Sorry to hear about the service. It can be hard to get through to some of the guys at everlast but you just have to stay persistent. It sounds to me like your pilot arc is lighting but the main arc isnt kicking in. I'm sure you checked the ground and all, but to me it sounds like a bad ground somewhere or air pressure problem. Did you happen to try out the TIG function at all before sending it in?

Once you do get it back, I would highly suggest you get the water cooler. It's a great price and works flawlessly with the rest of the system. For the price and the features, you can't really go wrong on these units. I did have a chip problem with mine and was playing games with the plasma but got it fixed and it's back to working great, however the problem really showed up when Tiging with the pedal and the chip that went out was the one that decoded the pedal signal. But it's fixed now and shouldn't be a problem any longer. Other than that it's been flawless. Best of luck and try getting a hold of Alex and he may be able to steer ya in the right direction