Everlast 210ext problem.

[Eastcoast86]

I have been running my 210ext for about a year and it has been a very good machine but today it quit and I could use some help. I was tacking together an aluminum project ( 1/8" plate) when mid tack the arc quit and now I can not get it to restart. I think I have the 2014 model 210ext
First the settings:
Machine set on Ac
120 Hz
Ac balance -20
Foot pedal with the amps set on 210 on the machine
2sec pre flow 4 second post flow
3/32 2% lanthanated blunt taper
Standard #7 cup
Ground directly to work piece

Symptoms:
Everything was running fine and then the arc went out while the pedal was still depressed and now it will not restart. When I step on the pedal I can hear the 2 sec pre flow and then I can hear and see the hf pilot arc but the welding arc does not start. With the pedal still depressed I can touch the tungsten to the work piece and I see a small spark but no arc. I turned the machine off and back on again and it worked great for 5 minutes and then began to have the same problem again. Now switching the machine off and back on does not fix the problem.
Here is what I tried to narrow down the problem:
Switched the machine to dc. Pre flow and pilot arc but no welding arc
Switched from the foot pedal to the torch switch. Pre flow and pilot arc but no welding arc
Turned hf off and preflow to 0 and tried scratch start. No arc
Switched to dcep and tried running some 7018 stick rods. They started and ran no problem. This also tells me that the ground cable is ok.
Switched to a different torch- no luck
Tried to strike the arc directly to the ground clamp. Pilot but no welding arc.
Tried to research how to adjust the hf points but from what I can tell this machine does not have adjustable points.

What do you guys think? I am mid project and could really use some help. I tried to call tech support but they are closed or not answering. Any help would be appreciated.
Thanks
Julian

[christian]

Gee,

I have a 210EXT also, a 2015. I'm guessing that yours is the two knob type.

I don't know if I can offer much help, as you've undoubtedly go more time on a 210 than I do.

But, if your Stick mode is functioning well, maybe your Pedal pot conked-out.

So, I'd undoubtedly try a TIG torch with the 2T torch switch, if you've got one around.

You didn't mention how much gas flow you were using.

Otherwise, I do believe the is a so-called hidden menu for the pre-2015 210EXT models, which does have a couple of settings for the HF start time and frequency. Maybe Mark can speak to that, as it seems like it's never been articulated that I can tell. But HF starts don't seem to be your problem.

I hear the standard pedal can lose its place on its gear drive, which may account for why the contact switch portion of it shows the HF current, but nothing more.

Please let us all hear how this turns out. I'll keep watching this thread, too, so that I may learn something.

[Eastcoast86]

Thanks Christian for the reply. I tried using a torch and torch switch as you suggested and saw the same results. I have heard about the hidden menue but I don't want to mess with the settings in it since the machine was running well until the minute it stopped working.

[Rambozo]

Sounds like you covered all the troubleshooting. Since it still stick welds, I would guess this might be another case of a software issue. There was another 210 EXT as I recall that needed the chip reflashed due to corrupted software. Just a guess. When you get a hold of tech support, they might have you make some other checks. Since you have good HF, you know that is working ok, and there is nothing to adjust on that machine anyway. I don't recall all the features of that machine, but will it stick weld in DCEN? Might be another clue for support. But it sure sounds like a board swap or a full machine repair issue.

[Eastcoast86]

So I have some news. I called and talked to ray from tech support and its not looking good. He had me check a few things and concluded the welder was experiencing a serious failure and then told me to call the main office. I called the office and spoke with Alex and he said I would need to send the welder in for repair.

After reading the experience of other customers I am a little worried that I will not get the welder back in a timely manner. It is embarrassing to have to explain to a customer that they will have to wait "a few weeks" for equipment to be repaired. Very in professional on my part.

I am very disappointed that my everlast 210ext did not even last 1 year of light to medium duty use but I am still hopeful that everlast will come through with their excelent warranty program. I believe their ability to swap out broken machines for new units in a timely manner will be the make or break of the company. Right now I am still a satisfied customer but we will see how this goes. Ill keep you all posted. Thanks for the help.

