Arcon IRONHORSE 300S User manual

2300 Northwood Drive
Salisbury MD 21801
Tel: [phone] Fax: [phone]
www.arconweld.com [email protected]
IRONHORSE 300S 700V DC
P/N 010350-006
OPERATING MANUAL

Table of Contents
User Responsibility 3
General Information 4
Warranty 4
Introduction to Ironhorse Stickweld 300S 4
1. Safety Precautions
IRONHORSE SET UP CHECKLIST 5
1.1 ELECTRIC SHOCK can kill! 6
1.2 ARC RAYS can burn! 6
1.3 FUMES AND GASES can be dangerous! 6
1.4 WELDING SPARKS can cause fire or explosion! 7
1.5 ELECTRIC AND MAGNETIC FIELDS may be dangerous! 7
1.6 PROTECT YOURSELF AND OTHERS! 8
2. Introduction and Installation 9
2.1 Unpacking and selecting a location 9
2.2 Input Connections 10
2.2.1 Connecting Input Power 10
2.3 Output Connections 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 3.1 13
3.2 Welding Operation 14
4. Maintenance 15
5. Electrical Specifications 16
5.1 Product Specifications 16
5.2 Theory of Operation 17
5.3Main Circuit Diagram 18
5.4Front Panel 19
5.5Rear Panel 20
5.6 Assembly Drawings 21
5.6.1 Bottom Chassis Drawing 21
5.6.2 Top Chassis Drawing 22
5.6.3 Inductor Plate Drawing 23
6. Replacement Parts List 24

3
User Responsibility
ARCON Welding warrants thatThe Ironhorse family of welders will perform
in accordance with the product description in this manual The Factory
Warranty will be null and void should the user attempt to operate The
Ironhorse after it has malfunctioned. Parts that are broken, missing or
worn must be replaced 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 ownerand
any repair requested to be done by ARCON Welding LLC will be charged
based on Arcon’s applicable hourly labor rate and cost of spare parts.

4
General Information
Warranty
The warranty of The Ironhorse welders covers any defect in materials or workmanship. The
warranty period is five years for parts and labor (US only) from the date of purchase. The
warranty period for rental units begins with the first rental or 45 days from the date of shipment to
the rental company, whichever is earlier.
Introduction to The Ironhorse 300S 700V DC
The Ironhorse 300 700V DC is a portable welder using an inverter type power supply to
generate the output power.
The Ironhorse 300 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 breaker. The output side of the breaker is connected to a diode, which
protects the welder from being connected to the wrong polarity.The DC voltage is converted to
AC by a DC to AC 60 HZ inverter. The 480V AC is connected to an auxiliary transformer which
transforms the voltage to 48V AC for the fan motor and the control board.

5
Ironhorse Setup Checklist
NEVER WELD ON THE LIVE THIRD RAIL!
These are basic instructions for installing cables and supplying power to The Ironhorse welding
power source. The individual connecting cables for welding should be certified (by the
employer) and be familiar with the fundamentals of welding and electricity.
All precautionary measures must be taken to provide maximum
protection against electrical shock. Work cables must always make a
good electrical connection with the metal being welded. Connection
should be as close as possible to the area being welded.
Operators must always insulate themselves from the workandground
using dry insulation. Wear dry gloves to insulate hands.Make certain
the insulation is large enough to cover the entire area of physical
contact 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) rail.
Attach the Power +DC cable to the +DC power rail.
CAUTION –this lead is connected to HIGH VOLTAGE!
6. Switch the breaker switch on the back of the welder ON.
7. Never leave the energized power source unattended.
8. Turn the breaker off before disconnecting the input power
conductors and welding cables, and BEFORE moving the welding
power source to a new location.
Remember -the electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do not touch these energized
parts with bare skin or wet clothing. Dry, hole-free gloves to insulate
hands should ALWAYS be worn.

