NewArc NewArc R4000CC Quick start guide

www.newarc.co.uk
Newcastle UponTyne
Tel. [phone]
[e-mail]
Powered by
®
Operational Manual
Newarc R4000cc
NA9910212

2R4000CC
WEEE Directive & Product Disposal
At the end of its serviceable life, this product should not be treated as household
or general waste. It should be handed over to the applicable collection point for
the recycling of electrical and electronic equipment, or returned to the supplier for
disposal.
Place and Date
Newcastle upon Tyne, UK
14/06/2016
DECLARATION OF CONFORMITY
The Low voltage Directive 2014/35/EU
The EMC Directive 2004/108/EC, entering into force 20 July 2007
The RoHS Directive 2011/65/EU, entering into force 2 January 2013
Type of Equipment
Welding power source for MMA
Brand name or trade mark
Newarc
Type designation etc.
R4000CC
Manufacturer or his authorised representative established within the EEA
Name, address, telephone no
Newarc
Newcastle upon Tyne
Phone: [phone]
The product has been designed to comply with the following harmonised standards:
IEC 60974-1 - Arc welding Equipment Arc striking and stabilizing devices
EN 60974-10 - Arc Welding Equipment Electromagnetic compatibility
Additional information: restrictive use, Class A equipment, intended for use in locations other than residential
We declare that the equipment named above has been designed to comply with the relevant sections of the
above referenced specications. The unit complies with applicable essential requirements of the directives.

Safety Guidelines
These general safety guides cover both arc welding machines and plasma cutting machines unless
otherwise noted. The equipment must only be used for the purpose it was designed for. Using it in any
other way could result in damage or injury and in breach of the safety rules. Only suitably trained and
competent persons should use the equipment. Operators should respect the safety of other persons.
Prevention against electric shock
The equipment should be installed by a qualified person and in accordance with current standards in
operation. It is the user’s responsibility to ensure that the equipment is connected to a suitable power
supply. Consult with your utility supplier if required. If earth grounding of the work piece is required,
ground it directly with a separate cable. Do not use the equipment with the covers removed. Do not
touch live electrical parts or parts which are electrically charged. Turn off all equipment when not in use.
Cables (both primary supply and welding) should be regularly checked for damage and overheating.
Do not use worn, damaged, under sized or poorly jointed cables. Ensure that you wear the correct
protective clothing, gloves, head and eye protection. Insulate yourself from work and ground using
dry insulating mats or covers big enough to prevent any physical contact with the work ground. Never
touch the electrode if you are in contact with the work ground, or another electrode from a different
machine.
Do not wrap cables over your body. Ensure that you take additional safety precautions when you are
welding in electrically hazardous conditions such as damp environments, wearing wet clothing, and
metal structures. Try to avoid welding in cramped or restricted positions. Ensure that the equipment
is well maintained. Repair or replace damaged or defective parts immediately. Carry out any regular
maintenance in accordance with the manufacturer’s instructions.
Safety against fumes and welding gases
Locate the equipment in a well-ventilated position. Keep your head out of the fumes. Do not breathe
the fumes. Ensure the welding zone is in a well-ventilated area. If this is not possible, provision should
be made for suitable fume extraction. If ventilation is poor, wear an approved respirator. Read and
understand the Material Safety Data Sheets (MSDS’s) and the manufacturer’s instructions for metals,
consumable, coatings, cleaners, and de-greasers. Do not weld in locations near any de-greasing,
cleaning, or spraying operations. Be aware that heat and rays of the arc can react with vapours to form
highly toxic and irritating gases. Do not weld on coated metals, unless the coating is removed from the
weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings on many
metals can give off toxic fumes if welded.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Wear an approved welding helmet fitted with a proper shade of filter lens
to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields
under your helmet. Never use broken or faulty welding helmets. Always ensure there are adequate
protective screens or barriers to protect others from flash, glare and sparks from the welding area. Ensure
that there are adequate warnings that welding or cutting is taking place.
3
R4000CC

