Unitor UWI 202 Owner'S Manual Download Page 9

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OM-244 324 Page 5

SECTION 2

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DEFINITIONS

2-1. Additional Safety Symbols And Definitions

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012

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Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe2 2012

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Protect yourself from electric shock by insulating yourself from work and ground.

Safe3 2012

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Disconnect input plug or power before working on machine.

Safe5 2012

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Keep your head out of the fumes.

Safe6 2012

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Use forced ventilation or local exhaust to remove the fumes.

Safe8 2012

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Use ventilating fan to remove fumes.

Safe10 2012

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Keep flammables away from welding. Do not weld near flammables.

Safe12 2012

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Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe14 2012

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Do not remove or paint over (cover) the label.

Safe20 2012

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Summary of Contents for UWI 202

Page 1: ...Processes Description TIG GTAW Welding Stick SMAW Welding OM 244 324C 2013 01 Arc Welding Power Source UNITOR UWI 202 CE ...

Page 2: ...ns 13 3 11 Stick DCEP Direct Current Electrode Positive Connections 14 3 12 Electrical Service Guide 14 3 13 Connecting Input Power 15 SECTION 4 OPERATION 16 4 1 Controls 16 4 2 Process Control 17 4 3 Lift Arc Start Procedure 17 4 4 Stick Start Procedure Scratch Start Technique 18 4 5 Amperage Control 18 4 6 DIG Control 18 SECTION 5 MAINTENANCE AND TROUBLESHOOTING 19 5 1 Routine Maintenance 19 5 2...

Page 3: ...iction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 2005 07 IEC 60974 10 Arc Welding Equipment Electromagnetic Compatibility Requirements edition 2 0 2007 08 EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc welding and allied proces...

Page 4: ......

Page 5: ...lds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant vol...

Page 6: ...rums or pipes unless they are properly prepared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards ...

Page 7: ...ING PARTS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all la...

Page 8: ...ention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 P...

Page 9: ...urself from work and ground Safe3 2012 05 Disconnect input plug or power before working on machine Safe5 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes Safe8 2012 05 Use ventilating fan to remove fumes Safe10 2012 05 Keep flammables away from welding Do not weld near flammables Safe12 2012 05 Welding sparks can cause fires Have a f...

Page 10: ...stributor for further information Safe37 2012 05 Disconnect input plug or power before working on machine Safe30 2012 05 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Safe38 2012 05 Become trained and read the instructions before working on the machine or welding Safe40 2012 05 60 Always lift and...

Page 11: ...2 Conventional Load Voltage U1 Primary Voltage IP Degree Of Protection I1max Rated Maximum Supply Current I1eff Maximum Effective Supply Current U0 Rated No Load Voltage Average Pulse Background Amperage Initial Amperage Increase Decrease Of Quantity Normal Trigger Op eration GTAW Two Step Trigger Operation GTAW Four Step Trigger Operation GTAW Percent Hz Hertz Recall From Memory Arc Force DIG HF ...

Page 12: ... There may be potential difficulties in ensuring electromagnetic compatibility in those locations due to conducted as well as radiated disturbances This equipment does not comply with IEC 61000 3 12 If it is connected to a public low voltage system it is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that t...

Page 13: ...erecurves show minimum and maximum voltage and amper age output capabilities of welding power source Curves of other set tings fall between curves shown 230 VAC Input Amperes Volts TIG Stick Max Stick Min TIG Min 100 80 60 40 20 0 0 50 100 150 200 250 ...

Page 14: ...erheats output stops and cooling fan runs Wait fifteen min utes for unit to cool Reduce amper age or voltage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 4 Minutes Welding 6 Minutes Resting 0 50 100 150 200 250 10 100 STICK TIG DUTY CYCLE OUTPUT AMPERES 50 ...

Page 15: ...on 1 Line Disconnect Device Locate unit near correct input power supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 Location And Airflow 1 18 in 460 mm 18 in 460 mm ...