[Rambozo]

If you have on ongoing job, I would not ask a customer to wait as you really can't say how long it will be. Go rent, buy or borrow another machine to finish the job. When taking on a new job you can set the time frame, so then it's ok to say that it will be a few weeks or more before you can get to it, but for a job in progress, you are committed to the time quoted when you took the job and it would be very unprofessional to extend that.
You mentioned that it was 1/8" aluminum plate, perhaps you can finish the job with MIG?

[everlastsupport]

If making a living with a welder, I would recommend a spare (even if smaller). Or go rent/borrow one in a pinch. No matter what brand, a welder can break. We have 3 MIGs, 2 TIGS and 2 Plasma cutters. As well, many grinders/cut off tools, 2 band saws (spare blades), etc.

Grant it, I started with one, but as the money came in, I bought backups. All my machines are now Everlast, and in 8+ years, only had one die and it was abused on a project when it did.

[Eastcoast86]

Rambozo I agree with you that it is not professional to make a customer wait. I will figure something out but renting a machine is not an option. I will have to sub the welding out to someone with functioning equipment.

[everlastsupport]

Maybe update your profile and add your location and someone local can help out? I am in So. Florida and have machines you are welcome to use. Torches too.

[Eastcoast86]

Update: I got the welder to a UPS pack and ship on Tuesday. The lady at the counter said that it should be arriving at everlast in California on Friday 1/15/16. It cost $253.91 for the box, ups packaging service and insurance that everlast requested. My $1400 welder has now become a $1650 machine. I can't wait to get it back.

Thanks everyone for the help and generous offers.

[performance]

No way. That unit ships out for well less than half that. You got hosed.

[everlastsupport]

Wow, you got ripped off bad. Also I find it hard believe anyone from Everlast would tell you how to ship it? Don't forget to added your location.

[Rambozo]

The lady at the counter said that it should be arriving at everlast in California on Friday 1/15/16.

I thought repairs are done in Idaho?

[Oleg]

Update: I got the welder to a UPS pack and ship on Tuesday. The lady at the counter said that it should be arriving at everlast in California on Friday 1/15/16. It cost $253.91 for the box, ups packaging service and insurance that everlast requested. My $1400 welder has now become a $1650 machine. I can't wait to get it back.

Thanks everyone for the help and generous offers.

Shipping from HI is NOT CHEAP , that is for sure. we do have arts locally for older 210EXT . should be fast warranty claim . Everlast will cover shipping back for free to help out Julian

[performance]

With a name like "East Coast86", it sounded more like a 48 state ship thing. No idea it was from HI. Explains some things.

[everlastsupport]

I asked him, I think, for his location or to fill it in, in the profiles. HI would seem to cost a bit more.

[christian]

Hey, look,

Here's a nice example of going the extra "nautical" mile for a fellow 210EXT user located on an island in the middle of the Pacific Ocean.

You're the man, Oleg!

May you and all of the staff at Everlast prosper well in the New Year, and beyond.

Rock On, Everlast!

[Eastcoast86]

Thanks Oleg for offering to pay the cost of the return shipping. Did the welder arrive at everlast safely? It should have been delivered on Friday 1/15/16 but I haven't heard anything yet. Let me know if the tech support guy has any questions.
Julian

[Eastcoast86]

Ok so here is an update for anyone interested.
The welder arrived at Everlast on 1/15/16

After a week I gave Everlast a call to see how the repair was going.
I was told that the welder was damaged by UPS and could not be repaired. Luckily I had followed Everlasts instructions and had the welder packed by ups and also insured for the full cost. Right now I am in the process of trying to recoup my money from ups so I can buy a new machine. Very frustrating. Over a month and still no welder!

To Everlasts credit they have been easy to deal with throughout the process.
They offered to refund my money if UPS did not come through with the refund but were unwilling to send me a replacement without the full cost of the additional welder paid upfront. I think this is fair.

[Rambozo]

Sorry to hear that. UPS usually comes through, but not always in a timely fashion. Last time I had to file a claim, it was over six months before it was all said and done. However, they did take care of everything in the end. I would always advise keeping the original packing materials for something like this.