My PM 215 is having problems, they started about 2 months ago then got better, now they are back and I am having many problems where I cant even use my machine.
Problem 1: First off whenI turn on the machine and pull the trigger, it does not work sometimes. I pull trigger mulitple times and eventualy it will start working. IT only does this when I turn the machine on first thing in the day when the machine is "cold". After I use it (weld with it)turn it off , then turn it on later during the daythe trigger works with out problems, no matter how long it was off or on. ( so what I am saying is the trigger issue only happens once per day).
Problem 2: When I first strike an arc the wire burn back inside the tip. No matter how low the voltage or how high it is set on the wire burn off inside the tip when I first start to weld 90% of the time. I have adjusted the wire speeds high and low settings and it still happens.
Problem 3: Then when I finally establish and arc, I am welding along, maybe 1 inch, 3inches, or one foot, and all of a sudden the wire burns back into the tip. I used 1 tip the entire last year in 2006, Now in the last 2 months I has ruined over 25 tips.
Problem 4: Tonight all my welds were poris. I set the gas at 25-35 CFH and played with it and still no go. Gun tip was clean not clogged. gas WAS comming out from nozzle. No drafts, 75/25 gas. I would be welding along and all of a sudden the weld would get many holes i it, sometimes it was at the begining sometimes in the middle of the weld or at the end. My metal was clean. Looks like I forgot to turn on the gas, but was was on and flowing (I could hear it and feel it). Bottle is what I have been using the last 10 months. It has 1200psi left in it.
Here is what I have done to try to fix my welders issues:
Wire burn back: I have roller set loose not to crimp wire. (when you put hand in front of wire the rollers spin but no birds nest). Next I tightened up my rollers, but not to tight. I thought my wire was slipping thats why the burn back. I made sure the cords are straight with NO kinks. Wire tentision is set loose for the roll. I changed tips several times. I have adjusted voltage and wire speed to many many many different settings and does not help. I have tried different wire. (lincoln superarc 56). I tried a an 035 tip for 030 wire, with no luck. This is very aggervating.It acks like at the start and somewhere throught out the weld it get a very large spike in current and burns off the wire. Where is what I though, I though the wire was just hanging up and it would burn off, but when I feed it out for minutes at a time, there is no sliping or stops in the wire feeding.
Any other suggestions? Right now I need to just get it to weld and I can full with the porisity later.
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