TPS/i Manual welding torches Weber Harald Fronius International GmbH Division welding technology Froniusplatz 1 A-4600 Wels Types of welding torches & specifications 2 Fronius International GmbH / TorchNews 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. 4 Fronius International GmbH / TorchNews 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 5 Fronius International GmbH / TorchNews Multilock 6 Fronius International GmbH / TorchNews Multilock MIG Torch Body = MTB MTB 250i W MTB 250i G MTB 320i W MTB 320i G MTB 500i W MTB 400i G 7 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 8 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 9 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 10 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 11 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 12 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) 13 Fronius International GmbH / TorchNews Wear parts and Basic kits 14 Fronius International GmbH / TorchNews 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 15 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 16 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 17 AW5000 Fronius International GmbH / TorchNews Contec / Available for the following types of welding torches: / MTG 320i / MTG 400i / MTW 320i / MTW 500i 18 Fronius International GmbH / Aitzetmüller Christian / TPSi Schweißbrenner / 12.09.2012 Guiding of the innerliner / Guiding of the innerliner takes over the wire guide nozzle 19 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 20 Fronius International GmbH / TorchNews 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 21 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) 22 Fronius International GmbH / TorchNews Clamping piece – now color coded Gray with groove ø0,8 for combi inner liners AD ø4,8 Red ø1,2 23 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 24 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 25 Fronius International GmbH / TorchNews Optimally cooled Welding torches 26 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 27 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. 28 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 29 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 30 Fronius International GmbH / TorchNews Further properties 31 Fronius International GmbH / TorchNews 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 32 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 33 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 34 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 35 Fronius International GmbH / TorchNews Options and accessories 36 Fronius International GmbH / TorchNews 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 37 Fronius International GmbH / TorchNews 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 38 Fronius International GmbH / TorchNews Design study: option long torch trigger Attention: Availability not yet fixed / Trigger in home position / Trigger activated 39 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 40 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. 41 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. 42 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 43 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 44 All information is without guarantee in spite of careful editing - liability excluded. 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