Buzzbox amp change while welding?

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Ok, i am the guy who reads a waring label ( i.e. do not adjust amperage while welding ) and wants to know why. What will happen? Why will said result happen? To put my question in laments terms, whats going to happen if i try and change my amp output on my Lincholn AC/DC 225/125 stick machine while I am welding?
Reply:You could fry your machine as well as become the ground and get fryed yourself dont do it or you might end up in the darwin awards.Hobart mega arc 250 Airco dipstick160 air liquide cutting torches arc air gouger and so many more goodiesIf you cant dazzle them with brillants baffle them with bullsh$t
Reply:touche. but again, WHY will it fry my machine. wise man once told me that the man who knows HOW it works will allways work for the man who knows WHY it works.
Reply:I would suspect that the arc in the contacts of the selector switch would fry the switch!-- fredLincoln 180C MIG
Reply:The switch will arc and ruin it, it is not meant to switch under load.A switch like the welder has, can carry a lot of current once it is switched, but the arcing inside of it will make it quit working.
Reply:I really don't see how your going to be able to adjust the amperage while your welding unless someone else does it for you. Either way you will damage the switch by causing it to arc out as your changing amps.
Reply:Originally Posted by d11btouche. but again, WHY will it fry my machine. wise man once told me that the man who knows HOW it works will allways work for the man who knows WHY it works.
Reply:Depends on the machine, selector switch no, rheostat yes.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Maybe i was fed with a silver spoon, Maybe not.Maybe I'll play your silly little game too. Maybe you have to make smart *** remarks because you feel stupid for not being able to give a mechanical answer to my question. I see that ones interest in knowledge is shunned here. Good to know. To every one else who posted a true response thank you.
Reply:The switch will arc when it goes from one position to the other. You may also have some feedback and blow the transformer.
Reply:The one on the left / upper, (rheostat) you can rotate while welding. The one on the right / lower, (selector switch), you'll arc the copper lugs if you switch while welding. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:7A749,,, CEP,,,,,exactly what I was looking for! Thank you. I never stated I was going to try, I just like to understand how and why things work. Now i have to ask, in CEPs picture what is the purpose of having both types in the same machine? EDIT OPSnever mind, re read the post from 7A749Last edited by d11b; 01-19-2011 at 08:48 PM.
Reply:The selector switch is a wide range amp control, the rheostat is a fine amp control.You can keep one of these right next to you, and change your settings as you're welding. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:This is what your buzzbox switch will look like when switching under load.  This is a shot of another members engine drive machine but the same switch.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:I'm thinking switch contacts will be destroyed by arcing.Devices that are meant to disconnect high currents have magnetic arc shutes etc. to keep contacts from being "welded".Miller a/c-d/c Thunderbolt XLMillermatic 180 Purox O/ASmith Littletorch O/AHobart Champion Elite
Reply:Originally Posted by CEPThe selector switch is a wide range amp control, the rheostat is a fine amp control.You can keep one of these right next to you, and change your settings as you're welding.
Reply:Because it would require a small cart to haul it due to the size it would need to be to stand up to the amperage.The Course Current taps are just that - taps from the transformer, reactor or welder coils depending on welder type.The Fine Current control (rheostat) varies the much lesser field exciter current thus regulating the actual current output of any particular Course Current tap.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:Originally Posted by duaneb55Because it would require a small cart to haul it due to the size it would need to be to stand up to the amperage.The Course Current taps are just that - taps from the transformer, reactor or welder coils depending on welder type.The Fine Current control (rheostat) varies the much lesser field exciter current thus regulating the actual current output of any particular Course Current tap.
Reply:For a little while.  The lower voltage to the machine would result in an overheated transformer and the factory smoke would get out.Is this just a curiosity question?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:Initialy this knowledge quest started out trying to figure out a way to incorperate an inexspensive foot pedal into my buzzbox that i use for crude TIG. I did a lot of searching on home made pedals, and realized i didnt know a hell of a lot about the mechanical operation of the buzzbox itself, so hence forth all the simpe stupid questions.
Reply:Rather then reinvent the wheel, why not just save some $$ and but something like a Miller Maxstar or keep an eye open for a good deal on a used machine.  If you do try this, when your done putting in the time and effort you will probably realize you would have been better off buying a real tig machine.
Reply:I can appreciate that as well as your being up front about it d11b.When having to TIG without fine amperage control one must learn to "adjust" by controlling travel/filler feed speed accordingly based on the closest appropriate tap setting.  Lots of practice.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by Jay ORather then reinvent the wheel, why not just save some $$ and but something like a Miller Maxstar or keep an eye open for a good deal on a used machine.  If you do try this, when your done putting in the time and effort you will probably realize you would have been better off buying a real tig machine.
Reply:I'd repeat what's been said and recommend you just buy a machine with current control built in.  If you were determined to build your own current control for your transformer machine, I'd probably also rectify it to DC, then duty cycle modulate a set of mosfets.  You can probably use something as simple as a 555 timer chip to generate the train of pulses that turn on/off your mosfets.  The 555 can be set up to change duty cycle based on a variable resistor (perfect for foot pedal, etc).  You'll probably going to spend a few $100 in parts, connectors, housings, etc, etc.  Add on any parts that get smoked.  Yes, it's a good learning experience.  No, it's not the way to go if you just want to weld.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:In the lincoln 225 the switch is in the primary of the transformer.Idle current.s are low. .'If swtched during welding the arc will destroy the contact s The switch has to be kept clean to work right..