Winpower Arc Welder User manual

x?!t
W INPOWER CORPORATION
175 AMP Dm Cm
PART I BELT AND PULLEY
Preliminary 'Check
1. Check for broken belt.
2.
check for .slipping belt or slipping
pulley.
If the belt or a1:crnator pulley is slipping, the
arc will start strong and die away as the alter-
nator-slows down.
It will be noticeable at high
amp settings. The belt should be tight and have
very little "give" when checked by hand after re-
moving the belt screen. (Fig.
1-1)
Caution - Replace screen before starting the
welder engine.
Note - The belt will burn (melt) and be ruined
if allowed to slip for any length of time.
Pulle-; Alignment and Belt Tension
If belt breaks, turns over or jumps out of the
grooves after a short period of time, or does not
last when replaced, THERE IS SO?!ETHING WRONG WITH
EITHER THE ALIGWENT OR THE TENSION OF THE BELT.
It will do no good to replace the belt without
correcting the problem.
SYMPTOMS PROBABLE CAUSE
7--
Belt burns, melts or has
small cracks on inside. Belt too loose.
Belt breaks with clean break. Belt too tight.
Belt breaks along one edge, Belt not in
jumps out of'groove or turns alignment or too
over in groove. tight.
Burr on Pulley
CORRECT BELT ALIGNMENT AND PROPER TENSION is cru-
cial to belt life. ELARE SURE BELT IS ALIGNED.
The belt should be checked for tightness after a
few hours of operation of a new machine.
Belt Adjustment
Remove belt screen (Fig. 1-1). CAUTION: Replace
screen before starting the welder engine. Loosen
the nut located between the belt and the belt
tension hole
(Fig. 1-2). Insert a screwdriver
through the belt tension hole and pry up on the
spacer behind the nut previously loosened. While
maintaining tension tighten the nut loosened above.
Check the pulley alignment, making sure the top
and bcttom pulleys are parallel and straight.
Check the belt tension. The belt should be
tight so that there
is very little give when
flexed by hand.
FIG. I

Pulley Removal
To remove the alternator pulley, remove the nut
and lockwasher, apply even pressure to the pulley
with a screwdriver and heat with a propane torch
_
until the Loctite loosens and the pulley will
slip off.
Note: Trying to remove the pulley without heat
will damage it. Both alternator and engine pulley
must have Loctite to keep them from slipping.
Use high strength Loctite, Cat. No. 271-41. Use
instructions supplied with the Loctite.
To remove the engine pulley, clean the shaft of
dirt and rust in front of the pulley, apply pres-
sure to the pulley with a wheel puller and a~ply
heat to the pulley until the Loctite loosens and
the pulley will slip off.
Note: Trying to re-
move with
a wheel puller without heat xi11 bed
the pulley.
PART I1 DETER4INE THE FAILIYC UWIT
Engine Lugs Down
If the engine powering a Winpower welder "lugs down"
this indicates an engine problem,
not a welder
problem. The problem
is simply that the welder
is calling for more power than the engine can
supply and the
RRl's drop. If a lugging condi-
tion occurs, more output can be obtained by turn-
ing the current adjustment knob
down to a lower
setting so the engine RP?I1s do not drop.
NOTE: A drop in output and engine lug can occur
because of an uncuned or worn engine, high
alti-
tude or extreaely hot days that cause a reduction
in engine power. (There
is a 1I drop for each 10
degrees
F above 60 degrees F and a 3% drop for
each 1000 feet above sea level. Contact engine
manufacturer for further details.)
Lov Open Circuit Vnltage-
The open circuit voltage will be low if the en-
gine
is not running Pull speed (3600 RPPl's).
Measure the open circuit voltage at the weldizg
receptacles with the engise running full speed,
not welding, no accessory power being used, and
the current adjustment knob setting at 175 amns.
Three Circuits
The alternator on the Winpower welder has three
separate circuits.
1. Control Circuit
2. Welder Circuit
3. Accessory Circl~it
All three of these circuits have their own indi-
vidual winding and are not connected electrically
to each other.
-.
Exciter Check
If the unit is completely dead, suspect excitation
problems, especially
.if :he unit hns heen sitting
unused for a long time. Check the exciter wire
connection at the engine and insure the exciter
wire
is not loose, broken or shorted to the frame.
The welder should be running full speed with the
knob setting at 17%.
Voltage Check to determine failing circuit
By using the following procedure and examples be-
fore removing the shroud, the failing circuit can
normally be determined
(i.z. welder, accessory,
or control). If the welder comes to you removed
from thc engine and no ex?lanation of the problem,
the checkout procedure in later parts of this book
will still Find the problem.
IT the welder is puttin:; out anytlling at all, mea-
sllrc the I1.C. onen circuit voltage of both the
r~elderand accessory. iiieldrr should be approxi-
mately 70 V.D.C. and the accessory should be about
125 V.11.C. >leasure with knob set at maximum amps.
SEFOHE C!IECKIXC VOLTAGE TO DETEY.ITNE FAILISG UNIT
iiAKE SURE PKOBLM IS HOT LO:.' ENGINE PGVER, LOW
ENGINE RPM's, OR EXCITER PROBLEM.
Examnle I Unit conpletely dead, no welder or
accessory voltzge. Problem is in the
control circuit.
Examnle 2 Low voltage outnut. The maximum open
--
circuit voltage welder is measured at
45 volts, (should he 70), and maximum
open circuit voltage accessory is 74
volts, (should be 125). Tlie problem
is in the control circuit.
Exanple 3 Low current outpuc . !laximum weider
--
open circuit voltage is 73, (o.k.),
and maximumaccessory open circuit
voLtage is 122 (0.k.). Again, pro-
blem
is in thc control circuit.
Example 4 No welder output. Welder own circuit
voltage zero (should be
70). Accessory
open circuit voltage 120 (0.k.). Pro-
blem
is in the welder circuit.
Sxample 5 Low welder output. Yaximl~mwelder open
circuit voltage is 48 (should be 70).
Xaximum accessory open circuit voltage
is 120 (0.k.). Problem is not in the
control circuit, but in the welder
circuit.
Example 6 No accessory output. Welder open cir-
cuit voltage 70 (0.k.). Accessory open
circuit voltage zero (should be 125).
Problem is in accessory circuit.
Example 7 Low accessory output. Welder open cir-
cuit voltage is 74 (0.k.). Accessory
open circuit voltage
is 80 (should be
125). Problem
is not in the concrol
circuit but is in accessory circuit.
Note - If problem is in the accessory circuit;
-
check the 4 fuses (1 on panel and 3 under thc
sllroud). Tlli. fl~scsaffect only the L20V accessory.

