GWS MIG 160 User manual

INSTRUCTION MANUAL
IMPORTANT: Read This Instruction Manual Completely before operating this equipment. Save this
manual and keep it handy for quick reference. Pay particular attention to the hazards and safety
precautions provided for your protection and for the protection of those in the immediate vicinity
where this device is to be used. Contact your distributor if you do not fully understand this
manual or require additional information.
160

1
Contents
Features
1.0 Recommended Safety Precautions ................. 2
1.1 Personal Safety Warning Signs .............................. 2
1.2 Safety Precautions Preface .................................... 2
1.3 Electrical Shocks ..................................................... 4
1.4 User Responsibilities .............................................. 4
2.0 Introduction ......................................................... 4
2.1 Working Principle ................................................... 5
2.2 Volt-Ampere Characteristics .................................. 5
3.0 Installation and Adjustment ............................ 6
3.1 Parameters............................................................... 6
3.2 Duty Cycle & Over Heating..................................... 6
3.3 Movement and Placement ..................................... 7
3.4 Power supply input connection.............................. 7
3.5 Polarity Connection (MMA).................................... 7
3.6 Assembling the equipment (TIG) ........................... 7
PLEASE NOTE that under no circumstances should your
MIG160 be altered or changed in any way from standard
factory configuration. Doing so, will void the machine
warranty.
• Multi Process MIG, TIG and STICK in one machine
• Fitted with a 10amp plug so you can plug in anywhere
with a 10amp outlet
• Suitable for gas and gasless welding
• Easily switch between mild steel, aluminum and stainless
steel settings
• Ideal for jobs around the home, workshop, farm or
worksite.
• A light weight and portable 15kg design
• Power Factor Correction (PFC)
The ultimate multi-process lightweight machine, ideal for
the DIY enthusiast, tradesman or farmer.
The MIG160 is MIG, TIG and STICK capable, fitted with a
10amp plug to get welding anywhere with a 10amp
standard household outlet.
The MIG160 is affordable and easy to handle in a wide
variety of applications, making it the ideal solution for
anyone looking for high performance without
needing to break the bank on several single process
welders.
4.0 Operation ............................................................. 8
4.1 Lay out For Front And Rear Panel........................... 8
4.2 Control Panel............................................................ 9
4.3 Argon ARC Welding Operation............................... 9
4.3.1 TIG Welding (4T Operation) ................................. 9
4.3.2 TIG Welding (2T operation)................................ 10
4.4 Welding Parameters............................................... 11
4.4.1 Joint form in TIG/MMA....................................... 11
4.4.2 The Explanation of Welding Quality ................ 13
4.4.3 TIG Parameters .................................................... 13
4.7 Operation Environment......................................... 13
4.8 Operation Notices .................................................. 13
6.0 Recommended Safety Guidelines.................. 15
7.0 Machine & Welding Hazards............................ 15
8.0 Warranty Schedule ............................................ 16
9.0 Package Contents & Optional Extras ............ 17
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1.1 Personal Safety Warning Signs
2
1.0 Recommended Safety Precautions
The above safety warning signs indicate the risk of personal
injury or even death. IMPORTANT! Hot or moving parts can
cause serious injury and electric shock can kill. Use the
following MIG160 operation guidelines to insure your own
personal safety and for those in the immediate vicinity of
your work area.
1.2 Safety Precautions Preface
• The following are explanations of dangers present while
operating the machine. Please remind yourself and others of
these dangers.
• Only people who are trained professionally can install,
debug, operate, maintain and repair the equipment.
• NEVER TOUCH electrical parts
• Use dry, hole-free gloves and other protective safety gear
• Protect yourself from work and ground using dry
insulation. Make sure inulation is sufficiently covering
the working area.
