Instruction manual - WSS Product Catalogue

Instruction manual - WSS Product Catalogue
Instruction manual
Unitor Welding Inverter
UWI 500 TP & UWF 102
MMA, ACA, TIG and Wire welding
Revision date: 24/03/2014
Page 1 of 34
CONTENTS
1. GENERAL DESCRIPTION
2. TECHNICAL DATA
3. INSTALLATION
4. FRONT PANEL CONTROLS
5. STICK ELECTRODE WELDING
6. AIR CARBON ARC GOUGING
7. TIG WELDING
8. WIRE WELDING
9. ROUTINE MAINTENANCE
10. TROUBLESHOOTING
11. WIRING DIAGRAM UWI-500TP
12. WIRING DIAGRAM UWF-102
13. COMPONENTS AND SPARES UWI-500TP
14. WIRING DIAGRAM FOR UWF-102
15. SAFETY INSTRUCTIONS
16. ORDERING INFORMATION
17. BASIC ACCESSORIES
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT
READING THIS MANUAL INCLUDING THE SAFETY INSTRUCTIONS
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1 GENERAL DESCRIPTION UWI-500TP
Automatic adjustment to any primary voltage between 380 and 440V.
Line Voltage compensation keeps output of the power source constant regardless of fluctuation in
input power from 10% below lowest to above highest rated input voltage.
Safe in use. Touchable open circuit voltage only 9V, providing optimal safety for the operator
Adjustable Hot Start for MMA provides optimal arc striking for all electrode types and prevents
electrode sticking.
Adjustable Arc Force for stick electrode welding allows the arc characteristics to be changed for
specific applications and electrodes.
Lift-Start in TIG mode provides easy and soft TIG arc start and remote control from 5 amp to max.
ensures total arc control both during welding and for the down-slope finish of the weld.
Casing of high grade aluminium and industrial plastic to eliminate corrosion damage also contributes
to low-weight which together with compact outer dimensions provides good portability.
Wind tunnel design for the internal cooling air flow protects electrical components and PC boards
from dirt, dust, debris, greatly improving reliability.
Thermal overload protection with indicator lights helps prevent machine damage if the duty cycle is
exceeded or airflow is blocked.
Total Protection function with indicator light prevents machine damage if one phase in the primary
power supply falls out or if over-voltage is supplied to the machine.
Separate characteristics for welding with standard electrodes, for cellulosic electrodes, for TIG, for
Air Carbon Arc gouging and for Wire welding with or without shielding gas ensures optimal properties
for all processes
The remote amperage control can be used for all processes, and also for two machines in parallel for
up to 1000 Amp. for Air Carbon Arc gouging.
Delivered as machine only, with
primary cable (correct plug must be
added) and instruction manual
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2 TECHNICAL DATA
Type of welding machine
Three-phase static transformer rectifier with frequency converter and DC output.
Standards
EN 60974-10 European Norm for electromagnetic compatibility.
EN 60974-1 European Norm for arc welding appliance: Current sources for welding.
Processes
MMA (Manual Metal Arc welding (stick electrode welding)
TIG Tungsten Inert Gas welding
MIG/MAG Metal Inert/Active Gas shielded welding (wire welding)
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Safety Marking
Suitable for use in areas with increased electric shock hazard
X: Duty cycle
Duty Cycle is the percentage of 10 minutes that the unit can weld at rated load without overheating.
It refers to a 40°C environmental temperature. If the unit overheats a thermal switch stops the output,
the warning light for over-temperature is lit and the cooling fan continues to run. Wait until the
warning light darkens, then reduce amperage or duty cycle before continuing to weld.
I2= Welding current.
Range 5 – 500A cover a range from the most small scale thin plate TIG welding to groove
preparations with chamfering electrodes and all normal Air Carbon Arc Gouging.
Parallel connection ability doubles the range.
Ur = No-load voltage
Is the voltage between welding terminals (touchable voltage) when the machine is idle and equipped
with a voltage reduction function for operator safety. Low value means high operator safety, and with
this in mind this machine satisfies the world’s strictest regulation: AS 1674.2-2007 Safety in welding
and allied processes (Australian standard) which allows for maximum 35V.
Note: Mean value measured according to IEC 60974-1 is used in AS 1674.2 and is 9V for UWI-500TP. This will show up as
12,7V on display 6 when V is selected as this instrument displays peak value, not mean value.
