NewArc R2500 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
R2500
Important Information
The R2500 is a 250 constant current welding power source
based on IGBT technology. The Inverter drive circuitry operates
above the audio requency spectrum making the R2500 virtu-
ally silent in operation. The high operational requency also
means that the R2500 is able to respond quickly to changing
arc dynamics, making or a very smooth , stable arc.
The R2500 is capable o TIG welding with the addition o an
external TIG control unit (TIG300).
MMA unit

R2500
SECTION 1 — SA ETY
1.1 - Servicing Hazards 4
SECTION 2 — SPECI ICATION
2.1 - Description_____________________________________________________________ 5
2.2 - Technical Speci ication__________________________________________________ 5
SECTION 3 — INSTALLATION
3.1 - Siting the R2500__________________________________________________________ 6
3.2 - Connecting to mains supply______________________________________________ 6
SECTION 4 — OPERATION
4.1 - Description o Controls__________________________________________________ 7
4.2 - Operation_____________________________________________________________ 7
SECTION 5 — AULT INDING AND MAINTENANCE
5.1 - MMA Welding Problems________________________________________________ 8
5.2 - Maintenance__________________________________________________________ 8
SECTION 6—PARTS BREAKDOWN
6.1 - Component Locations__________________________________________________ 9
6.2 - Parts List_______________________________________________________________ 10
TABLE O CONTENTS

R2500
SECTION 1 — SA ETY
ire and Explosions
Pay attention to fire and safety regulations in force at the
welding site.
• Remove all lammable or combustible materials rom
the welding area and the immediate vicinity.
• Suitable ire ighting equipment must always be present
where welding is carried out.
• Be aware that a ire risk is present or a considerable
time a ter welding operations 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 material, 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 ensure that a suitable irst
aid kit and a irst aid person quali ied in the treatment
o burns are available nearby.
umes
Welding operations give off harmful fumes that are haz-
ardous to your health.
• Make sure the welding area is well ventilated. Use suit-
able ume extractors or exhaust ans i necessary.
• I 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 R2500 on a wet sur ace.
• Avoid touching the work piece whilst welding.
• Do not use the R2500 without it’s protective cover.
• Keep your clothing and body dry.
The safe handling of gas cylinders
The R2500 uses argon when TIG welding using the TIG300.
This is an inert gases and can displace oxygen in the at-
mosphere leading to asphyxiation.
• Note! I dropped the gas cylinder may explode.
• Check the gas cylinder, pressure regulator and gas
hoses regularly or leaks and discard any suspect item.
• Do not try to directly connect a gas cylinder to the
TIG300 without using a pressure-reducing regulator de-
signed or use with argon.
• Do not use gas cylinders whose o contents you are
unsure.
• The Argon cylinder must be securely astened to a
wall or placed in a specially designed cylinder carrier.
• Always turn o the valve on the gas cylinder when you
have inished welding.
• Always install and use pressure regulators in accor-
dance with the manu acturers instructions.
• It is advisable, when attaching the regulator to the gas
bottle, to brie ly turn on the bottle valve to expel any
oreign objects that may be present. These may later
block the solenoid valve o the machine i not dealt
with. Turn your ace away rom the bottle valve when
carrying out this action.
urther information is available in publication HSG118
'The safe use of compressed gases in welding, flame
cutting and allied processes', which may be ob-
tained from the Health & Safety Executive.
Welding and earth return cables
• Earth return and electrode holder cables must have a
cross sectional area o at least 35mm
2
.
• Only use copper cables, the use o Aluminium cables
may have a detrimental e ect on the per ormance o
the machine.
• Regularly inspect welding cables and connectors or
wear abrasion and corrosion. Corroded 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 directly to the
job to be welded and ensure that the sur ace is ree
rom rust and paint.

