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Unitor UWW-161 TP, Instruction Manual

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Unitor UWW-161 TP Instruction Manual Download Page 31

 

Revision date: 23 09 2014 

Page 31 of 32 

 

 

 
USE THE UNITOR WELDING HANDBOOK FOR MARITIME WELDERS 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

You can download it here 

 

http://www.wilhelmsen.com/services/maritime/companies/buss/DocLit/PorductLiterature/Pages/Maintenanceandrepair.aspx

 

 

…or contact Wilhelmsen Ships Service for a paper copy 

 

 

Summary of Contents for UWW-161 TP

Page 1: ...Revision date 23 09 2014 Page 1 of 32 Instruction manual spare parts list Unitor Welding Inverter UWW 161 TP Multi Process MIG MAG MMA TIG TP total protection version from serial number 111194 ...

Page 2: ...e following standards apply EN 60974 1 EN 60974 5 EN 60974 10 Belvedere Maggio 2004 Amm Giorgio TONIOLO WECO srl Via S Antonio 22 BELVEDERE 36050 TEZZE SUL BRENTA VICENZA ITALY Tel 39 0424 561943 Fax 39 0424 561944 E mail info weco it www weco it P IVA 02783960244 C F 02710490281 Reg Impr VI n 52214 R E A N 274736 Capitale sociale i v 52 000 00 UWW 161TP s n 111194 and higher is also in compliance...

Page 3: ... OPERATING INSTRUCTIONS 9 WIRE WELDING CONSUMABLE SPARES 10 WIRE WELDING ACCESSORIES 11 SHIELDING GAS ACCESSORIES 12 TIG ACCESSORIES 13 MAINTENANCE 14 TROUBLESHOOTING 15 WIRING DIAGRAM 16 COMPONENTS AND SPARES 17 SAFETY INSTRUCTIONS 18 YOUR OWN NOTES DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT ...

Page 4: ...damage to the machine and sound an alarm tone to warn the operator if welding with the set wire welding parameters exceeds the capacity of the unit UWW 161 TP is easy to transport only 12kg weight and it is specifically designed for light fabrication maintenance and repair work on board It offers excellent MIG brazing characteristics using CuSi3 and CuSi6 type wires Polarity change for Euro connec...

Page 5: ...tgoing wire guide tube for mounting in the wire drive unit 1 piece 5 MIG MAG torch M 161 with 3m cable and euroconnector Product number 161163 1 piece 6 Steel liner fitted in torch cable Product number 613746 1 piece 7 Contact tip 0 8mm fitted in torch Product number 711994 1 piece 8 Return clamp with 3m cable and connector Product number 633164 1 set 9 Electrode holder with 3m cable and connector...

Page 6: ...The unique serial number for the machine will be printed here Always give serial number when ordering spares or in other communication with WSS concerning your machine One phase static transformer rectifier frequency converter DC output MMA Stick electrode SMAW TIG GTAW MIG MAG Metal Inert Gas Metal Active Gas GMAW Gas Metal Arc Welding FCAW Flux Cored Arc Welding TP ...

Page 7: ... I2 TIG U2 10 0 04 I2 MIG MAG U2 14 0 05 I2 Primary connection U1 Effective input voltage 230V I1max Maximum value of input current at the corresponding duty cycle I1eff Effective value of input current at the corresponding duty cycle Maximum input power is 5 4 kVA Power factor 0 79 Duty Cycle 35 Cooling COOLING AF Forced air cooling with a fan Protection class IP23S Ingress Protection class Prote...

Page 8: ...50 60Hz 1phase protective earth 2 5m cable 3x2 5mm with plug is included 2 Gas Cylinder with Argon Argon CO2 or CO2 not included with machine 3 Gas regulator with flow adjustment not included with machine 4 Gas hose not included with the machine 5 Hose socket with nut and hose clamp for 6mm 1 4 hose included with the machine Inside the machine 6 Spool of welding wire not included with the machine ...

Page 9: ...mal setting for MIG MAG welding For Self shielded wires without shielding gas and for TIG welding the minus polarity should normally be selected and the return clamp should be connected to the plus polarity For stick electrode welding MMA the cable in the picture is disconnected as shown in the drawing and electrode cable and return cable are connected to plus and minus according to the requiremen...

Page 10: ...ed down sufficiently The light will darken when the machine is live again When the machine is switched on this LED is lit for five seconds during which time there is no welding current available 3 Power on When this LED is on welding current is available In MMA stick electrode welding mode the open circuit voltage of 10V is present between and terminals 4 Warning light indicating live terminals 5 ...

Page 11: ...to start the welding completion procedure The supply of gas continue for the selected post gas time MMA stick welding In this mode a constant current characteristic for MMA welding is set and the terminals are live 10V An automatic hot start enables easy arc start And an automatic arc force maintains a smooth and stable arc by momentarily increasing the current if bigger droplets in the arc tends ...

Page 12: ...o ensure sufficient cooling of the weld pool to avoid oxidation Wire feed system with drive rolls and pressure adjustment Shaft for spool attachment and Friction Brake Adjustment The drive rolls have two grooves for two different wire sizes V groove 0 6 0 8mm for solid wires except aluminium GPS GPS W 200 IALBRO W 237 ICUNI W 239 Knurled V groove 1 0 0 8 1 2mm for flux cored wires MS W 201 S 316 M...

Page 13: ... only enough drag to prevent overrun of the spool and excess slack in the wire Too much drag may result in wire feeding problems Replace the cap 7 Carefully detach the end of the wire from the spool cut the bent portion of wire off and straighten the first 10cm Thread the wire through the ingoing guide tube 8 over the drive roll 3 and into the outgoing guide tube Close the idle roll arm 2 and latc...

