On Wed, 2 Jul 2008 16:57:12 -0700 (PDT), Eug
wrote:

I whish to thank everyone who answered, I was going to post this to a
welding forum but their registration process has malfunctioned.
In the interest of brevity, I left out many of the steps I have taken
in troubleshooting this problem.
Here are short answers to issues raised.
I have all manuals and schematics.
We have six machines in the shop from old dial arc 250s to 3
generations of Syncrowave 250s. Can’t run to dealer every time someone
rolls over a cable.
The foot pedal was eliminated.
I have reset to factory defaults.

Since my first posting, I have checked the wiring from the front panel
plug to the circuit board and found no problems.
Next I’ll remove pc1 board and check for damage as suggested by Jon
Elson.
Again, I want to thank everyone who replied
Eug

Did you make sure the replacement cable was the right one, and wired
correctly? You've swapped the pedals, but not the cables - try
swapping the new cable to the other machine and see if the problem
follows.

If you have then I have to agree with others, it might have fried
something on the mainboard inside the welder.

A short on a pedal shouldn't be able to blow up expensive bits
inside, but while chasing the dollar to the bottom companies can't
afford to build machines like that. If you build a 100% bomb proof
machine that keeps working no matter what - but it costs twice as much
as the competition, it's a hard sell to get people to pay a lot more.
A few will, but in mass production you need many...

-- Bruce --