Everlast ULTRA-ARC 205 Operator's Manual page 38

Section 4
TROUBLE:
Machine will not turn on. No fan, no display.
Air flows but arc does not start within 2-3 seconds.
Air flows but pilot arc does not start or spark but arc starts when nozzle is
rubbed on the metal.
Will not start arc.
Pilot arc will not light. Arc will start when torch is drug on the metal.
Pilot arc will not transfer and amps read approximately 25-27 amps while
switch is held. (Arc barely cuts or only "scratches" the surface of the metal
or cut is extremely slow on thin materials.)
Arc Sputters.
Consumables are dirty, smutty looking upon inspection. Premature wear on
consumables. Shortened consumable life. Tips are melted looking.
Premature wear on consumables. Short consumable life. Uneven wear of
consumables, melting of cup.
Arc will not start with pilot arc or by drag/scratch starting nozzle directly on
metal. Machine runs.
Over current/Duty cycle Error Code. Machine runs, but no output.
Unstable arc at lower amps.
Arc tries to start but irregular, dancing arc and/or arc melts through side of
nozzle.
Arc will try to start if touched to the metal, but no air flow while switch is
pressed.
Air flows continuously. Erratic or unpredictable shutting off of air after post
flow time has expired.
Excessively Beveled Cut.
Cup and/or nozzle is melting or cracking.
Power input circuit breaker trips repeatedly.
Arc "Blows Out" when ready to cut.
TIG/Plasma/ Stick ERROR CODES
E01 Overtemperature/ Duty Cycle Exceeded
E02 Over/Under Voltage/Current/Unit Fault
E04 No Torch or Loose Torch Cap (Plasma)
E05 Torch Switch Stuck (TIG/Plasma)
E06 Too Low or High of Air Pressure (Plasma)
CAUSE/SOLUTION
Check cords and wiring in the receptacle. Check circuit breaker. Check plug condi-
tion.
Check consumables for wear and tightness. Check fuse.
Check Air Pressure. Sticky or slow spring/piston on torch blow back mechanism.
Release trigger and try again.
Pilot Arc Wire broken or disconnected. Consumables worn.
Air Pressure too low. Torch electrode/blow back mechanism stuck in rear position.
Missing Swirl Ring (usually happens after consumable change).
Pilot arc wire broken or not connected. Cap loose.
Check work clamp connection. Make sure rust is removed from work clamp contact
area. Faulty Clamp. Arc continuity is not being sensed. If these steps do not correct
the issue, contact Everlast.
Inadequate air flow or air pressure. Improperly sized nozzle. Change to nozzle/Tip
with smaller diameter orifice as amps are lowered. Readjust air pressure. Loose con-
sumables. Check tightness. Worn Consumables
Moisture, oil contamination of consumable. Wrong consumables. Poor quality after-
market consumables. Drag cutting with wrong consumables. Wrong cutting technique.
Moisture, oil contamination of consumable. Excessive pilot arc time. Improper cutting
technique. Wrong piercing technique.
Torch cup is loose, safety contact pins dirty or not making contact with cup face.
Torch switch wire is loose. Problem with Central connector. Torch is not properly
connected. IGBT or PCB bad, contact Everlast.
Duty cycle exceeded or Over current. Allow machine to cool. Reset main power
switch after full cool down period. Make sure fan is not blocked. Check wiring and
remove excess/undersized extension cords. Operated on "dirty power" generator and
unit has failed.
Nozzle orifice size is too large. Use nozzle with smaller orifice.
Missing swirl ring, or worn electrode or both. Check and replace. Make sure swirl
ring is not cracked.
Stuck or dirty solenoid valve. Loose solenoid wire connection. Bad PCB. Contact
Everlast.
Place switch into "normal" or "cut" mode. Reduce post flow time. Solenoid is stuck.
Contact Everlast.
Worn consumables, too high of stand-off height.
Improper cutting technique/excessive piercing.
Improperly sized circuit. Internal issue. Contact Everlast.
Too high of air pressure.
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Troubleshooting