Plasma cutter won't cut

[NBraun]

A couple years ago I bought a cheaper Primeweld 3 in 1 machine. I've used it as a tig welder the last couple years and it's worked flawlessly. When I received it I verified the plasma torch worked but that's about it. I now need to use said plasma cutter and can't seem to get it to work. It has a pilot arc, work clamp is set on Positive, brand new consumables, air pressure at 60 PSI, clean new steel. When I pull the trigger the starting arc will "dance" around in the tip, but it won't actually light the plasma flame. It will intermittently fire it, but only enough to put a divot in the steel. Settings are correct. The tig welder still works fine. In talking with primeweld they said that the tig and plasma share the same board, so it's odd that the tig works but plasma doesn't.

I figured i'd ask here, and see if there's anything that could be user error that i'm missing?

 

[dnschmidt]

Primeweld has the best customer service in the industry. ASK THEM. Mike has been super helpful to me. If something is wrong they will fix it.

 

[Jswain]

Are they brand new consumables that came with the unit or did you get them separately from Amazon?

If it's the one with the ag60 torch I believe there are pilot arc and non pilot arc consumables.

 

[NBraun]

Primeweld has the best customer service in the industry. ASK THEM. Mike has been super helpful to me. If something is wrong they will fix it.

I did talk to them, and he said given the information I gave them it should be working. I plan on pulling the cover tonight to see if there was anything obvious on the machine that went bad.

Just figured i'd ask here as well, because it could be a Human error and I'm just missing something.

 

[NBraun]

Are they brand new consumables that came with the unit or did you get them separately from Amazon?

If it's the one with the ag60 torch I believe there are pilot arc and non pilot arc consumables.

These would be brand new consumables that came with the torch.

 

[Beerhippie]

Can you hear the air coming out of the plasma torch when you try to use it? There is a solenoid valve that controls the air. If it isn't opening, it would cause just what you describe. Should be pretty cheap and easy to replace if needed.

Also check the incoming air filter and water separator (if any).

 

[Jswain]

I did talk to them, and he said given the information I gave them it should be working. I plan on pulling the cover tonight to see if there was anything obvious on the machine that went bad.

Just figured i'd ask here as well, because it could be a Human error and I'm just missing something.

That doesn't sound very promising on their part. Did they not offer to help with troubleshooting?

 

[The Cobbler]

I assume you are grounding the work...
and try a lower setting on air pressure just for shits & grins

 

[Jswain]

Make sure the connection for the trigger is good too, I'm assuming it screws into the pedal position on your unit?

If the retaining screw is missing on the torch side of the connector it's easy for the connector to spin a bit and pull a wire off. Or if it's not connected all the way it may function as you describe

I would also assume it is just 2 wires being used in it on the torch end as it looks like it has a seperate connection for pilot arc so should be able to verify the torch/switch easy enough with a multimeter on ohms.

 

[LXCam]

Back the air pressure off a bit. My thermal dynamics plasma gives the same one finger salute if I’m not paying attention and get greedy.

 

[NBraun]

That doesn't sound very promising on their part. Did they not offer to help with troubleshooting?

They said based of what I had told them I was doing it should work, so the next step in the process would be to pull the cover and verify there's nothing obviously unplugged/burnt/corroded. I will do that tonight.

I assume you are grounding the work...
and try a lower setting on air pressure just for shits & grins

I am, but It does seem to act like I don't have the work clamp on. I'll try lowering the air pressure and see what I get.

Make sure the connection for the trigger is good too, I'm assuming it screws into the pedal position on your unit?

If the retaining screw is missing on the torch side of the connector it's easy for the connector to spin a bit and pull a wire off. Or if it's not connected all the way it may function as you describe

I would also assume it is just 2 wires being used in it on the torch end as it looks like it has a seperate connection for pilot arc so should be able to verify the torch/switch easy enough with a multimeter on ohms.

That would be correct. I will look into the torch as well, and see if there is a loose wire or something else.

