Newarc Ltd.
UK‘s Leading Manufacturer Of Weld ing Equipment
Newcastle +44 (0) 191 295 0111
Aberdeen +44 (0) 1224 771 063
www.newarc.co.uk
To maintain continued developments of our products we reserve the right to alter specifications as quoted without prior notice
R5000/4000 CV
Important Information
All persons authorised to use, repair or service the R4000/R5000
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 welding', which may
be obtained from the Health & Safety Executive. Please contact your distributor should you not understand any of the information within this document.
INSTRUCTION MANUAL 05/14
Processes
Description
Constant Voltage Power Source
R5/4000 CV
3
TABLE OF CONTENTS
SECTION 1 — SAFETY
1.1 General Precautions____________________________________________
4
SECTION 2 — SPECIFICATION
2.1 - Specification_____________________________________________________________ 5
SECTION 3 — INSTALLATION
3.1 - Siting the R5/4000________________________________________________________ 6
3.2 - Connecting to mains supply______________________________________________ 6
3.3 - Setting supply voltage tapping____________________________________________ 6
SECTION 4 — OPERATION
4.1 - Operating Controls ____________________________________________________ 7
SECTION 5 — FAULT FINDING AND MAINTENANCE
5.1 - MIG Welding Problems_________________________________________________ 8
5.2 - Maintenance__________________________________________________________ 9
SECTION 6 — ELECTRICAL DIAGRAMS
6.1 - System Diagram________________________________________________________ 10
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations__________________________________________________ 11
7.2 - Parts List_______________________________________________________________ 13
R5/4000 CV
4
SECTION 1 — SAFETY
1.1 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 any doubt do not attempt to weld them.
1.2 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.
1.3 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.
1.4 Electric Shock
• Do not touch live electrical parts.
• Do not work in wet or excessively humid areas and do
not site the unit on a wet surface.
• Avoid touching the work piece whilst welding.
• Do not use the unit without the protective cover.
• Keep your clothing and body dry.
1.5 The safe handling of gas cylinders
• 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 Newarc
equipment without using a pressure-reducing regulator
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 undertaking
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 processes', which may be obtained
from the Health & Safety Executive.
1.6 Welding and earth return cables
• Earth return and interconnecting power 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.
R5/4000 CV
5
SECTION 2 — SPECIFICATION
2.1 - Specification
Description
These heavy duty 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.
The R4000CV/R5000CV is capable of MIG welding when used with a peripheral wire
feed unit.
Technical data R4000 R5000
Models Available 380-480 Volts 3 Phase 380-480 Volts 3 Phase
Input Current at Max Output 24 amps 33 amps
Power Consumption 18.5 KVA 25 KVA
Recommended Mains Fuse
32A slow blow or type C
MCB
40A slow blow or type C
MCB
Mains Cable 4 x 4.0mm² flexible cable 4 x 4.0mm² flexible cable
Power Factor 0.95 0.95
Max Output Current 400 amps 500 amps
Open Circuit Voltage 40V 50V
Voltage Control 2 - 40V Infinitely Variable 2 - 50V Infinitely Variable
Duty Cycle at 40ºC
60% @400A
100% @350A
60% @500A
100% @400A
Insulation Class F F
H x W x L (mm) 450 x 310 x 570 450 x 310 x 570
Weight (kg) 33 37
R5/4000 CV
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SECTION 3 — INSTALLATION
3.1 Siting the R4000/R5000
•
Site the R4000/R5000 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 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 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 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
during welding as this will reduce the input
voltage to the machine and may cause overheating and degradation of the cable.
3.3 Setting supply voltage tapping
WARNING! All electric shocks are potentially fatal, 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 tapping 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.
R5/4000 CV
7
SECTION 4 — OPERATION
4.1 Description of controls
1. Output Demand Control - Adjusts the machines output Voltage.
2. Digital Display - Indicates welding current in Amps, welding voltage in Volts. The display also gives an indication when the machine is over tempera-
ture (-OT -) , or the optional cooling unit is turned off (-CU-).
