Paton PSI 160 Standard Leitfaden

1 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

TABLE OF CONTENTS

GENERAL INFORMATION .............................................................................................

1.1.

TECHNICAL CHARACTERISTICS .................................................................................

1.2.

CONTROLS AND CONNECTORS ..................................................................................

SETTING THE WELDING UNIT INTO OPERATION ...................................................

2.1

PROPER USE .....................................................................................................................

2.2

REQUIREMENTS FOR INSTALLATION .......................................................................

2.3.

CONNECTION TO A POWER SUPPLY SYSTEM .........................................................

2.4.

REQUIREMENTS FOR AN ELECTRICAL OUTLET ....................................................

MANUAL COVERED-ELECTRODE ARC WELDING PROCESS .........................

3.1

PREPARING THE WELDING UNIT FOR OPERATION ...............................................

3.2

OPERATIONAL CYCLE OF THE MANUAL ARC WELDING PROCESS ..................

3.3

INCREASED-CURRENT ARC STARTING "HOT-START" ..........................................

3.4.

REDUCED-VOLTAGE WELDING MODE "ARC-FORCE" ..........................................

3.5.

PROTECTION AGAINST ELECTRODE STICKING FUNCTION "ANTI-STICK" .....

3.6.

SETTING THE SLOPE OF THE VOLT-AMPERE CHARACTERISTIC OF THE

WELDING UNIT ...............................................................................................................

3.7.

SHORT ARC WELDING MODE ......................................................................................

3.8.

REDUCTION OF OPEN-CIRCUIT VOLTAGE ...............................................................

3.9.

WELDING AT PULSE WELDING CURRENT ...............................................................

ARGON ARC WELDING PROCESS (TIG) .................................................................

4.1

PREPARING THE WELDING UNIT FOR OPERATION ...............................................

4.2.

ARGON ARC WELDING PROCESS WITH TIG FUNCTION .......................................

4.3

TIT-LIFT CONTACT ARC STARTING FUNCTION ......................................................

4.4

LINEAR INCREASE OF WELDING CURRENT ............................................................

4.5

WELDING AT PULSE WELDING CURRENT ...............................................................

SEMIAUTOMATIC ARC WELDING PROCESS (MIG/MAG) ................................

5.1

PREPARING THE WELDING UNIT FOR OPERATION ...............................................

5.2

OPERATIONAL CYCLE OF THE WELDING PROCESS - MIG / MAG ......................

5.2.1

CYCLE WELDING PROCESS - MIG/MAG FUNCTION 2T .........................................

5.2.2

CYCLE WELDING PROCESS - MIG/MAG FUNCTION 4T& 4T_ ...............................

5.3

FUNCTION OF PRETREATMENT GAS CLEANING ...................................................

5.4

FUNCTION OF INCREASES THE WIRE FEED SPEED ...............................................

5.5

FUNCTION OF BURNING OUT AT THE END OF WELDING ....................................

5.6

FUNCTION OF POSTWELD GAS CLEANING ..............................................................

5.7

INDUCTANCE CONTROL FUNCTION ..........................................................................

5.8

WELDING AT PULSE WELDING VOLTAGE ...............................................................

SETTING THE WELDING UNIT .....................................................................................

2 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

6.1

SWITCHING TO THE REQUIRED FUNCTION .............................................................

6.2

SWITCHING TO THE REQUIRED WELDING PROCESS ............................................

6.3

RESETTING ALL FUNCTIONS CURRENT WELDING METHOD .............................

GENERAL LIST OF FUNCTION SEQUENCES .........................................................

7.1

MANUAL ARC WELDING PROCESS (MMA) ..............................................................

7.2

ARGON SHIELDED TUNGSTEN-ARC WELDING PROCESS (TIG) ..........................

7.3

SEMIAUTOMATIC ARC WELDING PROCESS (MIG/MAG) ......................................

7.3.1

WIRE FEEDER FUNCTION WELDING PROCESS (MIG/MAG) .................................

MAINTENANCE ...............................................................................................................

OPERATION WITH AN ELECTRIC GENERATOR ......................................................

10.

STORAGE ..........................................................................................................................

11.

TRANSPORTATION .........................................................................................................

12.

SPECIFICATION DATA ...................................................................................................

