Super wide etching on Aluminum!

[maxspeedman]

Lou,

I see the same wide etch on my 250EX as well.

I measured the AC balance range on my 250EX using an oscilloscope and found that the control range is from 27.1% DCEP (fully counterclockwise) to 71.0% DCEP (fully clockwise). This is the reason you are not able to get rid of the etching completely. You need to be in the 10% to 15% DCEP range to get the small etch you are looking for.

The spec sheet of the 250EX indicates that the balance range is form 10% to 90% and that all the other models are 30% to 70%. I have attached a picture of the table from the user manual.

It would be good if Everlast could clarify the AC balance range of the 250EX.


Max

[dlong]

I was going for the O scope, but you beat me to it. Thanks for the input. It clearly explains the etching issue with the 250 ex.

[trackmaster]

Excellent info guy's, Thanx max for the initiative and ability to hook it up to a scope! Maybe technical or a rep from engineering can clear up the discrepancy? Seems specs may be same as the 200 - 225lx? Still seems that at 30% or so the etching would not be quite this wide? I dont know enough electrical engineering to know what else could be affecting or causing it, but sounds like you are on the right track.

Man I am really digging this machine in just about every other respect! Just welded some mild steel tubing about 12mm O.D. with wall thickness of .015
Ceriated ground to long fine point for low amp arc starting and the stability was first class!! A few spots were less than ideal fit up and i was still able keep from losing it. If they can come up with a fix or mod on this etching issue i think the machine will be unbeatable! And really be a giant killer, ie Thermal Arc, Miller, Lincoln.

[performance]

Since Lou first reported this problem, it has become clear that it is not an operator issue in all circumstances. We have been investigating it, gleaning information from our customers, isolating possible causes, and making reports to the factory etc. I have refrained from posting here until we had more information to go on...Not that we weren't concerned, but that it wouldn't do any good until we had some idea of the answer.

So, here it is:

We have isolated at least 37 possible units according to serial numbers that were assembled with the wrong board in it that have the incorrect values in them. Specifically these were boards from the 225LX not intended for the 250EX. These appear to have been assembled by one employee added to increase production at the new facilities when it opens. This has been identified as the problem and the problem traced to what seems to be a single assembly point. It does not appear to affect all EX's.

Here's the deal:

The boards are not defective per se. But they do not fully meet the 250EX specs. They only have the AC balance adjustment values of the 225LX. Other welding functions are have not been affected and the units otherwise function normally. Other than the cleaning width percentage, they are up to full welding capability.

The boards are pretty much plug and play. We can send out boards for replacement as soon as the factory has produced them and expressed them in. Return of the units should not be necessary. It should not be a long process, but it won't be immediate either. Some of you may choose to keep the boards in your unit, which is your choice, and not a problem if you are satisfied with your product. Its not a "mandatory recall". It does not in anyway appear to affect functionality or stability of the welder platform, nor compromise safety. Its a service campaign that will be addressed on a customer by customer basis, should someone wish to exchange the board. At this time we do not see that it has affected all units in the EX line.

My personal recommendation is that if you need the extra AC balance control, contact the sales office and work out the details of the replacement. If not and your unit is stable, the 30-70% cleaning width that is in some of the EX units, will be satisfactory for most welding situations, and if you are happy, keep it as it is. We realize customers have paid for the performance feature of the EX, so you do have a right for the full range...on the other hand, if you are satisfied, then there is no need for replacing the board. We will work on replacing existing stock inventories ASAP as well.

We regret any inconvenience this has caused, but we are working to resolve the situation in a quick and timely manner. As tech representatives, we have asked customers to verify many aspects of their welding conditions before determining that the units have problems. It is part of our diagnosis process and in no way have we felt the issue was not happening. We have to be cautious and careful, as many tech calls are related to OE and not the units. But the forum here has done its job and the communication between customers and Everlast has been invaluable to addressing the problem directly with the factory. We appreciate your understanding and hope that we can resolve this issue to meet the customer's expectations.

Serial numbers of units affected will be forthcoming as soon as the factory provides the information on the exact units. However, in the mean time if you feel you have an issue, contact Everlast sales with the serial number found on the back of your unit so we can verify the problem and get your problem corrected quickly.

[trackmaster]

Thank you Mark, .... First class post!!! One of the reasons I chose to purchase from everlast was from researching the companies response to various customer issues prior to purchase. This cannot be over stressed as there are so many company's out there that once you by it's, "cricket, cricket" as far as support. Even if one is not particularly satified in a particular situation, the fact that the effort to respond and address has been made is all the difference. That fact alone told me that Everlast is in the "game" to stay, and let me feel better about sending of my $$ in tight economic times. The 250EX is an amazing welder period! And considering the price point value, ..... well nough said. Can it be improved? Sure, but i have seen in a very short period of time that, the company is dedicated to that end, and thats good enough for me. I love to root for the underdog, but will also not hold back any critisizem (spelling? ha) I think i have demonstrated that already for any wondering where are the negative reviews, I call it as i see it, and while there have been some quality control issues, so far everyone at Everlast has been a CLASS ACT!! And i have no doubt that any issue will be handled in a prompt and professional manner.

Thanx to all, Lou (Trackmaster)

[DisWeld]

Hey Trackmaster let me know if the new board works for you. I have a 250ex and it does not fall under any of the listed serial numbers and I have to have my machine balance turned all the way down and I still get a really wide etching effect. I have the same problem with the balance that once it goes any higher than about 10:00, my tungsten just disintegrates. Let me know how it goes.

[trackmaster]

I will Dis, ..... looking forward to seeing how the extra 20% negative electrode fairs, in regard to the etching. It's seriously my ONLY complaint with the unit. It just welds beautifuly in just about every other respect! And again what a GREAT value. Very close to being a giant killer!