Powertig 200dx issues

I've had this welder for a while now, don't use it much. Last use I was welding some mild steel 1/8" stock all was good. Went to use it again on some 16 guage exhaust piping the welder will not change current on the knobs, the data display reads -30. When I attempt to weld it gets a really weak ark not even enough to penetrate a tin can. I went through the manual it came with and the troubleshooting says to send it in for repair. Being that I needed the welder to finish my exhaust and get my car back on the road I took it to a welding repair shop here in germany. They opened the case and took one look at it and asked for a schematic. I told them I didn't have one and they basically said they wouldn't touch it. So now I need to get this thing repaired some how.

Best thing to do it call into tech support and get Ray on the phone. Ext 207, he will be your best bet. That issue does not ring a bell with me.

The current doesn't change on the panel with the older units. The -30 would barely generate an arc, as this probalby would be like setting the unit for 5 to 10 amps. The knob on the foot pedal controls this. Make sure the knob is tight and the belt on the cog hasn't slipped or that the cog is tight on the foot pedal rheostat. It's more likely a foot pedal issue. Did you try the torch switch ? This will give you true readout of amps.

Ahh, forgot about the order ones.

You can use and ohm meter, crank pedal knob to 10 and check pin 3-4 and 4-5 first before opening it. It should have 0-28K and 28K-0 range. Not exact, if it is not the cog if off you will see right away.

I actually don't use the foot pedal at all. This is with the torch switch. I'll give a ring to support.

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Originally Posted by performance

The current doesn't change on the panel with the older units. The -30 would barely generate an arc, as this probalby would be like setting the unit for 5 to 10 amps. The knob on the foot pedal controls this. Make sure the knob is tight and the belt on the cog hasn't slipped or that the cog is tight on the foot pedal rheostat. It's more likely a foot pedal issue. Did you try the torch switch ? This will give you true readout of amps.

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That's the issue, it creates an ark, but not enough to even generate heat.
Seems support is not answering the phones right now.

I got a hold of ray, the phone signal was horrible, don't know on which end. Needless to say he got me an RMA number, now I just need to get the time to box it up and send it to the repair facility.

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Originally Posted by jimbos'ss

I got a hold of ray, the phone signal was horrible, don't know on which end. Needless to say he got me an RMA number, now I just need to get the time to box it up and send it to the repair facility.

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I have Spoken with Ray a couple of times recently, in regaurd to a problem with my PP50, and the connection is horrible every time. It is definitely on his end. However, if you can make out a conversation, he is extremely helpful.

I hope it's nothing serious ... keep us informed ... I'm using a 200 DX myself so far it's fabulous (knock on wood). Did you check to make sure your ground clamp has good contact?

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Originally Posted by Winky

I hope it's nothing serious ... keep us informed ... I'm using a 200 DX myself so far it's fabulous (knock on wood). Did you check to make sure your ground clamp has good contact?

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yah the ground is good. The machine had been perfectly reliable and just stopped working correctly. I haven't lost faith in them yet.

Have you checked the basics like the wall outlet, extension cord, circuit breakers? Did you pinch a wire?

My 50A line is wired off 2 independent breakers and when using my old welding machine, one will trip but the other won't meaning you're only getting 115/120 instead of 230/240. That stopped happening once I got the Everlast because IGBT is much more efficient than copper coils.

BTW: If you have a multimeter, you might want to check the actual voltages and/or do continuity testing of your circuit.

Have you pulled the cover and checked the on and off switch with a volt meter to see if getting 240 volts . have seen a couple of posts on pad switches , if only one pole is working on switch machine will not work rite . i just had my cover off to show a person on the site how to open up pp50 Attachment 7745Attachment 7746Attachment 7747and noticed my wires on switch was not tight the white one pulled rite loose when i lightly pulled on it