Two 252's one runs a little different?

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I have a 2 year old 252 and a brand new one.  I didn't really pay much attention untill we got the second machine but now that we have i notice a little difference.With them both on the same settings the older machine appears to not start as well as the new one. On the new machine when you pull the trigger there is no popping, it welds. On the older machine i notice that it might pop a little when your starting to weld. you simply let off the trigger and then immediatly pull it again and the second time with the wire hot it starts off perfect. It doesn't do it everytime just say 50% of the time for example.Also, i never messed with any of the advanced settings on either welder, they should be as is on both machines from the factory.any suggestions, i have a new liner and the tip is pretty new  in the older machine although i don't remember that it really matters if the tip was new or old, the machine has that characteristic.  Same wire, same gas on both.
Reply:Further proof that no two machines are the same.Can you get the older machine to mimic the new machine performance by tweaking the settings?Have you compared the programed "run-in" settings of both machines?How many hours use on the 2yo unit?From a hardware standpoint, you could take a look at the contacts in the contactor.  Dirty contacts could affect the stabilizer effectiveness.Capacitor bank of the 2yo unit could be playing a factor as well.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Hey Chadwick,You don't need any suggestions. There is nothing wrong with your older unit just because it isn't exactly like your new one. You will find that anything that is perfectly identical in reality is not identical. He11, even my identical twin brother is different than me...... & he's only 15min. younger than me. Each one will have their "sweet" spots.... & yup, they'll be different. Use them & just try not to compare.DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:This doesn't surprise me.  We had three Millermatic 350P's with Python guns at the old job.  All of them running the same wire and gas and welding the same products on the same type of jigs with the same brand/model gas regulators, everything the same.  One was about a year or 2 newer than the first two machines, which we got together at the same time.  None of them would weld exactly the same, even with exactly the same settings and the same person welding.  Each was a little different.  No one of them was 'better' than the other 2, just all were different.  They are what they are.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:We have 16 252s and 4 251s. I bet there are two 252s that run the same...ish :P Its just the way it is.
Reply:If you want two or welding power supplies to produce the same output, the first step would be to characterize the dial or digital settings versus the actual measured output of the system.  For instance, run a range of wire feed speed settings, measure the length of wire that is fed in a given time, then calulate the inches per minute (ipm) and apply a + or - correction factor if the setting and measurement are not the same.Also check the relationship between the voltage setting and the measured voltage.  Measure the voltage at the same place for each system, as close to the arc as possible.If both systems have the same gun and work lead lengths, and you are using the same tip to work distance, shielding gas, wire type, etc., then the amperages for both machines should be very close.As stated, a constant voltage power supply puts out a constant voltage.  The weld current is primarily a function of the wire speed.  However, differences in the circuit resistance caused by different cable sizes or lengths, or poor connections, or a worn contact tip, will affect the weld current.Last edited by pulser; 10-17-2010 at 10:53 PM.
Reply:All machines run different.Ya gotta spend money to make money!