Unitor UWI 230 TP AC/DC User manual

Revision date: 29/07/2015
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Instruction manual
Unitor Welding Inverter
UWI 230 TP AC/DC
MMA (Stick) and TIG welder

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TP
CONTENTS
1 GENERAL DESCRIPTION…………………………. 3
2 TECHNICAL DATA…………………………………...4
3 INSTALLATION………………………………………6
4 FRONT AND BACK PANEL………………………...7
5 WELDING……………………………………………..9
6 PARALLEL CONNECTION…………………………10
7 ROUTINE MAINTENANCE………………………….11
8 TROUBLESHOOTING……………………………….12
9 WIRING DIAGRAM…………………………………...13
10 COMPONENTS AND SPARES……………………..14
11 ACCESSORIES………………………………………..17
12 SAFETY INSTRUCTIONS……………………………19
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENTWITHOUT
READING THIS MANUAL INCLUDING THE SAFETY INSTRUCTIONS

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1. GENERAL DESCRIPTION
Connects to any primaryvoltage between 195 and 265V without need for any actionfrom the
operator.
Line Voltage compensationkeeps output of the power source constant regardless of fluctuationin
input power from 10% below lowest to above highest rated input voltage.
Safe in use. Touchable Open Circuit Voltage only 9V, well below the 70V limit set by the Code of
Safe WorkingPractices for Merchant Seamen.
Automatic Hot Start for stick arc starts makes arc striking easy and prevents electrode sticking.
Automatic Arc Force for stick electrode weldingallows 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: 10 –180A in MMA mode, 5 – 200A in TIG
mode.
Casing of high grade aluminium and industrial plastic to eliminate corrosion damage also contributes
to low-weight whichtogether with compact outer dimensions provides good portability.
Windtunnel designfor the internal cooling air flow protects electrical components and PC boards
from dirt, dust, debris, greatly improvingreliability.
Thermal overloadprotection with indicator lights helps prevent machine damage if the duty cycle is
exceeded or airflow is blocked.
Total Protection function with indicator light prevents machine damage if the primary power supply exceeds
275V.
IDENTIFY COMPONENTS
UnitorWeldingInverter UWI 230TP AC/DC, product number 191- 230231 is delivered with
1 Carryingstrap mounted on the machine 1 pce
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2. TECHNICAL DATA
Type of welding machine
One-phase static transformer rectifier frequency converter, DC output.
Processes
MMA (Stick electrode / SMAW) TIG DC (GTAW) TIG (GTAW) ALUMINUM
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 thermalswitchstops 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 startingto weld.

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I
2 = Welding current.
Range 10 – 180A in MMA process; 5 – 220A in TIG processes.
U r = No-load voltage
Is the voltage between weldingterminals (touchable voltage) when the machine is idle and equipped
with a voltage reduction function for operator safety. Low value means high operator safety, and with
this in mind this machine satisfies the world’s strictest regulation: AS 1674.2-2007 Safety in welding
and allied processes (Australian standard) which allows for maximum 35V.
U 0 = Arc striking voltage
When electrode touches work piece the U r voltage will within a split secondjump to this value. It is
important that this value is high enough to enable quick and easy arc start for all welding
consumables.
U 2 = Arc voltage
Voltage present between the output outlets when weldingis beingcarried out, in relationto 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
U 1 = Effective input voltage 230V
I 1max = Maximum value of input current at the corresponding duty cycle.
I 1eff = Effective value of input current at the corresponding duty cycle.
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 intrusion of object greater than 12,5mm in diameter
3: Protection from sprayed water at an angle of 60º from vertical
S: Valid at standstill. (Should not be used for weldingoutdoors 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 statingconformity to all safetystandards and other standards required for sale
withinthe European Union
Dimensions and weight
Height : 325mm
Length : 460mm
Width : 230mm
Weight : 19,4kg

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3. INSTALLATION
Only qualified personnel should perform this installation.
Only personnel that have read and understoodthis Manualshouldinstall and operate this
equipment.
Machine must only be pluggedinto a receptacle which is groundedin accordance with valid
regulations.
Note
The power switch should be in the OFF positionwhen installingwork cable and electrode cable and
when connecting power cord to input power.
Select a suitable location
The UWI 230 TP AC/DC 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 placedon a secure, levelsurface, maximum 15º out of horizontal.
Assembly
Negative pole Positive pole
Select polarity to electrode based on recommendationson the electrode package and the job at
hand. For GTAW (TIG) welding negative (-) polarity shouldalways be to the torch.
1 phase 230V
50/60 Hz + PE
(16 A slow fuses
recommended)
Return cable and
ground clamp
Welding cable and
electrode holder
Welding cable and
Tig torch

