Problem with RFCS-6M Control (6-pin plug) foot pedal

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I have a RFCS-6M Control (6-pin plug) foot pedal on my Maxstar 150 STH.The pedal worked great for the past two months but now it is acting funny.It seems to start an arc fine although sometimes it is like a hair trigger.  It also does not seem to want to shut down at the end of the weld.  When I let my foot up it still runs with a little arc and I need to tap the pedal several times to get it to turn off.  Tonight I could not get it to turn off at all so I had to give up and shut down the machine.Other then the shutdown the pedal has been working fine.  I have good amp control and it seems to do fine across the range of action but it just never goes to zero.Any thoughts?I am going to call Miller tomorrow but hopefully someone here will have an idea of something I can check.  I was actually trying to get some welding done in the next few days so if it is something simple that I can check tips would be helpful.   I don't have any idea of how it is wired but I am starting the research process although until I talk with Miller I don't plan to open it up.
Reply:Originally Posted by febikesI have a RFCS-6M Control (6-pin plug) foot pedal on my Maxstar 150 STH.The pedal worked great for the past two months but now it is acting funny.It seems to start an arc fine although sometimes it is like a hair trigger.  It also does not seem to want to shut down at the end of the weld.  When I let my foot up it still runs with a little arc and I need to tap the pedal several times to get it to turn off.  Tonight I could not get it to turn off at all so I had to give up and shut down the machine.Other then the shutdown the pedal has been working fine.  I have good amp control and it seems to do fine across the range of action but it just never goes to zero.Any thoughts?I am going to call Miller tomorrow but hopefully someone here will have an idea of something I can check.  I was actually trying to get some welding done in the next few days so if it is something simple that I can check tips would be helpful.   I don't have any idea of how it is wired but I am starting the research process although until I talk with Miller I don't plan to open it up.
Reply:Sounds like the limit switch S1 (PN 183629) has failed.  But don't rule out harness black and white wires shorted together somewhere.  You can check out both with the Ohm setting of a VOM.http://www.millerwelds.com/om/o844g_mil.pdfIf the switch is bad you can get one for $9.37 at miller4less.com http://miller4less.com/advanced_sear...26c3&x=11&y=12Or your LWS may have the part in stock if they service Miller equipment.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Thanks duaneb55!It was the switch but only in that the little metal activator was not engaging well.  All it needed was a small bend and now it works perfectly.  Big thanks, i am back in action