 

[isb cornbinder]

I assume you are grounding the work...
and try a lower setting on air pressure just for shits & grins

The neighborhood genius bought a plasma cutter. On the advice of the customer service, he checked for air flow. He held the torch to his ear. The torch set his greasy hair on fire.
A few months before Mister Genius was bumming cigarettes from another guy. He asked for a lite. He checked the propane self igniting torch for gas by holding the torch near his ear.

 

[NBraun]

Alrighty, well have some more to add.

Pulled the welder case and can't find anything that really strikes me as odd or out of place.

I put new consumables in it and started to mess with the air pressure. If I lowered the air pressure way down, it would sometimes light the flame, but then promptly fuse the tip shut. For some reason it likes to blow the tips out almost immediately.

I also checked through trigger. All the wires check out there as being fully seated and having good contact.

I'm going to call tech support again tomorrow and see if this changes anything, but figured I'd throw an update out.

 

[steel 35]

Mine another brand needs 90 psi

 

[NUTTSGT]

Mine another brand needs 90 psi

I believe that's what my Hobart calls for.


What do your instructions state for air pressure ?

 

[MOS3522]

Is your air running through an air dryer? Wet air will screw up the jet.

 

[NBraun]

I believe that's what my Hobart calls for.


What do your instructions state for air pressure ?

Instructions state 50 PSI for 110V. So that's what I had it set at. I even regulated to 50 on my compressor incase the regulator on the cutter was incorrect.

Is your air running through an air dryer? Wet air will screw up the jet.

It is not, and one of the things i'm concerned about. However I figured even is moisture was the problem I could at least get brand new consumables to start even for a few seconds before they started having issues.

 

[tak1313]

What's the CFM rating of your compressor compared to the CFM need of the cutter? It looks like SOME kind of air restriction to me (lack of psi or cfm).

If you have a regulator at the cutter, have to tried regulating the air with just one regulator (either at the compressor OR at the cutter)?

This is going from memory, as I haven't used my Hyertherm in YEARS (maybe going on 10 now).

 

[Jswain]

Maybe take a few pictures of your setup. Right from the compressor, to the primeweld, all the way to the torch

 

[tak1313]

Instructions state 50 PSI for 110V. So that's what I had it set at. I even regulated to 50 on my compressor incase the regulator on the cutter was incorrect.

It is not, and one of the things i'm concerned about. However I figured even is moisture was the problem I could at least get brand new consumables to start even for a few seconds before they started having issues.

If you're regulating 50psi at the compressor, you're not getting 50 psi at the cutter (unless your hose is really short), THEN you're likely having additional loss from the regulator at the cutter.

I don't know what the psi/cfm of yours is, but my Hypertherm Powermax45 needs just under 6 cfm (350scfh) at 80-100 psi (with 360scfh at 90psi).

 

[bcradio]

If you're regulating 50psi at the compressor, you're not getting 50 psi at the cutter (unless your hose is really short), THEN you're likely having additional loss from the regulator at the cutter.

I don't know what the psi/cfm of yours is, but my Hypertherm Powermax45 needs just under 6 cfm (350scfh) at 80-100 psi (with 360scfh at 90psi).

mine is 90psi as well. 50 seems low to me

 

[Jswain]

I believe his unit is MAX 75 psi according to the label, which I think is common for the cheaper plasmas as my herocut is the same. But I regulate it 60-65psi at the unit only

 

[tak1313]

I believe his unit is MAX 75 psi according to the label, which I think is common for the cheaper plasmas as my herocut is the same. But I regulate it 60-65psi at the unit only

Do you know what the cfm rating is? The PSI is moot if not enough cfm is being provided. When I first got my Hypertherm and played around, I first tried it on my smaller compressor that could only do 4cfm @ 90psi and it just wasn't enough VOLUME to keep the plasma going. I assume it's likely less than my Powermax45, since that is a powerhouse of a portable cutter that only runs on 240v (had to install a 240v/50a outlet just for that).