• Use caution when working in confined spaces, in wet
environments or where falling is a risk
CLOTHING:
Suitable clothing must be worn to prevent excessive skin
exposure to UV radiation, sparks and molten metal. Flame-
proof, loose fitting cotton clothing buttoned to the neck,
protective leather gloves, spats, apron and steel toe safety
boots are also highly recommended. In addition, use a
helmet with the recommended shade lens for amperage
listed in the shade chart below.
FUMES AND GASES CAN BE DANGEROUS:
• Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. When
welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and
gases away from the breathing zone. When welding with
electrodes which require special ventilation such as stainless
or hard facing or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic fumes, keep
exposure as low as possible and below Threshold Limit
Values using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are also
required when welding on galvanized steel.
• Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with
solvent vapors to form phosgene, a highly toxic gas, and
other irritating products.
• Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
• Read and understand the manufacturer’s instructions for
this equipment and the consumables to be used, including
the material safety data sheet and follow your employer’s
safety practices.
ARC RAYS CAN BURN:
• Use a shield with the proper filter and cover plates to
protect your eyes from sparks and the rays of the arc when
welding or observing open arc welding.
Less than 150 amps
150 to 250 amps
250 to 300
300 to 350
Over 350 amps
Use one shade darker for aluminium welding
Shade 9
Shade 10
Shade 11/12
Shade 13
Shade 14
ELECTRIC SHOCK CAN KILL!
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3
ROTATING PARTS MAY BE DANGEOUS:
• Use only compressed gas cylinders containing the correct
shielding gas for the process used and properly operating
regulators designed for the gas and pressure used. All hoses,
fittings, etc. should be suitable for the application and
maintained in good condition.
• Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
• Cylinders should be located:
- Away from areas where they may be struck or subjected
to physical damage.
- A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
• Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
• Keep your head and face away from the cylinder valve
outlet when opening the cylinder valve.
• Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
ELECTRIC AND MAGNETIC FIELDS:
Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). The discussion
on the effect of EMF is ongoing all around the world. Until
now, no material evidences show that EMF may have effects
on health. However, the research on damage of EMF is still
ongoing. Before any conclusions are made, we should
minimize exposure to EMF as much as possible.
In order to minimize EMF, we should use the following
procedures:
• Route the electrode and work cables together – Secure
them with tape when possible.
• All cables should be put away and far from the operator.
• Never coil the power cable around your body.
• Make sure the welding machine and power cable are as
far away from the operator as possible.
• Connect the work cable to the workpiece as close as
possible to the area being welded.
• People with heart pacemakers should stay away from the
welding area.
The equipment complies with electromagnetic compatibility
on the class A which is intended for users in any locations
other than residential locations where the electrical power is
provided by public low-voltage supply system.
• Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
• Protect other nearby personnel with suitable, non-flam-
mable screening and /or warn them not to watch the arc nor
expose themselves to the arc rays or to hot spatter or metal.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION.
• Remove fire hazards from the welding area. If this is not
possible, cover them to prevent the welding sparks from
starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near hydrau-
lic lines. Have a fire extinguisher readily available.
• Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations.
• When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
• Do not heat, cut or weld tanks, drums or containers until
the proper steps have been taken to insure that such
procedures will not cause flammable or toxic vapors from
substances inside. They can cause an explosion even though
they have been “cleaned”.
• Vent hollow castings or containers before heating, cutting
or welding. They may explode.
• Connect the work cable to the work as close to the
welding area as practical. Work cables connected to the
building framework or other locations away from the
welding area increase the possibility of the welding current
passing through lifting chains, crane cables or other alter-
nate circuits. This can create fire hazards or overheat lifting
chains or cables until they fail.
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1.3 Electrical Shock
• Never touch ‘live’ electrical parts
• Earth clamp all work materials
• Never work in wet or damp environments
Avoid electric shock by:
• Wearing dry, insulated boots
• Using dry, leather gloves
• Never changing electrodes with bare hands or wet gloves
• Never cool electrode holders in water
• Work on a dry, insulated floor where possible
• Never hold the electrode or holder under your arm
1.4 User Responsibilities
• Read the Instructional Manual prior to using your
MIG160
• Unauthorised repairs to this equipment may endanger
the technician and operator and will void your Warranty.