U0 = Arc striking voltage
When electrode touches work piece the Ur voltage will within a split second jump to this value. It is
important that this value is high enough to enable quick and easy arc start for all welding
consumables.
U2 = Arc voltage
This is the voltage present between the output outlets when welding is being carried out, in relation
to a particular set welding current.
The relation between voltage and amperage for the various welding modes are the following:
MMA
TIG
MIG/MAG
→ U2=20+0,04* I2
→ U2=10+0,04* I2
→ U2=14+0,05* I2
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Primary connection
U1
I1max
I1eff
= Effective input voltage which must be between 380 and 440V
= Maximum value of input current at the corresponding duty cycle.
= Effective value of input current at the corresponding duty cycle.
32A slow fuses will be the right fuse size for this machine.
NOTE:
If two machines are to be used in parallel for up to 1000 amp output each machine needs a separate
32 Amp connection.
Cooling
COOLING AF= Forced air cooling (with a fan).
NOTE:
This cooling requires sufficient space to allow free air flow for cooling, a minimum of 50 cm on all
sides is recommended,
Protection class
IP23S= Ingress Protection class. Protection degree of the casing according to EN 60529
2: Protection against object 80mm in length and more than 12mm in diameter
3: Protection from sprayed water at an angle of 60º from vertical
S: Valid at standstill. (Can be used outdoors but not in heavy wind and rain)
NOTE:
Equipment with lower IP class should not be used outdoors.
Thermal insulation class
I.CL.H= Thermal class of the insulating materials and insulation systems.
Class H: resistant up to 180°C.
Conformity to the rules of the European Union
Mark stating conformity to all safety standards and other standards required for sale
and use within the European Union.
Recast Directive
This mark confirms that the product confirms to the RoHS directive which restricts the use of
specific hazardous or restricted substances in electrical and electronic equipment put on the
market in the European Union.
Restricted substances are:1.Lead (0.1%) 2. Mercury (0.1%) 3. Cadmium (0.01%) 4. Hexavalent chromium (0.1%)
5. Polybrominated biphenyls (0.1%) 6. Polybrominated diphenyl ethers (PBDE) (0.1%)
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3 INSTALLATION
Only qualified personnel should perform this installation.
Only personnel that have read and understood this Manual should install and operate this
equipment.
Machine must only be plugged into a receptacle which is grounded in accordance with valid
regulations.
Note
The power switch should be in the OFF position when installing work cable and electrode cable and
when connecting power cord to input power.
Dimensions and weight
Height
Length
Width
Weight
UWI-500
: 510mm
: 670mm
: 290mm
: 47kg
UWF-102
440mm
690mm
385mm
17,4kg
Select suitable location
UWI 500TP and UWF-102 have IP23S rating.
Locate UWI-500TP in a dry location where there is free circulation of clean air into the louvers in the
back and out the front of the unit. Ensure minimum 50cm free space on all sides. If free flow of air is
hindered the machine will overheat.
A location that minimizes the amount of smoke and dirt drawn into the louvers reduces the chance of
dirt accumulation that can block air passages and cause overheating.
The UWF-102 has no air cooling.
Avoid tilting
The machine must be placed on a secure, level surface, maximum 15º out of horizontal.
Rear panel functions
1: Primary cable. Mount plug and connect to
socket with 32A slow fuses
2
2: On/Off switch
3: When lit the Total Protection function has
been activated due to one missing phase
in the power supply. Switch machine off,
and correct the power supply before continuing.
3
4
5
1
4: Remote control connection.
Note: If remote control is connected it must
be activated by selecting remote control on
the front panel
5: Power supply transformer fuse,
slow, 530mA, 500V
6
6: Control cable to wire feeder (at the bottom)
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4 FRONT PANEL
6
5
4
7
3
1
2
Select process (1)
Normal stick electrodes
Cellulosic stick electrodes
Air Carbon Arc Gouging
TIG welding
Press button until light for the process is on. No light for wire welding
Select remote control (2)
Control from wire feeder: The wire feeder must be connected to the back panel bottom section
Remote control for electrode holder or TIG torch: Connect to the machine back panel top
section
Press button to turn light for remote control on.
Keep depressed for 3 seconds to activate control from wire feeder.
The display will then show the message: “---“
No light means front panel control
Arc force (3)
Arc force increases the short circuit amperage, allowing the welder to use very short arc without
sticking the electrode in the melt pool, and is useful when welding with stick electrodes at low
amperages. Set control to 0 for normal electrode welding and TIG welding.
