Dead 250EX, Help Please

[tom_tom]

After some intermittent TIG welding on a project, the arc will not start anymore. I get HF but no arc at all. The overcurrent light turns on and stays on as soon as I try to strike an arc in any mode and with any settings. Foot pedal, torch switch makes no difference. Power cycling the machine resets the light but attempting to initiate an arc will light it back up. Leaving the machine unplugged overnight didn't help either. If I can duck out of work early during the week, I'll try calling tech support. Funny thing, I just posted yesterday about the robustness of the 250EX. Halfway through my project... what a drag!

Tom

[tom_tom]

I went back out and tried the machine again only this time I set it to lift arc rather than HF. As soon as I pressed the torch button, there was a loud 'POP' along with a flash of blue light and some sparks on the right hand side of the machine at which point I immediately unplugged it. I'll await instructions on how to go about troubleshooting and/or returning the machine, if necessary.

Tom

[Rambozo]

Sounds like you may have released some magic smoke.

[mliebs]

And I was the one you recommended the 250EX to. Fortunately I work in a heavily saturated electronics trade so I know things like this can happen. For the most part if the electronics work out of the box it's usually good to go. A small percentage will fail within a short time period (infancy rate) if they're going to fail at all. I'm curious to know how many hours you have on the unit.

[Cippee]

The good thing is everlast stands behind their products so they will always take care of you.

[TheGary]

I went back out and tried the machine again only this time I set it to lift arc rather than HF. As soon as I pressed the torch button, there was a loud 'POP' along with a flash of blue light and some sparks on the right hand side of the machine at which point I immediately unplugged it. I'll await instructions on how to go about troubleshooting and/or returning the machine, if necessary.

Tom

I am dissapointed to hear of your problems. I have been eyeing a 250EX for about 4 months and was hoping to order one in the next month or 2 but I can not have problems with my machines. Especially brand new ones. This is the 3rd or forth one that has been posted as having problems soon after purchase that have been posted on here in the past few months. My work is mobil and everything I do is right in front of my customers . If I go in with a tool that they think is considered an off brand and then have a problem with it . They start to question my judgement in more than my choice of tools. I am sure that everlast will make it right for you but that would not solve a problem in my situation. I might still try one but if I do I will have to have a backup way of doing the job for them so that there is no lasting memory of any problems in my customers minds.

[Kempy]

The first week I had my Miller Syncrowave 250 it quite the main switch went the welding supply place could not get the part for 6 to 8 weeks loaned me a Hobart Tigwave 250 with every option you could think of to use till the Miller was fixed, still have it, never got the Miller back. Eleven months later the Lincoln water cooler went took 6 months to get a new one and it lasted two days they had problems with them, so they gave me a Hobart one and I still have it 26 years later. Lincoln finely fixed the problem with the water cooler 1 year later. I have had problems with my Everlast welders but was fixed in a very short time one in just hours over the forum and the other was replaced in a few days. I like the Everlast machines and I will buy them.
Yes things happen ask Miller, Lincoln, ESAB or other welding company’s if all they make are perfect welders and plasma cutters etc. or BMW, Mercedes-Benz, Rolls-Royce, Porsche, Ferrari if they have any problems.

[tom_tom]

Don't know how many hours on the machine. Just started on it's 3rd 125 cuber when it blew. Will have to contact tech support when I'm at home during work hours to see if it can be fixed in situ.

Tom - mobile

[performance]

TheGary,
The problems are posted here on this forum are visible, and of concern to all. But you must keep things in perspective.
1) The huge number of units sold relative to problems posted.

2) The fact that most of our sales are internet based and that we provide a forum here for tech support and general discussion. The bulk of our sales are done online where the unit cannot be taken back to a dealer ...where the problem can be quietly dealt with. While that may be a weakness for some, its also a strength for the educated buyer: Everything is out in the open for people to read and evaluate. But you are getting an "over sample" of what you would if we had more local local dealers.

3)We do not in general have issues with the 250EX, but when we do, it's usually within the first few weeks like mliebs said. We cover this under our 30 day policy which includes shipping etc.

4) Some issues being reported are from units that are near, at or past the end of the warranty period. It is normal to see a slight uptick in warranty at that point as well.

5) Go to the Miller forum, you'll find plenty of customer issues and horror stories (the ones that are removed). It happens.

