Troubleshooting - Fronius VarioStar 1500 Instructions De Service

Troubleshooting

Unsteady arc, severe spattering, pores in the welding material
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Uneven wirefeed speed, welding wire forms a loop between feed rollers and torch
wire inlet nozzle
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Welding wire is welded to the contact tube or weld pool
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Main torch body and hosepack become very hot
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poor earth connection
to ensure good contact between the earthing clamp and workpiece, use a
new earthing cable if necessary
phase missing on mains side
check mains fuses, mains sockets and plugs, notify After-Sales Service
operating mode selector switch set to interval 2-step/4-step mode
select suitable operating mode
wirespool brake applied too lightly/strongly
adjust wirespool brake
the borehole of the contact tube is too narrow
use correct contact tube
faulty wire feed liner in torch
check wire feed liner for kinks, dirt etc. Check inner diameter
feed rollers are unsuitable for the wire being used
match up feed rollers and welding wire
feed rollers have the wrong contact pressure
adjust the contact pressure
quality of welding wire is not up to standard
change welding wire
wirefeed into torch not adjusted to best effect
correct wire feed
welding torch incorrectly configured
reconfigure torch
afterglow time not set to best effect
correct afterglow time
design dimensions of the torch are not sufficient for this task
observe duty cycle and loading limit
on water-cooled machines: flow rate too low
check water level, flow rate and cleanliness
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