Powcon the legend

[Edward Teach]

Yes it is ticking,
Not particularly loud,
But is ticking, when not welding.

 

[carbon]

I’ve not used one on single phase, but would have thought that as the output is reduced to approx 200 amps the range switch and control values will not reflect the actual output from the welder and may it need to be set higher than expected.

 

[Edward Teach]

I’ve not used one on single phase, but would have thought that as the output is reduced to approx 200 amps the range switch and control values will not reflect the actual output from the welder and may it need to be set higher than expected.

This is the setting the welder was set at in the video.
I would assume somewhere around 60-70 amps !!!
I also set the machine to High and 100% with similar results.

 

[Edward Teach]

I am getting a measurement of 30vdc on 100% and 9vdc on 10% across the electrodes at Low and High settings !!!

 

[eddie49]

The maximum OCV is supposed to be 80 volts. It sounds like the thyristors are not getting triggered into full conduction, due possibly to an error in the control logic or the voltage or current feedback circuits. Maybe one thyristor is o/c.

I would suggest locating the initial rectifier and the two input capacitors. Should have about 325v DC output from the rectifier and across the caps. Note: usual safety precautions apply !!

Do you have access to a 3-phase supply? If so, you could try configuring back to 3-P and test in that mode.

 

[Treekiller802]

Hey @carbon I have had a powcon 225 smc for about 5 years and it's been an amazing multiprocess welder but recently it started acting up, the plasma cutter quit working first then the machine would stop working and it would light up the ground light on the front of the machine and you would have to restart it sometimes several times for the light to go off and start working again. The mig will not arc and now the flux core is doing the same. I haven't seen any smoke and I took it apart and can't see anything visably wrong with it and no bad oder coming off the machine.. I would love to get this beast going again thanks in advance for any help.

 

[Matthew Gunter]

Hi @Edward Teach did you manage to solve the issue with your 300SS?

I have another question about the wiring of your deform connector for 1ph use. In the manual it says about connecting green to ground, both the white and black to "hot legs" and isolate the red. Does it mean use the L & N in uk wiring as the hot legs?

Just want to check before i go buggering up my machine lol

 

[David N]

Hey @carbon I have had a powcon 225 smc for about 5 years and it's been an amazing multiprocess welder but recently it started acting up, the plasma cutter quit working first then the machine would stop working and it would light up the ground light on the front of the machine and you would have to restart it sometimes several times for the light to go off and start working again. The mig will not arc and now the flux core is doing the same. I haven't seen any smoke and I took it apart and can't see anything visably wrong with it and no bad oder coming off the machine.. I would love to get this beast going again thanks in advance for any help.

Hello Treekiller802 I am from New Zealand and just joined this forum thanks to your post. I have a few Powcons but am interested in finding out details about the 225 model. did you repair yours? if so did you discover if this was a common issue? I haven't found any yet for sale but am trying to do my research about them. I hope you can help. Regards, David

 

[carbon]

I’ve just found this website that has a selection of Powcon manuals available.

Powcon Manuals

It seems they have taken over production of the arcon machines

 

[fizzy]

I’ve just found this website that has a selection of Powcon manuals available.

Powcon Manuals

It seems they have taken over production of the arcon machines

Brilliant thanks!

 

[Erie Fred]

Yes, I have a model 300, and yes it ticks when on and not welding, is a bit un-nerving.

 

[fizzy]

Yes, I have a model 300, and yes it ticks when on and not welding, is a bit un-nerving.

Mine does as well - nice to know it is completely normal.

 

[zeppelin builder]

ihave 2x 300ss working

tick , tick ,boom shake the room

 

[carbon]

Yesterday I went to Philpot and Cowlin to get some case handles for my most recent powcon and spoke to Greg there about using one on 230v single phase, yes it can be done but he doesnt recommend doing it due to the high input current required when doing so

 

[Erie Fred]

I passed up qty (2) PowCon 600 amp units, they were $700 each,
when I noticed all the hardware was rusty.
These were very large units, looked like 2 of the 300's glued together side by side.
Also, I think they had the highest level of panel complication, pulse, MIG, TIG, & stick.

 

[fizzy]

Yes my Powcon went pop on the weekend. A spectacular amount of smoke but I wasn't too worried as I knew about this thread.
Many thanks to @carbon as usual for his help.
Ordered 3 genuine Rifa caps off Farnell.
Hardest job was opening the casing. 4 bolts seized solid and had been rounded in the past. Had to use a Dremel with a slitting disk. Very handy.
Resistor bottom left looks a bit dodgy. Definitely got very hot. Do I need to replace?

 

[Seadog]

Do I need to replace?

I would, it's on its last legs.

 

[Brad93]

Exact same caps that Kenwood Chef mixer have, awful smell!

 

[Erie Fred]

Exact same caps that Kenwood Chef mixer have, awful smell!

"It chops, it slices, it dices, it blends, it welds...."....

 

[fizzy]

Exact same caps that Kenwood Chef mixer have, awful smell!

I made the mistake of bringing the circuit board home with me. Got halfway had to pull into a petrol station. The thing was stinking out my pickup. Making me wheeze. I found an empty ice cream box and stuck it in there. Almost a week since it popped and it still stinks!