6) If your customers worry and critique your tools then those are customers that will never be happy. Do they judge the name brand of clothes you wear, the car/truck you drive too? Either that or they have other reasons to judge your tools based off the lack luster results of your work. I don't think that's the case...but a possibility. Think about it: When I take my car to a mechanic, I don't go through his tool box even if I wanted to stand there and watch. If I buy food from a Farmer's road side stand, I don't judge the food by the tractors or equipment brands he uses. When I go out to weld on a jobsite to make a welding repair...they want to know if I can do the job...the last thing on their mind is my old Pickup and my old Ranger 8 that looks like it was rolled upside down (and it was before I bought it and fixed it up).

I'm not going to sit here and pretend that we don't have problems. That's why we in part have a forum here, and sponsor others. More problems than Miller per units sold? Probably. But we also believe in the product and have maintained a 5 year warranty.

Personally, I believe that the new EXT units are likely to give less problems as they are built much more simply and do not have as much to go wrong as far as more parts etc. They are digitally controlled and are more of a "componentized" service system. We are working to more modular systems for all our units, but it takes time so that parts and pieces are more easily interchanged, and repairs can be done more quickly and cheaply, if needed.

As for the issue at hand, tom-tom...
Call Ray first thing this morning, explain the problem. Get an RMA. I don't think there is going to be much to do except return the unit, unless you are really good with electronics and want to get into things with the unit.

[letmeno]

TheGary,
The problems are posted here on this forum are visible, and of concern to all. But you must keep things in perspective.
1) The huge number of units sold relative to problems posted.

2) The fact that most of our sales are internet based and that we provide a forum here for tech support and general discussion. The bulk of our sales are done online where the unit cannot be taken back to a dealer ...where the problem can be quietly dealt with. While that may be a weakness for some, its also a strength for the educated buyer: Everything is out in the open for people to read and evaluate. But you are getting an "over sample" of what you would if we had more local local dealers.

3)We do not in general have issues with the 250EX, but when we do, it's usually within the first few weeks like mliebs said. We cover this under our 30 day policy which includes shipping etc.

4) Some issues being reported are from units that are near, at or past the end of the warranty period. It is normal to see a slight uptick in warranty at that point as well.

5) Go to the Miller forum, you'll find plenty of customer issues and horror stories (the ones that are removed). It happens.

6) If your customers worry and critique your tools then those are customers that will never be happy. Do they judge the name brand of clothes you wear, the car/truck you drive too? Either that or they have other reasons to judge your tools based off the lack luster results of your work. I don't think that's the case...but a possibility. Think about it: When I take my car to a mechanic, I don't go through his tool box even if I wanted to stand there and watch. If I buy food from a Farmer's road side stand, I don't judge the food by the tractors or equipment brands he uses. When I go out to weld on a jobsite to make a welding repair...they want to know if I can do the job...the last thing on their mind is my old Pickup and my old Ranger 8 that looks like it was rolled upside down (and it was before I bought it and fixed it up).

I'm not going to sit here and pretend that we don't have problems. That's why we in part have a forum here, and sponsor others. More problems than Miller per units sold? Probably. But we also believe in the product and have maintained a 5 year warranty.

Personally, I believe that the new EXT units are likely to give less problems as they are built much more simply and do not have as much to go wrong as far as more parts etc. They are digitally controlled and are more of a "componentized" service system. We are working to more modular systems for all our units, but it takes time so that parts and pieces are more easily interchanged, and repairs can be done more quickly and cheaply, if needed.

As for the issue at hand, tom-tom...
Call Ray first thing this morning, explain the problem. Get an RMA. I don't think there is going to be much to do except return the unit, unless you are really good with electronics and want to get into things with the unit.

Mark,
Have you guys had many problems with the dual voltage 200dx?

[TheGary]

TheGary,
The problems are posted here on this forum are visible, and of concern to all. But you must keep things in perspective.
1) The huge number of units sold relative to problems posted.

2) The fact that most of our sales are internet based and that we provide a forum here for tech support and general discussion. The bulk of our sales are done online where the unit cannot be taken back to a dealer ...where the problem can be quietly dealt with. While that may be a weakness for some, its also a strength for the educated buyer: Everything is out in the open for people to read and evaluate. But you are getting an "over sample" of what you would if we had more local local dealers.

3)We do not in general have issues with the 250EX, but when we do, it's usually within the first few weeks like mliebs said. We cover this under our 30 day policy which includes shipping etc.

4) Some issues being reported are from units that are near, at or past the end of the warranty period. It is normal to see a slight uptick in warranty at that point as well.

