PM-205 Plasma not working

Hi,

I received my PM-205 a couple of months ago and immediately put it through its paces. Everything worked great, both TIG and Plasma. However, after doing a few hours of TIG, I tried to cut again and it no longer works.

It will not start an arc with the torch a bit above the piece. It will start an arc if I touch the torch to the steel, but the arc dies as soon as I pull it slightly away. It seems that the pilot arc is not working?

The torch is assembled correctly. My air pressure is 65 PSI with plenty of flow.

thanks,
casey

Please call me at 406 586 3356 when you can.

thanks, casey

Mike will check this soon, but we do have a customer service line to tech support, and email. Check out the number below and dial the Mike/support extension.

I tried calling that number, but got an answering machine.

i left a message with both you and mike with my cell phone number. what time should i try calling you? i assumed normal west coast operating hours...

Thank Mike, for calling me back. Look forward to receiving the replacement parts and getting back cutting again!

Do you have a tracking number or an expected delivery date for my replacement parts? thanks, casey

Casey,

Tracking, shipping is all the duties of the home office. You can call them and do that quite easily. Neither Mike nor I have the tracking/shipping records for warranty. Please call the 800 number ext 201.

I am curious to know what was the problem with the unit?
What partes needed replacement?
Is the unit back to Normal?
Thanks for letting us know!

hi alex,

i am still waiting for the parts, so i do not know what the problem was yet.

the good news is that mike was very helpful, and more then willing to send replacement parts to me.

the bad news is that i had to call twice to get the parts sent, and have yet to receive a tracking number for the parts.

Quote:

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Originally Posted by junkfunnel

hi alex,

i am still waiting for the parts, so i do not know what the problem was yet.

the good news is that mike was very helpful, and more then willing to send replacement parts to me.

the bad news is that i had to call twice to get the parts sent, and have yet to receive a tracking number for the parts.

---

Alex said he will PM the tracking number to you here. Just talked to him.

Casey,
Alex told me he had sent out the parts...Sorry, but no tracking number right now. I just got home and am posting here and so that hopefully you will have them soon.

We do try to follow up and when you have a issue like this, sometimes someone drops the ball, but we try not to let it bounce. :)

I replaced the high frequency board and the cutting torch, and it still doesn't work. Same symptoms as before...air but no spark. I can still drag start an arc, but it goes away as soon as the tip loses contact with the metal.

Lost more productivity as a result....

Can I still use the RMA that was emailed to me last week? I would like to ship this broken unit back on Monday and hopefully receive the replacement before the end of the week.

Thanks,
Casey

Quote:

---

Originally Posted by junkfunnel

I replaced the high frequency board and the cutting torch, and it still doesn't work. Same symptoms as before...air but no spark. I can still drag start an arc, but it goes away as soon as the tip loses contact with the metal.

Lost more productivity as a result....

Can I still use the RMA that was emailed to me last week? I would like to ship this broken unit back on Monday and hopefully receive the replacement before the end of the week.

Thanks,
Casey

---

You will need to call the main office and get that set up.

This issue sounds similar to what I am dealing with right now, I finally got around to trying out the plasma (new machine 1 month old first time turning it on) and for some reason I had a difficulty getting the arc to start, all it would do it spark and the air would flow but thats all. After several attempts I finally got it to cut but had to make constant contact with the steel, any time I would pull away it would die. After that one good run cutting about 5", I couldn't get it going again, would just spark. I was cutting 1/4" steel at 30amps and the air pressure at 60psi.

After getting fustrated with the problem, I took a look at the torch electrodes and found that the tip looked melted.

http://i430.photobucket.com/albums/q.../IMG_03941.jpg

I'll put in the new electrode and try again, hoping it was just a defective tip. I will report back tomorrow with the results.

Jas329,

Make sure you have dry air going in. The looks of the consumable could be a number of things. I have one like that, I loaned my power plasma 50 to a neighbor and it came back flat like that.

I took the torch apart, cleaned the swirl ring, added new nozzle and electrode and it cuts fine. Not sure what he did or if it was a bad consumable. He said he got done what he wanted. So consumables would be the first thing to try.

If you still have a problem, give tech support a call. Yep, even works on Super Bowel Sunday.

When you fire the torch in the air do you have a pilot arc? You mention no plasma until you touch the metal.

I got two air/water seperators right now, one on the tank and another that came with the machine. I guess I'll pick up a dessicant air drier for it just to make sure.

