Fronius MTG 2500 S Instructions De Service page 38

Poor wirefeed
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The gas nozzle becomes very hot
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The welding torch becomes very hot
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Depending on the system, brake force in wire-feed unit or power source set
too high
Reduce the braking force
Hole in the contact tip is displaced
Replace the contact tip
The inner liner or wire-guide insert is defective
Check the inner liner and wire-guide insert for kinks, dirt, etc.
Change the faulty inner liner or wire-guide insert
The wirefeeder rollers are not suitable for the wire electrode being used
Use suitable wirefeeder rollers
Wirefeeder rollers have the wrong contact pressure
Optimise the contact pressure
The wirefeeder rollers are soiled or damaged
Clean the wirefeeder rollers or replace them by new ones
Inner liner wrongly laid or kinked
Replace inner liner
The inner liner has been cut too short
Replace the inner liner and cut the new inner liner to the correct length
Wire electrode worn due to excessive contact pressure on the wirefeeder roll-
ers
Reduce contact pressure on the wirefeeder rollers
Wire electrode contains impurities or is corroded
Use high-quality wire electrode with no impurities
No thermal dissipation as the gas nozzle is too loose
Screw on the gas nozzle as far as it will go
Only on Multilock welding torches: torch neck union nut is loose
Tighten the union nut
Welding torch operated above the maximum welding current
Reduce welding power or use a more powerful welding torch
The specification of the welding torch is inadequate
Observe the duty cycle and loading limits
Only on water-cooled systems: Inadequate coolant flow
Check coolant level, coolant flow, coolant contamination, the routing of the
hosepack, etc.
The tip of the welding torch is too close to the arc
Increase stick-out