Unitor UWI 203 TP Bedienungsanleitung

Revision date: 23 09 2014 Page 1of 24

Instruction manual

Unitor Welding Inverter

UWI 203 TP

MMA (Stick) / TIG welder

Revision date: 23 09 2014 Page 2of 24

CONTENTS

1. GENERAL DESCRIPTION

2. TECHNICAL DATA

3. INSTALLATION

4. FRONT AND BACK PANEL

5. WELDING

6. ROUTINE MAINTENANCE

7. TROUBLESHOOTING

8. WIRING DIAGRAM

9. COMPONENTS AND SPARES

10.ACCESSORIES

11.SAFETY INSTRUCTIONS

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT

READING THIS MANUAL INCLUDING THE SAFETY INSTRUCTIONS

Revision date: 23 09 2014 Page 3of 24

1 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

IDENTIFY COMPONENTS

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

Carrying strap mounted on the machine

1 pce

4 m primary cable, mounted on the welding machine, plug

not included.

1 pce

3 m welding cable with quick connector and electrode holder

1 set

3 m ground cable with quick connector and ground clamp

1 set

Instruction Manual

1 pce

Revision date: 23 09 2014 Page 4of 24

2 TECHNICAL DATA

Type of welding machine

Three-phase static transformer rectifier

frequency converter, DC output.

Processes

MMA (Stick electrode / SMAW) TIG (GTAW)

Safety Marking

Suitable for use in areas with increased electric shock hazard

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

Revision date: 23 09 2014 Page 5of 24

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+0,04*I2)

TIG →U2=(10+0,04*I2)

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.

Maximum input power is 6,7 kVA. Power factor 0,95. Duty Cycle 40%

Cooling

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

Protection class

IP23S= Ingress Protection class. Protection degree of the casing according to EN 60529

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

Revision date: 23 09 2014 Page 6of 24

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

3 INSTALLATION

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.

3 phase 380-440V

50/60 Hz + PE

(10 A slow fuses

recommended)

Welding cable and

electrode holder

Return cable and

ground clamp

Work Piece

Negative pole

Positive pole

Revision date: 23 09 2014 Page 7of 24

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:

Up: SMAW (MMA) welding with stick electrodes

Down: GTAW (TIG) welding.

4. Welding current adjustment potmeter. Rotate knob clockwise to increase amperage,

minimum to 200 Ampere

5. 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.

6. 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.

7. On/Off switch (Back panel)

8. Primary cable, 4 core 2,5mm², 3m long.

9. Missing phase warning. Warning light indicates that one of the three phases in the power

supply to the machine has fallen out.

Revision date: 23 09 2014 Page 8of 24

5 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.

1 Electrode

2 Workpiece

3 Arc

1 Electrode

2 Workpiece

Lift carefully and the arc will be

established

Touch the electrode to the work

piece. Only sensing voltage will be

present

Revision date: 23 09 2014 Page 9of 24

6 ROUTINE MAINTENANCE

Checkpoint

Action

Interval

Primary plug

and socket

Check connections

and stretch relief

3 months or more

often if needed

Primary cable

Check for damage

and replace if

necessary

3 months or more

often if needed

Primary cable

stretch relief

and connection

Check for damage

and tightness

3 months or more

often if needed

Labels

Replace damaged or

unreadable labels

3 months or more

often if needed

Internal dust

and dirt

Blow out or vacuum

inside

6 months or more

often if needed

Welding current

sockets

Check and clean

3 months or more

often if needed

Cable

connectors

Check, clean if

needed and tighten

Prior to use /

every 3 months

Welding cables

Repair or replace if

damaged

Prior to use /

every 3 months

Electrode

holders and

torches

Check, clean and

replace if damaged

Prior to use /

every 3 months

Ground clamps

Check tightness and

clean contact points

Prior to use /

every 3 months

Remote

controls,

if relevant.

Check function and

condition of cables

3 months or more

often if needed

Revision date: 23 09 2014 Page 10 of 24

7 TROUBLESHOOTING

SYMPTOM

POSSIBLE

REASON

SOLUTION

No output, no warning

light, fan not running

Primary power

does not reach the

machine

Mains fuses blown

Machine is not plugged in

Broken primary cable

Cable connection to machine is loose

Machine not switched on

On/off switch damaged

No output, yellow warning

light

Voltage protection

activated

Too high or too low input voltage, should be

within 342 - 484V

Thermal protection

activated

Used at too high duty cycle, wait until

machine has cooled down and power

returns.

Weld with more breaks or lower current

Cooling air flow is hindered, remove

obstructions

Heat development in loose electrode holder

or ground cable connections

Broken fan, repair or replace

Too much dirt in power source

compartment, clean out.

No arc, no warning light

Incomplete circuit

Check ground cable connections and torch

connection

Unstable arc

Polarity

Check that polarity set on the machine

matches the wire

Poor contact

Check ground clamp and torch connections

Contaminated work

piece

Clean

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