Fronius MTG 250i Gas Cooled Mig Torch Instructions

: June 4, 2024
: Fronius

Table of Contents

Fronius MTG 250i Gas Cooled Mig Torch
Safety rules
- Explanation of safety notices
EMC Device Classifications
Supporting measures for avoidance of EMC problems
During operation
**Disposal
References
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Fronius MTG 250i Gas Cooled Mig Torch

Fronius-MTG-250i-Gas-Cooled-Mig-
Torch-product

Safety rules

Explanation of safety notices

DANGER

Indicates immediate danger.
If not avoided, death or serious injury will result.

WARNING

Indicates a potentially hazardous situation.
If not avoided, death or serious injury may result.

CAUTION

Indicates a situation where damage or injury could occur.
If not avoided, minor injury and/or damage to property may result.

NOTE

Indicates a risk of flawed results and possible damage to the equipment

General The device is manufactured using state-of-the-art technology and according to recognized safety standards.

If used incorrectly or misused, however, it can cause:

injury or death to the operator or a third party,
damage to the device and other material assets belonging to the operating company,
inefficient operation of the device.

All persons involved in commissioning, operating, maintaining, and servicing the device must:

be suitably qualified,
have sufficient knowledge of welding and
read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

must be in a legible state,
must not be damaged,
must not be removed,
must not be covered, pasted, or painted over.

For the location of the safety and danger notices on the device, refer to the section headed “General” in the operating instructions for the device. Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety

Proper use The device is to be used exclusively for its intended purpose. The device is intended exclusively for the welding process described in the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be liable for any damage resulting from such improper use.

Utilization in accordance with the “intended purpose” also includes

reading carefully and following all operating instructions to the letter
studying and obeying all safety and danger notices carefully
performing all stipulated inspection and servicing work.

The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting. The manufacturer likewise accepts no liability for unexpected or incorrect results.

Environmental conditions
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

Ambient temperature range:

during operation: -10 °C to + 40 °C (14 °F to 104 °F)
during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:

up to 50% at 40 °C (104 °F)
up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of the operator
The operator must only allow persons to work with the device who:

are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device
have read and understood these operating instructions, especially the section “safety rules”, and have confirmed as much with their signatures
are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Obligations of personnel
Before using the device, all persons instructed to do so undertake:

to observe the basic instructions regarding safety at work and accident prevention
to read these operating instructions, especially the “Safety rules” section, and sign to confirm that they have understood them and will follow them. Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

Protecting yourself and others
Anyone working with the device exposes themselves to numerous risks e.g.:

Flying sparks and hot pieces of metal
Arc radiation, can damage the eyes and skin
Hazardous electromagnetic fields can endanger the lives of those using cardiac pacemakers
The electrical risk from the welding current
Greater noise pollution
Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties:

Flame-resistant
Insulating and dry
Covers the whole body, is undamaged, and in good condition
Safety helmet
Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

Protect eyes and face from UV rays, heat, and sparks using a protective visor and regulation filter
Wear regulation protective goggles with side protection (behind the safety visor)
Wear stout footwear that provides insulation even in wet conditions
Protect the hands with suitable gloves (electrically insulated and providing protection against heat)
Wear ear protection to reduce the harmful effects of noise and to prevent injury

Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. |
If, however, there are people in the vicinity:

Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.)
Provide suitable protective equipment
Alternatively, erect suitable safety screens/curtains

Danger from toxic gases and vapors
The fumes produced during welding contain harmful gases and vapors. Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the International Agency for Research on Cancer. Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device. Keep your face away from welding fumes and gases. Fumes and hazardous gases

must not be breathed in
must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times. Otherwise, a welding helmet with an air supply must be worn. If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values

The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:

Metals used for the workpiece
Electrodes
Coatings
Cleaners, degreasers, etc.
Welding process used

The relevant material safety data sheets and manufacturer’s specifications for the listed components should therefore be studied carefully. Recommendations for trade fair scenarios, risk management measures, and for identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org). Flammable vapours (e.g. solvent fumes) should be kept away from the arc’s radiation area. Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

Risks from welding current

An electric shock is life-threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG or TIG welding, the welding wire, the wire spool, the drive rollers, and all metal parts that are in contact with the welding wire are live.
Always set the wire-feed unit up on a sufficiently insulated surface or use a suitable, insulated wire-feed unit mount.
Make sure that you and others are protected with an adequately insulated, dry temporary backing or cover for the earth or ground potential. This temporary backing or cover must extend over the entire area between the body and the earth or ground potential.
All cables and leads must be complete, undamaged, insulated, and adequately dimensioned.
Loose connections, scorched, damaged, or inadequately dimensioned cables, and leads must be repaired/replaced immediately.

Do not sling cables or leads around either the body or parts of the body. The electrode (rod electrode, tungsten electrode, welding wire, etc) must

never be immersed in liquid for cooling
never be touched when the current is flowing.

