AC Problem with 200DV

I am wondering if anyone can help with this AC problem we are having with our brand new Everlast 200DV we purchased to use in the NYC CNC Introductin to TIG Welding classes. This unit is brand new and from the first time we used (or tried to use) the unit it presented the problem as shown in the video. SUPER embarrassing to have a machine not work when we are training paying clients. This is Roy Crumrine (Crummy Welding, @crummywelding) in the video doing the demo. We tried different tungsten, different foot pedals, thumb switch, etc. It seems to not cut out like this when welding on DC.

We called customer service and got the typical "what tungsten are you using and what gas flow" complete nonsense and are reaching out the the Everlast community for help instead. I'll be honest in saying we purchased this 200DV to expose our clients to different colors of machines and so far we are not impressed. Or course, Everlast wants us to pay for shipping both ways on a brand spanking new machine which is total nonsense.

https://youtu.be/5iOjdUvTsrU

-Jonathan Lewis
Superior Welding & Fabrication
@superiorwelding

What date did you buy this machine ?

Zoama,
I would have to look that up. Ordered a couple months ago (?) and arrived sometime last month. Serial number 158901649
-Jonathan

If you got it last month it should be within the month where Everlast picks up the shipping. But before sending it back I would have a look inside for loose connectors from rough shipping. Often re-seating them is all it takes to cure things like that. One of the downsides of modern light weight machines is they are thrown around in shipping, rather than fork lifted. :(

Well,

I'm not a Everlast employee, but it's not "total nonsense" for Everlast to follow their of warrantee offer of free parts and labor for the repair of their units for 5 years, with the customer paying for the shipping past the first 30-day period. Calling something "brand new" doesn't change the calendar.

Mark, from Everlast, may wish to assist you here as well. I mean, the 200DV is a long-standing and proven unit of Everlast, so he may know just where you might look.

Otherwise, yes, if it started having intermittant problems on AC after the first 30-days, or you didn't check it on AC during the first 30-days, that is unfortunate and inconvenient, but certainly solvable. Everlast will undoubted fulfill their promise to fix it. The staff there may even be willing to get you a better rate in shipping cost with their account, and have it picked up by UPS. They could probably get it done at about $50, each way. So, that's a $100 solution, plus the unit time away. No amount of embarrassment is needed though, certainly not a "SUPER" amount.

Otherwise, yeah, like Rambozo mentions, I'd open that baby up and reseat any connectors at the boards or switches that look like they're not fully seated, as I think I've seen a few posts here that had that as the simple remedy for problems like that. Easy peasy, Parcheesi!

Beyond that, an over-the-phone diagnosis is not an easy thing, so I wouldn't be so hard on Everlast staff, as they undoubtedly rule-out the obvious stuff first and probably can't see your video while they're on the phone with you. It's a process. I've gone through it with Everlast myself, and both me and the Everlast staff managed to go through it quite nicely, even though some patience was involved.

But, that's what I did first, is I opened that baby up!

See if you spot something obvious. If you do, take a picture of your happy face pointing to the spot you found it at and post it here in theis thread!!!!!

Quote:

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Originally Posted by Superiorweld

I am wondering if anyone can help with this AC problem we are having with our brand new Everlast 200DV we purchased to use in the NYC CNC Introductin to TIG Welding classes. This unit is brand new and from the first time we used (or tried to use) the unit it presented the problem as shown in the video. SUPER embarrassing to have a machine not work when we are training paying clients. This is Roy Crumrine (Crummy Welding, @crummywelding) in the video doing the demo. We tried different tungsten, different foot pedals, thumb switch, etc. It seems to not cut out like this when welding on DC.

We called customer service and got the typical "what tungsten are you using and what gas flow" complete nonsense and are reaching out the the Everlast community for help instead. I'll be honest in saying we purchased this 200DV to expose our clients to different colors of machines and so far we are not impressed. Or course, Everlast wants us to pay for shipping both ways on a brand spanking new machine which is total nonsense.

https://youtu.be/5iOjdUvTsrU

-Jonathan Lewis
Superior Welding & Fabrication
@superiorwelding

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Not completely sure, but diagnosis is a procedure. But It certainly isn't nonsense. And just because someone is an expert, doesn't mean that we or the customer can afford to skip or assume certain aspects. I can't see the arc, but it looks as if the torch is running high off the metal.

Post the settings. You can't start giving good advice without giving the context.

Yeah,

Please do let us all hear back on how you remedied your problem or what was the actual solution, e.g., the reseating of a loose connector somewhere.

I mean, many will know that Roy Crumrine is an outstanding TIG welder who is familiar with Everlast units, so it's undoubtedly not a simple oversight somehow.

Sorry for the delay in response guys. We resolved our shipping issue and sent it back to Everlast for warranty repair. If they let us know what was wrong I will post it up.

