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Unitor UPC 838, Owner'S Manual

The Unitor UPC 838 is a versatile and reliable product designed to meet your needs. Make sure to download the Owner's Manual for easy installation and operation. Get your free manual at manualshive.com and enjoy the full benefits of your Unitor UPC 838.

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OM-202 515 Page 27

Description

Dia.

Mkgs.

Item

No.

Figure 7-1. Complete Assembly

Quantity

Unitor

Part No.

1

671 222

WRAPPER, 206 278

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

2

671 073

HANDLE, molded, 126 416

2

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

3

671 065

CLAMP, molded, 126 415

2

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

4

LABEL, warning precautionary plasma cutting, 199 065

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . 

5

BUS BAR, output rectifier, 187 783

2

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

6

RS1

671 297

SWITCH, reed, 190 602

1

. . . 

. . . . . 

. . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

7

INSULATOR, screw, 181 853

4

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

8

WINDTUNNEL, lh, 193 969

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

9

LABEL, warning, 185 836

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

10

THERMISTOR, NTC, 173 632

2

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

11

C9,R2,C10

. . . 

. . 

C5,R1,C6

RESISTOR, capacitor, 189 352

2

. . . . . . . . . 

. . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

12

SR3,SR4

671 347

KIT, diode ultra fast (includes 2 diodes), 198 148

1

. . . 

. . . 

. . . 

. . . . . . . 

. . . . . . . . . . . . . . . 

13

STAND-OFF, insulator, 025 248

4

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

14

BRACKET, mtg filter board, 194 375

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

15

BRACKET, mtg contactor, 175 136

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

16

BRACKET, mtg valve, 188 142

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

17

PC6

670 794

CIRCUIT CARD ASSY, input filter, 185 697

1

. . . 

. . . . . 

. . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . 

18

GS1

671 271

VALVE, solenoid w/fittings, 190 586

1

. . . 

. . . . . 

. . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

19

PC1

671 305

CIRCUIT CARD ASSY, control, 206 140

1

. . . 

. . . . . 

. . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . 

20

C3,C4

671 081

CAPACITOR, elctlt, 174 980

2

. . . 

. . . . 

. . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

21

671 289

FILTER, air w/fittings, 190 590

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

22

BRACKET, mtg filter, 187 784

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

23

S1

671 057

SWITCH, tgl 3pst 60A, 045 835

1

. . . 

. . . . . . 

. . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

24

671 214

PANEL, rear, 187 781

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

25

636 985

NAMEPLATE, rear CE polycarb, 205 850

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . 

26

657 155

BUSHING, strain relief, 213 099

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

27

657 163

CABLE, power, 210 346

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

28

670 836

BOX, louver, 175 138

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

29

PC2

671 255

CIRCUIT CARD ASSY, interconnect, 190 427

. . . 

. . . . . 

. . . . . 

. . . . . . . 

(see Service Note on Figure 7-1)

1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

30

CHOKE, common mode, 182 108

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

31

CIRCUIT CARD ASSY, snubber, 193 653

2

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . 

32

Z1

671 321

STABILIZER, output, 194 602

1

. . . 

. . . . . . 

. . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

33

L1

671 339

INDUCTOR, input, 194 606

1

. . . 

. . . . . . 

. . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

34

W3

671 180

CONTACTOR, 200 677

1

. . . 

. . . . . . 

. . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

35

T2

XFMR, control, 201 308

1

. . . 

. . . . . . 

. . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

36

WINDTUNNEL, rh, 202 514

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

37

BUSHING, snap-in nyl, 177 547

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

38

CT1

XMFR, current, 175 199

1

. . . 

. . . . . 

. . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

39

C1

CAPACITOR, polyp, 188 446

1

. . . 

. . . . . . 

. . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

40

BRACKET, DI/DT, 175 140

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

41

L3,L4

COIL, DI/DT, 175 482

2

. . . 

. . . . . 

. . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

42

CORE, ferrite, 109 056

2

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

43

PM1,PM2

670 901

KIT, transistor IGBT module (includes 2 IGBT’s), 180 110

1

. . . 

. . . 

. . . 

. . . . . . . 

. . . . . . . . 

44

SR1

670 893

KIT, diode power module, 179 629

1

. . . 

. . . . . 

. . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

45

HEAT SINK, power module, 173 631

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . 

46

T1

671 313

XFMR, hf, 193 434

1

. . . 

. . . . . . 

. . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

47

HEAT SINK, rectifier, 189 354

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

48

INSULATOR, rectifier, 175 255

1

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

49

670 919

BASE, 175 132

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

50

FOOT, mtg unit, 173 693

4

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

51

SCREW, mtg foot, 176 736

4

. . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

52

FM

670 935

MOTOR, fan, 175 084

1

. . . 

. . . . . . 

. . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

53

PC3

671 230

CIRCUIT CARD ASSY, display, 189 387

1

. . . 

. . . . . 

. . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . 

54

R3

671 248

POTENTIOMETER, w/leads, 189 484

1

. . . 

. . . . . . 

. . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . 

55

671 206

PANEL, front, 187 780

1

. . . 

. . . . . . . . . . . . . . . . 

. . . . . . . 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Summary of Contents for UPC 838

Page 1: ...Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM 202 515C 2005 12 UPC 838...

Page 2: ......

Page 3: ...mation sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS 9 3 1 Warning Label Definitions 9 3 2 Air Supply Precaution 10 3 3 Manufacturer s Rating Label For CE Products 11 3 4 Symbols And Defini...

Page 4: ...e 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 August 1995 Safety Requireme...

Page 5: ...n cause fatal shocks or severe burns The torch and work circuit are electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on Pla...

Page 6: ...ied respirator Fumes from cutting and oxygen deple tion can alter air quality causing injury or death Be sure the breathing air is safe D Do not cut in locations near degreasing cleaning or spraying o...

Page 7: ...ces computers and communicationsequipment D Have only qualified persons familiar with elec tronic equipment perform this installation D The user is responsible for having a qualified electrician promp...

Page 8: ...10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 EMF Information Considerations About Welding Or Cutting And The E...

Page 9: ...antalons sans revers des bottes et un casque D Ne placez pas le poste sur une surface combustible ou au dessus de celle ci D Avant le coupage retirez tout combustible de vos poches par exemple un briq...

Page 10: ...u plasma d arc Intensit de courant en amp res Filtre de teinte minimum Moins de 20 no 4 20 40 no 5 40 60 no 6 60 80 no 8 Certaines applications de coupage produisent un bruit constant ce qui peut endo...

Page 11: ...he Danger D EXPLOSION D HYDROG NE D Lors du coupage d aluminium partiellement ou totale ment immerg dans l eau de l hydrog ne libre peut s accumuler sous la pi ce D Consultez votre ing nieur de coupag...

Page 12: ...es champs magn tiques basse fr quence Le courant de soudage ou de coupage passant dans les c bles de puis sance cr e des causera des champs lectromagn tiques Il y a eu et il y a encore un certain souc...

Page 13: ...from electric shock by insulating yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your he...

Page 14: ...econds after power is turned off before working on unit OR 6 Check input capacitor voltage and be sure it is near 0 before touching any parts 7 When power is applied failed parts can explode or cause...

Page 15: ...e V Volts Increase No Do Not Do This Temperature Protective Earth Ground Three Phase Constant Current Voltage Input On Off Percent Direct Current U0 Rated No Load Voltage Average U1 Primary Voltage U2...

Page 16: ...le 440 19 3 14 71 13 9 7 8 in 22 mm At 10 IPM Straight Polarity DCEN Air Or Nitrogen Only 350 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can cut at rated load wit...

Page 17: ...capabilities of the power source and torch for mild steel of various thickness Y Exceeding recommended cutting speeds will cause rapid erosion of the tip and electrode UPC 838 191 831 Cutting speed i...

Page 18: ...determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are present see NEC Article...

Page 19: ...pressure according to Section 5 2 Tools Needed 5 8 1 1 8 in From Gas Air Supply 3 4 Rear of Unit 5 1 2 4 6 Electrical Service Guide Max Recommended Standard Fuse Rating In Amperes Input Voltage Input...

Page 20: ...site 1 Input And Grounding Conductors 2 Line Disconnect Device See Section 4 6 Y Always connect green wire to supply grounding termi nal never to a line terminal Connect black brown and blue wires L1...

Page 21: ...ight Ready light comes On when unit is On to indi cate that all safety shutdown systems are okay If Ready light does not come On check trouble lights 7 Trigger Hold Switch To cut without holding torch...

Page 22: ...Pull knob and turn to adjust pressure Push knob in to lock setting Select desired cutting output with Output Control 5 2 Setting Gas Air Pressure Ref 802 140 Ref 802 803 A 1 Set Controls Turn On Gas A...

Page 23: ...nstantly restarted during postflow by pressing trigger Check Torch Tip Electrode And Retaining Cup Check Gas Air Pressure Set Controls Begin Cutting Turn On Power Source The pilot arc starts immediate...

Page 24: ...ere conditions Each Use Check Torch Tip Electrode And Shield Cup Check Gas Air Pressure Every Week Check Shield Cup Shutdown System 3 Months Service Air Filter Regulator Assembly Filter Replace Unread...

Page 25: ...ghts if power source overheats see Section 4 2 1 2 3 Difficulty establishing pilot arc may indicate consumables need to be cleaned or replaced 6 3 Checking Shield Cup Shutdown System Ref 801 300 A 1 T...

Page 26: ...Authorized Service Agent check for proper torch connections Check operation of gas valve GS1 and check gas air system for leaks Pressure Trouble light On Ready light off Check for correct gas air pre...

Page 27: ...OM 202 515 Page 23 Notes...

Page 28: ...OM 202 515 Page 24 SECTION 7 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram For Power Source...

Page 29: ...OM 202 515 Page 25 202 521...

Page 30: ...arate and discard breakaway portion of circuit card assembly located in lower right hand corner and replace with circuit card 670 349 Item 66 1 2 3 5 12 11 13 10 9 8 15 16 18 19 23 24 26 27 28 21 22 2...

Page 31: ...835 1 24 671 214 PANEL rear 187 781 1 25 636 985 NAMEPLATE rear CE polycarb 205 850 1 26 657 155 BUSHING strain relief 213 099 1 27 657 163 CABLE power 210 346 1 28 670 836 BOX louver 175 138 1 29 PC...

Page 32: ...176 830 1 671 131 TORCH replacement ICE 80C 15 2m 50ft 176 832 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial num...

Page 33: ...trode Wrench 671 479 Swirl Ring 670 299 O Ring 670 281 Cutting Gouging Extended Cutting 1 8 3mm stand off recommended ICE 80C CONSUMABLES UNITOR 206 301 A Shield 670 380 Apply silicone grease 639 591...

Page 34: ...Notes...

Page 35: ...Notes...

Page 36: ...ial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams C...

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