200DX Pedal Crapped Out

Hey gang,

So I tried really hard to buy an AHP 200DX, but getting one shipped to Canada turned out to be a bridge too far. So a picked up an Everlast 200DX instead.

I'm teaching myself how to weld aluminum. I have a couple of specific jobs I need to do, and this is a capability that I have always wanted.

I was running linear beads on plate with surprising success. Attempting to weld a 0.40 block to the plate was more of a mess... but Rome was not built in a day nor should I expect to master this in a couple of evenings.

Then one night, suddenly I can't run a bead. Filler balls up and won't flow into the puddle, the puddle itself seems dirty... just a mess. My first thought was that I'd run out of argon, but there's still plenty in the bottle.

Then I discovered that while the foot pedal was lighting off the arc, it wasn't tripping the gas solenoid - but intermittently. And when it was triggering, gas flow seemed less than I expected.

Then the pedal stopped working - until I figured out that if I pushed the pedal down, tipped it forward, and then let the back down with a "clunk", the impact would open the solenoid and light off the arc. Then the pedal would respond as normal until I shut it off. Then no more response until "clunk" again.

I ordered a replacement pedal from SSC Controls, and we'll see how that works - but the OEM pedal went wonky after maybe 6 hours of use.

There is only one switch in the pedal to both start the arc and the gas solenoid. So if the arc starts but no gas, that usually points to another area. But it sounds like you have some pedal problem, too. Sometimes the solenoid needs cleaning out. There is a description of how to do that on this forum, somewhere. As I recall there is a spring that sometimes needs a little attention, as well. Be sure to crack the valve of a new bottle before hooking up the regulator, to blow out any debris. That goes a long way to keeping everything in the system clean.

I recall something similar with the gas solenoid on the old Lincoln. There's a fine screen at the gas hook-up at the solenoid that was plain to see was full of 'swarf'......We back flushed the solenoid by removing the gas-to-torch and blew back (low pressure air) through the solenoid when the gas flow was started with the Amptrol we used back then. All sorts of chunks of 'stuff' came out of the screen and opened the flow back to normal. There is also a screen in these Everlast solenoids connector too....seems like a standard thing but the blast from the freshly opened bottle is (as Rambozo says) a good habit to get into. I'm sort-of miserly so thought that was a waste of gas....lesson remembered.

Well the new pedal made a world of difference.

I put a gas lens on at the same time as the new pedal. There's now an audible "whoosh" when the pedal is tripped. Flow itself seems low, but I had no issues with how the puddle was flowing so maybe that's just my imagination. I may try and check the solenoid to see if it got dirty.

I also have a CK torch coming so we'll see how that influences things.

I was able to successfully join two chunks of 2.5" OD x 16 ga tubing. It sure isn't pretty - I am new at this - but they *are* joined.

So bottom line here is that the pedal provided crapped out within a couple of hours of use. I suppose I could warranty it, but to what effect?

Change out your gas supply line from the regulator and use a harder hose something that won't ballon. You'll cut down on your whoosh. But make sure you have the right gas flow matched with the consumable first.

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Originally Posted by performance

Change out your gas supply line from the regulator and use a harder hose something that won't ballon. You'll cut down on your whoosh. But make sure you have the right gas flow matched with the consumable first.

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Can you make a recommendation for a harder hose?

Automatic Transmission line NAPA

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