Paton ECO-160 Instruction Manual

PATON ECO-series DC MMA 
- 2 -
CONTENTS
1. Generalprovisions4
2. Start‐up 7
2.1.Intendeduse7
2.2.Installation requirements 7
2.3.Powerconnection8
2.4.Mainsplugconnection8
3. Weldingwithstickelectrodes(MMA) 8
3.1.HotStartfunction9
3.2.ArcForcefunction9
3.3.Anti‐Stickfunction10

4. Attendanceandtechnicalmaintenance 10

5. Generatoroperationmode 11

6. Storagerules 11

7. Transportation 11

8. Technicalspecifications 11

9. Deliveryset 12

10. Troubleshooting 12

11. Safetyrules 13

12. Schematicelectricaldiagramofthesource 15

13. Warrantyliabilities 16

14. Acceptancecertificate 17


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PATON ECO-series DC MMA
Connectiontopowermains/powerboard(at25ºС):
ATTENTION:Makeprovisionforcablesroutedinthewallsandotherextensioncords!
ElectrodeusedSetcurrentvalue

Powercablecross‐
section,sq.mm
Maximumcable

length,m
Ф2mm80Aatmost
1.0


120

1.5

180

2.0

240

2.5

300

4.0

480

6.0

720

Ф3mm120Aatmost
1.5

120

2.0

160

2.5

200

4.0

320

6.0

480

Ф4mm160Aatmost
2.0

120

2.5

150

4.0

240

6.0

360

Ф5mm,low‐melting200Aatmost
2.5

120

4.0

190

6.0

290

Ф5mm,
high‐melting250Aatmost
2.5

100

4.0

150

6.0

230

ATTENTION:Supplybuttonontherearpanelofthemachineisnotapower
button,soitdoesnotprovidecompletede‐energizationofinternalelectronic
parts,whenthemachineisswitchedoff.Therefore,inaccordancewithsafety
rules,disconnecttheplugfromthemainsaftercompletionofwelding.

PATON ECO-series DC MMA 
- 4 -
1. GENERALPROVISIONS
InverterrectifiersPATONECO‐160,ECO‐200,ECO‐250aredesignedfordirect
currentmanualarcwelding(MMA).ThisEcoseriesisintendedfordemandingusers,
who need the most compact and powerful machine with full rated current of 160
A/200A/250Arespectively.Thiscurrentisenoughtoworkwithanyelectrodesfrom
Ф1.6mmtoФ5mmindiameter,includinghigh‐meltingelectrodes.Atthesametime,
its load duration is 40% and higher, which is more than enough for most
applications more demanding than household use (workshops, motor transport
servicesetc.).
All brand PATON™ ECO models produced by PATON are equipped
with a built‐in undervoltageprotectionunit.
Duetoincreasedfrequencyofvoltagesuppliedtothetransformer,the
transformercanbemadetenfoldsmaller.That’swhyweightandoveralldimensionsof
thismachineisseveraltimessmallerthanthoseofregularequipmentwithidentical
outputparameters.
Mainadvantages:
1. Inadditiontovoltagesurgeprotection,themachineisequippedwithastabilization
systemforlargelong‐termvoltagevariationsinthesupplymainsfrom170Vto260
V.However,minimumvoltageof170Vallowsweldingwithanelectrodenotmore
thanФ3mmindiameter.
2. Themachinefitsstandarddomesticpowermains.Duetohighefficiencyfactor,the
sourceprovidestwicelowerpowerconsumptioncomparedtoregularsources.
3. Convenientuseduetohighloadduration(LD)atratedcurrent,whichenables
continuousweldingwithФ3mmelectrodesattheirratedcurrent.
4. Increasedmachinereliabilityindustyproductionenvironment.
5. Allelectronicpartsofthemachineareimpregnatedwithtwolayersofhigh‐quality
varnishwhichensuresproductreliabilityduringtheentireservicelife.
6. Smoothadjustmentofarccurrent.
7. Enhancedarcingstability.

