To maintain continued developments of our products we reserve the right to alter specifications as quoted without prior notice
Newarc Equipment Ltd.
UK‘s Leading Manufacturer Of Welding Equipment
Newcastle +44 (0) 191 295 0111
Aberdeen +44 (0) 1224 771 063
www.newarc.co.uk
R7000
Important Information
All persons authorised to use, repair or service the R7000 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
Processes
Description
Constant Current Power Source
R7000
3
TABLE OF CONTENTS
SECTION 1 — SAFETY
1 - General Precautions_______________________________________________________ 4
SECTION 2 — SPECIFICATION
2.1 - Specification___________________________________________________________ 5
SECTION 3 — INSTALLATION
3.1 - Siting the R7000_________________________________________________________ 6
3.2 - Connecting to the mains supply_________________________________________ 6
3.3 - Setting supply voltage tapping__________________________________________ 6
SECTION 4 — OPERATION
4.1 - Operating Controls ____________________________________________________ 7
SECTION 5 — FAULT FINDING AND MAINTENANCE
5.2 - Welding Problems______________________________________________________ 9
5.3 - Maintenance__________________________________________________________ 10
SECTION 6 — ELECTRICAL DIAGRAMS
6.1 - System Diagram_______________________________________________________ 11
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations_________________________________________________ 12
7.2 - Parts List_______________________________________________________________ 14
4.2 - Operating ____________________________________________________________ 8
2.2 - Technical specification__________________________________________________ 5
5.1 - Operating problems___________________________________________________ 9
R7000
4
SECTION 1 — SAFETY
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 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.
The safe handling of compressed air
The R7000 uses compressed air when Arc-air gouging.
If using a separate compressor, read the manual for it carefully before use
particularly any safety instructions
•
Do not direct a compressed air jet at yourself or any other person.
•
Use suitable eye protection when using compressed air
•
Always turn off the valve on the compressor or airline when you have
finished using it.
•
Always install and use pressure regulators and other air handling devices
in accordance with manufacturers instructions.
•
The Arc-air gouging procedure is very noisy, it is advisable to wear suitable hearing protection when undertaking the operation.
The safe handling of gas cylinders
The R7000 uses argon gas when TIG welding with the external TIG300 TIG unit.
Argon is an inert gas and can displace oxygen in the atmosphere leading to
asphyxiation.
•
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.
Welding and earth return cables
•
Earth return and electrode holder cables must have a cross sectional area
of at least 90mm2.
•
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.
R7000
5
SECTION 2 — SPECIFICATION
2.1 - Description
The R7000 MMA D.C inverter power source has 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 R7000 is capable of TIG welding with the addition of an external TIG unit from the Newarc
range.
2.2 - Technical Specification
Technical data R7000
Input voltage range 380-480 Volts 3 Phase 50/60Hz
Input Current at Max Output 49 amps
Power Consumption 37 KVA
Recommended Mains Fuse 56A slow blow or type C MCB
Mains Cable 4 x 10mm² flexible cable
Power Factor 0.95
Max Output Current 700 amps
Open Circuit Voltage >90V
Current Control
20-700A Infinitely
Variable
Duty Cycle at 40ºC 70%
Insulation Class F
H x W x L (mm) 450 x 310 x 570
Weight (kg) 38
R7000
6
SECTION 3 — INSTALLATION
3.1 Siting the R7000
•
Site the R7000 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 can be 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
R7000 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.
R7000
7
SECTION 4 — OPERATION
4.1 Operating controls and connections
Description of controls
1. Current control - Adjusts the machines output current.
2. Digital Display - Indicates welding current in Amps, also gives an indication when the machine is over
temperature.
3. Arc force control - Operates in MMA mode only. This control alters the welding dynamics of the ma-
chine 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 fierce.
4. 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 “7000” and the machines output will be inhibited, after
4 seconds the display will clear and the machine is ready to be used.
5. Remote control socket - For connection of external remote control or TIG300 external TIG control unit.
There is no switch for remote operation, plugging an external unit into the socket automatically selects
remote operation and disables the internal current control.
6. -ve weld terminal - Main welding power output connector, negative polarity.
7. +ve weld terminal - Main welding power output connector, positive polarity.
8. Auxiliary supply fuse - protects the auxiliary supply from the remote control socket. Fuse type is 20 x
5mm glass body, 6.3A ‘slow blow’ rating.
9. Main supply fuse - Fuse 3.15A slow blow, 32 x 6.3mm ceramic body.
10. Main 3P Isolation switch - Switches the machine on and off.
11. Mains Input - Three phase mains cable.
4
5
1
3
6
7
2
10
11
8
9
R7000
8
SECTION 4 — OPERATION
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 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 R7000 is suitable for welding all types of electrodes within the current rating of the machine (see Technical Data)
4.2.2 MMA Welding with remote control
•
Select welding polarity as in paragraph 4.2.1.
•
Plug the control cable supplied with the remote control into the remote control socket on the front of the R7000.
•
Turn the mains switch to the on position, the machine is ready to weld.
