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Fronius MHP 280i G CMT User Manual

Fronius MHP 280i G CMT
148 pages
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Op erating
Instructions
MHP 280i G CMT
MHP 400i W CMT
42,0410,2154 012-29082023
DE
Bedienungsanleitung
EN
Operating Instructions
ES
Manual de instrucciones
CS
Návod k obsluze

Table of Contents

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Fronius MHP 280i G CMT Specifications

General IconGeneral
Input Voltage3 x 400 V
Rated Output Current280 A
Protection ClassIP23
Welding ProcessMIG/MAG
Input Frequency50/60 Hz
Output Current Range280 A
Duty Cycle280 A

Summary

General

Proper Use

Specifies the intended manual applications for the MIG/MAG welding torch.

Original Equipment and Tools

Details required original equipment kits for hosepack usage with various materials.

Functions of the Torch Trigger - Standard

Up/Down Function

Describes the functions of the Up/Down torch, including power control and error display.

JobMaster Function

Torch Trigger Deactivation and Activation

Deactivating Individual or Both Triggers

Instructions for deactivating individual or both torch triggers.

Activating Torch Triggers

Procedure for reactivating both torch triggers.

Safety

Warning Notices on the Device

Details safety symbols and rating plate warnings against incorrect operation and potential injury.

Operational Safety Warnings

Highlights critical operational warnings regarding incorrect use and electrical hazards.

Cautionary Safety Warnings

Lists cautionary warnings related to thermal hazards, coolant, and moving parts.

Start-up

Fitting Wearing Parts to the Torch Body

Step-by-step guide for fitting wearing parts to the torch body, including nozzle attachment.

Inner Liner Note for Gas-Cooled Torches

Important note on using a steel inner liner for gas-cooled torches at maximum power.

Inserting Inner Liner into Torch Body

Checking the Clamping Nipple

Clamping Nipple Issues in Push Applications

Identifies issues with push application clamping nipples and suggests using brass nipples.

Clamping Nipple Issues in Push-Pull Applications

Addresses issues with push-pull clamping nipples and recommends silver nipples.

Inserting Plastic Wire Guide into Torch Body

Fitting Wearing Parts Inside the Drive

Changing the Outlet Nozzle

Outlet Nozzle Selection for Wire Diameters

Guidance on selecting the correct outlet nozzle based on wire diameter, e.g., red for 0.8-1.2mm.

Fitting Inner Liner from Wire Buffer to FSC

Ensuring Hosepack Alignment for Liner Insertion

Note on ensuring the hosepack is straight for correct inner liner insertion.

Attaching the Torch Body

Torch Body Alignment and Union Nut Tightening

Instructions for attaching the torch body, ensuring alignment and tightening the union nut.

Fitting Inner Liner to Wire Buffer

Securing Sliding Contact at Torch End

Procedure for fitting the inner liner to the wire buffer, securing the sliding contact at the torch end.

Connecting Welding Torch to Wirefeeder

Connecting Torch to Power Source and Cooling Unit

Coolant Hose Connection

Details on connecting torch to power source and cooling unit, emphasizing coolant hose connection.

Threading the Wire Electrode

Safety Precautions During Wire Electrode Threading

Safety measures for handling the wire electrode, including preventing injury and arc ignition.

Setting the Contact Pressure

Adjusting Contact Pressure via Screw

Guide on setting contact pressure by turning the adjustment screw clockwise or counter-clockwise.

Changing and Rotating the Torch Neck

Removing the Torch Body

Procedure for removing the torch body, including cooling instructions and nozzle orientation.

Rotating the Torch Body

Rotating the Torch Neck by 360 Degrees

Steps for rotating the torch body, including cooling requirements and securing the union nut.

Care, Maintenance, and Disposal

General Maintenance Overview

Highlights the importance of regular preventive maintenance for trouble-free operation and heavy soiling.

Maintenance at Every Start-up

Details checks and replacements for wearing parts, gas nozzle, spatter guard, and coolant connections.

Spool Change Procedures

Cleaning Wirefeeding Hose and Replacing Inner Liner

Instructions for cleaning the wirefeeding hose and replacing the inner liner when changing the spool.

Recognising Faulty Wearing Parts

Changing or Cleaning Wire Guide Components

Identifying Worn Torch Components

Lists common faults and wear indicators for various torch components like nozzles and contact tips.

Fitting Inner Liner to Drive Unit

Ensuring Hosepack Alignment for Liner Insertion

Note on ensuring the hosepack is straight for correct inner liner insertion into the drive unit.

Troubleshooting

No Welding Current

Diagnoses and remedies for issues where there is no welding current despite power source indicators being lit.

Torch Trigger Not Responding

Troubleshooting steps for when the torch trigger does not activate any function.

No Shielding Gas

Identifies causes and solutions for the absence of shielding gas when other functions are operational.

Poor Weld Properties

Parameter, Grounding, and Gas Issues

Addresses poor weld properties due to incorrect parameters, grounding, and shielding gas issues.

Gas Contamination and Workpiece Condition

Discusses factors like contaminated shielding gas and workpiece condition affecting weld quality.

Nipple, Nozzle, and Gas Flow Turbulence

Covers problems related to clamping nipples, gas nozzles, and shielding gas flow turbulence.

Torch Distance and Angle Affecting Quality

Explains how torch distance and tilt angle impact weld seam quality.

Poor Wirefeeding

Wirefeed Component Mismatch and Brake Force

Troubleshooting wirefeeding issues caused by mismatched components or excessive brake force.

Contact Tip, Inner Liner, and Roller Problems

Addresses problems with contact tips, defective inner liners, and unsuitable wirefeeder rollers.

Roller Condition and Inner Liner Fitting

Covers issues with soiled rollers, incorrect inner liner fitting, and cut inner liners.

Wire Electrode Wear and Impurities

Discusses wire electrode wear due to contact pressure and issues with impurities or coating.

Gas Nozzle Overheating

Welding Torch Overheating

Loose Union Nut and Excessive Current

Addresses torch overheating due to loose union nuts, exceeding current limits, or inadequate coolant flow.

Torch Specifications and Coolant Flow

Examines torch overheating related to specifications, duty cycle, and coolant flow adequacy.

Contact Tip Short Service Life

Wirefeeder Roller Issues and Tip Wear

Identifies causes for short contact tip life, including roller problems, electrode quality, and tip dimensions.

Contact Tip Overheating and Loose Fit

Discusses contact tip overheating due to lack of thermal dissipation from a loose fit.

Torch Trigger Malfunction

Defective Connections and Dirt Buildup

Troubleshooting torch trigger malfunctions due to faulty plug connections or dirt buildup.

Weld Seam Porosity

Spatter, Gas Hose, and O-ring Issues

Addresses weld seam porosity caused by spatter, gas hose problems, or faulty O-rings.

Gas Flow, Electrode Quality, and Liner Issues

Covers porosity related to gas flow, electrode quality, and shielding gas escaping through liners.

Parting Agent Application

Discusses the impact of excessive parting agent application on weld seam quality.

Technical Data

General Specifications and Certifications

Provides general technical data, voltage measurements, trigger specifications, and product conformity.

Gas-Cooled Torch MHP 280i G CMT Specifications

Details technical specifications for the gas-cooled welding torch, including current and wire diameter.

Water-Cooled Torch MHP 400i W CMT Specifications

Current, Wire Diameter, and Cooling Power

Lists technical specifications for the water-cooled torch, covering current, wire diameter, and pressure.

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