Only qualified personnel should perform repairs
• Always disconnect mains power before investigating
equipment malfunctions
• Replace broken, damaged, missing or worn parts & hoses
immediately.
• Equipment should be cleaned & serviced periodically
4
2.0 Introduction
The MIG160 adopts the latest pulse width modulation
(PWM) technology and insulated gate bipolar transistor
(IGBT) power module, which allows this machine to be light
weight, small and portable with a low consumption.
The MIG160 also adopts ZVS and PFC full bridge inverter
technology.
In order to improve the efficiency of the power supply，this
machine uses ZVS technology and phase-shifting to control
the average current control mode, this results in a more
efficient power factor of the power supply for remarkable
improvement. On top of this, this machine is capable of
performing three types of welding: MMA (Stick), MIG & TIG.
The MIG160 is suitable for all positions welding for various
plates made of stainless steel, carbon steel, alloyed steel,
titanium, magnetsium, cuprum, etc, which is also applicable
to pipe installment, mould mend, petrochemical,
architectural decoration, car and bicycle repairs, handicraft
and common manufacture.
• ZVS soft switch technology reduces IGBT switching loss.
• The efficiency of the machine has a lot of improvement, in
the state of MMA, it can reach nearly 84%.
• The MIG160 uses the average current control mode and
has built in general protection including functions for
limiting pulse width, over-voltage, over-current, over-
heating etc. These functions obviously improve the
stability and security of the machine.
• MCU control system - instant response time to changes.
• Reduced weight of the machine improves portability
MMA——Manual Metal Arc welding
PWM——Pulse-Width Modulation
IGBT——Insulation Gate Bipolar Transistor
TIG——Tungsten Insert Gas welding
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2.1 Working Principle
The working principle of MIG160 is shown as the following
figure. Single phase work frequency AC 220V (50 Hz) AC is
rectified into DC (about 310V), then is converted to medium
frequency AC (about 44KHz) by the inverter device (IGBT),
after reducing voltage by the medium transformer (the
main transformer) and rectifying by the medium frequency
rectifier (fast recovery diodes), and is output by inductance
filtering. The circuit adopts current feedback control
technology to ensure current output stability. The welding
current parameter can also be adjusted continuously to
meet welding requirements.
Single Phase, AC
220V, 50HZ Rectify
DC
DC
AC
AC
DC
Inverter
Medium
frequency
transformer
Medium
frequency
rectify
Hall device
Current positive-
feedback control
2.2 Volt-Ampere Characteristic
The MIG160 has an excellent volt-ampere characteristic,
displayed in the following graph. The relation between the
conventional rated loading voltage U2and welding current
I2is as follows:
When I2 ≤ 600A，U2＝14＋0.05I2
（V)；
When I2 >600A2，U2＝44（V）.
67
0 600 I
2
（A）
U
2
（V）
Working
point
Volt-ampere characteristic The relation between the
conventional loading
voltage and welding current
14
44
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3. Installation & Adjustment
Note: The above parameters are subject to change with the improvement of machines.
3.2 Duty cycle & Over heating
The letter “X” stands for duty cycle, which is defined as the
proportion of the time that a machine can work continuous-
ly within a certain time (10 minutes).
The rated duty cycle means the proportion of the time that
a machine can work continuously within 10 minutes when it
outputs the rated welding current.
The relation between the duty cycle “X” and the output
welding current “I” is shown as the right figure.