•
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 New-Arc RC300 remote does not have current settings but is marked 1 to 10)
4.2.3 Arc-air gouging/cutting.
•
Connect Arc-air torch to the positive weld terminal (DCEP) and the earth return lead to the negative weld terminal.
•
Connect a hose suitable for use with compressed air up to a pressure of 10 bar (150 psi) between the air compressor
(or air output connector) and the connection on the Arc-air gouging torch.
•
Turn the mains switch to the on position, upon switching on, the display will read “7000” and the machines output will
be inhibited, after 4 seconds the display will clear and the machine is ready to be used.
•
Turn the current control to the recommended setting for the size and type of carbon to be used.
•
Most Arc-air torches have a button on the handle that needs to be pressed to facilitate the air flow, press this just
before commencing operations.
4.2.4 TIG Welding with TIG Unit
IMPORTANT : Do not use the TIG Unit until you have read and fully understood the TIG Unit manual.
•
Connect the TIG unit to the R7000 and the shielding gas supply as per the diagrams in the TIG unit manual.
•
Turn the mains switch on the R7000 to the on position, the digital displays on the R7000 and the TIG unit will light up,
you are now ready to weld.
•
Select welding mode and current by adjusting the controls on the TIG unit with reference to the manual.
R7000
9
SECTION 5 — FAULT FINDING AND MAINTAINANCE
5.1 Machine Operation Problems
Most problems with the R7000 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 ‘HOT’,
if it is, it means that the R7000 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 R7000 is overheating on a regular basis
or at current settings below the maximum, this
would usually indicate that the rear grill filter and/
or the inside of the machine is choked with dust
and therefore not being cooled correctly. For information about cleaning the dust out of the R7000
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 fitted. (Positive to positive, negative to negative).
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 qualified Welding Engineer, if the problem still persists have the R7000
checked by a trained New-Arc service engineer.
5.2 Welding Problems
MMA
If problems with the R7000’s operation while welding
are experienced, first refer to the section 3 the installation section, and section 4 the operating section
and also to the fault finding 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 finding and maintenance
section in the TIG unit instruction manual.
• Any welding problems not covered above must
be brought to the attention of a qualified Welding Engineer, if the problem still persists have the
R7000 checked by a trained New-Arc service engineer.
R7000
10
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 R7000 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 dam-
age 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.
• Remove the grill from the rear of the machine and remove the build up of dust and debris in it 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, 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 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 due to
overheating, this is generally caused by poor connection of 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 of welding set failure.
5.3.3 Annually
As per the three monthly schedule, plus :-
• The machines should be have its calibration checked, if necessary have the machine re-calibrated by
a New-Arc trained technician.
R7000
11
SECTION 6 — ELECTRICAL DIAGRAMS
6.1 - System Diagram
R7000
12
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations
1
2
3
4
5
6
7
8
9
10
13
12
11
14
15
R7000
13
SECTION 7—PARTS BREAKDOWN
7.1 - Component Locations
16
17
18
19
21
22
23
24
25
26
27
28
20
29
R7000
14
SECTION 7—PARTS BREAKDOWN
7.2 - Parts list for R7000
Item no.
Description
Part No.
3
1 Bridge carry handles: Top Lid handles (two fitted)
Front panel handles (two fitted)
M01084
M01393
2 24mm diameter knob M00464A
3 20mm diameter knob M00033A
4 On/Off front switch M70069A
5 Remote socket assembly M90762
6 95/120 panel mount Dix socket (two fitted) M09917
7 Mains Switch — 3 phase power
M70076
8 Fuse holder
Fuse 3.15A slow blow, 32 x 6.3mm ceramic body
M01088/89
M00020
9 Fuse holder
Fuse 6.3A slow blow, 20 x 5mm glass body
M00273
M00379
11 Soft start resistor assembly M90765
12 Soft start relay (two fitted) M70026
13 Diode bridge (two fitted) M60057
14 Filter Capacitor assembly M91123
15 Auxiliary transformer M00758
16 R7000 Control PCB M90744/7000
17 IGBT 200A (two fitted) M60073
18 Snubber Capacitors (two fitted)
M40794
19 IGBT Gate PCB Assembly
M90843/R7000
20 Power Resistor
M90999
21
Capacitor 20uF (six fitted)
M40108
22 R7000 Display PCB M90746/7000
23
Current transformer M01083
24 Current transducer M60248
25 Main transformer R7000 M10104
26 Main inductor R7000 M01094
27 De-coupling capacitors M90818
28 Diode module (six fitted) M60121
29 Cooling fan (four fitted) M00371
When ordering spare components please quote the serial number of the unit for which the parts are intended.
10 Rear filter grill M?
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
New-Arc Equipment Ltd warrants that its goods and services are guaranteed to meet the specific
performance under the stated conditions of use. New-Arc 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. New-Arc reserve the right to a) Repair. b)Replace. c)Authorise the reasonable cost of repair or replacement at an approved New-Arc 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. New-Arc accepts no liability for correctness in respect of any impending change in legislation
or health and safety requirements. New-Arc also reserve the right to amend the detail of the document content without any notification to the consumer. If reference is made to New-Arc 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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