Wear suitable protective flame resistant clothing. The sparks and spatter from welding, hot work pieces,
and hot equipment can cause fires and burns. Welding on closed containers, such as tanks, drums, or
pipes, can cause them to explode. Accidental contact of electrode to metal objects can cause arcs,
explosion, overheating, or fire. Check and be sure the area is safe and clear of inflammable material
before carrying out any welding.
Protection against noise
Some welding and cutting operations may produce noise. Wear safety ear protection to protect your
hearing.
Protection from moving parts
When the machine is in operation, keep away from moving parts such as motors and fans. Moving
parts, such as the fan, may cut fingers and hands and snag garments. Protections and coverings may
be removed for maintenance and controls only by qualified personnel, after first disconnecting the
power supply cable. Replace the coverings and protections and close all doors when the intervention
is finished, and before starting the equipment. Take care to avoid getting fingers trapped when loading
and feeding wire during set up and operation. When feeding wire be careful to avoid pointing it at other
people or toward your body. Always ensure machine covers and protective devices are in operation.
Precautions against fire and explosion
Avoid causing fires due to sparks and hot waste or molten metal. Ensure that appropriate fire safety
devices are available near the cutting / welding area. Remove all flammable and combustible materials
from the cutting / welding zone and surrounding areas. Do not cut/weld fuel and lubricant containers,
even if empty. These must be carefully cleaned before they can be cut/welded. Always allow the cut/
welded material to cool before touching it or placing it in contact with combustible or flammable
material. Do not work in atmospheres with high concentrations of combustible fumes, flammable gases
and dust. Always check the work area half an hour after cutting to make sure that no fires have begun.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the operation of pacemakers or electronically
controlled medical equipment. Wearers of vital electronic equipment should consult their physician
before beginning any arc welding, cutting, gouging or spot welding operations. Do not go near welding
equipment with any sensitive electronic equipment as the magnetic fields may cause damage.
RF Declaration
Equipment that complies with directive 2004/108/EC concerning electromagnetic compatibility (EMC)
and the technical requirements of EN60974-10 is designed for use in industrial buildings and not those
for domestic use where electricity is provided via the low voltage public distribution system. Difficulties
may arise in assuring class A electromagnetic compatibility for systems installed in domestic locations
due to conducted and radiated emissions. In the case of electromagnetic problems, it is the
responsibility of the user to resolve the situation. It may be necessary to shield the equipment and fit
suitable filters on the mains supply.
4R4000CC

5
LF Declaration
Consult the data plate on the equipment for the power supply requirements. Due to the elevated
absorbency of the primary current from the power supply network, high power systems affect the
quality of power provided by the network. Consequently, connection restrictions or maximum
impedance requirements permitted by the network at the public network connection point must be
applied to these systems. In this case the installer or the user is responsible for ensuring the equipment
can be connected, consulting the electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not contain any toxic or poisonous
materials dangerous to the operator. When the equipment is scrapped, it should be dismantled
separating components according to the type of materials. Do not dispose of the equipment with
normal waste. The European Directive 2002/96/EC on Waste Electrical and Electronic Equipment states
the electrical equipment that has reached its end of life must be collected separately and returned to an
environmentally compatible recycling facility.
Handling of compressed gas cylinders and regulators
All cylinders and pressure regulators used in welding operations should be handled with care.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Always secure the cylinder safely. Never deface or alter any cylinder.
The following signs and explanations are to remind the user of the potential
risks involved and the dangers of misuse or mistreatment of the welding
machine.
!
RUNNING PARTS MAY BE DANGEROUS!
Keep away from running components,
including the fan.
BE AWARE OF SPARKS AND SPATTER
Wear protective clothing, such as leather
gloves, Flame retardant overalls, boots and
eyewear.
DO NOT TOUCH THERMAL COMPONENTS!
Thermal components may cause severe burns
when in contact with unprotected skin.
ELECTRIC SHOCKS CAN KILL!
Never touch electrical parts. Keep the
equipment in good condition, replace
damaged parts, undertake regular
maintenance according to the instructions.
R4000CC

1. Preface 7
1.1 General 7
1.2 Introduction 8
1.3 Technical Specications 9
1.4 Overview of Machine 10
2. Installation 12
3. Operation 13
4. Fault Finding 14
4.1 Welding Problems 15
5. Maintenance 16
6. Electrical Diagram 17
7. Warranty 18
8. Parts 19
Contents
6R4000CC

