NOVA NVA-FT06 Wireless Foot Pedal Instruction Manual

NOVA NVA-FT06 Wireless Foot Pedal

Product Information

Specifications

• Model: NVA-FT06- Wireless Foot Pedal
• Frequency: 2.4 GHz
• Serial Number: [Serial Number]
• FCC Identifier: 2A8BFNVA-FT6-R1

Product Usage Instructions

Pairing Information

1. Ensure the foot pedal and receiver dongle are powered off.
2. Power on both the foot pedal and receiver dongle.
3. Press the pairing buttons on both devices simultaneously until they are successfully paired.

Connecting the Battery Wires

Before use, connect the battery wires to the foot pedal according to the provided instructions.

Charging the Battery

1. Make sure the foot pedal is powered off.
2. Connect the charger to the foot pedal for charging. Follow the recommended charging time.

Connecting the Receiver Dongle to Welder

1. Locate the receiver dongle port on the welder.
2. Insert the receiver dongle securely into the port.

Operation of the Nova Wireless Pedal

1. Turn on the foot pedal using the designated power button.
2. Use the foot pedal as instructed in your welding machine’s manual for precise control.

Troubleshooting

If you encounter any issues with the wireless foot pedal, refer to the troubleshooting section in the manual for guidance.

FAQ

Q: What should I do if my foot pedal is not pairing with the receiver dongle?

A: Ensure both devices are powered on and try pairing them again. If issues persist, contact customer support for assistance.

Q: How do I know when the battery of the foot pedal needs charging?

A: The foot pedal may indicate a low battery through LED lights or audible alerts. Refer to the manual for specific indicators.

GRANT OF EQUIPMENT AUTHORIZATION Certification

RECYCLE. DO NOT DISCARD THIS PRODUCT IN THE TRASH!

This Wireless Pedal has been designed for a long life. However, in the event part(s) or all of this product becomes nonserviceable:

• Do not discard this product or its parts in general waste. Do not burn or attempt to destroy this product or damage it further.
• Reuse or Recycle Waste Electrical And Electronic Equipment (WEEE) by disposing of it at a designated recycling or collection facility.
• Contact your local government or disposal/collection facility for recycling information and locations. Or contact NOVA for further recycling or repair information.

NOTICE:

Product Specifications and features are subject to change without notice. While every attempt has been made to provide the most accurate and current information possible at the time of publication, this manual is intended to be a general guide and not intended to be exhaustive in its content regarding safety, welding, or the operation/maintenance of this unit. Due to multiple variables that exist in the welding field and the changing nature of it and of the NOVA Welding Industries does not guarantee the accuracy, completeness, au- thority or authenticity of the information contained within this manual or of any information offered during the course of conversation or business by any NOVA employee or subsidiary. The owner of this product assumes all liability for its use and maintenance. NOVA does not warrant this product or this document for fitness for any particular purpose, for performance/accuracy or for suitability of application. Furthermore NOVA does not accept liability for injury or damages, consequential or incidental, resulting from the use of this product or resulting from the content found in this document or accept claims by a third party of such liability.

FCC Information

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy, and if not installed and used in accordance with instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a par-ticular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Relocate or reorient the transmitter (pedal) and/or receiving antenna (dongle).
• Increase the separation distance between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
• Consult NOVA, the installing electrician or an experienced radio/TV technician for help.
• If interference cannot be eliminated, discontinue use and contact NOVA.

Safe operation and proper maintenance is your responsibility.

• NOVA Welding Industries is dedicated to keeping safety a top priority. While we have compiled this operator’s manual to instruct you in basic safe operation and maintenance of your NOVA product, it is no substitute for observing safe welding practices and behavior. Safe welding and related operations require basic knowledge, experience and ultimately the exercise of common sense. Welding does significant hazards to your health and life! Exercise extreme caution and care in all activities related to welding or cutting. Your safety, health and even life depends upon it.
• WARNING! If you do not have proper knowledge or capability to safely install and operate this foot pedal, do not use this pedal until proper training has been received.
• While accidents are never planned, preventing an accident requires careful planning. Stay alert! Keep wires and chargers properly stored. Keep pedal switched to “OFF” when not in use.
• Please carefully read this manual before you install and operate your NOVA TIG foot pedal.

