Paton PRO-160 Instruction Manual
CONTENTS
1.Generalprovisions
2
2.Start‐up 5
2.1Intendeduse
5
2.2Installationrequirements 6
2.3Powerconnection
6
2.4
Mainsplugconnection
7
3.Manualmetalarcwelding(MMAwelding)
7
3.1Weldingcycle
–
MMA
8
3.2HotStartfunction
8
3.3ArcForcefunction
9
3.4Anti‐Stickfunction
10
3.5Functionofslopeadjustmentforacurrent‐voltagecurve
10
3.6Shortarc
weldingfunction
10
3.7Functionofanopen‐circuitvoltagereductionunit
10
3.8Pulsedcurrentweldingfunction
11
4.Tungstenarcinertgas
welding(TIG)
12
4.1.Weldingcycle
–
TIG‐LIFT
13
4.2TIG‐LIFTarcstrikingfunction
13
4.3Arccurrent
fade‐infunction
13
4.4Pulsedcurrentweldingfunction
14
5.Semiautomaticmetalinert/activegaswelding(MIG/MAG)
15
5.1Weldingcycle
–
MIG/MAG
17
5.2Functionofvoltagefade‐outintheendofwelding
17
5.3Pulsedvoltageweldingfunction
18
6.
Machinesetting
19
6.1Switchingtotherequiredfunction
19
6.2Switchingtotherequiredweldingmode
20
6.3Resetofallfunctionssettingsforthecurrentweldingmode
20
7.Generallistandsequenceoffunctions
20
8.Generatoroperationmode
22
9.Attendanceandtechnicalmaintenance
22
10.Storagerules
22
11.Transportation
23
12.Technicalspecifications
23
13.Deliveryset
23
14.Warrantyliabilities
24
15.Safetyrules
24
16.Acceptancecertificate
28
‐1‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
Connectiontopowermains/powerboard(at25°С):
ATTENTION:makeprovisionforcablesroutedinthewallsandotherextensioncords
Electrodeusedin
MMAmode
Setcurrentvalue
inMMAandTIG
modes
Wirecross‐section
diameterfor
MIG/MAGwelding
Powercablecross‐
section,sq.mm
Max.cable
length,m
PRO‐160
Ф2mm80AatmostФ0.6mmatmost
1
75
1.5
115
2
155
2.5
195
4
310
6
465
Ф3mm120AatmostФ0.8mmatmost
1.5
75
2
105
2.5
130
4
205
6
310
Ф4mm160AatmostФ1.0mmatmost
2
75
2.5
95
4
155
6
230
PRO‐200
Ф3mm120AatmostФ0.8mmatmost
1.5
75
2
105
2.5
130
4
205
6
310
Ф4mm160Aatmost
Ф1.0mmatmost
2
75
2.5
95
4
155
6
230
Ф5mm200Aatmost
2.5
75
4
125
6
185
PRO‐250
Ф3mm120AatmostФ0.8mmatmost
1.5
75
2
105
2.5
130
4
205
6
310
Ф4mm160AatmostФ1.0mmatmost
2
75
2.5
95
4
155
6
230
Ф5mm
Ф6mm,low‐
melting
250AatmostФ1.2mmatmost
2.5
60
4
100
6
150
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐2‐
1. GENERALPROVISIONS
Digital inverter rectifiers PATON PRO‐160/200/250/250-400V are designed for manual metal arc
welding (MMA), tungsten arc inert gas welding (TIG) and semiautomatic metal inert/active gas welding
(MIG/MAG)intheatmosphereofshieldinggasormixture(asasourcewithanexternalfeedingmachine)
using direct current Advantageous completely digital control implemented in thedesign of themachine
providesfreedomfromlimitationstypicalformulti‐functionalsystemsbasedonanalogouscontrolsystem,
which are always inherently geared towards a specific mode, while othermodes are additional and have
drawbacks in terms of control. On the contrary, control board of a completely digital system offers all
capabilitiesofthesourcewithintherangeofitsfullpower,regardlessofthemodeofuse.ThisProfessional
series is designed for industrial use. Due to additional adjustments, the inverter rectifier can be set to
optimumsettingsinvariousapplications.Theyprovidevirtuallyuninterruptibleloaddurationatfullfairrated
currentof160A,200Aand250Arespectively,whichissufficientforworkwithanyelectrodesfromФ1.6mm
in diameter up to low‐melting Ф6mm electrodes (for PRO‐250), as well as for semiautomatic solid
wire weldingfeaturingwirefromФ0.6mmtoФ1.2mmindiameter(forPRO‐250).Initially,thesourceisset
tosettings,whichareoptimumformostapplications,andisquiteeasytouseifyoudonotgointodetailsof
settings, which require good welder's skills. For safety in dangerous working conditions, the rectifier is
equipped with an in‐builtunit for open‐circuit voltage reduction inMMAmode, which can beenabled or
disabled.
This PRO m odelbyPATONisequippedwithaunitforundervoltage,aswellasshort-timeovervoltage,
protection.
Duetoincreasedfrequencyofvoltagesuppliedtothetransformer,thetransformercanbemadeseveral
tenfoldssmaller.Thatiswhyweightandoveralldimensionsofthismachineisseveraltimessmallerthan
thoseofregularequipmentwithidenticaloutputparameters.
