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Thread: miller AEAD 200LE electrical short Help

  1. #1
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    miller AEAD 200LE electrical short Help

    I recently acquired an AEAD 200LE engine driven welder and got it running descently. The engine runs fine, and it welded great during testing. So I cleaned it up and fixed the sheet metal on it and put it back together. I went to weld today and I couldn't get spark. When I glanced over at the front panel I noticed something glowing behind the louvers. So I shut down and removed the covers and found that the fine amperage control rheostat had shorted... may not have had it on 100% . The coil melted at about the 90% range of the scale. After looking around and scanning for a reason, I noticed that the one of the 180w 12 ohm resistor ( R4 i beleive) right under it was hot. I did notice that the grounding wire under the resistor was stuck/melted to the bottom of the R4 resistor. Could that have been the reason it was shorted and burned the rheostat... or is it just age/corrosion getting the best of the machine? Or is this part of a bigger problem? Any help or process diagnosis would be helpful. I have just purchased a new rheostat, but I don't want to put it on and fire up without checking to see if there is something else wrong. Can anyone tell me if there are any points to check before installing the rheostat to check the machine out?

    This machine welded really well (sadly better than my bobcat 225) in the beginning and barely made spark after cleaning it up.... So I really want to get this machine repaired and figure this out so I can leave the machine around our farm for quick repairs.



    Serial# HJ179340
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  2. #2
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    Re: miller AEAD 200LE electrical short Help

    clear the short and repair the damage. replace the rheostat. Next time run it with covers off and check for heating before it melts. when all working good, then put the covers on.

  3. #3
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    Oct 2011
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    Jacksonville Florida
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    Re: miller AEAD 200LE electrical short Help

    I had the same problem with my aead200le.
    Fine amperage rheostat had a bad spot so I replaced it.
    While I was looking at the machine I noticed both resistors clamps were rusted and broken.
    I replaced those and fired the machine up and everything was fine.
    I don't know for sure that the resistors caused the rheostat to burn through a wire but I haven't had any other issues.
    I would definitely look at the clamps and clean or replace them.

    I think I put the resistor clamp part number in my thread about the machine. I'll try to add it here in a min
    Airco Ac/Dc 300 Heliwelder
    MillerMatic 200 (stolen)
    Miller Maxstar 150STL
    Miller AEAD200LE (welding and generating power)
    Hobart MIG

  4. #4
    Join Date
    Oct 2011
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    Jacksonville Florida
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    Re: miller AEAD 200LE electrical short Help

    https://weldingweb.com/vbb/threads/7...ead200le/page2
    That's where I posted the part number for the resistor clamps.
    Airco Ac/Dc 300 Heliwelder
    MillerMatic 200 (stolen)
    Miller Maxstar 150STL
    Miller AEAD200LE (welding and generating power)
    Hobart MIG

  5. #5
    Join Date
    Mar 2018
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    Re: miller AEAD 200LE electrical short Help

    Here just simple

    https://www.alliedelec.com/product/o...15re/70022546/

    https://www.bing.com/shop?q=rheostat...OPTB&PC=EMMX01
    They still made today.

    Dave


    Quote Originally Posted by adilger1 View Post
    I recently acquired an AEAD 200LE engine driven welder and got it running descently. The engine runs fine, and it welded great during testing. So I cleaned it up and fixed the sheet metal on it and put it back together. I went to weld today and I couldn't get spark. When I glanced over at the front panel I noticed something glowing behind the louvers. So I shut down and removed the covers and found that the fine amperage control rheostat had shorted... may not have had it on 100% . The coil melted at about the 90% range of the scale. After looking around and scanning for a reason, I noticed that the one of the 180w 12 ohm resistor ( R4 i beleive) right under it was hot. I did notice that the grounding wire under the resistor was stuck/melted to the bottom of the R4 resistor. Could that have been the reason it was shorted and burned the rheostat... or is it just age/corrosion getting the best of the machine? Or is this part of a bigger problem? Any help or process diagnosis would be helpful. I have just purchased a new rheostat, but I don't want to put it on and fire up without checking to see if there is something else wrong. Can anyone tell me if there are any points to check before installing the rheostat to check the machine out?

    This machine welded really well (sadly better than my bobcat 225) in the beginning and barely made spark after cleaning it up.... So I really want to get this machine repaired and figure this out so I can leave the machine around our farm for quick repairs.



    Serial# HJ179340

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