TPS/i Manual welding torches
Weber Harald
Fronius International GmbH
Division welding technology
Froniusplatz 1
A-4600 Wels
Types of welding torches
& specifications
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Welding torches MTG / MTW = MIG Torch Gas / Water
MTG 250i
MTW 250i
MTG 320i
MTW 320i
MTG 400i
MTW 500i
MTG 5300 S
MTW 700i
(only standard version)
Versions: Standard / Standard LED / UpDown / Jobmaster (available from Q2 2014) Lengths: 3,5m / 4,5m
For the first time in the history of Fronius
we have especially gone into the Demands for the uses
of the gas – watercooled applications, in the development
of the Welding Torches.
…to get the very most out of both Variations.
(The Wear Parts and the Welding Torches are optimally matched to the Welding Power.)
…to get the best possible standing time for the Wear Parts and the
Welding torches.
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Technical Data
/ Air cooled (MTG = MIG Torch Gascooled):
/ MTG 250i - 250A 40% Duty cycle CO2 and mixed gas
/ MTG 320i - 320A 40% Duty cycle CO2 and mixed gas
/ MTG 400i - 400A 40% Duty cycle CO2 and mixed gas
/ MTG 5300 S - 530A 40% Duty cycle CO2 , 500A 40% ED mixed gas
/ Water cooled (MTW = MIG Torch Watercooled) :
/ MTW 250i - 250A 100% Duty cycle CO2 and mixed gas
/ MTW 320i - 320A 100% Duty cycle CO2 and mixed gas
/ MTW 500i - 500A 100% Duty cycle CO2 and mixed gas
/ MTW 700i - 700A 100% Duty cycle CO2 and mixed gas
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Multilock
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Multilock MIG Torch Body = MTB
MTB 250i W
MTB 250i G
MTB 320i W
MTB 320i G
MTB 500i W
MTB 400i G
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Angle: 15° / 30° / 45°
Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012
Multilock torch body Versions
Clamping nut is fixed and protects the Multilock
connector
15°
30°
45°
Torch body 360° rotateable
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Fronius International GmbH / TorchNews
Technical Data Multilock air cooled
/ Hosepacks air cooled (MHP = MIG HosePack):
/ MHP 250i G ML - 250A 40% Duty cycle CO2 and mixed gas
/ MHP 400i G ML - 400A 40% Duty cycle CO2 and mixed gas
/ Torch bodies air cooled (MTB = MIG TorchBody):
/ MTB 250i G ML - 250A 40% Duty cycle CO2 and mixed gas
/ MTB 320i G ML - 320A 40% Duty cycle CO2 and mixed gas
/ MTB 400i G ML - 400A 40% Duty cycle CO2 and mixed gas
Versions: Standard / Standard LED / UpDown / Jobmaster (available from Q2 2014) Lengths: 3,35m / 4,35m
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Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012
Technical Data Multilock water cooled
/ Hosepacks water cooled (MHP = MIG HosePack):
/ MHP 500i W ML - 500A 100% Duty cycle CO2 and mixed gas
/ MHP 700i W ML - 700A 100% Duty cycle CO2 and mixed gas
/ Torch bodies water cooled (MTB = MIG TorchBody):
/ MTB 250i W ML - 250A 100% Duty cycle CO2 and mixed gas
/ MTB 320i W ML - 320A 100% Duty cycle CO2 and mixed gas
/ MTB 500i W ML - 500A 100% Duty cycle CO2 and mixed gas
/ MTB 700i W ML - 700A 100% Duty cycle CO2 and mixed gas (available from 2014)
Versions: Standard / Standard LED / UpDown / Jobmaster (available from Q2 2014) Lengths: 3,35m / 4,35m
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Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012
PullMig – small, lightweight and powerful
/ Hosepacks (MHP = MIG HosePack):
/ MHP 280i PullMig G – 280A 40% Duty cycle CO2 and mixed gas
/ MHP 320i PullMig W – 320A 100% Duty cycle CO2 and mixed gas
/ One of the smallest and lightest push-pull welding torches in the world
/ Motor size and weight about ¼ of the current PullMig
/ Available from early 2014
Versions: Standard LED / UpDown / Jobmaster
(available from Q2 2014)
Lengths: 5,85m / 7,85m / 9,85m
SpeedNet
