Processes
Description
Newarc Ltd.
UK‘s Leading Manufacturer Of Welding 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
RT2500
Important Information
All persons authorised to use, repair or service the RT2500 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.
TIG unit
INSTRUCTION MANUAL
10/14
RT2500
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 RT2500_________________________________________________________ 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 - TIG Welding Problems__________________________________________________ 8
5.3 - Maintenance__________________________________________________________ 8
SECTION 6—PARTS BREAKDOWN
6.1 - Component Locations__________________________________________________ 9
6.2 - Parts List_______________________________________________________________ 10
TABLE OF CONTENTS
RT2500
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 RT2500 on a wet surface.
•
Avoid touching the work piece whilst welding.
• Do not use the RT2500 without it’s protective
cover.
•
Keep your clothing and body dry.
The safe handling of gas cylinders
The RT2500 uses argon when TIG welding. 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
RT2500 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.
SECTION 1 — SAFETY
RT2500
5
2.1 Description
The RT2500 is a 250A constant current TIG welding machine based on IGBT technology. The Inverter drive circuitry operates above the audio frequency spectrum. The high operational frequency also means that the RT2500 is able to respond quickly to changing arc dynamics, making for a very smooth, stable arc.
As well as TIG welding the RT2500 is capable of MMA welding with all types of
electrodes within the current rating of the machine, normally up to 5mm.
2.2 Technical Specification
Technical data RT2500
Input Voltage Range 380-480V 3 phase 50/60Hz
Power Consumption 9 KVA
Input Current at Max Output 13 amps
Mains Input Fuse 16 amps slow blow or type C MCB
Mains Cable 4 x 2.5mm² flexible cable
Power Factor 0.95
Insulation Class F
Current Control 5-250 amps
Duty Cycle at 40ºC
45% 250A (MMA)
100% 180A (MMA)
Degree of Protection IP21
Electrode Size 1.6 – 5.0
H x W x L (mm) 320 x 180 x 430
Weight (kg) 21
SECTION 2 — SPECIFICATION
RT2500
6
3.1 Siting the RT2500
•
Site the RT2500 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
•
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 38V 415V or 460V.
NOTE! Never attach the input tapping wire to the 220V
terminal.
SECTION 3 — INSTALLATION
RT2500
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 'MMA', 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 RT2500 is suitable for welding all types of electrodes within
the current rating of the machine, normally up to 5.0mm.
The RT2500 should never be used with arc-air gouging or cutting electrodes.
4.2.2 TIG Welding
•
NOTE: Post gas time. For a 5 seconds period after powering up
the RT2500 or when switching from MMA to TIG modes. The post
gas value is displayed as P# (The # value is the set post-gas time)
with the possibility to change the post-gas time by repeatedly
pressing the torch switch button. Every torch switch press the
post gas time is incremented by 1 second (from 0-30 seconds).
This setting is saved therefore it does not need re-setting each
time the machine is switched on.
•
Connect the Argon hose from the regulator on the gas cylinder
to the Argon in connection on the rear panel of the machine
and turn the regulator on. (see the paragraph on 'the safe handling of gas cylinders' in section 1, General precautions for more
information)
•
Connect the TIG torch power/gas lead to the TIG torch power/
gas connector.
•
Connect the TIG torch switch lead to the TIG torch switch connector.
•
Connect the earth return lead to the +ve weld terminal.
•
Turn the mode switch to '2s' or '4s'.(see paragraph 4.1 for details
of these settings)
•
Turn the Up slope and Down slope controls to the settings required. (see paragraph 4.1 for details)
•
Turn the on/off switch on the rear panel to the on position, the
digital display will light up and the machine is ready to weld.
•
While reading the digital display, adjust the current control to the
recommended setting for the size and type of welding electrode
to be used.
Note: Pressing the torch switch produces HF ignition, to allow the
operator to strike a welding arc. HU (High voltage) is indicated on
the display(5) when HF is present.
4.2.3 Welding with remote control
•
Select welding mode as in paragraphs 4.2.1 and 4.2.2.
•
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.
•
Turn the mains switch to the on position, the machine is ready to
weld.
•
While reading the digital display adjust the current control on the
remote to the value required.