5) Go to the Miller forum, you'll find plenty of customer issues and horror stories (the ones that are removed). It happens.

6) If your customers worry and critique your tools then those are customers that will never be happy. Do they judge the name brand of clothes you wear, the car/truck you drive too? Either that or they have other reasons to judge your tools based off the lack luster results of your work. I don't think that's the case...but a possibility. Think about it: When I take my car to a mechanic, I don't go through his tool box even if I wanted to stand there and watch. If I buy food from a Farmer's road side stand, I don't judge the food by the tractors or equipment brands he uses. When I go out to weld on a jobsite to make a welding repair...they want to know if I can do the job...the last thing on their mind is my old Pickup and my old Ranger 8 that looks like it was rolled upside down (and it was before I bought it and fixed it up).

I'm not going to sit here and pretend that we don't have problems. That's why we in part have a forum here, and sponsor others. More problems than Miller per units sold? Probably. But we also believe in the product and have maintained a 5 year warranty.

Personally, I believe that the new EXT units are likely to give less problems as they are built much more simply and do not have as much to go wrong as far as more parts etc. They are digitally controlled and are more of a "componentized" service system. We are working to more modular systems for all our units, but it takes time so that parts and pieces are more easily interchanged, and repairs can be done more quickly and cheaply, if needed.

As for the issue at hand, tom-tom...
Call Ray first thing this morning, explain the problem. Get an RMA. I don't think there is going to be much to do except return the unit, unless you are really good with electronics and want to get into things with the unit.

Mark, you make many good points . Believe me I have watched to see if problem posts and threads are deleted and to Everlasts credit I have not seen it. That is why I am still here . People do judge others work by their perceived appearance. I too drive a 17 year old truck for my business. I do not try to keep up with the joneses but I try to keep my truck looking decent and my tools clean and neat. I do not expect everlast to be perfect . I stated my concerns because it is little different perspective than most. That is one reason I purchased the plasma first, so Everlasts name would not be brand new to my customers yet it is not the main piece of equipment I am using at their job site. Remember that sometimes I am working shoulder to shoulder with some of my customers maintenance people. If you don't think they discuss every thing you do after your gone. Believe me , they do. Everything from your personal hygiene , tools , habits , if you clean up after yourself etc. If they are not happy they let their employer know it . Sometimes I feel like a fish in a fishbowl but you have to shake it off and just do your best and let the chips fall where they may. That does not mean I can ignore the fact that I must please them. One of the hard lessons I have learned over the years is to keep my mouth shut even when a customer employee has no clue what they are talking about. Diplomacy and a box of donuts at break time cover a lot of ground.

[performance]

I too have been on jobsites like that, but the conversation usually heard after someone leaves like that goes like this: "Old boy sure is crusty and needs a bath and looks like he came out of 'Deliverance', but he sure can weld. Rather work with him and than someguy who is a neat pen,but is stuck up and lazes around work. Nothing a little air freshener can't fix." I hope you can get some good guys to work around you. That just adds to the stress of the job if they are putting you under the microscope like that. Those guys are inescapably insecure about their own abilities if they do that. There's no reason, mature, responsible people that are secure in their abilities, and knowledge base should have reason to do that.

[performance]

letmeno,

The 200DV has been stable and for 2014 should be better than ever with more extensive testing and more intensive scrutiny going on.

[Paul Moir]

I too have been on jobsites like that, but the conversation usually heard after someone leaves like that goes like this...

Some quality programmes require outside contractors to be supervised when brought in. There's product defense, hygiene, and security implications to contractors and this is often the easiest way to resolve them. And if you've ever had to do hover duty, you'll see why you get onto the topic of tools, etc pretty quickly. Otherwise you look like a big creep!
And of course, the work does speak for itself. It's by far the most important thing since that's why the guy is there. If it's good, a way will be found for Mr. Stinky to be allowed to carry out his work!

[tom_tom]

Update:

After a couple of calls to tech support and then accounting(?), it was agreed that the machine needs to be shipped back to Everlast. The machine busted within 30 days of purchase/delivery so Everlast covered the return shipping. I got the RMA via email that same day. Even then, I dropped $50 in shipping materials and sent it off yesterday. She's pretty well UPS-proof (sorry brown). I opted for a refund instead of waiting for new stock to arrive and roll the dice again.

I'm sort of back to square one but have expanded my budget somewhat. I'm even considering a transformer machine in spite of weight and frequency limitations. I won't get into particulars here but I've narrowed it down to ~ 5 models that pretty much cover the rainbow spectrum and of which, two are inverters.