PART I11 CONTROL CIRCUIT MINTENANCE Ccrnponent T'esting
General
The control Circuit provides current to the rotor
(through the brushes), to provide a rotating elec-
tromagnet (rotor) which in combination with the
Stator (winding) generates
its own control cur-
rent. The control current
is generated in the
control winding, rectified to D.C. by the control
diodes, adjusted by the rheostat, filtered by
the capacitor and used by the rotor.
A failure in the control circuit will affect both
the welder and 120 Volt accessory output equally.
Since the control circuit has the most components
and wires, a majority of failures will be in the
control circuit.
All of the 4 fuses in the ma-
chine have to do with accessorv circuit and have
nothing to do with the welder output or co11trol.
The only instrument needed to check out the ma-
chine
is a Multimeter with an Ohmmeter. (RX1
scale). Do not start the engine while ciircking
the welder.
Exciter Wire
Initial excitation is accomplished by a
positive going pulse taken off the engine
magneto. This electrical pulse travels
along the yellow wire connected below
the engine carburetor, through the
brushes and returns by way of the ground
wire between the frame and the engine.
Either wire being broken can be determined
by checking between terminal
1 on the
control board (Fig.
3) and alternator
ground with the ohmmeter. The reading
should show a short (about 1/2 ohm) with
the wires connected to the engine.
Control Circuit Component Isolation
Brushes and Rotor (P. 10, Ref. 109 & 105)
Before the testing begins, the components must be
isolated so that "back circuits" will not give
erroneous readings. This
is done by taking the Check with an ohmmeter (Rxl) for a reading of
following steps:
4 to 20 ohms between the white brush wire
1. Take top shroud off the welder unit
(P. 7 Ref. 8).
2. Disconnect the rotor, control windings
and the capacitor by removing and
separating the two diodes, the two
white wires, and the bare wire from
ter~tinal 4 on the control circuit
board (P. 9 Ref. 90).
3. Disconnect the red and green control
grcund wires from the housing (P. 10.
Ref. 107).
disconnected from terminal 4 and ground. If
the reading
is bad, the problem is inside the
alternator in the brush area. After removing
the back housing from the alternator, check
the rotor for approximately
4 ohms, check the
brush area for problems.
NOTE: To service brushes or check rotor, do not
remove fans or release belt tension. Remove the
four screws holding the back housing and remove
the housing. CAUTION: Do not lose the two springs
which
will come 04: from behind the brushes.
These springs
MUST NOT BE LEFT INSIDE THE
ALTERNATOR. Insert a pin (paper clip) under the
brushes to hold the brushes and springs in place
while re-installing the brush block. Let the
pin come out the hole in the alternator back.
NO'TE: Reiaove pin after re-assembung
.
yellow I ,,, 4' white
TO EKGINE L/1
1
# 2 CONTROL
green orange
white
6fl
blue orange
red
FIG. 2 CONTROL CIhCUIT SC