R2500
2.1 Description
The R2500 is a 250 constant current welding power source based on IGBT
technology. The Inverter drive circuitry operates above the audio re-
quency spectrum making the R2500 virtually silent in operation. The high
operational requency also means that the R2500 is able to respond
quickly to changing arc dynamics, making or a very smooth , stable arc.
The R2500 is capable o TIG welding with the addition o an external TIG
control unit (TIG300).
2.2 Technical Specification
SECTION 2 — SPECI ICATION
Technical data R2500
Input Voltage Range 380-480V 3 phase 50/60Hz
Power Consumption 9KVA
Input Current at Max Output 12 amps
Mains Cable 4 x 2.5mm² lexible cable
Power Factor 0.95
Degree o Protection IP21
Insulation Class F
Current Control 5-250 amps
Duty Cycle at 40ºC 80%
Electrode Size 1.6 – 5.0
H x W x L (mm) 320 x 180 x 430
Weight (kg) 19.5

R2500
SECTION 3 — INSTALLATION
3.1 Siting the R2500
• Site the R2500 on a clean dry sur ace, pre erable
above ground level.
• Make sure there is at least 20cm clearance at the ront,
rear and right side o the machine to allow good circu-
lation 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 so
that particles created by grinding and cutting opera-
tions do not enter the machine.
Note! Damage caused by metal particles and water
entering the machine will not be covered under war-
ranty.
3.2 Connecting to mains supply
WARNING! All electric shocks are potentially fatal, a
competent electrician should carry out the fitting of
the mains cable and plug.
• Make sure that the mains supply is o the correct volt-
age and current capability or the machine.
• Make sure that the mains cable and any extension ca-
bles used are o su icient current carrying capacity.
• Make sure that the mains plug and socket (i itted) are
in good condition and are o the correct current carry-
ing capacity, i the machine is wired directly to the
mains supply then an isolator switch must be itted.
Note! See the technical specifications page for cor-
rect supply information.
Primary cable length
Long cable lengths may reduce the per ormance o the
machine, the welding arc may become unstable espe-
cially 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.
• Strip approximately 150mm o insulating sheath o the end
o the mains cable, strip back the insulation on the our
cores o the cable to a depth o 8mm.
• Attach the three phase cores to terminals L1, L2 and L3 on
the mains input PCB as shown; using 2.5mm x 6.3mm insu-
lated spade connectors, and attach a 2.5 x 5mm ring ter-
minal to the earth core and connect it to the earth stud,
bolting the terminal down irmly.
• Clamp the cable by tightening the screws on the integral
cable grommet/clamp. This must clamp down the external
insulating sheath o the cable and not the our cores.
When connecting mains cable refer to photo of mains
input connection below:
1 Cable In - Combined cable entry and clamp.
2 Earth - Welded earth stud.
3 Primary Connections - L1, L2 and L3.
4 Voltage Selection - Wire or voltage tapping, shown set
or 415V. Can also be set or 380V or 460V by moving the link
wire to the relevant terminal. Voltages are marked on the
PCB.
NOTE! Never attach link wire to the 220V terminal.

