Arcon IRONHORSE 300S Operating Instructions Manual Download

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300

Northwood Drive

Salisbury MD 21801

Tel: 410 572.6000 Fax: 410 572.6027

www.arconweld.com

[email protected]

IRONHORSE

300S 700V DC

P/N 010350-006

OPERATING MANUAL

Summary of Contents for IRONHORSE 300S

Page 1: ...2300 Northwood Drive Salisbury MD 21801 Tel 410 572 6000 Fax 410 572 6027 www arconweld com sales arconweld com IRONHORSE 300S 700V DC P N 010350 006 OPERATING MANUAL ...

Page 2: ...ns 10 3 Operation 11 3 1 Controls and Settings 11 3 1 1 Circuit Breaker Power on Off 11 3 1 2 Thermostatically Controlled Cooling 11 3 1 3 Range Switch 11 3 1 4 Weld Power 11 3 1 5 Arc Force 11 3 1 6 Process Switch 12 3 1 7 Power On Indicator 12 3 1 8 Remote Control Connector not used 3 1 9 Input Power Cord 12 3 1 10 Output Teminals 12 Cable size table Table 3 0 12 Process Control Selector Figure ...

Page 3: ...aced immediately Warranty Repairs are carried out by ARCON Welding LLC or its Authorized Repair Center The Ironhorse or any of its parts must not be altered without the prior written approval of ARCON Welding LLC Any malfunction which results from improper use faulty maintenance physical damage unapproved repair or alteration shall be the sole responsibility of the user or owner and any repair req...

Page 4: ...0 700V DC 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 stickwelding when possible The first range produces a softer arc than that of Range 2 See Paragraph 3 1 3 The Ironhorse operates on DC input voltage 500V to 800V DC The DC input voltage is connected to a circuit brea...

Page 5: ...t with the work pieces and the ground Basic Setup Procedure 1 Be sure the power breaker on back of welder is OFF 2 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 3 Hook up welding cables to welder 4 Attach ground GND cable to the work to be welded 5 Attach the Power GND cable to the GND ra...

Page 6: ...r metal to be welded to a good electrical earth ground 10 Keep the electrode holder work clamp welding cable and welding machine in good and safe work condition Replace damaged insulation and frayed cables 11 Never dip the electrode in water for cooling 1 2 ARC RAYS 1 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or while...

Page 7: ...he work piece which might produce flammable or toxic vapors Do not weld on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard 6 After the welding is completed inspect the work area to make certain there are no hot sparks or hot metal which c...

Page 8: ...ng operations Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal 3 Wear flameproof type gloves heavy long sleeve shirt cuff less trousers and a welding helmet or cap for hair protection to protect against arc rays and hot sparks or hot metal A flameproof apron may also be desirable as protection against radiated heat and sparks 4 Hot spar...

Page 9: ... for damage which may have occurred in transit After removing the components from the shipping container s check the container for any loose parts Remove all packing materials b Check air passages of power source for any packing materials that may obstruct airflow through the welder c If the equipment is not being installed immediately store it in a clean dry well ventilated area until installatio...

Page 10: ... two 5ft long single conductors The positive has red bands and will be connected to a third rail clamp or a catenary pole The negative will be connected to an alligator clamp 2 3 OUTPUT CONNECTIONS The standard supplied output connector types are female Dinse DIX Welders may be supplied with optional Tweco connectors as a special order ...

Page 11: ...ed the fan will continue to run and stop after approximately six minutes 3 1 3 Weld Current Range Selector Two different settings 10 180 Amps and 80 400 Amps are available Each setting defines a specific range of output current for the welder 3 1 4 Welding Power Control This continuous control is used to adjust the welding current from minimum to maximum value depending on the setting of the Weld ...

Page 12: ...If a 30 duty cycle is exceeded when drawing 400Amps output current the Main Transformer could overheat and shut down the welder If overheating occurs wait 1 minute before restarting This condition can also occur if a 60 duty cycle is exceeded when drawing 300 Amps output Wait 3 minutes before restarting Main Inductor If welding at 250 Amps for more than 30 minutes without stopping the Main Inducto...

