Jasic ARC 160GS User manual

INVERTER WELDER
ARC 160GS
WELDING MACHINE
USER MANUAL

Meet a better way of welding!
For your own and other people’s safety, please read the manual carefully before
operating. And the user manual must always be available near the welding machine.
Disclaimer and Warning
Thank you for purchasing our products. The content mentioned in this article concerns
your safety and legitimate rights and responsibilities.
The final interpretation of this document belongs to our company. It will be updated
without notice.
By using this product, you are deemed to have carefully read the disclaimer and
warning, understand, approve and accept all terms and contents of this statement.
You undertake to take full responsibility for the use of this product and any
consequences it may cause. You undertake to use the Product only for proper
purposes and agree to these terms and any relevant regulations, policies and
guidelines established by our company.
Version
Version: YF-TBE-0287, A0. Released on August 9, 2022.
NOTE
The pictures in this manual are for reference only. If the pictures are inconsistent
with the actual product, the actual product shall govern.

1
CONTENTS
1 Safety Guidelines and Precautions..................................................................................................................... 2
2Overview.................................................................................................................................................................. 6
2.1 Product Introduction....................................................................................................................................6
2.2 Technical Specifications............................................................................................................................ 7
3Installation................................................................................................................................................................ 7
3.1 Install the Output Cable..............................................................................................................................8
3.2 Install Accessories - braces (optional).....................................................................................................8
4 Operating Functions............................................................................................................................................... 9
4.1 Control Panel............................................................................................................................................... 9
4.2 Input/Output Panel...................................................................................................................................... 9
5 Operation............................................................................................................................................................... 10
6 Environment and Problems................................................................................................................................ 11
6.1 Environment............................................................................................................................................... 11
6.2 Problems During Welding........................................................................................................................12
7 Periodic Maintenance and Checking................................................................................................................ 13
8 Trouble Shooting.................................................................................................................................................. 15
Appendix A Welding Parameter............................................................................................................................ 16
Appendix B Circuit Diagram...................................................................................................................................17

2
1 Safety Guidelines and Precautions
Security Definitions
It indicates that ignoring safety warnings could result in a major accident, or
even death or serious injury.
It indicates that ignoring safety warnings could result in minor injuries or
property damage.
It indicates that ignoring safety warnings could result in equipment failure or
damage.
Personal Protection Precautions
The installation, operation, maintenance and repair of the power source must be
carried out by professionals or persons with relevant knowledge and skills.
Personal protective equipment (PPE), such as protective masks, overalls,
insulating gloves and insulating shoes, should be worn when working.
Keep fire extinguishing equipment at a handy location in the workshop.
Repair or replace defective cables immediately.
Never watch the arc except through lenses of the correct shade.
Supervisors shall be provided for working in high altitude or narrow places, such as
boxes, boilers, cabins, etc.
In confined spaces, adequate ventilation and constant observation are essential.
Those who use cardiac pacemakers shall not approach the power source in use
and welding workplaces without the permission of a physician.
The power source shall not be used for pipeline thawing, battery load or
motor start-up.

3
Operational Safety Guidelines
Electrical Shock
Grounded all working materials.
Never touch ‘live’ electrical parts.
Always repair or replace worn or damaged parts.
Wearing dry insulated boots, and dry leather gloves.
Disconnect power source before performing any maintenance or service.
Never change electrodes with bare hands or wet gloves.
Never cool electrode holders in water.
Never hold the electrode and holder under your arm.
Never work in moist or damp areas. If necessary, the floor near the operating table
must be covered with rubber insulation pad.
Fumes and Gases
You must always have enough ventilation in confined spaces. Be alert to thisatall
times.
Fumes from the welding of some metals could have an adverse effect on your
health. Don’t breathe them in. If you are welding on material such as stainless steel,
nickel, nickel alloys or galvanised steel, further precautions are necessary.
Keep your head out of the fumes rising from the arc.
If necessary, use forced ventilation or local exhaust to remove fumes.
Wear a respirator when natural or forced ventilation is insufficient.