 

[BukitCase]

My Hypertherm Powermax45 gets its air from my 5 horse 80 Gallon compressor (this one)

Industrial Diagnostics : Air Compressors | Dryers | Nitrogen Generators | Air Tools | Sales, Service and Maintenance in Baltimore, DC Metro and Maryland - 019 - TAPV-5052 MS

Industrial Diagnostics provides design, sales and rentals, installation, and maintenance services of new and used compressed air systems from 5-500 hp systems., 5 hp w/ 80 g tank

www.idaircompressors.com

Everything that comes out of the compressor (19 CFM @ 175 psi) goes thru a high flow painters filter (same as the yellow one in the pic below) then I have pre and post filter gauges to keep track of filter conditions - flow (pic) is top right to left, thru the SECOND painter's filter and Motorgard filter, then left to right and up the gray hose to PM45.

I've NEVER had a problem with this setup, I can use any length hose to the input and still get the output pressure/flow it needs. The upper right female coupler (see pic) is for a local full pressure blowdown, very handy instead of running TWO 50' hoses.

Dunno if other plasmas have this "quirk", but PM warns you in the manual NOT to tighten the torch head too much or it doesn't work - (backed up by my one-time experience )... Steve

Oh, every drawer on that rollaway the PM45 sits on is for consumables or spare parts for ALL my welding stuff (except the actual welders; duh

 

[Jswain]

Do you know what the cfm rating is? The PSI is moot if not enough cfm is being provided. When I first got my Hypertherm and played around, I first tried it on my smaller compressor that could only do 4cfm @ 90psi and it just wasn't enough VOLUME to keep the plasma going. I assume it's likely less than my Powermax45, since that is a powerhouse of a portable cutter that only runs on 240v (had to install a 240v/50a outlet just for that).

I do not, that is one of the reasons I asked for pictures of his setup, but unless he is running it on a 1/4" air hose after 50ft of 3/8" air hose then it should have enough to at least have the pilot arc, how long it will maintain would be compressor dependant. Some regulators are very restrictive though and you never know how someone has it rigged up.

 

[no704]

Are you Sure the work clamp should be +?

 

[Sumboodie]

Is your air running through an air dryer? Wet air will screw up the jet.

It'll still work, just wears the consumables fast.

 

[isb cornbinder]

Mine another brand needs 90 psi

I agree on the 90psi requirement. My Miller Spectrum 300 suggests a minimum of 90 psi and as much as 175psi. I have to wonder if the cutter tip is not getting enough pressure to keep the tip open.
Are your supply lines big enough to keep the pressure up when the machine calls for air? The only regulator that should be in the PC circuit should be as close to the machine as possible. Water separation was mentioned, I agree on the importance.
Is it possible to put a pressure gauge in the line just before the cutter? If there is a pressure drop MY Spectrum 300 will shut down and show a code. Spectrum 300 has a OEM gauge.
I do not know how much built in protection your machine has.
If you are looking inside the case, use extreme caution. I was advised that there is enough high voltage to kill a person.

 

[IRQVET]

I have a Hobart 12ci plasma cutter and I’ve never been able to use it. Tried to use it once, couldn't get the arch to stay lit, kinda gave up on the unit and its been sitting collecting dust for 5 plus years. I had no idea plasma cutting required an additional skillset ( I obviously do not possess).

 

[NBraun]

Alrighty, an update.
While I can agree that you need a good air compressor to make it work, I should at least be able to get an arc struck long enough to start cutting with a poor one. We tested this air compressor/cutter combo when it was bought and we were able to cut some 1/8th steel just fine. My setup is a 30 gallon compressor with 6 CFM.
I've been talking with Prime weld and they would prefer I send it in so they can take a look at it. This after I explained my setup, sent videos of what it's doing, etc. So we will see if they're able to come up with anything. Mike at primeweld has been very helpful, which i'm super appreciative of.

Either, I appreciate everyones input here as well.

 

[bb29510]

its the ground wire

 

[NBraun]

I figured I'd update this.

Prime weld sent me a new machine, with a new torch. This one works great. I wasn't able to learn what was wrong with the other machine, But they must have deemed it broken enough to send me a new one.

Either way, I appreciate their stellar customer service, and i'm glad to have a working machine.