Weldanpower 225 charging and battery problems

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Hello all.....I am not a professional welder but I do enjoy building my own things and having excuse to aquire more tools.   I have a cracker box which is the work horse thus far(simple/stupid) and a miller mig 225.  About a year ago I was given a code 8927 B&S machine...for free.  It did not have a carburator.  I replaced the carb, air cleaner housing, cleaned the fuel tank, and put a clear oversized fuel filter on it.  It runs fine on high and low idle.  All the receptacles work.  It welds(I only tried around 90a).  It will idle fine.  It idles up and down while applying loads ok but seems a little slow to react, maybe that is normal?  I have a new muffler from tractor supply that I hope will work on it.  I almost found Utopia except for one problem I cant seem find in the search function here.  Charging and a ground short killing the battery.If you leave the battery connected it will be dead by morning.  I put a test light between the battery ground and ground wire and it lights up like a spot light.  A meter shows a solid 12.1v.  During operation it does not charge.  It only reads battery voltage(12.1v).  When I connect a battery charger to the connected battery the circuit board that is labeled battery charger(m-13531?) immediately heats up and cooks.  It has signs of getting really hot, ie black marks.  Any ideas?It is a very clean machine from what I can tell.  The worst was mud dobbers and a rat nest. No dings, no drips, nothing cosmetically obvious that would point to an ill treated machine.  I am into this thing about $475 thus far.  The circuit board in question seems to be available reconditioned and new($70-$150) but after reading some of the threads I'm getting the idea that it may not be as simple as "replace the circuit board."   Any thoughts?Thanks in advanceSwhite
Reply:This circuit board is the one heating up.  Anyone have any ideas why?S Attached ImagesLast edited by swhite832; 02-06-2011 at 06:49 PM.
Reply:A pic of the machine Attached Images
Reply:Find wires 4 and 5 going to the battery charger board. They should have 25 to 50 volts AC on it with the engine running. Can't tell from the diagram what that voltage is. only that it could be 1/2 of the 115 VAC plug power. The diagram shows the AC power goes through a resister then into the pcb to an SCR. The resister sets the voltage and the SCR controls the current.Comes out of the pcb to the AMP meter and then to the battery.With the battery disconnected. Check the wires into the charger pcb. Ohm meter test to groundOnly wire 5 should be shorted to ground. Because it is a ground wire. Measure wire 208 to 206 they should read open to very high resistance.If you need a diagram. Go the Lincolns web site and ask for one.You can down load the owners manual. just enter the code number and get the one for your welder. The diagram in it will be real close to your unit.They do not republish the owners manuals just because they make a change to the welder. They paste the correct one inside the welder and will send you a new one if you ask for it.
Reply:Thanks for the info!!!!Finally had a chance to poke and prod the thing.  Battery was dead so i was unable to test voltage but....every wire going to the battery charging circuit board was shorted to ground.  Every one!So, I am assuming the board is bad and should be replaced.  Not a problem if the board self destructed but I would hate to replace the board the have the new one fry due to "some other" cause.Any ideas?
Reply:Well if you don't already have it, you can download the unit manual here http://www.lincolnelectric.com/asset...oln3/im308.pdf that ccawgc referred to where you can find the applicable wiring diagram showing the Battery Charger board on manual page 24 (file page 26).  The individual component values are a little hard to make out but the folks in Lincoln Customer Service should be able to clarify what the specifics are as needed.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 sent those guys a message via their website.  I did not get a response.  If the weather is bad I'll call them tomorrow.  I have downloaded the manual and have my magnifying glass ready.  Not that will mean anything to me.  Diagnosing this type of stuff is not my best suit.  I know nothing about resistors and capacitors.  I know what they do but not how they work in relation to "the big picture"Thanks
Reply:Talked to lincoln techs, "replace circuit board" was there suggestion.  We shall see.
Reply:PM sent.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:Blue wire 208 will be grounded if the run switch is in run. Switch it to stop and see if that short goes away. Red wire 4 will have to be disconnected from the pcb. If wire not shorted when disconnected and terminal is still shorted. A 1 amp diode on the pc board is shorted.Buy a 10 pack of 2 amp 1000v diodes and replace all the diodes on the pcb. Then retest.If you are lucky the scr is ok if not replace the scr.Price a new pcb. this will tell you if it worth you time to try to repair it.
Reply:The run switch was prolly on when I tested it.  I already replaced the board.  My local supply house happened to have one in stock.  So i jumped on it to get this off "the list"  It came with that 4" ceramic doohicky as well.  Before I fire it up I'll run those diagnostics you mentioned again.  Talking to the tech he was fairly certain that nothing would cause the issues I was having with the exception of a shorted winding.  Seeing how the generator outlets and welder ran fine he ruled that out.  I'm still a little leary about frying this board due to something else but he didnt believe anything else in the machine could hurt it.  Most likely it was something external like human stupidity.
Reply:Replaced the battery charger circuit board and problem appears to be solved.
Reply:Very nice, hairy mice, cheese and rice!!Looks just mine.. Where did you get the board, just so I know...?Lincoln Power MIG 210 MP ( boat anchor )Lincoln Weld-Pac 100 HDHobart IronMan 230Cutmaster 42Jackson NexGenSumner Ultra ClampsDWM120
Reply:lincoln still carries them.
Reply:Originally Posted by swhite832lincoln still carries them.