Mainadvantages:
1. Widerangeofweldingparametersadjustment:
a)inMMAmode–1(main)+7(additional)+3(forpulsedweldingmode)
b)inTIGmode–1(main)+1(additional)+3(forpulsedweldingmode)
c)insemiautomaticMIG/MAGmode–1(main)+1(additional)+3(forpulsedweldingmode)
2. Themachinehasaverywiderangeofpulsedweldingmodesettingsforalltypesofwelding.
3. Inadditiontovoltagesurgeprotection,themachineisequippedwithastabilizationsystemforlarge
long‐termvoltagevariationsinthe160Vto260Vsupplymains.However,itmustbekeptinmindthat
minimumvoltageof160VallowsforweldingwithanelectrodenotmorethanФ3mmindiameteror
semiautomaticweldingwithwireuptoФ0.8indiameter.
4.Themachinefitsstandarddomesticpowermains.Duetohighefficiencyfactor,thesourceprovidestwice
lowerpowerconsumptioncomparedtoregularsources.
5. Adaptivefanspeed–i.e.increaseswhenthemachineheatsup,increasesevenmoreduringthemachine
heat‐up,andslowsdownwhenitiscold,thusprolongingservicelifeofthefanandreducingamountof
dustaccumulatedinthemachine.
6. Convenientuseduetohighloadduration(LD)atratedcurrent,whichenablesvirtuallyuninterruptible
weldingwitheФ4mmelectrodes(forPRO‐160),Ф5mmelectrodes(forPRO‐200)andlow‐meltingФ6
mmelectrodes(forPRO‐250).Forexample,electrodesАNО‐4,АNО‐21,АNО‐36,МR‐3canbeused.
7. Increasedmachinereliabilityindustyproductionenvironment,microelectroniccircuitryofthesourceis
locatedinaseparatecompartment.
8.Allheatingelementsofthesourceareprovidedwithanelectronicheatprotectionsystem.
9. Allelectronicpartsofthemachineareimpregnatedwithtwolayersofhigh‐qualityvarnish,whichensures
productreliabilityduringtheentireservicelife.
10.Enhancedarcingstability.
‐3‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
PARAMETERSPRO‐160 PRO‐200PRO‐250 PRO‐250‐400V
Ratedvoltageofmains50/60Hz,V2202202203х400+N
Ratedcurrentconsumptionfrommains,A18…2125…2832…3611…12
Ratedarccurrent,A160200250250
Maximumroot‐mean‐squarecurrent,A215270335335
Loadduration(LD) 70%at160A
100%at134A
70%at200A
100%at167A
70%at250А
100%at208A
70%at250А
100%at208A
Mainsvoltagevariationrange,V160~260160~260160~260±20%
Arccurrentadjustmentrange,A8~16010~20012~25012~250
Arcvoltageadjustmentrange,A12~2812~2812~2812~28
Stickelectrodediameter,mm1.6~4.01.6~5.01.6~6.01.6~6.0
Solidfillerwirediameter,mm0.6~1.00.6~1.00.6~1.20.6~1.2
Pulsedweldingmodes
MMA:0,2...500Hz
TIG:0,2...500Hz
MIG/MAG:5...500Hz
MMA:0,2...500Hz
TIG:0,2...500Hz
MIG/MAG:5...500Hz
MMA:0,2...500Hz
TIG:0,2...500Hz
MIG/MAG:5...500Hz
MMA:0,2...500Hz
TIG:0,2...500Hz
MIG/MAG:5...500Hz
HotStartinMMAmodeadjustableadjustableadjustableadjustable
ArcForceinMMAmodeadjustableadjustableadjustableadjustable
Anti‐StickfunctioninMMAmodeautomaticautomaticautomaticautomatic
Open‐circuitvoltagereductionunit on/offon/offon/offon/off
MMAopen‐circuitvoltage,V12/7512/7512/7512/75
Arcstrikingvoltage,V110110110110
Ratedpowerconsumption,kW4.0…4.65.5…6.16.9…7.96.9…7.9
Maximumpowerconsumption,kW6.28.011.011.0
Efficiencyfactor,%92929292
Coolingforcedforcedforcedforced
Operatingtemperaturerange–25…+45ºС –25…+45ºС –25…+45ºС –25…+45ºС
Overalldimensions,mm(length,width,height)330х110х250330х110х250330х110х250330х110х250
Weightexcludingaccessories,kg5.45.65.75.8
Ingressprotectionclass*IP33IP33IP33IP33
*ForProfessionalseriesmachines,theirframeprotectsthemfromingressofobjectsmorethan2.5mmin
diameter,aswellprovidesrainprotection,sothatwaterstreamingverticallyoratanangleof60ºtothe
verticaldoesnotinfringethemachineoperation
Recommendedlengthofpowerweldingcablesduringwelding:
Cablelength
(oneway)
Maximum
current
Cross‐section
areaCablegrade
4…8m160Aatmost16mm2КГ1х16
5…10m200Aatmost25mm2КГ1х25
6…12m250Aatmost35mm2КГ1х35
ATTENTION:Supplybuttonontherearpanelofthemachineisnotapowerbutton,
soitdoesnotprovidecompletede‐energizationofinternalelectronicparts,whenthe
machineisswitchedoff.Therefore,inaccordancewithsafetyrules,disconnectthe
plugfromthemainsaftercompletionofwelding.
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐4‐
1–LCDdisplay.
2–Buttonsforincrementationanddecrementationoftheselectedparameter.
