Fronius MTG Exento Operating Instructions Manual
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Fronius MTG Exento Operating Instructions Manual

Fronius MTG Exento Operating Instructions Manual

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Operating
Instructions
MTG Exento
MTW Exento
EN-US
Operating instructions
42,0426,0459,EA
006-22082023
manuals.fronius.com/
html/4204260459
e-Manual

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  • Page 1 Operating Instructions manuals.fronius.com/ html/4204260459 e-Manual MTG Exento MTW Exento EN-US Operating instructions 42,0426,0459,EA 006-22082023...

  • Page 3: Table Of Contents

    Checking the clamping nipple Procedure for commissioning welding torches with Fronius System Connector Procedure for commissioning welding torches with Euro connection Fitting inner liner in welding torch with Fronius System Connector Note on inner liner in gascooled welding torches Fitting the inner liner...

  • Page 5: Safety, Information On Correct Use

    Safety, information on correct use...

  • Page 7: Safety

    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.

  • Page 8: Intended Use, Requirements For The Extraction System

    Intended use, requirements for the extraction system Intended use The MIG/MAG manual welding torch is intended exclusively for MIG/MAG weld- ing in conjunction with a sufficiently powerful extraction system (see section quirements for the extraction system from page 8). Any other use is deemed to be "not in accordance with the intended purpose."...
  • Page 9 Rating plate on the welding torch...

  • Page 10: Extraction Information On The Rating Plate

    Extraction in- Type formation on the rating plate Art.No. www.fronius.com Charge No. EN ISO 21904-1 EN IEC 60974-7/-10 Cl.A X (40°C) MIXED Check ∆ [kPa] [m³/h] Q [m³/h] 11,0 Example of a rating plate Extraction information on the rating plate...

  • Page 11: Available Interfaces, Functions Of The Torch Trigger

    Available interfaces, functions of the torch trigger...

  • Page 13: Available Interfaces

    Available interfaces Up/Down-func- The Up/Down torch has the following tion functions: Changing the welding power in synergic operation by means of up/ down buttons Error display: in the event of a system error, all the LEDs turn red in the event of a data commu- nication error, all the LEDs flash red.

  • Page 14: Functions Of The Torch Trigger

    Functions of the torch trigger Functions of the two-staged torch trigger Function of the torch trigger at switch position 1 (torch trigger pushed halfway down) = LED lights up NOTE! An LED on the welding torch does not work for welding torches with optional top torch trigger.

  • Page 15: Commissioning

    Commissioning...

  • Page 17: Commissioning Procedure

    Perform the following activities for the correct commissioning of the welding commissioning torch: welding torches Fit the inner liner - Description from page with Fronius Connect the welding torch System Con- Description of power source from page nector Description of wirefeeder from page...

  • Page 18: Procedure For Commissioning Welding Torches With Euro Connection

    Set the extraction capacity with external air flow regulator - Description from page Procedure for Perform the following activities for the correct commissioning of the welding commissioning torch: welding torches Fit the inner liner with Euro con- Description of steel inner liner from page nection Description of plastic inner liner from page Connect the welding torch to the power source - Description from page...

  • Page 19: Fitting Inner Liner In Welding Torch With Fronius System Connector

    Fitting inner liner in welding torch with Fronius System Connector Note on inner NOTE! liner in gas- cooled welding Risk due to incorrect wire-guide insert. torches This can result in poor-quality weld properties. ▶ If a plastic inner liner with a bronze wire-guide insert is used in gascooled welding torches instead of a steel inner liner, the power data stated in the technical data of the welding torch must be reduced by 30%.

  • Page 20: Fitting The Inner Liner

    Fitting the inner liner Lay out the welding torch straight Lay out the inner liner straight; make sure that no burr protrudes into or out of the inner liner...
  • Page 21 If the extraction nozzle, gas nozzle, and contact tip are already mounted, remove them Push the inner liner into the welding torch (*this can be done from both sides) until it protrudes from the front and rear of the welding torch; make sure that the inner liner is not kinked or snapped...
  • Page 22 Push the inner liner with the contact tip back into the torch body; mount the contact tip, gas nozzle, and extraction nozzle; mark the inner liner at the end of the Schweißbrenners Pull inner liner 10 cm (3.94 in.) out of the welding torch...
  • Page 23 Left inner liner made of steel, right plastic: Cut and deburr the inner liner at the previously marked position; make sure that no burr protrudes into or out of the inner liner Screw the cap onto the inner liner up to the stop (the inner liner needs to be visible through the hole in the cap);...

