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R2500

 

SECTION 5 — FAULT FINDING AND MAINTAINANCE

 

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 ma-
chine. 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 due to overheat-
ing, 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. 

 

Annually 

 

As per the three monthly schedule, plus : 

 

Have the machines calibration checked,  if necessary have the machine re-calibrated by a New-Arc trained  

technician. 

 

 

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...

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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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