Another Cracked Regulator

[traderyoda]

I know I'm not the only one with this problem... and I'm sure Everlast is addressing this. But these regulators (Model GH-25 made by the Zhejiang Bril company in China are downright dangerous - mine split right down the middle (see pic)!!! If you have one of these regulators keep a close eye on it if it's not leaking. Personally, I'd pitch it in the nearest dumpster!

[performance]

We've changed regulator suppliers recently and most all the new ones are made from billet brass. This is the older style. If yours is less than 6 months, we can send you another unit.

On the other hand, I've got one of those I've had for nearly 4 year now. No issues.

[traderyoda]

As usual you guys are right on top of things. I just posted the picture for other users that might still have these units. Clearly this supplier had issues! Cheers!!!

[sportbike]

I have this style for my 200dx and just received (but haven;t yet tried) a new 185 with the newer regulator. New regulator looks nice. Haven;t had any issues with the onl one other than a bit of a high pressure burst each time I start an arc (I pre-purge before striking).

[Paul Moir]

My Aire Liquide one does that too. It's got nicer (and maybe smaller diameter) hose which helps though.

Builds up about 30 psi on the low pressure side when switched off with a fresh tank.

[Rambozo]

My Aire Liquide one does that too. It's got nicer (and maybe smaller diameter) hose which helps though.

Builds up about 30 psi on the low pressure side when switched off with a fresh tank.

The fix is to use a short, small diameter, and as non-ballooning hose as possible. Also you can add an orifice to help limit peak flow. There is a company that sells a gas saver system for TIG and MIG that does just that.

http://www.netwelding.com/How_GSS_Works.htm

In the past I've used braided stainless teflon hose for argon. It works great and was leftover from plumbing a race car.

[Paul Moir]

That's an idea. The AL one is reinforced rubber and might be 3/16".

Another idea is to relocate the gas solenoid up onto the regulator. IIRC on my 225LX it's a 240v solenoid, so that's a little tricky.

Fortunately I don't pay for the gas. Well, directly anyway. So I'm pretty content with just a bit of preflow to miss the blast.

When I finally build a cart, maybe I can do something about the hose length eh?

[everlastsupport]

On the other hand, I've got one of those I've had for nearly 4 year now. No issues.

I have a few of them even older (about 4 in use). Just gave my first one away with an IMIG-200 and 131 tank.

Maybe it was dropped somewhere along the way or over torqued at the factory. How old is it?

We have had a couple cracks over the years, but we have sold way more than a couple welders.

But either way, that needs to be remove ASAP, it could be really dangerous. Call Oleg and see what he can workout for you. I have used the local HF ones, Clarke knock-off if you need one this weekend in a hurry. If on sale, and a 20% off coupon they can be had for about $26-28 dollars.

[5440]

I tossed my regulator the day the 250EX arrived as I didn't trust it and bought a Smith instead. I bought the 250EX for the machine alone and it's been behaving ever since.

[zoama]

I've got 3 of the chrome regulators and never had a problem other than a blown pressure gauge. The new ones may be higher quality, but old design allows you to make a dual flowmeter for purge.

[jakeru]

Be careful out there, folks!

...
We have had a couple cracks over the years, but we have sold way more than a couple welders.

But either way, that needs to be remove ASAP, it could be really dangerous. ...

Mike, I'm surprised that you're only aware of "a couple" cracked Everlast flowmeters.

Over a year ago, I informally counted (and provided links to) six different forum members reporting cracked Everlast flowmeters in this related post:
http://www.everlastgenerators.com/fo...8076#post18076 {/quote]

[Oleg]

Jake

In 2012 we sold around 8k units
And possibly exchanged 30-50pc
Of regulators, maybe I am wrong, but I don't think it's called for massive recall
All costumers reported any issue once they start using the welder.

Oleg

[performance]

Additionally, all accessories are covered by a 6 month warranty, including regulators, foot pedals, torches, and clamps.

[everlastsupport]

Mike, I'm surprised that you're only aware of "a couple" cracked Everlast flowmeters.

Over a year ago, I informally counted (and provided links to) six different forum members reporting cracked Everlast flowmeters in this related post:
http://www.everlastgenerators.com/fo...8076#post18076 {/quote]

I didn't mentioned, we did have a bad batch of them "at one time" awhile back, as that was a unique case. And we handled that, sometimes we do have an issue like other companies, but all in all there is no problem with the regulator. And as always we resolved any problems. It was something sort of beyond our control.

Either way, I still use mine, and mine are even older than Mark's.

Also, I hope everyone knows to be careful when you turn on the tank, as hoses can blow off as well. I always stand on the other side of the regulator and hose. Always use caution when cracking the valve, I turn it on slowly then open it up. Just a habit, nothing to do with our regulator, just a safer way to do it.

[redbeard]

Also, I hope everyone knows to be careful when you turn on the tank, as hoses can blow off as well. I always stand on the other side of the regulator and hose. Always use caution when cracking the valve, I turn it on slowly then open it up. Just a habit, nothing to do with our regulator, just a safer way to do it.

Good tip Mike, I always try to open it slowly, but never much thought about standing out of the line of fire. Just like standing to the side of your bench grinder when you hit the switch.