13.

DELIVERY SET .................................................................................................................

14.

WARRANTY ......................................................................................................................

15.

WASTE ELECTRICAL & ELECTRONIC EQUIPMENT ...............................................

16.

SAFETY INSTRUCTIONS ................................................................................................

ELECTRICAL SCHEMATIC DIAGRAM ........................................................................

18.

ACCEPTANCE CERTIFICATE ........................................................................................

19.

WARRANTY CARD .........................................................................................................

3 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

EC Declaration of Conformity

The following products have been tested by us with the listed standards and

found in compliance with the European Community Low Voltage Directive

2014/35/EU and Electromagnetic Compatibility Directive 2014/30/EU.

AUTHORISED

REPRESENTATIVE:

MASTERWELD Sp. z o.o., Poland

Przemysłowa 14 st.,

PL35105 Rzeszów

Ust.ID. PL8133751525

MANUFACTURER

ADDRESS

Limited Liability Company “Pilot Plant of Welding

Equipment of Electric Welding Institute named after

E.O. Paton”

Ukraine, 03045, Kyiv, 66 Novopyrohivska St.

PRODUCT:

DIGITAL SEMIAUTOMATIC INVERTER PATON

PSI-160S, PSI-200S, PSI-250S, PSI- 250S-400V

DC MMA/TIG MIG/MAG

The statement is based on a single evaluation of one sample of above mentioned products. It

does not imply an assessment of the whole production. The manufacturer should ensure that all

product in series production are in conformity with the product

sample detailed in this report.

The applicant should hold the whole technical report at

disposal of the competent all the right.

Applied EC Directives:

2014/35/EU (Low Voltage)

2014/30/EU (Electromagnetic Compatibility)

Applied Standards:

EN 60204-1:2006. Safety of machinery - Electrical equipment of

machines –Part 1: General requirements; EN 60974-1:2012 Are

welding equipment –Part 1: Welding power sources; EN 60974-

10:2014 Are welding equipment –Part 10: Electromagnetic

compatibility (EMC) –requirements.

Issued Date: 12 September 2017

Expiry Date: 11 September 2022

General Manager

We, MASTERWELD Sp. z o. o., hereby declare that specified above conforms covering

European Parliament and Council Directives, 2014/35/EC Low Voltage Directive of 26

February 2014 and 2014/30/EU Electromagnetic Compatibility of 26 February 2014.

The CE mark above can be used under the responsibility of manufacturer. After completion of

an EC declaration of conformity and compliance with all relevant EU Directives.

4 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

ATTENTION!When connecting the welding unit to the power distribution

board (at a temperature of 25 ºC), take into account through-the-wall wiring and

the lengths of extension cables.

Electrode

diameter for a

MMA welding

process (mm)

TIG welding

processes (A)

Electrode wire

diameter for a

MIG/MAG

Cross-section

area of the

power cable

Maximum

cable length

(m)

PSI 160 STANDARD

Ф2 mm

Not more than 80

Not more than

Ф0,6 mm

1,0

1,5

115

2,0

160

2,5

195

4,0

310

Ф3 mm

Not more than 120

Not more than

Ф0,8 mm

1,5

2,0

105

2,5

130

4,0

205

6,0

310

Ф4 mm

Up to 160 А

Not more than

Ф1,0 mm

2,0

2,5

4,0

155

6,0

230

PSI 200 STANDARD

Ф3 mm

Not more than 120

Not more than

Ф0,8 mm

1,5

2,0

105

2,5

130

4,0

205

6,0

310

Ф4 mm

Not more than 160

Up to Ф1,0 mm

2,0

2,5

4,0

155

6,0

230

Ф5 mm

Not more than 200

Up to Ф1,0 mm

2,5

4,0

125

6,0

185

PSI 250 STANDARD 230 V

Ф3 mm

Not more than

120 А

Not more than

Ф0,8 mm

1,5

2,0

105

2,5

130

4,0

205

6,0

310

Ф4 mm

Not more than

160 А

Not more than

Ф1,0 mm

2,0

2,5

4,0

155

6,0

230

5 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

Ф5 mm

Ф6 mm topliwa

Up to 250 А

Up to Ф1,2 mm

2,5

4,0

100

6,0

150

PSI 250 STANDARD 400V

Ф3 mm

Not more than

120 А

Not more than

Ф0,8 mm

1,5

150

2,0

210

2,5

260

4,0

410

6,0

620

Ф4 mm

Not more than

160 А

Not more than

Ф1,0 mm

2,0

150

2,5

190

4,0

310

6,0

460

Ф5 mm

Ф6 mm topliwa

Up to 250 А

Up to Ф1,2 mm

2,5

120

4,0

200

6,0

300

1. GENERAL INFORMATION

The digitally controlled invertor-rectifier welding units PATON®PSI-160S / 200S / 250S /

