TOTAL UTW22005 200 Amp Inverter Welding Machine Instruction Manual

INVERTER MMA/TIG LIFT WELDING MACHINE
UTW22005
INDUSTRIAL

UTW22005 200 Amp Inverter Welding Machine

https://totalqr.totaltools.cn/vs/adh?no=E31E9BAF8A89A0B145FF13A1D5AFD452 TOTAL TOOLS WORLD 200A

SAFETY PRECAUTIONS

WARNING: As with all machinery, there are certain dangers related to its operation and use. The exercise of respect and caution will greatly reduce the risk of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result. Failure to follow these rules may result in serious personal injury.

GENERAL PRECAUTIONS

A) Prevention of burns
Wear protective clothing: gauntlet gloves designed for use in welding, protective hat, and protective shoes. Button up shirt collars and pocket flaps, and wear cuffless trousers to prevent the entry of sparks and slag. Wear a helmet with safety glasses or glasses with side shields underneath, lenses or appropriate filter plates (protected by a transparent cover glass). This is a MUST for welding or cutting, (and chipping) to protect eyes from radiant energy and flying metal. Replace the protective glass when it is broken, chipped or spattered. Avoid oily and greasy clothes. A spark can ignite them. Hot metal, such as electrode stubs and work pieces, should never be handled without gloves. First aid facilities and a qualified first aid person must be available on each shift, unless there are medical facilities nearby for the immediate treatment of eye and skin burns. Earplugs should be used when working overhead or in a confined space. A helmet must be worn when working overhead. People who intend to weld or cut must not use flammable hair preparations.
B) Prevention of toxic fumes
Fumes, vapors, heat, or enrichment or depletion of Oxygen produced by welding (or cutting) can cause serious discomfort, illness or death. Avoid them with adequate ventilation.
NEVER ventilate with oxygen. Materials containing lead, cadmium, zinc, mercury and beryllium, when welded (or cut) can produce harmful concentrations of toxic fumes. Adequate local ventilation should be used, or each person in the area, as well as the operator, should wear a supplied-air respirator. In the case of beryllium, both must be used. Metals coated with materials that emit or contain toxic fumes should not be heated unless the coating is removed from the work surface, the area is well ventilated, or the operator is wearing a supplied-air respirator. Work in a confined space only while ventilating and, if necessary, while wearing a supplied-air respirator. Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eye irritants. The ultraviolet (radiant) energy of the arc can also break down trichlorethylene and perchlorethylene vapors to form phosgene. DO NOT WELD in locations where solvent vapors may be carried into the welding or cutting atmosphere or where radiant energy may penetrate atmospheres containing even trace amounts of trichlorethylene or perchlorethylene.
C) Fire and explosion prevention
The causes of fire and explosion are

1. combustibles reached by the arc, the flame, the sparks that skip, hot slag or heated material;
2. Short circuits.
   Be aware that falling sparks or slag can pass through cracks, along pipes, through windows or doors, and through openings in walls or floors, out of sight of the operator. operator with glasses. Sparks and slag can fly 10 m.
   To avoid fires and explosions: keep the equipment clean and operational, free of oil, grease and (in electrical parts) of metal particles that can cause short circuits. If there are fuels in the area, DO NOT weld. Move work, if possible, to a fuel-free area.
   Avoid paint spray rooms, dip tanks, storage areas, and fans. If it is not possible to move the work, move combustibles at least 10m away out of reach of sparks and heat; or protect against ignition with suitable tight-fitting, fire-resistant covers or shields.

Walls touching fuels on opposite sides should not be welded.
Walls, ceilings and floors near the work should be protected by heat-resistant covers or shields. A fire watcher with suitable fire extinguishing equipment must be present during and for some time after welding if:
a. Appreciable fuels (including building construction) are within 10 m.
b. The noticeable fuels are more than 10 m away but can be ignited by sparks.
c. Openings (concealed or visible) in floors or walls within 10 m can expose combustibles to sparks.
d. Combustibles adjacent to metal walls, ceilings, roofs, or partitions may be ignited by radiant or conducted heat.
After the work is done, check that the area is free of sparks, glowing embers and flames. An empty container that contains combustibles or that may produce flammable or toxic vapors when heated should never be welded unless the container has been previously cleaned. This includes…….a thorough cleaning with steam or caustic soda (or a wash with solvent or water, depending on the solubility of the fuel) followed by a purge and inerting with nitrogen or carbon dioxide, and the use of equipment of protection.
Filling with water just below the working level can replace blanketing.
A container with unknown contents must be cleaned (see previous paragraph), DO NOT rely on the sense of smell or sight to determine if it is safe to weld.
Hollow castings or containers must be vented before welding, as they may explode.
In explosive atmospheres, never weld where the air may contain flammable liquid dust, gas, or vapors.

