Paton VDI 150 MINI Manuel utilisateur

1 | Page PATON®VDI SERIES MINI DC 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 (MMA) ....

3.1

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

3.2.

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

3.3.

REDUCED –WELDING VOLTAGE FUNCTION "ARC-FORCE" ..................

3.4.

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

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

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

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

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

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

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

10.

TROUBLESHOOTING ........................................................................................

11.

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

12.

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

13.

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

14.

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

15.

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

16.

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

2 | Pa g e PATON®VDI SERIES MINI DC 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

ul. Przemysłowa 14,

35 -105 Rzeszów Poland

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:

INVERTER RECTIFIER

PATON VDI –150 MINI DC MMA

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.

3 | Pa g e PATON®VDI SERIES MINI DC MMA

ATTENTION!!! When connecting the welding unit to an electrical outlet (at

a temperature of 25 ºC) of a power supply system, it is necessary to consider

wall-buried wiring and the lengths of extension cables.

Electrode diameter

Set current

Cross-section area of

the power cable

conductor (mm2)

Maximum power

cable length (m)

Ф2 mm

Not more than 80

1.0

120

1.5

180

2.0

240

2.5

300

4.0

480

6.0

720

Ф3 mm

Not more than 120

1.5

120

2.0

160

2.5

200

4.0

320

6.0

480

Ф4 mm

Up to 150 A

2.0

120

2.5

150

4.0

240

6.0

360

1. GENERAL INFORMATION

The invertor-rectifier welding unit PATON®VDI MINI is designed for direct-current manual arc

welding (MMA). This welding unit’s series "MINI" is intended for exacting users who need a

portable fully functional welding unit with a rated current of up to 150 A. Such a current is sufficient

for welding by using any welding electrodes from Ф1.6 mm through Ф4.0 mm in diameter, at a load

factor not less than 40 percent, allowing welding works to be performed in household conditions, such

as at country sites, in small workshops, or in garages.

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

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

welding units with similar output characteristics.

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

1. 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 170

V through 260 V. It should be noted that welding at a minimum voltage of 170 V is allowed only

by using an electrode not more than Ф3 mm in diameter;

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

efficiency coefficient of the welding unit, the power consumed by the unit is reduced by 50

percent as compared with other similar welding units;

3. The welding unit is easily operated due to the optimal operating load factor in operation of the

unit at the rated current. Due to this, it is possible to perform welding works comfortably

using 3 mm welding electrodes at the rated current;

4. The enhanced reliability of the welding unit in operation in dusty environment;

5. All the printed-circuit boards with electronic elements of the welding unit are impregnated with

two layers of high-quality varnish in order to provide the high reliability of the welding unit

within its service life;

6. The possibility to adjust welding current smoothly;

7. The Improved welding arc stability.

4 | Pa g e PATON®VDI SERIES MINI DC MMA

1.1. TECHNICAL CHARACTERISTICS

PARAMETERS

VDI MINI

Rated power supply voltage 50/60 Hz, V

230

Rated power supply current, A

18.5

Rated welding current, A

150

Maximum operating current, A

180

Operating load factor, %

40% at 150 A

100% at 94 A

Power supply voltage range, V

170 … 260

Welding current control range, A

20 … 150

Increased-current arc starting function of the manual arc welding

process

Available

Reduced-voltage welding function of the manual arc welding process

Available

Protection against electrode sticking

Available

Open-circuit voltage, V

to 80

Welding arc starting voltage, V

110

Rated consumed power, kVA

4.0

Maximum consumed power, kVA

5.0

Efficiency coefficient, %

Cooling

Forced

Operating temperature range

-25 … +45 ºC

Overall dimensions (length width height), mm

200 100 200

Weight, kg

3.3

Protection class*

IP 21

*these Mini-series welding units are protected against ingress of foreign particles more than 12.5 mm in size

and against vertically falling raindrops.

THE RECOMMENDED LENGTHS OF THE WELDING CABLES ARE INDICATED

BELOW:

Unit model

One-direction

cable length (m)

Cross-section area of the

cable conductor (mm2)

Cable designation

VDI MINI

1 –4

KG 1 8

2 –5

KG 1 10

3 –8

KG 1 16

5 | Pa g e PATON®VDI SERIES MINI DC MMA

1.2. CONTROLS AND CONNECTORS

6 | Pa g e PATON®VDI SERIES MINI DC MMA

1–The control for smoothly adjusting welding current;

2–The indicator of operating condition of the welding unit:

a) Continuously lights green when the welding unit is in the operating mode;

b) Alternately flashes green and yellow when the power supply voltage is insufficient for arc

starting;

c) Continuously lights yellow when the welding unit is overheated;

d) Does not light when the power supply voltage is not available;

А(+) –The bayonet connector socket:

a) For connecting the electrode cable (or the grounding cable in some cases when special

electrodes are used for welding) for the manual arc welding (MMA);

B (-) –The bayonet connector socket:

b) for connecting the grounding cable (or the electrode cable in some cases when special

electrodes are used for welding) for the manual arc welding (MMA).

3–The push-button switch for switching on and off the welding unit (the push-button is without a

light indicator; the colour of the push-button is decorative).

2. SETTING THE WELDING UNIT INTO OPERATION

ATTENTION!!! Read Section 11, "Safety instructions", before setting the

welding unit into operation.

2.1 PROPER USE

The welding unit is designed exclusively for manual covered-electrode arc welding.

