NewArc RT5000 User manual

Newarc Equipment Ltd.
UK‘s Leading Manufacturer Of Welding Equipment
Newcastle +44 ( ) 191 295 111
Aberdeen +44 ( ) 1224 771 63
www.newarc.co.uk
To maintain continued developments of our products we reserve the right to alter specifications as quoted without prior notice
RT5000/4000
Important Information
All persons authorised to use, repair or service the
RT4 /RT5 Inverter welding unit, should read the section
on safety, before any work is undertaken. Further information
is available in publication HSG118 'Electric safety in arc weld-
ing', which may be obtained from the Health & Safety Execu-
tive. Please contact your distributor should you not understand
any of the information within this document.
INSTRUCTION MANUAL
Processes
Description
Constant Current Power Source
Integrated TIG

RT5/4000
3
TAB E OF CONTENTS
SECTION 1 — SAFETY
1 - General Precautions_______________________________________________________ 4
SECTION 2 — SPECIFICATION
2.1 - Description_______________________________________________________________ 5
2.2 - Specification_____________________________________________________________ 5
SECTION 3 — INSTA ATION
3.1 - Siting the RT5/4 ________________________________________________________ 6
3.2 - Connecting to mains supply______________________________________________ 6
3.3 - Setting supply voltage tapping____________________________________________ 6
SECTION 4 — OPERATION
4.1 - Operating Controls ____________________________________________________ 7
4.2 - Description of Controls_________________________________________________ 7
SECTION 5 — FAU T FINDING AND MAINTENANCE
5.1 - Machine Operation____________________________________________________ 9
5.3 - Maintenance__________________________________________________________ 1
SECTION 6 — E ECTRICA DIAGRAMS
6.1 - System Diagram________________________________________________________ 11
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations__________________________________________________ 12
7.2 - Parts List_______________________________________________________________ 14
5.2 - Welding Problems______________________________________________________ 9

RT5/4000
4
SECTION 1 — SAFETY
Fire and Explosions
Pay attention to fire and safety regulations in force at the
welding site.
• Remove all flammable or combustible materials from
the welding area and the immediate vicinity.
• Suitable fire fighting equipment must always be present
where welding is carried out.
• Be aware that a fire risk is present for a considerable
time after welding operations have ceased because of
sparks and hot slag etc. Take suitable precautions when
you have finished welding.
• Take care when welding containers that have held
flammable or combustible material, these should have
been specially cleaned before being given to the
welder. If in doubt do not weld them.
Burns
Be aware that burns may be the result of the heat involved
in the welding process, welding spatter or the Ultra Violet
Radiation given off by the arc itself.
• Wear suitable fireproof clothing over all your body.
• Wear protective gauntlets designed for welding use.
• Wear a welding facemask fitted with the correct filter
shade suitable for the current at which you’re welding.
• Avoid wearing oily or greasy clothing as a spark may
ignite them. Where possible ensure that a suitable first
aid kit and a first aid person qualified in the treatment of
burns are available nearby.
Fumes
Welding operations give off harmful fumes that are hazard-
ous to your health.
• Make sure the welding area is well ventilated. Use suit-
able fume extractors or exhaust fans if necessary.
• If the ventilation is not suitable then breathing appara-
tus may have to be used.
• Do not weld plated metals or metals which contain
Lead, cadmium, Zinc, Mercury or Beryllium unless you
are wearing suitable breathing apparatus.
Electric Shock
• Do not touch live electrical parts.
• Do not work in wet or excessively humid areas and do not
site the RT4 /RT5 on a wet surface.
• Avoid touching the work piece whilst welding.
• Do not use the RT4 /RT5 without it’s protective
cover
• Keep your clothing and body dry
The safe handling of gas cylinders
The RT4000/RT5000 uses argon when TIG welding. This is an
inert gas and can displace oxygen in the atmosphere lead-
ing to asphyxiation.
• Note! Gas cylinders are under pressure and can explode
if punctured. Please ensure the cylinder is secured in a
stable location, away from any heat source or potential
mechanical damage.
• The cylinder must be securely fastened to a wall or
placed in a specially designed cylinder carrier.
• Do not use gas cylinders whose contents you are unsure
of.
• Do not try to directly connect a gas cylinder to the
RT4 /RT5 without using a pressure-reducing regula-
tor designed for use with argon.
• Always install and use pressure regulators in accordance
with the manufacturers instructions.
• It is advisable, when attaching the regulator to the gas
bottle, to briefly turn on the bottle valve to expel any
foreign objects that may be present. These may later
block the solenoid valve of the machine if not dealt with.
Turn your face away from the bottle valve when under-
taking this action.
• Check the gas cylinder, pressure regulator and gas hoses
regularly for leaks and discard any suspect item.
• Always turn off the valve on the gas cylinder when you
have finished welding.
Further information is available in publication HSG118 'The safe use
of compressed gases in welding, flame cutting and allied proc-
esses', which may be obtained from the Health & Safety Executive.
Welding and earth return cables
• Earth return and electrode holder cables must have a
cross sectional area of at least 35mm
2
.
• Only use copper cables, the use of Aluminium cables
may have a detrimental effect on the performance of
the machine.
• Regularly inspect welding cables and connectors for
wear abrasion and corrosion. Corroded cables and con-
nectors may overheat and become a fire hazard.
• Ensure that all welding connectors are fully mated, the
connectors should be pushed fully home and then turned
clockwise to lock. If the connectors are not mated fully
they may overheat and become a fire hazard.
• If possible, fasten the earth return clamp directly to the
job to be welded and ensure that the surface is free from
rust and paint.