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PATON ECO-series DC MMA
PARAMETERS
ECO–160ECO–200ECO–250
Ratedvoltageof50Hzsupply

mains,V220220220
Ratedcurrentconsumptionfrom

mains,A202532
Ratedarccurrent,A

160

200

250

Maximumroot‐mean‐square

current,A190240300
Loadduration(LD)40%at160A
100%at101A
40%at200A
100%at126A
40%at250А
100%at158A
Mainsvoltagevariationrange,V

170~260

170~260

170~260

Arccurrentadjustmentrange,A

20~160

25~200

32~250

HotStart

yes

yes

yes

ArcForce


yes

yes

yes

Anti‐Stick


yes

yes

yes

Open‐circuitvoltage,V

80

80

80

Arcstrikingvoltage,V

110

110

110

Ratedpowerconsumption,kW

4.4

5.5

7.0

Maximumpowerconsumption,

kW5.56.98.8
Efficiencyfactor,%

90

90

90

Cooling

forced

Operatingtemperaturerange

–
25…+45ºС
–
25…+45ºС–25…+45ºС
Overalldimensions(length,

width,height)245х100х200270х110х200270х110х200
Weight,kg

3.75

3.95

4.30

Ingressprotectionclass*

IP21

IP21

IP21

*ForEcoseriesmachines,theirframeprotectsthemfromingressofobjectsmorethan5.5
mmindiameter,andverticallydrippingwaterdoesnotinfringethemachineoperation

Fig.1Controlelementsandindication
PATON ECO-series DC MMA  - 6 -
Recommendedlengthofpowerweldingcablesduringwelding:
Machinemodel

Cablelength,m

(oneway)
Cross‐section

area,sq.mmCablegrade
ECO–160
1…4

8

КГ1х8

2…5

10

КГ1х10

3…8

16

КГ1х16

ECO–200
1…4

10

КГ1х10

2…6.5

16

КГ1х16

3…10

25

КГ1х25

ECO–250
1…5

16

КГ1х16

2…8

25

КГ1х25

3…11

35

КГ1х35


- 7 -
PATON ECO-series DC MMA
1–Arccurrentcontroller,allowsforsmoothadjustmentofarccurrent.
2–Statusindicator:
a) permanentgreenlight–themachineisreadyforoperation;
b) flashingyellowlightduringstriking–mainsvoltageisnotsufficient;
c) permanentyellowlight–thesourceisoverheated;
d) nolight–nopowersupply.
3–Mainsswitch(doesnotlightup,thecolourisadoptedfordesignpurposes).
А–Powercurrentsocket"+"ofbayonettype:
incaseofMMAwelding–forconnectionofelectrodecable(veryoccasionally
"earth"cablecanbeconnected,ifspecialelectrodesareused).
B–Powercurrentsocket"‐"ofbayonettype:
incaseofMMAwelding–forconnectionof"earth"cable(veryoccasionally
electrodecablecanbeconnected,ifspecialelectrodesareused).
2. START‐UP
ATTENTION:Beforestart‐up,readthechapter"Safetyrules",paragraph11.
2.1INTENDEDUSE
Theweldingmachineisdesignedsolelyformanualarcweldingwithastick
electrode,aswellasforargonwelding.
Otheruseofthemachineisconsideredundue.Themanufacturerisnot
responsiblefordamagecausebyundueuseofthemachine.
Intendeduseofthemachineimpliesadherencetoinstructionsofthisoperating
manual.
ATTENTION:Donotusetheweldingmachineforpipesdefrosting.
2.2INSTALLATION REQUIREMENTS
Theweldingmachineisprotectedfromingressofforeignsolidobjectsofmore
than5.5mmindiameter.
Theweldingmachinecanbeplacedandoperatedoutdoors.Internalelectricpartsof
themachineareprotectedagainstdirectmoistureimpact.
ATTENTION:Donotswitchthemachineoffimmediatelyaftercompletionof
weldingworksinhotweatherorintenseweldingworksinanyweatherconditions!
Electronicpartsmustbeallowedtocooldownfor5minutes.
ATTENTION:Whenthemachineisswitchedoffandcoolsdownafteroperation
incoldseason,condensateformsinsideofit,sodonotswitchthemachineonagain
inlessthan3...4hours!!!
Therefore,don'tswitchthemachineoffincoldseason,ifyouaregoingtoswitchit
onwithin4hours.
ATTENTION:Themachinemaybelife‐threateningafterahardfall.Soplaceit
onstablesolidsurface.

