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  • Rheostat Failure

    Howdy.

    So at around 320 hrs, my wildcat 200 welder rheostat failed. (p/n 238905) Love this welder btw, it has been super.
    I am wondering if there are folks here that may have had similar experience and any suggestions about how I might prevent such a failure in the future.
    I did look about on the forums a bit, typed "rheostat" in search field returns many pages and after wading through a good number of them I did find that this may have something to do with the engine idle function perhaps.
    So I would be grateful if someone that knows for sure will share their knowledge.
    ty for your time, J

  • #2
    FWIW......A $98.00 problem... Easy Fix

    http://www.brweldingsupplies.com/mil...t-term-238905/

    .

    *******************************************
    The more you know, The better you know, How little you know

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

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    • #3
      Hi H80N
      ty for reply friend.

      Its only $77.38 US @ Miller4less ... LOL.. http://miller4less.com/product_info....ducts_id=65449

      getting the part and making the repair are not the solution I am looking for friend, I am asking if there is someone here that knows why it fried ....
      and if doing something in the future like not using the idle function or always starting the engine at max. or min. setting or something of the like may help me to avoid another rheostat failure..

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      • #4
        Originally posted by OctoberSnow View Post
        Hi H80N
        ty for reply friend.

        Its only $77.38 US @ Miller4less ... LOL.. http://miller4less.com/product_info....ducts_id=65449
        ..
        MUCH Better deal...............
        .

        *******************************************
        The more you know, The better you know, How little you know

        “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

        Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

        My Blue Stuff:
        Dynasty 350DX Tigrunner
        Dynasty 200DX
        Millermatic 350P w/25ft Alumapro & 30A
        Millermatic 200

        TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

        Comment


        • #5
          One thing that may help extend rheostat life is turning it from stop to stop multiple times periodically to clean any dirt or corrosion off of the resistance element. Once the contact resistance goes up, the wiper arm spring starts to heat and weaken the spring, resulting in poor contact, which makes more heat....until it fails.

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          • #6
            Originally posted by OctoberSnow View Post
            Its only $77.38 US @ Miller4less ... LOL.. http://miller4less.com/product_info....ducts_id=65449
            . . . plus $10 shipping charge for orders under $100.

            Originally posted by OctoberSnow View Post
            . . . is someone here that knows why it fried ....
            and if doing something in the future like not using the idle function or always starting the engine at max. or min. setting or something of the like may help me to avoid another rheostat failure..
            The biggest cause of rheostat failures (burned out winding) is poor contact between the wiper brush and dirty winding surface. Best solution is to clean the winding contact surface with fine 320grit) sand paper if the unit isn't used very often. Operating the Fine Voltage control from minimum to maximum a few times periodically helps to maintain good contact.

            Nothing at all to do with the idle function or starting the unit at minimum or maximum.
            MM200 w/spot controller and Spoolmatic 1
            Syncrowave 180 SD
            Bobcat 225G Plus LPG/NG w/14-pin*
            *Homemade Suitcase Wire Feeder
            *HF-251D-1
            *WC-1S & Spoolmatic 1
            PakMaster 100XL
            Marquette "Star Jet" 21-110
            http://www.millerwelds.com/images/sm...rolleyes.png?2

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            • #7
              thank you for your suggestions Aeronca41 and duaneb55 .. yeah duaneb, Miller4less has an additional charge for the under $100 orders so I just bought a couple other things I am fixin to need soon enough.
              I like the folks at the welding supply in the closest town to us but even they are a good clip from our ranch here. I try and do my trading with them but ended up ordering that pot online as they did not have it in stock.

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