Hot start (4)
Increased hot start makes arc striking easier and reduces the possibility for electrode sticking.
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Warning lights (5)
Power on warning. Green light when there is power to the +/- sockets.
Alarm light, see display for further information
AL.H
Display message: AL.H
The machine has overheated, the fan continues to run, all other functions are disabled.
Check first if the Total Protection LED is ON, if not check that the cooling air is unhindered and flows
freely through the machine.
When the machine has cooled down power will automatically be restored.
Reduce output power setting or operate at a lower duty cycle to avoid repetition
E.69
Display message: E.69
There is a fault in the wire feeder software, the fan continues to run, all other functions are disabled.
Disconnect the wire feeder and send it for service.
When another process is selected the machine will function normally.
Display setting (6)
Select button
Select A
The display will show the welding current which is set with adjustment knob (7)
Select V
The display will show no-load voltage when not welding, and arc voltage during welding
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5 STICK ELECTRODE WELDING
Normal coated electrodes
Electrodes with cellulosic coating
Select button
Select top setting, MMA welding for normal stick electrodes
Select setting CEL for optimal welding characteristic for cellulosic electrodes.
Connect return (ground) cable with good contact directly to the work piece.
Select polarity and amperage as recommended for the electrode and start the arc as follows:
1 Electrode
2 Workpiece
3 Arc
Drag electrode across work piece like striking a match and lift electrode slightly after touching work.
If arc goes out the electrode was lifted to high or the hot start setting is too low.
If electrode sticks to work piece, use a quick twist to free it before it becomes too warm.
If that is difficult switch off the machine or disconnect the electrode holder from the electrode before
restart
Hot start
Setting right level for hot start makes arc striking easier and reduces the possibility of electrode
sticking. If arc start is difficult the hot start setting should be increased until the arc starts satisfactory.
Arc Force
Use no or low Arc Force setting for smooth running electrodes like LH and SPECIAL.
Increased setting provides optimal characteristics for stiffer, more penetrating electrodes like E6010
types, chamfering electrodes like CH2 and electrodes for ACA gouging.
Increased arc force may also be an advantage in position welding
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6 AIR CARBON ARC GOUGING
Select ACA gouging on the front panel.
Select button
Select maximum Hot start and Arc force.
Connect electrode holder to plus (+) polarity.
Connect return (ground) cable to negative (-) polarity with good contact directly to the work piece.
If possible bring machine to the work place with a primary cable extension instead of welding cable
extensions.
If welding cable extensions are required minimum 95mm2 is recommended.
Set correct amperage for the selected electrode size
For larger electrodes than 8mm more than 500A may be required. Two machines may then be used
in parallel as follows:
-
Set both machines to identical parameters with ACA as selected process and with maximum
Hot start and Arc force
-
Set both machines to remote control and if extensions are necessary use same length
remote control cables from each machine to the work site where the remote control parallel
connection kit is used to connect both machines to the same remote control
-
If remote control is not used both machines should be set to the same ampere value on the
displays, half of the required value for the electrode
-
Return cables from both machines should be of equal length and clamps should be
connected close together directly on a clean part of the work-piece. Use minimum 95mm2
cable
-
Welding cables from both machines should be of equal length to the work site where the
ACA parallel connection kit is used to connect both machines to the same Air Carbon Arc
torch. Use minimum 95mm2 cable
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7 TIG (GTAW) WELDING
TIG welding
Select TIG process and connect the TIG torch to the
regulator with flow control. The torch should have gas valve
on the handle.
Connect TIG torch to the negative (-) terminal of the
machine.
Connect return (ground) cable with good contact directly to
the work piece.
Avoid long welding cable extensions if possible.
Use remote control attached to the torch
With the TIG process normal open-circuit voltage is not present before tungsten electrode touches
and lifts from work piece. Only a low sensing voltage is present between electrode and work piece.
The solid-state output contactor does not energize until after electrode is touching work piece.
This allows the electrode to touch the work piece without overheating, sticking, getting contaminated
or contaminate the work piece.
Start the arc as follows:
• Turn gas on.
• Touch tungsten electrode to workpiece at weld start point.
• Hold electrode to workpiece for maximum 1-2 seconds, and slowly lift electrode.
This may be done by tilting the electrode holder sideways until the gas nozzle touches the
wirk piece and the electrode is lifted.
• The arc is formed when the electrode is lifted.
.