PATON ECO-series DC MMA 
- 8 -
Themachinemustbeplacedsoastoensurefreeinletandoutletofcoolingair
throughventholesonthefrontandtherearpanels.Takecarethatmetaldust(for
example,duringemerygrinding)doesdrawndirectlyintothemachinebythecooling
fan.
2.3POWERCONNECTION
Theweldingmachineofseriesdesignisratedformainsvoltageof220V(‐23%
+18%).
ATTENTION:Allmanufacturer'swarrantyliabilitiesbecomevoidifthe
machineisusedwithsupplyvoltageexceeding270V!
Mainsconnector,cross‐sectionsofpowersupplycablesandsupply‐linefuses
mustbeselectedonthebasisoftechnicalspecificationsofthemachine.
2.4MAINSPLUGCONNECTION
ATTENTION:Mainsplugshallcorrespondtosupplyvoltageandcurrent
consumptionoftheweldingmachine(seetechnicaldata).Inaccordancewithsafety
practices,usereceptacleswithguaranteedearthing!!!
3. WELDINGWITHSTICKELECTRODES(MMA)
‐inserttheelectrodecableintothesourcesocketА"+";
‐insertthe"earth"cableintothesourcesocketB"‐";
‐connectthe"earth"cabletotheworkpiece;
‐connectthemainsplugtothesupplymains;
‐setpowerswitch3ontherearpaneltoposition"I";
Fig.2.Machineconnectiondiagramforweldingwithstickelectrodes
ATTENTION:Oncethepowerswitch3issettoposition"I",thestickelectrode
becomesenergized.Donottouchconductiveorearthedobjects,suchas,for
example,weldingmachineframeetc.,withtheelectrode.

- 9 -
PATON ECO-series DC MMA
3.1HOTSTARTFUNCTION
Advantages:
‐improvedstrikingevenwhenusingelectrodeswithbadstrikingproperties;
‐betterpenetrationofbasematerialduringstrikingand,consequently,less
poorpenetrations;
‐preventionofslaginclusions.
Theresultisachievedbythefollowingmeans:
Inthemomentofarcstriking,arccurrentincreasesby33%ofthesetarccurrent
valueforashorttime(Fig.3).
Example:weldingwithanelectrodeofФ3mmindiameter.
Arccurrentvalue,whichissetusingthecontroller,is90A.
Hotstartcurrentis90A+33%=120A.
3.2ARCFORCEFUNCTION
Advantages:
‐enhancedshort‐arcweldingstability;
‐bettertransferofmetaldropsintotheweldpool;
‐betterarcstriking;
‐reducedriskofelectrodesticking.
Theresultisachievedbythefollowingmeans:
Duetoreductionofarcvoltagebelowtheminimumpermissiblevoltageof
stablearcburning,arccurrentincreasesby30%ofthesetvalue(Fig.4).
Fig.3.HOTSTARTfunction
t,

s


PATON ECO-series DC MMA 
- 10 -
Fig.4.ARCFORCEfunction
3.3ANTI‐STICKFUNCTION
Duringinitialarcstriking,theelectrodecanstickorbetackedtotheworkpiece,
firstleadingtooverheatingandeventuallytodamageoftheelectrode.
Iftheelectrodehasstucktotheworkpiece,themachinereducesarccurrent
within0.6...0.8s.Thisfunctionhelpstheweldingoperatortoseparate(detach)the
electrodefromtheworkpiecewithoutrisktoburnhiseyeswithaccidentalarcstriking.
Oncetheelectrodeisdetachedfromtheworkpiece,theprocessofweldingcanbe
readilyresumed.
4. ATTENDANCEANDTECHNICALMAINTENANCE
ATTENTION:Beforeopeningthemachine,switchitoffanddisconnectthe
mainsplug.Waituntilinternalcircuitsofthemachinede‐energize(about5
minutes),andonlythenproceedwithotheractions.Whenleavingthemachine,
installarestrictiveplatewhichprohibitsswitchingthemachineon.
Inordertoensureproperoperationofthemachineformanyyears,adhereto
severalrules:
- conductinspectioninaccordancewithsafetypracticeswithintheestablished
timeintervals(see"Safetyrules"chapter);
- ifthemachineissubjecttoheavyuse,itisrecommendedtopurgeitwithdry
compressedaironcepersixmonth.Attention:Ifthemachineispurgedfroma
veryshortdistance,electroniccomponentsmaybedamaged;
- ifthemachineisverydust‐laden,cleanchannelsofthecoolingsystem
manually.
130