250S-400V are designed for direct-current gas-shielded welding according to such welding processes as a

manual arc welding process (MMA), an argon arc welding process (TIG), and a semiautomatic arc

welding process (MIG/MAG). The digital controller used in these welding units ensures significant

advantages for the welding unit as compared with multifunctional analog controllers, as the analog

controllers are designed for the specific operating modes of controlled equipment and are not optimal in

all operating modes. The digital controller of the MIG welding units allows all the capabilities of the

welding unit, up to its capabilities at full power, to be used in all the operating modes of the unit.

This welding unit is designed for household and semi-industrial use. It provides a good load duration at

full rated current of 200A and 250A, respectively, when powered by a powerful single-phase 220V,

which is enough for any electrodes 1,6 … 6 mm to free-melting electrodes 6 mm (for PSI-250S) and

semi-automatic welding with solid electrode wire 0.6 … 1.2 mm in diameter (for PSI-250S). The power

source is initially set to the optimum values and is simple enough for most applications if you do not go

deeply into setting that require great welder skills. It is possible to replace the polarity for welding flux

electrode wire. For dangerous work environment, there is built unit to reduce the open circuit voltage in

the MMA mode, with the ability to turn it off and on. The distinctive feature of the welding units is the

availability of a high-quality electrode wire feeding unit and a KZ-2-euro style connector, which allows

the operator to replace welding torches at his option.

The welding unit contains a module for protection against excess and low power supply voltage.

Due to the increased frequency of the input voltage of the rectifier transformer of the welding unit, the

weight and overall dimensions of the transformer are significantly reduced as compared with classic

welding units with similar characteristics.

6 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

The basic advantages of the PATON®welding units are the following:

1. The possibility to adjust welding parameters in wide ranges

a) 1 (basic parameter) + 10 (additional parameters) for the manual arc welding process

(MMA);

b) 1 (basic parameter) + 3 (additional parameters) for the argon arc welding process (TIG);

c) 2 (basic parameter) + 8 (additional parameters) for the semiautomatic arc welding

process (MIG/MAG).

2. The availability of the adjustable pulse welding mode for all the welding processes.

3. The welding unit is protected against long-time fluctuations of power supply voltage and ensures

welding arc stabilization when the input voltage of the unit changes in the range of 160 V through

260 V. It should be noted that welding at a minimum voltage of 160 V is allowed only by using an

electrode not more than 3 mm in diameter for the manual arc welding process, or electrode wire

not more than 0.8 mm in diameter for the semiautomatic arc welding process.

4. The welding unit is rated for operation with a standard power supply system. Due to the higher

efficiency coefficient of the unit, the power consumed by the unit is reduced by

50 % as compared with other similar welding units.

5. The rotation frequency of the driving motor of the ventilator of the welding unit can be

automatically varied depending on the temperature inside the unit. This feature allows the service

life of the ventilator to be increased and, additionally, dust content inside the unit to be reduced.

6. The welding unit is easy operated due to the optimal operating load factor in operation at the rated

current. This feature allows welding to be performed continuously using electrodes 4 mm in

diameter (for PSI 200 STANDARD) and electrodes 5 mm in diameter (for PSI 250

STANDARD). For example, using electrodes AHO 21/36 with a current 160 A and 200 A at a

temperature of 25 ºC.

7. The enhanced reliability of the welding unit in operation in dusty environment, electronic block is

placed in separate compartment.

8. The welding unit contains an electronic thermal protection system for protecting all the heat-

generating components of the welding unit.

9. All the printed-circuit boards with electronic elements are impregnated with two layers of high-

quality varnish in order to provide the high reliability of the welding unit within its service life.

