Lincoln 200D Burning/Smoking Rods

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I have an '09 200D with a little less than 3,000 hours on it and just recently it started burning up or smoking/snuffing my rods out with around 2-4" left on the rod (1/8 6010 5P+) and about 2" on 8010 5/32. I run my machine always in 240 Range and high idle nob is set on 2. I RARELY change gears unless I'm working on 3" pipe or below and I don't adjust the high idle. I run beads a lot and this started one day randomly after lunch. I run my heat starting on 40 and up to 60 by the end of the day (of course adjusting for speed and gap throughout.) I've never had a problem in the 3 years I've had the machine. Here's a list of things I troubleshooted:•RODS- Welding partner and I are running rods out of the same box, not the rods. Like I said this JUST started happening.•HEAT- Not my heat I've been running the same heat running beads for years now, never any issues.•WELDING LEAD/WHIP/STINGER- Welding lead is less than a year old (also I used a helpers brand new lead/stinger and it still acted up). I have a brand new whip and Stinger V on my setup.•REMOTE/REMOTE EXTENSION CORD- Bought a brand new heavy duty extension cord, problem persists. Remote box gets hot, but is roughly same temperature as partners.•GROUND LEAD- We're both grounded to the Morooka Buggy with a good ground lead running off the buggy. Once again, partner has no issues (and he also is running a 200D).•FOR ONCE ADJUSTED RANGE AND HIGH IDLE- I tried 190 range and adjusted high idle knob from 3-4-5-6-7, no change just welded worse. Adjusted high idle knob in 240 from 2-3-4-5, no change and put it back on 2.•BRUSHES- Exciter brushes are new, armature brushes look a little worn, but they're all seated well. Ran a stone on both to clean them up, no change.•VOLTAGE/AMPS- Had an inspector check mine and my partners machines (once again we both run 200D), running exactly the same. --Closing,I also just changed fuel filter, oil filter, and oil. I absolutely cannot figure this out. ANY HELP would be GREATLY appreciated. Thank you.
Reply:what did you all have for lunch, when this started happening?
Reply:What does your partner set his machine at?Let him run your machine at your settings and then his settings (if different from yours).MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:He runs his in 190, high idle on 7-8. I tried welding with mine like that, no difference except for less drive. Two other guys I've known for a while have 200Ds as well and they run more or less the same heat I do. Older guy runs his 240 and 5 1/2, other buddy runs his about 240 and high idle between 4-6. I've talkdd with all them and severL other people and no one has had the same problem. Like I said I never used to have this problem, just started one day and hasn't stopped. In fact I took off for a week (machine is on a morooka) and one of the other welders used it and he said it done the same to him. Only time it wouldn't is if he ran the rheostat on about 30. Runnin' beads you can't do that. The partner I had running beads we'd both use 2 rods on this 16" we're laying. One rod to tack, one to weld our sides. Once this problem started I would have to switch rods cause I'm losing so much travel cause I can't burn the whole rod. If I run it at 60 or higher (which I've done for years no problem) the rod actually smokes out before the final 4" but I can get a tad more distance before the flux just falls off. Like I said if it was just running too hot it would've been doing this since day one. It's even burning up 5/32. Something has changed or something is going out I just can't pin point it.
Reply:When running your remote, do you have the panel set to 100% or closer to your typical maximum of 60?Have you looked your rheostats (panel and remote) over very closely for burned/shorted windings and inspect the condition of the wiper contact?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Usually the heat is set on 10 on the machine (so you'll always know if it's in remote or local). I opened up my remote and inspected it, it's good. Haven't tried looking on the machine.
Reply:I've checked the wires and whatnot on the remote, everything looks to be in good shape. I haven't tried swapping remotes out yet I'll do that and check the range selector on my machine.
Reply:If the machine is set to 10, then the panel rheostat windings themselves are not in the picture but use some 320grit sandpaper to make sure the contact surface is clean.Do the same to your remote rheostat including the entire surface of the windings.And check all wiring connections to make sure all screw and nut connections are clean and tight.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Yeah if that's the case it'd have to be on the remote or the range adjustment 'cause they're the ones being used. I'll try swapping remotes and when I get to my machine I'll check my range selector and make sure everything that's hooked up is clean, tight, and has a good connection. We're off in the swamp lands right now they're trying to clean the ROW up good enough to shuttle us back there on some side by sides.
Reply:Can you swap remotes with your partne?
Reply:Tried swapping remotes and that wasn't it. I can't open the door on the side the range selector is on to get a good look, when I have more time I'll pull it and the hood off if I need to and check and see what it looks like. Once we got rolling today I didn't have any time to really check. I'll keep updating as I go along just in case anyone else runs into this problem.
Reply:Im interested to see what the problem might be. Looking forward to the rest of thisSent from my iPhone using Tapatalk