Weldanpower225 low voltage problem
Tue, 31 Aug 2021 09:58:45 GMT
I've been lurking here for weeks. I think I must have looked at every Weldanpower thread there is. Downloaded the manual for it, but I can't find anything that addresses my issue. Here's what I've done so far. Overhauled Briggs 16 hp engine. It runs good. Charges battery at about 13.5-14 volts.Cleaned slip rings, tension on brushes is good. Checked flashing diode, works as it should. Cleaned all the spade connectors on the circuit board. Auto idle works as it should. The problem is, I can only get about 86 vac out of the 120v recepts and about 146vac out of the 240v recepts with the voltage knob on 10. It will drop when I turn it it down. About 50vac and 50vdc O.C.V. out of the lead terminals. Now I can manually open the throttle and make it run wide open, then it will make full output 120 and 240 at the recepts, and about 80 on the leads, but I can only do that for a few seconds because it sounds like the engine is gonna eat itself. I mean it's screaming! I don't have a tach, but my guess would be about 4-5 grand, maybe more. Something's not right. It shouldn't have to rev that high. None of my two other generators rev that high to make voltage. I read in the manual about flashing the generator, but from what I understand, that's only required if it puts out no power at all. Is that correct? It has been idle for many years from what I know. Please tell me what my next move is. I haven't disconnected the capacitor bank yet and checked to see if they are within specs. It's a code 8928 if that helps. Nothing appears to be burnt, loose, or out of order. All my terminals have been cleaned. I tried to work things out for myself without bugging you guys, but I'm at a complete loss now. Thanks for any help in advance.
Reply:Well it could be one or more bad capacitors BUT it needs to run at 3600rpm (3750 no-load) for proper voltage output which does sound quite loud and fast.In the absence of a tachometer, for $20 you can use a Kill-A-Watt meter to measure the auxiliary output frequency which should be 62-62.5Hz no-load. You can pick one up at Home Depot, Lowes, Harbor Freight and likely a number of other sources.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:Thank you for your response Duane. I guess I will have to buy one of those. All my test instruments don't have a Hz readout. My concern is that this thing will throw a rod like it did to the p.o. when he got it to make correct power. My 8hp briggs generator doesn't need to be anything close to the speed this welder needs to be, nor does my Honda. Even when it's putting out low voltage, I still have to wind it up way too fast, atleast in my opinion. I mean it's screaming!!!! Probably close to 4-5k, just to get 86vac on the recepts. That is just a guess of course, but based on experience over the years with small engines. Actually, I don't even care if the aux power doesn't work. I've got generators for that purpose. I want it to weld, and I don't believe 50 O.C.V. is going to cut it. I'll take more tests and keep you posted. Thanks again.
Reply:Originally Posted by slowlaneThank you for your response Duane. I guess I will have to buy one of those. All my test instruments don't have a Hz readout. My concern is that this thing will throw a rod like it did to the p.o. when he got it to make correct power. My 8hp briggs generator doesn't need to be anything close to the speed this welder needs to be, nor does my Honda. Even when it's putting out low voltage, I still have to wind it up way too fast, atleast in my opinion. I mean it's screaming!!!! Probably close to 4-5k, just to get 86vac on the recepts. That is just a guess of course, but based on experience over the years with small engines. Actually, I don't even care if the aux power doesn't work. I've got generators for that purpose. I want it to weld, and I don't believe 50 O.C.V. is going to cut it. I'll take more tests and keep you posted. Thanks again.
Reply:O.k. guys, I have a welder! This morning I went back to basics. Pulled the plug and said to myself, self, this thing is running lean, very lean. I should have known better after all these years that 90% of problems are fuel. I had very little getting to the carb. Took the new paper inline filter off, went down and got a Briggs filter. The little red one with just the screen. Fuel went through it like it was scared. Must not of liked that paper one. The motor was just starving for fuel and I had to compensate by having the idle jacked up really high to get output. Idles great now. 115/230 on the aux. and 80 O.V.C. on the lugs. I haven't bought cables for it yet so I hooked up my heavy duty jumper cables. Clamped a rod in them and struck and arc. Sorry to bother you guys just because I was stupid and got ahead of my self, but thanks for your responses. I'm sure I will have more down the road. Here's some pics. Not sure exactly how to post them. Hope they came through. They're not very good, and I'm not quite done yet. Thanks again. Oh and if you're wondering about the beer can I used to cover the exhaust pipe, unfortunately yes, some beers were harmed in the making of this project. Attached ImagesLast edited by slowlane; 10-28-2015 at 04:56 PM.
Reply:Awesome!
Reply:Good News!Now, go make some sparks.Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:Glad you fixed the problem easily and the paint looks very good. That exhaust w/ the muffler hanging on it needs some support mounted on the engine, not the frame. Possibly a piece of angle iron bolted down w/ the head bolts and flat bar welded to it clamp to on the pipe out near the muffler. MikeOl' Stonebreaker "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Originally Posted by mla2ofusGlad you fixed the problem easily and the paint looks very good. That exhaust w/ the muffler hanging on it needs some support mounted on the engine, not the frame. Possibly a piece of angle iron bolted down w/ the head bolts and flat bar welded to it clamp to on the pipe out near the muffler. Mike
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