I bought a PowerPro 205 in 2011. It has worked well over the years for the most part. One of the things that has always bothered me was that I kept blowing through welds in TIG mode and would have to dial down my maximum amperage. I thought I was just not using the pedal correctly. I finally put two and two together and realized that my foot pedal is acting like a binary switch. It is either on full or off. There is no range to it. After a few tests in both AC and DC mode, that is exactly how it is behaving.Before I fork out some money for a new foot pedal, I want to put a multi-meter to it to see if the pedal really is bad or if my welding machine is not working properly. Does anyone have a pin diagram for the foot pedal?Longevity LS-200P Broken out of warranty
Everlast PowerPro 205
Reply:The pinouts are in the manual. You can go to our site and download them. But here is the direct link. https://www.everlastgenerators.com/s...PowerUltra.pdfEsab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:Just realized that manual doesn't have it, but the later manuals do. Just use one of the later manuals and it is the same pin out. 1 and 2 switch. 3 and 4 one side of wiper. 4 is common. 4 and 5 the other side. 6 and 7 should be bridged together.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:That make sense of my findings. 1-2 was binary which is should be. 3-4 had no change from the pedal but did change when I moved the limit switch. The same with 4-5. 6-7 was at about 1k. My foot pedal is toast.The range that I saw was roughly 1k to 48k resistance. I guess that means I should buy the 50k foot pedal.Thank you very much for the pin outs.Longevity LS-200P Broken out of warranty
Everlast PowerPro 205
Reply:I just took the foot pedal apart since I have nothing to lose. Now I am very unhappy.
It is not an electronic problem but a mechanical one. It never worked right from the day I pulled it out of the box brand new and I see why now. See the video. I am going to see what I can do to fix this cluster ****.Longevity LS-200P Broken out of warranty
Everlast PowerPro 205
Reply:Unfortunately we don't currently make a replacement for that pedal. It wasn't very good unless you attached another spring at the bottom of the rack when they started to give problems. New pedals are nothing like this. This one has the secondary pot to control upper amperage limit. The unit has to have that or you will have the full range of amps. That was the last year for that type of operation on that unit I believe. In fact I am not sure exactly when it ceased, but we went to another style that worked better. Our current generation of welders has a very good pedal, with an option to upgrade to a Nova Pedal. The Pedals and accessories only carry a 6 month warranty. The Nova pedal carries a 2 year warranty.Esab Migmaster 250Lincoln SA 200Lincoln Ranger 8Smith Oxy Fuel setupEverlast PowerPlasma 80Everlast Power iMIG 160Everlast Power iMIG 205 Everlast Power iMIG 140EEverlast PowerARC 300Everlast PowerARC 140STEverlast PowerTIG 255EXT
Reply:I am looking at the pedal options now. The EV-PowerPedal 50DL has a 6 month warranty and the 50k Nova pedal has a 1 year warranty.Longevity LS-200P Broken out of warranty
Everlast PowerPro 205
Reply:I found the root of the problem. I thought that there was not enough clearance above the arm. That is not the case. What is actually happening is that the bolt and nut that connect the rod to the foot pedal tighten every time the pedal is actuated. Eventually it becomes so tight that it can no longer stay on the potentiometer gear.The fix is simple. Add a jam nut. The nut is a M4-0.7 nut. Once the right tension is found, put the jam nut on and tighten it down on the original nut. It will no longer tighten or loosen.
I tested it out and the foot pedal works fine now. I can tell it is not as smooth as it could be. I put a meter on it and found that the potentiometer is pretty low quality. It does not change values as smoothly at all. There are a few spots where the resistance spikes. I'll talk to my electronics expert friend to see if I can upgrade it with a better one from digikey.Longevity LS-200P Broken out of warranty
Everlast PowerPro 205
Reply:I took it to my electronics expert friend. He soaked the main potentiometer in electronics cleaner. After that, its resistance change was much smoother with just a couple of spikes. I am going to buy some electronics cleaner myself and make a point of soaking it once a year.Everything works well now. I guess I don't have an excuse for my crappy welds anymore.Longevity LS-200P Broken out of warranty
Everlast PowerPro 205
发表于 2021-9-1 23:19:39