3–Buttonforselectingsourcefunctioninthecurrentweldingmode.
4–Weldingmodeselectionbutton:
a) manualmetalarcweldingwithastickelectrode(MMA);
b) tungstenarcinertgaswelding(TIG);
c) semiautomaticmetalinert/activegaswelding(MIG/MAG).
5–Machine operation indicator:
a) permanent green light – if there is open-circuit voltage, usually in MMA
mode;
b)permanent yellow light – in the operator wait mode during tungsten
arc inert gas welding and semiautomatic welding, as well as in case of
source overheating in any mode;
‐5‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
c) flashinggreenandyellowlight–duringweldinginanymode;
d) permanentredlight–incaseofmalfunctions;
e) nolight–incaseofmalfunctionsormainsvoltagedropbelowthe
normalvalue.
6–Slotforsourceonandoffsignalsfromthewire‐feedingmachine.
7–On/offsignalbuttonofthemachine(shapeandcolourareselectedfordesign
reasons).
А–Powercurrentsocket"+"ofbayonettype:
a) incaseofMMAwelding–forconnectionofelectrodecable(occasionally,
"earth"cablecanbeconnected,ifspecialelectrodesareused);
b) incaseofTIGwelding–only"earth"cableisconnected;
c) incaseofsemiautomaticMIG/MAGweldingwithsolidwire–cableofthe
feedermachineisconnected;
c) incaseofsemiautomaticMIG/MAGweldingwithfluxwire–"earth"cable
isconnected.
B–Powercurrentsocket"‐"ofbayonettype:
a) incaseofMMAwelding–forconnectionof"earth"cable(occasionally,
electrodecablecanbeconnected,ifspecialelectrodesareused);
b) incaseofTIGwelding–onlyargontorchisconnected;
c) incaseofsemiautomaticMIG/MAGweldingwithsolidwire–"earth"cable
isconnected.
c) incaseofsemiautomaticMIG/MAGweldingwithfluxwire–cableofthe
feedermachineisconnected.
2. START‐UP
ATTENTION:Beforestart‐up,readthechapter"Safetyrules",paragraph15.
2.1INTENDEDUSE
Theweldingmachineisdesignedsolelyformanualmetalarcweldingwitha
stickelectrode,tungstenarcinertgaswelding,aswellassemiautomaticmetal
inert/activegaswelding.
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐6‐
Otheruseofthemachineisconsideredundue.Themanufacturerisnot
responsiblefordamagecausebyundueuseofthemachine.
Intendeduseofthemachineimpliesadherencetoinstructionsofthisoperating
manual.
ATTENTION:Donotusetheweldingmachineforpipesdefrosting.
2.2INSTALLATION REQUIREMENTS
Theweldingmachineisprotectedfromingressofforeignsolidobjectsofmore
than2.5mmindiameter.
Theweldingmachinecanbeplacedandoperatedoutdoors.Internalelectric
partsofthemachineareprotectedagainstdirectmoistureimpact,butnotagainst
condensatedrops.
ATTENTION:Donotswitchthemachineoffimmediatelyaftercompletionof
weldingworksinhotweatherorintenseweldingworksinanyweatherconditions!
Electronicpartsmustbeallowedtocooldownfor5minutes.
ATTENTION:Whenthemachineisswitchedoffandcoolsdownafter
operationincoldseason,condensateformsinsideofit,sodonotswitchthe
machineonagaininlessthan3...4hours!!!
Therefore,donotswitchthemachineoffincoldseason,ifyouaregoingto
switchitonwithin4hours.
Themachinemustbeplacedtoensurefreeinletandoutletofcoolingair
throughventholesonthefrontandtherearpanels.Takecarethatmetaldust(for
example,duringemerygrinding)doesdrawndirectlyintothemachinebythe
coolingfan.
ATTENTION:Themachinemaybelife‐threateningafterahardfall.Soplace
itonstablesolidsurface.
2.3POWERCONNECTION
Theweldingmachineofseriesdesignisratedformainsvoltageof220V(‐27%
+18%)orthree‐phasemainsvoltageof3х400V(±20%).
ATTENTION:Allmanufacturer'swarrantyliabilitiesbecomevoidifthe
machineisconnectedtomainsvoltageexceeding270V!Suchasituationmay
occurduetolargeimbalanceofline‐to‐linevoltageinstandardmainsordueto
useofnon‐standardconnection.
Inaddition,manufacturer'swarrantyliabilitiesbecomevoidifmainslinehas
beenconnectedbymistaketotheneutralwireortothesourceearthingwire
duringconnectionofathree‐phasemachine.
Mainsconnector,cross‐sectionsofpowersupplycablesandsupply‐linefuses
mustbeselectedonthebasisoftechnicalspecificationsofthemachine.
‐7‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
2.4MAINSPLUGCONNECTION
Mainsplugshallcorrespondtosupplyvoltageandcurrentconsumptionofthe
weldingmachine(seetechnicaldata).Inaccordancewithsafetypractices,use
receptacleswithguaranteedearthingandneverusetheneutralwireforthis
purpose!!!
ATTENTION:Mainsswitch9isasignalbutton,whichonlyisolatespower
currentoftheweldingmachine,butdoesnotprovidecompletede‐energizationof
internalelectronicpartsofthemachine.Therefore,inaccordancewithsafetyrules,
remembertoremovetheplugfromthesocketwhenreconnectingthemachine.
