These come directly from Cable Control Kits. P/L Welder holds no responsibility for these suggestions, instructions, directions. If you have any questions, please call Cable Control Kits 318-292-4417
Problem: You have to turn your knob to 100 or more for grinder to work.
Solution: Plug the box directly into the switch pigtail. Check grinder, if it works, it's your cord. If it doesn't work, check the wiring in your Control Kit plugs. (See #6 in the instructions). If the connections are OK then take the back off of the box. Reverse the black and white wire on the Rheostat. Also recheck your blue scotch lock on green wire to make sure it's clipped into the wire.
Problem: Rheostat works but the grinder doesn’t.
Solution: Breaker is either burned up or the blue scotch lock connector under the hood that you connected the green wire to the factory ground has come apart or burned up.
Problem: The Rheostat burned up when I changed the plugs.
Solution: When replacing a plug on our 200 units, make sure you put the white wire on green screw, the green wire on silver screw and black wire on brass screw. On all 200 D's T.L. plug, the black wire goes to the Y screw - green wire to X screw and white wire to silver screw. On 300 D male T.L. plug, that goes into welding machine, put the red wire on Y screw and green wire on silver screw.
Problem: Grinder works but Rheostat will not register but Rheostat in welding machine does work.
Solution: The white wire is broken between the welding machine and box somewhere. On your extension cord it could be the green wire, but on the box pigtail it will be the white wire. SUGGESTION: plug your box directly into short pigtail hanging from your machine and try your grinder. If it works a wire is broken in your extension cord.
Problem: Switch complaints, (single pole, double throw)
Solution: Your switch should not be moved with machine running. It is not moisture proof. It's a slide bar and has a 55 DC amperage rating and it has a center OFF position.
Problem: Remote gets awful hot
Check female plug on extension cord. May have arc inside when unplugging box from extension cord with welding machine running. Also, it could be a loose connection in plugs or inside of box. Don't lay box on its back because it will stop flow of air. Also check the RPMs on your welding machine. If they're too high, it will cause box to run hot. RPMs should be 1550 high idle, no load.
Problem: Burned up switch
Solution: Until you can get another switch, transfer the white wire on switch to center screw on switch. Control on Remote only.
