LogoMHP 280i G CMT, MHP 400i W CMT
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    • Terms and Conditions
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    • 013-17072024
    • General
      • General
      • Proper use
      • Original equipment and tools
      • Functions of the torch trigger - Standard
      • Up/Down function
      • JobMaster function
      • Deactivating the left or right torch trigger
    • Safety
      • Warning notices on the device
      • Safety
    • Start-up
      • MTG d, MTW d - Fitting wearing parts to the torch body
      • Note regarding the inner liner with gas-cooled welding torches
      • Inserting a steel or CrNi inner liner into the torch body
      • Checking the clamping nipple
      • Inserting a plastic wire guide into the torch body
      • Fitting wearing parts inside the drive
      • Changing the outlet nozzle
      • Fitting the inner liner from the wire buffer to the FSC
      • Attaching the torch body
      • Fitting inner liner to wire buffer
      • Connecting the welding torch to the wirefeeder
      • Connecting the welding torch
      • Threading the wire electrode
      • Setting the contact pressure
    • Changing the torch neck, rotating the torch neck
      • Removing the torch body
      • Attaching the torch body
      • Rotating the torch body
    • Care, maintenance and disposal
      • General
      • Maintenance at every start-up
      • Every time the wirespool/basket-type spool is changed
      • Recognising faulty wearing parts
      • Changing or cleaning the wire guide wire buffer and sliding contact
      • Fitting the inner liner from the wire buffer to the drive unit
    • Troubleshooting
      • Troubleshooting
    • Technical data
      • General
      • Gas-cooled welding torch - MHP 280i G CMT
      • Water-cooled welding torch - MHP 400i W CMT

    MHP 280i G CMT, MHP 400i W CMT Operating Instructions

    Connecting the welding torch to the wirefeeder
    Connecting the welding torch to the power source and the cooling unit
    Attaching the torch body
    Maintenance
    Troubleshooting
    Technical data
    Spare parts

    General

    General

    In combination with the wire buffer on the hosepack, the integral wire drive motor can quickly reverse the wire electrode. Many different torch body designs facilitate easy access to the weld seam.

    The 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 conjunction with the available Multilock torch bodies, 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 for jobs in the workshop.

    The hosepack is particularly well-suited to:
    • General light-gauge sheet applications
    • Spatter-free MIG brazing of galvanised light-gauge sheets
    • Joining steel to aluminium
    1. General

    General

    In combination with the wire buffer on the hosepack, the integral wire drive motor can quickly reverse the wire electrode. Many different torch body designs facilitate easy access to the weld seam.

    The 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 conjunction with the available Multilock torch bodies, 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 for jobs in the workshop.

    The hosepack is particularly well-suited to:
    • General light-gauge sheet applications
    • Spatter-free MIG brazing of galvanised light-gauge sheets
    • Joining steel to aluminium
    1. General

    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.
    1. General

    Original equipment and tools

    To use the hosepack, an original equipment kit (BasicKit) that corresponds to the wire diameter and to the filler metal is required (see spare parts list):
    • Original equipment kit Alu W
    • Original equipment kit Steel
    • Original equipment kit CrNi
    • Original equipment kit Alu G / CuSi G/W
    1. General

    Functions of the torch trigger - Standard

    The torch trigger on the Standard welding torch has two switching positions.

    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.
    1. General

    Up/Down function

    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


    1. General

    JobMaster function

    The JobMaster welding torch has the following 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 parameter and value


    1. General

    Deactivating the left or right torch trigger

    The torch triggers on both sides are enabled as standard. If one side needs to be deactivated, proceed as follows:

    Deactivating the left torch trigger
    1Simultaneously press the "-" button on the left side and the "+" button on the right side. Hold for five seconds
    Deactivating the right torch trigger
    1Simultaneously press the "-" button on the right side and the "+" button on the left side. Hold for five seconds
    Deactivating the left and right torch triggers
    1Simultaneously press the "-" button on the right side and the "-" button on the left side. Hold for five seconds
    Activating the left and right torch triggers
    1Simultaneously press the "+" button on the right side and the "+" button on the left side. Hold for five seconds

    Safety

    Warning notices on the device

    The welding torch is fitted with safety symbols and a rating plate. The rating plate and safety symbols must not be removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage.

