Syncrowave 250DX high frequency issue

[jcpayton]

Hello Group, maybe a silly question, but how much time or inches of weld should one expect out of the high freq. sys. before needing to gap/grind the points to keep the arc alive and suitable for a/c?
Now the long winded explanation: I've had the machine 12 years now and have had this erratic issue since machine went out of warr. I hardly weld alumn. over 200 amps, balance set at #7, freq intensity set 50%. and after a new set of points I can get about 60 to 100 inches of smooth weld before the high freq. goes ape ****. I can regap (0.012) and go again for a while, then same thing. eventually have to clean and or replace points.

I know that there can be an infinite # of causes to a common symptom, being from a automotive electrical background, so it is understandable that everyone I ask I get a diff. answer.
I have updated the Points holder, C-3 cap, and all other caps in the sys that had been upgraded with new part #'s. tried a diff torch, etc..
Still I keep getting the same thing, Erratic high freq, after 60 - 100 inches if weld.

Simply Am I chasing a ghost or this is normal? should I be able to weld every other day for 3 months with no prob?

Thanks for any and all insight, Jimmy

[jcpayton]

Sorry about multiple posts, computer kept giving me error codes,

[jcpayton]

Sorry about multiple posts, computer kept giving

[H80N]

Hello Group, maybe a silly question, but how much time or inches of weld should one expect out of the high freq. sys. before needing to gap/grind the points to keep the arc alive and suitable for a/c?
Now the long winded explanation: I've had the machine 12 years now and have had this erratic issue since machine went out of warr. I hardly weld alumn. over 200 amps, balance set at #7, freq intensity set 50%. and after a new set of points I can get about 60 to 100 inches of smooth weld before the high freq. goes ape ****. I can regap (0.012) and go again for a while, then same thing. eventually have to clean and or replace points.

I know that there can be an infinite # of causes to a common symptom, being from a automotive electrical background, so it is understandable that everyone I ask I get a diff. answer.
I have updated the Points holder, C-3 cap, and all other caps in the sys that had been upgraded with new part #'s. tried a diff torch, etc..
Still I keep getting the same thing, Erratic high freq, after 60 - 100 inches if weld.

Simply Am I chasing a ghost or this is normal? should I be able to weld every other day for 3 months with no prob?

Thanks for any and all insight, Jimmy

Seems to need attention way too frequently... but..

should NEVER need to grind the points... just clean and regap... plus remove covers and blow the schmeck/dust out of it

you may have some crud bleeding off your HV.... .

have you looked at it in a dark room... covers off... HF on Continious...??

there have been several threads on this..... do a search on "spark gap" or "HF"

[jcpayton]

Ok thanks H80N, I'm dusting off my old oscilloscope, and fluke meter and going after some measurements. you have concurred with my thoughts that maybe some component in the circuit is causing premature wear in the points, which is leading to the erratic HF.
I am thinking maybe to high of voltage or current, or leaks in the HF circuit for some reason. I have been studying the service man and will carry on.
I was just not sure what a normal baseline is for this HF duration, and the short time fixes have been to clean the points, Thanks Jimmy

[H80N]

Looking for blue corona spark tracks in a darkened room will tell you bunch...

ALSO

If your unit uses the # 219927 XFMR,HIGH VOLTAGE 115V PRI 3600V SEC 34 MA ... a meter w/HV Probe should see 3600VAC on the output..

You never did give us a serial number... that would help... as there have been about ZILLION iterations of the Sync 250 in the last 30 plus years....

[Ironken]

I have nothing constructive to add, you guys are waaaay above my pay grade here! I just have to comment on how impressed I am that we have members here that can make sense outta some of this voodoo.

[cruizer]

Think I'd flip them and Gap em to 12 thousand. That should give you lots of spark jump. Now if you ground them down, that is a problem as there won't be any more irridium plating. Now if you haven't ground the other side down. Merely flip the pins and Gap them.