ELECTRIC ARC WELDING

Comply with the precautions in point 1 and in this section. Arc welding, if done correctly, is a safe process, but a careless operator can cause problems. The equipment carries high currents at significant voltages. The bow is very bright and hot. Sparks fly, smoke rises, ultraviolet and infrared energy is radiated, and welds become hot. The prudent operator avoids unnecessary risks and protects himself and others the rest of the accidents.

A) Protection against burns
Observe the precautions indicated in 2. The welding arc is intense and visibly bright. Its radiation can damage the eyes, penetrate light clothing, reflect off light-colored surfaces, and burn the skin and eyes. Skin burns resemble acute sunburn, while those from gas shielded arcs are more severe and painful.
DO NOT BURN YOURSELF! RESPECT THE PRECAUTIONS!

1. Protective clothing
   Wear long-sleeved clothing as well as gloves, hat and shoes (2A). As necessary, wear additional protective clothing such as leather jacket or sleeves, fire-resistant apron, and fire-resistant gaiters. Avoid untreated cotton outerwear. Protection of bare skin. Wear dark, good quality clothing. Button the collar to protect the chest and neck and button the pockets to prevent the entry of sparks.

2. Eye and head protection
   Protect eyes from arc flash exposure. NEVER look at a bow unprotected electrical.
   When welding, a helmet or shield containing a No. shade filter plate should be used. 12 or denser should be used when welding. Place on the face before hitting the bow. Protect the filter plate with a transparent cover plate. A cracked or broken helmet or screen should NOT be used; radiation can pass through and cause burns. Cracked, broken or loose filter plates must be replaced IMMEDIATELY. Replace the transparent cover plate when it is broken, chipped or splattered. WE SUGGEST 9 that flash goggles with side shields be worn under the helmet, to give some protection to the eyes in case the helmet is not lowered over the face before an arc occurs. Momentarily looking at an arc with unprotected eyes (especially a high-intensity, gas-shielded arc) can cause a retinal burn that can leave a permanent dark area in the field of vision. Before welding with contact lenses, ask your optician for advice.

3. PROTECTION OF CLOSE PERSONNEL
   For production welding, a separate room or closed hall is best. In open areas, surround the operation with low-reflective, non-combustible screens or panels. Allow free circulation of air, especially at ground level.
   Provide face shields to all persons who will look directly at the welding. Other people working in the area must wear protective glasses. Before you start welding, make sure the screen or shed doors are closed.

B) Prevention of toxic fumes
Observe the precautions in section 2-B. Exhaust gases from the generator engine must be vented to outside air. Carbon monoxide can kill.
C) PREVENTION OF FIRE AND EXPLOSIONS
Comply with the precautions in 2-C. Rated capacity of the equipment. Do not overload arc welding equipment. You can overheat the wires and cause a fire. Loose wire connections may overheat or cause a fire. Never strike a bow into a pressure vessel. It creates a fragile area that can cause a violent rupture or lead to such a rupture later if handled roughly.
D) Crash prevention.
Exposed live conductors or other bare metal in the welding circuit, or in electrically live, uncovered equipment, can cause a fatal shock to a person whose body becomes a conductor. Do not stand, sit, lie down, lean on, or touch a wet surface when welding without proper protection.
E) Protection for wearers of electronic life support devices (pacemakers)
Magnetic fields from high currents can affect the operation of pacemakers. People wearing electronic life support equipment (pacemakers) should consult with their doctor before approaching arc welding operations.
F) To protect against blows:
Keep body and clothing dry. Never work in a wet area without adequate insulation against electrical shock. Stay on a dry surfboard, or rubber mat when moisture or sweat cannot be avoided.
Sweat, seawater or moisture between the body and an electrically LIVE part – or a grounded metal – reduces the electrical resistance of the body’s surface, allowing dangerous and possibly lethal currents to flow through the body.

1. Equipment grounding
   When arc welding equipment is grounded, and the work is grounded, a voltage may exist between the electrode and any conductive object.
   Examples of conductive objects include buildings, power tools, work benches, welding power source boxes, work pieces, etc., but are not limited to. Never touch the electrode and any metal objects unless the welding power source is turned off. When installing, connect the frames of each unit, such as the welding power source, control, workbench, and water circulator, to the building ground.
   Conductors must be suitable to carry ground currents safely. Equipment that is made electrically LIVE by stray current can be shocked, possibly fatal. DO NOT CONNECT to electrical conduit or pipe carrying ANY flammable gas or liquid, such as oil or fuel.

2. Electrode holder
   Fully insulated electrode holders must be used. DO NOT use electrode holders with screws that protrude or are damaged in any way.