- 11 -
PATON ECO-series DC MMA
5. GENERATOROPERATIONMODE
Thepowersourcecanbeoperatedfromageneratoruponthefollowingcondition:
Whenworkingwith

electrodes
Setcurrentvalue

Minimumgenerator

power,kVA
Ф280Aatmost2.6
Ф3120Aatmost4.1
Ф4160Aatmost5.5
Ф5,low‐melting200Aatmost6.9
Ф5,high‐melting250Aatmost8.8
ATTENTION:Inordertoensuretrouble‐freeoperation,outputvoltageofthe
generatorshallnotfallbeyondthepermissiblerangeof170~260V!
6. STORAGERULES
Apreservedandpackagedsourceshallbestoredinstorageconditions4asper
GOST15150‐69for5years.
Ade‐preservedsourceshallbestoredindryclosedroomsatairtemperaturenot
lowerthanplus5°С.Theroomsmustbefreefromacidvapoursandotheractive
substances.
7. TRANSPORTATION
Apackagedsourcecanbetransportedbyanymeansoftransportation,which
provideitsintegrity,complyingwithalltransportationrulesestablishedforthistypeof
transport.
8. TECHNICALSPECIFICATIONS
ATTENTION:Ifasourceisdesignedforspecialsupplyvoltage,itstechnical
specificationsareprovidedontheidentificationplateonthefrontortherearpanel.
Inthiscase,mainsplugandmainscableshallbeselectedaccordingtothevoltage
used.
Parameters

ECO‐160 ECO‐200 ECO‐250
Ratedvoltageofmains50/60Hz,V

~220

~220

~220

Mainsvoltagevariationrange,V

170~260

170~260

170~260

Efficiencyfactor,%909090
Arccurrentadjustmentrange,A20~16025~20032~250
Arc

currentat:

5min./45%LD
5min./100%LD
160A
101A
200A
126A
250A
158A
Maximumpowerconsumption,kVA5.56.98.8
Normaloperatingvoltage:

‐MMAstickelectrode20.4~26V20.4~26.5V20.4~27.0V

PATON ECO-series DC MMA 
- 12 -
9. DELIVERYSET
1. Weldingarcsupplysourcewithamainscable – 1pce.
2. Shouldercarryingstrap – 1pce.
3. PATONbrandcorrugatedbox – 1pce.
4. 3mweldingcablewithanelectrodeholder – 1pce.
5. 3mweldingcablewithearthterminal – 1pce.
6. Operatingmanual – 1pce.
10. TROUBLESHOOTING
FaultCauseCorrection
Noarccurrent

Themainsswitchison,
butthestatusindicator
isnotlit.
Mainscablebreak

Checkthemainscable.

Supplymainsvoltageis

lowerthan155V
Disconnectthemachineand

connectittothemainswith
propersupplyvoltage
Supplymainsvoltage

exceedsthepermissible
valueof260V
Disconnectthemachineand

connectittothemainswith
propersupplyvoltage
Internalsourcesupply

unithasfailed
Contacttheservicefacility

Noarccurrent

Themainsswitchison,
thesourcestatus
indicatorlightsgreen
Weldingcablesare

disconnected
Checkplugconnection

Earthisnotconnectedor

connectedpoorly
Establishreliableconnectionof

theearthcablewiththework
piece
Noarccurrent

Themainsswitchison,
thesourcestatus
indicatorlightsyellow
Temperaturesensorhas

beenactuated
Waituntilthemachinecools

down;thenitwillswitchonagain
automatically
Insufficientcoolingair

supply
Providesufficientairinflow

Temperaturesensor

is

faulty
Contacttheservicefacility

Badstrikingduring

weldingwithastick
electrode,thesource
statusindicatorflashes
greenforshortperiods
Supplymainsvoltageat

thestartofloadingis
neartheminimum
permissiblevalueof
165V.
Ifitisimpossibletoincrease

cross‐sectionoffeedingmains
cables,tryreducingtheset
currentvalue,untilitwillallowfor
strikingthearc.Thenusean
electrodecorrespondingtothe
currentvalue.
Continuationoftableonpage14.

