Weldanpowerf 225d7 idle

admin

Hi all, I have a weldanpower 225g7 code 9444 that got a little while back, I have another post http://weldingweb.com/vbb/showthread.php?t=41764  about some of the problems on this but have seemed to have everything going except one issue and that is that the low idle speed should be at 2150-2300 rpm but if I set below about 2400 the idle will kick up and down and the idle solenoid does lose the 12v at wires 213 & 215 and the cr2 contact switch kicks out as it would go if you stick or use ac power. I can set idle down some after it warms up good to about 2300. Engine runs perfect All works good except that, high idle is about 3650 with 67v open circuit and 123v ac at 61 hertz and battery voltage is between 13.75 and 14 at low idle although my amp guage never shows much charge and tried a couple of different guages. I suppose this  not a big deal just would like to get it right and less noise at lower idle. Would appreciate any ideas on this.
Reply:HI, Just hav some new things I found on this, the voltage to the idle solenoid is only about 10.5 volts and have checked the ground to the board and is good, The wires 7 & 8 have weld voltage and have checked all connections and voltage to board and seem good, Another strange thing is that my amp gauge does show a charge when welding but that is the only time it does.Ac use don't do it, The battery voltage is up some when running as if charging but amp guage won't show it till you are welding. Also the idle delay don't always work.I think it is the board, Any other ideas?
Reply:HI all, Just for an update on this I had my circuit board redone again and resolved all the problems except the idle problem, It still will not stay at low idle if the idle is set at 2200 rpm and the strange problem that the amp guage won't show a charge unless I am welding. It does usually have over 13 volts at the battery. If anyone has any ideas I would appreciate it. ThanksLast edited by RRWITTER; 07-02-2010 at 09:56 AM.
Reply:Hi just another update, I got a different board and solved all problem except the battery charger which is the same, It still will show charge when welding dc although the voltage only comes up about .25 volts. I can't seem to find what the problem is on that issue. I know it does not charge as much as it should although it does slowly bring up the charge some. I would appreciate any help. Duane if you see this would appreciate your input and ideas on it. Thanks
Reply:You stated in your previous post that the battery usually has over 13V at the battery.  What exactly are you looking for in the rhelm of voltage above 12.5-13V?Does the battery not stay charged enough to start the unit?  If this is the case, I would have the battery load tested to get an idea as to its condition.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:Thanks for the reply, I have tried a different battery which is almost new, At this point just a few minutes ago the battery voltage was 11.98 volts not running and I ran it for about 30 minutes and the voltag came up to about 12.15 volts. The mystery to me is why the amp gauge comes up to about 20 amps when welding dc, wont' do that on ac weld or using ac power or on high idle by using the high idle switch. When I am welding the battery voltage only increases about .20 volts. Thanks again
Reply:So the amp gauge jumps up to read a 20A charge but the battery voltage only increases ~.2V and only when welding DC?  Sounds like an it may be an induced current that is somehow making the ammeter 'think' it has a higher charge rate passing thru it than it actually does.Is there a weld output cable inside the unit passing anywhere near the ammeter leads or battery cables?  The output cable would have to be after the rectifier or AC/DC mode selector switch.  It would have to run parallel with another wire for at least some distance.Just thinking outside the box a little here as stranger things have happened and I'm coming up empty otherwise.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:I  have looked at that and don't see anything close to it that should affect it other than than the rectifier board itself which is of course where it should be. I have replace all of the resistors and the bridge rectifiers d2 & d3 and have checked all the connections good and as I say inovat is last one to do the board and they sent a different board than I had so we Would know if it was a strange problem there. It is a mystery to them also. I replaced two of the main rectifier diodes as they checked somewhat different than the other two and the cable that went to the stator had been a little hot. It was the two diodes in the front that I replaced. I think that I have checked all that I know how to do and have learned guite alot but can't figure this one out. The Idle problem I refered too before is ok now and welds good and ac is good. The only other thing I'm not sure about is I have checked ocv at low idle and the dc is about 37 volts but I can put my meter on ac voltage and it shows about 17 volt ac. Any other Ideas?