    Rating plate with safety symbols
    Warning of moving parts
    Do not use the functions described here until you have fully read and understood the following documents:
    • These Operating Instructions
    • The enclosed "Safety rules" document
    • All the Operating Instructions for the system components, especially the safety rules
    Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:
    • Welders must be sufficiently qualified
    • Suitable protective equipment must be used
    • All persons not involved must be kept at a safe distance from the welding torch and the welding process

    Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

    Keep hands, hair, clothing and tools away from moving parts. For example:
    • Cogs
    • Feed rollers
    • Wirespools and wire electrodes

    Do not reach into the rotating feed rollers of the wire drive or into rotating drive components.

    The cover of the welding torch may only be opened while maintenance or repair work is being carried out.

    During operation
    • Ensure that the cover is closed.
    • Keep the cover closed.
    1. Safety

    Warning notices on the device

    The welding torch is fitted with safety symbols and a rating plate. The rating plate and safety symbols must not be removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage.

    Rating plate with safety symbols
    Warning of moving parts
    Do not use the functions described here until you have fully read and understood the following documents:
    • These Operating Instructions
    • The enclosed "Safety rules" document
    • All the Operating Instructions for the system components, especially the safety rules
    Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:
    • Welders must be sufficiently qualified
    • Suitable protective equipment must be used
    • All persons not involved must be kept at a safe distance from the welding torch and the welding process

    Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

    Keep hands, hair, clothing and tools away from moving parts. For example:
    • Cogs
    • Feed rollers
    • Wirespools and wire electrodes

    Do not reach into the rotating feed rollers of the wire drive or into rotating drive components.

    The cover of the welding torch may only be opened while maintenance or repair work is being carried out.

    During operation
    • Ensure that the cover is closed.
    • Keep the cover closed.
    1. Safety

    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 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.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    WARNING!

    Danger from electric current due to defective system components and incorrect operation.

    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 scalding.

    Before commencing any of the work described in this document, allow all welding torch components and the coolant to cool to room temperature (+25°C, +77°F).

    CAUTION!

    Danger from operation of water-cooled welding torches without coolant.

    This can result in damage to property.

    Never operate a water-cooled welding torch without coolant.

    During welding, ensure that the coolant is circulating correctly – this will be the case 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, and all claims against the warranty shall be void.

    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.

    CAUTION!

    Risk of injury from moving parts.

    This can result in injury and damage to property.

    Close the cover over the feed rollers before using the welding torch.

    Start-up

    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
    1. Start-up

    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
    1. Start-up

    Note regarding the inner liner with gas-cooled welding torches

    NOTE!

    If a plastic inner liner is used in the torch body of a gas-cooled welding torch, reduce the power figure shown in the technical data by 30%.

    To operate gas-cooled welding torches at maximum power, use a steel inner liner in the torch body.

    1. Start-up

    Inserting a steel or CrNi inner liner into the torch body

    1
    2

    * Use the welding torch cutting pipe (gas = 40 mm, water = 50 mm)

    1. Start-up

    Checking the clamping nipple

    Left: brass clamping nipple with seal ring. Right: silver clamping nipple without seal ring.

    * Check the clamping nipple before commissioning and whenever the inner liner is changed. To do so, carry out a visual inspection:

    • Left: brass clamping nipple with seal ring. You cannot see through the seal ring.
    • Right: silver clamping nipple with see-through bushing

    NOTE!

    Incorrect or defective clamping nipple in push applications

    Causes gas loss and poor weld properties

    use brass clamping nipples to minimise gas loss

    check that the seal ring is intact

    NOTE!

    Incorrect clamping nipple in push-pull applications

    Tangled wire and increased abrasion in the inner liner when using a clamping nipple with seal ring

    use silver clamping nipple to facilitate wirefeeding

    1. Start-up

    Inserting a plastic wire guide into the torch body

    1
    2

    * Use the welding torch cutting pipe (gas = 40 mm, water = 50 mm)

    1. Start-up

    Fitting wearing parts inside the drive

    A red outlet nozzle (1) for wires with a diameter of 0.8 - 1.2 mm is prefitted as standard. If a different outlet nozzle is needed, see "Changing the outlet nozzle".