RT5/4000
5
SECTION 2 — SPECIFICATION SECTION 2 — SPECIFICATION
2.1 - Description
The RT4 is a 4 A (5 A for the RT5 ) constant current welding power source
based on IGBT technology. The Inverter drive circuitry operates above the audio fre-
quency spectrum making the RT4 /RT5 virtually silent in operation. The high op-
erational frequency also means that the RT4 /RT5 is able to respond quickly to
changing arc dynamics, making for a very smooth and stable arc.
2.2 - Specification
Technical data RT4000 RT5000
Models Available 38 -48 Volts 3 Phase
5 /6 Hz
38 -48 Volts 3 Phase
5 /6 Hz
Input Current at Max Output 25 amps 35 amps
Power Consumption 18 KVA 25 KVA
Recommended Mains Fuse 32A slow blow or type
C MCB
4 A slow blow or type C
MCB
Mains Cable 4 x 4. mm² flexible ca-
ble 4 x 4. mm² flexible cable
Power Factor .95 .95
Max Output Current 4 amps 5 amps
Open Circuit Voltage >75V >8 V
Current Control 15-4 A Infinitely Vari-
able
15-5 A Infinitely
Variable
Duty Cycle at 4 ºC 7 % 7 %
Degree of Protection IP23 IP23
Electrode Size 1.6 – 6.3 1.6 – 6.3
Insulation Class F F
H x W x L (mm) 455 x235x5 455 x235x5
Weight (kg) 33 37

RT5/4000
6
SECTION 3 — INSTA ATION
3.1 Siting the RT4000/RT5000
• Site the RT4 /RT5 on a clean dry sur-
face, preferable above ground level.
• Make sure there is at least 2 cm 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 grind-
ing and cutting operations do not enter the
machine.
Note! Damage caused by metal particles and
water entering the machine will not be cov-
ered under warranty.
3.2 Connecting to mains supply
WARNING! All electric shocks are potentially
fatal, a competent electrician should carry
out the fitting 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 fitted) are in good condition and are of
the correct current carrying capacity. If the
machine is wired directly to the mains sup-
ply then an isolator switch must be fitted.
Note! See the technical specifications page for
correct supply information
Primary cable length
Long cable lengths may reduce the perform-
ance 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.
3.3 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 cover of the RT4 /RT5 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.

RT5/4000
7
SECTION 4 — OPERATION
4.1 Operating Controls and Connections
1
1
1
1
1
1
7
6
9
10
1
3
2
8
4
1
5
4.2 Description of controls
1. TIG2/TIG 4 switch - This control switches between 2s and 4s operation (normal and latch). In TIG2 position, when the
torch switch is pressed the arc ignites, when the switch is released the arc goes out. In TIG4 position, when the torch
switch is pressed and released the arc ignites, to extinguish the arc you must press and release the torch switch again.
2. TIG/MMA switch - This control switches the Viper's operating mode between MMA and TIG .
3. Slope up control - With the slope up control set to minimum the Viper will strike at the current set by the current con-
trol. With the slope up control set to anywhere but minimum the Viper will strike at 3 A and then gradually increase the
current to the setting on the current control, the time this takes is determined by the position of the slope up control.
4. Current control - Adjusts the machines output current.
5. Remote control socket - For connection of external remote control or TIG3 external TIG control unit. There is no
switch for remote operation, plugging an external unit into the socket automatically selects remote operation and dis-
ables the internal current control.
6. Torch switch socket - For connecting the TIG torch control switch lead using DIN plug.
7. Gas out connector - This is a female quick coupling with an internal shut- off valve.
To connect, push the male connection on the end of the TIG torch adaptor into the coupling until you hear a click. To
fully disconnect, push the knurled ferrule on the connector inwards towards the Viper until it stops.
The shut off valve in the connector automatically closes when the connection is separated.
8. Digital Display - Indicates welding current in Amps, slope up, slope down and post gas times and also gives an indica-
tion when the machine is over temperature.
9. Slope down control - With the slope down control set to minimum the current will shut down immediately the torch
switch is released. With the slope down control set to anywhere but minimum and the torch switch released, the current
will gradually decrease from the setting on the current control to 5 amps, where the current will extinguish, the time this
takes is determined by the position of the slope down control.
.