4.1 Description of controls
1.
TIG torch - switch connector.
2. Remote control socket - For connection of external remote con-
trol.
3. Current control - Adjusts the machines output current.
4. Up slope. Used on TIG only, sets the time period for the TIG arc to
'ramp' up from 5A to the level set by the current control. Maximum time period is 3 seconds.
5. Digital Display
6. Down slope. Used on TIG only, sets the time period for the TIG arc
to 'ramp' down from the level set by the current control, to approximately 30% of this value when the arc will extinguish. Maximum period is 15 seconds.
7. Mode switch - Selects the welding mode. 'MMA' sets the machine
in MMA mode.
'2s' sets the machine in 'normal' TIG mode, whereby pressing the
TIG torch switch initiates the arc and releasing it extinguishes the
arc.
'4s' sets the machine in 'latch' TIG mode, whereby pressing the
TIG torch switch and releasing it will initiate the arc, pressing the
torch switch again and releasing it will extinguish the arc.
8. TIG Torch - power/gas connector.
9. -ve weld terminal.
10. +ve weld terminal.
11. Off/On switch (on rear panel of machine).
12. Argon in connector (on rear panel of machine).
SECTION 4 — OPERATION
RT2500
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 TIG Welding problems
If problems with the RT2500s operation while TIG welding are experienced, first refer to the information in
paragraph 3.1 in the installation section and paragraph 4.2.2 in the operation section.
The common problems with TIG welding are poor
striking, porosity and poor appearance of the weld. If
you are experiencing any problems with TIG welding
follow the check list below, this will cure most problems :-
• If the RT2500 is suffering from poor striking, check
that all power leads are connected properly, check
that there is sufficient gas flow and that the correct
gas is being used, check that the earth clamp is
making a good connection to the work-piece.
• If there is porosity in the weld or the final weld is of
poor appearance, check that there is sufficient gas
flow and that the correct gas is being used, check
the condition of the TIG torch, particularly the gas
hose. Make sure that the collet or gas lens in the
torch head is not blocked in anyway. Check all gas
connections are secure and that there are no leaks,
use a leak detecting spray on all connections if
necessary.
Any welding problems not covered above must be
brought to the attention of a qualified Welding Engineer, if the problem still persists have the RT2500
checked by a trained maintenance person.
5.3 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 RT2500 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.
SECTION 5 — FAULT FINDING AND MAINTAINANCE
RT2500
9
6.1 Parts Locations
SECTION 6 — PARTS BREAKDOWN
34
RT2500
10
6.2 RT2500 Parts list
Item no. Description
Part No.
1 Cable Clamp M00825
2 Mains Switch 3 Pole 20A M70072
3 Mains Input PCB
(From June 2012,, replaced by a distribution board M01912, fuse holder
M01913 and transient suppressor assembly M91123)
M90543
4 Fuse 2 Amp M00274
5 Ribbon Cable M90546
6 Digital Display
M90003
7 Switch PCB M90080
8 Control PCB M90127A
9 Remote Socket Assembly M90542
10 TIG Control PCB M90132/NEW-RT2500
11 Plastic Foot (4 per machine) M00096
12 Auxiliary Transformer
M00789
13 HF PCB M90193
14
HF Inductor M90544
15 Capacitors C1 & C2 (2 per machine) M40108
16 Input 3 Phase Bridge Rectifier M60057
17 Gas Hose M00001
18 Flying Gas Hose M90219
19 IGBT PCB M90530
20 IGBT M60235
21 Thermostat M00332-80
22 Cooling Fan 24Vdc M00371
23 Output Diodes D1 & D2 (2 per machine) M60121
24 25mm Toroidal Core (10 per machine) M00089
25 Main Transformer M90557
26 Output Inductor M90556
27 Current Shunt M00309
28 Torch Socket Assembly M90098/NEWTIG
30 Control Knob (4 per machine) M00033/A
31 Power/Gas Connector M00041
32/33 Panel Mounted DIX socket (2 per machine) M00037
34
Gas valve assembly
Up to serial number NCL0009811
From serial number NCL0009812
M90183
M90176
SECTION 6 — PARTS BREAKDOWN
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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