3. Connectors
   Fully insulated locking connectors must be used to join the welding cable.

4. Wires
   Frequently inspect cables for wear, cracks and damage.
   IMMEDIATELY
   Replace those with excessively worn or damaged insulation to prevent possible lethal shock from the bare wire. Cables with damaged areas can be taped to give strength equivalent to that of the original cable. Keep the cord dry, free of oil and grease, and protected from hot metals and sparks.

5. Terminals and other exposed parts
   Terminals and other exposed parts of electrical units must have insulating covers secured before operation.

6. Safety devices
   Safety devices, such as interlocks and circuit breakers, must not be disconnected or bypassed. Before installing, inspecting or servicing equipment, turn off all power and remove line fuses (or red tag or lockout switches) to prevent accidental turning on of power. Do not open the power circuit or change polarity while welding. If, in an emergency, it must be disconnected, protect yourself from electric shock burns or flashover from the arc of the switch. Always turn off and disconnect all power to the equipment. The power disconnect switch must be available near the welding power source.

TIG/MMA welding

A) Connect the ground clamp lead to the negative (-) jack. Turn clockwise to lock.
B) Connect the TIG torch/electrode holder to the positive (+) socket. Turn clockwise to lock.
C) Plug the power cable into the 220Vac voltage.

MMA

Electrode (mm)| 1.6| 2.0| 2.5| 3.2| 4.0
Welding current(A)| 25-40A| 40-60A| 50-80A| 100-130A| 160-180A
Lift TIG
Electrode (mm)| 1.0| 1.6| 2| 2.4| 3.2
Welding current(A)| 10-75A| 40-130A| 75-180A| 130-230A| 160-310A

Basic TIG/MMA welding

READ THE ENTIRE SAFETY INFORMATION SECTION
IMPORTANT at the beginning of this manual, including all text under subheadings, before setting up or using this product.
WARNING
TO AVOID SERIOUS INJURY:
Protective equipment must be worn when using the welder; (full shield or minimum #10 welding helmet), ear protection, welding gloves, sleeves and apron, NIOSH approved heavy duty work clothing without pockets should be worn when welding. Arc light can cause permanent damage to the eyes and skin. Do not breathe arc fumes.
TIG DC welding is used to weld mild steel and stainless steel using a TIG rod and shielding gas.
Stick welding is used to weld mild steel and stainless steel using a stick electrode without shielding gas. Good welding requires a certain degree of skill and experience. Practice a few sample welds on scrap before welding your first project. Additional practice periods are recommended whenever welding:

• a different material thickness
• a different kind of material
• a different type of connection
• using a different process

Make practice welds on pieces of scrap metal to practice technique before welding anything of value.

PREPARATION OF THE WORK AREA The work area must be sufficiently spacious, not humid and well ventilated to avoid the fumes that develop in the welding process and incidental materials adhered to the parts to be welded (oils, paints, tars…) that can cause discomfort. to the operator.
The work area must be sufficiently spacious, not humid and well ventilated to avoid the fumes that develop in the welding process and incidental materials adhered to the pieces to be welded (oils, paints, tars…) which can cause discomfort to the pear.
Avoid welding in contact with wet parts and with nearby combustible liquids. Above all, do not weld on tanks that may contain flammable residues.
SAFETY PRECAUTIONS FOR ARC WELDING
ALWAYS ensure that free air circulates completely around the outer casing of the machine, and that the vents are not obstructed.
ALWAYS use a suitable welding helmet or helmet, with appropriate filter lenses. Appropriate gloves and work clothing must be worn at all times.
ALWAYS remove all flammable materials from the welding area.
NEVER remove any of the panels unless the machine is disconnected from power, AND never operate the machine with any of the panels removed.
NEVER attempt any electrical or mechanical repair without the help of a qualified technician.
NEVER use or store the machine in a humid environment. DO NOT EXPOSE THE MACHINE TO RAIN. NEVER continue welding if, at any time, you feel the slightest electrical shock. Stop welding IMMEDIATELY, and DO NOT attempt to use the machine until the fault is diagnosed and corrected.
NEVER use the welder with input connections longer than 10M. NEVER allow cables to wrap around the operator or anyone in the vicinity.

