Wilhelmsen UNITOR UWW-301 User manual

UWW-301 TP
Page 1 of 38 Revision: 1.0/June-/2020
Instruction Manual
UWW-301 TP WIRE WELDER

UWW-301 TP
Page 2 of 38 Revision: 1.0/June-/2020
TABLE OF CONTENTS
1 INTRODUCTION ..................................................................................................................................................................................... 3
2 INSTALLATION ...................................................................................................................................................................................... 3
2.1 CONNECTIONS TO THE MAINS POWER SUPPLY .............................................................................................................................. 3
2.2 FRONT PANEL........................................................................................................................................................................................ 4
2.3 REAR PANEL .......................................................................................................................................................................................... 4
2.4 PREPARING FOR MMA WELDING ........................................................................................................................................................ 4
2.5 PREPARING FOR TIG WELDING .......................................................................................................................................................... 6
2.6 PREPARING FOR MIG/MAG WELDING ................................................................................................................................................ 7
2.6.1 WIRE SPOOL POSITIONING.......................................................................................................................................................................................... 7
2.6.2 POSITIONING THE WIRE IN THE WIRE FEEDER ........................................................................................................................................................ 7
2.6.3 CONNECTIONS TO SOCKETS ...................................................................................................................................................................................... 8
3 COMMISSIONING ................................................................................................................................................................................... 9
3.1 USER INTERFACE ................................................................................................................................................................................. 9
3.2 UNIT POWER-UP.................................................................................................................................................................................. 11
3.3 RESET (LOAD FACTORY SETTINGS) ................................................................................................................................................ 11
3.4 GAS FLOW ADJUSTMENT IN MIG/MAG MODE ................................................................................................................................. 11
3.5 ALARM MANAGEMENT........................................................................................................................................................................ 12
4 WELDING SETTINGS ........................................................................................................................................................................... 13
4.1 TORCH TRIGGER MODES .................................................................................................................................................................. 13
4.2 SELECTION OF THE WELDING MODE AND TORCH TRIGGER PROCEDURE ............................................................................... 14
4.3 PARAMETERS ACTIVATION ............................................................................................................................................................... 14
4.4 WELDING PARAMETERS .................................................................................................................................................................... 15
4.5 ELECTRODE WELDING (MMA) ........................................................................................................................................................... 16
4.5.1 PARAMETERS SETTING: WELDING CURRENT ........................................................................................................................................................ 16
4.5.2 PARAMETERS SETTING: HOT-START ....................................................................................................................................................................... 16
4.5.3 PARAMETERS SETTING: ARC-FORCE ...................................................................................................................................................................... 16
4.6 DC TIG WELDING ................................................................................................................................................................................. 16
4.6.1 PARAMETERS SETTING: WELDING CURRENT ........................................................................................................................................................ 16
4.7 MIG/MAG WELDING ............................................................................................................................................................................. 17
4.7.1 PARAMETERS SETTING: MIG/MAG WELDING VOLTAGE ....................................................................................................................................... 17
4.7.2 PARAMETERS SETTING: WIRE FEED RATE ............................................................................................................................................................. 17
4.7.3 PARAMETERS SETTING: INDUCTANCE SETTING ................................................................................................................................................... 17
4.7.4 PARAMETERS SETTING: POST GAS TIME ............................................................................................................................................................... 17
4.7.5 PARAMETERS SETTING: SPEED LIMIT ..................................................................................................................................................................... 17
5 TECHNICAL DATA ............................................................................................................................................................................... 18
6 SPARE PARTS ..................................................................................................................................................................................... 20
6.1 WIRE FEED MOTOR ............................................................................................................................................................................ 22
6.2 WIRE FEEDER ROLLS ......................................................................................................................................................................... 23
7 ROUTINE MAINTENANCE ................................................................................................................................................................... 25
8 ORDERING INFORMATION BASIC ACCESSORIES .......................................................................................................................... 27
9 TIG AND WIRE TORCHES WITH SPARES ......................................................................................................................................... 28
10 ELECTRICAL DIAGRAM ...................................................................................................................................................................... 31
10.1 UWW 301 TP ......................................................................................................................................................................................... 31
11 SAFETY INSTRUCTIONS..................................................................................................................................................................... 33

UWW-301 TP
Page 3 of 38 Revision: 1.0/June-/2020
1 INTRODUCTION
IMPORTANT!
This handbook must be consigned to the
user prior to
installation and commissioning of the unit.
Retain these documents for future consultation.
KEY
DANGER!
This pictogram warns of danger of death or serious injury.
INFORMATION
This pictogram gives important information
concerning the execution
of the relevant operations.
This symbol identifies an action that occurs automatically as a
result of a previous action.
This symbol identifies additional information or a reference to a
different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
INTRODUCTION
The UWW 301 TP is a compact and heavy-duty power source for
MIG/MAG welding.
The reduced weight and compact size allow it to be carried wherever
it is needed: it is designed to give you the maximum power, reliability
and efficiency.
Set up the power source for MMA, MIG/MAG or TIG operation on the
selector switch located on the rear of the panel in the motor
compartment.
Wire reels of up to 200 mm in diameter can be mounted.
Sound alarm. A sound alarm has been provided to protect the power
source: it blocks the primary inverter in the event that the average
welding current should exceed 310 A for more than 0.6 seconds.
Fan. The fan is turned on only during welding, at the end of the
welding process it remains on for a fixed period of time according to
welding conditions. The fan is nonetheless controlled by specific
thermal sensors that guarantee a correct cooling of the machine.
2 INSTALLATION
DANGER!
Lifting and positioning
 Use the handles and straps solely for manual lifting of the
equipment.
 No specific hooking points are provided on the unit.
 Use the following for mechanical lifting:
- A forklift truck
- Ropes/chains that are slung around the base of the unit to be lifted.
 Do not stand under the welding power source when it is raised or
when it is standing on a raised platform.
 If the equipment is located on a raised platform, assess the risk of
hazardous falls and take the appropriate preventive and safety
measures.
 To avoid falls and overturning do not place the equipment on
gradients steeper than 10°.
2.1 CONNECTIONS TO THE MAINS POWER SUPPLY
The characteristics of the mains power supply to which the equipment
shall be connected are given in the section entitled “Technical data”
on page 18.
The machine can be connected to motor-generators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.

UWW-301 TP
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2.2 FRONT PANEL
1.
Positive pole welding socket.
2.
Negative pole welding socket.
3.
Polarity selector cable.
4.
EURO TORCH
welding socket.
2.3 REAR PANEL
1.
Connector for gas feed hose:
cylinder  power source
2.
Remote control connector
3. Welding power source ON/OFF switch.
4.
Mains protection ON LED. This LED illuminates in case of
an
absence of a phase in the power supply line.
5.
Power cable.
Total length (including internal part): 3,5 m
Number and cross section of wires: 4 x 1,5 mm
2
Type of plug supplied: not supplied
Wire feed motor power transformer fuse.
Type: Delayed acting (T)
Amperage: 630 mA
Voltage: 500 V
2.4 PREPARING FOR MMA WELDING
1. Set the welding power source ON/OFF switch to “O” (unit switched
off).
2. Plug the power cable plug into a mains socket outlet.
3.
Choose the electrode based on
the type of material and thickness
of the workpiece to be welded.
4.
Insert the electrode in the electrode holder.
5.
Connect the electrode holder cable to the welding socket based on
the polarity requested by the type of electrode used.
6. Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
7.
Connect the earth clamp to the workpiece being processed.
4
3
5
2
1
1 2
3 4

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DANGER!
Electric shock hazard!
 When the machine is switched on and set to work in MMA mode,
its welding sockets are live and ready to strike the welding arc.
 Do not touch the conductive part of the electrode holder and metal
parts at the same time with your hands.
 Do not touch metal parts with the conductive part of the electrode
holder or, with the electrode, while replacing the electrode.
 Do not touch two torches or electrode holders simultaneously.
 Do not work in humid or wet surroundings.
 Make sure the earthing system of the electrical mains is properly
connected and efficient.
 Always check the condition of the power cables and connection
cables between the various devices:
- the conductors of the power cable must not protrude from the plug
body.
- the unit cables must not be damaged.
 The risk of electric shock is higher if you touch metal parts and the
electrode simultaneously.
 The operator must be insulated with respect to metal components
connected to earth.
 Grounding of the workpiece can increase the risk of operator
injury.
8.
Set the welding power source ON/OFF switch to “I”
(unit
switched on).
9.
This button serves to select the following welding mode:
MMA
10.
Set the required welding parameter values on the user interface.
The system is ready to start welding.
Preparing for MMA (polarity to basic electrode)

UWW-301 TP
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2.5 PREPARING FOR TIG WELDING
1.
Set the welding power source ON/OFF switch to “O” (unit
switched off).
2
.
Plug the power cable plug into a mains socket outlet.
3
.
Choose the electrode based on the type of material and
thickness of the workpiece to be welded
.
4
.
Insert the electrode in the TIG torch.
5
.
Connect the
TIG torch plug to the negative
welding socket.
6
.
Connect the plug of the polarity selector cable to the welding
socket on the basis of the polarity required.
7
.
Connect the plug of the
ground clamp to the welding socket on
the basis of the polarity required.
8
.
Connect the earth clamp to the workpiece being processed.
9
.
Set the welding power source ON/OFF switch to “I” (unit switched
on).
1
0
.
This button serves to select the following welding mode:
TIG
1
1
.
Set the required welding parameter values on the user interface.
The system is ready to start welding.
LIFT-ARC WELDING
1.
Open the torch valve to let the gas out.
2.
Touch the workpiece with
the torch electrode.
3.
Slowly lift the torch to strike the arc.
The WELDING CURRENT reaches the preset value.
4. Quickly move the torch clear of the workpiece to extinguish the
welding arc.
5.
Close the torch valve to interrupt the gas flow.
Preparing for TIG (polarity for tungsten electrode)

UWW-301 TP
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2.6 PREPARING FOR MIG/MAG WELDING
2.6.1 WIRE SPOOL POSITIONING
1.
Open the unit side door to gain access to the spool compartment.
2.
Unscrew the cap of the spool holder.
3.
If necessary, fit an
adapter for the wire spool.
4.
Choose the wire on the basis of the workpiece thickness and
material type.
5.
Fit the spool in the spool holder, ensuring it is located correctly.
6.
Adjust the spool holder braking system by
tightening/loosening the
screw in such a way that the wire feed force is not excessive and
when the spool stops rotating no excess wire is released.
7. Refit the plug.
2.6.2 POSITIONING THE WIRE IN THE WIRE FEEDER
1.
Lower the wire feeder
pressure devices.
2.
Raise the wire feeder pressure arms.
3.
Remove the protective cover.
4.
Check that the feed rolls are suitable for the wire gauge.
(See § 6.2 page 23.)
The diameter of the roll groove must be compatible with the
diameter of the welding wire.
The roll must be of suitable shape in relation to the composition of
the wire material.
The groove must feature a "U" profile for soft materials
(Aluminium and its alloys, CuSi3).
The groove must be "V" shaped for harder materials (SG2-SG3,
stainless steels).
Rolls with a knurled groove profile are available for flux-cored
wire.
5.
Feed the wire between the wire feeder rolls and insert it into the
MIG/MAG TORCH connector plug.
6. Make sure the wire is located correctly in the roll grooves.

UWW-301 TP
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7. Close the wire feeder pressure arms.
8.
Adjust the pressure system so that the arms press the wire with a
force that does not deform it while also ensuring constant feed rate
without slipping.
9.
Refit the protective cover.
10.
Close the spool
compartment door in the side of the unit.
2.6.3 CONNECTIONS TO SOCKETS
1.
Set the welding power source ON/OFF switch to “O” (unit
switched off).
2.
Plug the power cable plug into a mains socket outlet.
3. Connect the gas hose from the welding gas cylinder to the
relative socket.
4.
Open the cylinder gas valve.
5.
Connect the MIG/
MAG torch
plug to the EURO TORCH welding
socket.
6.
Connect the plug of the ground clamp to the welding socket on
the basis of the polarity required.
7.
Connect the
plug of the polarity selector cable to the welding
socket on the basis of the polarity required.
8.
Connect the earth clamp to the workpiece being processed.
9.
Set the welding power source ON/OFF switch to “I” (unit switched
on).
10.
This button serves to select the following welding mode:
MIG/MAG
11.
Feed the wire through the torch until it protrudes from the tip by
lowering the selector located in the spool compartment.
The insertion speed is 2 m/min for 3 seconds, subsequently
increasing to 15 m/min. When the button is released wire, feed is
interrupted.
This function produces a slower feed rate and hence greater
precision when inserting the wire when it enters the torch nozzle.
12.
Select the torch trigger procedure on the user interface.
13. Open the gas solenoid valve by raising the lever (SEL1) located
in the spool compartment:
14.
Use the flow control valve to adjust the flow of gas as required
while the gas is flowing out.
15.
Close the gas solenoid valve by lowering
the lever
(SEL1)
located in the spool compartment:
16.
Set the required welding parameter values on the user interface.
The system is ready to start welding.
Preparing for MIG/MAG

UWW-301 TP
Page 9 of 38 Revision: 1.0/June-/2020
3 COMMISSIONING
3.1 USER INTERFACE
CODE SYMBOL DESCRIPTION
L1
This LED illuminates to show an anomaly in the operating conditions.
See § 3.5 ALARM MANAGEMENT page 12.
L2
Illumination of this LED indicates the display of the average voltage and current value measured during the final
moments of welding.
The value appears on the following displays: D1-D2
L3 This LED illuminates to confirm the presence of power on the output sockets.
L4
Illuminates to show a value in the following unit of measurement:
VOLTS
L5
Illumination shows that the VRD function has been activated
(reduction of the output voltage) reduces the potential
across the welding sockets when welding is not in progress.
L6
Illumination shows that the remote control has been activated.
L10 Illumination shows that the following function has been activated: 2 stroke procedure.
L11 Illumination shows that the following function has been activated: 4 stroke procedure.
D1
Parameters/functions setting
MIG/MAG mode: the display shows the programmed wire feed rate.
MMA Mode: the display shows the ampere value set for welding.
TIG Mode: the display shows the ampere value set for welding.
Welding
The display shows the effective amperes value during welding.
Menu function
The display shows the acronym of the parameter or function to be adjusted.

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D2
Parameters/functions setting
Manual MIG/MAG mode: the display shows the programmed voltage.
MIG/MAG mode: the display shows “MMA”.
TIG mode: the display shows “TIG”.
Welding
The display shows the effective voltage used when welding.
Menu function
The display shows the value of the parameter or function to be adjusted.
S1 The button selects the welding mode (MIG/MAG, MMA, TIG).
S2 The button enables the remote control
S3
MIG/MAG mode: this button selects the torch trigger procedure.
HOT-START adjustment
Hold down the button for 3 seconds to open the menu. (See § 4.5.2 page 16.)
POT1
MIG/MAG mode: the potentiometer sets the inductance value.
MMA Mode: the potentiometer sets the value of the following parameter:
ARC FORCE
POT2
Parameters/functions setting
MIG/MAG mode: the potentiometer sets the value of the following parameter:
WIRE FEED RATE
MMA/TIG mode: the potentiometer sets the value of the following parameter:
WELDING CURRENT
POT3
Parameters/functions setting
MIG/MAG mode: the potentiometer sets the welding voltage.
Menu function
The potentiometer sets the value of the selected function or parameter.
SEL1
MIG/MAG mode: the lever opens the gas solenoid valve to fill the circuit and calibrate the flow pressure with the
regulator located on the gas cylinder. Raise the lever to let the gas out for 15 seconds. Raise it again to stop the gas
flow.
POST
-
GAS adjustment
Keep the lever raised for 3 seconds to access the menu. (See § 4.7.4 page 17.)
MIG/MAG mode: this lever activates wire feed to insert it through the MIG/MAG torch. Lower the lever to activate wire
feed at a low speed (2m/min) and keep it lowered for more than 3 seconds to increase wire speed to 15m/min.
SPEED
LIMIT adjustment
Switch the unit off, keep the lever lowered and switch the unit to access the menu. (See § 0 page 17.)
Raise the lever to quit the menu.