Rheostat Failure

[OctoberSnow]

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

[H80N]

FWIW......A $98.00 problem... Easy Fix

http://www.brweldingsupplies.com/miller-rheostat-ww-150-w-50-ohm-frict-term-238905/

[OctoberSnow]

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..

[H80N]

Hi H80N
ty for reply friend.

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

MUCH Better deal...............

[Aeronca41]

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.

[duaneb55]

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

. . . plus $10 shipping charge for orders under $100.

. . . 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.

[OctoberSnow]

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.