7
1. Preface
Congratulations on choosing your Newarc R4000CC Inverter.
Used correctly, our products can signicantly increase the productivity of your welding, and provide
years of economical service. This operating manual contains important information on the use,
maintenance and safety of your Newarc product. Please read the manual carefully before using the
equipment for the rst time. For your own safety and that of your working environment, pay particular
attention to the safety instructions in the manual.
For more information on Newarc products, contact an authorised Newarc dealer, or visit the Newarc
website at www.newarc.co.uk. The specications presented in this manual are subject to change without
prior notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and personal harm
are indicated with the ’NOTE!’ notation. Read these sections carefully and follow the instructions.
Disclaimer
While every effort has been made to ensure that the information contained in this guide is accurate and
complete, no liability can be accepted for any errors or omissions. We reserve the right to change the
specication of the product described at any time without prior notice. Do not copy, record, reproduce
or transmit the contents of this guide without prior permission.
1.1 General
R4000CC

1.2 Introduction
These heavy duty MMA D.C inverter power sources have been designed using the latest developments
in power electronics. Electronic parts are enclosed in a separate sealed compartment for protection from
the environment.
This portable, versatile inverter power source responds to changes in the welding arc much faster than
conventional machines resulting in a more stable and controllable weld pool.
Due to the high efficiency and power factor these units provide energy and cost saving solutions.
Features
• Powerful 400 and 500 amps advanced inverter power source
• Fabricated in robust external casing to withstand the most extreme environments
• Cooling on demand system minimizes power consumption and dust ingress
• Very high duty cycle even at high ambient temperatures
• Large overhead of voltage available for use with long interconnection cables
8R4000CC

1.3 Technical Specications
9
R4000CC
Newarc R4000CC
Power voltage (V) 380-480 Volts 3 Phase 50/60Hz
Input Current at Max Output 24 amps
Power Consumption 18.5 KVA
Recommended Mains Fuse 32A slow blow or type C MCB
Mains Cable 4 x 4.0mm² exible cable
Power Factor 0.95
Max Output Current 400 amps
Open Circuit Voltage >80V
Current Control 20-400A Innitely Variable
Duty Cycle at 40ºC 60% @400A
Insulation Class F
100% @350A
Electrode Size 1.6 – 6.3
Dimensions (L x W x H) (mm) 570 x 310 x 450
Weight (kg) 33

1.4 Overview of Machine
10
Front View
Power source front panel layout
1. Current control
2. Digital display
3. Arc force control
4. +ve weld terminal
5. -ve weld terminal
6. Off/On switch al
7. Remote control socket
Rear View
8. Main 3P Isolation switch
9. Mains Input
10. Remote fuse
11. Auxiliary transformer supply fuse
R4000CC

11
R4000CC
1. Current control
Adjusts the machines output current.
2. Digital Display
Indicates welding current in Amps, also gives an indication when the machine is over temperature.
3. Arc force control
Operates in MMA mode only. This control alters the welding dynamics of the machine to facilitate welding
with different types of welding electrodes (e.g. general purpose, celulosic, low hydrogen and iron powder).
Turning towards maximum will increase penetration at the expense of increased welding splatter, turning
towards minimum will reduce penetration but the arc will be smoother and less erce.
4. +ve weld terminal
Main welding power output connector, positive polarity.
5. -ve weld terminal
Main welding power output connector, negative polarity.
6. O/On switch
Switches the machine on and off when the main 3 Phase isolation switched is in the on position. Upon
switching on, the display will read“4000”or“5000”and the machines output will be inhibited, after 4 seconds
display will clear and the machine is ready to use.
7. Remote control socket
For connection of external remote control or TIG300 external TIG control unit. There is no switch for remote
operation, plugging an external unit into the socket automatically selects remote operation and disables the
internal current control.
8. Main 3P Isolation switch
Switches the machine on and off.
9. Mains Input
Three phase mains cable.
10. Remote fuse
Protects the auxiliary supply from the remote control socket. Fuse type is 20 x 5mm glass body, 6.3A‘slow
blow’rating.
11. Auxiliary transformer supply fuse
Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.

