Just found you all and signed up. Plasma cutting Question

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Last night I was playing with a friends Plasma Cutter  Thermal Dynamics PAK25. I guess it's an oldie with some issues.  When it was cutting I loved it but the Pilot arc was working, then not working. I'm not an idiot so I know it can be a million things BUT is there an area that generally poops out on these things when you get this symptom? i.e. Failling internal Magnetics or transistors?HE bought a new one for his business and after he saw me drewling he said I can have this  ( I'm just a homeowner that tinkers ) one. I'd love to get a direction as to where to start.  I have electrical Schematics of this unit.Thanks
Reply:Welcome to the site, tony h!  hope you enjoy it. My experience with plasma cutters is limited, so I'm not sure I can help. The only time ours ever does that is when the air filters on the back get plugged up. I guess no air, no spark. Hope you get it fixed. Let us know.
Reply:This is a pretty nice older unit worth a couple or few hundred bucks used.  Consumables are readily available for it.  Nice snag!!!  Here is a website that may help you diagnose the issue.http://www.centricut.com/TA_StartingProblems_2004.htmSmithboy...if it ain't broke, you ain't tryin'.
Reply:you might want to make sure the electric in the garage is up to snuff mine does the same thing sometimes and I actually posted a ? on that....But nobody has answered it yet...I guess nobody likes me for some reason..now im not positive but I heard  that plasmas use a bunch of juice at first arc, then it settles down after a few seconds so if the breakers arent 30 amp or the wiring is messed up it will affect your arc...like I said I heard this from some other folks...it might not be true....Good Luck!!
Reply:Smithboy, good stuff. I wonder if it's just an air pressure issue.The Line cord to Breaker box:  This is nice and direct, I'm sure that is OK.Thanks everyone.
Reply:That would go along with what the website said.  You say you get the pilot but it then goes out, right?  If that is the case, it could be too much pressure or flow.  If you trust the pressure guage on the compressor, dial the regulator down until the pressure is limited to the max pressure of the plasma cutter.  That way you cant over do it.  Also, start with a piece of sheet metal, something thin and see if it holds a cutting stream.  If it does, you probably just need to adjust things correctly.  You can probably get a manual from the manufacturer that describes some of the adjustments.  Also, make sure you are using really dry air.  Moist air will cause the tips and electrodes to get used up very quickly.  If your tests work out, dont think too much about putting a hundred or so into getting it working well (new tips and electrodes might run $5-$10 each).  It would be well worth that, given you got it for nada'thang.  The current equivalant new would probably cost around $650-$900 new.Smithboy...if it ain't broke, you ain't tryin'.
Reply:In my experience with the HYPERTHERM POWERMAX when most problems occur with cutting it tends to be the consumables.  Usually the consumables are fairly inexpensive considering what the machine is capable of doing and time saved on project!  When unit was first bought it was set up as 110v unit and we had several cutting issues.  We took it in to have it serviced and they gave us a 220v loaner and boy what a difference.  Needless to say when our unit came back it was newly wired for 220v and that problem was solved.  So my $.02 worth is check and make sure you have correct line voltage, air pressure, and most importantly check the consumables
Reply:If that circuit didn't arc out at the tip maybe wire fatigue in the handle is the culprit. If it's that it might work when you twist the handle a bit. To find a wire that's broken on the inside see which one stretchs.
Reply:The pilot arc is on a timer and will only allow the arc to fire for about a second.New electrode and tip can help, the little swirl ring must also be in good condition.The reason it is on a timer is the pilot arc circit is a second earth, once the arc is made on the job it is supposed to turn off.Tom Baileyweldingsupplies
Reply:Tommy--I'm trying very hard to get my Max40 working-without spending mega$ bucks. The Hypertheme staff are useless. I get zero spark. What interests me is--what happens if I jimmy the spark coil to be on all times or install push button?--by theway--let everyone know-that blasting the gun with the  arc spark starter ,without proper volume air, the spark can eat the gun consumables away--in no time. I'm trying to figure out how the electronics works in max40 but the manual is sh!ts. Does anyone have the actual schematics of the IC ect-of the printed circuit boards. The unit has over 6 boards and replacing each to find the fault-is not in my budget. If some onehas extra boards to sell or loan-or actual schematics or any info let me know.The unit goes to white lite and air cycles for a short time and the red DC lite does not come on. George       [email protected]
Reply:Another note--stay away from Hypertherme units--the staff have the schematics but refuse to give them out.Sad,when other palsma  firms freely give them out.$300 USA for a single circuit board is robbery .   Get this; I needed the electrode-size of small 1/2" bolt--$8.00 each, $15.00--shipping Puralator, $4.95 for fuel tax--also consumption tax--total--$30.00--sucks--the unit--still the same.