Double the open circuit voltage of a welding machine can occur between the welding electrodes of two welding machines. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances. Switch off unused devices.

Meandering welding currents
If the following instructions are ignored, meandering welding currents can develop with the following consequences:

Fire hazard
Overheating of parts connected to the workpiece
Irreparable damage to ground conductors
Damage to the device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp. Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments, e.g. Insulation against conductive floor or insulation to conductive racks.
If distribution boards, twin-head mounts, etc., are being used, note the following:
The electrode of the welding torch/electrode holder that is not used is also live.
Make sure that the welding torch/electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wire feeder spool, or wire spool to the wire feeder.

EMC Device Classifications

Devices in emission class A

Are only designed for use in industrial settings
Can cause line-bound and radiated interference in other areas

Devices in emission class B:

Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public lowvoltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

Check and evaluate the immunity to the interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interference from the device include:

Safety devices
Power, signal, and data transfer lines
IT and telecommunications devices
Measuring and calibrating devices

Supporting measures for avoidance of EMC problems

Mains supply
- If electromagnetic interference arises despite correct mains connection, additional measures are necessary (e.g. use a suitable line filter).
Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
Equipotential bonding
Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
Shielding, if necessary
- Shield off other nearby devices
- Shield off the entire welding installation

EMF measures Electromagnetic fields that may pose as yet unknown risks to health:

effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids
wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
for safety reasons, keep distances between the welding cables and the welder’s head/torso as large as possible
do not carry welding cables and hose packs over the shoulders or wind them around any part of the body Specific areas of risk

Do not reach into the rotating cogs of the wire drive or into rotating drive components. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. Keep hands, hair, clothing, and tools away from moving parts, for example:

Fans
Cogs
Rollers
Shafts
Wirespools and welding wire

During operation

ensure that all covers are closed and all side panels are fitted properly.
keep all covers and side panels closed.

A high risk of injury exists when the welding wire emerges from the welding torch (piercing of the hand, injuries to the face and eyes, etc.). Always keep the torch well away from the body (devices with a wire-feed unit). Therefore always keep the welding torch away from the body (devices with wire feed unit) and wear suitable protective goggles. Never touch the workpiece during or after welding the risk of burns. Slag can sometimes fly off workpieces as they cool down. The specified protective equipment must therefore also be worn when reworking workpieces and steps must be taken to ensure that other people are also adequately protected. Welding torches and other parts with a high operating temperature must be allowed to cool down before handling. Special provisions apply in areas at risk of fire or explosion – observe relevant national and international regulations. The danger of scalding from escaping steam. Switch off the cooling unit before detaching water feed or return lines.

Safety measures in normal operation
Only operate the device if all of its protection devices are fully functional. If the protection devices are not in full working order, there is a risk of

injury or death to the operator or a third party,
damage to the device and other material assets belonging to the operator,
inefficient operation of the device.

Any safety devices that are not functioning properly must be repaired before switching on the device. Never bypass or disable protection devices

Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
Only the manufacturer’s original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer’s original coolant with other coolants.
The manufacturer accepts no liability for damage resulting from the use of a different coolant. In addition, all warranty claims will be forfeited.
The coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and international regulations. A safety data sheet may be obtained from your service center or downloaded from the manufacturer’s website.
Check the coolant level before starting to weld, while the system is still cool.

System cooling Fronius welding torches may only be used with Fronius cooling units and Fronius coolant. The manufacturer accepts no liability for any damage arising from the use of other cooling systems.

NOTE: Inadequate cooling can cause damage to property. Never operate welding systems without adequate cooling. The manufacturer accepts no liability for damage caused by inadequate cooling. The cooling liquid supply, the purity of the coolant, and the differential pressure in the cooling water system must always be checked before you start the welding system.

CAUTION

The danger of burns from the hot coolant.
Do not check the coolant until it has cooled down
Minimum requirements for the connection of a Fronius welding torch to the cooling circuit of a third-party system:
pressure 3 to 5 bar
coarse filter with a mesh size of 10 mm
flow of at least 1 liter/min.
return temperature max. 70 °C
flow temperature min. 10 °C

Recommended coolant quality in third-party systems:

pH value 7 to 8
hardness D max. 5 °dH
chloride max. 20 mg/l
nitrate max. 10 mg/l
sulfate max. 80 mg/l
electrical conductibility 100 to 150 mS/cm
additives to prevent corrosion and bacterial growth

Commissioning, maintenance, and repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements

Use only original spare and wearing parts (also applies to standard parts).

Do not carry out any modifications, alterations, etc. to the device without the manufacturer’s consent.
Components that are not in perfect condition must be replaced immediately.
When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and tightened to the specified torque.

**Disposal

**

Do not dispose of this device with normal domestic waste! To comply with the European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse effects on the environment and your health!

Safety symbols
Devices with the CE mark satisfy the essential requirements of the low- voltage and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series). Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text of the EU Declaration of Conformity can be found at the following address: http://www.fronius.com Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

Copyright
Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments