UWR-303 Conventional welding rectifier for maximum durability in marine environment + Dual process: Stick electrode and TIG welding characteristics with lit-arc start. * Remote control option provide ability to adjust ‘amperage during welding. Continuous adjustment of welding current 5-300 A + Adjustable arc force control, Automatic anti-stick function. * Overload protection with indicator light. * Connects to two 3-phase power supply; 230 V, 380 V or 440 V. Open circuit voltage below 70, ripple below 5% MS. 10% peak, and remote on/off for secondary voltage provides conformance with the ‘etish DOT: code of safe working practice for merchant seamen, Technical Data Description Unit Property Type uwa-303 Welding current range, DC A 5-300 Open circuit voltage, max. v 5 Duty cycle at max current % 35 Mains phases 3 Mains phase, frequency Hz 50/60 Mains voltage v 2730380/440 Recommended fuses (slow) A 35/20/16 Efficiency % - Insulation class H Protection class P23 Approval marks 8,CE Height mm 450 Longth mm 680 Width mm 450 Weight kg % ‘Ordering Information: ‘The order numbers include: wars Smprimary cable. iting gear with cable winding frame. ster carriage with two large wheels and support. Feigeble handles for wheeling along deck. Sestuction manual. Description Unit Productno. wR pes 191-670430 <—___—_ODE WELDING AND GOUGING ‘and welding cables. set-up for Stick Electrode welding Stick electrode accessories Description Accessories set for UWA-203 Consisting of: Ground clamp assembly. 400 A Dix 70, 3 m cable 50 mm2 Electrode holder assembly. 400 A Dix 70,3 m cable 50 mm2 Remote control unit Remote control cable 10m Welding gloves Face shield with flip-up front frame, head band and filter shade 11 glass Chipping hammer steel Wire brush steel, two rows Handbook for maritime welders Unit pes pes pes pes par pes pes pes pes Product no. 191-676908 195-594317 <— 196-594325<— 191-676916 191-676924 196-619080 ID no, 811002 <—cable HOIN2-D. Cable size comparison ING AND GOUGING Unitor Welding Cable Welding cables used on board, on deck or in an engine room, are exposed to both rough weather, oil and mechanical wear. The welding_ cable supplied by Unitor has wear, flame and oil-resistant insulation on a polychloroprene rubber basis. itis recognized by its marking at regular intervals with the text “Unitor oil resistant welding cable", size of cable, and the standard for welding HO1N2-D means that the cable is produced to an international harmonized standard, The conductor is built up from 0.2mm diameter tinned copper strands to ensure flexibility. The cable is available in cross section areas 35 mm?, 50 mm? and 70 mm?, and may be supplied in standard lengths of 10 m, 20 m or 50 m, fitted with Unitor Safety cable connectors. Itmay also be ordered in other lengths, without connectors mounted. Cable drum The cable drum with crank and floor stand is used for storage of up to 100 m cable. The crank may be disengaged to avoid accidents when unwinding cable. Note that welding cables should always be stretched out when used, and excessive lengths should not be used. A coiled up cable, whether on a drum or ina coil on deck will act as an electromagnet when welding current is flowing. This will cause increased resistance in the welding circuit which may have negative influence on the welding result. The electromagnetic field created may also influence vulnerable equipment in the vicinity of the coil. AWG mm? — | AWG mm? 3 27 | 2 336 =| 30 85.0 1 424 | 40 107.2 10 53.5 Ordering information Cross- section area Product no. Max Amp | Weight 1Omincl. | 20minct. | 50m incl. mm? __{at60%D/C| kom _| Pr meter_|connectors | connectors | connectors 35 290 042 __ | 195-175836 | 195-175794 | 195-175786 | 195-17578 50 365 0,56 4195-175828 | 195-175810 | 195-175802 70 460 078 _|195-175851 | 195-320002 | 195-320010 | 195-183665 95 560 1,03 | 195-655266 Cable drum for up to 100 m cable, order no. ———S 15-175729Cable Connectors Cable connector Dix 25 male/female complete 230 A / 60 % Duty Cycle. Cable size 10-25 mm? Product no. 195-632885 Cable connector Dix 70 male/female complete 460 A / 60 % Duty Cycle. Cable size 35-70 mm? Product no. 195-632893 <— Cable connector Dix 120 male/female complete 850 A / 60 % Duty Cycle. Cable size 90-120 mm? Product no, 195-736744 Cable connector Safety male/female complete 460 A /60 % Duty Cycle. Cable size 35-70 mm? Product no. 195-513044 Cable shoe for 35 mm? cable 10 pcs Product no. 195-632919 Cable shoe for 50 mm? cable 10 pcs Product no. 195-632927 Cable shoe for 70 mm? cable 10 pcs Product no. 195-632935, Cable shoe for 95 mm? cable 10 pes Product no. 195-738633The complete Unitor range of maintenance electrodes for shipboard use Productname | Diameter | Product no. | Application onboard GPO-302N 25 095-699165 | Unalloyed steel 32 095-699173<)— General applications 40 095-699181 <}~ Easy to weld, all positions including vertical down 32 095-699231 | Unalloyed stee! 40 095-699249 | Large welds in 5,0 (095-699256 <— flat position 60 095-699260 SPECIAL-303 N 20 095-699199 | Unalloyed & Low alloyed Steel. 25 095-699207 | Thin plate material 32 095-699215 | General applications 40 095-699223 | Double coated electrode, easy to weld. 1H-314.N 25 095-699264 | Unalloyed & Low alloyed Steel. 32 095-699272 | General applications 40 095-699280 LHH-314H 40 095-699298 | Unalloyed & Low alloyed Steel. 5,0 095-699306 Large welds in flat position LHV-316 N 32 095-699314 | _Unalloyed & Low alloyed Steel. 40 095-699322-<]- Specially suitable for vertical down welding LHT-318 N 28 095-699330 | High temp. stee! 32 095-699348 | Boiler plates and pipes up to 550 dgrC. Up to 1% Cr, 0,5% Mo LHL-319N 25 095-683631 | Low temp. steel 32 095-683649 | Ice Class hull plates. Up to 2,7% Ni LHR-320 N 28 095-683656 | Weather resistant steel 32 095-699389 | Corrosion resistant to sea-water and flue gases 18/8-321 N 16 095-699397 | Stainless steel 25 095-699405 | AISI 304/316 L Tanks, 32 095-699413 | piping, pumps and valves 23/14-322 N 25 095-699421 | Stainless steel 32 095-699439 | AISI 309. Joining stainless to steel. 40 095-699447 | Compound steel. Stainless steel overlays.ENERAL DETAILS Shines of the UWR 303 series are especially suitable for MANUAL {CTRODE and TIG welding ress in electronic component technology and extonsive research in file of closely related components such s diodes, thyristors, vanstor- 3 and inductances have made possible the development ofthe UR. welding rectifier, with optimum welding characteristic. SE] UR Si pow cra Some ma ang ae ed (eotenaironte cana ene) ‘The machines of this series stand out for thelr ig energy savings Jow open-cicuit voltage (SV) absolute operational reliably and safety excellent welding quality Other advantages welding curent can be continuously remote-controled continuously adjustable arc-orce, for adjusting the welding characteri- stice ‘current stabilisation: the pre-set weing-current value is kept constant by the control electronics, regardless of mains voltage fluctuations and the lengths ofthe welding and mains cables CONSTRUCTION AND TECHNICAL DESRIPTION Housing ~ Sheet stool, baked enamel nish resp. powder coated ~ The watertignt electionics case is welded directly onto the main case (Faraday cago) ~ Large wheels and fold-away carrying handles make these units ideally sullale for easy transport inside the faclory as well as for use on building sites. Franstomer = Three phase current mode, consisting of ron core, primary, secondary and autiiary windings. ‘The auxiliay windings serve to synchronise the thyristor ignition impul- 08 and as the power supply forthe electronics. ~ The entire transformer has been dipcostad twice In impregnating Varnish and oven-dried, and conforms to Insulation category H (= 180°C). Rectifier ‘The slicon rectifier stack is constructed as a fuly controled thres- phase bridge, and is fied with easy-to-replace screwrin diodes and thyristors, The inductance serves to = smoxth out the dreet current ~ limit he speed of curent