The Welder Died.......

[platypus20]

My God they are expensive............!!

My Powcon experience is terrible, I’d NEVER buy another one, I think I still have a couple dead bodies somewhere.

[digger doug]

Originally Posted by platypus20

My God they are expensive............!!

My Powcon experience is terrible, I’d NEVER buy another one, I think I still have a couple dead bodies somewhere.

Please...Please !

don't tease us like this...inquiring minds want to know...or "How the welder burns"....

[platypus20]

Per DD’s request...

My Powcon Saga.......

Powcon #1 - the output capacitors had failed, they installed new ones, ran on a load tester, worked perfectly. At pick up, plugged it in, flicked the switch, BANG, the output capacitors failed. Two days later, repaired, tested and rechecked by me, okay. Two days later plugged it in, flicked the switch, a loud whistling sound, then BANG, output capacitors failed. The repair shop kept the unit for another 3 months, trying to fix it, finally Powcon took the unit, they sent it back, allegedly repaired, it failed again within 2-3hours of operation. I finally gave up on Powcon #1. Sets in the trunk of my 69 Ramber American.

Powcon #2 - for about 2-3 yrs it was like a Bic pen (first time, every time), then there were issues with the unit shutting itself off, if it went idle for 3-4 minutes. I sent it in, they allegedly fixed the issue, then wild amp swings, while under operation, no penetration to burn through, back to no penetration, then said it was some rheostat issue, a couple hundred dollars, about a day later some kind of power transistor issue, they replaced numerous parts, within a week, same issue, they replaced the parts again, it lasted about 5 hrs, then the flames shot out the back, then finally the big BANG. Gave up on Powcon #2, I believe it’s sets next to Powcon #1.

Powcon #3 - yes, at times I’m a slow learner, compared to the other Powcons, this was the ugly sister, I believe every part except the case, was changed at least once or twice, Powcon had it 4-5 times, still a serious flawed piece, when it worked, it was excellent, it was probably a good concept, but poorly designed/manufactured welder. Finally, the LWS gave me the full purchase price toward a Lincoln Invertec V-300.

The Lincoln Invertec V-300 (one of Lincoln’s first inverter based welders), which worked perfectly, but had roughly a 45 minute procure to change input voltage, no really meant to be changed constantly. Also had a very high amp draw, making it a pain to hook up on the job. About 3-4 years later, I traded the V-300 toward a Lincoln Invertec V-350 Pro (still have it).

Then I went through a series of smaller (200 amp) inverter welders, ESABs, Thermal Arcs, Lincolns, Fornious (sp) and finally Millers, which seem better geared to the type of work we do.

Even mentioning the Powcon name, will probably cause me nightmares.

[digger doug]

Mckeanmachinery had a pair of the larger 600 amp units (and with all the bells, STM & pulse options)

Someone came in and bought them both up.

I picked up 2 of the 300 amp stick units ($200 each) and the amp draw is less than my dialarc (remote barn application with limited power).

But I don't like D.C. with the arc blow, prefer A.C.

I noticed one units ticks like a time bomb when turned on, other does not.

And yes that whistle arc...doo the other inverters doo that ?

[Ironman]

Originally Posted by digger doug

And yes that whistle arc...doo the other inverters doo that ?

When a capacitor of that size fails it heats, building gas pressure from the insulating fluid vaporizing. Escaping vapor whistles. I have heard Hibay lights do the same thing just before the darkness.

[digger doug]

Originally Posted by Ironman

When a capacitor of that size fails it heats, building gas pressure from the insulating fluid vaporizing. Escaping vapor whistles. I have heard Hibay lights do the same thing just before the darkness.

No, this is normal operation, the arc itself has a whistle.

[toprecycler]

Originally Posted by digger doug

No, this is normal operation, the arc itself has a whistle.

I remember someone saying it was like a Star Wars laser gun sound. After I heard that description, now that is what I hear when I use my powcon.


Sent from my iPhone using ShopFloorTalk

[platypus20]

The Miller Maxstar 200 (old unit) autopsy was released on Friday afternoon. As far as I’m concerned, the wounds are mortal, the repair cost far out exceeds the welder’s value, the estimate, final cost based on final load testing was in the $1100-$1200 range. The fan had to be replaced, there a circuit board damaged by the flying shrapnel and obviously some labor. As the value of the welder according to the rental department was $500-$700 and with it being 15+ yrs old, to me it is not worth fixing.

So the decision to buy the new Miller Maxstar 200 STR, at this time looks to be the correct choice.

[GWIZ]

Was it a muffin fan that came a part?
maybe there is a second fan not pictured.

The placement doesn't look as if it would damage much let alone get past the fans outer frame.

maybe a second problem with the welder.

[milomilo]

My Miller Bobcat 225G has been kind to me for the last 9 years. An electric fuel pump and a starter. I probably should not have put this in writing.