problem with new PowerTig torch

I just received (11-25-09) my new Power Tig 250EX and discovered a problem while setting the machine up for trial welds. First I welded in the ARC mode with no problems. The welds were beautiful and easy to make. Then I set the machine up for DC tig welding using the remote foot control. I could not get a stable arc and kept burning up electrodes (1/16" 2% thoriated, pure Argon @15CFH).Talking to Mike in customer service, he suggested using the torch only and eliminating the foot control for now. I did what he suggested and had the same results. After some brain storming with Mike and some experimenting on my end, it turns out that the torch is not connected to the argon line correctly. I has been set up so that the argon does not come out of the ceramic cup but instead comes out one of the cooling water lines. I will contact customer service and have the send me a new torch. If any one has problems establishing a good arc and burns up electrodes you may want to check and see if the torch is plumbed correctly so that argon comes out the ceramic nozzle and not one for the cooling lines. Today (12-7-09) I ordered a water cooler for my Power Tig. In addition to these machines I own a Cut 50 plasma cutter and just love it. I have it mounted on a cart by itself so that I can move it around as needed. As soon as I figure out how to send digital pictures I will send a picture of the set ups I have.

Ken,

I sent an email to Alex. He will take care of you on the torch.

Looks like they plumbed that one wrong at the torch factory. I told you that was the wrong hose going to the gas out :D

Glad we figured it out and thanks for being a great set of hands on the other end of the phone.

The quick connect fitting may be easily cut off and changed to the proper line. A hose clamp will secure the hose to the barb on the fitting once the old fitting is removed. This should take 2 minutes and a whole lot better than waiting on a new torch, since in essence there is nothing wrong with the operation or function, only a fitting on the wrong hose with a crimped hose clamp attaching it. Generally there is an extra hose clamp or two in the box...so there should be no time or money lost to secure this fitting correctly. At most it is a 69 cent fix. But if you indeed want a new torch, we can accomodate you. I am thinking of what I would do in the same situation.

Received my new 250EX on 01-26-10, and discovered that the torch assembly had the same problem as previously stated, with the argon connector being on one of the water hoses.

It was on the water inlet hose and not wanting to use a worm gear hose clamp I carefully removed the crimped strap and reused it when installing the barb connector on the proper hose.

Simple deal. Use care and slightly bend the locking tab only enough to release the strap end. Relieve the tension on the strap by bending the loose end up and then remove the parts. Before reinstalling the strap clamp, open the crimped section to lengthen it for easy re-installation. When it's installed on the correct hose, hold the end of the strap down and lock it down with the tab.

To re-tension the clamp I carefully used a pair of end nippers, because the surfaces are parallel, to tighten up the crimp. Not enough force to cut the stainless steel but enough to close it up properly.

Went out today and visited the closest dealer which is Airgas in Longview, WA. Got a "200" tank (250 cubic foot) filled with argon for $245. It will be $55 to refill which is only $10 more than they get to fill their "150" tank. Bigger is better.

Now I've got to learn how to use this very nice 250EX.

Rolynn
Clatskanie, OR

I too had to change the fitting over to the correct line. The swap was easy but as stated above it could cost some time in figuring out why you welds are looking bad.
Wayne

I'm curious as only some of my welds are dark and some have the rainbow colors and I hear gas coming out. Is my problem a bad argon setting rather then wrong fitting?

Thanks,

Rainbow is normal. If you are getting both, I think, that it is probably a torch angle issue. Too much of an angle, the torch will create a venturi and siphon air into the weld. Only about 10-15 degrees tilt on the torch is what you need. If you are leaning the torch too much, then you well not provide adequate gas flow behind the weld while it is cooling. Dark can also indicate overheating of the weld.

First, you need to practice with some mild steel since its cheap to get the manipulation down.