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1. Safety Precautions
1.1 ELECTRIC SHOCK
Precautionary measures must be taken to provide maximum protection against electrical shock.
1. Do not touch live electrical parts.
2. Turn OFF welding power source before servicing unless the procedure specifically
requires an energized unit.
3. Do not leave live unit unattended.
4. When testing a live unit, use the one-hand method. Do not put both hands inside unit.
Keep one hand free. Remove rings and watch.
5. Disconnect input power conductors from de-energized supply line BEFORE moving a
welding power source.
6. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
7. Insulate yourself from work and ground using dry insulation. Make certain the insulation
is large enough to cover your full area of physical contact with work and ground.
8. 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.
9. Ground the work or 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 observing open arc welding.
2. Use protective clothing specifically intended for work with welding equipment. It should
be made of durable flame-resistant material to provide ample protection from the arc
rays.
3. Protect other nearby workers with suitable, non-flammable screening. Caution other
workers not to watch the arc nor expose themselves to the arc rays or to hot spatter or
metal.
1.3 FUMES AND GASES
Fumes and gases can cause discomfort or harm, particularly in confined spaces. Take the
following precautions for appropriate health considerations.
1. Read the Material Safety Data Sheets (MSDS) and the manufacturer’s instruction for
metals, consumables, coatings, cleaners, and degreasers
2. Keep your head away from the fumes. Do not inhale welding fumes.
3If welding is done indoors, make sure proper ventilation is provided by using an adequate
exhaust system at the arc to remove welding fumes and gases.

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4When working in a confined space always have trained support personnel nearby.
Welding fumes and gases can displace air and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
5Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and
rays of the arcs can react with vapors to form highly toxic and irritating gases.
6Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel. The
coating must be removed from the area to be welded. Coatings and metals containing
above elements can generate toxic fumes when heated to welding temperature.
1.4 WELDING SPARKS
Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and
explosions.
1. Remove all combustible materials from the work area or cover thesematerials with a
protective non-flammable tarp. Combustible materials include wood, fabrics, sawdust,
liquid and gas fuels, solvents, paints and 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.
3. Do not weld, cut or perform other hot work until the work piece has been completely
cleaned so that there are no substances on the 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 could cause a fire. Use fire watches when necessary.
7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of
Cutting and Welding Processes”, available from the National Fire Protection Association.
1.5 ELECTRIC AND MAGNETIC FIELDS
Electric current flowing through any conductor causes localized Electro-Magnetic Fields (EMF).
Welding and cutting current creates EMF around welding cables and welding machines.
1. Operators having pacemakers should consult their physician before welding. EMF may
interfere with some type of pacemakers.
2. Exposure to EMF may have other health effects, which are unknown.
3. Operators should use the following procedures to minimize exposure to EMF:
a. Route the work cables together. Secure them with electrical tape when possible.
b. Never coil the work cable around any part of your body.
c. Do not place your body between the work cables. Route cables on the same side
of your body.
d. Connect the work cable to the work piece as close as possible to the area being
welded.
e. Keep welding power source and cables as far away from your body as possible.

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1.6 PROTECT YOURSELF AND OTHERS!
Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like
the sun, emits ultraviolet (UV) and other radiation and may injure skin and eyes. Hot metal can
cause burns. Training in the proper use of welding processes and equipment is essential to
prevent accidents.
1. Always wear safety glasses with side shields in any work area. In conjunction with eye
protection, welding helmets or face shields are also required.
2. Use a face shield fitted with the correct filter cover plates to protect your eyes, face, neck,
and ears from sparks and rays of the arc when operating or observing 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 sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and
collars should be kept buttoned, and open pockets eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable
partition or curtain.
6. Use safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly
far. Bystanders should also wear safety glasses.
7. DO NOT WELD ON LIVE 3RD RAIL.

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2. Introduction and 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 Ironhorse.
•Do not touch electrically hot parts.
This section provides detailed instructions for the proper installation of The Ironhorse. It is
recommended that these instructions be followed carefully to allow for the best possible
operating environment.
2.1 Unpacking and selecting a Location
a. Immediately upon receipt of the welder, inspect the shipping box for any damage
and notify the carrier of such damage before accepting delivery. Then inspect the
Ironhorse 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 installation.
a. The location of the power source should be carefully selected to ensure
satisfactory and dependable service. Choose a location relatively close to
a properly fused source of electrical power.
b. It is important that the machine be located in an open area where air can
circulate freely at front and rear openings. If space is at a premium, leave
at least 1 foot (300 mm) of clearance between the rear of the power source
and wall or other obstruction.

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2.2 INPUT CONNECTIONS
2.2.1 CONNECTING INPUT POWER
The primary cable supplied with the power source has 2 conductors, which split into 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.

