NewArc NA9910619 Quick start guide

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Operational Manual
Newarc R5000
NA9910619

R5000
2
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.
R5000
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.

R5000 3
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.

R5000
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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.

R5000 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.

R5000
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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. Warranty 17
7. Parts 18
Contents

R5000 7
1. Preface
Congratulations on choosing your Newarc R5000 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

R5000
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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
• Inverter conguration provides a more stable and faster response in CC and CV control resulting in
more stable welding conditions
• Fabricated in robust external casing to withstand the most extreme environments
• Cooling on demand system minimizes power consumption and dust ingress
• The construction technique ensures minimal contamination of internal electronic systems
• Large overhead of voltage available for use with long interconnection cables.

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1.3 Technical Specications
Newarc R5000
Input Current at Max Output 33 amps
Power Consumption 25KVA
Recommended Mains Fuse 40A slow blow or type C MCB
Mains Cable 4 x 4.0mm² exible cable
Power Factor 0.95
Max Output Current 500 amps
Open Circuit Voltage
Dimensions (L x W x H) (mm) 570 x 310 x 450
>90V
Current Control 5-250 amps 20-500A Innitely Variable
Duty Cycle at 40ºC 60% @500A
100% @400A
Electrode Size 1.6 – 6.3
Weight (kg) 37
Insulation Class F

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1.4 Overview of Machine
Front View
Power source front panel layout
1. Mode Indication
2. Digital Display
3. Off/On switchl
4. Output Demand Control
5. Slope control
6. Mode switch
7. Arc force control
8. Remote control socket
9. Inductance control
10. -ve weld terminal
11. +ve weld terminal
Rear View
12. Main 3P Isolation switch
13. Mains Input .
14. Auxiliary transformer supply fuse
15. Remote supply fuse
16. Main supply fuse to the cooling unit
17. Auxiliary Cooling unit supply fuse
R5/4000 CCCV
7
SECTION 4 — OPERATION
4.1 - Operating Controls and Connections
1. Mode Indication - LEDs to display welding mode.
2. Digital Display - Indicates welding current in Amps, welding voltage in Volts. The display also gives an indication when the machine is over temperature (-
OT -) , or the optional cooling unit is turned off (-CU-).
3. Off/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.
4. Output Demand Control - Adjusts the machines output current in CC mode or Voltage in CV mode.
5. Slope control - Operates in MIG mode only. This control alters the output voltage(V) to output current(I) relationship. This control is sometimes know as ‘Arc
Control’ or ‘Arc Pinch Control’ as it regulates the pinch effect of the welding arc.
6. Mode switch - Selects welding mode when there is no remote connection.
7. Arc force control - Operates in MMA mode only. This control alters the welding dynamics of the machine to facilitate welding with different types of weld-
ing electrodes (e.g. general purpose, celulosic, low hydrogen and iron powder). Turning towards maximum will increase penetration at the expense of in-
creased welding splatter, turning towards minimum will reduce penetration but the arc will be smoother and less fierce.
8. Remote control socket - For connection of external remote control, external TIG control unit or wire feed unit. There is no switch for remote operation,
plugging an external unit into the socket automatically selects remote operation and disables the internal control (4).
9. Inductance control - Operates in MIG mode only. This control alters the response time of the power source and is generally used in short circuit dip transfer
welding. Too little inductance will result in excessive spatter and too much inductance will not allow the welding current to rise fast enough causing the
electrode to stub into the base metal.
10. -ve weld terminal - Main welding power output connector, negative polarity.
11. +ve weld terminal - Main welding power output connector, positive polarity.
12. Main 3P Isolation switch - Switches the machine on and off.
13. Mains Input - Three phase mains cable.
14. Auxiliary transformer supply fuse - Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
15. Remote supply fuse - Protects the auxiliary supply from the remote control socket. Fuse type is 20 x 5mm glass body, 6.3A ‘slow blow’ rating
16. Main supply fuse to the cooling unit (Only fitted to cooling unit version) - Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
17. Auxiliary Cooling unit supply fuse (only fitted to cooling unit version) - protects the auxiliary supply to the cooling unit. Fuse type is 20 x 5mm glass body, 2A
‘slow blow’ rating.
12
13
1
5
8
3
4
6
2
9
10 11
7
14
16
15
17
1. Mode Indication
LEDs to display welding mode.
2. Digital Display
Indicates welding current in Amps, welding voltage
in Volts. The display also gives an indication when the
machine is over temperature (- OT -) , or the optional
cooling unit is turned off (-CU-).
3. 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.
4. Output Demand Control
Adjusts the machines output current in CC mode or
Voltage in CV mode.