I do want to thank Everlast for their support and willingness to resolve the issue. We want as pleasant an experience as we can with Everlast, especially since our students find these machines within their budget.
Jonathan

Quote:

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Originally Posted by Superiorweld

Sorry for the delay in response guys. We resolved our shipping issue and sent it back to Everlast for warranty repair. If they let us know what was wrong I will post it up.

I do want to thank Everlast for their support and willingness to resolve the issue. We want as pleasant an experience as we can with Everlast, especially since our students find these machines within their budget.
Jonathan

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Hey Jonathan,

Did you ever find out what was wrong with the machine? I am unfortunately experiencing the exact same issue with a PowerTIG 200DV (purchased approximately 2 months ago), went to weld in AC mode for the first time and I had the exact same issues as you.

https://www.youtube.com/watch?v=9zn50v83itY

Quote:

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Originally Posted by zedsix

Hey Jonathan,

Did you ever find out what was wrong with the machine? I am unfortunately experiencing the exact same issue with a PowerTIG 200DV (purchased approximately 2 months ago), went to weld in AC mode for the first time and I had the exact same issues as you.

https://www.youtube.com/watch?v=9zn50v83itY

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A couple of things. One it looks like you are bobbing up and down considerably. Also not sure on your work clamp location and preparation for mounting it. Also looks like you may have balance issues.

But IF all those things are perfect, then it looks like a foot pedal issue possibly. Try the torch switch and fix your torch to 1/16" or less stand off and try it. Also what type tungsten are you using?

Yeah,

A bad pedal could undoubtedly do that.

Otherwise, it's a new machine and this is apparently your first time using it on AC.

So, from what I see, your tungsten may be contaminated or could use a nice, longitudinal taper.

Then, as Mark mentions, your AC Balance setting. 40 EP is a bit high. And as he also mentions your grounding. The clamp is best kept on or close to the work piece.

Also, you begin by pulling your torch at the autogenous portion, rather than pushing. But when adding filler, you do seem to have a fair technique.

So, if giving the tungsten and the ground some attention don't remedy the problem, then I'd think the pedal might be it.

And, as Mark stated, use the 2T switch to rule that out.

But get the tungsten, grounding, and Balance squared away first. Maybe even double check the torch collet/fitting soundness, too.

And please let us all hear about how it goes.

https://www.youtube.com/watch?v=UNAAhwieNhU

Thanks kindly for all the responses & assistance. I think it's the angle I took the video on, ground is clamped onto the aluminium/welder bench. I've listed all the settings/specs used below:

Amps: 100 (controlled by foot pedal)
Control: Footpedal
Torch: CK9 Series
Frequency: 120 Hz
Balance: 40
Pulse: None
Ground: To the item & table
Gas: 100% Argon at 8 CFM - 10 CFM
Tungsten: CK Worldwide 3/32 Lathanated 2%
Material: 16 Gauge (1.6mm thick aluminum)

Tungsten has been grind down on a belt sander in the same direction the belt sander is driven, then polished - I followed the directions in the Everlast manual regarding how the tungsten should be sharpened, please note that I have absolutely no issues on DC (DC welds perfectly).

I'll try the torch (2T) and report back.

Has anyone learned what is causing this? I purchased a 2017 200dv in Jan. of 2018. This is my second unit. I have had a 2015 model with no issues & lots of use. When I received this 2017 unit, I ran some aluminum beads shortly thereafter just to test out the A/C function. It was great, no issues, ran beautiful beads, steady stable arc, good frost cleaning action running between 110-135hz 30% or less balance on 1/16 & 1/18 6061 aluminum with 4043 rod. 3/32 & 1/16 blue 2% lanthanated tungsten. Everlast 26 air cooled torch with a stubby gas lens setup. 100% argon.

I went on to do nothing but D/C steel projects for the last few months no problems. Last week I had to do some aluminum & switched back to the same exact setup that the machine ran perfectly on before. The same exact aluminum, the same exact filler rod. All of a sudden the machine started doing exactly what the other 2 machines in this thread are doing. I tried everything. Changed tungsten, gas lenses, disconnect & reconnect all leads, checked for gas leaks, tried all kinds of balance settings, tried no gas lens, ground on work piece every time. There is no simple oversight. This is my 20th yr welding. It will not hold a steady stable arc in A/C, welds very sooty with hardly no cleaning action/white frost. I would gladly post pics but the site is not allowing for anything larger than 147kb files. I have tried emailing photos to everlast tech support with no response. I don't know if the emails are even getting through. However, the machine, in A/C is acting identical to the 2 other machines already posted with the same problem in this thread. It's a great unit, I have never had a problem with everlast machines until now. Did anyone find out what's causing this? Or am I gonna have to send it in?

I am having the same problems you are having. I have not spoke to Everlast yet. I thought it was me, not having it set right.