3. MANUALMETALARCWELDING(MMAWELDING)
Procedureformachinepreparationtooperation:
‐inserttheelectrodecableintothesourcesocketА"+";
‐insertthe"earth"cableintothesourcesocketB"–";
‐connectthe"earth"cabletotheworkpiece;
‐connectthemainsplugtothesupplymains;
‐setthepowerswitch9ontherearpaneltoposition"I";
‐settheMMAweldingmodebypressingthebutton7–themodesswitchover
end‐around;
‐usebuttons3tosetthemainparameter,whichisarccurrent;
‐ifnecessary,additionalfunctionsofweldingprocesscanbeadjusted–see
changeoversequenceinparagraph6.1.
ATTENTION:Oncethepowerswitchissettoposition"I"intheMMAweldingmode,
thestickelectrodebecomesenergized.Donottouchconductiveorearthedobjects,
suchas,forexample,weldingmachineframeetc.,withtheelectrode,sincethe
machinewilltakethisasasignaltostarttheweldingprocess.
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐8‐
3.1WELDINGCYCLE–MMA
Seeparagraph6.1forsequenceofchangingthevalueofanyfunction
3.2HOTSTARTFUNCTION
Advantages:
‐improvedstrikingevenwhenusingelectrodeswithbadstrikingproperties;
‐betterpenetrationofbasematerialduringstrikingand,consequently,lesspoor
penetrations;
‐preventionofslaginclusions;
‐ manualadjustment;allowssettingthefunctionleveltominimumvalue,thus
significantlyreducingpowerconsumptionintheinitialmomentofstriking.This
allowsstartingthesourceatvaluesofmainsvoltagearoundthepossibleminimum
value,butcompromisesthequalityofthestrikingmoment(themachinebecomes
similartoatransformersource,butinsomecasesthisistheonlypossible
method).Thefunctioncanalsobeincreasedtomaximumvalueforevenbetter
qualityofthestrikingmoment(ifthemachineisoperatedfromgoodpower
mains).However,keepinmindthatboostedcurrentofthisfunctioncanburn
throughtheworkpiecewhenweldingthinmetalpieces,soitisrecommendedto
reducetheHotStartvalueinsuchacase.
Theresultisachievedbythefollowingmeans:
Inthemomentofarcstriking,arccurrentincreasesbythedefaultvalueof+40%
forashorttime.
Example:weldingwithaФ3mmelectrode,setbasevalueofarccurrentis90A.
Result:hotstartcurrentis90A+40%=126A.
Intheadditionalsettings,youcanchangebothHotStartmagnitude[H.St]and
HotStarttime[t.HS].DonotsetHotStartmagnitudeandtimetounnecessarilyhigh
values,sincelargelimitvaluesrequiredforverystrongpowersupplymains,andif
goodmainsisnotavailable,strikingprocesscanevenabort.Seeparagraph6.1for
sequenceofchangingthevalueofanyfunctioninthecurrentweldingmode.
t
,
s
‐9‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
3.3ARCFORCEFUNCTION
Advantages:
‐enhancedshort‐arcweldingstability;
‐bettertransferofmetaldropsintotheweldpool;
‐betterarcstriking;
‐reducedriskofelectrodesticking;however,itisnottheAnti‐Stickfunction,which
willbeexplainedinthenextparagraph;
‐ manualadjustment;allowssettingthefunctionleveltominimumvalue,thus
reducingpowerconsumption(althoughinsignificantly),aswellasheatinput
concentrationwhenweldingthinmetalpieces.Thisreducestheriskofburn‐
through,butalsoreducesstabilityofshortarcburning(themachinebecomes
similartoatransformersource).Thefunctioncanalsobeincreasedtomaximum
valueforevenbetterstabilityofshort‐arcburning,butthisrequiresforbetter
supplymainsandincreasestheriskofworkpieceburn‐through.
Theresultisachievedbythefollowingmeans:
Duetoreductionofarcvoltagebelowtheminimumpermissiblevoltageofstable
arcburning,arccurrentincreasesbythedefaultvalueof+40%.
IntheadditionalsettingsyoucanchangebothArcForcemagnitude[Ar.F]and
triggerlevelofthisfunction[u.AF].DonotsetArcForcemagnitudeandtriggerlevel
tounnecessarilyhighvalue,becauseathighlimitvalues,especiallyduringwelding
withthinelectrodeslessthanФ3.2mmindiameter,affectsactuationofAnti‐Stick
function,whichwillbeexplainedinthenextparagraph.
Seeparagraph6.1forsequenceofchangingthevalueofanyfunctioninthecurrent
weldingmode.
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐10‐
3.4ANTI‐STICKFUNCTION
Duringinitialarcstriking,theelectrodecanstickorbetackedtotheworkpiece.
Manyfunctionsofthemachineresistthisoccurrence,butitispossiblenevertheless,
firstleadingtooverheatingandeventuallytodamageoftheelectrode.
Insuchacase,thismachineactuatesthebuilt‐inAnti‐Stickfunction,whichis
constantlyoperatingintheMMAmode.Within0.6...0.8safterdetectionofthis
condition,thisfunctionreducesarccurrent.Inaddition,thisfunctionhelpsthe
weldingoperatortoseparate(detach)theelectrodefromtheworkpiecewithout
risktoburnhiseyeswithaccidentalarcstriking.Oncetheelectrodeisseparated
fromtheworkpiece,theprocessofweldingcanbereadilyresumed.
3.5FUNCTIONOFSLOPEADJUSTMENTFORACURRENT‐VOLTAGECURVE
Thisfunctionisprimarilydesignedforconvenientweldingusingelectrodeswith
differenttypesofcoating.Bydefault,current‐voltagecurveslope[CVS]issetto
1.4V/A,whichcorrespondstothemostcommonlyusedelectrodeswithrutile
coating(АНО‐21,МР‐3).Formoreconvenientworkwithbasic‐coatedelectrodes
(УОНИ‐13/45,ЛКЗ‐70),itisrecommended,althoughnotrequired,tosettheslope
[CVS]to1.0V/A.Ontheotherhand,celluloseelectrodes(ЦЦ‐1,ВСЦ‐4А)even
requireforsettingtheslope[CVS]to0.2...0.6V/A,andsometimesitisalsonecessary
torisetriggerleveloftheArcForceFunction[u.AF]upto18V.Seeparagraph6.1for
sequenceofchangingthevalueofanyfunctioninthecurrentweldingmode.
3.6SHORTARCWELDINGFUNCTION
Thisfunctionisespeciallyimportantforoverheadwelding,whenverylongarcis
undesirable.Forthispurpose,themachineprovidesthepossibilitytosettheShort
Arcfunction[Sh.A]to"On"position.Bydefault,itissetto"OFF"position.See
paragraph6.1forsequenceofchangingthevalueofanyfunctioninthecurrent
weldingmode.
3.7FUNCTIONOFANOPEN‐CIRCUITVOLTAGEREDUCTIONUNIT
Whenperformingweldingworksinvessels,tanksandapplicationsrequiringfor
enhancedelectricsafetysystem,onecanenablethefunctionofopen‐circuitvoltage
reduction.
In0.1saftertheelectrodeisdetachedfromtheworkpiece,voltageonthe
sourceterminalsdropstosafelevelbelow12V.
Toenablethisfunction,anopen‐circuitvoltagereductionunit[BSn]isrequired.
Thisunitisenvisagedinthisequipmentmodel,butissetto"OFF"positionby
default,i.e.disabled,sinceitisknown,thatenablingofanyfunctionofthiskind
‐11‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
resultsinsomewhatworsearcstriking.Seeparagraph6.1forsequenceofchanging
thevalueofanyfunctioninthecurrentweldingmode.
3.8PULSEDCURRENTWELDINGFUNCTION
Thisfunctionisdesignedtofacilitatecontroloverweldingprocessinspatial
positionsotherthandownhandposition,aswellasduringweldingofnon‐ferrous
metals.Thisfunctionaffectsdirectlyweldmetaldilutionandmetaldroptransfer
intotheweldpooland,consequently,onstabilityofweldformingandofthewelding
process.Inotherwords,thisprocesssubstitutesmovementsofwelder'shandto
someextent,whichisespeciallyimportantinhard‐to‐reachplaces.Correctsetting
determinesweldshapeandqualityofweldforming,thusreducingriskofporosity
andgrainstructureoftheweldandconsequentlyincreasingweldstrength.
Inordertoimplementthisfunctions,threeparametersmustbesetinthe
machine:pulsingpower[Po.P],pulsingfrequency[Fr.P]andmark‐to‐spaceratio(or
dutyratio)[dut].Bydefault,pulsingpower[Po.P],whichisthekeyparameter,isset
to"OFF"position,i.e.disabled,whilepulsingfrequency[Fr.P]anddutyratio[dut]
aresettomostcommonvaluesof5.0Hzand50%respectively.Inordertoenable
thisfunction,itisenoughtosetpulsingpower[Po.P]toavalueabovezero.This
parameterissetinpercentofcurrentsetvalueofbasearcwelding.
Example:weldingwithaФ3mmelectrode,setbasevalueofarccurrentis60A,
andpulsingpower[Po.P]=40%,whilepulsingfrequency[Fr.P]=5.0Hzandduty
ratio[dut]=50%bydefault.
Result:currentwillpulseintherangefrom36Ato84Awithfrequencyof5Hz,
pulseswillbeofthesameshapeintermsofbothmagnitudeandtime.Thedutyratio
parameterissetto50%bydefault.Ifthisparameterischangedtoavalueotherthan
50%,currentpulsetimeandcurrentpausetimebecomeasymmetric:
bydefault
dutyratio[dut]=50%dutyratio[dut]=20%dutyratio[dut]=70%
Inthiscase,themachinewillcalculatethemodeinsuchaway,thataverage
currentleveloftheweldingprocesswillbeatthelevelofthesetbasearccurrentof
60A(asitwasset).Accordingly,heatinputintotheweldwillremainatthelevelof
60A,butstabilityoftheweldingprocessanddilutionintheweldingpoolwill
change.Thisisaveryimportantconditionfortheuserwhenhe/sheneedsto
estimatetheexactchangeofheatinputintotheweldpool,forexample,when
he/shecomparesthiscurrentwithanotherbasecurrentwithoutthepulsedwelding
mode.
t,s
t,s
t,s
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐12‐
Theseparametersaresetdifferentlyindifferentsituationsinaccordancewith
weldingoperator'srequirements.Seeparagraph6.1forsequenceofchangingthe
valueofanyfunctioninthecurrentweldingmode
4. TUNGSTENARCINERTGASWELDING(TIG)
ATTENTION:Shieldinggasismostoftenpureargon"Ar",sometimeshelium"He",
aswellastheirmixtureswithdifferentratios.