  • Page 24: Fitting Steel Inner Liner In Welding Torch With Euro Connection

    Fitting steel inner liner in welding torch with Euro connection Fitting the steel inner liner Lay out the welding torch straight Lay out the inner liner straight; make sure that no burr protrudes into or out of the inner liner...
  • Page 25 If already mounted, remove the extraction nozzle, gas nozzle, contact tip, and cap from the Euro connection Push the inner liner into the welding torch (*this can be done from both sides) until it protrudes from the front and rear of the welding torch; make sure that the inner liner is not kinked or snapped...
  • Page 26 Push the inner liner with the contact tip back into the torch body; mount the contact tip, gas nozzle, and extraction nozzle; mark the inner liner at the end of the welding torch Pull inner liner 10 cm (3.94 in.) out of the welding torch, cut, and deburr; make sure that no burr pro- trudes into or out of the inner liner...
  • Page 27 Screw the cap onto the inner liner up to the stop; screw the cap into the welding torch...

  • Page 28: Fitting Plastic Inner Liner In Welding Torch With Euro Connection

    Fitting plastic inner liner in welding torch with Euro connection Note on inner NOTE! liner in gas- cooled welding Risk due to incorrect wire-guide insert. torches This can result in poor-quality weld properties. ▶ If a plastic inner liner with a bronze wire-guide insert is used in gascooled welding torches instead of a steel inner liner, the power data stated in the technical data of the welding torch must be reduced by 30%.

  • Page 29: Fitting The Plastic Inner Liner

    Fitting the plastic inner liner Lay out the welding torch straight Lay out the inner liner straight; ensure that no burr protrudes into or out of the wire-guide insert...
  • Page 30 If already mounted, remove the extraction nozzle, gas nozzle, contact tip, and cap from the Euro connection Push the inner liner into the welding torch (*this can be done from both sides) until it protrudes from the front and rear of the welding torch; make sure that the inner liner is not kinked or snapped...
  • Page 31 Push the inner liner with the contact tip back into the torch body; mount the contact tip, gas nozzle, and extraction nozzle; secure the inner liner in the welding torch Refer to the user documentation of the wirefeeder / power source used for instructions on how to correctly cut the inner liner to length...

  • Page 32: Connecting Welding Torches To Devices With Fronius System Connector

    Connecting welding torches to devices with Froni- us System Connector Connecting the welding torch to the power source * only with water-cooled welding torches...

  • Page 33: Connecting The Welding Torch To The Wirefeeder

    Connecting the welding torch to the wirefeeder * only with water-cooled welding torches...

  • Page 34: Connecting Welding Torches To Devices With Euro Connection

    Connecting welding torches to devices with Euro connection Connecting the welding torch * only with water-cooled welding torches; connect welding torch to the cooling unit ** the control line must be provided with the required control plug by the cus- tomer.

  • Page 35: Connecting Welding Torch To Extraction System And Measuring Extraction Capacity

    Connecting welding torch to external extraction unit * Recommendations for the extraction hose: Use Fronius extraction hoses. The design and material composition of Froni- us extraction hoses ensure maximum compatibility and leak-tightness Keep the extraction hose as short as possible; the shorter the extraction...
  • Page 36 Remove the extraction nozzle and close the air flow regulator - see the figure below Removing extraction nozzle and closing air flow regulator Place the Exentometer upright on a solid surface (for example, on a work- bench) Insert the welding torch into the Exentometer as far as it will go Since the extraction system is already running, the Exentometer immedi- ately displays the current extraction capacity * Ensure that the welding torch is fully inserted into the Exentometer and...
  • Page 37 Compare the measured extraction volumetric flow with the required extrac- tion volumetric flow if the two values match, no further measures are necessary if the two values do not match, increase or reduce the power of the ex- traction system until the extraction volumetric flow is in the correct range if the extraction volumetric flow is too low, there is a risk that the welding fumes will not be optimally extracted...