The warranty does not cover damage or harm created by improper use. neglect of the pedal or failure to follow safe operating practices.

NOTICE:

• Welding and cutting operations may generate undesirable High Frequency (HF) and EMF energy. This can interfere with surrounding electronic equipment such as computers, routers, CNC equipment, televisions, communication equipment, radios, fluorescent lighting, navigation equipment, etc.
• This unit uses low-level radio frequencies
• Only use licensed electricians or qualified electronics installers familiar with similar electronic equipment to install this equipment for use.
• The user is responsible to have any suspected interference resulting from the installation and use of this product investigated and corrected by a qualified individual in a prompt manner.
• If notified by the FCC that the unit is causing interference, you must stop using this equip-ment at once.
• Do not attempt to modify this equipment or change the way this unit operates in any way.
• Keep the unit in good repair, including batteries, antennas and cables.

Safety Warnings, Dangers, Cautions and Instructions

Specifications

*The stated charging cycles are expected charging cycles based on lab and industry testing. Ultimately it depends upon battery storage, and operation temperatures and charging conditions. Extreme temperatures may reduce battery charging cycles that can be obtained. Improper battery cyling and charging techniques may also reduce battery life. This unit uses Lithium-ion type batteries and has the typical requirements of Lithium-ion batteries.
**The duration of a single charge of the battery may vary depending upon actual use. The charge duration is based on an average usage and expected time on of the foot pedal. Leaving foot pedal switched on in storage or while not in use will drain battery.

Model Compatibility For The NOVA Wireless Pedal

Model Compatibility For The NOVA Wireless Pedal

Adapter/Pedal Part #| TO FIT FOLLOWING MODEL NUMBER(S) / PART NUMBER(S)*
NVA-WL-FP200-AH07| AHP® and NOVA® 7Pin Alpha TIG 225Xi, and 203XD with 7 Pins
NVA-WL-FP200-EB08A| ESAB® FirePower© Thermal Arc® 8 Pin (NOT FOR PEDAL WITH SWITCH)

P/N: 10-4015, 10-4016, 600285, 1442-0025

NVA-WL-FP200-EB08B| ESAB (Rebel       EMP 205ic AC/DC, EMP 215ic, EMP 235ic)

P/N: W4014450

NVA-WL-FP200-EV07| Everlast® and NOVA® 7 Pin, Large, 22k and 47K. PowerTIG, PowerPro, PowerARC (models that are foot pedal capable only), PowerUltra, UltraARC. Some MTS with large 7 pin connection (verify size before purchasing)

P/N: EV/NVA-FP22NWI, EV-FP50DL, EV-FP22DL

NVA-WL-FP200-EV07MTS| Everlast® and NOVA® 7 Pin, Small. MTS models, small connector (verify before purchase) Does not fit old MTS 160/200S.

P/N: EV/NVA-FP22NWI-MTS, EV-FP47DL-MTS

NVA-WL-FP200-LN06| Lincoln® 6 Pin

P/N: K870

NVA-WL-FP200-ML14| Miller® Hobart® 14 Pin Standard

Model: RFCS-14 and RFCS-14HD P/N : 043554, 194744

NVA-WL-FP200-ML06| Miller® 6 Pin (Maxstar 161STL, 161STH, Multimatic 200)

Model: RFCS-6M P/N: 195183 and 195504

Others| Call to Inquire. Specifications and availability subject to change.