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Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012
Length definition
fixed
Welding torch
Length 3,5m / 4,5m
Multilock
Welding torch
~ 0,15m
Length 3,35m / 4,35m
Length 3,5m / 4,5m
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Fronius International GmbH / TorchNews
Fronius System Connector (FSC)
/ MTG and MTW torches are equipped with the FSC connection
/ Tool-free, simple and quick welding torch change without missoperation
/ Process security because of defined current transfer
/ No external control connectors - all control signals are integrated in the central connection
/ One central connector for all applications (Manual-, Machinesand Robot systems – PAP and conventional)
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Wear parts and
Basic kits
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Wear parts
/ Screwed gas nozzle
/ Easy operation
/ Optimum temperature derivative
/ no loss of gas through the slots
/ All wearing parts are replaceable
/ also gas nozzle holder can be changed from repair department
Gas cooled:
/ Gas nozzle, Contact tip, Nozzle stock made of copper to lead off temperature
/ Insulating ring is made of ceramic for high temperature resistance
/ Ceramic spatter guard for Heavy Duty applications, available as an option
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Fronius International GmbH / TorchNews
ø8
M6
Spiky contact tips
Types:
L=24mm
/ M6 – external diameter 8mm (MTG 250i, MTW 250i)
/ M8x1,5 – external diameter 10mm (MTG 320i, MTG 400i, MTW 320i, MTW 500i, MTW 700i)
ø10
/ Material: CuCrZr
M8x
1,5
Properties:
/ No center hole in the contact tip
L=32mm
/ Guiding of the innerliner via nozzle stock
/ Less contact tips variants now 15 variants, previously 52
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Fronius International GmbH / TorchNews
Why spiky contatct tips?
/ Low absorption of radiant heat
by new top-contact tip geometry
MTW 500i
/ Up to 70 ° lower temperature
on the wear parts
/ Therefore longer lifetime
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AW5000
Fronius International GmbH / TorchNews
Contec
/ Available for the following types of welding torches:
/ MTG 320i
/ MTG 400i
/ MTW 320i
/ MTW 500i
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Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012
Guiding of the innerliner
/ Guiding of the innerliner takes over the wire guide nozzle
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Fronius International GmbH / TorchNews
New innerliners for perfect process stability
Bare steel inner liners air- and water cooled:
/ ø 0,8: external diameter 4,3mm
/ ø 1,0 – 1,6: external diameter 4,8mm
CrNi-bare inner liners for CrNi air- and water cooled:
/ ø 0,8: external diameter 4,3mm
/ ø 1,0 – 1,6: external diameter 4,8mm
Combi inner liners for Al air cooled and CuSi for air and water cooled
/ ø 0,8 – 1,6: external diameter 4,8mm
Combi inner liners for Al water cooled
/ ø 0,8 – 1,6: external diameter 4,8mm
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Steel- and CrNi-inner liners without isolation for air- and
water cooled configuration
/ Gas Sealed with specific diameter clamping piece - almost no loss of gas
Water cooled
Highlight
Steel- and CrNi-inner liners
without isolation
Air cooled
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Fronius International GmbH / TorchNews
Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012
Clamping piece
/ Used for all materials and inner liners
/ Tool free installation of the inner liner by the meter
1) Clamping nut is placed on inner liner
2) Screw on rotation to the right
3) Push clamping piece incl. Inner liner into the FSC
4) Fixation in the FSC with a 90 ° rotation
(Correct fixing position is marked)
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Fronius International GmbH / TorchNews