1 Electrode
2 Workpiece
Touch the electrode to the work
piece. Only sensing voltage will
be present
Lift carefully and the arc will
be established
During welding the operator has continuous control of amperage and arc with the remote control on
the torch.
Stop the arc as follows:
•
•
•
Slope down welding current at convenient speed until arc stops
Hold the torch over the finishing point for a short while to provide gas shield and avoid
oxidation.
Close off gas flow
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8 WIRE WELDING (MIG/MAG, GMAW, FCAW)
The wire feeder UWF-102 Air is a wire feeder specially
developed for the multi-process welding power source
UWI-500TP.
By connecting UWF-102 to UWI-500TP it is, in addition
to wire welding, also possible to do stick electrode welding
and Air Carbon Arc gouging from the wire feeder without
reconnecting
Connecting UWF-102 to UWI-500TP and shielding gas
The wire feeder is delivered with the required hoses and
cables for connection to shielding gas and UWI-500TP
4m gas hose for shielding gas is connected here:
The other end has nut with 3/8” RH threads for
connection to a shielding gas regulator on a gas
cylinder
4m remote control cable for connection to the back side
of UWI-500TP is connected here:
The 4m connection cable for welding current is
connected here:
NOTE:
Correct polarity for the welding process must be selected
when connecting the welding cables to correct polarity for
welding and return at the power source.
If cable extensions are used the return cable should also be
extended to the work place for polarity selection there.
The welding cable should always be connected to the + or
– terminals on the front panel of UWI-500TP to ensure that
correct polarity for the wire is used is used.
Positive + polarity is normally used for gas-shielded wires
Negative – polarity is normally used for self-shielded wires
The 4m remote control cable from UWF-102 is connected at the back of the UWI-500TP here:
Select control of UWI-500TP from UWF-102 with the selection knob 2 on the front panel of
UWI-500, see section 4
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Front panel controls
9
11
10
7
8
5
6
4
3
12
2
1
Select process (1)
Wire welding (MIG / MAG / FCAW)
Coated electrodes, (not cellulosic)
Air Carbon Arc gouging
Select button
Wire welding torch connection
Stick electrode holder and ACA torch connection
For Stick electrodes:
Select + or – according to electrode spesification and connect this polarity from the welding machine
to the back of the wire feeder. The other polatity is return cable from workpiece to welding machine
For ACA gouging:
Connect to + polarity from the welding machine to the back of the wire feeder. The - polatity is return
cable from workpiece to welding machine
Set welding current on potmeter 5. Dispay 7 will show the set welding current in Ampères when
electrode welding or Air Carbon Arc gouging is selected
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Select wire welding process
Connect proper polarity for the wire from the front of the welding machine to the back of the wire
feeder, and the return cable from the work-piece to the welding machine
Select trigger function (2)
2-stroke function. Press trigger to start wire feed and welding, and keep trigger pressed.
Release trigger to stop wire feed and welding.
4-stroke function. Press and release trigger to start wire feed and welding, then
Press and release trigger to stop wire feed and welding.
2-stroke is used for shorter welds, 4-stroke is used for long continuous welds so that the welder does
not have to keep the trigger pressed through the whole welding sequence
Set shielding gas flow and post gas time (3)
Connect shielding gas from gas cylinder flow regulator to the back of the wire feeder
and open for gas.
Press and release this button and the gas valve in the wire feeder will open for 15
seconds to allow adjustment of correct flow on the cylinder regulator.
Press again for 2 seconds and the letters P.G. will appear on Display 7 and gas post flow in seconds
will appear on Display 8. Adjust post flow time with potmeter 6 if required, then press again to store
the value.
Cold wire feed (4)
When wire spool is properly inserted and drive rolls closed this button is pressed to
feed the wire through to the torch without voltage / welding current present, and
without shielding gas flow.
Set wire feed sped (5)
Set wire feed speed on potmeter 5. Dispay 7 will show the set wire speed in m/min when wire
welding is selected
Set welding voltage (6)
Set wire feed speed on potmeter 6. Dispay 8 will show the set voltage when wire welding is selected
Adjust inductance (12)
When welding with a short arc lower inductance will give crisper arc and easier arc start. The bead
will become taller and narrower.
More inductance will give a softer arc and flatter wider bead appearance. Too much inductance will
give difficult arc starts.
Low thermal conductivity materials like stainless steel need more inductance to get acceptable
wetting with short arc.