Page 16: ...eeding 30 m 100 ft or Less 45 m 150 ft 60 m 200 ft 70 m 250 ft 90 m 300 ft 105 m 350 ft 120 m 400 ft Welding Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 20 4 20 4 20 4 30 3 35 2 50 1 60 1 0 60 1 0 150 30 3 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 95 3 0 200 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 120 4 0 This chart is a general guideline and may not suit all applications If cab...

Page 17: ...al Connect TIG torch to negative weld output terminal 3 Gas Cylinder 4 Cylinder Valve Open valve slightly so gas flow blows dirt from valve Close valve 5 Regulator Flowmeter 6 Flow Adjust Typical flow rate is 15 cubic feet per hour 7 1 liters per minute Connect torch gas hose to regula tor flowmeter 7 Gas Valve Valve controls gas preflow and postflow Open valve on torch just before welding Tools N...

Page 18: ...hase 40 Duty Cycle 380 440 10 Input Amperes A At Rated Output 13 5 11 5 Max Recommended Standard Fuse Rating In Amperes 1 Time Delay 2 10 Normal Operating 3 20 Min Input Conductor Size In AWG 4 13 2 63 mm2 Max Recommended Input Conductor Length In Feet Meters 3 5 Min Grounding Conductor Size In AWG 4 13 2 63 mm2 Reference 2011 National Electrical Code NEC including article 630 1 If a circuit break...

Page 19: ...Or Green Yellow Grounding Conductor 4 Disconnect Device Grounding Terminal 5 Input Conductors L1 L2 And L3 6 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 7 Over Current Protection Select type and size of over current protection using Section ...

Page 20: ...icates a Stick function 1 Process Controls See Section 4 2 2 Amperage Control See Section 4 5 3 DIG Control See Section 4 6 4 High Temperature Shutdown Light See Section 3 6 5 Power On Light The power on light turns on when power is turned on 6 Power Switch Use switch to turn unit and indicator light On Off 1 2 4 3 5 UWI 202 ...

Page 21: ...llows 1 TIG Electrode 2 Workpiece Turn gas on Touch tungsten elec trode to workpiece at weld start point Hold electrode to work piece for 1 2 seconds and slowly lift electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present before tungsten electrode touches workpiece only a low sensing voltage is present between electrode and workpiece The solid state output conta...

Page 22: ...sent before electrode touches workpiece For models with stock numbers 907 036 and 907 037 normal open circuit voltage is not present before electrode touches work piece only a low sensing voltage is present between electrode and workpiece 1 2 3 4 5 Amperage Control 1 A Amperage Control Rotate knob clockwise to increase amperage Min 200 amps 1 Min 4 6 DIG Control 1 DIG Control Control increases SMA...

Page 23: ...n Repair l Replace To be done by Factory Authorized Service Agent Every 3 Months nl Labels n l Gas Hoses Every 3 Months n lCables And Cords Every 6 Months Durning heavy service clean monthly Do not remove case when blowing out inside of unit see Section 5 2 5 2 Blowing Out Inside Of Unit Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louve...

Page 24: ...ns 3 6 Erratic or improper weld output Use proper size and type of weld cable see Section 3 8 Clean and tighten all weld connections see Section 3 8 Fan not operating Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor Wandering arc Use proper size tungsten see Section 7 Use properly prepared tungsten see Section 7 Reduce gas flow rate see Sect...

Page 25: ...3 J3 J5 Z1 J1 REMOTE J6 J1 T2 J5 CON2 J8 J7 J6 DL1 ON SW1 J5 Z1 J4 J4 R1 CURRENT J2 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 1 1 2 3 4 5 6 1 1 2 3 4 5 6 7 8 9 10 1 2 1 1 1 1 1 2 3 4 5 6 7 8 1 1 2 3 4 5 6 1 J10 J9 J8 HS1 GND GND S1 0V 220V 440V I II III ARC TIG 0V 20V PC1 PC2 PC3 P T R1 R2 POSITIVE NEGATIVE L1 L2 L3 ...

Page 26: ... 11 to 35 CFH cubic feet per hour Figures listed are a guide and are a composite of recommendations from American Welding Society AWS and electrode manufacturers 7 2 Preparing Tungsten Electrode For DC Electrode Negative DCEN Welding Or AC Welding With Inverter Machines Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires Use local exhaust forced v...