Setup Guide

COMPONENT ID

NOTICE:
The foot pedal may arrive with the top separated from the bottom. Although this is not usual, this is not considered to be damage because the pedal is designed to be separated. It can be easily re-installed. To install the top, flip the pedal spring under the cover to the forward position (towards transmitter end). Align the spring-loaded pivot pins with the corresponding holes in the pedal top. The pins are spring-loaded and can be squeezed so that the top slides down onto the pins. The pins will pop out into the holes and allow the top to pivot once the pins and holes are properly aligned. If resistance is felt or the pedal does not want to go together, you may need to make sure the pressure return spring is flipped so that it pushes back against the pedal as it is assembled. There will be moderate resistance as the pedal goes together, but it should be a firm, evenly felt resistance. Similarly, the foot pedal may be disassembled for adjustment by simply by pressing in on the ends of the pins with a dull awl, or Phillips-type screwdriver on both sides to remove the top. Once both pins have been pressed in, the pedal top should pop up for access to the foot pedal switch travel adjustment and other parts.
SERVICE REMINDER: The pedal cover should be removed periodically (every 3 to 6 months) to check for dust/dirt buildup and condition of all connections and circuits. The pedal should be blown out with dry compressed air.

Getting Started

UNPACK YOUR UNIT.
Upon arrival, you will need to completely unpack your foot pedal, and test it. It is important to identify any potential issues with your pedal. If any issue is noted, you should contact NOVA and resolve it immediately. The pedal is well packaged, but shipping damage can occur.
You should have the following in your box:

1. Wireless foot pedal with built-in transmitter.
2. Charger for pedal.
3. Receiver dongle (Machine side) with magnetic backing.
4. Magnet (Used to help store pedal on welder or table)
5. Adapter plug for the dongle to fit welder brand (exact adapter varies by brand) Not pictured. (Not used for MTS versions)

When you receive your package, inspect the unit for damage. Check for the presence and general condition of the parts. Some slight rubbing or chaffing of some parts may be present, but this is considered normal. If any item is damaged or missing, please inform NOVA within 72 hours of product receipt. NOTICE: Shipping damage claims after 30 days may not be accepted unless extenuating circumstances exist such as overseas deployment, etc.

DESCRIPTION AND GENERAL OPERATION.
The NOVA Wireless pedal has been designed to operate on a common 2.4 Ghz wireless design which allows the pedal to be operated in an environment where multiple wireless NOVA pedals may be present. The design is aimed at preventing cross-talk between multiple units and accidental activation of the arc from another pedal. Long life Lithium-type batteries are used in the transmitter located in the pedal. These batteries are rechargeable and can be recharged up to 300 times or more. Each charge of the battery is capable of lasting up to 40 days on normal 8-hour shifts. The pedal is capable of operating and controlling the welder up to 100 feet away from the receiver mounted on the welder.
The pedal is used to both start the arc and incrementally control the up and down ramping of the Amperage from minimum to maximum selected Amperage. The maximum Amp output is governed by the maximum Amp setting selected by the user on the welder control panel. Minimum start setting is governed by the welder default or start setting selected by the user.

PAIRING OF PEDAL AND RECEIVER.

NOTICE:
When the welder is set to high Amperages, the pedal will become more sensitive to Amperage change due to the change of ratio between the fixed pedal travel length and the Amp range it is required to control. When set to high maximum Amp settings, fine Amp control may be more difficult to achieve and the unit may seem to “accelerate” throughout the Amp range very quickly. When set to a very low maximum Amp setting, by comparison, the pedal will require more movement to make significant changes in Amperage and the rise and fall of Amperage will change more slowly throughout the range. At low maximum Amp settings, greater movement of the pedal may be required for a stable arc start at low Amps if starting Amperage is at or below the threshold of the Tungsten size used. This is not a pedal fault or flaw. It’s the limitation of welding at low maximum Amp settings and incorrect Tungsten size.

The pedal arrives already paired (synchronized) to the receiver from the factory. There is no need to pair the pedal again unless a repair or replacement of the pedal or receiver has been done. The pedal can be paired again however in the event the pairing is lost.

Use the following directions only if pairing has been lost:

1. With the foot pedal switched to off, and the dongle/receiver disconnected from welder, connect the dongle/receiver to power source.(NOTE: The dongle does not need to be disassembled in this process.)
2. Disconnect all other receivers (dongles) in use in the facility.
3. Access the transmitter board depicted below by removing the top cover of the pedal. See Page 11 for pedal cover removal.
4. Find and orient the board as shown to find the button(1) and the LED (2)
5. With the receiver on, press the button 1. The small LED (2) will light and should stay on constantly for a few moments.
6. The LED should begin to blink when the pairing link has been made. When the LED begins to blink, press button 1 again.
7. Press down on the foot pedal fully to complete the pairing.
8. Replace pedal cover and check for proper operation.

