AEAD 200LE doesn't weld

[tpierce]

I just hooked up welding leads to my newly acquired Miller AEAD 200LE. I can't strike an arc. It has power to the receptacles, but no weld output. I looked in the manual, but there was no mention of what to check. Can anyone tell me where to start? Thanks in advance for any help.

Tim

[duaneb55]

Did you change the mode selector toggle switch from the POWER to WELD position?

If yes, then I'd start by checking the switch for being bad (contacts for wires #22, 26 & 60).

[Andy]

The one I have will still strike an arc with the switch set in power mode. It just won't run the rpms up to give you full power.

[duaneb55]

Is this the same '87 machine you posted about on WW that "runs good, generates and welds"?

Got a SN? Should be a JHxxxxxx if it is.

[tpierce]

Duane, yes it IS the same machine. The seller said "as far I know it welds". He di'n't have lead, and the leads I have fit a Maxstar 150STL, so I couldn't check it. CAVEAT EMPTOR. The serial no. is JH214127. The machine looks almost new, and the engine runs well and starts easily. I have power at the recepticals, and the rpms jump up when I flip weld/power switch. I did pull the side cover off to have look, and didn't see anything burnt, However the rotating rings that the brushes ride on look like they could use a cleaning. I haven't removed the brushes yet to check. Thanks for any help.

Tim

[tpierce]

I cleaned up the slip rings the brushes ride on , and checked the brushes, they're fine. I didn't see anything that appeared burnt on the circuit boards. I still don't DC, not even a spark. I tried the AC, and did get a spark, but no sustained arc, just some sparks. After trying the AC, I notice wisps of smoke coming from the bottom of what is listed on parts sheets as the reactor, so I shut it down. Any ideas?

[duaneb55]

Doesn't sound good for the reactor. Did you check it on all the current settings? If it's shorted/fried you should be getting a high resistance reading when you check each of its taps (leads #10-16) to output leads #17 & #18 with an Ohm meter.

[tpierce]

I'll pull the front cover off and check it tonight after work. I'm gonna do whatever I can to get it to work. It's such a clean machine. The engine looks and runs like it has very low hours, and the inside looks very clean. I'll report back what I find. And thanks for your help Duane!

[tpierce]

Ok, I checked #10-16 with #17 & 18, everything checked out. I also checked all connections, and they're tight. What should I check next? I remove the top cover, so I have good access.

[tpierce]

Anybody have any more ideas? Is there a way to check the rectifier, and excitation coil? I haven't found any loose or bad connections. Isn't there a way to jumper the exciter to see if that induces weld current?

[tpierce]

I found what I think is the flashing diode wired in the harness near the brush holder. How can I check it with VOM?

[duaneb55]

With power at the receptacles the flashing diode is fine as it's required for auxiliary power output as well as weld output.

The smoke was coming from the reactor so that's where you need to be looking. You stated it checked out OK but didn't give any resistance reading results. Did you check for shorts to ground on the 10-16 leads?

Disconnect lead #8 from the Coarse Current selector switch to by-pass the reactor and check for 80VAC +/- between lead #8 and #9 (AC WORK output receptacle).

[tpierce]

Duane, I didn't show resistance on any of the meter settings when I checked 10-16 with 17-18. I disconnected 8 from the selector, and checked for AC volts with the work receptacle, it showed 43.5 volts at idle(power) speed, and 65.9 Vollts at weld speed. Does it matter if the fine current knob was set on 100 when I checked it?
I also double checked that I have power at the outlets, and it read 177-118 volts.
Thanks for your help!

[duaneb55]

Well then there's weld output but it's not getting thru the reactor.

By "I didn't show resistance. . ." do you mean as in an open circuit as the VOM would show with the test probes not touching each other or showing continuity or short circuit as if the test probes were connected?

If the former, the reactor is "open", if the later the reactor is likely "shorted". It may have started out shorted (source of smoke) and is now open (cause of no weld output thru it).

[tpierce]

Duane, it showed as if the test probes were touching each other-indicating continuity.I may have a lead on a good reactor here locally.They are going to check it and make sure it's good.
Oh, I meant to tell you I didn't find any shorts to ground on #10-16.