Welding remote

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I got tired of walking back and forth to the machine and I didn't feel like paying $200ish so I just made my own.The box is some 1/8 flat stock I had in the scrap bin.  I copied the wiring on the variable resistor from my foot pedal.  The foot pedal has a 1k resistor, but I only had a 100k resistor.  Still seems to work fine.  The redish blobs are capacitors.  The foot pedal had them so I have them.  I'm guessing it helps cut any noise you might pick up from the welding lead.The switch is the contactor that turn off and on the welding output.I also added red and green LEDs.  The green light is between contactor's + voltage (A on the 14pin) and the ground (G on the 14pin).  This makes it light up whenever the welder is powered on.  The red light is connected between the contactor return (B on the 14pin) and ground.  This makes it light up whenever the weld output is on.  The resistors on the LEDs are 1k and keep them from drawing too much current and burning out.For the cable I used regular ethernet cable.  It's probably not a durable as the cable that would come on an expensive remote.  It's cheap (about $0.10 per foot) and I already had some leftover of a 1000ft spool.  It was too small to tighten up in the strain relief on the 14 pin connector.  So I tied a knot in it.  The knot tightens up well and won't break the wires where they solder to the back of the 14 pin connector.  The box has a "butt connector" and I use an inline connector on the 14pin.  This way you can easily replace the cable in the field if it gets cut.  There's a magnet stuck on the back of the box.  You can plop the box in any position and it'll stay where you put it. Attached ImagesDynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Thats awesome what machine u running it on ? I think the lan cable is the same thing the finger controls use....I forgot how to change this.
Reply:I've only used it on the dynasty, but I think it should work on any miller 14 pin.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Sweet, so the only real question i have is do you think if you go over 100' u will have to much voltage loss for it to be useful? lets say if you wanted to use it on a portable or something like that?I forgot how to change this.
Reply:Works fine with the 100k resistor.  If you drop back to the 1k like the foot pedal has, it would take a LOT of cable to get back up to 100k of resistance.  I don't think you'll have any problems with 100ft.  There's not much current drawn on the variable resistor.  You only get voltage drop if there's current across resistance.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Excellent computer parts re-use. I always save hard drive magnets.
Reply:Excellent computer parts re-use. I always save hard drive magnets.
Reply:Pardon my ignorance but..   What is it ???
Reply:It lets your change the amperage setting on the machine remotely.  You carry this box where ever you carry your lead.  You can turn the knob up or down to get more or less current.  This is very nice when you're up on a ladder or scaffolding and you are welding various thicknesses or horiz/vert and you need to change the heat often.  There's also a switch that you can turn off to kill power to the lead.  This is nice when you have to climb on the workpiece and you're all sweaty.  It saves you from getting shocked when you put in a new rod.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Originally Posted by farmallExcellent computer parts re-use. I always save hard drive magnets.
Reply:I didn't know hard drives had magnets. Oh to think about all the ones I threw out as junk...Miller thunderbolt 250Decastar 135ERecovering tool-o-holic ESAB OAI have been interested or involved in Electrical, Fire Alarm, Auto, Marine, Welding, Electronics ETC to name a just a few. So YES you can own too many tools.
Reply:nice work !!    now build me one   lol                    were  can i get the 14 pin plug   that goes into the welder  ?     id like  to build something similiar  ..     and could u possiablie put up a wire diagram   .....>Innovations are what i leave behind for History
Reply:Originally Posted by AndyAIt lets your change the amperage setting on the machine remotely.  You carry this box where ever you carry your lead.  You can turn the knob up or down to get more or less current.  This is very nice when you're up on a ladder or scaffolding and you are welding various thicknesses or horiz/vert and you need to change the heat often.  There's also a switch that you can turn off to kill power to the lead.  This is nice when you have to climb on the workpiece and you're all sweaty.  It saves you from getting shocked when you put in a new rod.
Reply:Originally Posted by Thiel-Metal-Fabnice work !!    now build me one   lol                    were  can i get the 14 pin plug   that goes into the welder  ?     id like  to build something similiar  ..     and could u possiablie put up a wire diagram   .....
Reply:The connector used by Miller for 14-pin connections is a amphenol #97-4106A-20-27-P with strain relief #97-3507-12 http://www.ee-usa.com/warehouse/amph...06a-20-27p-662 12.08$ call for this pricethe pins are for 12 gauge wire 9738-12-16p-4(0920) bag of 100 44.00 bag strain relief 97-3057-1012-1 4.53$Female Connector cable mounted97-4101A-20-27s(662) 14.60$ eachSocket pins 9738-12-16s-4(0920) 100 pieces 47.00$ Strain relief 97-3057-1012-1 4.53$ these prices are from Electronics expeditors if a person could just buy the sockets and pins else where instead of buying a bag of 100 it wouldnt be a bad deal imo.  here is a link to the amphenol catalog with these connectors http://www.amphenol-aerospace.com/ca...zip/12-022.zip Double check your machine these may not fit all machines.I forgot how to change this.
Reply:The letters correspond to the pins on the 14pin connector.The foot pedal uses a 1k variable resistor.  I used a 100k and it works fine.  You can probably use anything in between.The 100nf capacitors can probably be substituted with just about anything else.  Larger capacitors will provider better noise rejection.  If you use electrolytic, be sure to put the + lead toward the C pin.You may need to swap the C and D lead on the variable resistor if the knob behaves backwards from what you want (you turn the knob 'up' but the machine goes down). Attached ImagesDynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Love seeing cool, cost saving ideas!Brilliant!
Reply:Nice job AndyA.   I love seeing things like this. Originally Posted by LawsonWeldingLLCThe connector used by Miller for 14-pin connections is a amphenol #97-4106A-20-27-P with strain relief #97-3507-12 http://www.ee-usa.com/warehouse/amph...06a-20-27p-662 12.08$ call for this pricethe pins are for 12 gauge wire 9738-12-16p-4(0920) bag of 100 44.00 bag strain relief 97-3057-1012-1 4.53$Female Connector cable mounted97-4101A-20-27s(662) 14.60$ eachSocket pins 9738-12-16s-4(0920) 100 pieces 47.00$ Strain relief 97-3057-1012-1 4.53$ these prices are from Electronics expeditors if a person could just buy the sockets and pins else where instead of buying a bag of 100 it wouldnt be a bad deal imo.  here is a link to the amphenol catalog with these connectors http://www.amphenol-aerospace.com/ca...zip/12-022.zip Double check your machine these may not fit all machines.
Reply:Originally Posted by duaneb55Nice job AndyA.   I love seeing things like this.Allied Electronics will have all the Amphenol parts you'll need and the plug/socket assemblies come with the terminals.