4
Welding sparks can cause fire or explosion
Do not carry out welding operations in degreasing, cleaning and spraying areas.
Do not weld/cut gas-filled pipes, sealing grooves (boxes) and other devices,
otherwise explosions or fires are likely to occur.
Do not weld/cut near flammable gases or devices with flammable substances,
otherwise explosion or fire may occur.
When not welded, make sure that any component in the wire circuit does not
contact the workpiece or the earth, otherwise it may cause overheating and fire.
When the welding operation is stopped, remove the electrode in the welding pliers
or cut off the welding wire in the nozzle of the torch.
Arc flash can burn eyes and injure skin
Make sure you’re wearing a helmet or safety glasses, gloves, welding jackets to
protect yourself.
Protective barriers are set around the welding site to prevent arc or welding spatter
from injuring others.
Electric and Magnetic Fields
Those who use cardiac pacemakers shall not approach the power source in use
and welding workplaces without the permission of a physician.
It is strictly forbidden to place or wrap welded cables around the body.
Do not place the body between the welding wire and the workpiece cable. If the
welding wire cable is on the right side of the body, the workpiece cable should also
be on the right side of the body.

5
Noise produced during welding can easily cause hearing loss
In order to avoid the harm of noise to you and others, please wear the prescribed
protective equipment.
Matters needing attention in hoisting
The power source with strap or hand is prohibited from using strap or hand for
lifting.
When lifting power source with lifting forklift truck, in order to prevent dumping,
please fork-fit and fix it from side.
When lifting power source with crane, the cable should be tied to the suspension
ring, and the angle between the cable and the vertical direction should not exceed
15 degrees.
When the power source with cylinder and wire feeder is hoisted, the two
equipments should be unloaded from the power supply first. When moving the
power source on the ground, it is necessary to fix the cylinder with a strap or chain
to prevent dumping and injuring people.
If the wire feeder is hoisted by lifting lugs for welding, it is necessary to ensure that
it is firm and insulated.
STOP
PLEASE NOTE that under no circumstances should any equipment or parts be altered or
changed in any way from the standard specification without written permission given by
our company. To do so, will void the Equipment Warranty.
Handle
Rings

6
2 Overview
2.1 Product Introduction
Manual Metal Arc welding is the proces
s
of joining metals where an electric arc i
s
struck between the metal to be welde
d
(workpiece) and a flux-coated filler wir
e
(the electrode). The heat of the arc melt
s
the parent metal and the electrode whic
h
mix together to form, on cooling,
a
continuous solid mass.
The welding power source can offer stronger, more concentrated and more stable arc.
When stick and work piece get short, its response will be quicker. It means that it is
easier to design into welding machine with different dynamic characteristics, and it
even can be adjusted for specialty to make arc softer or harder.
MMA welding machine has the following characteristics: effective, power saving,
compact, stable arc, good welding pool, high no-load voltage, and good capacity of
force compensation. It can weld stainless steel, alloy steel, carbon steel, copper and
other color metal. It can apply to electrodes of different specifications and materials,
including acidity, and alkalescence. It can apply in high altitude, the open air and inside
and outside decoration. Compared with the same products of home and abroad,itis
compact in volume, light in weight, easy to install and operate.
Thanks for purchasing our product and hope for your precious advice. We will dedicate
to producing the best products and offering the best service.

7
2.2 Technical Specifications
Item
Model
ARC 160GS
Power voltage (V) 1 phase 110V15% 1 phase 220V15%
Frequency (Hz) 50/60 50/60
Rated maximum supply current (I1max/A) 32 30
Maximum effective supply current (I1eff/A) 14.3 13.4
Output current range (A) 40-110 40-160
Output voltage range (V) 19.6-22.4 19.6-24.4
Duty cycle (%) 20% 20%
No-load voltage (V) 57 57
Power factor 0.75 0.70
Efficiency (%) 80% 82%
EMC grade A
Insulation grade F
Housing protection grade IP21
Weight (kg) 4.0
Overall dimensions (mm) 339*136*235
Note: The weight in this table is the net weight of the machine. If it is inconsistent with the physical
object, the physical object shall prevail.