R5000 11
5. Slope control
Operates in MIG mode only. This control alters the output voltage(V) to output current(I) relationship.This control
is sometimes know as‘Arc Control’or‘Arc Pinch Control’as it regulates the pinch effect of the welding arc.
6. Mode switch
Selects welding mode when there is no remote connection.
7. 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.
8. Remote control socket
For connection of external remote control, external TIG control unit or wire feed unit. There is no switch for
remote operation, plugging an external unit into the socket automatically selects remote operation and
disables the internal control (4).
9. Inductance control
Operates in MIG mode only. This control alters the response time of the power source and is generally used
in short circuit dip transfer welding. Too little inductance will result in excessive spatter and too much will not
allow the welding current to rise fast enough causing the electrode to stub into the base metal.
10. -ve weld terminal
Main welding power output connector, negative polarity.
11. +ve weld terminal
Main welding power output connector, positive polarity.
12. Main 3P Isolation switch
Switches the machine on and off.
13. Mains Input
Three phase mains cable.
14. Auxiliary transformer supply fuse
Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
15. Remote supply fuse
Protects the auxiliary supply from the remote control socket. Fuse type is 20 x 5mm glass body, 6.3A‘slow
blow’rating
16. Main supply fuse to the cooling unit (Only tted to cooling unit version)
Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
17. Auxiliary Cooling unit supply fuse (only tted to cooling unit version)
Protects the auxiliary supply to the cooling unit. Fuse type is 20 x 5mm glass body, 2A‘slow blow’rating.

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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
Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other impurities
to enter the machines cooling air ow. Preferably site the machine above oor level; for example on a
suitable carriage unit.
Notes for positioning the machine
• Make sure there is at least 20cm clearance at the front, rear and sides of the machine to allow good
circulation of the cooling air.
•Ensure that the machine is positioned in such a way that particles created by grinding and cutting
operations do not enter the machine.
NOTE! Protect the machine from heavy rain and if used in hot climates, against direct sunlight.
WARNING! All electric shocks are potentially fatal, a competent electrician should under-take the tting
of the mains plug.
Setting supply voltage tapping
To enable the setting of the supply voltage tapping, the front
panel display cover of the R4000/R5000 has to be removed.
• The photograph opposite shows the voltage tapping set to
415V, with the red wire from thefuse holder connected to the
415 terminal.
• This connector can be moved to the requiredvoltage terminal
to select the desired input voltage.
Assure that the mains supply is of the correct voltage and current
capability for the machine. Make sure that the mains cable and
any extension cables used are of sufficient current carrying capacity.
Check the mains plug and socket (if tted) are in good condition. If the machine is wired directly to the
mains supply then an isolator switch must be tted.
Primary cable length
Long extension cable lengths may reduce the performance of the machine, the welding arc may
become unstable especially at higher currents. Ensure the mains cable is not coiled up when you
are welding as this will reduce the input voltage to the machine and may cause overheating and
degradation of the cable.
R5/4000 CCCV
6
SECTION 3 — INSTALLATION
3.1 Siting the R4000/R5000
• Site 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 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 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.

