AEAD 200LE Low Power No Weld

[farmboy57]

I have a AEAD 200LE was welding fine until sit under shelter about six months, started occasionally and run for short time. Went to do a welding job week ago and only get small spark when striking arc. Engine revs up but will not weld, check power output and only getting 18 - 20 volts. Brushes and slip rings OK, rectifier checks OK, D4 diode checks OK, whatever happened was while sitting under shelter.
Would appreciate any help

[farmboy57]

Sn je760609

[D Auger]

Welcome to the forum! Make sure it's running at the proper rpm at weld speed and at gen speed for proper excitation you can check it with a multimeter at the single power output socket it should put out around 62.8 hertz at 3000 rpm .If it's been in a damp location for awhile it could have corrosion on the connections behind the panel check there you can down load a manual using this site and your serial # you may have to scroll through the machine list under aead 200
le click on that then scroll through to get your Aprox serial # I've used these methods to get my machines going from great people and info on this forum .
Someone else with more info should chime in soon ,the manual has a decent trouble shoot section also D

[Aeronca41]

I'm not a welder expert but fix a lot of things. D Auger is right on with checking RPM first. Do the power outlets work? What voltage is on them? First thing you need is accurate RPM measurement. If your voltmeter doesn't have a Hz range, get a Kill-a-Watt meter at HF or HD or Lowes and check frequency. That, and whether utility outlets work is the first step I would try.

[farmboy57]

RPM's are good, getting 18-20 volts on duplex receptacle at 1800 RPM and 18 volts on 115 volt receptacle in weld mode at 3000 RPM. What ever is wrong happened while not being used over six months. Has worked great over the 25 years I have had it.

[D Auger]

There are two resisters under the right side panel as your facing the control panel they are mounted vertical check the tap bands under neath for corrosion and make sure to check the spade connections for corrosion also .I had to do that on mine .Make sure you put them exactly back in place were they were .Hopefully Duane55 or Cruizer will check in on this ,they are pretty sharp with these machines .

[D Auger]

There is a lot of great people with good info on these machines on this site your in good hands ,Oh and Aeronca41 told me the hertz trick for that setup I know a little about them I'm still learning as I go .But start there sounds like something simple .D

[duaneb55]

Definitely check the resistor tap straps that D Auger mentioned and are you 100% sure bridge rectifier SR2 is good? Considering you're getting the same voltage at the 60Hz duplex at 1800rpm POWER speed and single 115V/100Hz outlet at 3000rpm WELD speed, it sounds like you're only getting battery voltage at the rotor brushes. I'd check voltage at the brushes too. Center brush is (+), outside brushes are (-).

I would also check the WELD/POWER switch contacts for wires #51 and #54. Make sure they make contact in POWER mode.

[duaneb55]

To calculate RPM based on Hz the equation is:

RPM = (Hz x 120) / 4 for 1800RPM 4-pole generators (such as yours)
RPM = (Hz x 120) / 2 for 3600RPM 2-pole generators

[farmboy57]

Will check these items again tomorrow if get home in time. Never hurts to recheck, there was some rust on resistor tap, cleaned off but will recheck. Thanks for the suggestions.

[Aeronca41]

There is a lot of great people with good info on these machines on this site your in good hands ,Oh and Aeronca41 told me the hertz trick for that setup I know a little about them I'm still learning as I go .But start there sounds like something simple .D

...and I learned it from Cruizer. This group is great-always someone to learn from.

[farmboy57]

Took a chance and replaced sr2 rectifier no luck. Checked power at brushes and get 4 volts at front, 13 volts at middle, 0 at rear. Took straps off resistors and cleaned still only 17 volts

[D Auger]

Did you check the weld /power contacts at the back of switch make sure there clean?

[farmboy57]

Yes, if I strike arc welder kicks up RPMs but only get small spark

[D Auger]

Hopefully Duane55 will check back in on this