200 LX intermittent output (current)

Hi, I hope to get a resolution for this problem that I can fix without sending the unit back.

Problem: I get an intermittent lack of full current flow. For example if I set the unit at 130 amps, sometimes when I fully depress the pedal while welding aluminum everything works fine and I get 130, then sometimes it will not go past about 20 or 21 amps even with the pedal down all of the way for 10+ seconds. It will go back and forth without touching any knobs on the machine. There is no middle of the road either. It's either full power or 20 amps. I have checked the pedal with a multi-meter. It seems to have perfect change in resistance from 0 to 70k something ohms. It does not seem to matter if the machine is cold (just turned on) or hot either.

Thanks for any input.

Buck

Quote:

---

Originally Posted by Bucket

Hi, I hope to get a resolution for this problem that I can fix without sending the unit back.

Problem: I get an intermittent lack of full current flow. For example if I set the unit at 130 amps, sometimes when I fully depress the pedal while welding aluminum everything works fine and I get 130, then sometimes it will not go past about 20 or 21 amps even with the pedal down all of the way for 10+ seconds. It will go back and forth without touching any knobs on the machine. There is no middle of the road either. It's either full power or 20 amps. I have checked the pedal with a multi-meter. It seems to have perfect change in resistance from 0 to 70k something ohms. It does not seem to matter if the machine is cold (just turned on) or hot either.

Thanks for any input.

Buck

---

Check it without the pedal, just using the torch switch. There are several things that can go wrong with the pedal and by testing without it, you can narrow your issue down to the pedal or the machine.

Yes, sounds like a pedal too. Make sure your cog is not slipping on the shaft. Otherwise, it's time for a new pedal likely. Give us a call if you need help.

Rambozo you were spot on. Checked with the torch switch. Works like a champ.

Performance, I checked the pedal, the cog is not slipping. I adjusted it when I first bought it and it has been fine since then.

Recommendations for a new pedal?

You can get a new chinese pedal or order the SSC. I believe yours does not have a separate rheostat on the pedal does it? That would be the 47k (you can confirm this by looking at the pot in the pedal and it should be marked). That would be the same as what we produce now. Simply call ext 202 and purchase one. Pedals, torches etc. are only warrantied for 6 months. The welder of course is for 5 years.

Also, I took the multi-meter to the connector again. Pins 3-4 gives 0-40k ohms, then shorts during the last inch of pedal travel. Pins 5-6 gives 40-0 kohms.

Ok, the short is likely the cause. Give 202 a call if you want another pedal.

Another option is to just replace the pot in the pedal you have.

The pot is easy to replace. Yours does not have the separate pot, so you have 3 choices.

The SSC is a US made lower profile pedal, never used one but everyone seems to like them. Depends on that you want to spend.

The short at the end of the 47K is not good though, weird it would short at the end. Maybe tweak the cog back a hair .

Am I right in assuming that the SSC is the pedal for sale here that says "US Made"?

Also, I confirmed the POT is 47k.

Buck

Yes. It is made in the USA. I left the A off, sorry.

My 225lx did the same thing when the pot went flaky. I got one from a local electronics shop, and asked for the best one they had. It turned out to me Made In Canada; go figure! I thought they only made the other kind out in BC... :)

The only deal was it turned out to have a little more range angle than the old one, so I had to put the pedal stop way down. Now it's a bit uncomfortable to go full throttle. Watch out for that.

I checked out the old one before tossing it. It had a few wiper contacts so not a bad design. Unfortunately only one was actually in contact...

Also, upon replacing I got my downslope overriding my pedal back after replacing it, which was a surprise. I kind of like that: it allows me to be lazy when ending a weld without cratering.

Ordered the new pedal

Our pedals. No SSC in the picture, just Everlast pedals. They range from 3.5" high (far left 210ext only 1K) to 8" old school far right (47K). Our low profile is 4.25" high (47K) in the middle and not a bad pedal at all.

Attachment 8336
Attachment 8335