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Wilhelmsen UNITOR UWI MAXIMUS 503 Manual

Welding inverter
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UWI MAXIMUS 503
Unitor Welding Inverter
UWI MAXIMUS 503 & UWF 513
MMA, ACA, TIG and Wire Welding
Cod.006.0001.2350
01/04/2025 R0

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Summary of Contents for Wilhelmsen UNITOR UWI MAXIMUS 503

  • Page 1 UWI MAXIMUS 503 Unitor Welding Inverter UWI MAXIMUS 503 & UWF 513 MMA, ACA, TIG and Wire Welding Cod.006.0001.2350 01/04/2025 R0...

  • Page 2: Declaration Of Conformity

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 DECLARATION OF CONFORMITY Waste electrical and electronic equipment (WEEE) Electromagnetic compatibility (EMC) Applied directives Low voltage (LVD) Restriction of the use of certain hazardous substances (RoHS) Eco Design of energy-related products Construction standards EN 60974-1; EN 60974-10 Class A Equipment compliant with European directives in force Equipment compliant with UK directives in force Equipment suitable in an environment with increased hazard of electric shock...

  • Page 3: Table Of Contents

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 GENERAL INDEX GENERAL INFORMATION ......................... 4 Meaning of the symbols ..........................4 SAFETY INSTRUCTIONS ........................5 SAFETY WARNINGS ............................9 TECHNICAL DATA ..........................11 Presentation ............................... 11 INSTALLATION AND ASSEMBLY ....................12 Connections and sockets ........................13 USER INTERFACE ...........................

  • Page 4: General Information

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 GENERAL INFORMATION IMPORTANT! For your safety This handbook must be consigned to the user prior to installation and commissioning of the unit. Retain these documents for future consultation. 1.1 Meaning of the symbols DANGER! This pictogram warns of danger of death or serious injury.

  • Page 5: Safety Instructions

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 SAFETY INSTRUCTIONS DANGER 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.
  • Page 6 UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 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.

  • Page 7: Cylinders Can Explode If Damaged

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 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.
  • Page 8 UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 WARNING! 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. WARNING! FALLING UNIT CAN CAUSE INJURY.

  • Page 9: Safety Warnings

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 2.1 SAFETY WARNINGS The following safety symbols are used in this manual. MANUAL LIFTING • Use the handles and straps solely for manual lifting of the equipment. • Manual lifting equipment must be correctly sized to lift the weight of the single unit where the equipment is installed.
  • Page 10 UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 • The risk of electric shock is higher if you touch metal parts and the electrode simultaneously. • The operator must be insulated with respect to metal components connected to earth. • When welding is required to be carried out in close contact with the ship’s structure or is likely to make contact during ordinary movements (i.e.

  • Page 11: Technical Data

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 TECHNICAL DATA UWI MAXIMUS 503 Dimensions and Weight Height : 368mm Length : 499mm Width : 214mm Weight : 23,4kg 3.1 Presentation UWI MAXIMUS 503 is a compact but powerful 500 A welding inverter for all types of welding on board ship. It can weld all normal coated electrodes up to 6.0 mm.

  • Page 12: Installation And Assembly

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 INSTALLATION AND ASSEMBLY DANGER! Lifting and positioning Read the warnings highlighted by the following symbols in the section “SAFETY WARNINGS”. DANGER! Cylinder handling and positioning Read the warnings highlighted by the following symbols in the section “SAFETY WARNINGS”. DANGER! Disconnect the equipment from the mains before performing any assembly operations.

  • Page 13: Connections And Sockets

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 4.1 Connections and sockets FRONT VIEW REAR VIEW ○ [1] Negative polarity welding socket. ○ [2] Positive polarity welding socket. ○ [3] Switch for switching the welding inverter off and on. ○ [4] Power cable. •...

  • Page 14: User Interface

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 USER INTERFACE ELEMENT FUNCTION The key enables: - The remote control. - The wire feeder mechanism. This button selects the welding mode. ENCODER WITH BUILT-IN BUTTON S3/ENC Turning the knob sets the welding current. Setup Menu: Press the button for 2 seconds to access the Setup menu.
  • Page 15 UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 ELEMENT FUNCTION The LED on signals the display of the last current and voltage value measured during welding. The LED will turn off when the welding resumes and the actual values will be displayed. The LED on indicates that the [VRD= VOLTAGE REDUCTION DEVICE] function is enabled.

  • Page 16: Preparing For Welding

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 PREPARING FOR WELDING DANGER! Electric shock hazard! Read the warnings highlighted by the following symbols in the section “SAFETY WARNINGS”. 6.1 Preparing for coated electrode welding (MMA) FRONT VIEW REAR VIEW Set the welding inverter ON/OFF switch to “O” (unit switched off). Choose the electrode based on the type of material and thickness of the workpiece to be welded.

  • Page 17: Welding Current Adjustment

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Welding current adjustment Press the [S2] key to set the MMA welding mode Turn the knob to set the welding current. The Display [D1] displays the value of the set current. Information By connecting and activating the remote control [RC] the current value will be adjusted through it. (Activation of remote control page 28).

  • Page 18: Welding Parameters

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Welding parameters HoS (HOT-START) ► Adjustment range: minimum (0) - default (50) - maximum (100) ► This parameter regulates the intensity of the current during the striking of the arc to facilitate its being switched on. The value of the parameter is set as a percentage referring to the main current value.

  • Page 19: Gouging With Air Carbon Arc (Aca)

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 6.2 Gouging with Air Carbon Arc (ACA) WARNING! Gouging is a process that generates several sparks and it is therefore very important that the operator is equipped with the appropriate protection devices. DANGER! Ensure that the projected melted material does not reach flammable or explosive substances. If necessary, use protective screens.

  • Page 20: Gouging Current Adjustment

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Gouging current adjustment Press the [S2] key to set the ACA welding mode Turn the knob to set the gouging current. The Display [D1] displays the value of the set current. Information By connecting and activating the remote control [RC] the current value will be adjusted through it. (Activation of remote control page 28).

  • Page 21: Configuration Of Two Welding Inverters In Parallel For Gouging

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Configuration of two welding inverters in parallel for gouging For electrodes larger than 8 mm, more than 500 A may be required. It is possible to exceed the 500 A threshold of a single machine and reach 1000 A by placing two distinct UWI MAXIMUS 503 welding inverters in parallel.

  • Page 22: Front Configuration

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 - Connect the ACA torch 600A (product number 528703) gripper and ground gripper sockets following the diagram below. FRONT CONFIGURATION REAR CONFIGURATION Information Welding cables from both machines must be of equal length to the work site where the parallel con- necting three-way connector DIX70 male-female-female is used to connect both machines to the same ACA torch and the same ground socket.

  • Page 23: Remote Control

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Information The connection of the parallel cable establishes the configuration of the two welding inverters. REMOTE CONTROL MASTER SLAVE 1. The current value is regulated exclusively by the 1. No settings from the slave panel. master panel.

  • Page 24: Preparing For Tig Welding

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 4.1 Preparing for TIG welding DANGER! Electric shock hazard! Read the warnings highlighted by the following symbols in the section “SAFETY WARNINGS”. FRONT VIEW REAR VIEW Set the welding inverter ON/OFF switch to “O” (unit switched off). Connect the torch plug to the negative polarity welding socket.

  • Page 25: Continuous Tig Welding Current Adjustment

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Continuous TIG welding current adjustment Press the [S2] key to set the CONTINUOUS TIG welding mode Turn the knob to set the welding current. The display shows the value of the set current. Information By connecting and activating the remote control [RC] the current value will be adjusted through it. (Activation of remote control page 28).

  • Page 26: Pulsed Tig Welding Current Adjustment

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Pulsed TIG welding current adjustment Press the [S2] key to set the PULSED TIG welding mode Turn the knob to set the welding current. The display shows the value of the set current. Pulsed TIG characteristics - Reduction of the average heat input at the same welding speed.

