UNITOR UWI-203 TP MMA or TIG Welding Inverter Instruction Manual

UNITOR UWI-203 TP MMA or TIG Welding Inverter

Product Information

Unitor Welding Inverter UWI 203 TP

The Unitor Welding Inverter UWI 203 TP is a versatile MMA (Stick) / TIG welder. It is designed for professional use and offers a range of features to ensure efficient and high-quality welding.

General Description

Connects to any primary voltage between 380 and 440V without need for any action from the operator. Line Voltage compensation keeps output of the power source constant regardless of fluctuation in input power from 10% below lowest to above highest rated input voltage. Safe in use. Open Circuit Voltage only 65V, from serial number 129431 with Automatic Voltage Reducing Function VRD reducing “touchable” voltage for the operator to max. 13V. Automatic Hot Start for stick arc starts makes arc striking easy and prevents electrode sticking. Adjustable Arc Force for stick electrode welding allows the arc characteristics to be changed for specific applications and electrodes: Lift- Start in TIG mode provides easy and soft TIG arc starting. Step-less adjustment of welding current through whole current range: 5 –200A. Casing of high grade aluminium and industrial plastic to eliminate corrosion damage also contributes to low-weight which together with compact outer dimensions provides good portability. Wind tunnel design for the internal cooling air flow protects electrical components and PC boards from dirt, dust, debris, greatly improving reliability. Thermal overload protection with indicator lights helps prevent machine damage if the duty cycle is exceeded or airflow is blocked. Total Protection function with indicator light prevents damage to the machine if one phase in the power supply falls out The welding inverter can be connected to any primary voltage between 380 and 440V without the need for any action from the operator. Line voltage compensation ensures a constant output regardless of fluctuations in input power. The inverter is safe to use, with an open circuit voltage of only 65V. From serial number 129431, it also features an Automatic Voltage Reducing Function (VRD) that reduces touchable voltage for the operator to a maximum of 13V. The inverter has an Automatic Hot Start for stick arc starts, making arc striking easy and preventing electrode sticking. It also has an adjustable Arc Force for stick electrode welding, allowing the arc characteristics to be changed for specific applications and electrodes. In TIG mode, it provides easy and soft TIG arc starting with its Lift-Start feature. The casing is made of high-grade aluminum and industrial plastic to eliminate corrosion damage. This also contributes to its low weight and compact dimensions, making it highly portable. The inverter features a wind tunnel design for internal cooling air flow, protecting electrical components and PC boards from dirt and debris, thus greatly improving reliability. It has thermal overload protection with indicator lights to prevent machine damage if the duty cycle is exceeded or airflow is blocked. Additionally, it has a Total Protection function with an indicator light to prevent damage if one phase in the power supply falls out.

IDENTIFY COMPONENTS
Unitor Welding Inverter UWI 203 TP, product number 191- 203203 is delivered with

Technical Data

The Unitor Welding Inverter UWI 203 TP is a three-phase static transformer rectifier frequency converter with DC output. It supports MMA (Stick electrode / SMAW) and TIG (GTAW) welding processes. The welding machine is suitable for use in areas with increased electric shock hazard. It has a duty cycle marking (X) to indicate its duty cycle.

Type of welding machine

Processes

Safety Marking

X: Duty cycle

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. It refers to a 40°C environmental temperature. If unit overheats a thermal switch stops the output, the warning light for over- temperature is lit and the cooling fan continues to run. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld.

I2= Welding current.
Range 5 – 200A

U0 = No-load voltage
Also called open circuit voltage, is the maximum voltage (excluded any stabilization voltage or arc ignition) found between the output outlets when the welding machine is not welding. This is the voltage a welder can be exposed to between electrode holder and work piece.

Ur= rated reduced no-load voltage
No-load voltage of a welding power source fitted with a voltage reducing device

U2 = Arc voltage
Voltage present between the output outlets when welding is being carried out, in relation to a particular set current. The relation, for the various welding modes is the following:
MMA→U2=(20+0,04I2)
TIG →U2=(10+0,04I2)

Primary connection

• U1
  • = Effective input voltage 380 – 440V
• I1max
  • = Maximum value of input current at the corresponding duty cycle.
• I1eff
  • = Effective value of input current at the corresponding duty cycle.

Cooling
COOLING AF= Forced air cooling (with a fan).

Protection class

• IP23S=
  1. Ingress Protection class. Protection degree of the casing according to EN 60529
  2. 2: Protection against object not greater than 80mm in length and 12mm in diameter 3: Protection from sprayed water at an angle of 60º from vertical
     S: Valid at standstill. (Should not be used for welding outdoors in heavy wind and rain)

Thermal insulation class
I.CL.H= Thermal class of the insulating materials and insulation systems. resistant up to 180°C.