Install the Fuse.
The pedal is purposefully shipped with the fuse uninstalled for safety and shipping purposes. This prevents the Lithium Ion battery pack from being accidentally engaged or damaged.
To Connect the Battery to the Transmitter:

CHARGE THE BATTERY
The battery carries a charge from the factory that was used to pair the transmitter and receiver. However, before use, the battery should be charged. Each charge can last up to 40 days between charges with average use on 8-hour shifts. If the pedal acts irregularly, or the Dongle/Receiver indicates a low battery charge recharge the battery.

FOOT PEDAL /TRANSMITTER ASSEMBLY

• Set the transmitter toggle switch on the front of the pedal to the “OFF” position. (See Foot Pedal/Transmitter Assembly Diagram.)
• Locate the charger in the packaging. (See Foot Pedal Charger Diagram.)
• Connect the charger to the charging port on the front of the pedal.
• Plug the charger into a suitable 120V (100-240V permissible) receptacle.
• The LED light at the bottom of the charger will turn red.
• Charge for at least 4 hours until the LED turns from red to green.
• Once the LED turns green, remove the charger.
• Keep the pedal switched to “OFF” until the pedal is ready for use. Remember to turn the switch to “OFF” position when not in use or when stored to preserve battery life and prevent accidental operation of the pedal.

CONNECT THE RECEIVER DONGLE TO WELDER.
The Receiver/Dongle assembly requires 100-240V power to operate. In the North American Market, this will typically be used with a standard NEMA 5-15 120V outlet. The Dongle may be powered with an extension cord if the outlet is not near the welder, but be mindful that there is an additional trip hazard.

DANGER!
When left unattended, when work is completed, or when the pedal is otherwise not being used for welding purposes such as in transporting or carrying, turn the pedal/transmitter switch to the “OFF” position to prevent accidental activation. Shock, burn, arc flashing and/or injury could result from accidental activation of the pedal. Damage to high-value parts may result as well if torch is left on work and the pedal is accidentally activated and an arc starts.

FOOT PEDAL CHARGER (100-240V)

IMPORTANT!
Charge the pedal only when the toggle switch is placed in the off position. Do not use the pedal with the charger connected. Keep the pedal stored with the switch in the “OFF” position to prevent discharge of the batteries. As a “best practice” switch the pedal switch to the “OFF” position whenever the pedal is not be used or left unattended to prevent accidental arcing.

To connect the Dongle

• Turn on welder power.
• Switch the Foot Pedal/Transmitter to “OFF”.
• Locate a magnetic surface on the welder or nearby work surface and attach the Dongle via the hidden magnet located on the back side of the dongle housing.
• Locate the correct Dongle Adapter and connect it to the Dongle connector.
• Connect Dongle to machine control/remote terminal of the weld-er. (This is the normal location for the foot pedal or remote.)
• Plug Dongle into the power source (100 to 240V). The “On” LED should be lit. North American standard is 120V, NEMA 5-15R
• Switch the Foot Pedal/Transmitter to “ON”.
• The NOVA Wireless pedal is now ready for use.

OPERATION OF THE NOVA WIRELESS PEDAL.
The NOVA wireless pedal operates simply and accurately. It is already paired with the receiver so it is ready to go when connected and turned on. The wireless nature of the pedal means that the pedal operates best by line of site. Large obstructions, walls, and signifi-cant metal structures in the path of transmission will likely interfere with pedal operation. After charging initially, and following the

DONGLE RECEIVER CONNECTOR

“Getting Started” directions in the previous information, the pedal will be ready for use.