8
3Installation
3.1 Install the Output Cable
There are two welding methods for MMA welding, please choose according to the
actual needs.
Direct Current Electrode Negative (DCEN): The positive output terminal is connected
to the workpiece, and the negative output terminal is connected to the electrode holder.
The DCEN is suitable for acid electrodes.
Direct Current Electrode Positive (DCEP): The positive output terminal is connected
to the electrode holder, and the negative output terminal is connected to the workpiece.
The DCEP is suitable for basic electrodes.
3.2 Install Accessories - braces (optional)
Note: Some machines can be equipped with braces. Please refer to the following figure
for installation steps.
Braces Components Installation Procedure
Power Supply
Earth clamp
Electrode holder
Workpiece

9
4 Operating Functions
4.1 Control Panel
The panel components of MMA series are described in the following table.
Icons Name Description
Adjusting Knob Used to adjust welding current
Power indicator
(110V) When the power supply is 110V, the indicator light up.
Power indicator
(220V) When the power supply is 220V, the indicator light up.
Abnormal Indicator This indicator lights up when the machine is
overheated, overcurrent, or other abnormal.
Stand-by button
Turn on the power switch on the rear panel, and press
the stand-by button, the power indicator lights on. The
machine enters working state.
Power Switch
Turn on/off the power.
Turn on the power switch，the machine enters the pre-
working state, and self-test.
4.2 Input/Output Panel
Output Terminals
Input Cable
The I1eff determines the input cable, correct plug and input current required for each
machine.
Note: Please check the nameplate o
r
the section “2.2 Technical Specifications” for the value of I1eff.
No. Name
1 Negative output terminal
2 Positive output terminal
Max. effective supply
current (I1eff)
Input cable size
I1eff ≤10 A 1.5-2.5 mm2
I1eff ≤16 A 1.5-4 mm2
I1eff ≤25 A 2.5-6 mm2
I1eff ≤35 A 4-10 mm2
I1eff ≤50 A 6-16 mm2
I1eff ≤63 A 10-25 mm2
Input cable

10
5Operation
Instructions of Operation Steps
Steps Description
1Select electrode
It is suggested to choose the diameter of electrode according to the
thickness of the workpiece refer to the following table (Diameter of
Electrode).
2Starting up Turn on the power switch on the rear panel. Then press the stand-by
button on the front panel.
3Set up parameters
Set welding current according to electrode, workpiece and welding
process.
After the setup is complete, you can begin the welding operation.
Note:
1. Generally, welding current is adequate for electrode, see the “Appendix A Welding Parameter” for details.
Diameter of Electrode
Thickness of workpiece (mm) Diameter of electrode (mm)
＜4The diameter of the electrode shall not exceed the
thickness of the workpiece.
4~12 3.2~4.0
＞12 ＞4.0
Note: 5mm electrode is rarely used for horizontal and vertical welding, and 3.2mm electrode is used for jam
welding.

11
6 Environment and Problems
6.1 Environment
Note: The power source should not be used in rain or snow environment.
The recommended external environment for welding is as follows:
Please place the power source in a horizontal position. The inclination of the power
source shall not exceed 10°.
The environment where the equipment is stored should be clean and protectedby
sand and dust.
Dust, acids, corrosive gases or substances in the surrounding air do not exceed
normal levels, except those produced by the welding process.
The environment where the equipment is stored needs to be dry. The air relative
humidity requirements are as follows:
No more than 50% at 40℃.
No more than 90% at 20℃.
The environment where the equipment is placed should not be surrounded by heat,
fire and welding spatter. The ambient temperature requirements are as follows:
During welding: -10℃~+40
℃.
During transportation and storage: -20℃~+55
℃.

12
6.2 Problems During Welding
Fittings, welding materials, environment factor, supply powers maybe have something
to do with welding. User must try to improve welding environment.
No. Problems Solutions
1Arc starting is difficult and easy to
break.
1. Make sure the quality of electrode.
2. If the electrode is not dried, it will cause
unstable arc, welding defect increases and
the quality is down.
2 Output current not to rated value
1. Make sure the quality of electrode.
2. If the electrode is not dried, it will cause
unstable arc, welding defect increases
and the quality is down.
3. If use extra-long cable, the output voltage
will decrease, so please shorten the cable
3Current is not stabilizing when
machine is being operated
When power voltage departs from the
rated value, it will make the output current
not matched with rated value; when
voltage is lower than rated value, the max
output may lower than rated value.
4 Too much spatter
1. Maybe current is too big and electrode
diameter is too small.
2. Output terminal polarity connection is
wrong, it should apply the opposite
polarity at the normal technics, which
means that the stick should be connected
with the negative polarity of power source,
and workpiece should be connected with
the positive polarity. So please change
the polarity.