12 R4000CC
2. Installation
Unpacking
Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging
until the installation is complete.
Positioning of the machine
Position the R4000/R5000 on a clean dry sur-face, preferable above ground level.
• Make sure there is at least 20cm clearance at the front, rear and right side of the ma-chine to allow
good circulation of the cool-ing air.
• Protect the machine from heavy rain and if used in hot climates, against direct sunlight.
• Ensure that the machine is positioned in such a way that particles created by grinding and cutting
operations do not enter the machine.
NOTE! Damage caused by metal particles and water entering the machine will not be covered under
warranty.
Connecting to mains supply
WARNING! All electric shocks are potentially fatal, a competent electrician should carry out the tting of
the mains plug.
• Make sure that the mains supply is of the correct voltage and
current capability for the machine.
• Make sure that any extension cables used are of sufficient
current carrying capacity.
• Make sure that the mains plug and socket (if tted) are in good
condition and are of the correct current carrying capacity. If the
machine is wired directly to the mains supply then an isolator
switch must be tted.
NOTE! See the technical specications page for correct supply
information
Primary cable length
Long cable lengths may reduce the perfor-mance of the machine, the welding arc may become
unstable, especially at higher cur-rents. Ensure the mains cable is not coiled up during welding as this
will reduce the input voltage to the machine and may cause over-heating and degradation of the cable.
Setting supply voltage tapping
WARNING! All electric shocks are potentially fa-tal, a competent electrician should carry out any supply
voltage tapping adjustments required.
• To enable the setting of the supply voltage tapping, the front panel display cover of the R4000/R5000
has to be removed.
• The photograph below shows the voltage tap-ping set to 415V, with the red wire from the fuse holder
connected to the 415 terminal.
• This connector can be moved to the required voltage terminal to select the desired input voltage.

13
MMA Welding
• For straight polarity welding, connect the electrode holder to the positive weld terminal and the earth return
lead to the negative weld terminal. For reverse polarity welding, reverse these connections.
• Turn the mains switch to the on position, the digital will light and after a 4 second delay the machine is ready
to weld.
• Adjust the current control to the recommended setting for the size and type of welding electrode to be used.
• Adjust the Arc Force control to your personal preference for the size and type of welding electrode to be used.
• The R4000CC/R5000CC is suitable for welding all types of electrodes within the current rating of the machine.
MMA Welding with remote control
• Select welding polarity.
• Plug the control cable supplied with the remote control into the remote control socket on the front of the
R4000/R5000.
• Turn the mains switch to the on position, the machine is ready to weld.
• Plug the remote control onto the other end of the control cable.
• Adjust the current control on the remote to the recommended setting for the type and size of welding
electrode being used. (The standard Newarc RC300 remote does not have current settings but is marked 1 to
10, for the R4000CC allow 40A per division and for the R5000CC al-low 50A per division).
TIG Welding with TIG Unit
IMPORTANT! Do not use the TIG Unit until you have read and fully understood the TIG Unit manual.
• Connect the TIG unit to the R4000/R5000 and the shielding gas supply as per the diagrams in the TIG unit
manual.
• Turn the mains switch on the R4000/R5000 to the on position, the digital displays on the R4000/R5000 and
the TIG unit will light up, you are now ready to weld.
• Select welding mode and current by adjusting the controls on the TIG unit with reference to the manual.
3. Operation
R4000CC

14 R4000CC
Most problems with the R4000/R5000 can be overcome by following the procedures below.
No Digital Display on switch on
• Check that the machine is attached to a working mains supply that it is correctly plugged in and any
isolator switches are closed.
• Check the condition of the 2A fuse on the rear panel of the machine and replace if necessary.
NOTE! Note : make sure the fuse is replaced with one of the correct type and rating. It should be a
32 x 6.3mm (1¼”x ¼”) ceramic bodied type with a rating of 2A ‘slow blow’
Have a competent electrician check that there are no mains fuses or overload devices interrupted, that
the mains plug is tted correctly and that there are no loose wires or connections, check that there are
no breaks in the mains cable.
Digital display lit but no output
• Make sure that the display is not reading‘HOT’, if it is, it means that the R4000/R5000 has over-heated,
normally by exceeding its ’Duty Cycle’, and the power stages of the machine have been shut down.
In this case, leave the machine switched on until it has cooled down, if you turn the machine off, the
cooling fans will be turned off also and the cooling down period will be lengthened considerably.
NOTE! If the R4000/R5000 is overheating on a regu-lar basis or at current settings below the maximum,
this would usually indicate that the inside of the machine is choked with dust and therefore not being
cooled correctly. For information about cleaning the dust out of the R4000CC/R5000CC please refer to
the three monthly service schedule.
TIG unit is not working
• Check the condition of the 6.3A fuse on the rear panel of the machine and replace if necessary.
• Check interconnection cables are correctly tted. (Positive to positive, negative to negative).
NOTE! Make sure the fuse is replaced with one of the correct type and rating. It should be a 20 x 5mm
glass bodied type with a rating of 6.3A ‘slow blow’.
Any welding problems not covered above must be brought to the attention of a qualied welding
engineer, if the problem still persists have the R4000/R5000 checked by a trained Newarc service
engineer.
4. Fault nding