SYMBOLS
The following symbols will appear on your welder

OPERATING PRINCIPLES

Shielded metal arc welding uses the heat of the arc to melt the base metal and the tip of a flux-coated electrode.
The electrode and the workpiece are part of an electrical circuit. This circuit begins with the electrical power source and includes welding cables, an electrode holder, a workpiece connection, the workpiece, and an arc welding electrode. One of the two cables from the power supply connects to the part. The other is connected to the electrode holder.
Welding begins when an electric arc occurs between the tip of the electrode and the workpiece. The intense heat of the arc melts the tip of the electrode and the surface of the workpiece near the arc. Small globules of molten metal quickly form at the tip of the electrode and are transferred via the arc flow to the molten weld pool. In this way, the filler metal is deposited as the electrode is progressively consumed.
The arc moves over the part at an appropriate arc length and travel speed, melting and fusing a portion of the base metal and continually adding filler metal. Because the arc is one of the hottest heat sources on the market (temperatures exceeding 90,000F (50,000C) have been measured at its center), melting of the base metal occurs almost instantaneously upon arc initiation.
If welds are made in a flat or horizontal position, metal transfer is induced by the force of gravity, gas expansion, electrical and electromagnetic forces, and surface tension. For welds in other positions, gravity acts against the other forces.
The process requires sufficient electrical current to melt both the electrode and an adequate amount of base metal. It also requires adequate clearance between the electrode tip and the base metal or molten weld pool. These requirements are necessary to set the stage for coalescence.
The sizes and types of electrodes for metal arc welding protected define arc voltage requirements (within the global range of 16 to 40V) and current requirements (within the global range of 20 to 550A). The current can be alternating or direct, depending on the electrode used, but the power source must be able to control the current level within a reasonable range to respond to the complex variables of the welding process itself.

WELDING TECHNIQUES

Arc welding cables are supplied with this machine. To prepare the unit for arc welding, it is important that you follow the following procedure.

1. With the ON/OFF switch, located on the rear panel, in the OFF position, connect the welding cables as follows:
   – The wires from the welding electrode to the positive “+” terminal.
   – Wires from the ground clamp to the negative “-” terminal.

2. Attach the work clamp to the piece, as close as possible to the area to be welded.
   Clean with a wire brush where necessary to ensure the connection is as clean as possible.

3. Next, a suitable current must be set by turning the welding current selector located on the front panel of the machine. With practice you will get a feel for the correct setting of the current for different thicknesses of welding electrodes.

4. Turn on the machine with the switch located on the rear panel. The green light on the front panel should glow, indicating that the machine is on.
   NOTE: If the machine stops at any time and the amber light comes on, a thermal overload has occurred.

5. The most difficult aspect of the arc welding process, especially for beginners, is forming the arc. We strongly recommend that you practice on some pieces of scrap metal to get the feel of the operation, before starting on a real welding job.

6. Keep the electrode about 10 mm from the workpiece and at an angle of about 70° to 80° with respect to the work surface; Be careful not to accidentally touch the piece until you are ready to begin.

7. Holding the welding helmet close to the face, give a short stroke with the electrode on the workpiece. As soon as the arc strikes, remove the electrode from the work to leave a small gap about 1/16″ (1.5 mm). Current will flow through the gap with a crackling noise and a bright arc. Continue welding in one direction, maintaining the small separation as it goes. In the end
   of the stroke, completely remove the electrode from the workpiece.
   NOTE: When striking the arc, be sure to remove the electrode fairly quickly to leave the 1.5mm gap, otherwise the electrode will weld to the workpiece. If this occurs, give the electrode a small, sharp tug to release it and, if necessary, re-strike the arc. If you cannot release the electrode, immediately turn off the machine and release it.

8. Inspect the work carefully. With the correct combination of electrode size and current setting, the weld area should be a complete fusion of the electrode metal with the metals being joined. Slag that forms on the surface should be removed with a hammer or pick. ALWAYS wear safety glasses when removing slag.
   NOTE: If the resulting weld looks rough or messy, or shows signs of porosity or slag contamination, you almost certainly have not gotten the right match, (or there is dirt/oil on the part). Don’t worry, as practice will fix it soon.

HEALTH WARNING:
When welding, always make sure there is adequate ventilation in the work area, since the welding process gives off toxic fumes.

MAINTENANCE

The ARC Inverter welder requires very little maintenance, apart from the guidelines shown below. Under normal working conditions, it is sufficient to remove the covers and clean them with dry compressed air at reduced pressure once a year. Cleaning at more frequent intervals is advised if the unit is operating in a dusty and dirty environment.

1. Keep the ventilation grills clean to avoid the accumulation of dirt and oxides inside the machine, which can reduce its performance.
2. Periodically check all cables: They must be in good condition and not cracked.
3. Always try to prevent metal particles from getting inside the machine, as they could cause a short circuit.

IMPORTANT: Disconnect the appliance from the mains before cleaning it.

SPECIFICATIONS

| UTW22005
---|---
Rated input voltage| 110-120V∼| 220-240V∼
Input rated frequency| 50/60Hz
No-load voltage| 83V
Rated output current| 15-130A| 15-200A
Rated Duty Cycle| 60%@130A| 60%@200A

UTW22005 Exploded view

UTW22005 Spare parts list

INVERTER MMA/TIG LIFT WELDING MACHINE
www.totalbusiness.com
TOTAL TOOLS CO., PTE. LTD.
No. 45 Songbei Road, Suzhou Industrial Park, China.
MADE IN CHINA
T0122.V01
200A

References

• piel.no in parked
• TOTAL – TOTAL® Tools Official Site

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