Power Pro 205 -- Plasma Question

I found myself running into a problem and maybe someone can help me out.

When I try plasma cutting, sometimes it will cut fine and sometimes it will pilot arc and then goes out and sets off the warning light on the machine. I cannot try to plasma cut again until I shut of the machine and turn it back on.

My air pressure is good, and amperage is high enough. Torch is negative and ground is clean. I just can't seem to get it to plasma cut for longer than 3" because the warning light always comes on and sets the machine to safe mode.

Any suggestions?

Are all the other knobs turned all the way down when you try to cut? From reading around this site, that appears to be a gotcha for a few people that can't get the plasma to cut right. Not exactly the problem you describe, but it may be worth trying.

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Originally Posted by agent4573

Are all the other knobs turned all the way down when you try to cut? From reading around this site, that appears to be a gotcha for a few people that can't get the plasma to cut right. Not exactly the problem you describe, but it may be worth trying.

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No I did not change any of the other knobs. I can give that a try and see what happens.

I had the same problem this weekend cutting some 1/8" sheet steel and the torch would turn start with the arc then about 1-2 seconds it would shut off then start again and repeat the cycle. If I had it on the metal and started the cut it would sometimes stay on and continue the cut. I troubleshot it with the manual that wasn't very helpful, changed the nozzle and electrode made sure the would move/spring back and free, reassembled and not difference checked all connections, PSI on air in and ground. Got there the cuts I needed to make but they looked pretty rough. Will try the knob adjustments suggested. Thanks.

Did either of you two get it to work properly? I'm interested in the results.

Unfortunately I have not had time to test as Im back to college. I was just home for a break to make something. I will try it sometime in December and get back to you. I am going to try the knob idea and see how that works. It is weird, it will randomly just stop the cut after 2 seconds, sometimes it goes into safe mode and sometimes you can try again.

Longest cut I was able to get was approx 24" in 16ga aluminum. But most of the time it does the weird safe mode thing.

I will tonight after work.

Alright let me know how it works

Just got done with some test cuts and it worked perfectly. Strange that every knob had to be turned to its lowest value except amps setting but it worked. Thanks for the fix.

Good to know, I will deffinately post back on here when I get a chance to try the knob trick. If it does turn out to be the fix, it is probably something worth mentioning in the instruction manual.

Well I thought I'd post up on my results.

Turned all of the knobs to 0 except the amperage setting I wanted to run. I was able to run the machine perfectly. Cut up a bunch of 1/8" angle to make a stand for my belt sander. I would have cut it with my dry cut but it seemed to have a high carbon content and cutting was difficult so I stopped before damaging an expensive blade.

Anyways with the knobs turned "off" everything worked great. Sometimes it would have problems making the arc continue after the pilot arc, but whenever I turned up the amperage by 2amps that went away. I was using approximately 38 amps to cut the material with at least 60psi.

I did have a problem with the water trap leaking air around the fittings. They seem to be straight cut threads and to me need an o-ring but an o-ring there and it still leaked. I ended up just wrapping the fittings with a bunch of teflon tape and no leaks at 60 psi. Hope this helps someone. If I get a chance Ill post some pictures of my stand for the belt sander in the projects section. Unfortunately I did not have pictures throughout the whole process.

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Originally Posted by scootarida1

Well I thought I'd post up on my results.

Turned all of the knobs to 0 except the amperage setting I wanted to run. I was able to run the machine perfectly. Cut up a bunch of 1/8" angle to make a stand for my belt sander. I would have cut it with my dry cut but it seemed to have a high carbon content and cutting was difficult so I stopped before damaging an expensive blade.

Anyways with the knobs turned "off" everything worked great. Sometimes it would have problems making the arc continue after the pilot arc, but whenever I turned up the amperage by 2amps that went away. I was using approximately 38 amps to cut the material with at least 60psi.

I did have a problem with the water trap leaking air around the fittings. They seem to be straight cut threads and to me need an o-ring but an o-ring there and it still leaked. I ended up just wrapping the fittings with a bunch of teflon tape and no leaks at 60 psi. Hope this helps someone. If I get a chance Ill post some pictures of my stand for the belt sander in the projects section. Unfortunately I did not have pictures throughout the whole process.

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Turn the postflow up fairly high to cool the consumables after a cut and make them last longer. The trap threads are bspp and need an o-ring or gasket to seal. You can swap the fitting for a 1/4 npt with no teflon tape but don't over tighten or you may crack the housing.

Glad to hear that's all it was. Definitely on my list of things to buy next year.

Yeah I was glad to.

FWIW if you go into the wood section with the select wooden boards, there are some smaller 3/8" thick boards I found and used my miter saw to cut some 45* into them and then use that as a guide to cut on. The 3/8" thick seemed to be perfect for standoff as well. I originally had 1/2" thick and it burned up an electrode pretty quick.

Also yeah I have seen with the post flow for extra cooling. My cuts were only 2" in 11 gauge and plenty of time in between them so the post flow didn't seem like it was needed as much for me. If i was going thicker I would deffinately turn up the post flow.

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Originally Posted by scootarida1

Also yeah I have seen with the post flow for extra cooling. My cuts were only 2" in 11 gauge and plenty of time in between them so the post flow didn't seem like it was needed as much for me. If i was going thicker I would deffinately turn up the post flow.

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Which plasma torch do you have ?

Torch is the S45