Fronius MTG 2500 S Instructions De Service page 43

Welding torch gets very hot
Cause: Only in multi-lock welding torches: Union nut of the torch body loose
Remedy: Tighten union nut
Cause: Welding torch has been operated above the maximum welding current
Remedy: Reduce welding power or use more powerful welding torch
Cause: Welding torch is inadequately sized
Remedy: Observe duty cycle and load limits
Cause: For water-cooled systems only: Coolant flow too low
Remedy: Check coolant level, coolant flow, coolant contamination, displacement of
the hosepack, etc.
Cause: Tip of the welding torch too close to the arc
Remedy: Increase stick out
Short service life of the contact tip
Cause: Incorrect feed rollers
Remedy: Use correct feed rollers
Cause: Wear of the wire electrode due to excessive contact pressure at the feed
rollers
Remedy: Reduce contact pressure at the feed rollers
Cause: Wire electrode soiled/rusted
Remedy: Use high-quality wire electrode without soiling
Cause: Uncoated wire electrode
Remedy: Use wire electrode with suitable coating
Cause: Incorrect dimensions of the contact tip
Remedy: Use contact tip of the correct size
Cause: Duty cycle of the welding torch too long
Remedy: Reduce duty cycle or use more powerful welding torch
Cause: Contact tip overheats. No heat dissipation due to contact tip being fitted too
loosely
Remedy: Tighten contact tip
NOTE!
In CrNi applications, greater contact tip wear may occur due to the surface finish
of the CrNi wire electrode.
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