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3. OPERATION
WARNING!
PLEASE READ CHAPTER 1 REGARDING SAFETY
3.1 Controls and Settings
3.1.1 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 minutes indicating that correct power connections have been
applied.
It is imperative that you switch off the circuit breaker before disconnecting from the third
rail. When resuming, it is equally imperative that you verify that the circuit breaker is in
the “OFF”position before reconnecting to the 3rd rail.
3.1.2 Thermostat-controlled Cooling Fan
The cooling fan starts automatically when welding current exceeds 100 Amps. If the current
drops below 100 A, the fan will stop after approximately 6 minutes. If the fan is operating when
the work is discontinued, 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 Current Range Selector.
3.1.5 Arc Force Control
This control is used to adjust the Arc Force on constant current applications. The control is fully
adjustable from 0 to 100%, with 0 being very soft and 100% being very hard. When adjusting the
Arc Force, the low settings will produce a soft arc and the high settings will produce a more
forceful or driving arc. Please note that the higher settings will produce higher levels of spatter.
The higher setting will create a more stable arc for electrodes that easily become
unstable, such as cellulose (5P). If you do not know the optimal setting for the electrode
you are using, start at the highest setting and lower it until the arc just begins to become
unstable.

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3.1.6 Process Control Selector
The Process control selector has three settings, Stick, TIG and Stick. The Ironhorse 700VDC
has the same characteristics for both Stick settings. The pipe-welding version has a cellulose
characteristic, allowing 1 inch of arc length when this method of whipping is used.
The TIG position allows Lift Start, which allows contact between material and electrode with no
damage to the electrode.
When the tungsten (wolfram) electrode touches the work piece, 10 Amps of current will flow.
When the electrode is lifted a small distance from the work surface the full welding current (as
set on the Welding Power Control knob) will flow.
When the selector is at the TIG position, the open circuit (no-load) voltage is reduced from 78
Volts to 9 Volts. This feature prevents the tungsten electrode from sticking to the work piece.
3.1.7 Power-On Indicator
Indicates 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 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 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 temperature sensor will protect the output capacitor.
•Input Capacitor
Should one phase be lost when welding with three-phase input power, current to the Input
Capacitor could increase causing it to potentially overheat or be destroyed. Wait 10 minutes
before restarting the welder
•Fan Motor: Some operation with restricted airflow will overheat the fan motor. Wait 10
minutes before restarting the welder.
3.1.9 Input Power Cord
The primary cable supplied with the power source has 2 conductors, which split into two 5-foot
long single conductors. Additional power cable length can be provided as an option if requested.

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3.1.10 Output Terminals
Select output cable size based on table 3.0 below.
Duty cycle(%) Current (A) Length (Ft) Cable Size (AWG)
30 180 1 –50 8
60 300 1 –150 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

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3.2 Welding Operation
1. After both the third rail clamp (or catenary pole clamp) and the ground clamp are
connected, close the circuit breaker on the welder.
2. The Power-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.

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4. Maintenance
WARNING!
Please see Chapter 1 regarding Safety
•Turn the input power OFF before working on any ARCON welder
•Do not touch electrically live parts or electrode with your skin or wet clothing
•Insulate yourself from work and ground
•Always wear dry insulating gloves
•Have an electrician install the ARCON welder
•All maintenance and repairs that require taking off the cover must be performed by a certified
repair facility.
If The Ironhorse does not operate properly, stop work immediately and investigate the cause of
the malfunction. Please note: Opening up the case voids the Warranty. Maintenance or repair
should only be performed by an authorized ARCON Service Center, or 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 to remove the cover from the case, and wearing protective
goggles, remove accumulated dust and dirt from the air passages and the interior components,
using clean low-pressure air. It is imperative that the air passages to the interior of the unit be
free of dirt to ensure adequate circulation of cooling air, especially over the rectifier bridge plates.
The frequency of cleaning will depend on the location of the unit, the amount of dustin the
atmosphere and number of operating hours.

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5. Electrical Specifications
5.1 Product Specifications
THE IRONHORSEStickweld 300 S 700 V DC
Product Specifications
Rated
Welding Welding
Open Input Amperes at Weight, Including
cable
Primary
Current
(Amps) Amp Circuit Rated Load
Output
KW Eff. Dimensions
Input 60% Duty
Cycle Range Voltage DC Net Ship
500
V600V 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)

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5.2 Theory of Operations
The inverter function 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

5.3 Main Circuit Diagram
18

5.4 Front Panel
19

5.5 Rear Panel
20