- 13 - PATON ECO-series DC MMA
Continuationoftablestartedonpage13.
11. SAFETYRULES
GENERALPROVISIONS
Theweldingmachineismanufacturedinaccordancewithtechnicalstandardsand
establishedsafetyrules.However,incorrecthandlingresultsinthefollowingdangers:
‐injuryofmaintenancepersonnelorthirdpersons;
‐damageofthemachineorpropertyoftheenterprise;
‐derangementofefficientworkingprocess.
Allpersonsdealingwithstart‐up,operation,attendanceandmaintenanceofthe
machinemust:
‐undergorelevantqualifyingexamination;
‐haveknowledgeaboutwelding;
‐carefullyfollowtheseinstructions.
Malfunctionsthatcanreducesafetymustbeeliminatedimmediately.
USER'SRESPONSIBILITIES
Toensureindividualprotection,adheretothefollowingrules:
‐wearrobustfootwear,whichretainsinsulatingpropertiesinmoistconditionsaswell;
‐protectthehandswithinsulatinggloves;
‐protecttheeyeswithaheadshield,withisequippedwithablack‐lightfiltercomplying
withsafetystandards;
‐wearonlyproperlow‐flammableclothes.
INDIVIDUALPROTECTIVEEQUIPMENT
Toensureindividualprotection,adheretothefollowingrules:
‐wearrobustfootwear,whichretainsinsulatingpropertiesinmoistconditionsaswell;
‐protectthehandswithinsulatinggloves;
‐protecttheeyeswithaheadshield,withisequippedwithablack‐lightfiltercomplying
withsafetystandards;
‐wearonlyproperlow‐flammableclothes.
Fault

Cause

Correction

Sporadicarc

extinctionoccurs
duringwelding
Arcburningvoltageis

toohighforthe
electrodeused
Ifpossible,useotherelectrodes

oranotherweldingmachine
designedforhigherpower
Stickelectrodeis

stickingtothework
piece
Arccurrentvalueistoo

low
Setarccurrenttoahighervalue

Badweldingquality

(intensesplashing)
Incorrectpolarityofthe

electrode
Changepolarityoftheelectrode

(inaccordancewithdataofthe
electrodesmanufacturer)
Poorcontactwithearth

Connectearthterminalasclose

totheweldingzoneaspossible

PATON ECO-series DC MMA 
- 14 -
DANGEROFHAZARDOUSGASESANDVAPOURS
‐ ifsmokeandhazardousgasesemergeintheoperatingzone,removethemwith
specialmeans;
‐providesufficientfreshairinflow;
‐arcradiationfieldmustbefreefromsolventvapours.
DANGEROFSPARKING
‐removeflammableobjectsfromtheoperatingzone;
‐itisnotallowedtoweldvesselswheregases,fueloroilproductsarestoredorusedto
bestored.Residuesoftheseproductsmayexplode;
‐ whenworkinginfire‐dangerousorexplosion‐dangerousrooms,adheretospecial
rulesincompliancewithnationalandinternationalregulations.
DANGEROFMAINSANDARCCURRENT
‐electricshockcanleadtodeath;
‐ magneticfieldscreatedbythismachinecanhaveadverseeffectonoperabilityof
electricalappliances(suchascardiacpacemakers).Peoplewhousesuchappliancesshall
consultwithadoctorbeforeapproachingtheoperatingweldingarea;
‐weldingcablemustberobust,intactandinsulated.Looseconnectionsanddamaged
cablesmustbeimmediatelyreplaced.Mainscablesandcablesoftheweldingmachinemust
becheckedforinsulationintegritybyanelectricalengineeronaregularbasis;
‐whenusingthemachine,neverremoveitsoutercase.
INFORMALSAFETYMEASURES
‐themanualmustbealwaysstoredneartheplacewheretheweldingmachineisused;
‐ inadditionaltothemanual,adheretogeneralandlocalsafetyandenvironmental
rules;
‐allinstructionsontheweldingmachineshallbekeptreadable.
STRAYWELDINGCURRENTS
‐makesurethattheearthcableterminalissecurelyconnectedtotheworkpiece;
‐ifpossible,avoidinstallingtheweldingmachinedirectlyontheconductivecoatingof
floororworktable,useinsulatingpads.
SAFETYMEASURESINNORMALCONDITIONS
Checkthemachineforexternaldamagesandperformanceofsafetydevicesatleat
onceaweek.