Clamping piece – now color coded
Gray with groove ø0,8
for combi inner liners
AD ø4,8
Red
ø1,2
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Gray ø0,8
for steel inner liners
with AD ø4,3
Black
ø1,6
Blue
ø0,9/ø1,0
Green
ø2,0
Fronius International GmbH / TorchNews
Basic kits
Basic kits M6
/ Steel ø0,8 / ø0,9 / ø1,0 / ø1,2 / ø1,4 / ø1,6 for MTG 250i, MTW 250i
/ CrNi ø0,8 / ø0,9 / ø1,0 / ø1,2 / ø1,4 / ø1,6 for MTG 250i, MTW 250i
/ Aluminum (G) & CuSi ø0,8 / ø1,0 / ø1,2 / ø1,6 for MTG 250i, MTW 250i
/ Aluminum (W) ø0,8 / ø1,0 / ø1,2 / ø1,6 for MTW 250i
Basic kits M8
Content: Inner liner L=5m,
contact tip, clamping piece
/ Steel ø0,8 / ø0,9 / ø1,0 / ø1,2 / ø1,4 / ø1,6 – for MTG 320i, MTG 400i, MTW 320i, MTW 500i
/ CrNi ø0,8 / ø0,9 / ø1,0 / ø1,2 / ø1,4 / ø1,6 – for MTG 320i, MTG 400i, MTW 320i, MTW 500i
/ Aluminum (G) & CuSi ø0,8 / ø1,0 / ø1,2 / ø1,6 – for MTG 320i, MTG 400i, MTW 320i, MTW 500i
/ Aluminum (W) ø0,8 / ø1,0 / ø1,2 / ø1,6 / ø2,0 for MTW 320i, MTW 500i
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Fronius International GmbH / TorchNews
Packaging
/ Contact tip 10 pcs. / 100 pcs. / 1.000 pcs.
/ Gas nozzle, nozzle stock, spatter guard, insulating stop, clamping piece 5 pcs. / 50 pcs. /
500 pcs.
/ For the packaging there will be a graduation of prices
/ Price benefit for customers
/ Available from September 2013
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Fronius International GmbH / TorchNews
Optimally cooled
Welding torches
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Fronius International GmbH / TorchNews
Cooling of water cooled welding torches
MTW500i
example: MTW500i
/ Cooling was pulled as far as possible
forward and on the outside
/ At 500A the gas nozzle can be
replaced after about 1 min 30 sec by
hand without gloves.
L=46mm
For comparison: Cooling of AW5000
L=67mm
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Fronius International GmbH / TorchNews
Temperature comparison Gas nozzle
Welding power: 500A / duty cycle 100%
/ AW5000
/ Gas nozzle temperature 600°
/ 55° after approx. 4 min.
/ 50° after approx. 4 min. 45 sek.
Measuring point:
/ MTW 500i
/ Gas nozzle temperature 400°
/ 55° after approx. 1 min. 30 sek.
/ 50° after approx. 1 min. 40 sek.
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Fronius International GmbH / TorchNews
Cooling of MTW 700i
Gas nozzle piece
Cooling jacket
/ With fitted gas nozzle, the water circulates to 100% above the gas nozzle.
/ When the gas nozzle is removed, the water is still circulating through the torch body
nevertheless, the integrated water stop prevents the outflow of water
/ Gas nozzle is made of two parts: gas nozzle end cap (changeable) and cooling jacket
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Fronius International GmbH / TorchNews
Cooling of Multilock welding torches
/ With integrated water stop
/ Without mounted torch body water can
circulate further
/ Cooler runs for 2 minutes after
/ Hosepack and coolant liquid are cooled even
further despite removed torch body
/ When the torch body is connected, the water
circulates to 100% above the torch body and
the wearing parts
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Further properties
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Properties
/ Stainless steel outer pipe for maximum stability
/ Insulation for the torch body below the outer pipe (no external
insulation required)
/ Torch body mount is compatible to the welding torches of the
TPS generation
/ W6 grip plate (like TransSteel welding torches)
/ Swivel mounted wire feed hose
/ Flexible, rotating rubber anti kinck feature for better handling
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Fronius International GmbH / TorchNews
Properties
/ Torch body length and angle are optimally aligned
(balanced) for each type of welding torch.