  • Page 38: Adjusting The Extraction Capacity

    Adjusting the extraction capacity Setting the ex- The air flow regulator can be opened to reduce the extraction capacity. If the air traction capacity flow regulator is fully open, this reduces the extraction capacity of the welding on the welding torch by 40%.
  • Page 39 Welding of a fillet weld; air flow regulator open = extraction capacity reduced When welding on open surfaces (such as square butt welds), it may be necessary to close the air flow regulator and thus use the maximum extraction capacity. This provides the best possible extraction of welding fumes.

  • Page 40: Setting Extraction Capacity With External Air Flow Regulator

    Setting extrac- Particularly in the case of central extraction systems, it may be necessary to ad- tion capacity just the extraction capacity manually using the optionally available external air with external air flow regulator: flow regulator by completely opening the external air flow regulator, the air flow remains al- most unchanged by completely closing the external air flow regulator, the air flow is reduced to a minimum level...

  • Page 41: Fault Diagnosis, Troubleshooting, Maintenance

    Fault diagnosis, troubleshooting, maintenance...

  • Page 43: Troubleshooting

    Troubleshooting Troubleshooting Porosity of weld seam Cause: Extraction too strong Remedy: Reduce extraction Extraction too low Cause: Holes in the extraction hose Remedy: Replace extraction hose Cause: Displaced extraction unit filter Remedy: Replace extraction unit filter Cause: Air passages otherwise blocked Remedy: Remove blockages Cause:...
  • Page 44 No function after pressing torch trigger Power source switched on, power source indication illuminates Cause: FSC (‘Fronius System Connector’—central connector) not inserted up to the stop Remedy: Insert FSC up to the stop Cause: Welding torch or welding torch control line faulty...
  • Page 45 Poor-quality weld properties Cause: Incorrect welding parameters Remedy: Correct settings Cause: Poor ground earth connection Remedy: Establish good contact with workpiece Cause: Too little or no shielding gas Remedy: Check pressure regulator, gas hose, gas solenoid valve, and welding torch gas connection. For gas-cooled welding torches, check gas seal, use suitable inner liner Cause: Welding torch leaks...
  • Page 46 Cause: Wirefeed components do not correspond to the diameter of the wire electrode/the material of the wire electrode Remedy: Use correct wirefeed components Poor wirefeeding Cause: Depending on the system, brakes in the wirefeeder or power source set too tightly Remedy: Set the brakes to be looser Cause:...
  • Page 47 Welding torch gets very hot Cause: Only in multi-lock welding torches: Union nut of the torch body loose Remedy: Tighten union nut Cause: Welding torch has been operated above the maximum welding cur- rent Remedy: Reduce welding power or use more powerful welding torch Cause: Welding torch is inadequately sized Remedy:...
  • Page 48 Malfunction of the torch trigger Cause: Faulty plug connections between the welding torch and the power source Remedy: Establish correct plug connections/send power source or welding torch to service team Cause: Soiling between torch trigger and torch trigger housing Remedy: Remove soiling Cause: Faulty control line...

  • Page 49: Maintenance

    Maintenance Detecting de- fective wear parts Nozzle fitting Burnt outer edges, notches Heavily coated with welding spatter Spatter guard (only for water-cooled welding torches) Burnt outer edges, notches Extraction nozzle Burnt outer edges, notches Contact tip Ground (oval) wire entry and wire exit bores Heavily coated with welding spatter Penetration at the tip of the contact tip Gas nozzle...

  • Page 50: Maintenance At The Beginning Of Each Working Day

    Maintenance at Check extraction nozzle and replace if damaged: the beginning of each working day Clean gas nozzle, contact tip, spatter guard (only for water-cooled welding torches), nozzle fitting, and insulating parts from welding splatter, check for damage, and replace damaged parts: In addition to the steps listed above, prior to starting up water-cooled weld- ing torches always: Ensure that all coolant connections are leak-tight...