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Warning signals
9: The welding machine has overheated and needs cooling
See ch.4:5
10: “HOLD”: The displays 7 and 8 show last real measured
values. The light will go out when welding starts again
and real values will be shown
11: When lit this light informs that power is available at the wire feeder terminals
Display 8 warning messages
Set Gen
Remote control from wire feeder has not been selected on the welding machine, see
ch.4:2
Err.Cxx
When communication between welding machine and wire feeder does not function
properly message Err.C0, Err.C11 or Err.C12 will be displayed.
AL.HEA
The welding machine has overheated and needs cooling. This message will be
displayed together with warning light 1. See ch.4:5
Spool box and wire feed compartment
UWF 102 wire feeder has a separate spool box outside
The wire feed compartment. The spool box is angled
slightly upwards for operator ease of use, and facilitates
all standard spool sizes.
Spool box lid
Note: Keep closed when welding, the wire will then be
Electrically live.
Spool box
Shaft for wire spool
Locking
cap for
shaft
Locking stud.
Fits corresponding
hole in spool and
prevents spool from
sliding on the shaft
Friction brake adjustment.
Correctly set the brake will stop the spool at
the instant welding stops to prevent wire from
unwinding from the spool, but not hold back so
much that smooth wire feeding is prevented
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Wire feed system
with drive rolls and
adjustment of the
drive roll pressure in
the wire, see next
page.
Wire loading
Pull the pressure arm (1) outwards to release
the spring loaded wire feed drive rolls (2).
1
Check that correct wire feed drive rolls
for the wire is installed with correct
groove size in position (see next section),
if not unscrew the fixing caps (3+4) and
turn rolls or replace with correct rolls.
Place the wire spool in place on the wire
spool spindle. Make sure that the locking
stud engages in the corresponding hole
in the wire spool.
2
2
6
5
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 (5), over the drive roll (3), through the
intermediate guide (6), over the drive roll (4)
and into the outgoing guide tube (7).
This guide tube starts very close to drive roll
(4) and reaches through the torch connector to the torch
3
Close the wire feed drive rolls (2) and latch the spring loaded pressure arm (1) in place. The roll
pressure on the wire is adjusted with the screw on the pressure arm. It should be tightened
sufficiently to ensure smooth feeding of the wire and still slide on the wire if the wire is stopped by a
blocked torch nozzle
Drive rolls
V-groove smooth drive rolls are used for all solid vires except aluminum.
U-groove drive rolls prevents deformation and is specially designed for Aluminum which is soft and
will be deformed when sufficient pressure for smooth feeding is applied towards a V-groove drive
roll, resulting in poor welding results.
Knurled V-groove drive rolls are specially developed for flux-cored wires and provides excellent grip
on the hard surface of these wires without requiring a pressure that will deform these tubular wires.
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4
9 ROUTINE MAINTENANCE
Checkpoint
Action
Interval
Primary plug
and socket
Check connections
and stretch relief
3 months or more
often if needed
Check for damage
and replace if
necessary
3 months or more
often if needed
Check for damage
and tightness
3 months or more
often if needed
Primary cable
Primary cable
stretch relief
and connection
Labels
Replace damaged or
unreadable labels
Internal dust
and dirt
Blow out or vacuum
inside
Welding current
sockets
Check and clean
3 months or more
often if needed
Cable
connectors
Check, clean if
needed and tighten
Prior to use /
every 3 months
Welding cables
Repair or replace if
damaged
Prior to use /
every 3 months
Electrode
holders and
torches
Check, clean and
replace if damaged
Prior to use /
every 3 months
Ground clamps
Check tightness and
clean contact points
Prior to use /
every 3 months
Remote
controls,
if relevant.
Check function and
condition of cables
3 months or more
often if needed
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3 months or more
often if needed
6 months or more
often if needed
10 TROUBLESHOOTING
SYMPTOM
No output, no
warning light, fan
not running
POSSIBLE REASON
Primary power does not
reach the machine
One phase is missing in
primary power supply
No output, yellow
warning light
Thermal protection
activated
SOLUTION
Mains fuses blown
Machine is not plugged in
Broken primary cable
Cable connection to machine is loose
Machine not switched on
On/off switch damaged
Check the supply power from the vessel for blown
fuses, loose connections etc.
Used at too high duty cycle, wait until machine has
cooled down and power returns.
Weld with more breaks or lower current
Cooling air flow is hindered, remove obstructions
Heat development in loose electrode holder or
ground cable connections
Broken fan, repair or replace
Too much dirt in power source compartment, clean.