If the welder overheats, the IGBT over-heat protection unit
inside it will output an instruction to cut the output welding
current, and will light up the over-heat pilot lamp on the
front panel. In the even this occurs, the machine should be
relaxed for 15 minutes to cool the fan. When operating the
machine again, the welding output current or the duty cycle
should be reduced.
x
I(A)
100%
60%
25%
The relation of the welding current and
duty cycle for MIG160
130 150 200
3.1Parameters
MIG 160
Machine
Power Supply Voltage (V)
Dimensions (mm)
Frequency (Hz)
Rated Input Power (KW)
Rated Input Current (A)
Effective Current (A)
No Load Voltage (V)
1-200/220/230/240±10%
50/60Hz
29.4
9.1
20%160A
60%90A
100%70A
45(Controlled)
MIG MMA
Function TIG
Duty Cycle (40°C 10min)
Welding Current Range (A)
Efficiency (%)
Power Factor
Wire Diameter (mm)
Net Weight (Kg)
468x223x421
10~160
10~26
80
0.7
15.5
Cooling
Protection Class
Insulation Class
Welding Voltage Range (V)
0.71
0.73
Fe: 0.6/0.8/0.9/1.0 Ss:0.8/1.0 Al: 0.9/1.0 Flux 0.9 (self-shield)/1.0/1.2
AF
F
IP23
24.7 20.4
9.6 9.3
15%160A
60%80A
100%60A
20%160A
60%65A
100%50A
5.9 4.9 7.1
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3.3 Movement and placement
Take care for the welder when moving it, ensure the machine is stood upright and refrain from sloping the machine.
It can also be moved by using the handle on top of the welder. When the machine gets to the destination, it needs to be securely
mounted to avoid sliding.
3.4 Power supply input connection
3.5 Polarity Connection (MMA)
Workpiece
-+-+
MIG160 MIG160
Holder
Workpiece
Holder
Electrode Electrode
DC POSITIVE CONNECTION DC NEGATIVE CONNECTION
MMA (DC): Choosing the connection of DCEN or DCEP according to different electrodes. Please refer to the electrode
manual.
3.6 Assembling the equipment (TIG)
-+
MIG160
Workpiece
Welding Torch
Ar
DC POSITIVE CONNECTION
MIG160
rear panel front panel
Gas Hose
Argon Gas
Cylinder
Pipe
Welding Cable
Control Cable of
torch switch
Shield gas
input joint
Shield gas
connector
Aero socket
• The workpiece is connected to the positive electrode of the welding machine, with the welding torch connected to the
negative electrode, called the DC positive connection. Otherwise, it’s called the DC Negative connection. Generally it is usually
operated as a DC positive connection when TIG welding.
• The control cable of the torch switch consists of 2 wires, pedal control of 3 wires and the aero socket has 14 leads.
The MIG160 welding machines’ power supply connects to 220V.
When the power supply voltage is over/under the safe work voltage, the over voltage or under voltage protection inside the
welder will trigger, turning the alarm light on and cutting the current output off.
If the power supply voltage continually goes beyond the safe work voltage range, it will shorten the machines life-span.
The below measures can be used:
• Change the power supply input net - connect the welder with the stable power supply voltage of the distributor
• Set the voltage stabilization device in the front of the power cable input
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4. Operation
4.1 Layout For Front And Rear Panel
1. Digital amp display Displays welding current amperage
2. Welding current knob Adjusts welding current amperage
3. Digital voltage display Displays voltage
4. Voltage knob Used to adjust voltage downslope/arc force
5. Power light Is lit when the machine is powered on
6. Alarm light Is lit when the machine’s protection is triggered
7. Inductance knob Used to adjust inductance
8. Diameter selection Selects specified wire diameter
9. Material selection Selects type of material being welded - Fe/Al/Ss
10. TIG Selection Selects either 2T (short) or 4T (long) when TIG welding
11. Welding type selection Selects a type of welding style - MIG/TIG or MMA
12. MIG gun quick connector The MIG welder’s positive polarity output
13. Positive output The welder’s positive polarity output
14. Shield gas connector Is connected to the gas input pipe of torch
15. Aero socket Is connected to torch switch control wire
16. Negative output The welder’s negative polarity output
17. Power source switch Turns the machine ON/OFF
18. Shield gas input joint To connect one head of the gas hose while the other head is connected to argon gas cylinder
19. Power source input Connects to power source
8
9
10
11
1 2 3
4567
12
13
14 15 16
18 1917
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4.2 Control Panel
V O LT
DOWNSLOPE
ARC FORCE
In different welding modes, this knob has different
functions:
MMA Adjusts the arc force, the range is 0~10
TIG Adjusts the time of down slope
MIG Adjusts the welding voltage, the range is 10~25V
4.3 Argon ARC Welding Operation
4.3.1 TIG Welding (4T Operation)
The start current and crater current can be pre-set. This function can compensate the possible crater that appears at the
beginning and end of welding. Therefore, 4T is suitable for the welding of medium thickness plates.