15
R4000CC
MMA
If problems with the R4000/R5000’s operation while welding are experienced, rst refer to the
information in the installation section and in the operating section and the fault nding procedure
earlier in this section.
• Most problems with MMA welding are the result of not setting the correct welding parameters for the
welding rod being used. All welding rod packets have information on them in symbolic format , giving
suitable current range, polarity and type of weld (normally called ‘position’). If you are in doubt about
what these symbols mean, ask your welding rod supplier to explain them. Choose an initial current
setting towards the middle of the quoted range and if necessary practice on a piece of scrap the same
thickness as the job to be welded.
TIG
• If problems are experienced whilst TIG welding, please consult the fault nding and maintenance
section in the TIG unit instruction manual.
• Any welding problems not covered above must be brought to the attention of a qualied Welding
Engineer, if the problem still persists have the R4000/R5000 checked by a trained Newarc service
engineer.
4.1 Welding problems

16 R4000CC
5. Maintenance
Note!
All Electric shocks are potentially fatal, switch off the machine and unplug from the
mains supply before carrying out any maintenance work.
It is very important that the R4000/R5000 is regularly maintained. The amount of use and the
working environment must be taken into account when scheduling the maintenance periods.
Careful use and regular preventative maintenance will prolong the life of the machine and
ensure trouble free operation.
Weekly
• Clean the exterior of the machine.
• Inspect the machines exterior for obvious signs of damage.
• Check the condition of the welding cable, earth clamp and welding output connectors for damage
and any sign of over-heating
• Check the condition of the mains cable and plug.
Three monthly
As per the weekly schedule, plus:
• Remove the lid from the machine and remove the build up of dust and debris from inside the machine
using, either, compressed air at low pressure or an industrial type vacuum cleaner.
• Make a thorough visual inspection of the interior of the machine, look particularly for pieces of welding
wire, or stubs of old welding rods that may have got through the cooling air intakes.
• Check the condition of the mains input connector, look for loose terminal block screws and make sure
the sheath of the mains cable is still clamped securely in the combined cable entry/clamp. Make sure
the earth wire is still securely fastened to the earth stud.
• Check the condition of the welding output connectors, look for any signs of discoloration. This could be
an indication of overheating and can be a cause of welding set failure.
Annually
As per the three monthly schedule, plus:
• The machines should be have its calibration checked, if necessary have the machine re-calibrated by
a Newarc trained technician.

17
R4000CC
6. Electrial diagram
11
R5/4000 CC
11
SECTION 6 —ELECTRICAL DIAGRAMS
6.1 - System Diagram

18 R4000CC
7. Warranty
Guarantee
Newarc Ltd warrants that its goods and services are guaranteed to meet the specic performance under
the stated conditions of use. Newarc cannot be held responsible for general wear and tear or for failure
occurring due to misuse or abuse arising out of circumstances outside the stated condi-tions of use.
The stated conditions of use are that considered normal industrial practice and are not exhaustive. Each
machine is identied with a unique serial number and accompanied with the guarantee. Newarc reserve
the right to a) Repair. b)Replace. c)Authorise the reasonable cost of repair or replacement at an approved
Newarc service agent. d)Credit for any purchased equip-ment (less reasonable depreciation for actual
use and condition) at its entire discretion. This in no way affects your rights as a consumer. The guarantee
is enclosed with each machine.

19
8. Parts
R4000CC

8. Parts
13
R5/4000 CC
13
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations
25
26
21
23
24
15
16
18
22
20
19
17
27
20 R4000CC
8. Parts