Powermaster 205 Plasma problem

[Cobraphx]

When I got my Powermaster 205, it worked great. Now I've used it a few times and the plasma cutter is barely working. I did a little bit of DC TIG welding on steel last week, Saw some slow pulsing of the Plasma of the TIG welder, it seemed to increase and decrease in intensity a bit every couple seconds, not sure this is normal.

The bigger problem is plasma.. this weekend I switched back to Plasma. When I first moved the torch to the metal to be cut I got a big spark before pulling the trigger. As I started to try to cut, I got airflow, but instead of plasma I just a of couple short popping arcs.

I changed to a new tip and electrode, upped the pressure from 60psi to 65psi and increased the amperage from 25amps to 30amps and tried again... This time I got a plasma formed, but it seamed weak and ended up blowing back across the metals surface after an inch or so. Checked the tip and found it blown out.

Checked all connections, changed the tip and electrode again, upped the pressure to 80psi and increased the amperage to 35amps. This time got a good plasma, but still a bit weak compared to my Miller plasma cutter set at 15amps. The plasma cut ok for about 8 inches then I could tell the tip blew out again.

Not sure what to do next, I'm out of consumables, will try and pick up some on the way home Monday.
These are the tips:

This is the connections and settings, everything centered except Base Current at 35 for last attempt.

[performance]

Cobra,

What I see is signs of moisture in your air line. That may not explain the problem. But it certainly might be part of the issue. Drop the air pressure to 65.
Its possible that the electrode may be seizing in the torch head. Make sure that the electrode can be pressed fully in and it returns easily.
Also, make sure that the ground is making full contact. Its possible you are getting pilot arc current and the arc isn't transferring. Make sure the swirl ring isn't clogged or missing. I have seen this damage with out the swirl ring installed.

The pulsing of the current is related to your pulse settings. The operator's manual may have an error in it regarding the setting of the buttons. It was written pre-release based off of factory test units. Try the opposite setting regarding base peak operation. That should stop the problem. However, if you still see pulsing, match the base/peak amperage settings. Turn down the pulse width

[Cobraphx]

Thanks for the help Mark.

It's almost always the simple things.

Seems I misplaced the swirl ring after putting in a new tip a couple weeks ago. Didn't even notice it missing as I burned up 2 tips. Put the swirl ring back in and the plasma cutter works like a champ.

Thanks again,

-Matt

[performance]

Well,
It helps to have a little experience...too bad I had to learn it the hard way myself.

But Cobra, it still won't hurt to add an 'extra' air dryer to your setup...Particularly one as it leaves the tank. The machine unit is sort of the "catchall" dryer and does a fair job. I just found, especially in humid areas or times of year with rapid temperature changes, it helps to have a little extra protection. Your other air powered equipment will thankyou too...

[Cobraphx]

Thanks Mark,

I do have a moisture trap, and here in AZ the Humidity is normally in the low teens. But It has been more humid than normal lately - 60% some days. I need to add a desiccant dryer before I get to the painting stage of my project anyway. Maybe I'll just get one ordered this week to be on the safe side.

Thanks, again for the help.

[FabGTO]

Thanks for the help Mark.

It's almost always the simple things.

Seems I misplaced the swirl ring after putting in a new tip a couple weeks ago. Didn't even notice it missing as I burned up 2 tips. Put the swirl ring back in and the plasma cutter works like a champ.

Thanks again,

-Matt

Damn those swirl rings BTDT

[Oleg]

Hey FabGTO

Did you finally for your check from Mr Sr ?

How do you like your PowerTig and cutter ?

let me know and try to psot some pics

[WAYNESWORLD]

I have a small disposable filter that they sell for paint guns on my plasma as a precautionary measure and it helps trap moisture and dirt from entering the machine. Any body shop or paint supply store or online supplier should stock them. They are ¼ npt threads and cost around $20.
Wayne