SA200 help request

[DD-YATES]

I have finished putting together a redface round barrel 200 and I'm getting a perfectly running and tuned engine and nothing at the welding or power end. I have performed the following tests;

1) Generator shunt winding test. I got 40 ohms
2) Exciter shunt/series test. I got .5 on series and 175.5 on shunts
3) Checked volts at receptacle. nada
4) Checked volts at exciter terminals. nada
5) Checked OCV's at ouputs. nada
6) Pulled exciter armature (26A), replaced it with another (26A), still nothing.
7) Performed armature 3 step test to verify both armatures were good. Both are good.
8) Main series coils have continuity between them and the range selector.
9) Brushes have been contoured and seated.
10) Cleaned all commutators.
11) Flashed exciter 5 times. Flashed the other one 5 more times.
12) Output studs not shorted to frame.

Main armature? What else do you think it could be?

Another issue I'm not understanding is the test on page F-16, paragraph 11.

I have performed this test on multiple machines before and the meter read nothing on all of them. I tried all the different ohm setting on the meter and nada. I tried 4 different meters even. I don't know if this is some kind of errata or I'm just not doing it right. I did this test on perfectly running and welding machines and still got no ohm reading at all. Simply each of the four wires and to ground, right? If someone could clarify this for me I'd appreciate that too. But three machines, one of them welding like a charm all give the same results.

Thank you.

[smithdoor]

On any generator most it is bugs have form a insulation between the brush and rings.
I will clean that part and works again.

Dave

I have finished putting together a redface round barrel 200 and I'm getting a perfectly running and tuned engine and nothing at the welding or power end. I have performed the following tests;

1) Generator shunt winding test. I got 40 ohms
2) Exciter shunt/series test. I got .5 on series and 175.5 on shunts
3) Checked volts at receptacle. nada
4) Checked volts at exciter terminals. nada
5) Checked OCV's at ouputs. nada
6) Pulled exciter armature (26A), replaced it with another (26A), still nothing.
7) Performed armature 3 step test to verify both armatures were good. Both are good.
8) Main series coils have continuity between them and the range selector.
9) Brushes have been contoured and seated.

Main armature? What else do you think it could be?

Another issue I'm not understanding is the test on page F-16, paragraph 11.

I have performed this test on multiple machines before and the meter read nothing on all of them. I tried all the different ohm setting on the meter and nada. I tried 4 different meters even. I don't know if this is some kind of errata or I'm just not doing it right. I did this test on perfectly running and welding machines and still got no ohm reading at all. Simply each of the four wires and to ground, right? If someone could clarify this for me I'd appreciate that too. But three machines, one of them welding like a charm all give the same results.

Thank you.

[DD-YATES]

On any generator most it is bugs have form a insulation between the brush and rings.
I will clean that part and works again.

Dave

I forgot to mention that I did clean the commutators, main and exciter. That's what you meant right?

[smithdoor]

Next look for burned wire and connections. It can be a loss connection too.
They all can test good on a VOM but when power applied it does not work.

Dave

I forgot to mention that I did clean the commutators, main and exciter. That's what you meant right?

[DD-YATES]

Next look for burned wire and connections. It can be a loss connection too.
They all can test good on a VOM but when power applied it does not work.

Dave

Dont see any on the outside. I guess at some point I'll pull the front panel and exciter housing so I can peer inside the genny better. I think I'm going to have to pull it all apart anyway.

[rexcormack]

I am only vaguely familiar with engine drives.
I can tell you that you are getting exactly what paragraph 11 expects.
Paragraph 11 is expecting MORE than 500,000 ohms.
If you meter is reading __._ or OL or ∞ all of those mean more than 500,000.
There are a couple guys on here that are really good with these and they will probably chime in later this evening.

Good luck.

[Oldiron2]

I am only vaguely familiar with engine drives.
I can tell you that you are getting exactly what paragraph 11 expects.
Paragraph 11 is expecting MORE than 500,000 ohms.
If you meter is reading __._ or OL or ∞ all of those mean more than 500,000.
There are a couple guys on here that are really good with these and they will probably chime in later this evening.

Good luck.

Rex is correct. As long as the resistance reading is above 500K, it complies with what the manual wants. The manual implies that, if the resistance were less, current could 'bleed off' wherever the short is and the following wouldn't happen.
Some generators are supposed to retain a slight amount of magnetization in the armature and when turned, it produce a small current in other windings. Some of the generated current is fed back to the armature winding, increasing its magnetic field, causing its rotation to increase the current induced in the outer windings, this having a cascading effect until eventually a regulating system controls the armature current and thus the maximum output of the unit.

"Flashing" is running current through the armature to create a magnetic field, some of which is supposed to re-magnetize the core.

I can't suggest what is wrong, but if you understand how this all works, careful examination should show where something isn't connecting properly, or something else is wrong.

[DD-YATES]

Okay we got the paragraph 11 figured out. thanks for clarifying that. I checked all wiring and cabling on top of it. So what else do ya'll think it could be?

[guajilloweld03]

Have you tried weldmarts trouble shóoting guide.

http://www.weldmart.com/main/technical/index.html

[duaneb55]

With the test results you listed in your opening post my guess is something isn't wired up correctly.