PowerPro 256 no arc? Help!

I have a PowerPro 256, and have been using it successfully since last June. Tonight I went out to weld, and I can't get an arc. I even tried to strike an arc on the ground clamp, and I just get a tiny little spark, but no arc.

Wired for 220v 50A

Settings are:
TIG/HF
no pulse
DCEN
all connections are clean and tight
The argon flow is working, I have pre and post flow
Arc start is 75A, arc end is 50A
3/32 tungsten 2% Lanthanated, clean and tight

I use the foot pedal, and the digital display shows the amperage changing when I move the pedal... just no arc.

I'm confused. It has always worked flawlessly. Anyone have any ideas? Thank you!

Have you tried the other processes, like stick or plasma? How about AC? Making a list of what works and what doesn't can help support determine your problem. Give them a call and if possible be at the machine so they can walk you through some basic troubleshooting.

Sorry to hear you're having troubles. Checking out the machine's other processes is a smart idea. And just to tick items off the list, you might put a volt meter on your wall outlet to make sure that hasn't failed somehow. Tech support *will* ask that question, so doing it in advance will just speed things up a touch.

Make sure both hot legs are there, correct. Ground to each should give you 120VAC roughly or better. 240plus across them.

Points could be a hair to wide as well.

Best to call tech support Monday 9AM PST and ask for Ray, he will get you straight. 877-755-9353 (877-755-WELD) ext 207.

Check that a wire has not come loose in your plug...minor issue that can cause a lot of bigger symptoms.

OK, I tried AC stick and it worked fine. Then I tried TIG again, and I could get an arc, but had to scratch start. Seems like the HF has a problem. Sound like a points adjustment issue?

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Originally Posted by HemiRod23

OK, I tried AC stick and it worked fine. Then I tried TIG again, and I could get an arc, but had to scratch start. Seems like the HF has a problem. Sound like a points adjustment issue?

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Yes, after the machine has been unplugged for about 30 min, pull the cover (rear and side screws) and adjust the points to .030-.035
When you put the side screws back in just lightly snug them because they're easy to strip.

I pulled the cover and checked the points. They were at .037" before, and I adjusted them to .030" just to see if it would change anything. It didn't. Still no HF. There were no signs of arcing or anything out of place inside except for a loose screw rolling around the bottom of the case. I hope it isn't from anything important...

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Quote:

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Originally Posted by HemiRod23

I pulled the cover and checked the points. They were at .037" before, and I adjusted them to .030" just to see if it would change anything. It didn't. Still no HF. There were no signs of arcing or anything out of place inside except for a loose screw rolling around the bottom of the case. I hope it isn't from anything important...

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You have the new points that should last a long time between adjustments. Call the tech line and they will help diagnose the problem.

Tried calling tech support, and after a lot of rings got a message that said no one was available and to leave a message. Then it said the message box was full and hung up. Guess it's just not my day...

Quote:

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Originally Posted by HemiRod23

Tried calling tech support, and after a lot of rings got a message that said no one was available and to leave a message. Then it said the message box was full and hung up. Guess it's just not my day...

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VM is fixed. please call again OR email tech@everlastwelders.com

OK, called and talked to Ray today, and he thinks it may be the HF board. We'll try that and see what happens. (Thank you Ray!)

Hope things get fixed up quickly for you, HemiRod23. Ray's a good guy. You are in good hands.

OK, an update! The replacement HF circuit board Ray sent was delivered to someone in Wisconsin (I'm in Illinois), so he sent out a second one. It was a little over 2 weeks altogether, but it finally got here.

When I opened it, I discovered it was the early style HF board with the stamped contact points, unlike the one in my machine with the new style points (threaded brass/carbon tipped). I modified the new board by installing my "old" new style points on it. Rewired, set points to .035, and installed the board. Works great! I hope this one out lasts the previous one. 9 months seems like a short life for such a necessary part.

Thanks to Ray and the other folks at Everlast!

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From what I have seen around here, that's a bit of a rarer failure. Used to be that on some machines one of the blue capacitors was sometimes a bit close to the points, and it would arc into it. That happened to me. But I doubt that could ever happen with those new points.

Nice work!

Actually, the good brass points on the right in the picture are the old ones. I removed them from the bad board and mounted them on the new board on the left that didn't come with them. I wasn't going to move backwards in quality. The blue capacitors were glued together so they couldn't move out of place. I thought that was odd when I saw it, but now it makes sense.

Thanks for the great pictures. You've answered a few peoples question of what it would take to upgrade to the new style points. It's nice to know that it's basically the same board and looks like a pretty easy upgrade.

Good to see you up and running again. Extra points for the modification so you can keep the new style points.

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Originally Posted by Rambozo

Thanks for the great pictures. You've answered a few peoples question of what it would take to upgrade to the new style points. It's nice to know that it's basically the same board and looks like a pretty easy upgrade.

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I am one of "a few people" who has asked to purchase a set of these new beefed-up points, to no avail.

How about it Oleg, can I buy a set?

I believe that many others would also be interested.

Thanks,
Andy