Example:argon+helium"40%Ar+60%Не".
EXCLUDEusageofcombustiblegases!Othergasescanonlybeusedupon
approvaloftheequipmentmanufacturer.
Procedureformachinepreparationtooperation:
‐insertthetorchcableintothesourcesocketB"‐";
‐insertthe"earth"cableintothesourcesocketA"+";
‐connectthe"earth"cabletotheworkpiece;
‐installpressurereduceronthegasbottle;
‐connectgashoseofthetorchtopressurereducerofthegasbottle;
‐openthecockofthegasbottleandcheckitfortightness;
‐connectthemainsplugtothesupplymains;
‐setpowerswitch9ontherearpaneltoposition"I";
‐settheMMAweldingmodebypressingthebutton7–themodesswitchover
end‐around;
‐usebuttons3tosetthemainparameter,whichisarccurrent;
‐ifnecessary,additionalfunctionsofweldingprocesscanbeadjusted–see
changeoversequenceinparagraph6.1.
ATTENTION:Argontorchshallbeavalvetorch,withabayonetconnectorofФ9
mm (PRO‐160) or Ф13 mm (PRO‐200/250). Select maximum torch current
dependingonyouroperatingrequirements.
ATTENTION:Acommonmistakeis"needle‐like"electrodesharpening;inthiscase,
arcmaywagfromsidetoside.Acorrectlysharpenedelectrodehasslightlyblunted
‐13‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
neg,andthesmalleristhe"butt"withstandingsetcurrent,thebetter.Remember
thataverysharp‐pointedelectrodeflashesoffveryeasilyathigharccurrentsdueto
lowheatemission.Inaddition,sharpeningnotchesshallbelocatedalongthe
electrodeaxis.
4.1.WELDINGCYCLE–TIG‐LIFT
Seeparagraph6.1forsequenceofchangingthevalueofanyfunction
4.2TIG‐LIFTARCSTRIKINGFUNCTION
Thisfunctionisinstalledbydefaultinthismodelofequipmentandisdesigned
fortorcheswithcontactarcstriking,withoutuseofhigh‐frequencyinjectionunits
andothersimilarunits.However,unliketheconventionalmethod,itcompletely
eliminatessurgecurrentinthemomentofstriking,thusreducingseveral‐fold
destructionofthenon‐consumabletungstenelectrodesandingressofitsinclusions
intotheweld,whichisveryadverseeffect.
ATTENTION:Theworkpiecemustbecleanedintheplaceofarcstriking.
Thisfunctionisimplementedbytouchingtheworkpiecewiththeelement.The
usercankeeptheelectrodeinthispositionforanunlimitedtime,andwhenhe/she
decidesthathe/sheisreadytoproceedwithwelding(forexample:he/shehas
coveredtheeyeswithaheadshieldandsufficientlypurgedtheplaceofweldingwith
shieldinggas),itisenoughtostartSLOWLYliftingthetipofthesharpened
electrodefromtheworkpiece.Themachinewilldetectthismomentandtakeitas
asignaltostarttheweldingprocess.Thus,itwillstartFADINGarccurrentuptothe
setvalue.Thehigherisbaseoperatingcurrent,thefastertheelectrodeshallbe
lifted,otherwiseitwillflashoff.Youshallgetusedtotheoptimumelectrode
detachmentspeed.Timeofcurrentfade‐in[t.uP]uptothesetvaluewillbereviewed
inthenextparagraph.
4.3ARCCURRENTFADE‐INFUNCTION
Exceptforsavingoperatinglifeoftheelectrodeand,tosomeextent,ofthe
torchitself,thisfunctionisalsorequiresforconvenientuseofthetorch.Iteliminates
initialsplashingofweldpool.Inaddition,onecanguidethetorchexactlytothe
ts
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐14‐
requiredweldingplaceduringthesettimeofcurrentfade‐in[t.uP],sincetheplace
ofarcstrikingoncritical‐dutyworkpiecesisnotalwayscoincidentwiththeplaceof
welding.Placeofweldingcanalsobepreliminarilyheated.Bydefault,thetimeisset
to1.0s.Seeparagraph6.1forsequenceofchangingthevalueofanyfunctioninthe
currentweldingmode
4.4PULSEDCURRENTWELDINGFUNCTION
Thisfunctionisdesignedtofacilitatecontroloverweldingprocessinspatial
positionsotherthandownhandposition,aswellasduringweldingofnon‐ferrous
metals.Thisfunctionaffectsdirectlyweldmetaldilutionand,consequently,onstability
ofweldforming.Itsubstitutesmovementsofwelder'shandtosomeextent,whichis
especiallyimportantinhard‐to‐reachplaces.Italsosomewhatforcesdroptransferfrom
thefillerwireintotheweldpool.Correctsettingdeterminesweldshapeandqualityof
weldforming,thusreducingriskofporosityandgrainstructureoftheweldand
consequentlyincreasingweldstrength.
