SA200 Breaking Arc

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Course control on lowest setting (first gear) and fine control between 68 to 78 it will break arc, set above 80 and up no problem.1990 SA 200Miller 225  Rip Miller302Miller 135Lincoln 200 MigHypertherm 600 PlasmaPlasma Cam Cutting TableMikita Cold SawJL Welding Tx . com
Reply:What rod?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:Sorry about that, 5P+, 5P, fleetweld180 which is a 6011. I have not tryed a 7018. It just started doing this about three days ago, I thought it was just me then I payed close attention and started lighty draging a 5p+ and noticed it.1990 SA 200Miller 225  Rip Miller302Miller 135Lincoln 200 MigHypertherm 600 PlasmaPlasma Cam Cutting TableMikita Cold SawJL Welding Tx . com
Reply:Should have asked what size?So this just started?  If so, check for stuck brushes, weak springs, dirty commutator, etc.How does how you're operating compare to this:http://www.lincolnelectric.com/asset...oln3/im109.pdfMM200 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 cleaned the commulator with a stone and pushed in on the brushes and they did not seem to be stuck. Should I have pulled brushes and clean the face of the brush? Anyway it still cuts out, nothing changed. And it does do it with 7018, all 1/8 inch rods. When it cuts out it does break completey and fire right back up. A buddy of mine, who knows it all- just ask him- says shunt coils.This is a 1990 modle, never been into untill I cleaned the brushes, I dont know if that meas anything. 2009 hr.Last edited by JLWelding; 10-30-2011 at 01:54 PM.1990 SA 200Miller 225  Rip Miller302Miller 135Lincoln 200 MigHypertherm 600 PlasmaPlasma Cam Cutting TableMikita Cold SawJL Welding Tx . com
Reply:I've fixed arc breaks in the past by fixing my welding leads and their connections.  A bad lead or a bad connection can do that for sure.One time I found out it was a remote control cable.  It was old and burned up (black and brittle).  A new cable fixed my arc break problem.I've had old rheostats cause arc breaks.  Sometimes I could lightly clean and sand the wires and the little brush and fix them, but a cracked ceramic or worn wire-wrap means a new one. lolBrushes can do it too and I always fix them with water.  I like to take a 16oz plastic water bottle and using my knife puncture a small hole in the cap.  With the engine running I squirt water onto the brushes.  What I want to see is the commutator turn black with carbon from the brush.  If it doesn't seem to want to turn black then I usually put a small load on the machine while I'm squirting water.  I like to use the smallest load I can and on a 200 in good shape I'd want to use MIN and 10 and not for very long if I could.  Yea, I've been in a hurry before and on some pretty junky machines with glazed brushes and used 200 and 50, but I wouldn't do that on my machine I wouldn't think.  A dead short isn't good on any welder, but to cut the glaze off of badly glazed brushes some load is usually necessary.  You can use a armature stick to first remove the glaze then use the water to seat them.  this usually makes the process not require being loaded.Sticking brushes is usually easy to find.  Pull the spring off then slide the brush up and down in it's holder.  If it doesn't move very freely then there usually is carbon buildup on the sides of either the brush or the holder.  This needs to be cleaned off.  All brushes should be very free to move up and down.  A little crud and make it stick and sometimes enough to break arc.Later manGood luck
Reply:Not knowing much about the inners of welders or anything electrical, is any of this work/maintenance ever needed on a welder like my Commander? I only read about this when it comes to the SA's."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:A.F.A.I.K a Commander is what I call a transformer machine which means to me it will never need such work done to it.  A generator DC welder like the SA200 has brushes so yes they will. lolGood luck man
Reply:I'm sorry for my incorrect assumption above.  After glancing at the schematic of the Commander I see it as a:  3Phase rectified direct power machine which contains some form of the more famous lincoln chopper board (IGBT's) (lol - insulated gate bipolar switching transistor).To me, at a quick glance,  the schematic looks kinda similar to a Vantage. Good luck manLast edited by slowhand; 11-01-2011 at 08:47 PM.
Reply:Originally Posted by slowhandI'm sorry for my incorrect assumption above.  After glancing at the schematic of the Commander I see it as a:  3Phase rectified direct power machine which contains some form of the more famous lincoln chopper board (IGBT's) (lol - insulated gate bipolar switching transistor).To me, at a quick glance,  the schematic looks kinda similar to a Vantage. Good luck man
Reply:I looked at the AUX fields on the schematic last night but I don't remember now if it too was 3phase or not.My 3phase comment above is about the welder end only.  It is a 3phase A/C generator putting out probably 32VAC (my rough guess  ).  This generator makes welding current (amps) at whatever the rated output of the machine is.I don't figure this machine has the downhill pipe mode like the vantage does.  I'd guess at least CC (maybe labeled Stick???).  I don't know.It should weld fine I'm imagine by looking at the schematic.  My guess is that the arc is between 18k-28k hertz (depending on the heat setting), so the arc should be quite smooth.   And for structural I'd say its a good machine with a smooth arc.  And its heat is consistent.Good luck man
Reply:Actually it does have downhill pipe mode.  Commander 500, Code 10599, Model K-1639-1.I haven't really had too much time on it since I got it. There are a couple of questions I have and I'd also like to know more about the pipe mode. If ya don't mind, I would like to send you a PM maybe tomorrow. Thanks, and sorry to JLWelding for the hijack."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
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