Control Windine
The only thing that normaily happens to a winding
is for the wire to break or short to ground. Check
with the Ohmmeter
(MI) to make sure there is a
short, (about 112 ohm) between terminal
2
and 3 (Fig. 3). Check for an open circuit
(infinite ohms) between terminal
2 and the
alternator housing. If these readings
are correct the control windings are good.
NOTE: Winding must be isolated fro* ground or
incorrect reading will result. See instructions
above under
"CONTROL CTRCU IT C(\?IPoNENT ISOLATION."
Capacitor (p. 9, Ref. 89)
Touch the ohmmeter leads (MI] to ground
and the bare capacitor wire which was
removed from terminal
4 in step 2 of the
control circuit component isolation.
hten first touched the ohmmeter pointer
should flick as thc capacitor charges and
then returns to a high resistance reading.
Reverse the leads and the pointer should
'flick' again.
NOTE:
~hzcapacitor can fail while the engine is
running due to a breakdown when voltage is applied
and still test normal with the ohmmeter. This
will
cause hard to analyze problems with the welder. IF
THE CAPACITOR IS SUSPECTED, TEST IT BY REPUCE-
WENT. tllso intermittent problems can be caused by
the faulty capacitor. for instance the machine
will work when cold but fade out when hot.
NOTE: If the capacitor is not isolated (see in-
structions above), incorrect reading will resvlt.
Diodes (Control) (P. 9, Ref. 80)
.
Check each diode (3) on the control board for
high resistance one way and low resistance with
the leads reversed.
NOTE: Diodes must be isolated or incorrect read-
-
ings will result.
Rheostat (P. 9 Ref. 87)
With the ohmmeter leads (RYl) between terminal 4
and 5, (Fig. 31, turn the control knob from
maximum to minimum. The ohmmeter reading
should vary with the knob setting from
0 to 6
ohms.
If the control circuit checks O.K. or when the
problem
is found and corrected then reconnect
the two diodes, the two white wires, and the
bare capacitor wire to terninal
4 of :he
control diode board, and reconnect the red
and green controi ground wires to the
alternator housing.
;f2 CCNTROL
1 oronge
yellow
1
CAPACITOR
white orange
BRUSHES
FIG. 3 CCtNThOL DlOLE BOAKL

PART IV WELDER CIRCUIT MAINTENANCE
General
The welder circuit provides the D. C. welding cur-
rent and consists of a 3-phase winding and a full
wave, 3-phase rectifier.
Welder Circuit Check (Fig.
4)
1. Check diodes with ohmmeter (Rxl) by touch-
ing the wire ends and the corresponding heat sink
(P. 9 Ref. 71 & 73). The ohmmeter reading should
read high resistance one way and low resistance
with leads reversed.
2. Check welder windings at insulating terminals
for infinite reading to alternator housing and
make sure they are shorted one to another (RX1).
If a diode opens (not very likely) the open cir-
cuit voltage (should be approximately 70V) will
be reduced. The welder output will also be re-
duced. The accessory voltage will be normal.
(Approx. 125) .
Main Diode Change
1. Remove the #16 fuse wire by melting the solder
and unwrapping
it with needle-nose pliers.
2.
Screw out the faulty diode with an 11/16
socket.
3. Screw in the new diode, being careful not to
damage
it.
Replace the #16 fuse wire and
check with an ohmmeter after completing.
Component Isolation
Note that because of back circuits through the
main winding, checking one diode at a time
is not
possible. Normally there
is no need to unsolder
or disconnect the diodes to check them. A shorted
diode, which
is the normal way the diodes fail,
will cause all the welder current to go into one
phase of the winding and damage the fuse wire.
The burned wire will indicate the bad diode.
CAUTION: If a fuse wire
is burned be sure to
change the bad diode or the fuse wire will burn
open again.
FIG. 4 WELD CIRCUIT SCHEMATIC