[jakeru]

Mark: I'm disappointed by the initial reply you posted here, which appears to downplay the severity of the safety problem reported by the original poster, by instead discussing how one flowmeter that you own has been in service for 4 years (which has nothing to do with the potential safety risk of the *cracked* flowmeter, intended to contain in excess of 2000 psi in normal use, as not only reported by the OP but similarly reported by apparently many other users.)

Have you actually tested *in a reliable way* the flowmeter you mentioned is in service to verify it's actually crack-free, and also otherwise safe? (e.g., has a properly functioning safety valve, and no main valve seal leaks?) The problem with these "hairline fractures" is that a simple visual inspection is insufficient to find them. Finding them reliably, IMO, requires using something like a leak-detection solution applied liberally while a flowmeter is under pressure, or submerging it under water while under pressure. Or at least verifying that the tank pressure gauge on the flowmeter registers full pressure long after the tank knob has been turned off, to hopefully provide some assurance that there are no cracks which are leaking.

If your flowmeter hasn't passed at least one of those tests, how do you know it doesn't actually have the same hairline fracture reported by many others? I can add some personal experience with a cracked regulator, that such crack is not something I'd expect someone to be able to easily find by naked eye.

FYI, I did some quick, unsuccessful searching on OSHA and the Web for examples of failed inert gas flowmeters/regulators, but the closest thing I can find were reports of some failed oxygen regulators (which generally are more severe, because the oxygen, unlike inert gas, can support violent combustion during a failure, releasing far more energy than just the pressurization of the gas inside the tank. The inert gas would be limited to only releasing the energy stored by the pressurization of the inert gas stored in the tank. However, common sense indicates that even without injury examples to cite, a crack on a device holding back > 2000 psi of considerable volume is a safety risk, as there is still probably a lot of stored energy that could be fairly quickly released. (So, I still wouldn't want to anywhere near the presense of a flowmeter with cracks that's holding back >2000 psi, myself.) (If anyone knows of an actual safety incident caused by a defective inert gas flowmeter like the ones being discussed here, please tell us.)

Oleg: I agree that a wide-reaching recall may be excessive (and very costly), and didn't mean to imply this is necessarily what Everlast should have done. I'm glad to hear the issue is at least on your radar (e.g., knowing the numbers of exchanged flowmeters), and also for your and Mike's informative, and responsive replies in this thread. The news about one batch of flowmeters being particularly prone to defects coming from Mike is also informative.

I think only Mike (and not Mark) gave the proper guidance coming from Everlast to the OP (and to anyone else who also may be reading this thread, who may encounter a similar situation) of removing the cracked flowmeter from service immediately for safety reasons. Everlast should consider making this guidance more readily visible to it's customers who may have the faulty flowmeter, such as by making a thread with such guidance a "sticky." And consider providing more info about the batch of flowmeters known to be unreliable (e.g., to help users identify flowmeters coming from this batch, if possible. E.g., when was the bad batch distributed? Are there serial numbers which can be used to identify?)

Unfortunately, reliably identifying these hairline fractures is probably not easy for most users to do. So I simply can't fault the advice given by the OP, here, to simply not chance it, and discard any flowmeter that have a similar visual appearance as those which are known to be flaky, if in doubt.

OK, I'll get off my stump now. I hope you guys understand my intention with these posts is to inform, with your best long-term interests (as well as your customers') in mind. Thanks for listening!

[performance]

For one, I have had background training in metallurgical failure in heavy/farm equipment. My flow meter holds pressure for days/weeks. And yes, I regularly "bubble" check my equipment. I have way more than one regulator, everlast or not. Last count was bout 9. The tone you use here treats me as if I am to be scolded like a little child. I've always respected your voice here, but tonight's post went beyond where it should have. The customer stated what his intentions were about not using it (pitching it), and nothing more needed to be said. It was a moot point. I was addressing his concern in the most expedient manner possible. His warning to all sufficed in my opinion. My regulators are fine as well as 10s of thousands of others. I've had many regulators from Everlast pass through my hands, and only one had any issue at all...and it was not in anyway a danger to operation. This issue has been addressed before on the forum multiple times. We've always replaced a problematic regulator if it is under warranty. Regulators new and old can be defective of all brands. Common sense dictates a cracked regulator under thousands of pounds of pressure should not be used...ever. I've seen some failures personally, of aforementioned brands. Stand to the opposite side of any regulator when turning it on. Don't stand in front of it.

[geezer]

Yep had one crack on me,,,worked fine for a while then one day heard a leaking sound and sure enough there was a crack on it,,,was it still covered by warrenty...couldn,t remember so I just sucked it up and bought a new one at the local bumper to bumper,,,shiit happens,,,why sweat it ,,,I probably cracked it opened too fast,,, can I complain,,,not really ....takes more effort to do that then it's worth..the rest of them that came with my Everlast outfits are holding up fine..is there an issue with certain producrion runs,,,maybe,,,bottom line I saved so much money with buying Everlast equipment,, I don't care if the odd regulator craps out..

[Kempy]

Regulator for MTS250S plugged with thread sealant when I was going to use a second bottle with different gas I thought I would use to regulators and a Y manifold but it would not flow took it apart and the tank inlet was full of sealant.

Model GH-25