Arcon WORKHORSE 300S Operating Manual Download Page 1

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WORKHORSE 300S

Stick / Lift Start TIG P/N 010300

240V, 400V, 480V, 575V, Dual Voltage 240V/480V

OPERATING MANUAL

REVISED SEPTEMBER 2009

2203 Northwood Drive, Bldg.10 Salisbury, MD 21801

Phone: 410.572.6000 Toll Free: 888.512.7266 Fax: 410.572.6027

[email protected]

www.arconweld.com

Summary of Contents for WORKHORSE 300S

Page 1: ...P N 010300 240V 400V 480V 575V Dual Voltage 240V 480V OPERATING MANUAL REVISED SEPTEMBER 2009 2203 Northwood Drive Bldg 10 Salisbury MD 21801 Phone 410 572 6000 Toll Free 888 512 7266 Fax 410 572 6027 sales arconweld com www arconweld com ...

Page 2: ...S Model Numbers 010300 x5x 010301 x5x Conforms to the following standards Safety EN 60974 1 2002 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 Technical Contact Mike Bell ARCON Welding Equipment LLC 2203 Northwood Drive Bldg 10 Salisbury Maryland 21801 Fax 410 572 6027 Email mike arconwe...

Page 3: ...orse 300S Stick 1 Warhorse 2 Low Open Circuit Voltage 2 480V 010303 Workhorse 300S for Mining 7 Robot control 4 Digital Meter if not standard 3 240V 010310 Workhorse 300MS MIG Stick 9 Custom 5 CE Approved 4 240V 480V 010320 Workhorse 300ST TIG Stick 9 CE Approved Digital Meter 5 575V 010350 Ironhorse 300S Stick TIG 6 700V DC 101001 Studhorse 1000DM 101201 Studhorse 1200DM ...

Page 4: ...ling and Unpacking the Welder 11 3 2 Selecting a Location 12 3 3 Selecting Suitable Supply Cables 12 3 4 Connecting Input Power 12 3 5 Fuses Table 3 0 13 3 6 Output Connections 13 3 7 Front Panel Digital Meter Optional 13 4 OPERATION 4 1 General Description 14 4 2 Design Features 14 4 3 Controls and Settings 14 4 3 1 Circuit Breaker Power on Off 14 4 3 2 Thermostatically Controlled Cooling 14 4 3 ...

Page 5: ...ns 20 6 3 Block Diagram of the Inverter 21 6 4 Main Circuit Diagrams for Various Voltages 22 6 5 Front Panel 23 6 6 Rear Panel 24 6 7Chassis Plate Drawing 1 25 6 8 Chassis Plate Drawing 2 26 6 9 Inductor Plate Drawing 27 7 PARTS ACCESSORIES 7 1 Replacement Parts 28 7 2 Accessories 31 8 TROUBLE SHOOTING GUIDE 32 ...

Page 6: ...ard 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 Note Coatings used on circuit boards are not epoxy based thus allowing board components to be repaired...

Page 7: ...your new machine and is limited to defect in materials or 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...

Page 8: ... Operators 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 prot...

Page 9: ...ctors 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 source to provide heat for ...

Page 10: ...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 11: ...om the front of clothing 2 PRODUCT DESCRIPTION AND INFORMATION 2 1 INTRODUCTION TO THE WORKHORSE 300S The Stickweld 300S is a portable welder using an inverter type power supply to generate the output power The Stickweld 300S is primarily designed for stick welding SMAW It can also be used for TIG GTAW welding using the Lift Start principle as well as arc gouging and stud welding Use Range I when ...

Page 12: ...gree of Enclosure Protection IP 24 in accordance with ISO 60529 Protection against full penetration 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 befor...

Page 13: ...e standard power input cable for the Workhorse 300S welder is a high quality 10 gauge that is 12 5 feet long The secondary cables that connect the electrode holder or TIG torch vary in length according to needs but are normally 1 0 gauge 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 gauge and 25...

Page 14: ...nd ground clamps They are often current and use specific and customers should use care in determining 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 Front Panel Mounted Digital Meter optional The Digital Meter provides real time Voltage and Current switchable output ...

Page 15: ...rses unique SCR type inverter frequency Operators should rest assured that the sound is normal and not a defect 4 3 Controls and Settings 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 approximately 6 minut...

Page 16: ...cates power on off The power indicator will blink if any component is overheated Allow the welder to cool down This may take 3 minutes or more depending on which component is overheated The following components are temperature monitored Main Transformer If a 30 duty cycle is exceeded when drawing 400A output current the Main Transformer could overheat and shut down the welder If overheating occurs...

Page 17: ...50 2 60 300 1 150 1 0 60 300 150 200 2 0 4 3 11 Voltage Change Over The Voltage Change Over opening is located on the rear panel to the right of the input power cable Voltage change over is easily facilitated by inserting a flat blade screwdriver into the opening and rotating a quarter turn In the Low Voltage 240V setting the blade is horizontal and for the High Voltage 480V setting the blade is v...