13
7 Periodic Maintenance and Checking
Maintenance
In maintenance of the unit, take into consideration the rate of use and the environment
it is used in. When the unit is used properly and serviced regularly you will avoid
unnecessary disturbances in use and production.
Check electrical connections of unit at least twice a year. Repair or replace
broken/damaged cables.
Clean oxidised connections and tighten.
Inner parts of machine should be cleaned with a vacuum cleaner and soft brush.
Avoid water or moisture in the machine, if water or moisture should be blown dry in
time, and use megohm meter to measure the insulation condition, qualified before
use.
If it is not used after welding for a long time, it should be returned to the original
packing box and placed in a dry environment without direct sunlight.
Checking
WELDING POWER
Position Checking keys Remarks
Operation
control board
Operation, conversion and
installation of the switch
Check the state of the power
indicator light
Lead to unstable arc and wire
sending
Cool-down fan
Check if the fan state and the
sound is normal or not
Clean the residue and check the
reason and solve it
Power part
Check if there is abnormal
liberation and sound when the
power is on
Check if there is smell when the
power is on
-

14
Whether the outside color change
or get warm
Outer parts
Whether the wire feeder pipe is
broken,and the connector is loose
Whether the outer shell or other
connecting parts are loose.
CABLE
Position Checking keys Remarks
Output cable
Wearing-out of the cable insulated
material
Cable connecting head naked
(insulation damage), or loosen (the
end of power supply, and cable of
main material connecting point)
For life security and stable
welding, adopt suitable method to
check according to working place
Simple check daily
Careful and in-depth check on
fixed period
Input cable
If the connection between the plug
and the power socket is firm
If the power input end cable fixed
If the input cable is worn out and
bares the conductor
Earth cable
If the earth cable that connects the
main part is broken and connects
tightly
In case of leakage and to ensure
safety, please do perform daily
checking

15
8 Trouble Shooting
IMPORTANT: Only authorised repair agents with valid certifications should carry out
repairs and internal servicing.
Faults symptom Reasons Solutions
1 Fan is not working
2 No welding current
output
1 Power switch is broken.
2 The silicon bridge is
damaged.
3 There is malfunction that
occurs in the supplementary
power source on control
board.
1 Replace the power switch
2 Replace the silicon bridge.
3 If problem persists, please
contact a service agent.
1 Fan works normally;
2 No welding output
1 There is open circuit or
badness of connection at
the joint of output terminal.
2 The control cable on the
torch is broken off or the
switch is damaged.
3 The control circuit is
damaged.
1 Check if all the sockets in the
machine are connected well.
2Replacethetorch.
3 If problem persists, please
contact a service agent.
1 Fan is not working
2 It has abnormal
indication
1Thefanisbroken.
2 Internal fault.
1Replacethefan.
2 If problem persists, please
contact a service agent.
1 Fan is working, it has
abnormal indication
2 No welding current
output
1Overheatprotection.
2 The circuit of auxiliary
power supply is broken.
1 The machine will automatically
return to normal in 5–10 minutes.
2 If problem persists, please
contact a service agent.
1 Power switch doesn’t
work
1 Power switch is broken.
2 Three phase rectifier
bridge is broken.
1 Replace the power switch.
2 Replace the three phase rectifier
bridge.
3 Check if there is any short circuit
of inner machine.

