Everlast 250 EXT TIG WELDER

[todmorg]

I looked under the cap of the flow switch ( the bright red cap in the photos ), and it is a coolant flow detection switch, there is a normally open microswitch mounted above a plunger. It is not a relay or solenoid to control or stop the flow. It closes the microswitch sending a signal to the large control board on top when there is water flowing, thats why I was wondering if it throttles the amperage when there is no flow, for torch protection.

[performance]

Again Todd, I have the specs on that. It is a solenoid to stop and start the water flow. I can't remember how it is designed, but I know that it works as such. Pressing and hold the select switch for more than 3 seconds actually deactivates it. You yourself said it is mounted above a plunger. It may actually stop water flow when it is deactivated for use with a air cooled torch. But its not a sensor according to the factory information I have on it.

[todmorg]

Again Todd, I have the specs on that. It is a solenoid to stop and start the water flow. I can't remember how it is designed, but I know that it works as such. Pressing and hold the select switch for more than 3 seconds actually deactivates it. You yourself said it is mounted above a plunger. It may actually stop water flow when it is deactivated for use with a air cooled torch. But its not a sensor according to the factory information I have on it.

A picture can be worth a thousand words, when I push with the knife blade, the switch contacts close.

[performance]

I just went back over several different materials from a couple of years worth of correspondence and information. The early information and discussion was it was a solenoid. That is what stuck in my head. Indeed it is now called a "water flow switch"...for use with an air cooled torch. So my best guess is that somewhere along the early planning stages that they either changed the use of the switch or they mis-translated its function, which would not be unheard of. You should see today's mistranslation from one of our factories (I'm still scratching my head). From the time they translate my english into chinese and their chinese back into english things seem a little different than they are sometimes. So now, reading the newer "Flow switch" information, its to stop welding functions (hence the error code 806) until water flow is restored.

Now since it operates without an error without water flow, and if it is a flow switch, then I can guess that the exact function is to first create a flow to initiate the cutout protection function, while the machine is powered up. If not, then the machine automatically detects the absence of water and operates in an override mode.

As a side item, IF you see and error code of 806 it is as a result of this switch. Press one of the select function keys for 3 seconds to clear and operate without using these lines.

[jakeru]

Thanks for sharing the pics, todmorg. Those three transformers on the top level I bet aren't lightweights. The flat bulkhead separating the top and lower compartments internally looks pretty beefy. And that looks like some really huge aluminum choke inside the machine near the front? Aside from that, nothing really jumped out at me, which is good. Looks pretty clean actually. I didn't see any microprocessor. Interesting that there are no surface mount electronics to be seen either (that's a good thing though actually... makes it more possible to "do it yourself service" in my book.)

If I had the machine, I'd consider routing my coolant lines through the machine, with cooler plumbed into the back. That would give the front a nice, uncluttered, clean look. That coolant flow sensor is not a bad feature! I've fried a couple expensive tig torch cables because in one case, someone shut off the water flow when I was welding. Here is a fried ck "superflex":

That was a very expensive mistake. (It stank pretty badly too.)

The dynasty 350 setup I used (at one of my customer's shops), has the cooler turn on automatically when you power up the welder. It was a pretty foolproof setup. I think that's good for a watercooler (to be as foolproof as possible), because all it takes is one welding event with it being forgotten to be turned on, and you can cause some expensive damage to your TIG torch leads. The flow swtich, if that's what that is inside the 250EXT, sounds like good insurance to me. Those hose clamps inside the machine look pretty good too!

[redbeard]

I didn't see any microprocessor. Interesting that there are no surface mount electronics to be seen either (that's a good thing though actually... makes it more possible to "do it yourself service" in my book.)

It is an ATmega64L and is the only SMD I recall seeing in there. I'm kinda surprised they didn't cover it completely.

[DVA]

So my supplied TIG torch does not allow any water/air flow thrugh the cooling lines. Any idea what to check for? I have checked out both connectors and put a 1/16" filler rod up the line to see if there is any plugs and see no problem. I have tried to blow air with no kinks or bends in the line and no luck.

I am assembling a water pump, just waiting for the pump. I am going to use a Flojet pump that has about 50 psi of head and rated at just above 1 gpm. I will run a bypass back to the tank to regulate the supply pressure to the torch between 40-50 psi.