Pulsed TIG long welding (4T):
Introduction:
• 0: Press and hold the gun switch, Electromagnetic gas valve is turned on. The shielding gas starts to flow
• 0~t1: Pre flow time, adjustment range of pre flow time: 0.1~1.0S
• t1: Striking success, adjustment range of start current 10~200A
• t2: Loosen the gun switch, the output current slopes up from start current. If the output pulse function is turned on, the
output current is pulsed
• t2~t3 Output current slopes up to the setting current value; adjustment range of up slope time 0~10.0S
t( s)
0
I( A)
t1
switch
t5
Loosen the
t7
Striking success
Stop arc
t3 t4t2 t6
switch
Loosen the
Welding current (peak
current) setting value
Base current setting
value Start
current Crater
Repress down the
switch
current
Press and hold the
welding gun switch
• t3~t4: Welding process. During this period, the gun switch is loosened
• t4: Repress down the gun switch, the output current slopes down to crater current
• t4~t5: Down slope time, adjustment range of down slope time: 0~10.0S
• t5~t6: Crater current holds time; adjustment range of crater current: 10~200A
• t6: Loosen the gun switch, stop arc, and keep on argon flowing
• t6~t7: Post flow time, adjustment range of post flow time: 1.0~10.0S
• t7: Electromagnetic valve is closed and argon flowing stopped. Welding is finished.
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4.3.2 TIG Welding (2T operation)
TIG short welding (2T):
•0: Press and hold the gun switch, Electromagnetic gas valve is turned on. The shielding gas starts to flow
• 0~t1: Pre flow time, adjustment range of pre flow time: 0.1~1.0S
• t1~t2: Striking success, the output current slopes up to the setting current from minimum current (10A)
• t2~t3: During the whole welding process, the gun switch is pressed and held without releasing
• t3: Loosen the gun switch, the output current slopes down
• t3~t4: The output current slopes down to minimum current (10A), stop arc; adjustment range of down slope time: 0~5S
• t4~t5: Post flow time, adjustment range of post flow time: 0.1~10.0S
• t5: Electromagnetic valve is closed and argon flowing stopped. Welding is finished
Introduction:
Short circuit protection function:
1. TIG /DC/LIFT：If the tungsten electrode touches the workpiece when welding, the current will drop to 30A, which can reduce
tungsten spoilage，prolonging the life of the tungsten electrode，and prevent tungsten clipping.
2. TIG /DC/HF：If the tungsten electrode touches the workpiece when welding, the current will drop to 0 within 1s, which can
reduce tungsten spoilage，prolonging the life of the tungsten electrode，and prevent tungsten clipping.
3. MMA：if the electrode touches the workpiece for over two seconds, the welding current will drop to the 0 automatically to
protect the electrode.
Prevent arc-break function：TIG operation，Avoid arc-break with special means, even if arc-break occurs the HF will keep the
arc stable.
4. TIG: If the TIG torch is pressed quickly, the welding current will drop by half, then if the TIG torch is
pressed quickly again, the welding current will go back.
t( s)
0
I(A)
Loosen the
switch
welding gun
t1 t5
Striking
success
Press and hold the
welding gun switch
Arc is
turned off
t3 t4t2
Welding current Is
The setting base
current lb
Notices:
•Check the condition of welding and connection units first, otherwise there may be malfunctions such as ignition sparks, gas
leakages, loss of control and so on.