R2500
SECTION 4 — OPERATION
4.1 Description of controls
1 Remote control socket - For connection o external remote
control or TIG300.
2 Overload indicator - Indicates duty cycle has been ex-
ceeded and the thermostat inside the machine has oper-
ated.
3 Mode switch - Selects the welding mode.
4 Current control - Adjusts the machines output current.
5 Power indicator - indicates mains power, lights up when
machine is switched on.
6 -ve weld terminal.
7 +ve weld terminal.
8 O /On switch, (on rear panel o machine).
4.2 Operation
4.2.1 MMA Welding
• For straight polarity welding, connect the electrode
holder to the positive weld terminal and the earth re-
turn lead to the negative weld terminal. For reverse po-
larity welding, reverse these connections.
• Turn the mode switch to 'local', the machine is now in
MMA mode.
• Adjust the current control to the recommended setting
or the size and type o welding electrode to be used.
• Turn the mains switch to the on position, the power on
indicator will light and the machine is ready to weld.
• The R2500 is suitable or welding all types o electrodes
within the current rating o the machine, normally up to
5.0mm.
The R2500 should never be used with arc-air gouging
or cutting electrodes.
4.2.2 MMA Welding with remote control
• Select welding polarity as in paragraph 4.2.1.
• Turn the mode switch to remote.
• Plug the control cable supplied with the remote into the
remote control socket.
• Plug the remote control onto the other end o the control
cable.
• Adjust the current control on the remote to the recom-
mended setting or the type and size o welding elec-
trode being used. (The standard New-Arc RC300 remote
does not have current settings but is marked 1 to 10, or
the R2500 allow 25A per division).
• Turn the mains switch to the on position, the machine is
ready to weld.
4.2.3 TIG Welding with TIG300
Do not use the TIG300 until you have read and fully
understood the TIG300 manual.
• Connect the TIG300 to the R2500 as per the diagrams in
the TIG300 manual.
• Turn the mode switch to TIG remote, All control o the
welding procedure is now passed to the TIG300.
• Select welding mode and current by adjusting the con-
trols on the TIG300 with re erence to the TIG300 manual.
• Turn the mains switch to the on position, the power on
indicator on the R2500 and the display on the TIG300 will
light up, the machine is ready to weld.

R2500
SECTION 5 — AULT INDING AND MAINTAINANCE
5.1 MMA Welding Problems
Most problems with MMA welding are the result o not setting the correct welding parameters or the welding
rod being used.
All welding rod packets have in ormation on them in symbolic ormat , giving suitable current range, polarity
and type o weld (normally called 'position').
I 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 o the quoted range and i necessary practice on a
piece o scrap the same thickness as the job to be welded.
5.2 Maintenance
Note! All Electric shocks are potentially fatal, switch the machine off and unplug from the mains supply before
carrying out any maintenance work.
It is very important that the R2500 is regularly maintained. The amount o use and the working environment
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.
Weekly
• Clean the exterior o the machine
• Inspect the machines exterior or obvious signs o damage.
• Check the condition o the welding cable, earth clamp and welding output connectors or damage and
any sign o over-heating.
• Check the condition o the mains cable an plug.
Three monthly
As per the weekly schedule, plus:-
• Remove the side panels rom the machine and remove the build up o dust and debris rom inside the ma-
chine. Either use compressed air at low 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 mains input connector, look or loose terminal block screws and make sure the
sheath o the mains cable is still clamped securely to the chassis. Make sure the earth wire is still securely
astened to the earth stud.
• Check the condition o the welding output connectors, look or any signs o discoloration due to overheat-
ing, 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.
Annually
As per the three monthly schedule, plus :
Have the machines calibration checked, i necessary have the machine re-calibrated by a New-Arc trained
technician.

R2500
6.1 Parts Locations
SECTION 6 — PARTS BREAKDOWN

R2500
SECTION 6 — PARTS BREAKDOWN
6.2 R2500 Parts list
Item no. Description Part No.
1 Cable clamp M00825
2 Main switch 3P/70A M70072
3 Mains input PCB M90543
4 Fuse 2A M00274
5 Switch PCB M90558
6 Plastic oot M00096
7 Control PCB M90127A
8 Auxiliary trans ormer M00289
9 PM Dix socket M00037
10 Current shunt M00309
11 Capacitors C1/C2 M40108
12 3ph Bridge M60056
13 IGBT PCB M90530
14 IGBT M60073
15 Thermostat M00332/80
16 Cooling an M00311
17 Diodes D1/D2 M60126
18 25mm Torroids M00089
19 Main trans ormer M90557
20 Main choke M90556
21 Remote socket assembly M90542
22 n/a
23 Small control knob M00033
24 Large control knob M00464
25/26 PM Dix socket M00037

Head O ice
6 Wincomblee Road
Walker Riverside
Newcastle upon Tyne
NE6 3P
Tel: [phone]
ax: [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]
ax: [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.