PART V ACCESSORY CIRCUIT MAINTENANCE
General
The accessory circuit has its own separate 3-
phase winding which is rectified to.,DC by the
accessory diodes
(P. 9, Ref. 91). The winding is
fused on the inside of the machine to prevent
an external short (If the 15 anp fuse
(P. 9 Ref.
80) has been bypassed) from damaging the accessory
winding.
Accessory Circuit Testing (Fig. 5)
1. Isolate accessory circuit by removing the
three 15 amp Ecses (P. 9, Ref. 91) and the 15
amp fuse on :he faceplate (P. 9 Ref. 80).
XOTE - If there is a short'to the alternator
-
housing or an open between two leads, check the
winding 'visually' for a loose wire, and repair
if possible. If the short
is inside the winding,
the winding must be replaced.
'NOTE - WIXDING XUST BE ISOLATED FROX GROUND BY
-
RNOVING THE THREE FUSES OR INCORRECT
READING WILL RESULT.
3.
Check diodes with ohmmeter for high resis-
tance one way, low resistance with leads
reversed. (Fig.
6).
4.
Check accessory circuit wiring from access-.
ory circuit board to fuse and receptacle
(P. 9, Ref. 91, 80, b 92).
2. Check accessory winding on the winding side
of the three Fuse holders to make sure the
three leads from the alternator are shorted
to each other and do not read to ground.
- black
15 A
ACCESSORY 15 A
f \ 0
black
47 Kn
f ',
4 1
black
white
FIG. 5 ACCESSORY CIRCUIT SCtiEMATI C
FUSE BLOCK
TO FAC
FUSE
EFtATE
HOLDER
-
black
TO LOW SIDE
EPTAC
FIG. 6 ACCESSORY DIODE BOARD

REF.
1.
2.
3.
4.
5.
6.
7.
DEsCSLP1Trn
PA. - ii 5
Belt ,- ;4,-'/3 'L
screw-*& (12) fi-if 5-3
kk Washer (12)
" ' ''
--
Flat Washer (12)
2% - ;( 5 3
Screen, Belt - /a 7
Right ,+, d 5 ?
PART NO. REF. DESCRLPTIOP~ PART NO.
2356 8. ~opshrd )t,.-il&l .- 2293
1024 9.
Left shroud h .- ,is -< 2291
1970 10.
Welder Unit (Ref. to other figures
0975 -
>q-t/ k -r-
2040 for breakdown. )
2030 11. Pulley, Engine
- r;, .- i 1 L- L"
2312 12. Key fi -/I.' 1210 fi -/f b'
2292 Not Shm:
Briggs & Stratton 11 HP Ehgine 1124
IV - /' '

REF.
DESmON PNiT ItJ. REF.
-
kt, ~lternator &-t fi- li7' 2210 41.
Lock Washer, Shaft fie- 1' ? 1560 42.
Adley, Alternator PA -IJ '# 1266 43.
Fan h-ir73
1627 44.
spacer /\--"GL
1695 45.
~ut,Alternator bhting m-l/B i 2180 . so.
Lock Washer p., 4/
2110 51.
Nut, Spacer
~q - I 1 2 '{
2453 53.
~ltemator htf4-l 1 6 2281 54.
Bolt, Alternator Momting fi- '/'
1901
Bracket, Insulated Tee1 fh- !iqd
2443
H ~rme fld11?~/ 2335
slnxhmmt, Small 17- !'
4 3
1370
Shdmt:Large )l -
1t-7~
1371
Lock Washer (12) ,m -- "4 2100
Nut (12) yyll?~ 2170
q.,
blt, mgine &mt- (2) 1%- '! 1877
~olt, Qine kting(2) pt - :!" . 1875

71. Fat
Sink Assembly - Pos. 19 -it/ 6
Positive Diode (6) $7 - i f
72. Fhenolic Insulator j? -( 7'
73. Heat sink ~ssa~lbly-~eg. J/ik .
Negative Diode (6)
i5 .-i/ ; 6
@. Faceplate n -
,;?;-I
80 Fuseholder /r? - i /.2
Fuse
Fuseholder Cap
82. Rheostat Locknut fq -.i( 22
84. Rheostat Knob fl --/I2 LJ
PART NO. REF. DESCRIPTION
Weldiw Plus (2)
Weldkg Receptacle
Rheostat
y7 - it/ Ci
ClmJ
Capacitor
Control Cir.
M. Asm.
Diode (3)
Accessory Cir.
Bd. Am.
Fuseblock - 1% -//c ''
Fuse (3)
Diode (6)
Accessory Receptacle

REF. DESCilPTION
101. Alternator Housing,, Drive End
102. Bearing, Drive Ehd
103. F&tainer Screws (3) n, - 1
104. Spacer m.-lmq
/
105. Rotor '/M-io4 '
1.06. ~lt,Alternator (4) fi "
PART tD. REF. DESCRZTON PART NO.
. .
. )C!!
,,ck
1635 0' ' 107. Alternator Housing, Slip liin~ End 1631
,4,.
~590~-"f08. me, & .YG)-/T)C 3580
1663 109.
Brush Itit Assembly I!: -! 9 16L5
i696 110. Screw, Bwh Folder (2) VM-~G~' 1946
1677
%her, flat (2) 1935
1866
111. Winding 1)1 - J Dd7 2646