Standards
EN 60974-10 European Norm for electromagnetic compatibility.
EN 60974-1 European Norm for arc welding appliance: Current sources for welding.

Mark stating conformity to all safety standards and other standards required for sale within the European Union

Dimensions and weight

• Height : 325mm
• Length : 460mm
• Width : 230mm
• Weight : 12,2kg

Recast Directive
This mark confirms that the product confirms to the RoHS directive which restricts the use of specific hazardous or restricted substances in electrical and electronic equipment in EU

Components Included

The Unitor Welding Inverter UWI 203 TP, product number 191-203203, comes with the following components:

• 1 Carrying strap mounted on the machine
• 1 pce 4 m primary cable, mounted on the welding machine (plug not included)
• 1 set 3 m welding cable with quick connector and electrode holder
• 1 set 3 m ground cable with quick connector and ground clamp
• 1 Instruction Manual

Product Usage Instructions

Installation

Before installing the Unitor Welding Inverter UWI 203 TP, ensure that you have read the instruction manual, including the safety instructions. Follow the provided guidelines for installation, ensuring proper connection to a primary voltage between 380 and 440V. Only qualified personnel should perform this installation. Only personnel that have read and understood this Manual should install and operate this equipment. Machine must only be plugged into a receptacle which is grounded in accordance with valid regulations.

Note
The power switch should be in the OFF position when installing work cable and electrode cable and when connecting power cord to input power. Select a suitable location The UWI 203 TP inverter welder has an IP23S rating. Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. Ensure minimum 50cm free space on all sides. If free flow of air is hindered the machine will overheat. A location that minimizes the amount of smoke and dirt drawn into the louvers reduces the chance of dirt accumulation that can block air passages and cause overheating.

Avoid tilting
The machine must be placed on a secure, level surface, maximum 15º out of horizontal.

Assembly

Select polarity to electrode based on recommendations on the electrode package and the job at hand. For GTAW (TIG) welding negative (-) polarity should always be to the torch.

4 FRONT AND BACK PANEL

Description

1. Power on warning. Green light when the machine is connected and switched on.
2. Thermal protection activated. Yellow light indicates that the protection thermostat has cut the output. Do not switch the machine off. The fan will be running and the thermostat resets automatically when the machine has cooled down sufficiently. The light will darken when the machine is live again.
3. Selection of welding process:
4. Up:
5. SMAW (MMA) welding with stick electrodes
6. Down:
7. GTAW (TIG) welding.
8. Welding current adjustment potmeter. Rotate knob clockwise to increase amperage, minimum to 200 Ampere
9. Arc force increases the short circuit amperage providing a crisper arc, allowing the welder to use very short arc without sticking the electrode in the melt pool. It is useful when welding with stick electrodes at low amperages but gives more spatter. Set control to 0 (soft arc) for normal electrode welding and TIG welding.
10. Active VRD signal. When lit this shows that the Voltage Reducing Device is active, reducing the voltage across the welding sockets. This will happen within 2 seconds after the welding arc is broken to protect the welder from electric chock. Full arc striking voltage will automatically be re-established when the welding circuit is re-established by touching the electrode to the work-piece.
11. On/Off switch (Back panel)
12. Primary cable, 4 core 2,5mm², 3m long.
13. Missing phase warning. Warning light indicates that one of the three phases in the power supply to the machine has fallen out.

Welding

MMA (SMAW stick electrode) welding
Select MMA welding (selector switch up). Connect ground (return) cable with good contact to the work piece. Select polarity and amperage as recommended for the electrode and start arc as follows: Drag electrode across work piece like striking a Match and lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to work piece, use a quick twist to free it.

Hot start
The machine has automatic Hot Start for stick electrode welding. This makes arc striking easier and reduces the possibility of electrode sticking

TIG (GTAW) welding
Select TIG process (selector switch down) and connect TIG torch to negative (-) terminal on the machine. The torch should preferably have gas valve on the handle. Connect ground (return) cable with good contact to the work piece. When the TIG process is selected normal open-circuit voltage is not present before tungsten electrode touches and lifts from work piece. Only a low sensing voltage is present between electrode and work piece. The solid-state output contactor does not energize until after electrode is touching work piece. This allows the electrode to touch the work piece without overheating, sticking, getting contaminated or contaminate the work piece.

Start the arc as follows:

• Turn gas on.
• Touch tungsten electrode to workpiece at weld start point.
• Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode. The arc is formed when the electrode is lifted.

