250 EX overheating problem

[broberts5]

Thus far my 250EX has performed very well. I love the machine. I work about half the time in my own shop, the rest of the time in an industrial environment. Yesterday, in job shop, after 7 hours of welding it quit welding. No overheat light. The machine ran at idle for long periods but actual welding was in short bursts. When I brought it home at end of day it worked fine. So today I took it back and began working. After 2 1/2 hours it quit again. It sat there idling 75% of the time. All the welding was at 160, well within duty cycle. Again, once I brought it home, it worked fine. Never an overheating light. Ambient temp was 75*.
When I bought this machine, the website said it was good for light industrial. I am hoping this is a robust machine, not a weekend warrior.
No complaints otherwise. A very fine machine. Is this a temporary issue or the way it's going to be?
Help! I can't afford break downs!

[Rambozo]

Thus far my 250EX has performed very well. I love the machine. I work about half the time in my own shop, the rest of the time in an industrial environment. Yesterday, in job shop, after 7 hours of welding it quit welding. No overheat light. The machine ran at idle for long periods but actual welding was in short bursts. When I brought it home at end of day it worked fine. So today I took it back and began working. After 2 1/2 hours it quit again. It sat there idling 75% of the time. All the welding was at 160, well within duty cycle. Again, once I brought it home, it worked fine. Never an overheating light. Ambient temp was 75*.
When I bought this machine, the website said it was good for light industrial. I am hoping this is a robust machine, not a weekend warrior.
No complaints otherwise. A very fine machine. Is this a temporary issue or the way it's going to be?
Help! I can't afford break downs!

Just a thought, have you checked the supply power at that site? Since it works fine at home, I would look to see what is different.

[JimMinKent]

Just a thought, have you checked the supply power at that site? Since it works fine at home, I would look to see what is different.

I would second Rambozo 's advice. I was on site in Wyoming with my Maxstar remodeling some institutional stainless kitchen sinks. While I was there they mentioned that they keep burning out the clocks and timers in their ovens, hmm? I plugged a 4.5" angle grinder into a kitchen outlet and it spooled up like a MotoTool! Checked into it and found they had used "Wild Leg B" as a source for some 110v circuits. Someone here would know but, I think it had 220 or 230 volts or more on those 110 circuits.

[broberts5]

Thanks for the suggestions. I'll check it next time I'm there.

[srp]

I do just the opposite. I spend a lot time behind the helmet, welding 3 hours straight is common with stopping just long enough to rotate a part on days I weld on DC at 35 amps. On Aluminum days the machine does idle a lot but only for 30 minutes or so at a time while I do fit up work.

It does not seem likely that a welder could over heat at idle unless it has a faulty part or the fan is not working correctly.

It is guys like us that make a living using Everlast welders that will tell if they are truly industrial or not. Good luck!

[broberts5]

That's exactly right. Can this machine withstand a hard days work? Previous to this, I used Lincoln for 15 years. Never had a single breakdown!

[performance]

Most older lincolns didn't have safety protection built in and people used and abused them. But that was when they were dumb as box of rocks. Now these welders think for themselves, and self diagnose and stop if something isn't 100%.

I too would check the voltage, from leg to leg, then to ground. I have had a few talks with an experienced industrial electrician friend of mine, he says he has seen issues with running a load across the "high" leg, and one of the regular legs.

Broberts5
We have plenty of machines out there in the trenches. There are issues with Miller and others as well from time to time. If something isn't right with it, it's going to be hard to isolate until something major happens. We can work to diagnose it over the phone when/if it happens, But until then we can work to eliminate any environmental factors. I've seen a couple of times with different units, where excessive idling would shut down the machine. No propblems once it was restarted.

Maybe Mike or Ray (if he's checking today) could comment on other possibilities. My guess, if it's anything internal, could be a loose wire or coupling that looses connection when things warm up.

[acourtjester]

Another thing is to check the time it happens there may be another power drain that happens when you have a problem. Years ago we had a problem with a machine that was to have a direct line back to main power. The electricians had put us on the same line as an elevator.

[TheGary]

If I remember correctly on a 240 volt 3 phase system one leg will be 177 volts the other two legs will be 120 volts. If all three were 120 volts the system would be 220 volt.
I to am interested in this thread. I am thinking of buying a 250EX soon myself and it will be used to make me a living and I do not want breakdowns. A savings on purchase can become very costly if there are problems with the product .

[performance]

No, the voltage should be over 200, if it's a common delta type. Also, had a thought they may be using 480. This is not a common problem and is likely an issue with a ground or another problem somewhere. I have also seen where one leg would loose its connection in either the panel box or the receptacle when it got warm, and stop putting out full power. This could happen and the machine would still be on, but not weld.

[TheGary]

No, the voltage should be over 200, if it's a common delta type. Also, had a thought they may be using 480. This is not a common problem and is likely an issue with a ground or another problem somewhere. I have also seen where one leg would loose its connection in either the panel box or the receptacle when it got warm, and stop putting out full power. This could happen and the machine would still be on, but not weld.

One feature I wish the 250EX had is the capability to run on 480. I have a 1999 Thermal Arc 250 inverter that will automatically convert to anything from 208 to 575 volts. I go into a lot of buisnesses with my equipment and it is nice to be able to plug into whatever they have. I just carry an assortment of plugs and adapters with me. If I get a 250EX I will be limited and will have to plug into my trailblazer more often than I do now. It is a minor problem but it sure would be nice to not burn gas and use the customers power.
I will say the 250EX is still a great machine for those of us that prefer to have an analog machine. ( cheaper to buy, less to go wrong and for me, it is easier to use , but is still as capable to do state of the art welding )
I will still keep my Thermal Arc for a backup but I expect it to die sometime ( there are a couple of features that do not work anymore now , like lift arc ) since the inverter welders have come a long way in the last 13 years since it was made.

[performance]

It can be special ordered 480.

as far as less to go wrong, the digital units are much less complex internally.

[TheGary]

I will call you in a few weeks when I am ready to buy so we can discuss it.

[performance]

6-8 weeks special order delivery, so be warned.

[TheGary]

I figured it would be. My concern is having a one of a kind welder . It would need to be usable on 220 single phase as well if it couldn't then I would want the standard voltage. I do not work in the winter anyway. I run my buis. may 1 -nov. 30th so It could take 3 months and it would not bother me.

6-8 weeks special order delivery, so be warned.