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4. FRONT AND BACK PANEL
Description
1. Thermal protectionactivated. Yellow light indicatesthat the protection thermostat has cut the
output. Do not switch the machine off. The fan will be running and the thermostat resets
automatically whenthe machine has cooled down sufficiently. The light will darken when the
machine is live again.
2. Power signal. When lit this shows the presence of power on the output sockets.
3. Active VRD signal. When lit this shows that the Voltage Reducing Device is active,
reducing the voltage across the weldingsockets. This will happen within 2 seconds after
the welding arc is brokento protect the welder from electric chock.
Full arc strikingvoltage will automatically be re-establishedwhen the weldingcircuit is
re- established by touchingthe electrode to the work-piece
4. The display show the value of the welding current.
5. Weldingcurrent adjustment encoder. Rotate knob clockwise to increase amperage,
minimum to 180 Ampere in MMA; minimum to 220 Ampere in TIG.
6. SMAW (MMA) signal. When lit this shows the selectionof electrode process.
7. GTAW (TIG) DC signal. When lit this shows the selection of TIG DC process.
8. GTAW (TIG) ALU signal. When lit this shows the selection of TIG ALU process for aluminum welding.
9. Selection of welding process:
- SMAW (MMA) welding with stick electrodes
- GTAW (TIG) DC welding.
- GTAW (TIG) ALU welding.
10. Selection of welding current adjustment
- On front panel
- With remote control
11. Remote control signal. When lit this shows the selection of Remote Control.
12. The display shows the various welding processes relative to the selected process.
13. Selection of Turbo ALU function
14. Turbo ALU signal. When lit this shows the selection of Turbo ALU. This function increases
welding speed and penetration on aluminum welding.
1
2
3
4
1
4
1
3
1
2
1
1
1
0
9
5
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8

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15. Socket for remote control.
16. On/Off switch
17. When lit this warning light indicates that the Total Protection function has been
activated and input power has been cut because it has exceeded 285V ac.
18. Primarycable, 3 core 2,5mm², 4m long.
1
8
1
7
1
5
1
6

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5. WELDING
MMA (SMAW stick electrode) welding
Select MMA welding.
Connect ground(return) cable with good contact to
the work piece.
Select polarity and amperage as recommendedfor
the electrode and start arc as follows:
Drag electrodeacross work piece like strikinga
Match and lift electrode slightly after touchingwork.
If arc goes out electrode was lifted to high.
If electrode sticks to work piece, use a quick twist to
free it.
1 Electrode
2 Workpiece
3 Arc
Hot start
The machine has automatic Hot Start for stick electrode welding. This makes arc strikingeasier and
reduces the possibility of electrode sticking
Arc Force
Automatic Arc Force 50% for stick electrode welding provides optimal arc characteristics for various electrodes.
TIG (GTAW) welding
Select TIG process and connect TIG torch to negative (-) terminalon 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 selectednormalopen-circuit voltage is not present before tungsten
electrode touches and lifts from work piece. Only a low sensingvoltage is present between
electrode and work piece.
The solid-stateoutput contactor does not energize until after electrodeis touchingwork piece.
This allows the electrode to touchthe work piece without overheating, sticking, getting contaminated
or contaminate the work piece.
Start the arc as follows:
Turn gas on.
Touch tungstenelectrode to workpiece at weld start point.
Hold electrode to workpiece for 1-2 seconds, and slowly lift electrode.
The arc is formed whenthe electrode is lifted.
Touch the electrode to the
work piece. Onlysensing
voltage willbe present
1 Electrode
2 Workpiece
Liftcarefully and the arc will
be establishe

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6. PARALLEL CONNECTION
Two pcs UWI-230 TP AC/DC may be parallelconnected and will then supply up to 360Acurrent
for stick electrode welding. This is done as follows:
- Set both machines to MMA welding.
- Set both machinesto remote controland if extensions are necessary use same length
remote control cables from each machine to the work site where the remote control parallel
connection kit, product number 676973, is used to connect both machines to the same
remote control
- If remote controlis not used both machinesshould be set to the same ampere value on the
displays, half of the required value for the electrode
- Return cables from both machines should be of equal length and clamps should be
connectedclose together directly on a clean part of the work-piece. 70mm2 cable is
recommended. NB! Same polarity for both on the welding machines.
- Weldingcables from both machines must be of equal lengthto the work site where the
parallelconnectingthree-way connector DIX70 male-female-female,product number
632901 is used to connect both machines to the same electrode holder.