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24

6.3 Block Diagram of The Inverter

The Principle Of The Inverter Design

The inverter function is perhaps easiest understood using the simplified block diagram below.

AC INPUT

FIGURE 6

RECTIFIER

INVERTER

MAIN

TRANSFORMER

RECTIFIER

OUTPUT

FILTER

CONTROL

BOARD

TIME/CURRENT

CONTROLLED

FAN

AUXILIARY

TRANSFORMER

WELDING

OUTPUT

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Summary of Contents for 10310

Page 1: ...alisbury Md 21801 USA Tel 410 572 6000 Toll Free 888 512 7266 Fax 410 572 6027 sales arconweld com www arconweld com WORKHORSE 300MS MIG Stick P N 010310 240V 400V 480V 575V Dual Voltage 240 480V OPERATING MANUAL REVISED MARCH 2009 ...

Page 2: ...accordance with ISO 60529 This product is in conformity with the requirements of the Low Voltage Directive 73 23 EEC and Machinery directive 89 392 EEC 91 368 EEC 93C 133 04 93 68 EEC Compliance verified by Goran Hedberg Design Engineer Technical contact Mike Bell Product Engineering 2203 Northwood Drive Bldg 10 Salisbury MD 21801 410 572 6000 Fax 410 572 6027 mike arconweld com For further detail...

Page 3: ... and Unpacking the Welder 11 3 2 Selecting a Location 12 3 3 Selecting Suitable Supply Cables 12 3 4 Connecting the Power 12 3 5 Fuses 13 3 6 Output Connections 13 3 7 Connection to the Wire Feeder 13 3 8 Remote Pin Configuration 15 3 9 Front Panel mounted Digital Meter 15 4 OPERATION 4 1 General Description 16 4 2 Design Features 16 4 3 Controls and Settings 16 4 3 1 Circuit Breaker Power on Off ...

Page 4: ...uct Specifications 23 6 3 Block Diagram of The Inverter 24 6 4 Main Control Board 25 6 5 Main Circuit Diagram 26 6 6 Front Panel 27 6 7 Rear Panel 28 6 8 Chassis Plate Drawing 1 with Part Number Reference 29 6 9 Chassis Plate Drawing 2 with Part Number Reference 30 6 10 Inductor Plate Drawing with Part Number Reference 31 7 PARTS ACCESSORIES 7 1 Replacement Parts 32 7 2 Accessories 34 8 TROUBLESHO...

Page 5: ...r workmanship The original purchaser must furnish notice of defect or failure to ARCON Welding Equipment or one of Arcon s authorized repair centers using an approved Warranty Claim Form Forms can be downloaded from the company Web Site at http www arconweld com The guarantee against corrosion related failures can be extended to five years by completing the Registration Form Any equipment that has...

Page 6: ...tput board encapsulated in repair friendly material to eliminate the failures Control board coated to protect against salt water arc over Input board coated to protect components from corrosion Resistors replaced with porcelain coated ceramic resistors Fan motor totally encapsulated winding coil to withstand corrosive conditions Terminal screws coated to prevent electrical arc overs This anti corr...

Page 7: ...ators must take caution in the method and manner of handling or using the machine when this symbol is displayed 1 2 Safety Precautions Do not install operate or repair The Workhorse welding equipment without reading this manual and all safety precautions stated within This machine was designed and built with operator safety in mind but safety begins with you Every effort has been made to protect t...

Page 8: ...isconnect input power conductors from de energized supply line before moving a welding power source 9 Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded 10 Turn OFF welding power source before servicing unless the procedure specifically requires an energized unit 11 Never use the power ...

Page 9: ...coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire Make certain that such openings are protected from hot sparks and metal 1 7 ELECTRIC AND MAGNETIC FIELDS Electric current flowing through any conductor causes localized Electro Magnetic Fields EMF Welding and cutting current creates EMF around welding cable...

Page 10: ...d from the front of clothing 2 PRODUCT DESCRIPTION AND INFORMATION 2 1 INTRODUCTION TO THE WORKHORSE MIGweld 300MS The MIGweld 300MS is a portable welder using an inverter type power supply to generate the output power The MIGweld 300MS is primarily designed for MIG welding GMAW It can also be used for SMAW Stickwelding as well as arc gouging and stud welding with a controller Use Range I when sti...

