help with Dialarc ( Airco lic ) 250

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Hi guys!  I've had this welder for ~ 10 years now, I use it exclusively as a TIG and have never used it as a MIG,. in that 10 years I've never had so much a bump in the road with it, even though I've welded some pretty heavy materials.. however my ' bullet proof monk' as I like to call the dialarc has a slight problem now;  Mild steel welds like a dream still, Stainless is so-so but thats been happening over a few years now.. The big problem is now aluminum, I'm welding a heavy pc. 1/2" 6061, to a 1/4" of the same material. What I've noticed is that I do get a sound from my machine that sounds the same as you heare from those large residential transformers.. a higher pitched 'buuuuzzz' that stays pretty constant, I've got a a tungsten that is spitting and being consumed at a ridiculous rate ( 5mm every 30sec. ). my weld puddle is being blown around like I'm spraying it with a high pressure air hose and it's very dirty.. the current/arc dips and drops out and when it does the buzzing stops... I've regapped to .007 and that made it worse, I opened it up to .010 and that had it working very well for ~ 10 sec, then it went back to what it was doing originally....ANY help would be welcome.. there are no welding repair places anywhere near me to get this too..  thanks
Reply:So do you think the buzz is HF or welding transformer?Is it a problem with HF continuous or HF start? Or both?How ‘bout without HF?Maybe the foot pedal is maxing out the current?How ‘bout if you try to weld with panel control rather than remote control.I guess if I suspected main transformer issues I'd throw the leads on and see how it stick welds.Anyone else?Good Luck
Reply:Have you been tig'ing aluminum fine in AC mode all along and this problem just cropped up, or is this the first time you have tried to tig aluminum with it?   You have the torch connected to the negative terminal, the machine in AC output mode and the HF set to continuous-on mode, right?MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:I figured I was going to have to be prompted for more info so this is good. Yes I have been welding aluminum for years with this setup, nothing has changed at the moment except the size of my tank, normal tank is a T size I'm using a Q?, the next size down. from .024" up to .5" but mostly it's .065"  6061 tube. I have moved shops since last nov. and my transformer is maxed at 200-208V single, thing is my dialarc has the 230V  transformer in it, I know this is a problem but as I was saying , except for a bit more pedal, everything has been welding fine in that time.. until now. upon thinking about it more, it seems my arc is wandering drastically as well, a finished weld is very contaminated, ( it almost looks like my gas tungsten is severely contaminated but it's not) and .. ripple-y.. ( back to that previous description of the weld pool been pushed around and in some cases thrown out of the pool it's self. ).  The Dialarc is set to it's medium lever point and 'continuous; is on. The buzzing is not immediate, it seems like it takes a 30 sec for it to become a low hum, but when I try to weld aluminum, thats when it's get really loud, like high tension lines humming but more so. from reading about other dialarc issues it seems that the HF circuit seems to be the main culprit, how would i go about testing this system with a volt meter? or can I even do that.. ? Denrep, I only have the TIG welding parts for this unit, none of the MIG or stick acc. were ever used with this welder, since new in 76, it's always been in an aircraft shop, used as a TIG. thanks for all the help guys..Last edited by S&S Fabrication; 09-02-2010 at 12:19 PM.
Reply:oh one thing I forgot to mention/ask, I use a WP9 with this , undersized I know, ( I'll be geting a WP-20 flex neck shortly), but it's worked and anything bigger got in the way of welding header runners.  The WP9's cup gasket is torn , I'm wondering is this could be causing some of my contamination issues  when using a gas lens setup..?
Reply:S&S,Many of your comments have me shaking my head.  Maybe a little clarification can get us all on track.You comment that you've only used your dialarc for Tig not Mig.  I hope so since the only Dialarc's I've seen are CC machines.You mention that "your" transformer is maxed out at 200-208 volts?  What does this mean.  Are you feeding the unit with commercial power?  I've not checked the Owners Manual for the Dialarc, but doesn't the machine have jumpers for 208V power as well as jumpers for 230V power.A broken gasket on your torch (air cooled/gas lens) can definitely cause problems.If I'm reading this correctly, you're trying to weld 1/2" aluminum with a 9 Series torch.  Good luck.  Torch is rated at 125A.  Going to the 20 Series takes it up to 250A, but also involves the use of a cooler or water supply.  Don't think the Dialarc has a water solonoid.As I mentioned, a lot of your comments have me scratching my head.  Off the bat, I'd say you've got a LOT of different problems that have to be addressed.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:I would say it is time to buy a better welder.
Reply:sorry about some of the confusion, proper nomenclature escapes me as I'm 100% self taught and have not had the formal in depth training regarding systems... But to answer a few questions you have;  Canadian machines did not ship with 200/208 transformer as an option, they only shipped with the 230+ option.. at least from Airco. I'm looking for a 230 reduction transformer now but.. it's slow going. But you are right about the torch, at first I just wanted to find a wp-9 collet gasket but after going to the welding supply store and trying one torch body when the rubber housing crumbled off the torch... I bought a 17F and the the gas lens parts I needed to go to the larger format and BINGO!!!! nice pretty welds again.. the screwy buzzing is gone as well.. so a little bit of air contaminating the gas pocket really does play merry hell with everything.. Thank you very much guys, if for nothing else then trying to give me answers to my questions and helping me work through the issues... awesome forum, I'm not going anywhere.
Reply:To be fair it still holds the title of bullet proof monk at the shop, beyond the basic soft items wearing out and some of the face plate print gone, it has never broken down since new in 76'..  However when my business starts to grow bigger I've got my eye on a Lincoln Precision TIG 225   Originally Posted by Booger WelderI would say it is time to buy a better welder.
Reply:Originally Posted by SundownIIIDon't think the Dialarc has a water solonoid..