aead-200 le No Power out put

[krisp3]

I recently purchased an AEAD- 200 le model # 13-118, serial #HG 080830, circuit diagram CB-900 468-1h was laminated to the inside of the cowling.
(actually a Marquete, but the parts are labled aead under the cowling, #'s work in millers site for manuals, etc).
when I bought it, the engine didn't have spark, but the previous owner stated it welded excellent last time it was run. I cleaned the points and it runs great, I'm hoping it is something similar that is wrong with the welder/ generator.
The engine runs strong but no output from any outlets, or welding plugs. When its running I get 1.5 v dc out of the D.C. outlet, I cleaned the collector rings and brushes, checked every rectifier I could find( just continuity( aprox 400 ohm) across terminals, then reverse polarity and the all come up as open), cant find any loose, burnt or corroded wiring and the fuse and circuit breaker all had continuity. The switch (s2) was jumped out on it so both wires#51 and #52 are connected all the time. If I unhook a battery cable while its running it dies.
I was wondering, does the exciter coil need power from some where to make the 125 v dc? or does it create it on its own.
any help or ideas on what to check would be greatly appreciated

[duaneb55]

First of all, if you don't already realize it, use EXTREME caution with throttle safety switch S2 by-passed. Its purpose is to kill the engine should the operator attempt to increase speed above POWER rpm thus preventing an auxiliary power over voltage condition. It may have been by-passed due to a failed switch or just because it wasn't adjusted properly but give consideration to correcting it.

Second, you've certainly investigated much more than most people and I commend you for that.

If you don't have a manual you can download it here: http://www.millerwelds.com/om/o411f_mil.pdf

In it you will find a troubleshooting section on manual page 12 (file page 20) and in it note the last item regarding no weld or power output and the instruction that a momentary increase in engine rpm (above weld speed) may correct a no output condition.

This is because the AEAD is self-exciting and relies on residual magnetism in the rotor to kick things off upon start up. If this magnetism isn't strong enough to initiate sufficient exciter output current, an increase in engine speed may be enough of an exciter voltage increase to resolve the matter. Once up and running, adequate magnetism would be restored and the problem is solved.


If that doesn't do it, you mentioned you checked for corroded connections but didn't indicate if you checked the tap band on field trim resistor R5 which has been known to become corroded and prevent proper field excitation. You can see the location of R5 in the parts break-down in the manual but this photo of another owners similar machine shows the resistor and tap strap I'm referring to. The second resistor in the photo serves a slighly different function and won't be on your machine.

Check these things and let us know the results.
Duane

[krisp3]

got power!

I replaced the microswitch with a new one, tried running it up past govenor speed, no luck, looked at resistor r5 contacts, they all looked clean, figured what the heck I ll take it off and clean it and sure enough under the band was some rust! a little scotch brite and some elbow grease and it works great. AC power out put is 109 volts and dc is 124volts with the fine adjustment at max. THANK YOU FOR ALL YOUR HELP!!
I saw an earlier post about cleaning r5 and blew it off because it looked nice and clean on the outside and had continuity from the terminal to the other end of the wire, guese it never hurts to double chedk!
Thanks again

[duaneb55]

Congrats on getting the unit up and running.

The thing with checking for continuity thru a switch, breaker, connection, etc is it can show good but under a load it can go away. Sounds like that's what you experienced.

[magix4u2000]

Same machine

Hey I have a Miller Legend also. I have had mine for about 15 yrs. Killer stick welder. Also I hooked a WC115 I believe it is to mine. It will give you AL 30A spool gun ability. It is a little hard to get the arc started on the 30A but when you do your off to the races. Welds great.