical data:

U_max = 5 V
I_max = 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.

Voltage measurement (V-Peak):

for manually-operated welding torches: 113 V
for mechanically-driven welding torches: 141 V

Torch trigger technical data:

U_max = 5 V
I_max = 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.

		MTG 250i	MTG 320i
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		40% ED* 250 60% ED* 200 100% ED* 170	40% ED* 320 60% ED* 260 100% ED* 210
	[mm] [in.]	0.8-1.2 0.032-0.047	0.8-1.6 0.032-0.063
	[m] [ft.]	3.5/4.5 12/15	3.5/4.5 12/15
*ED = Duty cycle

		MTG 250i TT-SH Torch body position FRONT
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		40% ED* 250 60% ED* 200 100% ED* 170
	[mm] [in.]	0.8-1.2 0.032-0.047
	[m] [ft.]	3.5/4.5 12/15
*ED = Duty cycle When the torch body is in the REAR position, the duty cycle values are reduced by up to 20%.

		MTG 400i	MTG 550i
I (ampere) 10 min/40°C C1 (EN ISO 14175)		-	30% ED* 550
I (ampere) 10 min/40°C M21 (EN ISO 14175)		-	30% ED* 520
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		40% ED* 400 60% ED* 320 100% ED* 260	60% ED* 420 100% ED* 360
	[mm] [in.]	0.8-1.6 0.032-0.063	1.2-1.6 0.047-0.063
	[m] [ft.]	3.5/4.5 12/15	3.5/4.5 12/15
*ED = Duty cycle

		MHP 250i G ML	MHP 400i G ML
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		40% ED* 250 60% ED* 200 100% ED* 170	40% ED* 400 60% ED* 300 100% ED* 260
	[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

		MHP 550i G ML
I (ampere) 10 min/40°C C1 (EN ISO 14175)		30% ED* 550
I (ampere) 10 min/40°C M21 (EN ISO 14175)		30% ED* 520
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		60% ED* 420 100% ED* 360
	[mm] [in.]	1.2-1.6 0.047-0.063
	[m] [ft.]	3.35/4.35 11/14
*ED = Duty cycle

		MTB 200i G ML	MTB 250i G ML
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		40% ED* 200 60% ED* 180 100% ED* 160	40% ED* 250 60% ED* 200 100% ED* 170
	[mm] [in.]	1.0-1.2 0.039-0.047	0.8-1.2 0.032-0.047
*ED = Duty cycle

		MTB 320i G ML	MTB 330i G ML
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		40% ED* 320 60% ED* 260 100% ED* 210	40% ED* 330 60% ED* 270 100% ED* 220
	[mm] [in.]	0.8-1.6 0.032-0.063	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 ISO 14175)		-	30% ED* 550
I (ampere) 10 min/40°C M21 (EN ISO 14175)		-	30% ED* 520
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		40% ED* 400 60% ED* 320 100% ED* 260	- 60% ED* 420 100% ED* 360
	[mm] [in.]	0.8-1.6 0.032-0.063	0.8-1.6 0.032-0.063
*ED = Duty cycle

		MTW 250i / TT-SH	MTW 400i / TT-SH
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		100% ED* 250	100% ED* 400
	[mm] [in.]	0.8-1.2 0.032-0.047	0.8-1.6 0.032-0.063
	[m] [ft.]	3.5/4.5 12/15	3.5/4.5/6 12/15/20
		550/600 W	1200/1500/1300 W
		1 0.26	1 0.26
		3 bar 43 psi.	3 bar 43 psi.
		5 bar 72 psi.	5 bar 72 psi.
*ED = Duty cycle
**Lowest cooling capacity according to IEC 60974-2

		MTW 500i	MTW 700i
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		100% ED* 500	100% ED* 700
	[mm] [in.]	1.0-1.6 0.039-0.063	1.0-1.6 0.039-0.063
	[m] [ft.]	3.5/4.5/6 12/15/20	3.5/4.5 12/15
		1400/1700/2000 W	1800/2200 W
		1 0.26	1 0.26
		3 bar 43 psi.	3 bar 43 psi.
		5 bar 72 psi.	5 bar 72 psi.
*ED = Duty cycle
**Lowest cooling capacity according to IEC 60974-2

		MHP 400i W ML TT-SH
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		100% ED* 400
	[mm] [in.]	0.8-1.6 0.032-0.063
	[m] [ft.]	3.35/4.35/5.85 11/14/19
		1200/1500/1300 W
		1 0.26
		3 bar 43 psi.
		5 bar 72 psi.
*ED = Duty cycle
**Lowest cooling capacity according to IEC 60974-2

		MHP 500i W ML	MHP 700i W ML
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		100% ED* 500	100% ED* 700
	[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	3.35/4.35 11/14
		1400/1700/2000 W	1800/2200 W
		1 0.26	1 0.26
		3 bar 43 psi.	3 bar 43 psi.
		5 bar 72 psi.	5 bar 72 psi.
*ED = Duty cycle
**Lowest cooling capacity according to IEC 60974-2

		MTB 220i W ML	MTB 250i W ML
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		100% ED* 220	100% ED* 250
	[mm] [in.]	1.0-1.2 0.039-0.047	0.8-1.2 0.032-0.047
		1 0.26	1 0.26
*ED = Duty cycle

		MTB 330i W ML	MTB 400i W ML
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		100% ED* 330	100% ED* 400
	[mm] [in.]	0.8-1.6 0.032-0.063	0.8-1.6 0.032-0.063
		1 0.26	1 0.26
*ED = Duty cycle

		MTB 500i W ML	MTB 700i W ML
I (ampere) 10 min/40°C M21+C1 (EN ISO 14175)		100% ED* 500	100% ED* 700
	[mm] [in.]	1.0-1.6 0.039-0.063	1.0-1.6 0.039-0.063
		1 0.26	1 0.26
*ED = Duty cycle

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

General

Safety

WARNING!

WARNING!

WARNING!

WARNING!

CAUTION!

CAUTION!

CAUTION!

Safety

WARNING!

WARNING!

WARNING!

WARNING!

CAUTION!

CAUTION!

CAUTION!

General

Intended use

Options

Pistol grip

Pistol grip

Heat shield

Potentiometer

Additional torch trigger on the top

Extraction Exento

Torch trigger extension

Description of available functions

Up/Down-function

Up/Down-function

JobMaster-function

Functions of the two-stage torch trigger

NOTE!

Special functions

Variants

TT-SH torch trigger, top - straight torch handle

TT-SH torch trigger, top - straight torch handle

Installation and commissioning

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

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

Variant MTB 200i G / MTB 220i W

Assembling Multilock welding torches

NOTE!

Note regarding the inner liner with gas-cooled welding torches

NOTE!

Checking the clamping nipple

NOTE!

NOTE!

Fitting the inner liner inside the torch hosepack

Connecting the welding torch to the wirefeeder

Connecting the welding torch

Twisting the Multilock welding torch body

CAUTION!

Changing the torch body on a Multilock welding torch

CAUTION!

CAUTION!

Care and maintenance

General

CAUTION!

General

CAUTION!

Recognising faulty wearing parts

Maintenance at every start-up

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

Troubleshooting

Troubleshooting

Troubleshooting

NOTE!

Technical data

General

General

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

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

Gas-cooled torch body - MTB 200i, 250i, 320i, 330i, 400i, 550i G ML

Water-cooled welding torch - MTW 250i, 400i, 500i, 700i

Water-cooled hosepack - MHP 400i, 500i, 700i W ML

Water-cooled torch body - MTB 220i, 250i, 330i, 400i, 500i, 700i W ML