Disappointed

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Hello all, I bought a new PM350 several weeks ago and straight out of the box have had a big problem with it.At it is burning back into into the tip very badly and popping badly also.  I started out on mode 5 and left all settings on defaults. Then went to mode 10.   Then I adjusted wfs and heat up and down on both modes with no luck.  It welded really poorly on the lower settings.  I had set the tension knob in the middle at 5 for steel, SS wire.Then this past weekend I loosened the Tension knob to about one and then tightened until it just stopped slipping while running wire against my hand. Ended up about 4 on the Tension knob.  Slight popping of the wire but didn't seem to burn back to the tip much.  Was welding very close to acceptable.  I even tried a bottle of 75/25 with expected results. smoother and nicer looking weld.  I was able to weld at the very low settings also.So tonight I went out and it's right back to burning back to the tip again and popping.  I almost am getting the feeling there might be something with the wire going on.  It seems to spool out fine with out the wire catching. But the wire seems to have a larger than normal molten ball of wire on the end of the wire when I stop weldingNot much knowledge from the Airgas dealer I bought it from.Tried setting start up, run-in, arc control, etc with no luck eitherTried 75/25 with same resultsstraight co2  20psiRadnor .035 wireI'm an experienced welderseveral new tipsadjusted the distance away from the coupon in and out adjusted speed of travel and every combination of bead pattern I could come up with.Checked all swithes and disassembled gun thinking something might be arcing inside it but found nothing evident.I did get one of the local suppliers to order me a roll of Lincoln wire to compare but have not recieved it yet.Would appreciate any advice or help you can offer.Thank you   Cletis
Reply:gas leak.I had a similar problem when I first bought my Hobart.  Come to find out I didn't have the gun shoved in far enough in the motor block.  Pushed it in a bit more (was tough to get seated) & problem solved.Since it's new, go back & look at the basics.  Correct polarity, gas turned on, gun installed properly, no leaks in the gas line, correct sized tip.......... you get the idea.  If that doesn't fix the problem, take it back to the dealer for warranty work.  Have an expert check it out to see if a PCB is fried.  I would suspect if it were fried, it wouldn't strike an arc at al.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:It should go with the radnor fine. Don't yell at me but check a second time that the torch is tight in the machine. Then be certain the drive rolls are the right set.Now for the input power, if your input voltage is 240 the synergic modes will be correct, if it's higher "volt up" a bit and the opposite if it's lower (I know this sounds funny but try it).If you're gonna use Co2 with both mode 5 & 10 you'll need to spend a little time with the arc control to make the machine sing pretty.I tossed the sledge hammer (used once) torch for a Binzel. Since the machine is new I would ask the LWS for the lincoln area rep if things don't get better fast.Oh I forgot, if you have any crater fill you need to also have some burnback set. I leave run in at 100 (.035"), preflo .2/postflo 2 arc start = off.MattLast edited by Matt_Maguire; 02-23-2011 at 12:07 AM.
Reply:I have run many rolls of Radnor .035 through mine so it's probably not the wire. I have not run straight co2 though.
Reply:Thank you for the replies.  I have done all that has been mentioned but will do it again.  I'm thinking it's gonna have to go back but weird how it just took off welding good this past weekend.Thank you again  Cletis
Reply:Straight CO2 with SS??C-25 for short circuit SS (you confirmed this worked).98/2 (argon/O2) or Tri-mix for spray SS.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:Went back over everthing again and when I removed the gun cable from the reciever bushing I noticed the oring had left a mark across the gas port.  It seemed like it was too close and could have let some gas escape.  I checked where the locking thumb screw went into the locking groove and it had left an impression on the side of the locking groove.So I don't think it was positioned correctly even though I had thought it was aligned correctly the last time I checked it.I tried it and it is welding correctly (for now anyway).Question is if the weld does not have porosity in it from the lack of gas, how would a supposed lack of gas cause the wire to pop and burn back to the tip?Hopefully it stays working now!!Thanks  Cletis
Reply:Great, now show us some pictures of the projects.Any welding needs flux to shield the arc.  Flux core works in some instances, the coating on stick does it, shielding gases protect the arc in MIG/TIG welding.  Without the gas, the wire melts too quickly, burns back, then re-strikes the arc.  I bet if you did a bend test on the weld without gas & with gas, the one without gas wouldn't hold.  Even if the settings are the same.Glad you got it figured out.  I ended up having to use a bit of soapy water to get the o rings in.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:You may have been getting just enough gas to weld. But the gas cloud was so small you could move the gun out of it. Then the weld explodes (pops) and burn to the tip.If you want to use the pulse modes, you will need pulse arc gas. 90/10 to 98/2.Your welder is a software controlled welder. Read the owners manual and make sure your set ups are right. To make best use of the programing.If Lincoln updates the programs. All you need is a computer with internet, rs232 serial cable, to get the free update. Information on how should be in your manual.