[todmorg]

It is an ATmega64L and is the only SMD I recall seeing in there. I'm kinda surprised they didn't cover it completely.

That chip is an Atmel programmable microcontroller, I wonder if they've left pins for flashing?

[todmorg]

Thanks for sharing the pics, todmorg. Those three transformers on the top level I bet aren't lightweights. The flat bulkhead separating the top and lower compartments internally looks pretty beefy. And that looks like some really huge aluminum choke inside the machine near the front? Aside from that, nothing really jumped out at me, which is good. Looks pretty clean actually. I didn't see any microprocessor. Interesting that there are no surface mount electronics to be seen either (that's a good thing though actually... makes it more possible to "do it yourself service" in my book.)

If I had the machine, I'd consider routing my coolant lines through the machine, with cooler plumbed into the back. That would give the front a nice, uncluttered, clean look. That coolant flow sensor is not a bad feature! I've fried a couple expensive tig torch cables because in one case, someone shut off the water flow when I was welding. Here is a fried ck "superflex":

That was a very expensive mistake. (It stank pretty badly too.)

The dynasty 350 setup I used (at one of my customer's shops), has the cooler turn on automatically when you power up the welder. It was a pretty foolproof setup. I think that's good for a watercooler (to be as foolproof as possible), because all it takes is one welding event with it being forgotten to be turned on, and you can cause some expensive damage to your TIG torch leads. The flow swtich, if that's what that is inside the 250EXT, sounds like good insurance to me. Those hose clamps inside the machine look pretty good too!

That picture is sad, it looks like a car runned over a snake.

Once I get my cooler, I'm going to figure out just how that flow safety works.

[redbeard]

That chip is an Atmel programmable microcontroller, I wonder if they've left pins for flashing?

God I hope so, unless there are some firmware updates in the future, I can tell already that I won't be very happy with this machine. At the top of the picture, I do notice J17 is a 2x5 header that could be for that purpose, or something else entirely.

[redbeard]

Once I get my cooler, I'm going to figure out just how that flow safety works.

I'm thinking I won't even wait that long! Too bad it didn't stay a shutoff solenoid, that would have been handy since I plan on using the hose and drain method, for a while at least.

[todmorg]

So my supplied TIG torch does not allow any water/air flow thrugh the cooling lines. Any idea what to check for? I have checked out both connectors and put a 1/16" filler rod up the line to see if there is any plugs and see no problem. I have tried to blow air with no kinks or bends in the line and no luck.

I am assembling a water pump, just waiting for the pump. I am going to use a Flojet pump that has about 50 psi of head and rated at just above 1 gpm. I will run a bypass back to the tank to regulate the supply pressure to the torch between 40-50 psi.

I can blow through mine, It has small long tubes so there isn't much volume, but I can feel the air on my cheek from the other line when I blow on either one.

These small torches are not designed to handle much amperage without water.

[DVA]

Finally found some time to look into the torch issue and find the clog in the water lines. It appears that the torch head water passage is clogged. I was able to get air to blow through the power cable when disconnected from torch. I was also able to notice that the water supply line flexes/moves up to the torch when pressurized indicating that the water lines are not clogged but rather the torch head is clogged.

Attached are some pictures of the torch for performance (Mike - I ment Mark sorry) for the warranty.

I like the supplied lines because they are crimped nicely and are extremely flexible. I will have a warranty torch coming in soon so we can get to some more welding with the 250 EXT.

[performance]

actually that is MARK!
Please, as I asked, send that in an email to me at performance@everlastwelders.com.

We'll probably need to retrieve the torch. I think I can get it cleared after you return it, but we'll send out another as soon as we can.

[DVA]

Email has been sent, sorry Mark, for some reason I thought your name was Mike.

[everlastsupport]

Mike is the good looking one. Sorry, could not resist. People get us mixed up all the time.

[performance]

Ramos v. Lugo...got some latin good looking genes in there somewhere. Sounds like a boxing match in Miami.

[everlastsupport]

Ramos v. Lugo...got some latin good looking genes in there somewhere. Sounds like a boxing match in Miami.

That it does or a $59.95 good Pay Per View.