I dont get anything when I try to fire the torch in the air, only sparks when it is contacting the steel and I hit the trigger. The machine makes a clicking noise when I hit the trigger and it starts to spark like it wants to fire up but cant.

I forgot to mention that it doesnt seem like its getting any air flow prior to the HF start, but I know its flowing during and after I hit the trigger. Is there some setting that I'm missing like pre-flow adjustment?

So I checked the swirl ring, its clear; checked the cup, looked fine like new; put in the new electrode and new cutting tip. I set the machine at 35amps and 55psi got it to fire only when touching the metal. Won't even make a sound when it was just slightly above the material. When I tried to start cutting it dies immediately. It didn't make it through 1/4" steel so I turned it up to 40amps, tried again and got it to cut for about 2" and it just died. It still didn't make it through the material. Yesterday when I did make it through it left a lot of slag on the underside of the cut, I had the air at 60psi yesterday. I'm lost at whats causing the problem, even checked the electrode and its starting to eat away at the center so I stopped. I'll get a picture posted of the second electrode that I just put in.

Got the picture of the 2nd electrode that seems to be burning up, the right set is from yesterday and the left is from today, I stopped after seeing it start to pit in the center. I can't cut more than 6" before the electrode burns up and looking at the cost of getting new electrodes and cutting tips, it would cost me a fortune to cut anything. I think I'm going to hold off for a while with the plasma cutting until I can figure out whats going on.

http://i430.photobucket.com/albums/q.../IMG_04051.jpg

Jas329,

Can you PM me a phone number. I need to ask some questions. The center wear is normal over time.

It is possible that there is a defect in the torch. If the piston isn't pushing in all the way, it would cause a constricted arc and cause radial melting if the tip wasn't fully retracting.

Push in on the electrode and see how far it give when it goes in. Also see how fast it returns. Watch for any binding or freezing up of the piston mechanism.

The torch ignites an arc when the electrode is "blown" back by the flow of air pressure. The electrode is spring loaded and acts as a "piston" to go from a grounded condition to an open position, creating a spark gap. The basic concept is the same in breaker points ignition on a vehicle, where the spark jumps across the air gap when the points open. However in this cause, the spark generated ignites the plasma stream (sort of star trek sounding, I know, but that is really basically what happens).


Just as points that don't have good gapping will burn, this seems to be a similar situation. Its possible also that a hose is kinked inside the machine and its preventing full air flow to the torch, causing a reduced gap.

Now, of course, Mike is the electronics expert, but having a lot of experience with that torch, I am only offering some things to check.

Mike PM Sent.

Mark, when everything is screwed tight, the cup compresses the electrode against the tip and there is no movement in the tip. When not in use the electrode makes constant contact with the cutting tip. It looks like tip can be pushed back about 1/16" before the swirl ring makes contact with the torch body where the electrode screws in.

Just pushing in the electrode by itself it has about 1/4" travel. looking at the small holes for air flow near the electrode, when the swirl ring and tip is compressed against the electrode it seems like the holes are almost covered up by the torch body. when the electrode is fully compressed in agianst the torch body the holes are completely covered up.

The spring return on the electrode is decent, seems a little rough/rubbing when pushing it in though.

junkfunnel

you have PM

For anyone interested, Everlast shipped a replacement for my PM205 after the plasma went out. Everything on the new unit is functioning great. Hopefully this one doesn't quit working, but I feel good knowing that Everlast will exchange faulty units. Thanks!

I guess for anyone that is still interested and have a similar issue with the plasma cutter, if the electrodes are pitting faster than normal, best to check the connections to the unit. Make sure the ground clamp is connected to the positive port on the unit and the torch is connected to the negative port. You should be able to hold the torch up in the air with the unit plugged in and air flowing, the torch should spit out about 1/4" electric bolt. Now the plasma is working like a charm and the electrodes seems to be holding up just fine.

oh forgot to mention that it Mike and Mark were very helpful, I got a call from Mike that same day I PM'd him and he was very patient as he walked me through things to check on the machine and asking me about my setup. It was helpful to pick their brains to get a better understanding of the machine. The next day I was able to solve the problem (it didn't take 9 month to fix, I just forgot to post it earlier, sorry). I gave Mike a call to let me know the good news and he was kind enough to give me some pointers on how to set up and use the machine to get the most out of it. Thanks guys for all the support.