Weldanpower low output, Damage?

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Weldanpower 225,code 9108 was a good running machine till today, I had it blocked on a cart, after not running much during the winter I started it to charge the battery, rolled it out of the garage and went to do something else. Cart rolled down a very slight incline about 15 feet and came to rest against a machine in the driveway.Machine slipped off 1 block and may have created a torque between the motor and generator. Although they are mounted rigid they will bind if you twist them. Anyway no change in motor tone but I saw sparks coming from the cabinet as indicated in the picture. May have run 15 or 20 seconds and I shut it down right away. removed cabinet but found no evidence of arcing or burning, no smell or damaged wires. slip rings were dark so I polished them up but machine had sat all winter anyway. It was also a damp day, but machine was not wet. Restarted fine and motor sounds fine but now on max. settings I only have 20 AC volts at the 115 receptacles, 52 AC at the 220 plugs and on the terminals I only get 29.8 DC volts.  I have not checked the brushes much as they are quite hard to get at on this machine with my big hands.Turning the motor by hand it feels smooth with no binding.The impact likely was very easy just causing the machine to shift off it's blocks. No more improvised carts, I should know better. Any thoughts of what to check first? Also I don't think the sparks came from the louvered vent, but from between the cabinet joint, seems strange I know. Attached Images"Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:From the voltages you've listed it sounds as though the rotor is only getting battery voltage to the brushes.  You're going to have to check for AC exciter voltage at the exciter bridge rectifier D2 wires #4 and #5.  If AC voltage at D2, check for DC voltage at D2 wires #200 (+) and #201 (-).  If no DC voltage, bridge rectifier D2 is failed.Check the above and post what you find.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:Duane,Looks like the roll and crash may have been incidental, found that lead #4 had been rubbing on the corner of the stator frame support and had arced completely opening the wire. Repaired the wire with solder and shrink wrap. Now the check you asked me to make gave me the following. #4 to #5 , 9 volts AC.    wires 201- to 200+  showed 4 volts DC.  Any furter test?  Would that # 4 shorting to ground take out any component in particular? Thanks."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:Do you know how to check bridge rectifier D2?  Sounds like one of its diodes has failed as aresult of the direct AC short on #4.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:Duane, no I don't but my son said something about diodes might be bad on the Bridge Rectifier and that he has a diode tester. He is more knowledgeable about electronics than I am, don't tell him I said so though,LOL. He is almost 20 and has good exposure to electonics and electric motors. He also said you can build your own Bridge if it is bad, don't know if that is a good Idea. If you don't mind , give me the procedure if it isn't to complicated and you have the time. Is that and expensive part, and question also if it is available. Might be able to solder in a new diode.   Well it's mid Sunday afternoon, Think I will take my wife out somewhere, check back this evening. Thanks.Last edited by kolot; 05-01-2011 at 02:22 PM."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:Easier for you to look at this rather than me describe it.Bridge Rectifier Testing.pdfUnit you're looking for will look like the one in the test example.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, will make checks tonight, also check for a PM."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:Duane , my meter shares the diode test mode with the continuity check mode together. I don't know if it matters but my numbers come up with out a decimal point, In the pdf. it shows normal range .200-.900 my meters shows infinity when it should and all numericals are 519 and 520 range but no decimal points. Is that correct or am I way to high. It is like this for all four checks.If Ok then my bridge is OK. any further ideas? Thank You."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:I'm a little more than concerned about that 9VAC reading between #4 and #5.Did you check resistance between them disconnected from the bridge rectifier?  Should be very little if the exciter windings are OK and not damaged from the direct short.Did you check field flashing fuse F1 and diode D3 for being open?Did you try flashing the field with battery voltage to the brushes?  (+) to #219 / (-) to #201MM200 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:Duane, I completed all the checks you suggested, everything checked out OK, so the last effort was a re flash and it seems to have cured the problem. Now I will let it set for a week and try it again. If it holds it should be OK. Glad it is up and running again and no major components were taken out. Thanks again."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400