Everlast 250 EXT TIG WELDER

[performance]

Ok...
Couple quick notes of explanation... The unit does not come with a cord as a factory standard item and was a point of confusion that we identified before they shipped the units. They threw it in in a hurry to get things shipped. It'll work though. Notice the effective current draw. That combined with the NEC's specifications for derating their standards for duty cycle limited machines means it should be well within the standards. The I1max is a temporary start up demand not likely to heat up the wire or cause issues. Where you see it connected to the rear, that is where it was originally intended for the customer to take over. When we figured out what was going on, we asked them to put a cord on the end of the machine. Its a first shipment and there is always going to be minor issues like this. The cord is fine if you cut the plug, but I'd suggest that customers put their own on the unit, tying in at the back. Green/Yellow is the ground on this line. Other two are hot. This is a european plug. Wire is fine though. The piece of plug you have in the box WAS the original plug that was used for the orginal test design, without a foot pedal. They included it because they were going to include it anyway. The line I believe, is for installing the water line back into the unit, which we deleted...for safety concerns. Other than that, I have no idea and should have no bearing on the operation or use of the welder.

The switch missing on the rear was a last Second change quite literally before they shipped. We sent our specs on our foot pedal and they had a different one they wanted to use. Theirs needed a switch, ours do not...ours are wired so that the plug itself acts as a switch when the unit is plugged in...

Edit, yellow wire is connected internally inside. It should be screwed to the case inside...however, originally the third slot there was going to be for customer attachment of ground, but when they put the plug on it, they just went and connected directly. If you see the manual, that is how it should/would have been connected and it should still be capable if you'd like. 8 gauge is a suggestion, not a requirement. Post up pics IF you do decide to change it.

[todmorg]

Thanks Mark,
Is it a problem if I remove the covers from the welder to install a heavier cable?

are the flowmeter and foot pedal shipped seperate?

[performance]

No, go ahead, it should be a confidence builder in the unit...as far as construction and design.

The flow meter is another item that is not standard on the unit, but Oleg was going to provide them anyway as well as the foot pedal. Contact him that you did not get a flow meter. The foot pedals are on the way from our pedal factory...Oleg said they were being air lifted. Remind him when you talk to him about the flow meter.

[todmorg]

Thanks again!

Can I use my 225LX pedal for testing on this unit?

[performance]

should work.

[DVA]

I removed the top off of my welder and the ground is just inside the top cover and can be easily removed. I already have a 50 amp plug end and will pick up an 8 gauge extension cord at the hardware store. It should be 8 gauge wire, current plug provided with the machine is about 13 gauge.

Also what is mint by running the water back into the machine? The 250EXT has water lines that allow the water to be hooked up from the back of the machine and connect to the torch in the front side of the machine. I will not use this feature as if any leaks develop it will spray water inside the cabinet. Plans are to build a cart with a built in water cooler in the cart. I will just plumb the cart to feed the water lines out the torch side of the welder for easy connection.

[todmorg]

WOW,

You would have to try this thing to feel how smooth the arc is, very nice! The digital contols a very intuitive and seem to work just as expected. The #20 torch is very compact and the cables are very flexible. I am using the included power cord at the moment, but will upgrade to a heavier one sometime.

I keep reaching for a knob ( insert joke here ), but I am already liking the digital and have a couple numbered settings already.

[DVA]

When I fired mine up the other night I was surprised how nice the arc is compared to the transformer welder TIG I had used previously. I still am waiting for a gas regulator, hope to have this thing up and running soon.

The WP-20F torch does have nice flexible hoses, the denim cover is a little cheesy but that can be easily replaced. It is nice that the head is a flex head also for getting the correct torch angle without too much trouble.

[performance]

Honestly guys, the gauge wire is sufficient to carry the current...but...It doesn't hurt things to change it if you want...since access is so easy.

The arc IS better in my opinion than anything we have.
I wanted the unit to be vetted in someplace it would get real world treatment as far as regular use and period of use when used. I put it in a local welding school full of probably 30+ Miller inverters, and transformer welders, plus a couple of Lincolns and an old hobart. The teacher is a friend of mine, but also an old pipe and steam fitter guy that started welding on pressure valves way back in the mid 80's.


His comments, to me, after he had a month or two of use were: That (expletives deleted) is ( multiple expletives deleted) smooth...real smooth. Smooth as I've ever run.

I saw the results myself after some guys test coupons, 3/8" steel and 1/4" aluminum ( and I even ran a few steel plates myself) and they were nearly flawless after the bend test.

It took a lot of work to get this welder to market...and I know a couple things like the cable need work, but that was a last minute stab. I think though this is a real contender for the future.

This is the first truly digital and fully featured welder from Evelast. As you can see, it won't be the last.

[TD2593]

WOW. machine looks great ! I really like the packing on the new EXT's my 250EX came in a cardboard box and UPS roughed up the box and cracked the front bezel a little. I wish I had of waited and go the new EXT machine, Im jealous LOL.

[todmorg]

Well,

I've got a couple hours on it and it is working great. So far the cord size seems fine, but I will switch to a longer cord with a different strain relief.