- 15 -
PATON ECO-series DC MMA
12. SCHEMATICELECTRICALDIAGRAMOFTHESOURCE
Schematicelectricaldiagram
oftheSourceECO‐160/200/250DCММА

PATON ECO-series DC MMA
- 16 -
13. WARRANTYLIABILITIES
PilotPlantofWeldingEquipmentnamedafterYe.O.Patonguaranteesproper
operationofthesupplysource,providedthattheconsumerobservesoperating,storageand
transportationconditions.
ATTENTION:Freewarrantyservicingisnotprovidediftheweldingmachineis
mechanicallydamaged!
BasicwarrantyperiodforweldinginvertersofEseriesis__years.Basicwarranty
periodiscalculatedfromthedateofsaleoftheinverterequipmenttotheultimatebuyer.
Duringthebasicwarrantyperiod,thevendorisobligedtoprovidetheownerofPATON
TMinverterequipmentwiththefollowingservicesforfree:
‐performdiagnosticsandrevealthecauseoffault;
‐provideunitsandelementsnecessarytoperformtherepair;
‐replacebrokendownelementsandunit;
‐conducttestingoftherepairedequipment.
Basicwarrantyliabilitiesdonotapplytoequipment:
‐whichhasmechanicaldamagesaffectingoperabilityofthemachine(deformationofthe
frameanddetailsduetofallfromheightordropofheavyobjectsontheequipment,
buttonsandslotsfallingout);
‐withevidenceofcorrosionwhichcauseditsnon‐operability;
‐brokendownduetoexcessmoistureaffectingitspowerandelectronicelements;
‐brokendownduetoaccumulationofconductivedust(coaldust,metalchips,etc.)insideof
themachine;
‐iftheuserattemptedtorepairtheunitsofthemachineand/orreplaceitselectronic
elementsathisowndiscretion;
‐dependingonoperatingconditions,itisrecommendedtocleaninternalelementsandunits
ofthisequipmentwithcompressedaironcepersixmonths,inordertopreventbreak‐down
ofthemachine.Beforecleaningthemachine,removetheprotectivecover.Cleaningshall
beperformedcarefully,withcompressorhoseheldfarenoughfromthemachinesoasnot
todamagethesolderingofelectronicelementsandmechanicalparts.
Inaddition,basicwarrantyliabilitiesdonotapplytobrokendownexternalelementsof
theequipment,whicharesubjecttophysicalcontact,andassociated/consumablematerials
whichcanbeclaimedtwoweeksafterthesaledateatthelatest:
‐ONandOFFbutton,
‐weldingparametersadjustingknobs,
‐slotsforconnectionofcablesandhoses,
‐controlslots,
‐mainscableandmainscableplug,
‐carryinghandle,shoulderstrap,case,box,
‐electrodeholder,earthterminal,weldingcablesandhoses.
Thevendorretainstherighttorefusetoperformwarrantyrepair,ortosetthewarranty
liabilitiesstartdaytomonthandyearoftheequipmentmanufacture(theycanbedetermined
fromtheserialnumber):
‐iftheownerhaslostthedatasheet;
‐ifthevendordidnotfillinthedatasheetorfilleditincorrectlywhensellingtheequipment,

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PATON ECO-series DC MMA
‐warrantyperiodisextendedbytheperiodofwarrantyservicingoftheequipmentatthe
servicefacility.
14. ACCEPTANCECERTIFICATE
ArcinverterrectifierPATONECO‐_______Е
Serialnumber__________________ЕcomplieswithGOST13821‐77
andhasbeenapprovedforoperation.
Dateofsale”_______”_____________20____
Stamphere ________________________
(vendorsignature)

PATON ECO-series DC MMA
- 18 -
Dateofreceiptforrepair”_____”_________________20____
__________________
(signature)
Symptomsofnon‐operability:
____________________________________________________________________
Cause:______________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
================================================================
Dateofreceiptforrepair”_____”_________________20____
__________________
(signature)
Symptomsofnon‐operability:
____________________________________________________________________
Cause:______________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________
____________________________________________________________________