Inordertoimplementthisfunctions,threeparametersmustbesetinthemachine:
pulsingpower[Po.P],pulsingfrequency[Fr.P]andmark‐to‐spaceratio(ordutyratio)
[dut].Bydefault,pulsingpower[Po.P],whichisthekeyparameter,issetto"OFF"
position,i.e.disabled,whilepulsingfrequency[Fr.P]anddutyratio[dut]aresettomost
commonvaluesof10.0Hzand50%respectively.Inordertoenablethisfunction,itis
enoughtosetpulsingpower[Po.P]toavalueabovezero.Thisparameterissetin
percentofcurrentsetvalueofbasearcwelding.
Example:weldingwithanon‐consumabletungstenelectrodeof2mmindiameter,
setbasevalueofarccurrentis100A,andpulsingpower[Po.P]=30%,whilepulsing
frequency[Fr.P]=10.0Hzanddutyratio[dut]=50%bydefault.
Result:currentwillpulseintherangefrom70Ato130Awithfrequencyof10Hz,
pulseswillbeofthesameshapeintermsofbothmagnitudeandtime.
Thedutyratioparameterissetto50%bydefault.Ifthisparameterischanged
toavalueotherthan50%,currentpulsetimeandcurrentpausetimebecome
asymmetric:
bydefault
dutyratio[dut]=50%dutyratio[dut]=20%dutyratio[dut]=70%
Inthiscase,themachinewillcalculatethemodeinsuchaway,thataverage
currentleveloftheweldingprocesswillbeatthelevelofthesetbasearccurrentof
100A(asitwasset).Accordingly,heatinputintotheweldwillremainatthelevelof
100A,butstabilityoftheweldingprocessanddilutionintheweldingpoolwill
t,s
t,s
‐15‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
change.Thisisaveryimportantconditionfortheuserwhenhe/sheneedsto
estimatetheexactchangeofheatinputintotheweldpool,forexample,when
he/shecomparesthiscurrentwithanotherbasecurrentwithoutthepulsedwelding
mode.
Theseparametersaresetdifferentlyindifferentsituationsinaccordancewith
weldingoperator'srequirements.Seeparagraph6.1forsequenceofchangingthe
valueofanyfunctioninthecurrentweldingmode.
5. SEMIAUTOMATICMETALINERT/ACTIVEGASWELDING
(MIG/MAG)
Themachinecanserveasasemiautomaticweldingsource.Forthispurpose,it
providestherequiredcurrent‐voltagecurveontheoutputofpowerterminalsincase
ofswitchingtothismode.Anyindependentfeedingunit,whichisoperatedby
specificsupplyvoltageofthein‐builtmotor,canserveastheexternalwire‐feeding
machine.Inordertodothat,itmusthaveitsownsupplysourceorbesuppliedby
thesourcevoltage(thisoptionislessdesirable,becausesuchsystemsrarelyprovide
goodandstablewirefeeding).
ATTENTION:Inthemostgeneralcase,carbondioxide"СО2"isusedasshielding
gasforweldingofiron,andaluminiumisweldedonlyusinginertgases,suchas
argon"Ar"andsometimesexpensivehelium"He".Forstainlessandhigh‐alloy
steels,mixtureswithdifferentratiosareoftenused,suchas"80%Ar+20%CO2".
Othergasescanonlybeuseduponapprovaloftheequipmentmanufacturer.
Procedureforpreparationtoweldingwithsolidwire:
‐insertthe"earth"cableintothesourcesocketB"‐";
‐connectthe"earth"cabletotheworkpiece;
‐connectoneendthepremanufacturedpowerjumperwithcablecross‐sectionofat
least16mm2tothesourcesocketА"+",andtheotherendtopowerterminalof
thewire‐feedingmachine,whichiscase‐specific,sothereisnopointinlistingall
possibleoptions;
‐connectthesemiautomaticweldingtorchtothewire‐feedingmachine;
PATONPRO-seriesDCMMA/TIG/MIG/MAG‐16‐
‐ installpressurereduceronthegasbottlewithshieldinggas"СО2","Ar"or
"Ar+CO2";
‐connectgashosetopressurereducerofthegasbottleandtofittingonthewire‐
feedingmachine;methodofconnectioncanbedifferent;
‐openthecockofthegasbottleandcheckitfortightness;
‐connectmainsplugofthesourcetothesupplymains;
‐ connectsupplyunitofthewire‐feedingmachinetothesupplymains(ifthe
machinehasindependentpowersupply);
‐turnthefeedingmachineonwithitsownswitch;
‐installthecoilwithwireoftherequireddiameter;
‐feedthelooseendofwireintotheweldingtorchviatheinletchannel;
‐setthepowerswitch9ontherearpaneltoposition"I";
‐settheMIG/MAGweldingmodebypressingthebutton7–themodesswitchover
end‐around;
‐usebuttons3tosettherequiredarcvoltage;
‐settherequiredspeedofwirefeedingonthewire‐feedingunit;
‐ ifnecessary,additionalfunctionsofweldingprocesscanbeadjusted–see
changeoversequenceinparagraph6.1.
Controlslot8ontherearpanelprovidescontroloverswitchingthesourceon
andoff.Connectiondiagram:
Contacts1and2aretheonlyusedcontacts,whichareclosedattherequired
time.Whenthesourcemustoperate,closethecontacts,andwhenitmustbe
switchedoff,openthem.
ATTENTION:Connectiondiagramanditsconfigurationinwire‐feedingunitsis
individualforeachparticularcase,soitisnotprovidedinthisoperationmanualfor
thesource.Youcanfinditintheoperationmanualofthefeedingunit.