Page 14: ...and straighten the gun cable assembly 10 Press wire feed knob 6 on the front panel to feed the wire out through the torch neck 11 Replace the contact tip and nozzle 12 Set wire speed and voltage in accordance with the wire specifications and proceed with the welding 13 When finished close the gas cylinder and press the trigger shortly to vent off gas pressure in hoses and machine before switching ...

Page 15: ...on liner can be used for all welding wires but wears down quicker than steel liners Steel liner is a more wear resistant alternative for black steel welding but should be avoided for stainless and non iron wires to avoid contamination of the weld 10 WIRE WELDING ACCESSORIES The Anti spatter spray prevents the spatter from the welding arc from sticking to the metal surface adjacent to the weld By s...

Page 16: ...valve for gas inlet pcs 197 597310 Argon CO2 mix gas is used for steel and stainless steel Pure Argon is used for all non iron metals Both gases are available in 10 and 50litre cylinders Pure CO2 may also be used as shielding gas but only for black steel with maximum thickness 2mm A special regulator for the CO2 cylinder is then required 12 TIG ACCESSORIES TIG Torch T 161 with 4m cable euro connec...

Page 17: ...ce Do not lubricate shaft TORCH 1 Check wire feed liner for damage or wear at regular intervals This is especially important for the non iron liner which may wear quickly if used for extensive shelf shield welding 2 Replace worn contact tips as required A variable arc is a typical symptom of a worn contact tip 3 Remove spatter from inside of gas nozzle and from tip after each 10 minutes of arc tim...

Page 18: ...el does not activate one of the switching power supply unit outputs is broken The power board must be replaced Check the mosfet of the switching power supply unit on the power board If it s damaged it must be replaced picture 6 The MMA MIG TIG output voltage is about 11V but the machine does not weld The output voltage wiring of the front panel is interrupted picture 1 The primary current alarm on...

Page 19: ...ttering and crackeling occurs on starting Decrease the wire speed setting or increase voltage setting No gas from the solenoid valve Excessive gas pressure Damaged solenoid valve wiring The solenoid valve control relay on the front panel is damaged Solenoid valve is damaged Reduce gas flow setting Unplug the machine If break in a circuit single out the break and repair it Make sure that the wiring...

Page 20: ... front panel and the white 4 pin connector if connections are not interrupted replace the front panel The motor board must be replaced PICTURE 1 PICTURE 2 Position of the connector in which they are inserted thermal protection device position 2 5 yellow wires Wire for the output voltage reading position 3 red Shunt wire pin 1 4 Check the conductivity of contact of the thermal protection device wit...

Page 21: ...on one of these measurements or an OL instead of a numeric value the power board must be replaced The varistor is a blue disc near the ground wire of the power board This device is necessary to protect the board from input overvoltage When there is overvoltage it explodes normally causing a short circuit If the extent of the short circuit is very high its becomes an open circuit ...

Page 22: ...E 7 To check the mosfet of the switching power supply unit carry out the following measurements Should there be a short circuit on one of these measurements or an OL instead of a numeric value the power board must be replaced Digital multimeter OL Open Loop ...

Page 23: ...Revision date 23 09 2014 Page 23 of 32 15 WIRING DIAGRAM ...

Page 24: ...ONENTS AND SPARES Spare part kit for UWI 150TP and UWW 161TP includes power board necessary additional components and complete instructions for replacement Order no 191 150161 For ordering spares please state Model UWW 161 TP Serial no Pos no Code ...

Page 25: ...001 0001 TWO POLE SWITCH 13 021 0001 0229 FIXED SOCKET 200A 41 050 0001 0003 SNUBBER BOARD 14 021 0000 0003 KIT FOR GAS CONNECTORS 42 011 0006 0001 SLIDE CLOSURE 15 021 0001 0029 MOVABLE PLUG 43 012 0000 0001 SPOOL COVER 16 050 0001 0042 TORCH CONNECTOR BOARD 44 003 0002 0002 FAN 17 010 0006 0033 FRONT PLASTIC PANEL 45 011 0000 0208 DOOR PLATE 18 040 0003 1080 TERMAL SWITCH 46 010 0007 0001 PLANAR...

Page 26: ...bles Do not drape cables over your body If earth grounding of the work piece is required ground it 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 Maintain unit according to manual Wear a safety harness if working above floor leve...

Page 27: ...hen not in use Wear oil 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 doing any 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...

Page 28: ...injury Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified ...

Page 29: ...02269 9101 phone 617 770 3000 website www nfpa org and www sparky org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 websit...

Page 30: ...Revision date 23 09 2014 Page 30 of 32 18 NOTES ...

Page 31: ...E THE UNITOR WELDING HANDBOOK FOR MARITIME WELDERS You can download it here http www wilhelmsen com services maritime companies buss DocLit PorductLiterature Pages Maintenanceandrepair aspx or contact Wilhelmsen Ships Service for a paper copy ...

Page 32: ...svaerk Fredrikshavn Faaborg Gedser Great Belt Grenaa Graasten Gulfhavn Haderslev Halsskov Hanstholm Helsingor Hirtshals Hobro Holbaek Horsens Kalundborg Kertminde Koge Kolding Korsor Lemvig Mariager Marstal Oslo Middlefart Naestved Nakskov Nyborg Nykobing Falster Nykobing Mors Nykobing Skjaelland Odense Orehoved Falster Randers Ronne Rudkobing Sakskobing Skaelskor Skaerbaek Skagen Skive Sonderborg...

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