RT5/4000
8
SECTION 4 — OPERATION
4.2 Description of controls (cont..)
10 Post Gas time - This control sets the post gas delay, This is the period of time that the gas will continue flowing after
the arc has extinguished. The length of this period is determined by the position of the control.
11. -ve weld terminal - Main welding power output connector, negative polarity.
12. +ve weld terminal - Main welding power output connector, positive polarity.
13. Auxiliary supply fuse - protects the auxiliary supply from the remote control socket. Fuse type is 2 x 5mm glass body,
6.3A ‘slow blow’ rating.
14. Main supply fuse - Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
15. Mains Input - Three phase mains cable.
16. Main 3P Isolation switch - Switches the machine on and off.
17. Gas in connector - Must be connected to the pressure regulator on the gas cylinder by means of a suitable hose.
4.3 Operation
4.3.1 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 RT4 /RT5 is suitable for welding all types of electrodes within the current rating of the machine (see Technical
Data)
The RT4000/RT5000 should never be used with arc-air gouging or cutting electrodes.
4.3 2 MMA Welding with remote control
• Select welding polarity as in paragraph 4.3.1.
• Plug the control cable supplied with the remote control into the remote control socket on the front of the RT4 /
RT5 .
• 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 New-Arc RC3 remote does not have current settings but is marked 1 to 1 , for the
RT4 allow 4 A per division and for the RT5 allow 5 A per division).
• Turn the mains switch to the on position, the machine is ready to weld.
4.3.3 TIG Welding
• Switch the mode switch to ‘TIG’ and select either 2T or 4T torch mode.
• Connect the TIG torch power cable to the negative output connector.
• Connect the TIG torch gas connector to the gas quick coupler.
• Connect the welding ground to the positive output connector.
• Connect a supply of pure argon to the connector at the rear of the machine.
• Turn the mains switch on the RT4 /RT5 to the on position, the digital display will indicate current when the
machine is ready for use.
• Adjust the slope, current and post gas controls to the required settings, you are now ready to weld.

RT5/4000
9
SECTION 5 — FAU T FINDING AND MAINTAINANCE
5.1 Machine operation
Most problems with the RT4 /RT5 can be over-
come by following the procedures below.
No Digital Display on switch on.
• Check that the machine is attached to a work-
ing 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 : 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 rat-
ing of 2A ‘slow blow’
• Have a competent electrician check that there
are no mains fuses or overload devices inter-
rupted, that the mains plug is fitted correctly
and that there are no loose wires or connec-
tions, 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 RT4 /RT5 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 ma-
chine switched on until it has cooled down, if
you turn the machine off, the cooling fans will
be turned off and the cooling down period will
be lengthened considerably.
Note : If the RT4000/RT5000 is overheating on a
regular basis or at current settings below the maxi-
mum, 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 RT4000/RT5000 please
refer to the relevant part of section 5.3.2, the three
monthly service schedule.
5.2 Welding Problems
MMA
If problems with the RT4000/RT5000’s operation while
welding are experienced, first refer to the informa-
tion in paragraph 3.2 in the installation section and
paragraphs 4.3.1 and 4.3.2 in the operating section
and the fault finding procedure earlier in this sec-
tion.
• 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 neces-
sary practice on a piece of scrap the same
thickness as the job to be welded.
TIG
If problems with the RT4000/RT5000’s operation
while TIG welding are experienced, first refer to the
information in paragraph 3.2 in the installation sec-
tion and paragraph 4.3.3 in the operation section.
The common problems with TIG welding are poor
striking, porosity and poor appearance of the
weld. If you are experiencing any problems with
TIG welding follow the check list below, this will
cure most problems :-
• If the unit is suffering from poor striking, check
that all power leads are connected properly,
check that there is sufficient gas flow and that
the correct gas is being used, check that the
earth clamp is making a good connection to
the work-piece.
• If there is porosity in the weld or the final weld is
of poor appearance, check that there is suffi-
cient gas flow and that the correct gas is being
used, check the condition of the TIG torch, par-
ticularly the gas hose. Make sure that the collet
or gas lens in the torch head is not blocked in
anyway. Check all gas connections are secure
and that there are no leaks, use a leak detect-
ing spray on all connections if necessary.
Any welding problems not covered above must be
brought to the attention of a qualified Welding En-
gineer, if the problem still persists have the
RT4 /RT5 checked by a trained New-Arc ser-
vice engineer.

