NewArc r1500 User manual

Processes
Description
INSTRUCTION MANUAL
Newarc Equipment Ltd.
UK‘s Leading Manu acturer O Welding Equipment
Newcastle [phone]
Aberdeen [phone]
www.newarc.co.uk
To maintain continued developments o our products we reserve the right to alter speci ications as quoted without prior notice
R1500
Important Information
All persons authorised to use, repair or service the R1500 In-
verter based welding machine should read the section on
sa ety, be ore any work is undertaken. Further in ormation is
available in publication HSG118 'Electric sa ety in arc welding',
which may be obtained rom the Health & Sa ety Executive.
Please contact your distributor should you not understand any
o the in ormation within this document.
MMA unit

R1500
SECTION 1 — SAFET
1.1 - Servicing Hazards 4
SECTION 2 — SPECIFICATION
2.1 - Description______________________________________________________________ 5
2.2 - Technical Speci ication__________________________________________________ 5
SECTION 3 — INSTALLATION
3.1 - Positioning the 1500______________________________________________________ 6
SECTION 4 — OPERATION
4.1 - Operation Controls and Connections___________________________________ 7
4.3 - Operation_____________________________________________________________ 7
SECTION 5 — FAULT FINDING AND MAINTENANCE
5.1 - Machine Operation____________________________________________________ 8
5.2 - Maintenance__________________________________________________________ 8
SECTION 6—PARTS BREAKDOWN
6.1 - Component Locations__________________________________________________ 9
6.2 - Parts List_______________________________________________________________ 10
4.2 - Description o Controls_________________________________________________ 7
TABLE OF CONTENTS

R1500
SECTION 1 — SAFET
Fire and Explosions
Pay attention to fire and safety regulations in
force at the welding site.
• Remove all lammable or combustible ma-
terials rom the welding area and the im-
mediate vicinity.
• Suitable ire ighting equipment must al-
ways be present where welding is carried
out.
• Be aware that a ire risk is present or a
considerable time a ter welding opera-
tions have ceased because o sparks and
hot slag etc. Take suitable precautions
when you have inished welding.
• Take care when welding containers that
have held lammable or combustible ma-
terial, these should have been specially
cleaned be ore being given to the welder.
I 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 ireproo clothing over all
your body.
• Wear protective gauntlets designed or
welding use.
• Wear a welding acemask itted with the
correct ilter shade suitable or the current
at which you will be welding.
• Avoid wearing oily or greasy clothing as a
spark may ignite them. Where possible en-
sure that a suitable irst aid kit and a irst
aid person quali ied in the treatment o
burns are available nearby.
Fumes
Welding operations give off harmful fumes
that are hazardous to your health.
• Make sure the welding area is well venti-
lated. Use suitable ume extractors or ex-
haust ans i necessary.
• I the ventilation is not suitable then breathing
apparatus may have to be used.
• Do not weld plated metals or metals which
contain lead, cadmium, Zinc, Mercury or Beryl-
lium 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 R1500 on a wet sur ace.
• Avoid touching the work piece whilst welding.
• Do not use the R1500 without it’s protective cover
• Keep your clothing and body dry
Welding and earth return cables
• I using long (above 10 meters in length) earth
return and electrode holder cables then they
must have a cross sectional area o at least
35mm
2
Only use copper cables, the use o Alu-
minium cables may have a detrimental e ect
on the per ormance o the machine.
• Regularly inspect welding cables and con-
nectors or wear, abrasion and corrosion. Cor-
roded cables and connectors may overheat
and become a ire hazard.
• Ensure that all welding connectors are ully
mated; the connectors should be pushed ully
home and then turned clockwise to lock. I
the connectors are not mated ully they may
overheat and become a ire hazard.
• I possible, asten the earth return clamp di-
rectly to the job to be welded and ensure
that the sur ace is ree rom rust and paint.
Further information is available in publication
HSG118 'Electric safety in arc welding', which
may be obtained from the Health & Safety Execu-
tive.