rise atthe moment of drop transfer (reduces ‘patting, forms softer orc). Conta electrnies ‘The unitis attached tothe front control panel, which in turns fastened. to the front panel of the machine by means of four screws. = Operating erors are unlikely thanks to the clear labeling on the front contra panel The powersupply connection bebween the power source and the control Units via one ental multipole plug-in connector. = Modes with and without rc. connection are interchangeable = Changes inthe mains voltage, arc length and other influencing factors ‘usualy result in changes in the welding curent. The built-in control, ensues thatthe welding current. wich apart from minor deviations is identical to the set current, remains constant set current = scale value set on the machin), Cootng system Forcet-ir cooling by means of fan ‘Thefan stats running as soon as the main switch © has been switched ‘The wel thought-out arrangement of transformer, rectifer and induc- tance gives an optimum cooling effect, ths helping the machine to kaep tits specified duty cyte. Heat protection + Ifthe duty cycle is exceeded, a thermastat bul into the inductance witches the machine of onthe secondary sie. = The venilator continues to run = Once the temperature has dropped sufciently, the machine is automa- tically rendered operational once more. POSSIBLE APPLICATION SET-UPS Wi 8 aa lore weg Un wa RAIA em ETO nel aos fa? ‘UW 309 a 9 TS wang at wih a mena te cna wl 1 Toh cl seeing cable Feo 2a/saSTART-UP: GENERAL POINTS TECHNICAL DATA unio custo veh ax wacecig matress [SSGSSias Soa Aniniterabcsdscmcnvetens fore | ol nar es eet a SRT TE Be UW! 303 can be run as standard on a mains ‘voltage of 3x230/380!- Mains fuse Ey 3S Asiow #0V, provided that the transformer inside the machine is ‘connected to the 380 20Asiow Sroct value for the operating-voltage supply. (Figs. 4,5; 6) MOV ABA slow Brae He sptavane PM F . egg [RBS OR a See en _ Yolow-greon lead protective eath conductor (PE). Theotherconduc- | SPM 088 (00A) gi eet arenes phase sequence Is not important. ‘Welding current range 5-300 aa [on be mate conmcedin ou vo fo om ES sr reading: "WARNING! MACHINE CONNECTED AT a 100% 5 Ok = 7 ACHTUNG - ATTENTION aaner ; MASCHINE GESCHALTET AUF Protection class P23 Ae eT A ra : MACHINE CONNECTEE EN 440 V_ 50/60 Hz ‘Attention! On mectines designed for use with a special volage, the technical data on the machine rating plat wll apply. {Attention! The mains plug used must correspond exactly to the ‘mains voltage and current rating ofthe welding machine in quest- ‘on, 2 given in the technical datal ‘Attention! The fuse forthe mans lead shoulé be suitable forthe current consumption of he welding machine! 3x230V nove. ___i i feo 2 ——— ®@® @ @ @@@ 3x380V a Se le @ @e@e @@ 6 3x440V = @o°e | [@_@ @| Top ew Weg rensloenercoecion/ Teri conection er HZSOVSEOVIIOV|ETTING-UP INSTRUCTIONS n-air operation ‘As indicated by is protection category, the machine may be sot up and ‘operated inthe open air. However, the buit-n electrical parts must be protected from direct weting caused by e.g external wet cleaning ete. Hing air ‘The machine must be setup in such a way that the cooling ir can enter ‘and leave the machine feely through the louver-type slots atthe font ‘and rear of the machine respectively. st Make sure that any metal dust caused by 6.9. grinding work is not ‘sucked into the machine by the cooling fan. lent temperature The power source must be positioned well away from such sources of heat as radiates, heating or annealing furnaces, direct hot sunshine fc, which would raise ts temperature stil further. IMPORTANT WHEN MACHINE IS HOISTED! Warning! The machine must NEVER be crane-hoisted unioss it has been fitted wih 2 single-hook iting device Holsting sequence = Fasion the crane-hook inthe lug ofthe single-hooklitng device and secure it (as per menufecture' instructions) = Detach all welding cables and other lose pars, or atch them tothe ‘machine so securaly that they cannot fll