R2500
Important Information
The R2500 is a 250 amp constant current welding power source
based on IGBT technology. The Inverter drive circuitry operates
above the audio frequency spectrum making the R2500 virtually silent in operation. The high operational frequency also
means that the R2500 is able to respond quickly to changing
arc dynamics, making for a very smooth , stable arc.
The R2500 is capable of TIG welding with the addition of an
external TIG control unit (TIG300).
Description
MMA unit
Processes
INSTRUCTION MANUAL
UK‘s Leading Manufacturer Of Welding Equipment
Newcastle +44 (0) 191 295 0111
Aberdeen +44 (0) 1224 771 063
To maintain continued developments of our products we reserve the right to alter specifications as quoted without prior notice
Newarc Ltd.
www.newarc.co.uk
10/14
TABLE OF CONTENTS
3
SECTION 1 — SAFETY
1.1 - Servicing Hazards________________________________________________________ 4
SECTION 2 — SPECIFICATION
2.1 - Description_____________________________________________________________ 5
2.2 - Technical Specification__________________________________________________ 5
SECTION 3 — INSTALLATION
3.1 - Siting the R2500__________________________________________________________ 6
3.2 - Connecting to mains supply______________________________________________ 6
SECTION 4 — OPERATION
4.1 - Description of Controls__________________________________________________ 7
4.2 - Operation_____________________________________________________________ 7
SECTION 5 — FAULT FINDING 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
R2500
SECTION 1 — SAFETY
4
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 will be
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 hazardous to your health.
•
Make sure the welding area is well ventilated. Use suitable fume extractors or exhaust fans if necessary.
•
If 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 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 surface.
•
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 atmosphere leading to asphyxiation.
•
Note! If dropped the gas cylinder may explode.
•
Check the gas cylinder, pressure regulator and gas
hoses regularly for leaks and discard any suspect item.
•
Do not try to directly connect a gas cylinder to the
TIG300 without using a pressure-reducing regulator designed for use with argon.
•
Do not use gas cylinders whose of contents you are
unsure.
•
The Argon cylinder must be securely fastened to a
wall or placed in a specially designed cylinder carrier.
•
Always turn off the valve on the gas cylinder when you
have finished welding.
•
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
carrying out this action.
Further information is available in publication HSG118
'The safe use of compressed gases in welding, flame
cutting and allied processes', 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 35mm2.
•
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
connectors 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.
R2500
SECTION 2 — SPECIFICATION
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 frequency spectrum . The high operational frequency also means that the
R2500 is able to respond quickly to changing arc dynamics, making for a
very smooth , stable arc.
The R2500 is capable of TIG welding with the addition of an external TIG
control unit (TIG300).
2.2 Technical Specification
Technical data R2500
5
Input Voltage Range 360-480V 3 phase 50/60Hz
Power Consumption 9KVA
Input Current at Max Output 13 amps
Mains Cable 4 x 2.5mm² flexible cable
Power Factor 0.95
Degree of Protection IP21
Insulation Class F
Current Control 5-250 amps
180A 100% (MMA)
Duty Cycle at 40ºC
250A 45% (MMA)
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 surface, preferable
above ground level.
•
Make sure there is at least 20cm clearance at the front,
rear and right side of the machine to allow good circulation of the cooling 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 so
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.
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 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.
•
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 supply 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 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.
Setting supply voltage tapping
6
•
To enable the setting of the supply voltage tapping the
lid of the machine has to be removed.
•
The photo below shows the voltage tapping set to
415V. The red wire connection from the fuse can be
moved to the required voltage input terminal to select
the input voltage of 380V 415V or 460V.
380 415 460
NOTE! Never attach the input tapping wire to the 220V
terminal.
R2500
SECTION 4 — OPERATION
4.1 Description of controls
1 Remote control socket - For connection of external remote
control or TIG300.
2 Overload indicator - Indicates duty cycle has been ex-
ceeded and the thermostat inside the machine has operated.
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 Off/On switch, (on rear panel of machine).
7
4.2 Operation
4.2.1 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 mode switch to 'local', the machine is now in
MMA mode.
•
Adjust the current control to the recommended setting
for the size and type of 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 for welding all types of electrodes
within the current rating of 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 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 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 of the
welding procedure is now passed to the
•
Select welding mode and current by adjusting the controls on the TIG300 with reference 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.
TIG300.
R2500
SECTION 5 — FAULT FINDING AND MAINTAINANCE
8
5.1 MMA Welding Problems
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.
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 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.
Three monthly
As per the weekly schedule, plus:-
• Remove the side panels from the machine and remove the build up of dust and debris from inside the machine. Either use 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 to the chassis. 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 :
Have the machines calibration checked, if necessary have the machine re-calibrated by a Newarc trained
technician.
R2500
SECTION 6 — PARTS BREAKDOWN
6.1 Parts Locations
9
R2500
SECTION 6 — PARTS BREAKDOWN
6.2 R2500 Parts list
10
Item no. Description
1 Cable clamp M00825
2 Main switch 3P/70A M70072
3 Mains input PCB
4 Fuse 2A M00274
5 Switch PCB M90558
6 Plastic foot (
7 Control PCB M90127A
8 Auxiliary transformer M00789
9 De-coupling capacitor assembly M90089
10 Current shunt M00309
11 Capacitors C1/C2
12 3ph input Bridge
(From June 2012,, replaced by a distribution board M01912, fuse holder M01913 and transient suppressor assembly M91123)
4 per machine)
(2 per machine)
Part No.
M90543
M40108
M00096
M60057
13 IGBT drive PCB M90530
14
IGBT M60246
15 Thermostat M00332/80
16 Cooling fan 24V DC M00371
17 Output Diodes D1/D2
18 25mm Torroids
(10 per machine)
(2per machine)
M00089
M60121
19 Main transformer M90557
20 Main choke M90556
21 Remote socket assembly M90542
22 n/a n/a
23 Small control knob M00033
24 Large control knob M00464
25/26 Dix socket
(2 per machine)
M00037
R2500
Head office
Newarc (Newcastle) LTD
6 Wincomblee Road
Walker Riverside
Newcastle upon Tyne
NE6 3PF
Tel: +44 (0)191 295 0111
Fax: +44 (0)191 295 0077
Website: www.newarc.co.uk
e-mail: sales@newarc.co.uk
Aberdeen office
Newarc (Aberdeen) LTD
4 Howe Moss Drive
Kirkhill Industrial Estate, Dyce
Aberdeen
AB21 0GL
Tel: +44 (0)1224 771063
Fax: +44 (0)1224 724536
E-mail:
scotlandsales@newarc.co.uk
Guarantee
Newarc Ltd warrants that its goods and services are guaranteed to meet the specific 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 conditions of use. The stated conditions of use are that considered normal industrial practice and are not
exhaustive. Each machine is identified 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 equipment (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.
Waiver
Whilst every endeavor is made to ensure the details of this document are correct at the date of
print. Newarc accepts no liability for correctness in respect of any impending change in legislation
or health and safety requirements. Newarc also reserve the right to amend the detail of the document content without any notification to the consumer. If reference is made to Newarc while utilising the document for spare parts purchase or instruction please advise the revision of the document
to ensure correctness of information.
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