Unitor UWI 230 TP AC/DC User manual

Revision date: 29/07/2015
Page 1 of 24
Instruction manual
Unitor Welding Inverter
UWI 230 TP AC/DC
MMA (Stick) and TIG welder

Revision date: 29/07/2015
Page 2 of 24
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
6
7
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.

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7. 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

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8. TROUBLESHOOTING
SY
M
P
T
O
M
P
O
SS
I
B
LE
REASON
S
O
L
U
T
IO
N
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 connectionto machine is loose
Machine not switched on
On/off switchdamaged
No output, yellow warning
light Thermal protection activated
Used at too high duty cycle, wait until
machine has cooled down and power
returns.
Weldwith more breaks or lower current
Coolingair 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, cleanout.
No output, red warning
light in the rear panel
Voltage protection
activated
Too high or too low input voltage, should
be within 190 - 265V
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 groundclampand torch connections
Contaminated
work piece Clean

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9. WIRING DIAGRAM

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10.COMPONENTS AND SPARES

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No.
Code Item Name
1 005.0001.0007 Belt
2 011.0001.0156 Upper cover
3 050.0001.0136 Overcut board
4 050.0002.0070 Power board
5 032.0001.3506 Rectifier bridge
6 040.0003.0075 Thermal switch
7 044.0004.0025 Output inductance
8 011.0008.0029 Lateral plate
9 010.0002.0004 Inversion inductance
10 050.5037.2400 Logic front panel
11 014.0002.0003 Knob
12 022.0002.0206 Led cable
13 021.0001.0259 Fixed socket 400A
14 010.0006.0038 Front plastic panel
15 050.0001.0075 Output filter board
16 016.0009.0003 Rubber foot
17 042.0003.0049 Power transformer
18 041.0004.0300 Hall sensor
19 011.0008.0001 Lower cover
20 040.0003.0075 Thermal switch
21 050.0002.0065 Snubber board
22 032.0002.2006 Diode
23 011.0008.0011 Internal fan support
24 003.0002.0004 Fan
25 011.0008.0010 External fan support
26 010.0006.0034 Rear plastic panel
27 013.0000.7005 Rear panel
28 045.0000.0007 Cable clamp
29 045.0002.0008 Supply cable
30 040.0001.0011 Single-phase switch
31 016.4107.0001 Led cap
32 016.0010.0001 Board support
33 015.0001.0006 Heat sink
34 044.0004.0017 Boost inductor
35 011.0008.0031 Upper plate
36 050.0001.0074 Line filter board
37 022.0002.0304 Remote control cable
38 050.0001.0099 IGBT module
39 050.0003.0071 Inversion board
Spare part kit for UWI-230TP AC/DC includes power board, inversion board, necessary additional
components and complete instructions for replacement Order no191-230233
For ordering spares please state:
Model: UWI 230 TP AC/DC
Serial no: ……………………..
Pos no: ……………………..
Code: .…………………….

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11.ACCESSORIES
Basic accessories for UWI-230 TP AC/DC
Basic accessories kit for UWI-230 TP AC/DC 196 670406
Consistingof: (Order numbers to be used when re-ordering)
Flip-Visionshield with flip-upframe, head band and filter shade 11 glass 196 709485
Long lined welding gloves, 1pair (re-orderingnumber is for 6 pairs) 196 632786
Electrode holder with 3m cable and connector 196 594325
Ground clampwith 3m cable and connector 196 594317
Wire brush, steel, 2 rows, 1 pcs (re-orderingnumber is for 6 pcs) 196 632976
Chipping hammer steel, 1 pcs (re-orderingnumber is for 2pcs) 196 633008
Remote control with 8m cable 191 670414
Cable Extensions
Welding cable 50mm² (max 20m extension is recommended), per m 195 175844
Cable connector DIX 70 male – female for weldingcable extension 195 632893
Remote control cable extension, 25m 191 670422
TIG welding Accessories for UWI-230 TP AC/DC
Specially thin and soft TIG gloves, 6 pairs 197 632794
TIG-torchT-200 with gas valve and DIX 70 connector 197 200000
Accessories kit for TIG-torch 197 607810
Argon regulator with flow adjustment 0-32 l/min 197 510010
Flow control meter for use at torch nozzle 197 597328
Flow control needle valve for gas flow adjustment 197 597310
Argon for TIG shieldingis available in 10 l cylinders (E-10) and 50 l cylinders (E-50)