  • Page 51: Maintenance Every 48 Hours

    Maintenance Open and close the air flow regulator every 48 hours: every 48 hours Switch on the extraction system Opening and closing the air flow regulator If the air inlets are dirty and / or the air flow regulator can no longer be opened smoothly, clean the air inlets with compressed air: Ensure that any particles released during cleaning are picked up by the extraction system...

  • Page 52: Maintenance At Every Wirespool/Basket-Type Spool Replacement

    Maintenance at Clean the wirefeeding hose with reduced compressed air: every wirespool/ basket-type spool replace- ment Dismantling the wearing parts Switch on the extraction system Cleaning the hosepack; ensure that any particles released during cleaning are picked up by the ex- traction system...
  • Page 53 Recommended - When replacing the inner liner, clean the wearing parts before re-installing the inner liner: Cleaning the contact tip, spatter guard, and nozzle fitting with compressed air; ensure that any particles released during cleaning are picked up by the extraction system Cleaning extraction nozzle and gas nozzle with brush...

  • Page 55: Technical Data

    Technical data...

  • Page 57: Technical Data Of Water-Cooled Welding Torches

    Technical data of water-cooled welding torches General Voltage rating (V-peak): For hand-held welding torches: 113 V For machine-guided welding torches: 141 V Torch trigger technical data: = 5 V = 10 mA The torch trigger can only be operated within the limits of the technical data. This product meets the requirements set out in standard EN IEC 60974-7 / - 10 CI.
  • Page 58 MTW 300i Exento | Welding torch length = 4.5 m (14 ft. 9.17 in.) Welding current at 10 min / 40 °C (104 °F); 100% D.C. / 300 A Values apply with CO and mixed gas as shielding gas (EN ISO 14175) Extraction volumetric flow at the front end of the weld- 52 m /h (1837 cfh)
  • Page 59 MTW 300d Exento | Welding torch length = 4.5 m (14 ft. 9.17 in.) Required negative pressure Δp at the extraction con- 15 kPa (150 mbar) nection of the welding torch (EN IEC ISO 21904-1) Required minimum cooling power according to standard 900 W IEC 60974-2 Required minimum coolant flow Q...
  • Page 60 MTW 500i Exento | Welding torch length = 4.5 m (14 ft. 9.17 in.) Maximum permissible coolant pressure p 5.5 bar (79 psi) 1 - 1.6 mm Permissible wire electrodes (diameter) (0.039 - 0.063 in.) MTW 500d Exento | Welding torch length = 3.5 m (11 ft. 5.8 in.) Welding current at 10 min / 40 °C (104 °F);...

  • Page 61: Technical Data Of Gascooled Welding Torches

    Workpiece geometry (open or closed design, etc.) Volumetric flow of the shielding gas Work angle of the welding torch Environmental conditions MTG Exento MTG 250i Exento | Welding torch length = 3.5 m (11 ft. 5.8 in.) welding torch 40% D.C.
  • Page 62 MTG 250i Exento | Welding torch length = 4.5 m (14 ft. 9.17 in.) 40% D.C. / 250 A Welding current at 10 min / 40 °C (104 °F); Values apply with mixed gas as shielding gas 60% D.C. / 210 A (EN ISO 14175) 100% D.C.
  • Page 63 MTG 320i Exento | Welding torch length = 3.5 m (11 ft. 5.8 in.) Welding current at 10 min / 40 °C (104 °F): 40% D.C. / 320 A Values apply with CO as shielding gas 60% D.C. / 260 A (EN ISO 14175) 100% D.C.
  • Page 64 MTG 320d Exento | Welding torch length = 3.5 m (11 ft. 5.8 in.) 0.8 - 1.6 mm Permissible wire electrodes (diameter) (0.032 - 0.063 in.) MTG 320d Exento | Welding torch length = 4.5 m (14 ft. 9.17 in.) Welding current at 10 min / 40 °C (104 °F): 40% D.C.
  • Page 65 MTG 400i Exento | Welding torch length = 4.5 m (14 ft. 9.17 in.) Extraction volumetric flow at the extraction connection 94 m /h (3320 cfh) of the welding torch Q (EN IEC ISO 21904-1) Required negative pressure Δp 11 kPa (110 mbar) at the extraction con- nection of the welding torch (EN IEC ISO 21904-1) 0.8 - 1.6 mm...

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