Any other use of the welding unit is considered as improper. The manufacturer of the welding unit is

not responsible for damages caused by any improper use of the unit.

The use of the welding unit is proper if all the requirements of this Operation Manual are satisfied.

ATTENTION!!! Do not use the welding unit to unfreeze pipes.

2.2 REQUIREMENTS FOR INSTALLATION

The welding unit is protected against ingress of foreign particles more than 12.5 mm in size.

The welding unit is allowed for outdoor operation. The internal electrical and electronic elements of

the welding unit are protected against moisture but are not protected against atmospheric condensate

drops.

ATTENTION!When operating the welding unit in cold season, after the unit

was switched off and cooled, condensate may appear inside the unit, so switch

on the welding unit only 3 –4 hours after the switching off!!!

7 | Pa g e PATON®VDI SERIES MINI DC MMA

For this reason, do not switch off the welding unit if it is anticipated that the unit is to be switched on

not later than 4 hours after switching off.

Install the welding unit so as not to block or cover the ventilation slots on the front and rear panels of

the unit. Prevent ingress of metallic particles (for example, when grinding the weld) sucked into the

welding unit by the unit ventilator.

ATTENTION!!!After fall from a height, the welding unit might be a source

of electrical shock. Install the unit on a firm stable surface.

2.3 CONNECTION TO A POWER SUPPLY SYSTEM

The commercial welding unit is rated for an input power supply voltage of 230 V (- 26% / +13%).

ATTENTION!!! If the welding unit has been damaged in the result of

increase of the input power supply voltage of the welding unit to more than 270

V, possible in the case of large unbalance of phase voltages in the standard

power supply system, the warranty of the manufacturer of the welding unit will

be invalid.

The power supply connector, cross-section areas of the power cable conductors, and power supply line

fuses should be selected with consideration for the technical characteristics of the welding unit.

2.4 REQUIREMENTS FOR AN ELECTRICAL OUTLET

ATTENTION!!! The parameters of an electrical outlet for the power supply

of the welding unit must correspond to the power supply voltage and

consumption current of the unit (see "Technical characteristics"). Connect the

welding unit to an electrical outlet that is rated for a three-wire plug with a

grounding conductor!!!

3. MANUAL COVERED-ELECTRODE ARC WELDING PROCESS (MMA)

3.1 PREPARING THE WELDING UNIT FOR OPERATION

Preparation the welding unit for MMA operation:

1. Insert the plug of the electrode cable into socket A (+) of the welding unit;

2. Insert the plug of the grounding cable into socket B (-) of the welding unit;

3. Connect the grounding cable to the workpiece;

4. Connect the power cable of the welding unit to the outlet of the power supply

system;

5. Set switch 3 to position 1 (switching on).

6. The device is ready for use. Enjoy Your work.

8 | Pa g e PATON®VDI SERIES MINI DC MMA

ATTENTION!!! In the manual arc welding process, after switching on the

welding unit by switch 3, the welding electrode is under voltage. Do not allow

the electrode to contact current-conducting or grounded parts, such as the

casing of the welding unit etc.

3.2 INCREASED-CURRENT ARC STARTING HOT-START

The advantages ensured by the increased-current arc starting function are the following:

1. Improved arc starting even when low-quality electrodes are used;

2. Better base metal penetration during the arc starting period and, as a result, the lesser number

of defects associated with incomplete penetration;

3. Prevention of slag inclusions.

What is achieved by:

During the short time interval of arc starting, the welding current increases by 33 percent of the

welding current set by default (see Figure 1).

Example: The electrode diameter is 3 mm.

The set welding current is 90 A.

The current at the increased-current arc starting stage is 90A + 33% = 120 A.

Figure 1. Increased-current arc starting HOT-START

ELECTRODE HOLDER

GROUNDING CLAMP

t (s)

WORKPIECE

9 | Pa g e PATON®VDI SERIES MINI DC MMA

3.3 REDUCED WELDING VOLTAGE FUNCTION ARC-FORCE

The advantages ensured by the forced arcing at reduced welding voltage function are the

following:

1. Improved arc stability in the short arc welding mode;

2. Improved transfer of molten metal drops into the welding pool;

3. Improved arc starting;

4. Reduced probability of electrode sticking.

What is achieved by:

When the arc voltage is lower than the minimum voltage required for stable arcing, the welding

current increases by 30 percent relative to the set current (see Fig. 2)

Figure 2. Forced arcing at reduced welding voltage ARC-FORCE

3.4 PROTECTION AGAINST ELECTRODE STICKING “ANTI-STICK”

At the stage of arc starting, the electrode can stick to the workpiece and, as a result, the electrode can

be damaged due to overheating.

If the electrode has stuck to the workpiece, the welding current decreases within 0.6 … 0.8 s after the

sticking. The temporary reduction in the welding current makes it easier for the welder to peel off the

stuck electrode. After separating the electrode from the product, the welding process can be resumed

without any problems.

4. MAINTENANCE

ATTENTION!!! Before maintenance, switch off the welding unit and

disconnect the power cable from the outlet of the power supply system. Wait

for about 5 minutes until static charges in the electrical circuits of the unit

disappear, and then perform the maintenance operations. After the completion

of works with the welding unit, apply to the unit a plate with a warning text

prohibiting switching on the unit.

130

Uoc

U (V)

Umin

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