Superultra 205 Tig Pedal

[Jeff9]

Hi,

I am new to the forum and Everlast Welders. I received my Superultra 205 yesterday and have tried out stick and tig features. Great machine and I am very happy!

Question I have though concerning the foot pedal. Is it suppose to just be on or off for the tig or is it suppose to increase and decrease amperage as you rotate it down or up?

Thank you for your help,
Jeff9

[performance]

Yes it is supposed to ramp your amperage up and down.

[Jeff9]

Yes it is supposed to ramp your amperage up and down.

Do I need to be actually welding to see the amperage display on the machine change? Reason I ask, I was not welding while depressing the foot pedal and watching the amperage readout. I did not see the amperage fluctuate when I rotated the foot pedal, the reading just showed where I had the amperage set prior to hooking up the foot pedal and didn't change.

[performance]

The arc has to start.

[Jeff9]

Oh, so the pedal will not change the amperage until the arc starts?

[Jeff9]

When I got home from work today, I practiced some more on tig welding. I paid attention to the arc while I manipulated the foot pedal. There was no difference in arc size. Next, I turned the amperage knob to 10 amps, started and arc and manipulated the foot pedal, very little arc even with the foot pedal fully depressed. Then I set the amperage to 100 amps, started an arc, manipulated the foot pedal and no change in the arc size.

Next I shielded the arc from my eyes and watched the amp reading on the machine while I manipulated the foot pedal, the reading dropped 2 amps (from 90 to 88) as soon as I started the arc, but no change from 88 no matter the position of the foot pedal.

I took the top off of the foot pedal to see if the gear was rotating the gear on the potentiometer in the foot pedal, and it does.

Using a multimeter, I check OMHs at terminals 3,4,5 on the plug from the foot pedal. Pushing the pedal down, I got 0 to 19k OHMs between 3 & 4. Pushing the pedal down, I got 19k OHMs to 0 between 4 & 5.

What else should I look for or do?

Thank you for the help,
Jeff9

[zoama]

When I got home from work today, I practiced some more on tig welding. I paid attention to the arc while I manipulated the foot pedal. There was no difference in arc size. Next, I turned the amperage knob to 10 amps, started and arc and manipulated the foot pedal, very little arc even with the foot pedal fully depressed. Then I set the amperage to 100 amps, started an arc, manipulated the foot pedal and no change in the arc size.

Next I shielded the arc from my eyes and watched the amp reading on the machine while I manipulated the foot pedal, the reading dropped 2 amps (from 90 to 88) as soon as I started the arc, but no change from 88 no matter the position of the foot pedal.

I took the top off of the foot pedal to see if the gear was rotating the gear on the potentiometer in the foot pedal, and it does.

Using a multimeter, I check OMHs at terminals 3,4,5 on the plug from the foot pedal. Pushing the pedal down, I got 0 to 19k OHMs between 3 & 4. Pushing the pedal down, I got 19k OHMs to 0 between 4 & 5.

What else should I look for or do?

Thank you for the help,
Jeff9

Do you have the rocker switch set to 2T for foot pedal operation ? A picture of the front of your machine always makes it easier to diagnose problems because we can see all the settings.

[Jeff9]

Do you have the rocker switch set to 2T for foot pedal operation ? A picture of the front of your machine always makes it easier to diagnose problems because we can see all the settings.

Hi Zoama, I do not believe the SuperUltra has a 2T switch...

[joshuab]

Assuming you have a seven pin connector, is there continuity between pins 6 and 7?

[zoama]

Hi Zoama, I do not believe the SuperUltra has a 2T switch...

Is there an amp control on the foot pedal ?

[Jeff9]

Is there an amp control on the foot pedal ?

No Amp Control knob on this foot pedal... There is pot inside that gets rotated when you depress the pedal.

[Jeff9]

Assuming you have a seven pin connector, is there continuity between pins 6 and 7?

Hi Joshuab, yes it is a 7 pin and there is continuity between 6 & 7...