Page 27: ...nmentally safe way Wear proper face hand and body protection Keep flam mables away 1 Workpiece Make sure workpiece is clean before welding 2 Work Clamp Place as close to the weld as possible 3 Torch 4 Filler Rod If Applicable 5 Gas Cup 6 Tungsten Electrode Select and prepare tungsten according to Section 7 Guidelines The inside diameter of the gas cup should be at least three times the tungsten di...

Page 28: ...rch to front of pool Repeat process 75 75 Welding direction Form pool Tilt torch Add filler metal Move torch to front of pool Repeat process Remove rod Welding direction 15 8 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 75 70 90 20 20 10 15 75 20 40 30 15 75 90 15 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint ...

Page 29: ... is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Section 9 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp cracklin...

Page 30: ... ALL ALL ALL FLAT HORIZ FILLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER MED 9 3 Striking an Arc S 0049 S 0050 1 Electrode 2 Workpiece 3 Arc Scratch Technique Drag electrode across workpiece like striking a match lift electrode slightly after touc...

Page 31: ...d Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 9 6 Good Weld Bead Characteristics S 0052 B 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Metal 1 5 2 3 4 ...

Page 32: ... of base metal 9 8 Electrode Movement During Welding S 0054 A Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide ar...

Page 33: ...n 5 mm 30 2 1 1 16 in 1 6 mm 3 4 9 10 Lap Joint S 0063 S 0064 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength 30 Or Less 30 Or Less 1 1 2 3 9 11 Tee Joint S 0060 S 0058 A S 0061 1 Electrode 2 Fillet Weld ...

Page 34: ...orm near weld bead Possible Causes Corrective Actions Amperage too high for electrode Decrease amperage or select larger electrode Arc length too long or voltage too high Reduce arc length or voltage Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrod...

Page 35: ...ase and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes ...

Page 36: ...44 324 Page 32 SECTION 10 PARTS LIST Figure 10 1 Main Assembly Hardware is common and not available unless listed 1 Fig 10 2 Fig 10 4 Fig 10 3 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ...

Page 37: ...put Filter PCB 1 15 PC4 56130021 PC4 Line Filter Board 1 16 PC1 57084137 PC1 Circuit Card Assy Primary Inverter 1 17 156118055 Support Inverter PCB 1 18 T1 57059006 Auxiliary Transformer 1 19 PC2 57084138 PC2 Circuit Card Assy Secondary Inverter 1 20 Z1 57059007 Stabilizer Assy 1 21 756084029 Mylar insulating 1 22 156006061 Intermediate Panel 1 23 756005028 Support Intermediate Panel 2 24 195663 S...

Page 38: ...te Unitor UWI 202 1 5 656014013 Cover Selector Switch 1 6 193919 Knob Pointer 1 250 Dia X 250 ld 1 7 193920 Knob Pointer 840 Dia X 250 ld 1 8 207253 Plug Gas Fitting 1 9 RC1 156007041 Cover 6 Pin receptacle 1 10 56076257 Female Socket Dinse 1 11 56076258 Female 6 Pin Receptacle Wiring Harness 1 12 156005137 Panel Front Lower 1 13 956142634 Nameplate Dinse 6 Pin 1 To maintain the factory original p...

Page 39: ...t No Dia Mkgs Item No 1 V16118098 Panel Rear Lower 1 2 194242 Panel Front Rear 1 3 207723 Plug Gas Fitting 1 4 V15024100 Panel Rear Upper 1 5 656089039 Bushing Strain Relief 1 6 956142657 Switch Label 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor ...

Page 40: ...igure 10 1 Item 5 Quantity Description Part No Dia Mkgs Item No 1 156006060 Base 1 2 V56110090 Mount Nprn 4 3 956142631 Rating Plate 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor ...

Page 41: ...OM 244 324 Page 37 Notes ...

Page 42: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 43: ...Notes ...

Page 44: ...PRINTED IN USA 2013 01 Unitor ASA Drammensveien 211 P O Box 300 Skoyen N 0212 Oslo Norway Tel 47 22 13 14 15 ...

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