R1500
2.1 Description
The R1500 is a 150 amp constant current MMA welding machine based on IGBT technol-
ogy. The inverter drive circuitry operates above the audio requency spectrum making
the R1500 virtually silent in operation.
The high operational requency also means that the R1500 is able to respond quickly to
changing arc dynamics, making or a very smooth stable arc.
The R1500 is capable o welding with all types o electrodes within the current rating o
the machine, normally up to 4mm.
The R1500 is able to TIG weld using a TIG torch with a built in gas valve using the 'scratch
start' technique.
The R1500 is available in three versions, a dedicated 230v, dedicated 115V and a
115/230V auto switching dual Voltage version.
SECTION 2 — SPECIFICATION
1.3 Technical data
Rated Supply Voltage 230 volts single phase 115V/230V/Dual Voltage
Power Consumption 5.1 KVA
Supply Current
230v 21 amps
115v 42 amps
Mains Input Fuse
230v 20 amp s slow blow or type C MCB
115v 40 amps slow blow or type C MCB
Mains Cable
230v 3 x 2.5mm² lexible cable
115v 3 x 6mm² lexible cable
Output Current Range 5-150 amps
Duty Cycle at 40ºC 100%
Insulation Class F
Degree o Protection IP21
H x W x L (mm) 275 x 152 x 415
Weight (kg) 15

R1500
SECTION 3 — INSTALLATION
3. Installation
Positioning the R1500
• Site the R1500 on a clean dry sur ace, pre erably above ground level.
• Make sure there is at least 20cm clearance at the ront, rear and sides o the machine
to allow good circulation o the cooling air.
• Protect the machine rom heavy rain and i 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 is not covered
under warranty.
Connecting to mains supply
WARNING! All electric shocks are potentially fatal; a competent electrician should under-
take the fitting of the mains plug.
Note! The Dual Voltage version of the machine is fitted with circuitry that senses the mains
input voltage and automatically configures the machine. This requires no changing of tap-
ping points inside the machine or intervention on the operator’s part; just fit the relevant
type of mains plug for the supply the machine is to be used on.
• Make sure that the mains supply is o the correct voltage and current capability or the
machine.
• Make sure that the mains cable and any extension cables used are o su icient current
carrying capacity.
• Make sure that the mains plug and socket (i itted) are in good condition. I the ma-
chine is wired directly to the mains supply then an isolator switch must be itted
IMPORTANT! 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 that the mains cable is not
coiled up when you are welding.
Note! See the technical specifications page for correct supply information

R1500
SECTION 4 — OPERATION
4.1 Operational Controls and Connections
4.2 Description of controls
1 On-Off switch
Upon switching on, the overload indicator will
light, a ter 15 seconds the overload indicator
will extinguish and the machine is ready or
use.
2 Power on indicator
Indicates that the machine is connected to
the mains supply and turned on
3 Current control
Sets the output current o the R1500
4 Overload indicator
Indicates that the thermal cut-out has oper-
ated (see the ault inding and maintenance
section or possible reasons)
5 Arc-force control
Operates in MMA mode only and controls the
welding dynamics o the machine to acili-
tate welding with di erent types o welding
electrodes Turning clockwise will increase
penetration at the expense o increased
welding spatter, turning anti-clockwise will
reduce penetration but the arc will be
smoother and less ierce.
6 Negative weld out connector.
Main welding power output connector, nega-
tive polarity.
7 Positive weld out connector
Main welding power output connector, posi-
tive polarity.
4.3 Operation
MMA Welding
• For straight polarity welding, connect the elec-
trode holder to the positive weld terminal and
the earth return lead to the negative weld ter-
minal. For reverse polarity welding, reverse
these connections.
• Turn the mode switch to 'MMA', the machine is
now in MMA mode.
• Turn the mains switch to the on position, the
power-on and overload indicators will light. A -
ter approximately 15 seconds the overload indi-
cator will extinguish and the machine is ready
to weld.
• Turn the current control to the recommended
setting or the size and type o welding elec-
trode to be used.
• When welding, adjust the Arc- orce control to
achieve the arc condition you require.
• The R1500 is suitable or welding all types o
electrodes within the current rating o the ma-
chine, normally up to 3.2 or 4mm depending on
the type o rod.