RT5/4000
1
SECTION 5 — FAU T FINDING AND MAINTAINANCE
5.3 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 RT4 /RT5 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 trou-
ble free operation.
5.3.1 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.
5.3.2 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 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 en-
try/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 due
to overheating, this is generally caused by poor connection of the welding power leads due to
loose connection bolts inside the set, or poor quality welding connectors on the electrode
holder or earth return lead and can be a common cause of welding set failure.
5.3.3 Annually
As per the three monthly schedule, plus :-
• The machines calibration should be checked, if necessary have the machine re-calibrated by a
New-Arc trained technician.

RT5/4000
11
SECTION 6 — E ECTRICA DIAGRAMS
6.1 - System Diagram

RT5/4000
12
4
2
3
5
7
6
10
12
11
14
8
9
1
13
SECTION 7—PARTS BREAKDOWN
7.1 - Component ocations

RT5/4000
13
SECTION 7—PARTS BREAKDOWN
7.1 - Component ocations
15
20
22
25
21
16
17
28
26
19
29
30
32
35
24
18
23
27
31
33
34

RT5/4000
14
SECTION 7—PARTS BREAKDOWN
7.2 - Parts list for RT5000/4000
Item no. Description Part Number
3
1 Bridge handle (x 2) M 1 84
2 2 mm diameter knob M 33A
3 Torch switch socket assembly M9 79
4 Standby switch M7 69A
5 5 / 7 panel mount Dix socket (x 2) M 547
6 Remote socket assembly M9 762
7 Gas quick connector M 957
8 Fuse holder
Fuse 3.15A slow blow, 32 x 6.3mm ceramic body
M 1 88/89
M 2 A
9 Fuse holder
Fuse 6.3A slow blow, 2 x 5mm glass body
M 273
M 379
1 Diode bridge M6 57
11 Soft start resistor assembly M9 765
12 Auxiliary transformer M 14 6
13 HF Relay M7 26
14 Soft start relay M7 26
15 Mains Switch — 3 phase power M7 71
16 Control PCB M9 744
17 TIG Display PCB M 923
18 TIG PCB M9 65
19 Current Transducer M 1 83
2 IGBT (x 2) M6 245
21 Snubber Capacitors (x 2) M4 794
22 IGBT Gate PCB (x 2) M9 843
23 HF Transformer M 1126
24 Power Resistors M9 999
25 Gas Valve Assembly M9 183/TIG
26 Capacitor Assembly M95 4
27 Thermostat M 332/8 V
28 HF PCB M8 36
29 Filter Capacitor assembly (x 3) M91123
3 Diode module (x 4) M6 121
31 Main inductor M 1 94
32 Current transducer M6 112
33
Main transformer
R4
R5
M 1 93
M 878
34 Cooling fan (x 2) M 371
35 De-coupling capacitor M9 818
When ordering spare components please quote the serial number of the unit for which the parts are intended.

Head Office
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Walker Riverside
Newcastle upon Tyne
NE6 3PF
Tel: [phone]
Fax: [phone]
Website: www.newarc.co.uk
e-mail: [email protected]
Aberdeen Office
Unit 23 Kirkhill Place
Kirkhill Industrial Estate, Dyce
Aberdeen
AB21 0GU
Tel: [phone]
Fax: [phone]
Guarantee
New-Arc Equipment Ltd warrants that its goods and services are guaranteed to meet the specific
performance under the stated conditions of use. New-Arc 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 conditions of use. The stated conditions of use are that considered normal industrial prac-
tice and are not exhaustive. Each machine is identified with a unique serial number and accompa-
nied with the guarantee. New-Arc reserve the right to a) Repair. b)Replace. c)Authorise the reason-
able cost of repair or replacement at an approved New-Arc service agent. d)Credit for any pur-
chased equipment (less reasonable depreciation for actual use and condition) at its entire discre-
tion. This in no way affects your rights as a consumer. The guarantee is enclosed with each machine.
Waiver
Whilst every endeavour is made to ensure the details of this document are correct at the date of
print. New-Arc accepts no liability for correctness in respect of any impending change in legislation
or health and safety requirements. New-Arc also reserve the right to amend the detail of the docu-
ment content without any notification to the consumer. If reference is made to New-Arc while utilis-
ing the document for spare parts purchase or instruction please advise the revision of the document
to ensure correctness of information.