No arc, no
warning light
Incomplete circuit
Check ground cable and torch connections.
Unstable arc
Polarity
Poor contact
Unclean work piece
Check that polarity on the machine matches the wire
Check ground clamp and torch connections
Clean
RESETTING SOFTWARE
Unidentified software problems may prevent the welding
power source from functioning correctly.
If normal troubleshooting does not help the below
software reset procedure should be used.
The reset procedure involves complete restoration of the
default values, parameters and memory settings to
original values.
UWI-500TP
-Switch the welding machine off.
-While pressing buttons A and B switch the machine on.
-Release buttons A and B.
The message REC will appear on the display.
When the message disappears the machine is ready
A
B
UWF-102
-Switch the welding machine off and connect the wire
feeder.
-While pressing buttons C and D switch the machine on.
-Release buttons C and D.
The message rEC FAC will appear on the displays of
the wire feeder.
When the message disappears the machine is ready
C
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D
11 WIRING DIAGRAM UWI-500TP
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12 COMPONENTS AND SPARES UWI-500TP
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N°
CODE
DESCRIPTION
1
040.0003.1002
TERMAL SWITCH L=200mm
2
040.0003.0060
TERMAL SWITCH
3
011.0013.0009
LATERAL PLATE
4
050.5308.2400
LOGIC FRONT PANEL 500
5
014.0002.0009
KNOB
6
014.0002.0017
KNOB
7
011.0013.0010
FRONT SOCKET PLATE
8
041.0004.0500
HALL SENSOR
9
044.0004.0012
OUTPUT INDUCTANCE
10
021.0001.0279
SOCKET 500A
11
011.0013.0001
LOWER COVER
12
050.0002.0056
OUTPUT FILTER BOARD
13
011.0013.0002
INTERNAL PLATE
14
042.0003.0047
POWER TRANSFORMER
15
032.0002.2003
ISOTOP DIODE
16
015.0001.0012
HEAT SINK
17
050.0001.0081
SNUBBER BOARD
18
011.0001.0512
LATERAL RIGHT COVER
19
030.0017.2202
RESISTOR
20
032.0001.8216
THREE PHASE RECTIFIER
21
011.0013.0006
UPPER PLATE
22
011.0013.0005
CONVEYOR PLATE
23
011.0013.0007
INTERNAL FAN SUPPORT
24
003.0002.0010
FAN
25
011.0013.0004
FRONT/REAR PLATE
26
010.0006.0035
FRONT/REAR PLASTIC PANEL
27
040.0001.0016
THREE-POLE SWITCH
28
013.0000.7006
REAR PANEL
29
045.0000.0017
CABLE CLAMP
30
045.0002.0009
SUPPLY CABLE
31
040.0006.1880
FUSE HOLDER
32
016.0011.0004
FUSE HOLDER CAP
33
022.0002.0268
REMOTE CONTROL WIRING
34
050.0001.0057
POWER SUPPLY CONTROL BOARD
35
050.0001.0055
BUS BOARD
36
041.0006.0006
TOROIDAL TRANSFORMER
37
050.0002.0053
LINE FILTER BOARD
38
011.0000.0500
UPPER COVER
39
031.1005.0228
CAPACITOR
40
050.0001.0052
SUPPLIES BOARD
41
050.0001.0054
POWER BOARD
42
011.0009.0047
HANDLE SUPPORT PLATE
43
016.0002.0001
PIN
44
012.0000.0005
COVER FOR HANDLE SUPPORT PLATE
45
011.0013.0013
HANDLE
46
011.0001.0513
LATERAL LEFT COVER
47
022.0002.0156
REMOTE DEVICE CONNECTION WIRING
48
011.0013.0018
REAR SOCKET PLATE
For ordering spares please state: Model: UWI 500 TP Serial no: ..………..….….
Pos no: ………………….
Code: ………………….
