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Seeking powcon 300se pcb schematics

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  • lars66
    replied
    Originally posted by 1997CST View Post
    Miller either copied or purchased the design from Powcon for their early XMT 300.s. They even had the same case design, 2 piece with nuts and bolts holding them together in the middle. I haven't seen or worked on either in about 20 years. I thought all of them had expired by now.
    Still have a working 300SM that was purchased as a demo unit in 1985.

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  • Aeronca41
    replied
    Fantastic! Thank you, Jon!

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  • jjohn76
    replied
    Aero, Red-d-Arc has the service manual for the EX300, which is the same as the XMT 304.

    https://www.red-d-arc.com/equipment-resources.aspx

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  • Aeronca41
    replied
    Well, I guess I won't print any out. I was going on the assumption that there might be some board schematics in the very earliest XMT or Dynasty manuals, but I didn't find any. If anyone has a control board schematic for one of these older machines, I would sure like to find a way to get a copy.

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  • Aeronca41
    replied
    Thanks, Jon--good info. I'll print a few out to take along. Just been studying the Powcon diagrams; not a lot to be seen there. Printing out the Spectrum 2050 info now.

    Now, if I can just make the potty stops over 350 miles without getting COVID!

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  • jjohn76
    replied
    Sounds good. I have never taken the time to draw out the schematic for the control boards on these. It probably won't be for a while, but looking to do it sometime. The 300SE uses IGBTs, so the control circuit would look more like what you would see in the XMT of Dynasty DX control board schematics.

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  • Aeronca41
    replied
    Well, I've gathered up my tools, test equipment, and what data I have, and am taking the drive to Washington, PA where this guy lives. Family funeral next week-so will spend an extra day and see what I find inside the kaPOWCON! Thanks for all the info. Will post back with what I find out.

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  • jjohn76
    replied
    Sounds good Aero. I am guessing the inverter circuit is pretty close too.

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  • Aeronca41
    replied
    Originally posted by jjohn76 View Post
    Aero, one of the POWCONs I haven't seen/owned, and dubbed the kaPOWCON... It has a Power Factor Correction input circuit, similar to what was in the Miller Spectrum 2050, that tended to fail more often than the previous rectifier/inrush surge resistors. Schematics, particularly for that one, are not available. Depending on what went, I might be able to help get it running. Arconweld sold the manufacturing company to their chief tech, Mike, and there is a lot of parts commonality between the Arcon Workhorse and the POWCONs. The PFC input is built around a Semikron SKM100GAL, low side chopper IGBT module (integrated IGBT and forward diode for buck or boost converters).
    Finally stopped my outdoors work (putting a roof on the house, painting--have to take advantage of every minute of every nice day in upstate NY this time of year!) long enough to take a look at the Spectrum 2050 schematic--looks like they copied that front end from POWCON virtually part for part. Still haven't had time to download and post all the pics from the 300 SE that started this thread--some time soon, I hope.

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  • Aeronca41
    replied
    >>I thought all of them had expired by now.

    ...Like the one I'm working with..... :-)

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  • 1997CST
    replied
    Miller either copied or purchased the design from Powcon for their early XMT 300.s. They even had the same case design, 2 piece with nuts and bolts holding them together in the middle. I haven't seen or worked on either in about 20 years. I thought all of them had expired by now.

    Leave a comment:


  • ryanjones2150
    replied
    I’d be in for a deal like that if I could find it.

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  • jjohn76
    replied
    And to add to the POWCON-ness, I just had an alert pop up on my phone for a working POWCON 300SM with feeder for $300. It's washington, but it is unbelievable how cheap the thermal arcs and POWCONs go for up here, with Miller machines still selling quite fast at $1k and above, whether they're still supported or not...

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  • jjohn76
    replied
    I just received the parts from Mirabel Industrial Welding Equipment (the owner was the Arconweld resident tech and bought the welding equipment line from the company), which look to be a direct fit for the POWCON - I'll confirm this weekend. No more need to hack the machines (maybe the boards, but there are companies that already have test fixtures to get them right) with parts still available. Not sure why I looked in the Arcon Workhorse manuals for the parts section, but I quickly realized they are pretty close to the same. The Arcon Workhorse welders do have some updates on the capacitors (integrated PTC either to sense overheating or prevent overcurrent, not sure which) and other components to make them more reliable in their target environment (mines and powerplant) that tends to have dirty power. Not to sound like a salesman, I have just talked with Mike often over the last several years.

    I tend to only wire feed with .035 solid, .045 FCAW-G, or 3/64 aluminum, so don't really have too many opinions on feeders. Biggest thing for me is component availability. The POWCON PD I/E feeders use what I want to say was the old L-TEC power pin and I have had to really look for the Tweco power pin adapter. The drive rolls are special order too, and I haven't even tried to source U-groove (Abicor Binzel Push-pull). It's nice to have the feeder connect right in to the top of the power supply though. I would rather go with a Miller feeder because it is much easier to find rolls, whips, parts, etc. The 200SM will get a Miller S-22P and the 400SMT is getting the POWCON feeder. I found a Pulser for it, and set one up for someone else, but haven't had the time to experiment. If you get a 400SMT, I would recommend a 115V or VS feeder. It has 30V and 115V AC power circuits at the remote socket. Hopefully someone else has an idea why it's 30 VAC and other feeder options.

    Here are the parts I just received for the 200SM. I had to also fix the rectifier, but chose to buy the individual diodes on eBay for much less. The capacitors are about $40 each, which is a bit pricey for their size, but much less than I paid for XMT or Lincoln Powerwave capacitors. And Mike is the only source that I know of that doesn't have a 16-week wait. The chassis components are not to expensive, and I needed one after hacking the original to fit my own capacitor bank...

    Click image for larger version

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  • Aeronca41
    replied
    Not to hijack the living daylights out of Wayne’s thread here...

    Not a problem!

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