  • Page 27: Preparing For Welding Mig/Mag

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 4.2 Preparing for welding MIG/MAG DANGER! Electric shock hazard! Read the warnings highlighted by the following symbols in the section “SAFETY WARNINGS”. FRONT VIEW REAR VIEW Set the welding inverter ON/OFF switch to “O” (unit switched off). Install the wire feeder unit using the connection extension Information For installation, refer to the user manual UWF-513.

  • Page 28: Activation Of The Wire Feeder Unit Uwf-513

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Activation of the wire feeder unit UWF-513 Press the [S1] key for 3 seconds. The LED of the wire feeder unit lights up The panel is disabled. The UWF-513 wire feeder unit panel is activated Information Refer to the user manual UWF-513 for information on parameters and settings of the wire feeder unit.

  • Page 29: Remote Control Activation

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 Remote control activation Press the [S1] key to activate the remote control. The remote control LED lights up The current adjustment knob is disabled. The current parameter can only be adjusted by remote control. To disable, return to step 1 and press S1 key again.

  • Page 30: Routine Maintenance

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 ROUTINE MAINTENANCE CHECKPOINT ACTION INTERVAL Primary plug and Check connections 3 months or more often socket and stretch relief if needed Check for damage 3 months or more often Primary cable and replace if if needed necessary Primary cable stretch...

  • Page 31: Quick Troubleshooting Guide

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 QUICK TROUBLESHOOTING GUIDE 6.1 Alarm (error codes) management E04: VOUT DISCONNECTED ALARM ► Indicates that there is a short circuit between the (+) and (-) welding sockets. ► Solution: - Check that the welding torch is not resting on the piece to be welded connected to the ground. - Check that when the welding inverter is switched on there is no short circuit between the sockets (the volt- age must be greater than/equal to Ur).
  • Page 32 UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 E32: SECONDARY THERMAL ALARM ► It indicates that the welding inverter thermal cut-out switch has tripped. ► Solution: - Leave the equipment running so that the overheated components cool as rapidly as possible. When the problem is solved, the welding inverter will reset automatically.

  • Page 33: Fault Symptoms And Possible Solutions

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 6.2 Fault symptoms and possible solutions SYMPTOM POSSIBLE REASON SOLUTION Mains fuses blown Machine is not plugged in No output, Broken primary cable Primary power does not reach the No warning light, machine Cable connection to machine is loose Fan not running Machine not switched on On/off switch damaged...

  • Page 34: Wiring Diagram

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 WIRING DIAGRAM MAINTENANCE & TROUBLESHOOTING...

  • Page 35: Spare Parts List

    UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 SPARE PARTS LIST SPARE PARTS...
  • Page 36 UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 [WSS PART NO. 503505] SPARE PART KIT F/UWI-MAXIMUS 503 Spare part kit for UWI-MAXIMUS 503 consists of: WSS PART NO. DESCRIPTION CONTROL BOARD POWER BOARD INPUT FILTER BOARD TEMPLATE FOR THERMIC INTERFACE 503505 THERMIC INTERFACE THERMIC GREASE (10 g) SCREWS INSTRUCTIONS FOR INSTALLATION...
  • Page 37 UWI MAXIMUS 503 Cod.006.0001.2350 01/04/2025 R0 SPARE PART LIST (ON-REQUEST BASIS) WSS PART NO. DESCRIPTION 1000732 KNOB WITH CAP 1000733 COMPLETE LOGIC FRONT PANEL 1000734 PLEXIGLASS PROTECTION 1000735 PIPE HANDLE 1000643 COMPLETE FIX PLUG 500A 1000736 INPUT INDUCTOR 1000737 OUTPUT INDUCTOR 1000738 POWER TRANSFORMER 1000739...
  • Page 38 Please use these Unitor products exclusively for the purpose indicated by WSS and only if the operator fully understands current practices and procedures. If any further information or assistance is required please contact your local WSS specialist. www.wilhelmsen.com Cod.006.0001.2350 01/04/2025 R0...

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