•Check whether there is enough Argon gas in the shield gas cylinder, you can test the electromagnetic gas valve via the switch
on the front panel.
• Do not let the torch aim at your hand or other parts of your body. When you press the torch switch, the arc is ignited with
a high-frequency, high-voltage spark and the ignition spark can cause interferences in equipment.
• The flow rate is set according to the welding power used in the job. Turn the regulation screw to adjust the gas
flow which is shown on the gas hose pressure meter or the gas bottle pressure meter.
• The spark ignition works better if you keep the 3mm distance from the workpiece to the tungsten electrode during the
ignition.
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4.4 Welding Parameters
4.4.1 Joint forms in TIG/MMA
4.4.2 The Explanation of Welding Quality
The relation of welding area colour & the protection eect of stainless steel
Welding area
colour
Protect
effect
argent, golden blue red-grey grey black
best better good bad worst
The relation of welding area colour & the protection eect of Ti-alloy
Welding area
colour
Protect
effect
bright argent orange-yellow blue-purple caesious white powder of
titanium oxid
best better good bad worst
4.4.3 TIG Parameters
Gas Nozzle
diameter/mm
Electrode
diameter/mm
6.4 8 9.5 11.1
0.5 3.21.6 or 2.4 1.0
The corresponding relationship between gas nozzle diameter and electrode diameter
Welding current
range/A
DC Positive Connection
Gas Nozzle Diameter/mm Gas Flow Rate/L · min-1
10~100
101~150
151~200
201~300
4~9.5
4~9.5
6~13
8~13
4~5
4~7
6~8
8~9
11

Electrode Diameter Constant Included
Angle, Degrees
Current Range
A
1.0
1.6
1.6
2.3
2.3
3.2
3.2
.125
.250
.500
.800
.800
1.100
1.100
.500
12
20
25
30
35
45
60
90
2-15
5-30
8-50
10-70
12-90
15-150
20-200
25-250
MM IN
Diameter At Tip
MM IN
1.0
.040
1/16
1/16
3/32
3/32
1/8
1/8
.040
.005
.010
.020
.030
.030
.045
.045
.060
Workpiece
Thickness
/MM
0.8
1.5
1.5
2.4
2.4
3.2
3.2
1.0
1.6
1.6
1.6
1.6
1.6
1.6
1.6
1.0
Butt
Butt
Corner
Butt
Corner
Butt
Corner
Butt
Joint
Form
Tungsten
Electrode
Diameter/MM
Welding Wire
Diameter/MM
Argon Gas
Flow Rate/
L · min-1
Welding
Current
(DCEP)
Welding
Speed/
cm · min-1
4.8
4.8
Butt
Corner
2.4
3.2
1.6
1.6
1.6
1.6
2.4
2.4
2.4
2.4
3.2
3.2
5
5
7
7
7
7
7
7
8
9
20~50
50~80
65~105
75~125
85~125
95~135
100~135
115~145
150~225
175~250
66
56
30
25
30
25
30
25
25
20
12

4.7 Operation Environment
• Height above sea level is below 1000m.
• Operation temperature range:-10°C~+40°C.
• Relative humidity is below 90 %(+20°C). relative humidity
is below 50% (40°C).
• The inclination of the power source does not exceed 10°.
• Protect the machine against heavy rain or in hot circum-
stance against direct sunshine.
• The content of dust, acid, corrosive gas in the surrounding
air or substance can not exceed normal standards.
• Take care that there is sufficient ventilation during
welding. There is at least 30cm free distance between the
machine and wall.
4.8 Operation Notices
• Read section 1 carefully before attempting to use this
equipment.
• Connect the ground wire with the machine directly, and
refer to section 3.
• In the case of closing the power switch, no-load voltage
may be exported. Do not touch the output electrode with
any part of your body.