R1500
SECTION 5 — FAULT FINDING AND MAINTAINANCE
5.1 Machine operation
Most problems with the operation of the R1500 can
be overcome by following the procedures below.
No power-on indicator on switch on.
• Check that the machine is attached to a working
mains supply and that it is correctly plugged in and
any isolator switch is closed.
• Have a competent electrician check that there are
no uses or overload devices interrupted, that the
mains plug is itted correctly and that there are no
loose wires or connections, check that there are no
breaks in the mains cable.
Power-on indicator lit but no output.
• Make sure that the overload indicator goes o a ter
15 seconds. I not see paragraph 'thermal cut-out indi-
cator' below.
• This indicator must be o or normal operation. I on it
indicates that the R1500 has overheated and the
power stages o the R1500 have been shut down so
you will get no current output.
In normal climate conditions (25°C and below) the R1500
has a 100% duty cycle so operation o the thermal cut
out indicates that the inside o the
machine is likely to be choked with dust and there ore not
being cooled properly.
In Hot climates (above 25°C) it may indicate that you are
exceeding the duty cycle o the R1500.
Leave switched on or a ew minutes and the R1500
should return to normal operation, do not switch the R1500
o as this will stop the operation o the cooling an and
greatly extend the cool down period.
Frequent tripping o the thermal cut-out, especially at low
current settings is indicative that the inside o the machine
is likely to be choked with dust.
For information about cleaning the dust out of the R1500
please refer to the relevant part of the next section.
Any operating problems not covered above should be
referred to a trained New-Arc service engineer or returned
to the factory for repair.
5.2 Maintenance
Note! All Electric shocks are potentially fatal, switch
the machine off and disconnect from the power
supply before undertaking out any maintenance
work.
• It is very important that the R15000 is regularly main-
tained. The amount o use and the working environ-
ment must be taken into account when scheduling the
maintenance periods.
• Care ul use and regular preventative maintenance will
prolong the li e o the machine and ensure trouble ree
operation.
5.2.1 Weekly
• Clean the exterior o the machine
• Inspect the machines exterior or obvious signs o dam-
age.
• Check the condition o the welding cable, earth
clamp, welding output and power in connectors or
damage and any sign o over-heating.
• Check the condition o the mains lead and plug.
5.2.2 Three monthly
As per the weekly schedule, plus:-
• Remove the side covers rom the machine. Remove
the build up o dust and debris rom inside the ma-
chine, particularly rom the Heat-sink extrusion, by use
o either compressed air at reduced pressure or an
industrial type vacuum cleaner.
• Make a thorough visual inspection o the interior o the
machine, look particularly or pieces o welding wire, or
stubs o old welding rods that may have got through
the cooling air intakes.
• Check the condition o the welding output connectors,
look or any signs o discolouration due to overheating,
this is generally caused by poor connection o 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 o welding set ailure.
5.2.3 Annually
As per the three monthly schedule, plus :-
• Have the machines calibration checked, i neces-
sary have the machine re-calibrated by a New-Arc
trained technician.

R1500
6.1 Parts Locations
SECTION 6 — PARTS BREAKDOWN
16
1616
16
17
1717
17
18
1818
18
15
1515
15
14
1414
14

R1500
SECTION 6 — PARTS BREAKDOWN
6.2 R1500 Parts list
Item no. Description Part No.
3
1 Cooling an (230Vac) M00311/A
2 Diode module (behind bracket) (2 o ) M60121
3 Main trans ormer M90136
4 Secondary Inductor M90133A
5 Plastic eet (4 o ) M00096
6 Auxiliary trans ormer M00305
7 200A Shunt M00309
8 24v relay (Dual voltage only) M70026
9 Diode bridge (2 o on Dual Voltage machine) M60079
10 Main PCB 230V M90125/A
10 Main PCB Dual voltage M90148/1
11 Control PCB M90127
12 IGBT module M60074
13 Thermostat (80ºc) M00332/80
14 Auto-switching PCB (Dual voltage only) M90961
15 Rocker switch M70069
16
Current control potentiometer (10K linear) M20105
Control knobs M00033A
17
Arc- orce control potentiometer (470K linear) M20099
Control knobs M00033A
18 Panel mount Dinse type connectors (2 o ) M00037
Misc. 2 amp, 20mm use (Quick blow) M00274

Head O ice
6 Wincomblee Road
Walker Riverside
Newcastle upon Tyne
NE6 3PF
Tel: [phone]
Fax: [phone]
Website: www.newarc.co.uk
e-mail: [email protected]
Aberdeen O ice
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 speci ic
per ormance under the stated conditions o use. New-Arc cannot be held responsible or general
wear and tear or or ailure occurring due to misuse or abuse arising out o circumstances outside
the stated conditions o use. The stated conditions o use are that considered normal industrial prac-
tice and are not exhaustive. Each machine is identi ied with a unique serial number and accompa-
nied with the guarantee. New-Arc reserve the right to a) Repair. b) Replace. c) Authorise the rea-
sonable cost o repair or replacement at an approved New-Arc service agent. d) Credit or any
purchased equipment (less reasonable depreciation or actual use and condition) at its entire dis-
cretion. This in no way a ects your rights as a consumer. The guarantee is enclosed with each ma-
chine.
Waiver
Whilst every endeavor is made to ensure the details o this document are correct at the date o
print. New-Arc accepts no liability or correctness in respect o any impending change in legislation
or health and sa ety requirements. New-Arc also reserve the right to amend the detail o the docu-
ment content without any noti ication to the consumer. I re erence is made to New-Arc while utilis-
ing the document or spare parts purchase or instruction please advise the revision o the document
to ensure correctness o in ormation.