Lincoln AC-225 DOA?

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I bought a new-in-box AC-225 from an estate sale, never been used and all parts were still in their original, sealed plastic bags.I added a 240VAC50A outlet to my garage workshop strung with armoured 6/3 and tested, showing two hots at 120VAC each with one ground. When I was ready to test it I clamped two pieces of scrap together, clamped the workpiece, set the amps to 150, put in a 6011 rod into the stinger, turned the power switch upward to on, and there was no noise, no strike, no arc, no nuthin' but silence.The breaker was on, and I've checked all power levels with a meter to show that the lines were definitely hot. I  pulled out the AC-225's power plug just enough to confirm with the meter that the blades were also hot. My next step was to take the cover off the AC-225. This unit is one of the newer aluminum ones. I measured the proper 120VAC going to the power switch terminals, but when I turned the power switch on again the fan still remained off and the machine was dead silent.So, is there anything I should be checking further or doing differently, or is this one DOA?
Reply:make sure you get 240 volts across the power switch. with the switch on the fan should run.When testing 240 volts circuits it is best to measure hot to hot and not hot to ground.If you read 120 to ground on both hots, you could get a zero reading across the hots. Because they are coming from the same side buss in your breaker box.some times you can get the same reading because you have an open line and a 40 device is plugged in. you are reading the same voltage through the other device.You can do an ohm check from the power cord hot pins. See a low ohm reading come and go with the power switch. If that is good. Just get 240 power to it.
Reply:If you are lucky the total lack of response will be something simple that's not letting the power in to the machine in the first place. I've had a couple of those welders over the years and we could not make them quit no matter what.I guess I would start at the switch to be sure power is getting to it and then out of it. With nothing at all happening, I would be looking there very closely.Tom Hintz, publisherwww.newmetalworker.comLincoln Pro Mig 180Lincoln AC 255Determination
Reply:Thanks guys - I just came back in from my shop after I tested everything for continuity with my multimeter and it all checks out fine (power switch, fan, windings). This unit is a virgin, so everything is clean and shiny inside so it would be easy to see any electrical problems - none to be seen.   I'll follow up on the power line advice to make sure this box is fed properly.
Reply:"I added a 240VAC50A outlet to my garage workshop strung with armoured 6/3 and tested, showing two hots at 120VAC each with one ground"but do you have 240 BETWEEN the hots? (perhaps they are on the same leg)-- fredLincoln 180C MIG
Reply:Nope, there is no voltage difference between the hots. I must be using the wrong type of breaker then, right? It's a 50A breaker with 2 switches in one housing that takes up 2 slots...
Reply:are alternating bus bar positions showing 240 v ?? sounds like your breaker is correct,  is there a fuse (vs breaker) feeding panel?  a fuse could be blown. the other buss could be seeing voltage coming through a 240 load. Are there any other 240v loads fed from that panel??maybe panel was only fed with 110v?? ( how many wires are feeding the panel??)if you had a 3phase panel being used on single phase, someone could have tied the 3rd phase to one of the others, in that case shift your breaker up or down one position.  you would see a jumper where the panel is fed I would think.  is a strange one. If you arn't comfortable working in the panel with power on, I would seek qualified help!how about pictures of panel??fredLast edited by fredf; 10-28-2010 at 10:39 PM.-- fredLincoln 180C MIG
Reply:Id go to Lowes and buy a new one and try it out.. If it works then put your dead one in the box and return it... Used to work there and if a welder is returned for any reason they would throw it in the compactor....
Reply:It's a 48-space Federal Pioneer Stab-lok panel with 240VAC/200A service. The breakers run off a central bus in either the left or right direction. I have a ton of empty spaces.Our electric range runs at 240 through a 40A 2-slot breaker and the clothes dryer runs at 240 through a 30A 2-slot. All other circuits are 120VAC each except for my welder breaker at 50A.I'll take some photos in the morning and put them up.
Reply:Here are some photos of my service panel and the voltage readings I'm seeing. Originally Posted by ccawgcmake sure you get 240 volts across the power switch. with the switch on the fan should run.When testing 240 volts circuits it is best to measure hot to hot and not hot to ground.If you read 120 to ground on both hots, you could get a zero reading across the hots. Because they are coming from the same side buss in your breaker box
Reply:You may have to relocate your welder breaker to the top of the stack.  Your 245v reading is from the leg the breaker is connected to and the leg the meter probe is touching.  Move the probe up one slot and you should see 0v.  More importantly, what is the reading between the red and black leads on the breaker?  0v is my guess.See how your range and dryer breakers are down 1/2 a slot due to the single breaker above them?  They're seeing voltage from each leg whereas both sides of your welder breaker is connected to the same leg.  Box may be designed to only accept 220 breakers at the top of the bussbar as it looks like the double unit won't fit down lower as it would have to drop down 1/2 slot.At least that's how it appears to me.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:When I read Federal Pioneer I knew what was wrong. DuaneB is right, move the breaker down 1/2 slot and you will be good to go! That's why I don't use any thing but SquareD and in a total emergency GE. They are ALMOST fool proof.
Reply:Oh, and by foolproof I was referring to ME not you!
Reply:Yep, it was exactly what you said it was - I moved the breaker down a half slot and the problem is fixed so now I have a brand new AC-225 that just came to life for the very first time... gotta go do some welds. Thanks for all your help with this. Now I understand all those meter readings I got. Cheers!