• Do not watch the arc with no eye protection.
• Ensure good ventilation of the machine to improve duty
ratio.
• Turn off the engine when finished to save power.
• When power switch shuts off protectively because of
failure, don’t restart it until the problem is resolved.
Otherwise, the range of potential problems will be
exacerbated.
Piping
Diameter
Φ/MM
38
60
76
108
133
159
219
42
2.0
2.0
2.5
2.0
Tungsten
Electrode
Diameter/MM
Gaas Nozzle
Diameter/MM
Welding Wire
Diameter/MM
Welding
Current/A
Arc
Voltage/V
Welding
Rate/
cm · min-1
273
325
75~90
75~95
75~100
80~105
90~110
90~115
95~120
100~120
110~125
120~140
11~13
11~13
14~16
14~16
14~16
14~16
14~16
14~16
14~16
6~8
6~8
7~9
8~10
9~11
10~12
11~13
12~14
12~14
12~14
4~5
4~5
4~5
4~5
5~6
5~6
5~6
5~6
5~6
5~6
Argon
Flow Rate/
L · min-1
2.5
2.5
2.5
2.5
2.5
2.5
2
2
2.5
2
2.5
2.5
2.5
2.5
2.5
2.5
8
8
8~10
8
8~10
8~10
8~10
8~10
8~10
8~10
11~13
13

14
5.0 Troubleshooting
If there are simple troubles with your MIG160 welding machine, you can consult the following overhauling chart:
When the machine is powered
on, the fan works but the
power light is not on
Light damaged or has a bad
connection
Power PCB Failures
Test/repair the inside circuit of power
light
Repair or change control panel
When the machine is powered
on, the power light is on
but the fan doesn’t work
There is something in the fan
The fan motor is damaged
Clear out
Change fan motor
When the machine is powered
on, neither the fan or power
light work
No input voltage Check whether there is power supply
The fuse inside the machine
is damaged
Change it (10A)
No no-load voltage output
(MMA)
The machine is damaged Check the main circuit
The max and min value
displayed doesn’t match
the set value
No Gas Flow (TIG)
Something in the valve
Gas cylinder is closed or gas
pressure is low
Electromagnetic valve is
damaged
Remove it
Open or change the gas cylinder
Change it
The displayed current on the
screen doesnt match output The LED screen is broken Change the LED screen
The welding current can
not be adjusted
The welding current
potentionmeter in the front
panel has a bad connection
or is damaged
Repair or change the potentionmeter
The penetration of the molten
pool is not enough
The welding current is
adjusted too low
Increase the welding current
Gas always flows
Something in the valve
The gas test on front panel is on
Electromagnetic valve
is damaged
Remove it
Turn off
Repair or change it
Repair or change it
The alarm light is on
Over heat
protection
Over current
protection
Over welding
current
Working time
too long
Unusual current
in the main
circuit
Reduce the welding current output
Reduce the duty cycle (interval work)
Use a stable power supply/ ensure
not too many machines are using the
same power supply
1
2
3
4
5
6
7
8
9
10
11
S/N Troubles Reasons Solutions
The max value isn’t in
accordance
The min value isn’t in
accordance
Adjust potentiometer Imin on the power
board
Adjust potentiometer Imaxin the current
meter
The adjustment kob of pre-gas
timeon the front panel is
damaged
Low-Voltage
Protection
Over-Voltage
Protection
Power supply
fluctuates Use a stable power supply
160

15
160
6.0 Recommended Safety Guidelines
7.0 Machine & Welding Hazards
Safety precautions & recommendations include:
• Repair or replace defective cables immediately
• Never look directly at the arc except through an
appropriate protective shade level lens
• In confined spaces, adequate ventilation and constant
observation are essential
• Leads and cables should be kept clear of foot traffic areas
to prevent accidental tripping or stumbling
• Keep fire extinguishing equipment in a handy location
nearby
• Keep primary terminals and live parts effectively covered
• Never strike an electrode on any gas cylinder
• Never use oxygen for venting containers
Fumes and gases produced during
the welding process are harmful
Disconnect from power before
assembling or adjusting machine
Welding arc rays are harmful
to eyes and skin
Do not operate in confined spaces
or inadequate ventilation
Use forced ventilation or exhaust
to remove welding fumes
Always use a welding helmet with
appropriate shade level lens
Read instructional manual
fully before operating
Seek proper training
before operating
Electric shock hazard Wear dry, insulated welding gloves
while operating
Insulate yourself from work &
ground to prevent shock
Welding electrode may
cause electric shock

16
160
8. Warranty Schedule 2021
GWS welding equipment is designed and tested for professional industrial environments.