    1
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    15
    1. Start-up

    Changing the outlet nozzle

    An outlet nozzle for wires with a diameter of 0.8 - 1.2 mm (red) is prefitted as standard. If wires with a diameter of 1.4 or 1.6 mm are to be used, the 1.6 mm outlet nozzle (black) must be fitted.

    1
    2
    3
    1. Start-up

    Fitting the inner liner from the wire buffer to the FSC

    NOTE!

    Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner might not be inserted correctly.

     

    1
    2
    3
    ** Steel inner liner
    *** Plastic inner liner
    4
    **** Screw the cap onto the inner liner as far as it will go. The inner liner must be visible through the hole in the cap.
    5
    6
    7
    8
    1. Start-up

    Attaching the torch body

    CAUTION!

    Risk of damage to the welding torch.

    Always tighten the union nut on the torch body as far as it will go.

    NOTE!

    Before fitting a torch body, ensure that the interface between the torch body and the hosepack is clean and undamaged.

    NOTE!

    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.

    This is normal. Always tighten the union nut on the torch body as far as it will go.

    1
    2

    NOTE!

    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
    *
    Ensure that the union nut is tightened as far as it will go.
    1. Start-up

    Fitting inner liner to wire buffer

    IMPORTANT!

    • Do not subject the wirefeeding hose to tensile stress!
    • Fit the sliding contact at the torch end.
    1
    2
    3
    4
    5
    6
    1. Start-up

    Connecting the welding torch to the wirefeeder

    1


    1. Start-up

    Connecting the welding torch

    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
    1. Start-up

    Threading the wire electrode

    CAUTION!

    Risk of injury and damage from the welding current and accidental ignition of an arc.

    Before starting work, disconnect the ground earth connection between the welding system and the workpiece.

    CAUTION!

    Risk of damage to the welding torch from sharp end of wire electrode.

    Deburr the end of the wire electrode well before threading in.

    CAUTION!

    Risk of injury due to springiness of spooled wire electrode.

    When inserting the wire electrode into the 4-roller drive of the wirefeeder, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back.

    1
    2

    CAUTION!

    Risk of injury and damage from wire electrode emerging.

    While working:

    Hold the welding torch with the end directed away from the face and body

    Wear suitable protective goggles

    Do not point the welding torch at people

    Make sure that the wire electrode does not touch any conductive or earthed parts (e.g. housing)

    The covers of the wire buffer and the grip must be closed.

    NOTE!

    Before feeding in the wire electrode, lay out the hosepack in a straight line as shown below.

    Maximum permitted feeder inching speed = 10 m/s.

    3
    4
    5
    1. Start-up

    Setting the contact pressure

    Only set the contact pressure once the wire electrode has been threaded in.

    *
    Use the values shown on the inside of the cover as a guide when setting the contact pressure.


    NOTE!

    The contact pressure is set as follows:

     

    Turn the screw counter-clockwise = reduce the contact pressure

    Turn the screw clockwise = increase the contact pressure

    Changing the torch neck, rotating the torch neck

    Removing the torch body

    CAUTION!

    Risk of burns from hot coolant and hot torch body.

    Before carrying out any work, allow the coolant and torch body to cool to room temperature (+25 °C, +77 °F).

    NOTE!

    Some coolant will always remain in the torch body.

    Only remove the torch body with the gas nozzle pointing downwards.

    1
    1. Changing the torch neck, rotating the torch neck

    Removing the torch body

    CAUTION!

    Risk of burns from hot coolant and hot torch body.

    Before carrying out any work, allow the coolant and torch body to cool to room temperature (+25 °C, +77 °F).

    NOTE!

    Some coolant will always remain in the torch body.

    Only remove the torch body with the gas nozzle pointing downwards.

    1
    1. Changing the torch neck, rotating the torch neck

    Attaching the torch body

    CAUTION!

    Risk of damage to the welding torch.

    Always tighten the union nut on the torch body as far as it will go.

    NOTE!

    Before fitting a torch body, ensure that the interface between the torch body and the hosepack is clean and undamaged.

