Amp difference questions

[Ram48]

I have a 250 ex.
I am using the foot pedal and have a question about Amps. With the setting on the machine reading 144 amps Butt welding 1/8 steel on DC I get readings anywhere between 54 and 85 while maintaining an arc with the foot pedal fully depressed. I get no penetration. Being pretty new to Tig Is it something I am overlooking or could there be an issue with the foot pedal or welder?

[Grizzly1944]

Make sure that your pulse is off. For 1/8 with this welder about 100 amps will do just fine.

I usually set the amperage so that your desired amperage is about a 3/4 of the pedal movement.

That allows you to relax without flooring it.

[Grizzly1944]

Also make sure that your welder is set at 2t.

[Ram48]

Grizz
It is set at 2t and pulse is off any other thoughts?

[Grizzly1944]

How does it work with the switch on the torch?

[Grizzly1944]

On the pedal there is a cogged slider and a round gear on the pot. There is a possibility that it has slipped during packing and shipping. I've had this happen to me before. It's easy to readjust once you take a closer look at it.

[Ram48]

Grizzly
I am on the way out to the shop to play with it some. At one point the arc did not shut off when I removed my foot from the pedal so I am thniking it is a foot pedal issue and will check to see if the cog wheel slipped the drive belt
Ill let you know.
thanks

[Ram48]

Grizzly

I took the foot pedal apart and there is just a bit of movement left on the pot at both Min and Max. as it should be.
I turned on the welder and rotated the pot by hand from Min to Max the readout at the welder was set at 127 amps and when I rotated the pot the amps increased up to about 73 amps at about half way then as I kept increasing the pot my readouts actually decreased to about 45 at full max.
Bad pot maybe

[Grizzly1944]

Sounds like a faulty pot. It's a common 47K pot. Either you can give EL a call, or any good electronics store like radio shack should have one. A 50k pot will work just as well.

[jakeru]

I agree it sounds like you may have a faulty pot (potentiometer). To verify, if you have a multimeter, put it on the pot wiper (middle leg) and an outer leg, and as you rotate the pot, observe for any "sudden jerkiness" in the ohm value reading. With a good pot, the ohm value reading should change smoothly / continuously. If you find the ohm value is "spiking" or jerking around, it's time to replace the pot.

[performance]

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[Ram48]

Mark
I did not understand your post
Ray

[performance]

Nor did I....lol

I had a new "smart" phone that made me ;ook like a dummy.

I use a prepaid monthly wireless because of the price for unlimited minutes. The phone is an LG but its not quite up to par with some of the other touch phones...something went kerflewy.

Anyway, Turn off the up slope/downslope and the start and end amps. Make sure it is on 2T and use the torch switch and tell us what you have.

[Ram48]

Mark
I hooked up the original torch and ran it in 2t set readout at 101 amps and read 98 to 100 while maintaining an arc, the puddle was like it is supposed to be. So I am guessing (hoping) it is the pot on the foot switch? Do you know if the low profile foot switch is available yet? The high one is somewhat bulky and uncomfortable and if I need to replace it I would just as soon get the newer version.
Man that original torch is like holding a baseball bat after using the small one.
Thanks
Ray

[Grizzly1944]

Ray,

Sounds like it is your pot. I'm thinking of getting a low profile pedal myself. I would of course keep the OEM pedal for backup. I did change out the pot on it though. It's a simple r@r for most of us on this forum.

Fortunately a pot is about the cheapest part on the whole welder.

As a side note, that decorative ironwork that you do is pretty neat.

[performance]

We have a new pedal available for 149.00 plus 15 shipping IF you want the really good one. Otherwise we will be glad to go over some things with you. Ray or Mike can help you check out the pot...Be sure to have a 9.99 cheap analog volt/ohm meter handy....Won't take long at all.

[Ram48]

Mark
I will catch up with Mike and see where it goes.
With the coaching of Courtjester I built a foot pedal for my bead roller when I added a motor and VSR to it so I may just try to build another for thr 250. But either way I will talk to Mike to confirm that it is indeed the foot pedal.
Thanks again for all the help you have given me.
Ray

[jakeru]

Sounds like a faulty pot. It's a common 47K pot. Either you can give EL a call, or any good electronics store like radio shack should have one. A 50k pot will work just as well.

I was just at a radio shack last night, and can verify they have a 50k pot. It looked decent quality, and only cost $3.xx.

IMO, you should have your footpedal adjusted so it can reach as close to 100% max power output the machine is capable of as possible (i.e., with pedal at full down, and current adjustment knob cranked all the way up.)

[performance]

A two watt is required.

[Longlasting]

Here is a pot schematic and it is a 50 k pot to test with an ohm meter.If you want to go to a Miller style check out scc electronics, they have everlast pedals.