Plasma cutter consumable question

[WhoWhatNow]

I picked up an Eastwood Versa Cut plasma for cheap at an auction over the weekend and just got a few minutes to try it out. The unit powers up, the fan comes on and I get air flow but when I go to cut I only get sparks, no sustained arc. The work was reasonably clean and the ground attached firmly. The torch looked like it had only been used for a few cuts. The nozzle was charred but not too beat up. Opening the torch revealed pretty new looking consumables. The only thing I noticed is the electrode: it appears that there should be a very small hole in the center but when I shine a light from one end it appears to be closed. It this normal? Should the air travel through the electrode or around it?

The only other thought I had was I may have had the air pressure set too high (above 60psi). Does anyone know if this unit has a high pressure safety cutoff?

 

[WhoWhatNow]

Bump for the early crowd. I won't have time to play with it again until Friday but would like to order a new electrode if I need to so I have it.

Thanks

 

[Kev442]

Are you using an inline air dryer? Damp air = no flame.

 

[WhoWhatNow]

There is a filter/regulator on the line about 50ft from the compressor but I don't have a Motorguard directly on the plasma yet. I have a cheap filter I could put on the back of the unit.

 

[koditten]

Air travels around the trode.

 

[WhoWhatNow]

Thanks. I'll see if I get a few minutes to try it again tonight.

 

[brucer]

I think you have the trafimet s45 torch, but not certain.. I think the 40amp plasmas used the trafimet s45 and the 60amp machines used a Trafimet S75...

air travels out through the swirl ring and then travels around the electrode and out the nozzle, there is a small halfnium insert (it will be slightly different color) on the end of the electrode..
as for consumables, you should have the swirl ring also known as a diffuser (little plastic bushing with holes in it) electrode and a nozzle,the nozzle will have a small hole in it.. the shield cup (the black cap/cover) screws onto the torch and covers everything except the end of the nozzle..

How much air pressure are you running? you will need about 70psi of pressure, some plasma cutters are more finicky about consistent air pressure.. but if your pressure is too low it will put out a disrupted arc, or maybe nothing but air.. I had a 40amp import plasma cutter and it liked 65-75psi depending on which nozzle i was using..

Make sure you have the torch hooked up correct.. mainly the pilot arc connection, I think the 60amp units it was built in with the euro connection torch, but the 40amp model the pilot arc wires were hooked up separate.. also check the little fuse in the front of the machine if there is one...


the next thing to check would be the air solenoid inside the machine, when the spring in the solenoid gets weak it messes with things, makes the plasma cutter act erraticand not fire correct.. you can open up the solenoid and stretch the solenoid spring out about an 1/8" to 3/16 and put it back together and see if that helps..

 

[dbabicky]

If you're using an extension cord make sure it is of sufficient gauge. You could be suffering from voltage drop if you have too light of a cord. Just a thought.

 

[WhoWhatNow]

brucer - I think the torch is a copy of the old Hypertherm Max 40. Thanks for the description of the electrode. The insert is what I was seeing that I thought was a clogged hole. All the pieces are there and assembled correctly. I think I was close to 90psi when I tried it on Sunday. The instructions say 30-60 and I had read somewhere that some machines have a cut off if the pressure was too high or low. I'll take a look inside the machine on Friday.

dbabicky - no extension, plugged directly into a 50Amp circuit.

Thanks again for the help

 

[Thruxton]

I have the same machine, and a similar problem, which was caused by an air leak at the air connection on the rear of the machine. Do your hear any leaking with the machine off? If so, check for leaks. Mine was caused by a badly machined bushing, easy fix.

 

[brucer]

check your hose, a 3/8" hose isnt the greatest to use, also your regulator...

I found real quick when I got a real plasma cutter I didnt have proper components in my air system, I had plenty of compressor, but I was gettign huge restrictions at my regulator and air hose... My regulator was a craftsman 3/8" port, but when you took the fitting off and looked at the regulator the hole inside the regulator was about 1/4".. Also the air hose I was using was about 10ft long and said 3/8" on it, yet the id sure as heck wasnt 3/8" i could tell by looking.. I have since replumbed with 3/4" line and adding a volume tank just to be safe, got some 1/2" line and working on sourcing a 1/2" port regulator..

I will also add a pressure gauge inline at the plasma cutters air inlet just to verify no pressure loss while I'm running on my cnc plasma table.

 

[metalmagpie]

What a nightmare! Glad I bought a real-by-God Hypertherm!

metalmagpie

 

[chadman]

What a nightmare! Glad I bought a real-by-God Hypertherm!

metalmagpie

That's funny because my Hypertherm is pretty much doing the same thing his Eastwood is. It just makes sparks and melts the metal a little bit but won't cut.