There is a flow sensor in the incoming water line, is this to protect the torch? Does it limit the amperage somehow? I am using gas cooled with no water flow and it seems to work fine.

[performance]

No, if you have that, its a solenoid to start/stop water flow I think. It should not limit amps. Pressing and holding the select button for three seconds should discontinue it if it still seems to be functioning.

[todmorg]

It doesn't seem to be a solenoid, I can blow through with little resistance. It appears to be a normally open switch on either a pressure or flow switch. I'm guessing it's a flow switch because there is an arrow on it, the rest of the markings are in a foriegn language.

Just want to make sure this will not cause problems with the gas cooled torch

[performance]

no problem there.

[jakeru]

Thanks for posting the info on your guys 250EXT's, todmorg and DVA!

One question - how loud is the cooling fan? I've gotta say that's one thing that turned me off about the 250EX. (The fan that is so loud, you can't have a conversation near it without raising your voice.)

Also, anyone got any pictures of the inside? I'm sure others would love to see what it looks like under the cover as well.

I'm curious which components are substantially contributing to the 140lb rated weight of this thing... Big transformers? Massive heat sinks? Thick gauge steel frame? All of the above? That mass is coming from somewhere.

Also, it is really true that if you set the amperage (EP) to the max (250), and also set the AC Bias (EP/EN boost) to the max (+ 30%), that it effectively gives you an EN current output of 325 AMPs? If so, that sounds pretty decent. ...and, I've gotta say I'm pleasantly surprised how it was conservatively marketed as only a 250EXT rather than a 300-325EXT.

Also, from the specs, it looks *very* power efficient for its class.

[DVA]

At first I thought the fan was loud but when I started playing with the welder in the shop I did not notice the fan noise or find it annoying. The fan is not as loud as my Millermatic 252 but that machine does have fan on demand and it comes on rarely.

By looking in the front of the lower portion of the welder there are some thick conductors. I will work on getting some pictures of the inside when I change out my cord.

I did play with DC pulse tonight and that is awesome. I could only get it to go to 99.9 HZ, do not know how to get it up to the 500 HZ still playing with the programing.

I will be welding quite a bit of sheet metal at the end of the month and see that the TIG machine will have a huge advantage over the MIG welder on keeping the distortion down. I just need to improve my skills.

I was also talked into purchasing cerated tungsten by the welding store. I need to pick up some lanthanated or thorated tungsten that will hold up a little better.

[performance]

DVA,
I beg you and others forgiveness. The unit currently does max at 100 Hz, but it is not what I specified, and was in the dark about it until you just said something and I confirmed this. 100hz is still a lot but not what we said in the manual when I wrote it.

[parkour]

Lanthanated > thoriated
http://www.youtube.com/watch?v=bpanERwagaU

[todmorg]

Thanks for posting the info on your guys 250EXT's, todmorg and DVA!

One question - how loud is the cooling fan? I've gotta say that's one thing that turned me off about the 250EX. (The fan that is so loud, you can't have a conversation near it without raising your voice.)

Also, anyone got any pictures of the inside? I'm sure others would love to see what it looks like under the cover as well.

I'm curious which components are substantially contributing to the 140lb rated weight of this thing... Big transformers? Massive heat sinks? Thick gauge steel frame? All of the above? That mass is coming from somewhere.

Also, it is really true that if you set the amperage (EP) to the max (250), and also set the AC Bias (EP/EN boost) to the max (+ 30%), that it effectively gives you an EN current output of 325 AMPs? If so, that sounds pretty decent. ...and, I've gotta say I'm pleasantly surprised how it was conservatively marketed as only a 250EXT rather than a 300-325EXT.

Also, from the specs, it looks *very* power efficient for its class.

It is a larger unit, but there is no wasted space, it is built very industrial. One of the heat sinks is a solid machined aluminum block 12" high 10" long and 1/2" thick with huge fins hanging off the back. The other heat sink is almost as big. The fan is large, about 10" diameter, it's louder than I would like, but I am used to my silent sycrowave, where the fan only turns on once in a while. The fan is a little louder than the syncrowave when its on, about the same as a millermatic mig and quieter than a hypertherm plasma. With the wind tunnel design, I can see why there is a need for constant air flow, but a 2 speed or variable speed blower would be great for when the unit is sitting idle.

There is a flow switch in the water line that has me scratching my head, I've only been using the unit with a gas cooled torch until my cooler arrives, but I am curious to the function of the flow control, it must be some sort of torch protection.

The cover is a neat 3 piece design, any one panel can be removed while leaving the others.

Here's a bunch of pics -

[performance]

The water switch should switch open up when the power is fired to the torch. I think Miller used to have a similar setup. However for the future this should be completely eliminated. This is for an "on demand" water cooler, or for a loss type cooling circuit.

NOW as for the orange tubing, it is for use with an argon regulator. The tubing slides over the rear hose barb fitting, and the brass fitting screws to the base of the regulator. This helps prevent that "burst" that we see sometimes with the softer tubing. It is something they threw in. I do believe from the looks of it, when you receive your regulators, that this will fit up to the base of ours.