To operate the wireless pedal:

• Confirm the welder is turned on.
• Confirm the dongle is plugged in and receiving power.
• Confirm the foot pedal has been switched on.
• Select the “Pedal” function of your welder, or appropriate setting that you would use with your welder when using a foot pedal.
• Select the maximum Amperage you wish to use with the pedal.
• Set your welder normally as you would with any foot pedal, including start settings, tungsten diameter etc. for best starts.
• Press lightly on the pedal until you hear/feel a slight click. This will start the arc. Pressing further down will increase the Amper age. Raising the pedal will decrease the Amperage. You can continue to modulate the Amperage throughout the entire range by varying the pedal position.
• To stop the arc, smoothly raise your foot off the pedal so that it completely goes back to the pre-start position.
• If you maintain pressure on the pedal, the arc will not terminate until the pedal is fully released back to the pre-start position.

There are a couple of additional pieces of information that will help you to understand the function of the pedal, transmitter, and receiver.

• The Dongle includes 3 LED lights. See the diagram, the next page.
• The top green LED (1) indicates the dongle is receiving power.
• The middle LED (2) will light and flash red as the pedal is in use. (This is used as a diagnostic to confirm the dongle is receiving signal as well when the pedal is pressed.)
• The bottom LED (3) will light if the Dongle senses a weak bat-tery. If this happens stop and charge the battery on the foot pedal/transmitter as soon as possible. Do not attempt to completely run down the battery or battery life will be shortened.
• The Dongle must have a power source. It is not battery operated. It can be powered by voltage ranging from 100V-240V.
• Unplug the Dongle when not in use. The Dongle does not have an ON/OFF switch.
• Not all units require an adapter. If the supplied adapter does not fit your welder, contact NOVA as soon as possible. Not all welders can be used with the NOVA wireless pedal. Older, non-digitalized welders will often not be able to work with this unit. If in doubt, consult the NOVA product compatibility information on the specifications page, or contact NOVA directly before purchase.

100-240V Dongle/Receiver

MAGNET USEAGE.
The unit includes a cylinder-shaped magnet. This magnet is designed to be used to store the pedal. The pedal has a magnetic steel reinforcement bar inside that can attach to the magnet. This magnet can also attach to a metal surface so that the pedal can be stored out of the way.

IMPORTANT NOTE: The magnet is not strong enough to hold the pedal vertically. This magnet helps to keep the rough bottom surface of the pedal off of painted or fine surfaces as well. The magnet will hold the pedal in place in a flat position on most any magnetic surface that is flat and horizontal to the ground.

MAGNET IN USE

Troubleshooting

Check Dongle indicator, Recharge battery. Dongle is not plugged in. Plug in Dongle.

Foot pedal transmitter is switched off. Turn switch on

Battery to transmitter wires are unplugged, Plug wires into each other . Wrong mode selected on welder. Set to proper mode such as “Pedal”.

Welder reacts sluggishly or irregularly and arc lights irregularly or is delayed| Battery charge is low. Check Dongle indicator. Recharge battery. Obstruction. Remove obstruction. Operate line-of-sight.

Too far away from receiver. Move closer.

Arc is shut off suddenly and reinitates.| HF point gap (if used) is incorrect, or HF starting device is emitting too much High Frequency at start.
Arc does not shut off cleanly or properly| Improper machine settings. Turn off down slope.

Pedal is not fully back to stop. Press on rear of pedal to make sure the pedal is in the fully up position and the micro switch is not being activated.

Microswitch is out of adjustment. Remove cover and make sure microswitch is adjusted so that there is no contact when pedal top and the microswitch when in fully up position.

Arc cuts out or doesn’t seem stable as pedal is swept up or down. Response is not as expected. (Wired pedal operates normally.)| Interference. Turn off all other electronics in shop one at a time to isolate.

Bad potentiometer or broken internal wires on the pedal. Contact NOVA

Another foot pedal is controlling the welder.| Foot pedal has been improperly paired, or lost pairing. This should not nor- mally happen unless the pedal has been worked on or replaced. Follow re- pairing instructions in this manual. Contact NOVA.

If another brand, is interfering, discontinue use of the other pedal and contact NOVA.

References

• No Admittance No Entry Symbol Label / Sticker - White Reflective
• P65warnings.ca.gov

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