10. Improved arc stability.

1.1. TECHNICAL CHARACTERISTICS

PARAMETRY

PSI 160

Standard

PSI 200

Standard

PSI 250

Standard 230 V

Rated power supply voltage, 50Hz, V

230

Rated power supply current, А

19 … 21

25 … 27

32 … 35

Rated welding current, А

160

200

250

Maximum operating current, А

200

250

320

Operating load factor

45 % - 160 A

100 % - 107 А

45 % - 200 A

100 % - 134 A

45 % - 250 A

100 % - 167 A

Power supply voltage range, V

160 –260

Welding current control range, А

8 –160

10 –200

12 –250

7 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

Welding voltage control range, V

12 –24

12 –26

12 –28

Wire feeding speed control range, m/min

2.0 –16

Diameter of electrode, mm

1.6 –4.0

1.6 –5.0

1.6 –6.0

Number of pressure rolls

Diameter of electrode wire, mm

0.6 –1.0

0.6 –1.2

Coil weight, not more than, kg

Welding processes with pulse welding modes

MIG/MAG

MMA; TIG;

MIG/MAG

MMA; TIG;

MIG/MAG MMA;

TIG;

Increased-current arc starting function of the

manual arc welding process

Adjustable

Reduced-voltage welding function of the

manual arc welding process

Adjustable

Protection against electrode sticking

Automatic

Reduction of open-circuit voltage

ON/OFF

Open-circuit voltage in the manual arc

welding process, V

12 / 75

Welding arc starting voltage, V

110

Rated consumed power, kVA

4.2 … 4.6

5.5 … 6.0

6.9 … 7.7

Maximum consumed power, kVA

5.5

7.0

9.3

Efficiency coefficient, %

Cooling

Forced

Operating temperature range

–25 … +45 ºС

Overall dimensions, mm (length width 

height)

415 х 245 х 298

415х245х298

Weight without the coil and accessories, kg

11.0

11.2

11.5

Protection class*

IP21

*These Standard Series welding units are protected against ingress of foreign particles more than 12.5 mm in size and

against rain drops if the rain drops fall at an angle to the vertical surfaces of the welding unit does not impair its operation.

8 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

THE RECOMMENDED LENGTHS OF THE WELDING CABLES ARE INDICATED

BELOW:

Cable length (m)

Maximum current (A)

Cross-section area of

the cable conductor

(mm2)

Cable

designation

4… 12 m

Not more than160 А

16 mm2

KG 1х16

5… 15 m

Not more than 200 А

25 mm2

KG 1х25

6…18 m

Up to250 А

35 mm2

KG 1х35

1.2. CONTROLS AND CONNECTORS

9 | Pa ge PATON®PSI STANDARD SERIES DC MIG/MAG TIG/MMA

1. The buttons for setting the welding current and parameters of the welding function (by default: in

MMA mode - welding current, in TIG mode - welding current, in MIG/MAG mode - welding

voltage);

2. Digital display showing the current value and welding functions;

3. Button for adjusting the function of the selected welding method

4. Button for selecting welding method:

a) Manual covered-electrode arc welding (MMA);

b) Argon arc welding with a no consumable electrode (TIG);

c) Gas-shielded semiautomatic arc welding (MIG/MAG);

5. Indicator of the operating condition of the welding unit, do not light normally (blinks when

machine is overheating)

6. Button "WIRE INSTALLATION" (When the button is pressed, gas feed is switched off);

7. Button for adjusting the wire feed speed and parameters of the feeder function

8. Digital display showing the wire feed speed and feeder functions,

9. The buttons on the MIG/MAG handle (2T/4T mode);

10. Button “GAS TEST” When the button is pressed, only the gas supply valve is switched on

11. Button for adjusting the function of wire feeder.

12. Euro connector socked for connecting the MIG/MAG holder

13. Polarization change cable

14. Push-button switch for switching on and off the welding unit

15. Fuse

16. Socket for supplying protective gas to the welding torch in MIG/MAG method

17. Protective cover

18. Protective cover lock;

А. (+) The bayonet connector socket for connecting:

a) The electrode cable (or the grounding cable in some cases when special electrodes are used

for welding) for the manual arc welding process (MMA);

b) Only the grounding cable for the argon arc welding process (TIG);

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