As a guarantee of high quality, we offer a warranty. Valid only from the sale by GWS or an accredited distributor of the
equipment or product.
In no event shall the warranty period extend more than the time stated. The warranty period includes parts and labour.
GWS reserves the right to request documented evidence of the date of purchase.
Warranty terms are for single shift operation on all equipment and product. Warranty terms are a back to base warranty.
All costs associated with lodging the warranty claim, including the return of goods to the Accredited Service Provider, are
the responsibility of the consumer.
Any claim under this warranty must be made within the warranty period which commences on the date of purchase on the
equipment or product. For the warranty to be approved the equipment or product has to be assessed by accredited GWS
personnel.
Any modifications or alterations made to the equipment or product including electrical modification will result in the
equipment or product not being covered under warranty. Any failures under the warranty period that are due to incorrect
operation of the equipment or product will not be covered under warranty.
Consumers are reminded to only use the product in accordance with the operating instructions.
For additional operating instructions or to make a warranty claim call 0800 536 774
Main transformers - Output
inductors
3 years
Power sources - Wire feeders -
Cooling units
2 years
Cooling pumps - Automa�on
products - Ven�lators - Main
contactors - Wire feeder
motors - Solenoid valves -
Welding Masks (welding
helmet)
1 year
Mig, Tig & Plasma Torches
Work leads, electrode holders
3 months
Mig, Tig, Plasma consumables,
Welding consumables
Nil
Gas Regulator brass body
2 years
Flowmeter, elastomer seals, O
rings, gauges
1 year

SAH1000F ArcOne Vision Welding
Helmet Black 1000F
GRAM GASpro® Regulator
ArgonTwin Gauge Side
Inlet
MCART MIGARC®Black Trolley
WWCS Water Cooler 230V 1Phase
Small 580x180x230mm
5L Tank
WSAL2504 WELDARC®ARC Lead
OKC Male
MMPLN MIGarc® Mig Pliers
Multipurpose long nose
WSEL2504 WELDARC®Earth Lead
OKC Male 250 Amp
4 Meters 35-50mm
MMT153
MIGARC Binzel Style 15
Torch 3 Meter
GRA GASpro Regulator Argon
Compact Flowmeter
0-25LPM
SPWH
MIGarc® Nozzle Gel 300g
Silicone Free / Non Toxic
MNG
SAFETYarc® Blue Proban
Welders Hood
SGMGXL MIGarc® Gloves Gold
Welding Gauntlet 40cm
L/XL (6/Pkt)
Package Includes
Optional Extras
MIGARC Binzel Style 15 Torch
MMT153
MMT154
3 Meters
4 Meters
MIGARC Binzel Style Starter Kits, MB15, 24, 25, 36
MIGARC Binzel Style 24 Torch
MMT243
MMT244
3 Meters
4 Meters
MMT245 5 Meters
MIGARC Binzel Style 25 Torch
MMT253
MMT254
3 Meters
4 Meters
MMT255 5 Meters
MIGARC Binzel Style 36 Torch
MMT363
MMT364
3 Meters
4 Meters
MMT365 5 Meters
MMTSG Binzel Style Black Handle
Alloy Spool Gun 3Mtr
Parts & Accessories
Product code: RDMM160P
160