Miller 350p Question

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Have Miller 350p. Always on pulse. 4043 wire .035. Straight Argon obviously. Problem I have had with it for awhile is inconsistency. Might weld perfect for a couple days, even a week. Next day I come in to shop and it welds horribly. Settings are all same every time. We have tried many different things to try to remedy it, but no matter what I try it happens again. Have pictures. Welding 1/8” to 3/16” 5053 and 6061 aluminum. Will post pictures once i figure out how to. Thanks.
Reply:gremlins?

What have you done to make it weld well again? Presumably you're doing something that fixes the problem, if it then manages to weld well for another few days.Soft wire is always a pain, your liner and tip have to be in absolutely mint condition. The wire oxidizes over time as well, it's maybe worth changing out if its old or if its a cheap brand. We had to chuck out about 30kg of 1050 grade wire a few years back as it just wouldn't run right, but switched back to a brand new good brand reel - no problems.Murphy's Golden Rule: Whoever has the gold, makes the rules.
Reply:Nothing at all. Just like a light switch then it is back to normal. For example, I was welding boat ribs yesterday and for 3/4 of the rib it was a nasty soot covered weld with lots of splatter. Got to a certain point and it just turned into a very pretty weld, like it is supposed to. Still trying to figure out how to put pictures on here. Our wire is never too old. I run XR Aluma-Pro push pull and run through a 16lb spool per week. Run Radnor wire though.
Reply:The fact that its sputtering and spattering rather than burning back definitely suggests its a power source issue rather than a wire feed issue.Murphy's Golden Rule: Whoever has the gold, makes the rules.
Reply:Well it still has the buzzing sound like it is supposed to. Just a quiet crackling sound at same time. This week I have went through about 25 tips and have had well over 50 burnbacks. We have a 252 we run as well and I switched push pull guns this morning and have only had 1 burnback. So that problem is solved i believe. Still not welding correctly though. Let me try getting on the computer real quick and see if I can attach photos. I am on phone and I do no see an “attach file” anywhere.
Reply:I thought it was power source for awhile. We have a very large shear and press brake off three phase. But that was not the isssue.Last edited by Gunner3235; 5 Days Ago at 11:20 AM.
Reply:Have you checked your SUP sync to the gun? From what I remember the value on the display should be set to the value printed on the gun. I had that go out of sync once. And just for kicks you could push some 5356 through the liner to clean it. I have had to replace the liner a few times.Weld like a "WELDOR", not a wel-"DERR"

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Reply:tips and burnbacks = feed problem. 99.9999% this is the problem.It's EXTREMELY unlikely to be the power source itself, it might be some dirty/undervoltage power.Even a push-pull gun needs a good condition liner... for the hassle you get, it's easier to regard it as a consumable item and replace it every 2 or 3 reels (6kg/13lb reels that is)How have you got the liner meeting the push rolls? trimmed right up to it?Murphy's Golden Rule: Whoever has the gold, makes the rules.
Reply:Are you sure you don't have a primary power source issue?One night in the shop I noticed my lights flashing/flickering in an unusual way. I asked my electrician friend about it. Before he could get over he found out that the power company had had a transmission line issue that caused the same thing for a bunch of people.