I'll report back when I get my refund for those of you who may have doubts about Everlast's warranty and whether or not they truly back up their claims and products (not that I have any reason to doubt). It sucks that my 250EX broke but sh-stuff happens and if/when it does, it's good to have the peace of mind that the company will take take care of it and you.

Tom

[performance]

I am sorry the unit did what it did. Not par for the course by any stretch. It could have happened with any brand and has if you start reading around on the internet more than 2 minutes. But I think you would still be much better off in the long run by $ wise and probably have been happy in the long run with a 250EX replacement or repair. I am sure you won't have a problem with your refund. We don't issue very many, but when we do, we do. If we had to issue a lot, we'd not be around very long. But it doesn't mean that we don't like having to loose a customer. The 250EX is stable and well, the best deal you can find out there...easy to use, easy on power, easy to carry, and easy to fix in the long run. Off the shelf parts, and items that aren't going to cost you. A simple board for a similar blue brand will cost you almost as much as the entire 250ex costs. It's nice to know the warranty is there 2 years longer as well! But Tom we understand that a "bad" taste is something some people can't get over and why the policy is in place.

[Kempy]

Tom
I am also sorry to have you give up on the Everlast PowerTig 250EX, I have had mine for a year now and love it hope some day you will buy another one. Good Luck.

[Oleg]

I am dissapointed to hear of your problems. I have been eyeing a 250EX for about 4 months and was hoping to order one in the next month or 2 but I can not have problems with my machines. Especially brand new ones. This is the 3rd or forth one that has been posted as having problems soon after purchase that have been posted on here in the past few months. My work is mobil and everything I do is right in front of my customers .

So you saw 3-4 issues with a PowerTig250EX in past few month and you think you will have problems if you get one? Don’t you want to ask how many were sold and what is the ratio? What about the defect percentage? Why don’t you ask people that posted here with PowerTig250EX problems, when they actually purchased the unit? Or you assume we sell 10 units in few month and have 4 with issues? Feel free to go to Miller forum and COUNT how many dynasties blow up last few month! Maybe will change your mind on Miller as well ?

[Oleg]

Update:

After a couple of calls to tech support and then accounting(?), it was agreed that the machine needs to be shipped back to Everlast. The machine busted within 30 days of purchase/delivery so Everlast covered the return shipping. I got the RMA via email that same day. Even then, I dropped $50 in shipping materials and sent it off yesterday. She's pretty well UPS-proof (sorry brown). I opted for a refund instead of waiting for new stock to arrive and roll the dice again.

I'm sort of back to square one but have expanded my budget somewhat. I'm even considering a transformer machine in spite of weight and frequency limitations. I won't get into particulars here but I've narrowed it down to ~ 5 models that pretty much cover the rainbow spectrum and of which, two are inverters.

I'll report back when I get my refund for those of you who may have doubts about Everlast's warranty and whether or not they truly back up their claims and products (not that I have any reason to doubt). It sucks that my 250EX broke but sh-stuff happens and if/when it does, it's good to have the peace of mind that the company will take take care of it and you.

Tom

Unfortunately it happens and happens very rarely . Once we get the unit back will refund same way you paid us . Good luck

[tom_tom]

Hmm, actually I haven't given up on Everlast machines talis qualis. My disappointment isn't so much with Everlast nor the 250EX. It's more to do with PARTING with the 250EX. For the record, I loved my 250EX -- short lived as it may have been. It has the right combination of price, features, weight/bulk, etc. The only fault in my specific case was the durability. As for Everlast (the company), I don't have anything bad to say, personally.

Mark and all who say other manufacturers have problems too: You're right. All my research has led me to believe that for the most part, inverter-based welding machines still have a considerable road ahead of them in order to compete with transformer-based welding machines in the durability arena. Inverters are capable of delivering lots of power with adjustable parameters at high efficiency. From my own past experience, they apparently still have a chink in the armor in that they don't coexist well with HV/HF. I've built IGBT based circuits for high current applications (such as electric furnace with digital temperature control loops) where the power output is jaw-dropping for such a compact circuit. However, the slightest static discharge or even inductive kickback from a dirty switch or relay can fry an IGBT. It's a bizarre David and Goliath situation.

Anyway, I'm going to keep my eyes and ears open for my next welding machine. Green isn't out -- just wish they came in a TCR variety.

Tom