pp256 plasma cutter issues

Bought a pp256 a few weeks ago from everlast Canada and really haven`t had mutch seating time on this machine yet, when using it in cut mode it seems it just does not cut worth anything, been trying to cut 3/8 plate and cannot penetrate through the plate, just cuts half the thickness, checked my point gap ,points are straight and gapped to .35, air pressure, i`ve varied from 45 - 80 psi, amps varied from 45 up to 60, checked the assembly of the gun and everything was assembled corectly and tight. the last compressor i used was a twin screw 15 hp with air dryer, so i do have clean dry air. One thing i did notice on a thinner piece of material i was trying to cut, when i would start penetrating the steel you`d hear a louder buzzing sound( just like the hypertherm we used to have) this only lasts a few seconds and it quits,almost like its a secondary winding or relay cutting out. the other thing i noticed is the low air light noes not illuminate when your running too low of a pressure. this is the only quark i have with the machine so far, haven`t tried the tig yet, still working on my cooler, stick part of the machine works really well, as good or even better than my old lincoln

Give Duncan a call over there. He'll be able to help.

Likely, its sounds as if its an arc transfer issue that can be fairly simple to resolve. What does the panel say while you are cutting. You need to look and cut at the same time and determine actual amp output.

Do you have your torch in the negative terminal? You are running it wired up correctly? Have you tried the other functions?

Clean up the contact surfaces for the work clamp. Clean the metal good where it attaches...Make sure it is attached as close and directly as possible. Also dissassemble the work clamp lead cable and take some emery paper and clean up the surfaces where it attaches to the clamp and reassemble. See if that helps.

torch is in the negative terminal, i have turned all the knobs on the control panel counterclockwise in case one of the functions would be causing this problem, as for amps not sure never checked them while i was cutting, tried even thinner new material, even cleaned off with the grinder, at a very slow crawling speed i can sometimes have full penetration through the metal, removed the supplied torch guide and did not help, i did read on another forum that there are different torch tips so i`ll check that tonight and give them a call tomorrow, thanks for the reply!

Its in DC and you have the post flow set?

When you say crawling speed, 3/8" plate though it will handle it won't be zipping through exactly...A torch tip could be the issue, IF its too small, but usually a small torch tip will quickly become a large one if it is over amped. Your stand off height should be around 3/32-1/16 of an inch and torch should be held vertically at that thickness.

yes its in DC, the post flow is slightly on, isen`t post flow only for cooling the torch after the cut and trigger is released?? crawling speed, i can darn near count to a minute before i move and still no penetration through the plate, the torch is angled roughly 1/16 off the material, removed the tip and i have a 1.2 tip, isen`t it supposed to be a 1.0?? the only other concern i have is the low pressure light does not illuminate,

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Originally Posted by charger891

yes its in DC, the post flow is slightly on, isen`t post flow only for cooling the torch after the cut and trigger is released?? crawling speed, i can darn near count to a minute before i move and still no penetration through the plate, the torch is angled roughly 1/16 off the material, removed the tip and i have a 1.2 tip, isen`t it supposed to be a 1.0?? the only other concern i have is the low pressure light does not illuminate,

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Sounds like your only getting the HF and not the main arc. The torch comes with 1.2mm tips, you can use 1.0mm for thinner material at 30amps or so.

The light is a target pressure light. The light should stay on while it is in the correct range...

I'd agree, sounds like you are getting pilot arc only. Don't wait around to call Duncan.

Tip size isn't the problem.

When you say angled, you mean standing off? The torch should be held vertical and perpendicular to the work.

Talked to Duncan this morning, will finish my tig cooler this weekend and try the tig function and it should point us to the problem

tig works really well, Duncan is getting 1.0 tips sent to me.