Possible problems with POWERULTRA 205P

[putz]

I recently purchased a new powerultra 205p and finally got it all set up last week but when I tried using the plasma cutter it constantly starts and stops. Seemed to be doing the same thing with stick as well. It acts like the pulse is on but I checked that and it was turned off. Sent a message to Everlast tech support last week but have not heard anything back. Just thought somebody on here might have had similar issues.

Thanks,

[m j mauer]

putz try calling them and rember they are picific time zone, you dont show were you are located,
but just the same welcome to the forum.

[putz]

Finally got a chance to call today and spoke with Ray. He thought it might be in the tip of the torch so i checked it out but all was good. Tried again to cut and now it cuts out and gives a high pitched tone when you pull the trigger. Eventually something trips inside and it will cut again for another 10 or 15 seconds and then it goes out again. Guess I will have to try and get another chance to call and see what other ideas he has. Just a real pita when the unit isn't even a month old and already has problems.

[joshuab]

Just a real pita when the unit isn't even a month old and already has problems.

With electronic stuff especially, there is a certain failure rate that will occur in the first 30 days or so, and then after that, they tend to run for a good long time. That's why manufacturers like Everlast give a 30 day return period--to catch units that sneak through normal QC. You just happen to be one of the unlucky ones that got one of those units. Sucks, but don't read too much into it.

[performance]

What is your air pressure? Running on 120V or 240V? What amps? What size tank are you running on your compressor? If you have a torch misfire, don't sit and hold the trigger. It needs to reset. Let go. Let the post flow finish and try again. (Set post flow to minimum until things clear up).

[putz]

What is your air pressure? Running on 120V or 240V? What amps? What size tank are you running on your compressor? If you have a torch misfire, don't sit and hold the trigger. It needs to reset. Let go. Let the post flow finish and try again. (Set post flow to minimum until things clear up).

Air is at 75 as suggested by Ray running 240v 25amps and I have a 60 gallon tank on my compressor. I have let it sit through post flow and still has the high pitched squeal. After a minute or so it will blow air for few seconds and the it will cut again but goes less than a half inch and quits again. It acted the same way in stick mode with 6010 at various amps using 240v.

[performance]

I think Ray may have misunderstood.
The plasma side is separate...so...
At 25 amps, you have an issue with having too large of a nozzle and too much air. The arc is blowing out.
If you need to operate under 40 amps, you'll need to drop nozzle sizes. Unfortunately we do not carry the really smaller sizes, but they are out there.
75 is a wee bit much anyway as that is the MAX air pressure at max amps, actually 2.5 lbs over recommended max. Try 50, then 60 then 65 to see if it improves, though that isn't a fix, it's just a get by until you can get a smaller nozzle. Is the squeal coming from the torch or from the unit itself? Some inverters have a characteristic whine to them. In fact inverters like these with a certain switching speed are called "screamers". It can vary a little from machine to machine, especially when new. If its from the torch, then I have heard that too. Have you changed out the consumable itself? Make sure the swirl ring is firmly seated and centered.

This unit WILL NOT weld 6010. Never has, never will, never promised. In fact we have made many forum posts about the lack of 6010 capability with these machines. The arc will go out! It will not be stable. 6011 is better though. Try some 6013 or 7018.

[putz]

I think Ray may have misunderstood.
The plasma side is separate...so...
At 25 amps, you have an issue with having too large of a nozzle and too much air. The arc is blowing out.
If you need to operate under 40 amps, you'll need to drop nozzle sizes. Unfortunately we do not carry the really smaller sizes, but they are out there.
75 is a wee bit much anyway as that is the MAX air pressure at max amps, actually 2.5 lbs over recommended max. Try 50, then 60 then 65 to see if it improves, though that isn't a fix, it's just a get by until you can get a smaller nozzle. Is the squeal coming from the torch or from the unit itself? Some inverters have a characteristic whine to them. In fact inverters like these with a certain switching speed are called "screamers". It can vary a little from machine to machine, especially when new. If its from the torch, then I have heard that too. Have you changed out the consumable itself? Make sure the swirl ring is firmly seated and centered.

This unit WILL NOT weld 6010. Never has, never will, never promised. In fact we have made many forum posts about the lack of 6010 capability with these machines. The arc will go out! It will not be stable. 6011 is better though. Try some 6013 or 7018.

Mark, thanks for the quick response I will try the settings you recommended when I get to class tomorrow night. So are the nozzles that came with it the wrong size to be using? I have not changed the consumable yet as it still looks brand new.The squeal comes from the machine when the trigger is pulled and the arc does not start. Not real sure if it does it all the time due to noise of cutting. As far as the 6010 I must have misread I thought is said 6010 and 6011 but I checked again and it says 6011 only. I think we have some 6013 in class so I will try that also. Again thanks for your help and I will post my results as soon as I can.

Thanks,
Putz

[performance]

The nozzles are the correct size if you are using it near maximum amps, like most customers do. But if you need to operate it in the lower amp range, then you need the smaller consumables. You'll probably want the .6 or .8 consumables.

[putz]

The nozzles are the correct size if you are using it near maximum amps, like most customers do. But if you need to operate it in the lower amp range, then you need the smaller consumables. You'll probably want the .6 or .8 consumables.

Mark,
Been out of service for a bit for surgery but finally was able to get back on the machine and I got the plasma cutter to work okay but I noticed the LED readout seems to bounce back and forth between 50 and 20. Checked all connections and they were tight so I switched over to stick mode and was running 3/32 6013 at 70 Amps an would bounce from 70 to 06 and then back to70 and would keep an arc. Any help would be greatly appreciated.

Thanks