To start welding using the Unitor Welding Inverter UWI 203 TP, follow these steps:

1. Ensure that you have appropriate safety gear, including welding gloves, helmet, and protective clothing.
2. Connect the primary cable to a suitable power source within the specified voltage range.
3. Connect the welding cable with the electrode holder to the appropriate output outlet on the inverter.
4. Connect the ground cable with the ground clamp to the workpiece or a suitable grounding point.
5. Refer to the instruction manual for specific welding techniques and settings based on the desired welding process (MMA or TIG).
6. Adjust the Arc Force setting for stick electrode welding, if necessary.
7. For TIG welding, use the Lift-Start feature to initiate a soft arc start.
8. Ensure that you maintain proper welding technique and safety precautions throughout the welding process.

Routine Maintenance

To ensure the optimal performance and longevity of the Unitor Welding Inverter UWI 203 TP, regular maintenance is recommended. Follow the routine maintenance guidelines provided in the instruction manual. This may include cleaning, inspection, and servicing of the inverter components.

Troubleshooting

If you encounter any issues or problems while using the Unitor Welding Inverter UWI 203 TP, refer to the troubleshooting section in the instruction manual. It provides guidance on identifying and resolving common issues.

WIRING DIAGRAM

COMPONENTS AND SPARES

Spare part kit for UWI-203TP includes power board, necessary additional components and complete instructions for replacement Order no191-203205

For ordering spares please state:

• Model:
  • UWI 203 TP
• Serial no: ………….
• Pos no: .………….
• Code: .………….

ACCESSORIES

TIG torch T-200 Order number 197-200000

Additional Information

For detailed wiring diagrams, component information, spare part details, and available accessories for the Unitor Welding Inverter UWI 203 TP, refer to the respective sections in the instruction manual.

Safety Instructions

Ensure that you carefully read and follow all safety instructions provided in the instruction manual. Failure to do so may result in personal injury or damage to the equipment. Prioritize safety at all times during installation, operation, and maintenance of the welding inverter.

Arc Welding Hazards
The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on unit. Disconnect input power before installing or servicing this equipment. Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in the cord plug and that the plug is connected to a properly grounded receptacle outlet. When making input connections, attach proper grounding conductor first − double-check connections. Frequently inspect input power cord for damage or bare wiring −replace cord immediately if damaged − bare wiring can kill. Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the work-piece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to work- piece or worktable as near the weld as practical. Insulate work clamp when not connected to work-piece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Turn off inverter, disconnect input power, and discharge input capacitors before touching any parts.

FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Do not weld in locations near degreasing, cleaning, or spraying operations.The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields under your helmet. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.

WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared Connect work cable to the work as close to the welding area as practical to prevent welding current from travelling long, possibly unknown paths and causing electric shock and fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Wear oil-free protective garments such as leather gloves, heavy shirt, cuff-less trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. Wear approved safety glasses with side shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved air-supplied respirator.

HOT PARTS can cause severe burns.
Do not touch hot parts bare handed. Allow cooling period before working on gun or torch.

MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.
Noise from some processes or equipment can damage hearing. Wear approved ear protection if noise level is high.

CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder − explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. Turn the face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in use or connected for use. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

Additional precautions for installation, operation, and maintenance
Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to weld again. Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and boxes to store, move, or ship PC boards.

MOVING PARTS can cause injury.
Keep away from moving parts. Keep away from pinch points such as drive rolls.

WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

MOVING PARTS can cause injury.
Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place.

H.F. RADIATION can cause interference.
High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

ARC WELDING can cause interference.
Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

EMF Information
Considerations about welding and the effects of low frequency electric and magnetic fields. Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.

However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

DECLARATION OF CONFORMITY

WECO srl
Via S. Antonio, 22 – BELVEDERE
36050 TEZZE SUL BRENTA (VICENZA) ITALY
Tel. +39 0424 561943
Fax +39 0424 561944
E-mail info@weco.it 
www.weco.it
P. IVA 02783960244
C.F. 02710490281
Reg. Impr. VI n° 52214
R.E.A. N° 274736
Capitale sociale i.v. € 52.000,00

FOR FULL INFORMATION ON THE UNITOR WELDING OFFER

USE THE UNITOR WELDING HANDBOOK FOR MARITIME WELDERS

You can download it here
http://www.wilhelmsen.com/services/maritime/companies/buss/DocLit/PorductLiterature/Pages/Maintenanceandrepair.aspx

…or contact Wilhelmsen Ships Service for a paper copy

Revision date: 23 09 2014 Page 24 of 24
www.wilhelmsen.com/shipsservice

References

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