[Jeff9]

So I am assuming the machine has a way of sensing that that foot pedal has been attached because there is no switch to switch from panel to foot pedal. I have read on other sites that the best amperage control you can expect from these pedals is 20%. Is this true? maybe that is why I am not seeing a difference in arc size or force?

I would assume that the readout on the panel would show the amperage change as you manipulated the foot pedal...

[performance]

Are you running with gas?

[Jeff9]

Hi Mark, yes I am . Argon at 7 liters

[joshuab]

So I am assuming the machine has a way of sensing that that foot pedal has been attached because there is no switch to switch from panel to foot pedal.

On my machine (PA160-STH), it is the continuity between 6-7 that tells the machine that the pedal is attached. I assume yours is the same.

I would assume that the readout on the panel would show the amperage change as you manipulated the foot pedal...

That's how mine works, and every other TIG welder I've seen, although I haven't seen a huge number. If it were me, the next thing I would be wondering about would be whether the internal plug connecting pins 6-7 to the control board had come loose. In that case, the welder would never detect that the pedal was connected, and would stay in front-panel amps mode.

I see that Everlast support is commenting here, and I'm sure Mark will have you sorted out in no time.

[Jeff9]

On my machine (PA160-STH), it is the continuity between 6-7 that tells the machine that the pedal is attached. I assume yours is the same.



That's how mine works, and every other TIG welder I've seen, although I haven't seen a huge number. If it were me, the next thing I would be wondering about would be whether the internal plug connecting pins 6-7 to the control board had come loose. In that case, the welder would never detect that the pedal was connected, and would stay in front-panel amps mode.

I see that Everlast support is commenting here, and I'm sure Mark will have you sorted out in no time.

Thank you Joshuab. I love digging in and figuring mechanical things out, just not right at the git go

[Jeff9]

Opened up the machine this afternoon and started looking for the obvious.. Nothing standing out like plugs not connected etc. There are two yellow wires come off of terminals 1 & 2 on the male connector mounted on the machine that go to a small circuit board and connect to it by a two prong connector. On the top of this circuit board, there is a second two prong connector with nothing connected to it. 1 & 2 terminals connect to the on/off switch of your foot pedal or finger trigger on the torch. This is working correctly on mine as the foot pedal will start the arc.

The switching between the panel mounted pot and the pot in the foot pedal is what is not working. I am assuming there is a relay not working to switch to the foot pedal pot when the foot pedal is attached. Or, that is not it and they are accomplishing this by the mismatched pots. The pot mounted to the panel is a 1k and the pot in the foot pedal is 22k.

Have no idea and am frustrated. Not been a good experience so far.

[Oleg]

Jeff

Please cal my cell phone .. 415 613 6664


Oleg Gladshteyn
Oleg@everlastwelders.com
415 613 6664 cell

[Rambozo]

Opened up the machine this afternoon and started looking for the obvious.. Nothing standing out like plugs not connected etc. There are two yellow wires come off of terminals 1 & 2 on the male connector mounted on the machine that go to a small circuit board and connect to it by a two prong connector. On the top of this circuit board, there is a second two prong connector with nothing connected to it. 1 & 2 terminals connect to the on/off switch of your foot pedal or finger trigger on the torch. This is working correctly on mine as the foot pedal will start the arc.

The switching between the panel mounted pot and the pot in the foot pedal is what is not working. I am assuming there is a relay not working to switch to the foot pedal pot when the foot pedal is attached. Or, that is not it and they are accomplishing this by the mismatched pots. The pot mounted to the panel is a 1k and the pot in the foot pedal is 22k.

Have no idea and am frustrated. Not been a good experience so far.

I thought all of this was pretty much moot anyway, as you got the wrong welder and it would be swapped? More than likely, since it sounds like there was clearly a mixup, my guess is that is not the right pedal for that machine. I'm sure Oleg will get you all sorted out. I wouldn't waste anymore time with fooling around with a mistake.