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13 COMPONENTS AND SPARES UWF-102
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N°
CODE
DESCRIPTION
1
011.0006.0003
SLIDE CLOSURE
2
050.5324.2400
LOGIC FRONT PANEL WF102 AIR
3
014.0002.0005
KNOB WITH POINTER
4
014.0002.0009
KNOB WITH POINTER
5
021.0001.2014
STING
6
021.0001.2000
COUPLING EURO
7
021.0001.2004
PLASTIC HOUSING
8
021.0001.2027
CAPILLARY TUBE
9
021.0001.0279
FIXED SOCKET 500A 95mmq
10
002.0000.0268
SPOOL HOLDER CAP
11
046.0004.0013
PLASTIC SUPPORT
12
011.0014.0005
LOWER COVER
13
050.0001.0041
MOTOR BOARD
14
011.0014.0012
SLIDING KIT
15
011.0001.0632
DOOR
16
021.0001.0379
FIX PLUG 500A 95mmq
17
011.0002.0018
SOLENOID VALVE PLATE
18
022.0002.0155
REMOTE LOGIC CABLE
19
017.0001.5542
SOLENOID VALVE
20
011.0014.0016
FIXING CABLE BUNDLE PLATE
21
011.0014.0018
SUPPORT CABLE BUNDLE PLATE
22
011.0014.0007
LOGIC PROTECTION PLATE
23
011.0014.0002
POSTERIOR PLATE
24
011.0014.0006
SPOOL SUPPORT PLATE
25
011.0006.0054
SPOOL SUPPORT
26
012.0000.0003
LOWER SPOOL COVER
27
016.0008.0003
CYLINDRICAL PLUG
28
012.0000.0004
UPPER SPOOL COVER
29
011.0001.0652
UPPER COVER
30
011.0014.0013
INTERNAL PLATE
31
011.0014.0008
UPPER COVER SUPPORT PLATE
32
011.0006.0021
HANDLE
33
011.0006.0007
PLASTIC HINGE
34
002.0000.0012
WIRE FEED MOTOR
35
011.0014.0001
FRONT PLATE
For ordering spares please state:
Model:
Serial no:
Pos no:
Code:
Revision date: 24/03/2014
UWF 102
………….
………….
.………….
Page 25 of 34
14 WIRING DIAGRAM UWF-102
Revision date: 24/03/2014
Page 26 of 34
15 SAFETY INSTRUCTIONS
Arc Welding Hazards
The safety information given below is only a summary of the more complete safety information found
in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep
everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit
is electrically live whenever the output is on. The input power circuit and machine internal circuits are
also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll
housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or
improperly grounded equipment is a hazard.
Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate
yourself from work and ground using dry insulating mats or covers big enough to prevent any
physical contact with the work or ground. Do not use AC output in damp areas, if movement is
confined, or if there is a danger of falling. Use AC output ONLY if required for the welding process. If
AC output is required, use remote output control if present on unit.
Disconnect input power before installing or servicing this equipment. Always verify the supply
ground − check and be sure that input power cord ground wire is properly connected to ground
terminal in the cord plug and that the plug is connected to a properly grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check
connections. Frequently inspect input power cord for damage or bare wiring −replace cord
immediately if damaged − bare wiring can kill. Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables. 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 level. Keep all panels and covers
securely in place. Clamp work cable with good metal-to-metal contact to work-piece or worktable as
near the weld as practical. Insulate work clamp when not connected to work-piece to prevent contact
with any metal object. Do not connect more than one electrode or work cable to any single weld
output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Turn off inverter,
disconnect input power, and discharge input capacitors before touching any parts.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper
shade of filter to protect your face and eyes when welding or watching. Wear approved safety
glasses with side shields under your helmet. Use protective screens or barriers to protect others from
flash and glare; warn others not to watch the arc. Wear protective clothing made from durable, flameresistant material (leather and wool) and foot protection.
Revision date: 24/03/2014
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FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your
health. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area
and/or use exhaust at the arc to remove welding fumes and gases. If ventilation is poor, use an
approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator.
Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations.The heat and rays of the
arc can react with vapors to form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating
is removed from the weld area, the area is well ventilated, and if necessary, while wearing an airsupplied respirator. The coatings and any metals containing these elements can give off toxic fumes
if welded.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can cause sparks, explosion,
overheating, or fire. Check and be sure the area is safe before doing any welding. Protect yourself
and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable
material. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly
cover them with approved covers. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire
extinguisher nearby. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire
on the hidden side. Do not weld on closed containers such as tanks, drums, or pipes, unless they are
properly prepared Connect work cable to the work as close to the welding area as practical to
prevent welding current from travelling long, possibly unknown paths and causing electric shock and
fire hazards. Do not use welder to thaw frozen pipes. Remove stick electrode from holder or cut off
welding wire at contact tip when 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 side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use. Always ventilate confined spaces or use approved airsupplied respirator.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed. Allow cooling period before working on gun or torch.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away. Wearers should consult their doctor before going near arc welding,
gouging, or spot welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing. Wear approved ear protection if
noise level is high.
