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SECTION 5 — FAULT FINDING AND MAINTAINANCE
5.1 Machine operation
Most problems with the operation of the R1500 can
be overcome by following the procedures below.
No power-on indicator on switch on.
Check that the machine is attached to a working
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mains supply and that it is correctly plugged in and
any isolator switch is closed.
Have a competent electrician check that there are
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no 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.
Power-on indicator lit but no output.
Make sure that the overload indicator goes off after
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15 seconds. If not see paragraph 'thermal cut-out indi-
cator' below.
This indicator must be off for normal operation. If on it
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indicates that the R1500 has overheated and the
power stages of the R1500 have been shut down so
you will get no current output.
In normal climate conditions (25°C and below) the R1500
has a 100% duty cycle so operation of the thermal cut
out indicates that the inside of the
machine is likely to be choked with dust and therefore not
being cooled properly.
In Hot climates (above 25°C) it may indicate that you are
exceeding the duty cycle of the R1500.
Leave switched on for a few minutes and the R1500
should return to normal operation, do not switch the R1500
off as this will stop the operation of the cooling fan and
greatly extend the cool down period.
Frequent tripping of the thermal cut-out, especially at low
current settings is indicative that the inside of the machine
is likely to be choked with dust.
For information about cleaning the dust out of the R1500
please refer to the relevant part of the next section.
Any operating problems not covered above should be
referred to a trained New-Arc service engineer or returned
to the factory for repair.
5.2 Maintenance
Note! All Electric shocks are potentially fatal, switch
the machine off and disconnect from the power
supply before undertaking out any maintenance
work.
It is very important that the R15000 is regularly main-
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tained. The amount of use and the working environ-
ment must be taken into account when scheduling the
maintenance periods.
Careful use and regular preventative maintenance will
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prolong the life of the machine and ensure trouble free
operation.
5.2.1 Weekly
Clean the exterior of the machine
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Inspect the machines exterior for obvious signs of dam-
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age.
Check the condition of the welding cable, earth
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clamp, welding output and power in connectors for
damage and any sign of over-heating.
Check the condition of the mains lead and plug.
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5.2.2 Three monthly
As per the weekly schedule, plus:-
Remove the side covers from the machine. Remove
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the build up of dust and debris from inside the ma-
chine, particularly from the Heat-sink extrusion, by use
of either compressed air at reduced pressure or an
industrial type vacuum cleaner.
Make a thorough visual inspection of the interior of the
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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 welding output connectors,
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look for any signs of discolouration 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.
5.2.3 Annually
As per the three monthly schedule, plus :-
Have the machines calibration checked, if neces-
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sary have the machine re-calibrated by a New-Arc
trained technician.
R1500
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