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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 R4000/R5000 is suitable for welding all types of electrodes within the current rating of the machine
(see Technical Data)
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 R4000/R5000
• 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 R4000 allow 40A per division and for the R5000 allow 50A per division).
• Turn the mains switch to the on position, the machine is ready to weld.
TIG Welding with TIG unit
• Connect the TIG unit to the R4000/R5000 and the shielding gas supply as per the diagrams in the TIG
unit manual.
• Select welding mode and current by adjusting the controls on the TIG unit with reference to 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.
MIG Welding with Wire Feed Unit
• Connect the WFU to the R4000/R5000 and the shielding gas supply as per the diagrams in the
WFU unit manual.
• Select welding mode and current by adjusting the controls on the WFU with reference to the
WFU manual.
• Turn the mains switch on the R4000/R5000 to the on position and select MIG on the mode switch,
(this will be automatic if a remote connection is being used). The digital displays on the R4000/R5000
and the WFU will now light up, you are now ready to weld.
3. Operation

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14
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!
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‘OT’, if it is, it means that the R4000/R5000 has overheated,
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 regular 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 R4000/R5000 please refer to the
relevant part of section 5.3.2, 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).
MIG Unit is not working
• Check the condition of the 6.3A 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 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

R5000 15
MMA
If problems with the R4000/R5000’s operation while welding are experienced, rst refer to the
information in the installation section and paragraphs 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.
MIG
If problems are experienced whilst MIG welding, please consult the fault nding and maintenance
section of the WFU 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

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16
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 an plug.

R5000 17
6. 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.
PLEASE NOTE
The manufacturer reserves the right to change and alter the equipment without prior notice. This
includes but is not limited to: operating procedures, technical specications, technical schematics
and manuals
CAUTION
• There are no user serviceable parts/modules inside this equipment.
• Removing lids or covers will/may expose hazardous voltages
• Removal of lids or covers WILL invalidate the warranty on this equipment.

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7. Parts
R5/4000 CCCV
12
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations
5
1
2
6
4
3
9
12
11
13
7
8
14
10

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

R5000
20
23
22
21
20
19
18
17
16
15
14
13
12
11
10
8
7
6
3
Item Part number
Front bridge handles (2 per machine) NAM01393
Lid Bridge handle (2 per machine) NAM01084
70/90 panel mount Dix socket (2 per machine) NAM09916
20mm diameter knob (3 per machine) NAM00033A
On/Off switch NAM70069A
Remote socket assembly
Mains Switch — 3 phase power NAM70071
24mm diameter knob NAM00464A
NAM90762
Filter Diac assembly NAM91123
Fuse holder NAM01088/89
Auxiliary transformer NAM01408
Fuse holder NAM00273
Fuse 6.3A slow blow, 20 x 5mm glass body NAM00379
Soft start resistor assembly
Soft start relay NAM60057
Fuse 3.15A slow blow, 32 x 6.3mm ceramic body NAM00020A
NAM90765
Diode bridge NAM60057
Control PCB R4000CC/CV NAM90744-R4000CC/CV
Display PCB R4000CC/CV NAM90771-R4000CC/CV
IGBT (2 per machine) R4000CC/CV NAM60245
IGBT (2 per machine) R5000CC/CV NAM60229
IGBT gate drive assembly (1 per machine)
Display PCB R5000CC/CV NAM90771-R5000CC/CV
Control PCB R5000CC/CV NAM90744-R5000CC/CV
NAM90843
Current transducer NAM60112
Capacitor Assembly NAM90456
Main inductor R5000CC/CV NAM01094/ M10106
Current transformer NAM01083
Main transformer R4000CC/CV
Main inductor R4000CC/CV NAM01094/ M10105
NAM01093/ M10102
Description
Ordering information
1
2
4
5
9
Main transformer R5000CC/CV NAM00878/ M10103
24 De-coupling capacitor NAM90818
25 Diode module (4 per machine) NAM60121
26 Cooling fan (2 per machine) NAM00371
27 Rear lter grill assembly NAM91157
When ordering spare components please quote the serial number of the unit for which the parts are intended.