Page 11: ... of solid foreign objects of 12 5mm diameter and larger Protection against harmful effects from splashing water against the enclosure from any direction 3 INSTALLATION WARNING Only qualified personnel should perform this installation Turn the input power off at the disconnect switch or fuse box before working on The Workhorse Migweld 300MS Do not touch electrically hot parts This section provides ...

Page 12: ...rse 300MS welder is a high quality 14 gauge that is 12 5 feet long The secondary cables for arc welding vary in length according to needs but are normally 1 0 diameter and 25 feet in length Heavier 2 0 gauge cables can be used to extend the distance between the machine and work surface Standard ground cables are 1 0 in diameter and 25 feet in length Work cables automatic wire feeders and gas relat...

Page 13: ...etermining the accessories that they will require Always consult the manuals or instructions provided with these accessories to ensure safe use and that the connections are properly made 3 7 CONNECTION TO THE WIRE FEEDER The MIGweld power source uses the same type of Amphenol 14 pin connector that Miller and several other manufacturers are using today The pin locations are marked with letters to a...

Page 14: ...R SECTION 3 7 The schematic diagram to the right illustrates how the typical wire feeder should be connected to the remote plug for either 24 Volts or 115 Volts depending on the power requirement for the wire feeder ...

Page 15: ... Supply may optionally replace the 24V AC Supply This is an option from the manufacturer and can also be converted by a qualified repair technician 3 9 Front Panel mounted Digital Meter The Digital Meter provides real time Voltage and Current switchable output readings The front panel meter can be switched into two modes by pressing the black mode button 1 Output Voltage of the welder in real time...

Page 16: ...inverter frequency Operators should rest assured that the sound is normal and not a defect 4 3 Controls and Settings Front and Rear Panels See Figure 4 4 3 1 Circuit Breaker Power On Off The Circuit Breaker is located on the control panel at the rear of the machine Move the switch lever up to the ON position to start the machine This also activates the Thermostat controlled Cooling Fan for approxi...

Page 17: ... In SMAW the lower settings are designed for minimum arc force with the higher settings set for maximum arc force NOTE The process selection switch must be in GMAW short mode for the short arc puddle control to be operative The puddle control can be adjusted while the unit is under load Use the puddle control to adjust the weld puddle characteristics you desire to suit your application Typically t...

Page 18: ...tor If welding at 250 Amps for more than 30 minutes without stopping the Main Inductor will overheat and shut down the welder If this occurs wait 7 8 minutes before restarting Output Capacitor When welding at the lower current settings in Range 2 or when arc gouging for long periods the Output Capacitor may overheat and shut down the welder If this occurs wait 10 minutes before restarting The temp...

Page 19: ...er into the opening and rotating a quarter turn In the Low Vorlage 240V setting the blade is horizontal and for the Hight Voltage 480V setting the blade is vertical See 4 5 Dual Voltage Changeover for additional information FIGURE 4 RANGE SWITCH 4 3 3 POWER ON INDICATOR 4 3 8 PROCESS CONTROL STICK SHORT ARC MIG SPRAY MIG 4 3 7 WELD POWER 4 3 4 ARC FORCE PUDDLE CONTROL 4 3 5 CIRCUIT BREAKER POWER O...

Page 20: ...ade close the main wall disconnect switch or circuit breaker Place the primary power selector in the ON position This will turn on the control circuitry The Power On light on the front panel will be lit Turn the Mode Selector in the Stick position The welding output will be energized and the electrode holder will become electrically hot Turn the Arc Force Control Selector in its mid position Adjus...

Page 21: ...welder Have a certified repair facility perform all maintenance and repairs that require opening the case If The Workhorse 300MS does not operate properly stop work immediately and investigate the cause of the malfunction Please note Opening up the case voids the Factory Warranty Maintenance should only be performed by an authorized ARCON Service Center or by the factory Do not permit untrained pe...

Page 22: ...werful current surges by R7 withstanding surges of up to 40 000 Amps EMI Electro Magnetic Interference The Electro Magnetic Interference from the inverter is supressed by two capacitors in paralell between phase and neutral These capacitors C2 C3 C5 C6 C7 and C8 must be of type X to be allowed to be connected between phases and also to comply with European CE norms The X capacitors are connected t...

