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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 circu-
lation 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 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  of  the  correct  volt-
age and current capability for the machine. 

• 

Make sure that the mains cable and any extension ca-
bles 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 carry-
ing  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 cor-

rect supply information.

 

 

Primary cable length 

Long cable lengths may reduce the performance of 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 of insulating sheath off the end 
of  the  mains  cable,  strip  back  the  insulation  on  the  four 
cores of the cable to a depth of 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 firmly. 

• 

Clamp  the  cable  by  tightening  the  screws  on  the integral 
cable grommet/clamp. This must clamp down the external 
insulating sheath of the cable and not the four 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 for voltage tapping, shown set 

for 415V.  Can also be set for 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.

  

Summary of Contents for R2500

Page 1: ...ut 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 frequency spectrum making the R2500 virtu ally 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 R250...

Page 2: ......

Page 3: ...____________________ 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...

Page 4: ...thout 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 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...

Page 5: ...namics 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 SECTION 2 SPECIFICATION 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 5mm flexible cable Power Factor 0 95 Degree of Protection IP21 Insula...

Page 6: ...ator switch must be fitted Note See the technical specifications page for cor rect supply information Primary cable length Long cable lengths may reduce the performance of 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 of insula...

Page 7: ...odes 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 A...

Page 8: ...age 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 ma chine Either use compressed air at low pressure or an industrial type vacuum c...

Page 9: ...R2500 6 1 Parts Locations SECTION 6 PARTS BREAKDOWN ...

Page 10: ...0127A 8 Auxiliary transformer 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 fan M00311 17 Diodes D1 D2 M60126 18 25mm Torroids M00089 19 Main transformer M90557 20 Main choke M90556 21 Remote socket assembly M90542 22 n a 23 Small control knob M00033 24 Large control knob M0...

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Page 12: ...ith 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 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 dis cretion This in no way affects your rights as a consumer The guarantee is enclose...

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