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TIG torch T-200 Order number 197-200000
Pos.
1
Order number
197-551192
Unit
pcs
Product description
Short back-cap
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12.SAFETY INSTRUCTIONS
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 semiautomaticor automatic wire welding, the wire, wire reel, drive roll
housing, and all metalparts touchingthe welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
Do not touch live electricalparts.Wear dry, hole-free insulatinggloves and body protection. Insulate
yourself from work and ground using dry insulatingmats or covers big enoughto prevent any
physical contact with the work or ground. Do not use AC output in dampareas, if movement is
confined, or if there is a danger of falling. Use AC output ONLY if required for the weldingprocess. If
AC output is required, use remote output control if present on unit.
Disconnect input power before installingor servicingthis equipment. Always verify the supply
ground − check and be sure that input power cord ground wire is properly connectedto ground
terminalin the cord plug and that the plug is connectedto a properly groundedreceptacle outlet.
When making input connections,attach proper groundingconductor first − double-check
connections. Frequently inspect input power cord for damage or bare wiring −replace cord
immediatelyif damaged − bare wiringcan 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 groundingof the work-pieceis required, groundit 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. Maintainunit
accordingto manual. Weara safety harness if workingabove floor level. Keep all panels and covers
securelyin place. Clamp work cable with good metal-to-metalcontact to work-piece or worktable as
near the weld as practical. Insulate work clampwhen 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.
SIGNIFICANTDC VOLTAGE exists after removal of input power on inverters. Turn off inverter,
disconnect input power, and discharge input capacitors before touchingany parts

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FUMES AND GASES can be hazardous.
Weldingproduces 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 weldingfumes and gases. If ventilationis poor, use an
approved air-supplied respirator. Read the MaterialSafety 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 wearingan air-suppliedrespirator.
Always have a trained watchperson nearby.Weldingfumes and gases can displace air and lower the
oxygenlevel causinginjury or death. Be sure the breathingair 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 irritatinggases.
Do not weld on coatedmetals, such as galvanized, lead, or cadmium plated steel, unless the coating
is removedfrom the weld area, the area is well ventilated, and if necessary, while wearingan air-
supplied respirator. The coatings and any metals containingthese 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 andeyes when weldingor 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 clothingmade from durable, flame-
resistant material (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Weldingon closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks
can fly off fromthe welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metalobjects can cause sparks, explosion,
overheating, or fire. Check and be sure the area is safe before doingany welding. Protect yourself
and others from flying sparks and hot metal. Do not weld where flyingsparks canstrike flammable
material. Remove all flammables within 35 ft (10.7 m) of the weldingarc. If this is not possible, tightly
cover them with approved covers. Be alert that weldingsparks and hot materials from welding can
easily go throughsmall 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 closedcontainers 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 weldingcurrent from travelling long, possibly unknown paths and causingelectric 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.Wearoil-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 doingany 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 confinedspaces or use approved air-
supplied respirator.

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HOT PARTS can cause severe burns.
Do not touch hot parts bare handed. Allow cooling periodbefore working on gun or torch.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away. Wearers shouldconsult 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 protectionif
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 themcarefully. Protect
compressedgas cylinders from excessive heat, mechanicalshocks, slag, open flames, sparks, and
arcs. Install cylinders in an upright position by securingto a stationary support or cylinder rack to
prevent fallingor tipping. Keepcylinders away from any welding or other electrical circuits. Never
drape a weldingtorch over a gas cylinder. Never allow a welding electrode to touch any cylinder.
Never weld on a pressurizedcylinder − explosion will result. Use only correct shieldinggas cylinders,
regulators, hoses, and fittings designed for the specific application; maintain them and associated
parts in good condition. Turn face away from valve outlet whenopeningcylinder valve. Keep
protectivecap in place over valve except whencylinder is in use or connectedfor use. Readand
follow instructions on compressedgas cylinders, associatedequipment, and CGA publication P-1
listed in Safety Standards.
Additional precautions for installation, operation, and maintenance
Do not installor 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 protectedto handle this unit.
FALLING UNIT can cause injury.
Use liftingeye 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 enoughto extend beyondopposite side of unit.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before startingto
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.
Keepaway from movingparts. Keep away from pinch points such as drive rolls.
WELDING WIRE can cause injury.
Do not press gun trigger until instructedto do so. Do not point gun toward any part of the body, other
people, or any metal when threading weldingwire.