Page 23: ...00 575 Three 300 amps Height 17 9 Phase 32V Range 1 40 28 33 23 14 9 12 05 79 60 45 5 cm 60 Duty Cycle 30 180 200 amps 28V 100 duty cycle Range 2 80 400 80 max Width 10 5 Approx 80lbs Approx 85lbs 26 7 cm 36 3 Kg 38 6 Kg Single 200 amps 50 NA NA NA NA NA NA Depth 19 5 Phase 28V 49 5 cm 100 Duty Cycle 240V 480V DUAL VOLTAGE 240V 400V 480V 575V SINGLE VOLTAGE Use with 208V power may result in reduce...

Page 24: ...erter Design The inverter function is perhaps easiest understood using the simplified block diagram below AC INPUT FIGURE 6 RECTIFIER INVERTER MAIN TRANSFORMER RECTIFIER OUTPUT FILTER CONTROL BOARD TIME CURRENT CONTROLLED FAN AUXILIARY TRANSFORMER WELDING OUTPUT ...

Page 25: ...inductor the fan and the output capacitor J4 monitors the temperature inside the input capacitor The PTC Positive Temperature Coefficient sensors are all connected in a serial daisy chain The resistance of each sensor at room temperature is approx 100 ohms When the PTC sensor reaches its nominal temperature its resistance value very quickly increases from 100 ohms to 2000 ohms When the total resis...

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Page 32: ... 7 010553 001 LAMP INDICATOR 010554 001 POTENTIOMETER 5K 010555 011 POTENTIOMETER DUAL 10K 10K 10 010556 001 RANGE SWITCH 1 DECK 10 010556 002 RANGE SWITCH 240V DUAL VOLT 11 010557 002 MODE SWITCH 3 POSITION 3 DECK 010558 001 VOLT SELECT SWITCH DUAL VOLT 010560 002 FRONT LOUVER 13 010601 001 BOOT CIRCUIT BREAKER WEATHER 14 011210 001 INDUCTOR CHASSIS 15 011215 001 FAN ASSY 17 011216 001 FAN BLADE ...

Page 33: ...551 001 INPUT CAPACITOR w PTC 011620 001 DIGITAL METER PCB FRONT PANEL 72 012210 003 REMOTE CONNECTOR ASSY MIG 013102 001 WARRANTY WARNING LABEL 43 015101 001 OUTPUT CAPACITOR w PTC 74 016002 001 CAPACITOR CHASSIS 74 016002 012 CAPACITOR CHASSIS CE 41 016010 001 INPUT CAPACITOR 800uF 44 016020 001 OUTPUT CAPACITOR 1500uF 77 016201 001 RESISTOR 40 OHM CENTER TAPPED 016202 001 SURGE RESISTOR 0 15 OH...

Page 34: ...OUTPUT JACK TWECO FOR METAL 018704 102 REMOTE SEALING CAP METAL 019052 001 SHIELD FOR CONTROL PCB CE 019301 001 WASHER INSULATING LOCATING 019450 001 MOV SHORTING BAR 575V WARHORSE 019900 002 STRAIN RELIEF 019900 102 STRAIN RELIEF NUT 7 2 ACCESSORIES REF NUMBER DESCRIPTION NOTE WA300 001 ELECTRODE HOLDER w 25 2 0 CABLE WA300 011 WORK CLAMP w 25 2 0 CABLE WA300 021 REMOTE AMP HAND CONTROL WA300 031...

Page 35: ...DE HOLDER 300A WAP300 011 WORK CLAMP 300A WAP310 001 RING TERMINAL 1 0 2 0 WAP310 011 REMOTE CONNECTOR 5 PIN WAP310 012 REMOTE CONNECTOR 3 PIN WAP310 013 REMOTE CONNECTOR 14 PIN WF200R WIRE FEEDER 24V 2 ROLL WF200R 42 WIRE FEEDER 42V 2 ROLL WF200R 115 WIRE FEEDER 115V 2 ROLL WF400R WIRE FEEDER 24V 4 ROLL WF400R 42 WIRE FEEDER 42V 4 ROLL WF400R 115 WIRE FEEDER 115V 4 ROLL WFG350 MIG GUN 350A WFR U2...

Page 36: ...ect input voltage Connect to proper input voltage for the machine Reset the breaker Output is lower than normal Phase missing in input wiring Cables damaged or the wrong gauge wire Check and tighten input wiring connections Check length size and condition of cables Replace as necessary Cooling fan stops after the machine has been idle for six minutes The Power Indicator Lamp starts flashing while ...

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