    NOTE!

    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.

    This is normal. Always tighten the union nut on the torch body as far as it will go.

    1
    2

    NOTE!

    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
    *
    Ensure that the union nut is tightened as far as it will go.
    1. Changing the torch neck, rotating the torch neck

    Rotating the torch body

    CAUTION!

    Risk of burns from hot coolant and hot torch body.

    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.

    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 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.



    1. 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 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.



    1. Care, maintenance and disposal

    Maintenance at every start-up

    • 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
    1. Care, maintenance and disposal

    Every time the wirespool/basket-type spool is changed

    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
    2
    3
    1. Care, maintenance and disposal

    Recognising faulty wearing parts

    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
    1. Care, maintenance and disposal

    Changing or cleaning the wire guide wire buffer and sliding contact

    IMPORTANT! Remove the wire electrode before replacing the wire guide and sliding contact.

    1
    2
    3
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    6
    1. Care, maintenance and disposal

    Fitting the inner liner from the wire buffer to the drive unit

    NOTE!

    Ensure that the hosepack is straight when fitting the inner liner, otherwise the liner might not be inserted correctly.

    1
    2
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    7

    Troubleshooting

    Troubleshooting

    1. Troubleshooting

    Troubleshooting

    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 grounding (earthing) connection
    Remedy:Ensure good contact to workpiece
    Cause:Too little 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:Unfavourable welding conditions: shielding gas is contaminated (by moisture, air), inadequate gas shield (weld pool "boiling", draughts), contaminants in the workpiece (rust, paint, grease)
    Remedy:Optimise the welding conditions
    Cause:Shielding gas escaping at clamping nipple
    Remedy:Use the correct clamping nipple
    Cause:Clamping nipple seal ring defective, shielding gas escaping at clamping nipple
    Remedy:Replace clamping nipple to ensure a gas-tight seal
    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:Distance between the welding torch and the workpiece too great
    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/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

    Technical data

    General

    Voltage measurement (V-Peak):
    • for manually-operated welding torches: 113 V
    • for mechanically-driven welding torches: 141 V
    Torch trigger technical data:
    • Umax = 5 V
    • Imax = 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.

    1. Technical data

    General

    Voltage measurement (V-Peak):
    • for manually-operated welding torches: 113 V
    • for mechanically-driven welding torches: 141 V
    Torch trigger technical data:
    • Umax = 5 V
    • Imax = 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.

    1. Technical data

    Gas-cooled welding torch - MHP 280i G CMT

    I (ampere) 10 min/40°C
    M21+C1 (EN ISO 14175)
    Standard

    40% D.C.* 280
    60% D.C.* 220
    100% D.C.* 170

    I (ampere) 10 min/40°C
    M21+C1 (EN ISO 14175)
    CMT

    40% D.C.* 180

    [mm (in.)]

    0.8-1.6 (0.031 - 0.063)

    [m (ft.)]

    3.85 / 5.85 / 7.85 / (12.6 / 19 / 26)

    [A]

    1.45 RMS

    [V] AC

    38

    [m/min (ipm)]

    1-60 (0.039 - 0.236)

    * D.C. = Duty cycle

    1. Technical data

    Water-cooled welding torch - MHP 400i W CMT

    I (ampere) 10 min/40°C
    M21+C1 (EN ISO 14175)
    Standard

    100% D.C.* 400

    I (ampere) 10 min/40°C
    M21+C1 (EN ISO 14175)
    CMT

    100% D.C.* 280

    [mm]
    [in.]

    0,8-1,6
    0.031-0.063

    [m]
    [ft.]

    3,85 / 5,85 / 7,85
    12.6 / 19 / 26

    Pmin

    [W]**

    600 / 850 / 1050

    Qmin

    [l/min]
    [gal./min]

    1
    0.26

    pmin

    [bar]
    [psi]

    3
    43.51

    pmax

    [bar]
    [psi]

    5,5
    77.77

    [A]

    1,45 RMS

    [V] AC

    38

    [m/min]
    [ipm]

    1-60
    0.039-0.2362

    * D.C. = Duty cycle

    ** Lowest cooling power according to IEC 60974-2