16
Appendix A Welding Parameter
Please refer to the following table for the welding process parameters of MMA welding,
and the details shall be subject to the actual conditions.
Electrode
type
Electrode
model
Connection
type
Welding
post
Diameter
(mm)
Current
range (A)
Structural
steel
electrode -
acid
electrode
E4313/ J421
E4303/ J422
E5003/ J502
DCEN
Flat position
2.5 50~90
3.2 90~140
4.0 150~210
5.0 210~270
Horizontal
position
3.2 90~120
4.0 120~180
Vertical
position
3.2 90~110
4.0 120~150
Overhead
position
3.2 95~120
4.0 120~180
Structural
steel
electrode -
basic
electrode
E4315/ J427
E4316/ J426
E5015/ J507
E5016/ J506
E5018/ J506LMA
E5015-G/ J507R
E5015-G/ J507RH
E5515-G/ J557
E6015-D1/ J607
E8015-G/ J807
E8515-G/ J857CrNi
E9015-G/ J907
DCEP
Flat position
2.5 50~90
3.2 80~125
4.0 140~180
5.0 180~240
Horizontal
position
3.2 80~120
4.0 140~170
Vertical
position
3.2 80~105
4.0 120~150
Overhead
position
3.2 80~120
4.0 120~170
Stainless
steel
electrode
A112
E308-16/ A102
E347-16/ A132
E309-16/ A302
DCEN /
DCEP Flat position
2.5 50~80
3.2 80~110
4.0 110~160
5.0 160~200
Surfacing
electrode
EDPCrMo-A2-03/
D132
EDPMn2-15/ D107
DCEN /
DCEP Flat position
3.2 90~110
4.0 140~180
5.0 180~220
EDCoCr-A-03/ D802 DCEN /
DCEP Flat position 4.0 120~160
5.0 140~190
DCEN: Direct Current Electrode Negative.
DCEP: Direct Current Electrode Positive.

17
Appendix B Circuit Diagram
A
1
C2
K3
C
4
DB1 C5
820UF /4 00V
C6
820UF/400V
R5
75K/3W*3
R4
75K/3W*3
34 12
K1
1
PCON1
1
PCON2
34 12
K2 *
+24V
+24V
C1
472/3KV
C2
472/3KV
R86100K
VG ND
1
2
3
D1 2
STTH 60RL03 CW
1
2
3
D9
STTH 60RL03 CW
1
2
3
D1 0
STTH 60RL03 CW
C1 1
2.2nF/2KV
R2 2 33R 1W
C1 2 2.2nF/2KV
C1 4
472/3KV
C1 3
472/3KV
1 2 3 4
T1 18:4+4
R25
6. 8K
LP /CURRENT
LP 1
LP 2
电路
3
RZ13 3- 01A _Samp lin g.s ch
LP /CURRENT
LP 1
LP 2
1 2
CO N2 *
GND
GND
电流互感 器
温度传感器
1
2
3
D11
STTH 60RL03 CW
1
122
L3
GND
1 1 1
PCON
5
S=1*1
6
R2 3 33R 1W R2 4
R1 9
33R 1W
R2 0
33R 1W
R2 1
33R 1W
R26
6. 8K
R27
6. 8K
1
2
10
6
T4 200:1
1 1 1
PCON
6
CO N1
2
1
3
Q1
40H12 0
2
1
3
Q2
40H12 0
R1 5 10R R1 6
10R
R1 7
4.7R
R1 8
4.7R
D8
SUF4007
D7 SUF4007
C8 4.7uF C7 4.7uF R1 3 3 3R
R6 3 3R
C9
471
R1 2 3 3R R7 33R
C1 0
471
VCC VGND
+24V
GND
NETVO L
+3. 3V
电路
1
RZ13 3- 01A _P owe r.s c h
VCC VGND
+24V
GND
NETVO L
+3. 3V
Driv e G2
Driv e E2
Driv e G1
Driv e E1
+24V GND NETVO L MO T/ COO L POWER/EN
LP /CURRENT
TEMP/ CHECK
DOUBLE_VOL T
+3.3V
电路
2
RZ13 3- 0 1A -0 1A _MCU. Sc h
Driv e G2
Driv e E2
Driv e G1
Driv e E1
+24V GND NETVO L MO T/ COO L POWER/EN
LP /CURRENT
TEMP/ CHECK
DOUBLE_VOL T
+3.3V
1
2
CO N3 * 风机
+15V
t
RR1 PTC
t
RR2 NT C
1
2
4
5
CO N5
D6
IN4007
D3 IN4007
D4
IN4007
D5 IN4007
C3
47UF
C4
47UF
R2 330K R3 330K
R1 1 3 3R R1 0 3 3R
R8 3 3R R9 3 3R
D24 SUF4007
D13 SUF4007
R87 100K
R8 9
470K/0.5W
R8 8
470K/0.5W
面板
1
2
3
4
5
6
7
8
CO N4
1
2
3
4
5
6
7
8
CO N1