erratic arc a/c on syncrowave 350

[FABMAN]

guys
every once in a while i get a very erratic arc when running on a/c and welding thick aluminum. its about to drive me crazy.
running the balance at 7, amps at 300, 75/25 argon helium anywhere from 15-35cfh. i have tried cleaning the ground area, clamping ground directly to the part, two different bottles of gas, etc... i am at a loss.
one day everything could be fine, and the next it drives me crazy.
the arc kind of wanders all over the place and it even sounds different then when it runs good. and the paareacne of the bead is really flat. when its acting up i can not get a good apperaing bead at all.
i have searched the internet and found something called "high frequency leakage",.....
the article stated, "if you have a part(s) of your torch/lead that is/are damaged, the HF will leak and thus reduce the amount that is available at the arc to properly stabilize it"..

my torch and 25ft cables are 4 1/2 years old. and being 25ft in length, they are wrapped around the machine handles.
have any of you had the "high frequency leakage" as stated above ? the article also went on to suggest running a bead with the lights in the shop turned off and having a coworker look for for arcing anywhere throughout the cables..

any help would be greatly appreciated on this subject.

after the holidays when i get back to work i am going to order a new set of cables and torch, probably 10ft in length, just to get them out of the equation.

[cdeal5760]

Sounds like contaminated tungsten to me, but I'm sure you've already ruled that out. I haven't heard about HF leakage before but it makes since, your current needs smooth surfaces to transfer across to be efficient.

[griff01]

guys
every once in a while i get a very erratic arc when running on a/c and welding thick aluminum. its about to drive me crazy.
running the balance at 7, amps at 300, 75/25 argon helium anywhere from 15-35cfh. i have tried cleaning the ground area, clamping ground directly to the part, two different bottles of gas, etc... i am at a loss.
one day everything could be fine, and the next it drives me crazy.
the arc kind of wanders all over the place and it even sounds different then when it runs good. and the paareacne of the bead is really flat. when its acting up i can not get a good apperaing bead at all.
i have searched the internet and found something called "high frequency leakage",.....
the article stated, "if you have a part(s) of your torch/lead that is/are damaged, the HF will leak and thus reduce the amount that is available at the arc to properly stabilize it"..

my torch and 25ft cables are 4 1/2 years old. and being 25ft in length, they are wrapped around the machine handles.
have any of you had the "high frequency leakage" as stated above ? the article also went on to suggest running a bead with the lights in the shop turned off and having a coworker look for for arcing anywhere throughout the cables..

any help would be greatly appreciated on this subject.

after the holidays when i get back to work i am going to order a new set of cables and torch, probably 10ft in length, just to get them out of the equation.

You have answered your own question:

" and being 25ft in length, they are wrapped around the machine handles."

Do not wrap your cables around the handles. It will cause problems with your arc and can damage the boards.

Griff

[FABMAN]

You have answered your own question:

" and being 25ft in length, they are wrapped around the machine handles."

Do not wrap your cables around the handles. It will cause problems with your arc and can damage the boards.

Griff

WOW.... no kidding ? i have been welding this way for over 4 years.... and this may explain why this situation arises from time to time. when i get back to work after the new year i will take them off the handles and lay them on the floor....man i hope that is all it is.... been driving me crazy over the years.

[griff01]

WOW.... no kidding ? i have been welding this way for over 4 years.... and this may explain why this situation arises from time to time. when i get back to work after the new year i will take them off the handles and lay them on the floor....man i hope that is all it is.... been driving me crazy over the years.

Same story on my end.

Griff

[FABMAN]

guys,
when i take the cables off the handles, is it ok to wind the 25' cables in a circular coil, on the ground, or will that still possibly cause a problem ?
thanks

[Helios]

guys,
when i take the cables off the handles, is it ok to wind the 25' cables in a circular coil, on the ground, or will that still possibly cause a problem ?

I don't think you want the cables in a coil, period.

That's the point, or one of the points, of taking them off the handles.

[FABMAN]

I don't think you want the cables in a coil, period.

That's the point, or one of the points, of taking them off the handles.

yea, i should have figured that... thanks.... cant wait to try it out next wednesday

[ja baudin]

Does the same hold true for pulse mig machines??

[billmccandless]

You shouldn't wrap ANY leads in a coil. I have seen the magnetic field actually pick stuff up off the floor when arc was struck. Mig, Tig, Plasma, Stick.......
It's like wearing a old wind up watch close to a rocker arm spot welder.