Revision date: 24/03/2014
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CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding process, be sure to treat them carefully. Protect
compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and
arcs. Install cylinders in an upright position by securing to a stationary support or cylinder rack to
prevent falling or tipping. Keep cylinders away from any welding or other electrical circuits. Never
drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result. Use only correct shielding gas cylinders,
regulators, hoses, and fittings designed for the specific application; maintain them and associated
parts in good condition. Turn face away from valve outlet when opening cylinder valve. Keep
protective cap in place over valve except when cylinder is in use or connected for use. Read and
follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1
listed in Safety Standards.
Additional precautions for installation, operation, and maintenance
Do not install or place unit on, over, or near combustible surfaces. Do not install unit near
flammables. Do not overload building wiring − be sure power supply system is properly sized, rated,
and protected to handle this unit.
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. Use
equipment of adequate capacity to lift and support unit. If using lift forks to move unit, be sure forks
are long enough to extend beyond opposite side of unit.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before starting to
weld again. Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling boards or parts. Use proper static-proof bags and
boxes to store, move, or ship PC boards.
MOVING PARTS can cause injury.
Keep away from moving parts. Keep away from pinch points such as drive rolls.
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
ARC WELDING can cause interference.
Electromagnetic energy can interfere with sensitive electronic equipment such as computers and
computer-driven equipment such as robots.
Be sure all equipment in the welding area is electromagnetically compatible.
To reduce possible interference, keep weld cables as short as possible, close together, and down
low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded according to this manual.
If interference still occurs, the user must take extra measures such as moving the welding machine,
using shielded cables, using line filters, or shielding the work area.
Revision date: 24/03/2014
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EMF Information
Considerations about welding and the effects of low frequency electric and magnetic fields.
Welding current, as it flows through welding cables, will cause electromagnetic fields.
There has been and still is some concern about such fields.
However, after examining more than 500 studies spanning 17 years of research, a special blue
ribbon committee of the National Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-frequency electric and
magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be examined. Until the final
conclusions of the research are reached, you may wish to minimize your exposure to
electromagnetic fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above
procedures is recommended.
Revision date: 24/03/2014
Page 30 of 34
16 ORDERING INFORMATION
UWI-500TP Multi process welding inverter 191-500500
Undercarriage for UWI-500TP 196-500103
UWF-102 Wire Feeder for UWI-500TP 191-500102
Revision date: 24/03/2014
Page 31 of 34
17 BASIC ACCESSORIES
Basic accessories
Basic accessories kit for UWI-500TP
196 670 406
Consisting of: (Order numbers to be used when re-ordering)
Flip-Vision shield with flip-up frame, head band and filter shade 11 glass
196 709 485
Long lined welding gloves, 1pair (re-ordering number is for 6 pairs)
196 632 786
Electrode holder with 3m cable and connector
196 594 325
Ground clamp with 3m cable and connector
196 594 317
Wire brush, steel, 2 rows, 1 pcs (re-ordering number is for 6 pcs)
196 632 976
Chipping hammer steel, 1 pcs (re-ordering number is for 2pcs)
196 633 008
Remote control with 8m cable
191 670 414
Air Carbon Arc gouging accessories
ACA-torch 600A with cable & safety onnector, air hose & quick
connector
Cable connector conversion, safety connector to DIX for UWI connection
196 528 703
195 634 121
Shielding gas supply
Argon regulator with flow adjustment 0-32 l/min
197 619247
Flow control meter for use at torch nozzle
197 597328
Flow control needle valve for gas flow adjustment
197 597310
TIG welding Accessories
Specially thin and soft TIG gloves, 6 pairs
197 632794
TIG-torch T-200 with gas valve and DIX 70 connector
197 200000
Accessories kit for TIG-torch
197 607810
Wire welding Accessories
Torch for gas shielded wire welding
193 607451
Torch for gasless wire welding
193 750179
Special pliers for wire welding
193 591990
Antispatter spray for nozzle protection
193 633149
Flowcontrol meter for use at torch nozzle
197 597328
Shielding gasses
Argon and Argon/CO2 80/20 is available in 10 l cylinders and 50 l cylinders, CO" on
request
FOR FULL INFORMATION ON THE UNITOR WELDING OFFER
Revision date: 24/03/2014
Page 32 of 34
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
Revision date: 24/03/2014
Page 33 of 34
Instruction manual
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in 2San
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Revision date: 24/03/2014
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