3. Inductance control - This control alters the response time of the power source and is generally used in short circuit dip transfer welding. Too little in-
ductance 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.
4. Slope control - 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.
5. +ve weld terminal - Main welding power output connector, positive polarity.
6. -ve weld terminal - Main welding power output connector, negative polarity.
7. Standby 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 mac hines output will be inhibited. After 4 seconds the display will clear and the machine is ready to use.
8. Remote control socket - For connection of external remote control 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 voltage control.
9. Main 3P Isolation switch - Switches the machine on and off.
10. Mains Input - Three phase mains cable
11. Auxiliary transformer supply fuse - Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
12. 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
13. Main supply fuse to the cooling unit (Only fitted to cooling unit version) - Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
14. Au xiliary 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.
7
8
1
4
3
9
10
2
5
6
11
12
13
14
R5/4000 CV
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SECTION 5 — FAULT FINDING AND MAINTAINANCE
5 Fault finding and maintenance
5.1 Machine operation
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 fitted 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 lengthening the cooling down period
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.
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’.
5.2 Welding Problems
•
If problems are experienced whilst MIG welding, please consult the fault finding and maintenance section of
the WFU instruction manual.
Any welding problems not covered above must be brought to the attention of a qualified Welding Engineer, if the problem still persists the R4000/R5000 should be checked by a trained Newarc service engineer.
R5/4000 CV
9
SECTION 5 — FAULT 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 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.
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
entry/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.
This could be an indication of overheating and can be a 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 Newarc trained technician.
R5/4000 CV
10
SECTION 6 — ELECTRICAL DIAGRAMS
6.1 - System Diagram
R5/4000 CV
11
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations
9
12
11
13
7
8
14
10
5
1
2
6
4
3
R5/4000 CV
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SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations
25
26
21
23
24
22
15
16
18
20
19
27
17
R5/4000 CV
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SECTION 7—PARTS BREAKDOWN
7.2 - Parts list for R4000CV/R5000CV
Item no. Description
Part No.
1
Front panel Bridge handle (2 per machine)
Lid Bridge handle (2 per machine)
M01393
M01084
2 24mm diameter knob M00464A
3 20mm diameter knob (2 per machine) M00033A
4 On/Off switch M70069A
5 Remote socket assembly M90762
6 70/90 panel mount Dix socket (2 per machine) M09916
7 Mains Switch — 3 phase power M70071
8 Filter Diac assembly M91123
9
Fuse holder
Fuse 3.15A slow blow, 32 x 6.3mm ceramic body
M01088/89
M00020A
10
Fuse holder
Fuse 6.3A slow blow, 20 x 5mm glass body
M00273
M00379
11 Soft start resistor assembly M90765
12 Auxiliary transformer M01408
13 Soft start relay M70026
14 Diode bridge M60057
15
Control PCB
R4000CV
R5000CV
M90744-R4000CV
M90744-R5000CV
16
IGBT (2 per machine)
R4000CV
R5000CV
M60245
M60229
17 IGBT gate drive assembly (1 per machine) M90843
18
Display PCB
R4000CV
R5000CV
M90771-R4000CV
M90771-R5000CV
19 Current transducer M60112
20 Capacitor Assembly M90456
21
Main inductor
(Quote serial number of the machine when ordering for correct part)
R4000CV
R4000CV
R5000CV
R5000CV
M01094
M10105
M01094
M10106
22
Current transformer M01083
23
Main transformer (
Quote serial number of the machine when ordering for correct part)
R4000CV
R4000CV
R5000CV
R5000CV
M01093
M10102
M00878
M10103
24 De-coupling capacitor M90818
25 Diode module (4 per machine) M60121
26 Cooling fan (2 per machine) M00371
27 Rear Filter grill assembly M91157
When ordering spare components please quote the serial number of the unit for which the parts are intended.
R5/4000 CV
14
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 endeavour 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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