 

[liquidh8]

I have an eastwood and LOVE it. Use it often. I can't help you with the troubleshooting though.

I run the 90psi shop air to the machine, and regulate it down for whatever metal I am cutting.

 

[WhoWhatNow]

Thanks for all of the suggestions. I had a few minutes to open it up today and take a few pics. Nothing looks burnt or out of place. There is a lot of stray hot glue but I didn't see anything obviously wrong. The internal air filter appears to be dry. The only this I saw that I questioned was the board with the transformers on it was bowed down at the front where the ground and torch connections are. This may have been pulling some of the connections off (see second to last picture). I pushed the board up a little and hopefully got a better connection. That did not seem to be help however. Anyone see anything I am missing?

A few notes about my setup. I have an 80gal Quincy in my basement with a run of about 50 feet of ¾’ black pipe up to the garage. I run full pressure (155 psi) up to the garage. In the garage I have a ¾’ ARO filter regulator then 50ft of 3/8’ hose. When I tried again today the compressor was full and had not been run since Friday night so the air should be pretty dry.

When I hit the switch the air starts and the gun only sparks when I touch the metal. When I release the trigger the air stay on for about 10 seconds then shuts off. Is this normal? Also, when I pull the trigger without touching the metal the air starts but I get no spark. I took a short vid of what is happening when I try to use it. It is entirely possible that the unit works but I am doing something wrong. The last pic is of the metal after this try. There is current going through the tip but it does not appear to be sustained? I had the air set at 70psi and the amps at 34.


















<iframe width="420" height="315" src="//www.youtube.com/embed/0E11B92fneA" frameborder="0" allowfullscreen></iframe>

 

[WhoWhatNow]

Last two pics

 

[WhoWhatNow]

Video

 

[brucer]

well one thing, you dont have to touch the torch to the metal..
The torch should ignite when you pull the trigger..

Turn the pressure to 70-75psi, change to new consumables, just to rule that out..


In your video I hear compressed air constantly, that shouldnt be happening... you should pull the trigger and get air and torch ignition, when you letoff the trigger after a couple seconds the air should stop.. if its just blowing air the entire time I would assume you have a solenoid issue or an internal air leak..

 

[WhoWhatNow]

Brucer- thanks I'll give that a try. In the video I had the trigger pressed the entire time. When I release it the air shuts off after about 10 seconds.

When I press the trigger without being near a piece of metal I get air but no torch ignition. I hope new consumables will take care of it. I will report back.

 

[WhoWhatNow]

No joy with new consumables and more air. If I pull the trigger without touching the metal I get air but no arc. Is this correct? Could there be a problem with the switch? What would I look for?

 

[countryss]

I have the same unit and air does come out for a brief moment after the trigger is released.

 

[WhoWhatNow]

Countryss - do you get an arc if you pull the trigger without being near a piece of metal? I am starting to think the trigger is bad. Thanks.

 

[waterss]

I have a Eastwood and when I pull trigger I get air and flame, arc what ever you want to call it. Have had no issues so no help with diagnosing though.

 

[WhoWhatNow]

I have a Eastwood and when I pull trigger I get air and flame, arc what ever you want to call it. Have had no issues so no help with diagnosing though.

Thanks. I am starting to think something may be wrong with the gun. I may take it apart this weekend.

 

[BoostAddiction]

Why not call Eastwood? They have probably seen the issue many times and will likely have a quick answer.

 

[metalmagpie]

99% of the time this problem is due to a bad ground lead connection.

 

[Jetfixr320]

I bought a Eastwood Plasma cutter 2 years ago.
The only way it would work was to have clean metal, touch the tip to the metal pull the trigger and pull away from the metal.

I used it quite a bit for a couple weeks then it sat for almost a year. I went to use it and the only way I could get it to work was to push in and hold where the gun connected to the plasma cutter unit ( front of the box). I still had to make contact with the metal to strike a arc.

Eastwood sent me a new unit after receiving mine even though it had been over a year.
The new unit works good but, you still have to touch the material to strike a arc.

I think I did some reading that there are two types of plasma cutters. one you touch the metal and one that you can jump the Arc.

I probably wouldn't buy a Eastwood unit again though.

Jet

 

[bigdav160]

The only thing I noticed is the electrode: it appears that there should be a very small hole in the center but when I shine a light from one end it appears to be closed. It this normal?

What? Like this? It goes all the way through.

I've cut a couple hundred feet of steel with my Versa cut (so far) and it works great.