Fronius VARIOSTAR 457 User Manual

17
ENGLISH
Irregular wirefeed; the welding wire forms
a loop between the feed rollers and the
wire inlet nozzle of the welding torch
Wirefeeder motor is not running, or cannot
be controlled properly
‘Ready’ indicator is lit up
Check the fuses
Wire electrode sticks to the contact tube
or weld pool
Burn-back time correction dial is not set to
optimum value
Correct the burn-back time
Design dimensions of torch are not sufficient for
this task
Torch body and hosepack become very
hot
Respect the duty cycle and loading limits
Cooling-unit pump is not running
High-pitched running noises from cooling-
unit pump
Insufficient cooling power
No gas Check the pressure regulator (gas flow rate),
gas hose (connections), gas solenoid valve,
torch gas connection etc.
Check the rectifierSecondary rectifier is defective
A phase is missing on the welding transformer Check the mains supply lead, main switch and
contactor
Internal machine fault
Wirespool brake is too tight Loosen brake-adjustment screw
Bore of contact tube is too narrow
Wire inner liner in torch is faulty
Wirefeed rollers are not suitable for the welding
wire being used
Wirefeed rollers have wrong contact pressure
Quality of welding wire is not OK
Use the right contact tube
Check the inner liner for kinks,correct internal
diameter, length, soiling etc.
Use suitable wirefeed rollers for the welding-
wire in question
Optimise the contact pressure
Change the welding wire
Contact After-Sale Service
Internal machine fault
Fuse F1, F2, F3 or F7 faulty
Wirefeeder motor is faulty
Wirefeeder controller is faulty
On 2-part version: Break in interconnecting
cable
Contact After-Sale Service
Check that the interconnecting cable is con-
nected up properly
Change the wirefeeder controller
Change the wirefeeder motor
On water-cooled machines: Coolant flow rate is
too low
Check the coolant level, the flow rate and the
cleanliness of the coolant
Cooling-unit pump is faulty Replace the pump
No supply voltage Check the supply voltage
Constriction or foreign body in the coolant circuit Eliminate the constriction
Fan is faulty
Cooling-unit pump is faulty
Coolant level is too low
Change the fan
Change the pump
Top up with more coolant
Replace the pumpCooling-unit pump is faulty
Coolant level is too low Top up with more coolant

Fronius VARIOSTAR 457 Specifications

General

Brand	Fronius
Model	VARIOSTAR 457
Category	Welding System
Language	English