Page 18: ...ltage the unit MUST BE TURNED OFF FOR AT LEAST 2 MINUTES This will give time for the capacitors to discharge The welder is equipped with a protection device to prevent an overvoltage condition If the unit is configured for 240V horizontal slot and connected to a 480V supply the circuit breaker switch will trip disconnecting the overvoltage DO NOT ALLOW THIS CONDITION TO BE REPEATED MORE THAN 10 TI...

Page 19: ... by the factory Do not permit untrained persons to inspect clean or repair The Workhorse Please call the factory for the location of the Authorized ARCON Service center nearest you Since there are no moving parts other than the fan in the power source basic preventive maintenance consists mainly of keeping the interior of the cabinet clean Periodically you should ask your Authorized Service Center...

Page 20: ...netic Interference from the inverter is supressed by two capacitors in paralell between phase and neutral These capacitors C 2 3 5 6 7 and 8 must be of type X to be allowed to be connected between phases and also to comply with the European community CE norms The type X capacitors are connected to a common point making it a virtual neutral This point is connected to safety ground via two type Y ca...

Page 21: ...0V 575V 400 amps 36V 29 Duty Cycle Three Range 1 10 180A Height 17 9 45 5 cm Phase 300 amps 32V 37 20 25 18 14 9 12 05 79 60 80 max 60 Duty Cycle 250 amps 28V 100 Duty Cycle Range 2 80 400A Width 10 5 26 7 cm Approx 80lbs Approx 85lbs 36 3 Kg 38 6 Kg Singe 200 amps 45 N A N A N A N A N A N A Depth 19 5 Phase 28V 49 5 cm 100 Duty Cycle Applicable to DUAL VOLTAGE 240V 480V based on selected voltage ...

Page 22: ...nverter Design The inverter function is perhaps easiest understood using the simplified block diagram below AC INPUT FIGURE 6 3 RECTIFIER INVERTER MAIN TRANSFORMER RECTIFIER OUTPUT FILTER CONTROL BOARD FAN CONTROLLER CIRCUIT AUXILIARY TRANSFORMER WELDING OUTPUT ...

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Page 29: ...S K 6 010551 001 PRINTED FRONT PANEL 300S 6 010551 041 PRINTED FRONT PNL DIGITAL METER 6 010551 908 PRINTED FRONT PANEL 300S K 7 010553 001 LAMP INDICATOR 10 010556 001 RANGE SWITCH 10 010556 002 RANGE SWITCH 240V DUAL VOLT 11 010557 002 MODE SWITCH 010558 001 VOLT SELECT SWITCH DUAL VOLT 010560 002 FRONT LOUVER 8 010570 001 WELD CURRENT ASSY 9 11 010575 001 MODE SWITCH ARC FORCE ASSY 13 010601 00...

Page 30: ...ECTIFIER CF ASSY 575V 76 011530 001 OUTPUT PCB 31 011540 001 SCR HEATSINK ASSY 31 011540 002 SCR HEATSINK ASSY 575V 41 011551 001 INPUT CAPACITOR w PTC 011620 001 DIGITAL METER FRONT PANEL 73 012210 001 REMOTE CONNECTOR ASSY METAL 73 012210 002 REMOTE CONNECTOR ASSY PLASTIC 013102 001 WARRANTY WARNING LABEL 43 015101 001 OUTPUT CAPACITOR w PTC 74 016002 001 CAPACITOR CHASSIS 42 016010 001 INPUT CA...

Page 31: ...01 005 POWER CABLE 12 AWG 5 COND 018001 008 POWER CABLE 10 AWG CE 50 018401 001 CIRCUIT BREAKER BRACKET 68 018500 001 OUTPUT JACK DINSE FOR PLASTIC 68 018500 005 OUTPUT JACK DINSE FOR METAL 68 018501 001 OUTPUT JACK TWECO FOR PLASTIC 68 018502 007 OUTPUT JACK TWECO FOR METAL 73 018704 101 REMOTE SEALING CAP PLASTIC 73 018704 102 REMOTE SEALING CAP METAL 019301 001 LOCATING INSULATING WASHER 019450...

Page 32: ...OR WA320 001 TIG TORCH 150A 25 AIR COOLED WA320 002 TIG TORCH 300A 25 AIR COOLED WA320 011 TORCH ACCESSORY KIT AK 2 WA320 012 TORCH ACCESSORY KIT AK 3 WA320 021 WORK CLAMP 200A w 15 2 CABLE WA320 031 REMOTE AMP FINGERTIP CTRL 27 WA320 032 REMOTE AMP FOOT CONTROL 25 WAP300 001 ELECTRODE HOLDER 300A WAP300 011 WORK CLAMP 300A WAP320 021 WORK CLAMP 200A WAP320 031 REMOTE CONNECTOR 14 PIN PLASTIC WAP3...

Page 33: ...uit breaker trips Incorrect input voltage Wire to correct 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 ...

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