from the machine while iis, being hoisted and cause injury or damage (te up the mains cable) ‘ottg te actin wie sigeook Wing deve Fa? 26/34=SCRIPTION OF CONTROLS 7 ) Mains switch ONIOFF ) "Machine operational” indicator “ON” tights up when mains switch is set fo position 17 D Welding current regulator ‘The welding cutent may be steplessy adjusted from 5-300 ‘The inner scale (1-10) sorvas as an approximate guide to welding current levels when remote control units are used. The remate contr! til FRI-1 is algo equipped with a scale from 1-10, thus making it _ To use tin combination with all machines inthe UWR series, ‘Are force control dial {atuonces the thot ciruit amperage atthe moment of dp tensor (from electrode to workpiece) joo 1502=SCO AN —— = Airforce contra ia 5 Ee Tren cn dl on enon arr chart i ae ot ‘ro crating Wang oats TOA [Atecalesatting "0" hore is ‘age atthe moment of drop transfer (soR arc) Range of application: = T1G wolding Wilding using rule electrodes (fine globules) | Caution! When welded alow load, basie-sheatned electrodes tené to"GET STUCK" on the wo piece. file increase inthe short cireuit emper- [At scale setting "10" there is an increase up t0 808 in the short crit amperage at the moment of drop transfer (hard arc) Range of application artpsc sheathed electrodes (coarse-globule), when these ar fo be ‘walded in the lower amperage renge (verfcabup seams, edge harafacng wold, root welding el.) Practical tipst ‘inen the setting on the ae force control dil is adjusted upwards, the following may be observed when rutle, besicsheathed or special electrodes are being used = Easy ignition Reduction in welding mistires > Less electrode burn-on » Goed root fusion in natrow-gap welding (driving ae) {When welding thin sheet metal the danger of "burning through” Inoteases Wit filing: wold, there wil be a tendency forthe are to become somewhat harder ‘With fine globule electrodes (suchas ttenium) the above wil not be ‘observed, a¢ metal transfer occurs without a short cicut being protuce. = Qevasionally an increase in spatering © Connecting socket for remote control Remote control operation: Pg in remote control cable plg and fx on using @ swivel nut @ Selector switch for INTERNAL - EXTERNAL welding current settieg Ts only ited if the machine is also equipped for remte-contol INTERNAL setting "The desired welding currents set using the welding curentregule- tour @ on the machine EXTERNAL setting 2 The desired welding current is set using remote contol unit FR 1-1 27/34MOTE CONTROL OPERATION sTIONAL ITEMS) ‘control units are intended for use wherever welding parameters to be set trom the workplace. The remote contol unt is connected fealy tothe power source by means of special cables, 10m, 20m or Jong, The contr! unit is gelvaicaly separated from the casing, thus fing the electronic components in the event of the remote coniro! being damaged. ‘oie rec rl abe aed aoe ol ae 1-1 REMOTE CONTROL UNIT welding current remote contol unit - may be attached tothe body to the workpiece @. The currant may be steplessly adjusted using he ing current regulator ©. ection of remote control unit Link the connecting socket @ onthe power source tothe sock- onthe remote conto unt electialy and mechanical by means of the remote contol cable. inserthe plug-in connections he correct wey ound and screwon asf, 4 they wil go. Shit the selector witch © on the front contol panel to position Tz WELDING START-UP ia Procedure for initial adjustments + Plug in mains pl, = Shift the mains switch © from *0" to “1* © The conrol lamp @ indicates thatthe machine is operational, = The air‘an should be operational: (check thet aris being erited tthe rear ofthe machine) + necessary, connect a remote contol unit Plug the welding cables (tbe type depends onthe ype of elctrode used = take care fo act in accordance with the manufacturer's instructions) Into sockets and[s] and secute by tuming in @ dochwise direction (re- ‘commended @: 35mm). = Preselect welding curent @ + Set arcforce contol dial © + Welding may now be sarted WELDING Settings TTable 2 ghes the ampacty init for the most important electrode diame- fers, as wel as rules of thumb for calculating them. The values given are ‘only valid for unalloyed and low-allay corerods and forthe sated electrode longths. For root-wedng, vertical-up and overhead welding the welier should use the lower iit, For ilt-welding in horizontal and lat postions and als fr vaticl-down welding, the amperage is set near tothe upper lt, enw f,| 20 | 2s [am] a9 | so | oo oman |, [amano] a0 [osose|sconso] oso | so ames | on [so10| we | aon oar | zoe = Ses | as | os a Table? Arpargwk, a ed By secs camaer 28/34ARE AND MAINTENANCE ser normal conditions of use, UR 303 machines require a minimum of fe and mainonance, However, f ensure continued Wouble-ree opera no you machine for years to come, 8 certain aunt of basic mainte- nice must be carted out ‘Check the mais plug and cable and the earth cable for damage from time to time ‘Once of (wice @ year, remove the cover and side panels from the ‘machine Dh. cation ich ofthe matin an pul out te oa fst ‘clean inside of machine using compressed air (be careful - blowing Compressed ai croctly onto some elecroniz comparents irom 9 cose distance may damge them) REPLACEMENT OF THE SLIDE-IN ELECTRONIC MODULE Am=™ should only be cared out by UNITOR service perstnnel of by other suitably trained and skiled technicians. Procedure ‘Swilch of machine = Pullout mains plug | Unscrew and remove the toggle from the mains switch © Unscrew the four screws on the front control panel and swing it out- wards = Uniatch he plugin connection (electric unitipower source) = ui outne iat plug connected tothe yellowlgreen earth lead = Replace the module = Assembe the uni inthe reverse order 29/34ROUBLESHOOTING GUIDE Minot Hatin may on bord by ae ec wr cause reMeDY vel ret rhe id cick in ks neh DON tem as sto chin id (ona) ro omen wh woes clk bth cemeon ect eal ol rate uy est at al dg cron canotbe gud ters eon ane a eet tn rect position beak in remote contol cable replace remote contol unit fauty seplace faulty electronic unit replace ns fuse blows as soon as machine is _detectivepowerthytstos, power diodesorrans- check thyristors, diodes and transformer, and iched on former replace if necessary ine constantly delivers maximum hurt cmestons ose (ited grey / lack gon omens enue core port) rent F welding characteristics h dsgree of spattering) wok cant inne oven eto aman, incorect polarity of welding electrode _are force control dial © is set on wrong position change polaiy (observe manufacturers in- structions) check mains fuse, msins switch and mains terminal board if using special voltages sel atc force conto! dial at postion >. {sot arc) faulty electronic unit replace defective thyristor check and replace if necessary inductance felty replace 30/341718 19 MITOR Pcrustroruvesns cinaansome ostPorno Product ne ___Desciton 4 Description 2 ‘Wa 303 WELBNG We aT ENCLOGURE DW 365 FoR WR Cae) TEANOLE UR 303 FOR UWRS rae "RUBBER HANOLE RO FOR OWS Go FRONT PANEL CONTROL FOR WR 3 B58 10108 D=50 REDELADCRED. FOR UWS er “TURN O06 O18 BUGAIGR FoR Wr Te CURRENT SOCKET 360 Mw FOR UW303 bas ‘CAP CURRENT SOCKET FO U0 AD OARS eee [STAR LOCK 0-20 FOR UWR05 Ca EEL WAT RIM 200 FOR UW 8S ‘OUTPUT CHE FOR UWRStS 1 ‘SHUNT SARA FOR UW 8 9 MANS SWITCH FOR UWA ‘1687 "TOGGLE FOR WANE GATE FOR UWA zr FOL GAPACTTOR i FOR UWS ezr703 ‘SNGLEHOOK UFTING DEVICE For UWA 7 amr ‘TRAN RELEF PVD PIS FOR UW eae TMANSCABLE HOSA Ba FOR UWS eT TERNAL STR BHA FOR UW. 2» eres HEAT SHC FOR UWI a ene THYRISTOR OOVTEDARGD FOR UW 2 ere VARISTOR C=1050¥ FOR UW Bern, ‘SLISON DIODE 60 25, FoR OW a errs HEAT SK FOR OWS 5 ere, ‘WREWOUND RESISTOR A7KGW Fon wa aera THERMOSTAT 160 C OPENER FOR OW 2 ein VARESTOR ao FOR WAS a are “ANNEX SCREWING PS 16 FOR UW 08 aes COUNTER NUT 16 PVE FOR UW 30 =e, FAN BADE D0 FOR UW ast FAN MOTOR WITHOUT BLADES FOR UWS eres FAN WOURTNG SOX FOR UWS UMITOR 2st ron uwnsca 33/342 season tte