Page 13: ...50 1 0 60 300 150 200 2 0 TABLE 3 0 FIGURE 3 1 Similar model used for illustration purposes RANGE SWITCH 3 1 3 POWER ON INDICATOR 3 1 7 PROCESS SWITCH STICK LIFT START TIG 3 1 6 WELD POWER 3 1 4 ARC FORCE 3 1 5 CIRCUIT BREAKER POWER ON OFF 3 1 1 OUTPUT TERMINALS 3 1 10 INPUT POWER CORD 25 FT 8 2m LONG 3 1 9 THERMOSTAT CONTROLLED VENTILATION 3 1 2 ...

Page 14: ...wer On light on the front panel will be lit 3 Put the Mode Selector in the Stick position The welding output will be energized and the electrode holder will become electrically hot 4 Put the Arc Force Control Selector in its mid position 5 Adjust the Weld Power Control to fit the type and diameter of electrode to be used as recommended by the electrode manufacturer ...

Page 15: ...by the facvtory Do not permit untrained persons to inspect clean or repair The Ironhorse 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 16: ...ble Primary Current Amps Amp Circuit Rated Load Output KW Eff Dimensions Input 60 Duty Cycle Range Voltage DC Net Ship 500 V 600V 700V 400 amps 36V 29 Duty Cycle Range 1 20A 10V 180A TIG 10 180 Height 17 9 45 5 cm DC 300A 32V 80 max 28 23 20 12 05 79 60 Width 10 5 95lb 105lb 500 to 60 Duty Cycle Range 2 26 7 cm 43Kg 47 7Kg 800 V 30 400 250 amps 28V 100 Duty Cycle Depth 19 5 49 5 cm ...

Page 17: ...ction is perhaps easiest understood using the simplified circuit diagram below DC INPUT FIGURE 5 2 AUXILIARY CONVERTER INVERTER MAIN TRANSFORMER RECTIFIER OUTPUT FILTER CONTROL BOARD TEMPERATURE CONTROLLED FAN AUXILIARY TRANSFORMER WELDING OUTPUT ...

Page 18: ...5 3 Main Circuit Diagram ...

Page 19: ...5 4 Front Panel 19 ...

Page 20: ...5 5 Rear Panel 20 ...

Page 21: ...5 6 1 Bottom Chassis Drawing with Part Number Reference ...

Page 22: ...5 6 2 Top Chassis Drawing with Part Number Reference 22 ...

Page 23: ...5 6 3 Inductor Plate Drawing with Part Number Reference 23 ...

Page 24: ...14 011215 001 FAN MOTOR ASSY WITH BRACKETS 15 011217 001 BRACKET FAN REAR 16 011216 001 FAN BLADE 17 011220 001 INDUCTOR OUTPUT 18 011230 001 INDUCTOR MAIN w PTC 19 011240 001 INDUCTOR COMMUTATING FRONT 20 011250 001 INDUCTOR COMMUTATING REAR 21 011270 113 TRANSFORMER AUXILIARY 23 011300 001 SHUNT 24 010420 004 ASSY REAR PNL DC Input 25 019900 002 STRAIN RELIEF 26 019900 102 NUT FOR STRAIN RELIEF ...

Page 25: ...2 001 CHASSIS CAPACITOR 74 011530 001 CIRCUIT BOARD OUTPUT ASSY 76 016201 001 RESISTOR POWER 40 OHM CENTER TAPPED 77 010520 001 PANEL REAR METAL 4 5 46 010401 020 CASE BOTTOM PAINTED YELLOW 010402 020 CASE TOP PAINTED YELLOW 010403 001 HANDLE BASE FOR TOP CASE 010404 001 HANDLE GRIP FOR TOP CASE 010410 002 CASE TOP ASSY IRONHORSE W HANDLES 010530 001 COVER NO REMOTE 011200 003 INDUCTOR PLATE ASSY ...

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