/ LED illumination
/ Illumination of the welding area before and after welding
/ Control via two-stage gun trigger
/ Up/Down and Jobmaster welding torches are equipped
as standard with LED, as well as MTG 400i, MTW320i
and MTW500i standard model
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Fronius International GmbH / TorchNews
Properties
/ Same grip plate for Standard, Up/Down and Jobmaster
/ Conversion from Standard LED to Up/Down and Jobmaster
possible
/ Full graphic OLED display (organic LED) on Jobmaster pc
board
/ Jobmaster welding torch air cooled (with coaxial cabel) now
without protection hose
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Fronius International GmbH / TorchNews
Power cable sizes
Gas cooled manual welding torches
MTG 250i / MHP 250i ML G
25mm2
MTG 320i
45mm2
MTG 400i / MHP 400i ML G
50mm2
MTG 5300S
65mm2
Water cooled manual welding torches
MTW 250i / MTW 320i
10mm2
MTW 500i / MHP 500i ML W
16mm2
MTW 700i / MHP 700i ML W
25mm2
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Options and accessories
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Option heat protection shield
/ Heat resistant material
/ Easy assembly and disassembly with click system
/ Rotating heat protection shield for shielding the radiation heat and spatter
/ Supplied as standard with MTG 400i, MTW 500i, MTW 700i, MHP 400i G, MHP 500i W,
MHP 700i W
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Torch trigger above
/ Can be ordered as a project
/ Is parallel switched to the standard-torch trigger
/ Welding process can be started and stopped via the two triggers
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Design study: option long torch trigger
Attention: Availability not yet fixed
/ Trigger in home position
/ Trigger activated
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Fronius International GmbH / TorchNews
Desig study: fume extractor set
Attention: Availability not yet fixed
/ Fume extractor can be mounted on each TPS/i welding torch
/ User welds with ergonomic W6 grip plate
/ Easy assembly and disassembly
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Fronius International GmbH / TorchNews
Adapter TPS/i welding torches on TPS and VS power
sources or competitor power sources
/ TPS/i welding torches water cooled on F++
44,0350,3331 Adapter-ZA F++/FSC-S-W
/ TPS/i welding torches air cooled on F
44,0350,3330 Adapter-ZA F / FSC-S-G
/ TPS/i welding torches on Euro-ZA
44,0350,3329 Adapter-ZA Euro/FSC
/ In the future, the adapter will be extended to the Up/Down function.
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Fronius International GmbH / TorchNews
New welding torch generation also available with F/F++
and Euro plug
/ In order to take advantage of the new welding torches for existing systems, they will also
be available with F / F + + and euro connector.
/ Article number for F/F++: ,000
/ Article number for Euro: ,001
/ Available from 2014
/ Also Up/Down and Jobmaster function possible (TPS User Interface) W5 grip plate
/ No Led function possible
/ Thus we can promote the new welding torches proactively.
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Fronius International GmbH / TorchNews
Variants
TPS/i F++ / Euro W6 Standard
TPS/i F++ / Euro W5 Up/Down
TPS/i – F++ / Euro W5 Jobmaster
TPS wire feeders
/ F++
/ Euro
Multilock TPS/i F++/ Euro W6 Standard
Multilock TPS/i - W5 TPS Up/Down
Multilock TPS/i - W5 TPS Jobmaster
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Highlights
Perfect Handling
/ Ergonomic grip plate
/ Swivel mounted wire feed hose
/ Flexible, rotating rubber anti kinck feature
/ balanced welding torches
/ 0° fixed by a anti twist protection at Multilock
Robustness
/ steel outer pipe
/ Protected isolation in the torch body
/ Air coold welding torches also for puls welding
/ Perfectly matched to the torch-type wear parts
/ Ceramic spatter guard thermal indestructible
/ Less heat absorpation because of spiky contact tips
/ Integrated water stop at Multilock
Modularity
/ Same grip plate for Standard, UpDown and Jobmaster
/ Gas nozzle partially compatible between different torch bodies
/ Same inner liner fixing system for all materials
/ Less contact tip-models
/ Stahl- and CrNi inner liners without isolation for air- and water cooled systems
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