Thenew‐generationindependentwire‐feedingunitsproducedbyPATONhave
everythingprearranged,sotheycanbeadaptedwithaminimumofeffort.Theonly
thingthattakessometimeissecuringthepluginthesocket8.
Remembertosupplyshieldinggas.Ifyouarenewtoweldinganddonothave
experienceinestablishingoptimumpressureforweldingofaspecificworkpiece,
youcanforthefirsttimesetgaspressureabovetheoptimumvalue~0.2MPa:this
willhaveminoreffectontheprocess,onlyincreaseconsumptionofshieldinggas.
However,followgeneralrecommendationsonsemiautomaticweldinginthefuture
‐17‐PATONPRO-seriesDCMMA/TIG/MIG/MAG
tosavegas.Startalsowithaveragepositionofwirefeedingspeedcontrolleronthe
feedingmachine(~6...8m/min.)andaveragesourcevoltage(~19V)forany
diameterofinstalledwire(Ф0.6...1.2m).Thisconfigurationmaybenotoptimum,
but,underconditionofcorrectwork,evenwirefeeding(withoutjerks)andcorrect
connection,this"source+feedingmachine"combinationshallbeabletoweldso
far.Forbetterresults,adjustsourcevoltagewithbuttons3andspeedofwirefeeding
bythefeedingmachineaccordingtogeneralrecommendationsonsemiautomatic
welding.Rememberthattheseparametersaredifferentforeachspecific
application.
5.1WELDINGCYCLE–MIG/MAG
Seeparagraph6.1forsequenceofchangingparametersoffunctions.Timeof
pre‐purging(t1)andpost‐purging(t2)withshieldinggasissetonthewire‐feeding
machine.
5.2FUNCTIONOFVOLTAGEFADE‐OUTINTHEENDOFWELDING
Thisfunctionisdesignedforsmoothfillingofacrater,whichisformedinthe
weldpoolbytheactionofelectromagneticdraftoftheelectricarcandsubsequently
becomesasourceofwelddefects.Releaseofthetorchbuttonintheendofwelding
becomesthesignaltostartthefunction.Oncethishappens,stopmovingthetorch
andweldthepothole(whichisacrater)intheweldwithfading‐outvoltage.
Smoothnessofthisprocesscanbecontrolledthroughvoltagefade‐outtime[t.dn]
bothinthesourceandinthewirefeedingspeedcontrolunit.Thesevaluesmustbe
t,s
t,s
t,s
PATONPRO-seriesDCMMA/TIG/MIG/MAG
‐18‐
matchingtoensurecorrectoperation.Bydefault,thisvalueissetto0.1s,i.e.
switchedoff.Itcanbechangedatuser'sdiscretion.Seeparagraph6.1forthe
procedureofchanging.
5.3PULSEDVOLTAGEWELDINGFUNCTION
Thisfunctionisdesignedtofacilitatecontroloverweldingprocessinspatial
positionsotherthandownhandposition,aswellasduringweldingofnon‐ferrous
metals.Thisfunctionaffectsdirectlyweldmetaldilution,thereforeitprimarily
affectstheshapeofweld.Italsoforcesdroptransferfromthefillerwireintothe
weldpooland,consequently,affectstheprocessstability.Justasothertypesof
welding,thisprocesssubstitutesmovementsofwelder'shandtosomeextent,
whichisespeciallyimportantinhard‐to‐reachplaces.Inadditiontoweldshape,
correctsettingalsodeterminesqualityofweldforming,thusreducingriskof
porosityandgrainstructureoftheweldandconsequentlyincreasingweldstrength.
Inordertoimplementthisfunctions,threeparametersmustbesetinthe
machine:pulsingpower[Po.P],pulsingfrequency[Fr.P]andmark‐to‐spaceratio(or
dutyratio)[dut].Bydefault,pulsingpower[Po.P],whichisthekeyparameter,isset
to"OFF"position,i.e.disabled,whilepulsingfrequency[Fr.P]anddutyratio[dut]
aresettomostcommonvaluesof20Hzand50%respectively.Inordertoenable
thisfunction,itisenoughtosetpulsingpower[Po.P]toavalueabovezero.This
parameterissetinpercentofvoltagesetvalueofbasearcwelding.
Example:weldingwithwireof0.8mmindiameter,setwirefeedingspeedis5.5
m/min.,setbasevalueofarcvoltageis18V,andpulsingpower[Po.P]=20%,while
pulsingfrequency[Fr.P]=20Hzanddutyratio[dut]=50%bydefault.
Result:currentwillpulseintherangefrom14.4VAto21.6Vwithfrequencyof20
Hz,pulseswillbeofthesameshapeintermsofbothmagnitudeandtime.
Thedutyratioparameterissetto50%bydefault.Ifthisparameterischanged
toavalueotherthan50%,voltagepulsetimeandvoltagepausetimebecome
asymmetric:
bydefault
dutyratio[dut]=50%dutyratio[dut]=20%dutyratio[dut]=70%
Inthiscase,themachinewillcalculatethemodeinsuchaway,thataverage
voltageleveloftheweldingprocesswillbeatthelevelofthesetbasearcvoltageof
18V(asitwasset).Accordingly,heatinputintotheweldwillremainatthelevelof
18V,butstabilityoftheweldingprocessanddilutionintheweldingpoolwillchange.
Thisisaveryimportantconditionfortheuserwhenhe/sheneedstoestimatethe
t,s
t,s
t,s
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