Jasic Arc 200 PFC User manual

Copyright©2022 Shenzhen JASIC Technology Co., Ltd.
ARC200PFC/ARC160PFC
ARC200/ARC160
IGBT INVERTER WELDER

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Thank you for selecting this new JASIC equipment!
This operating manual contains important information on the use and maintenance of this
product, as well as safe handling of the product. Please refer to technical parameters of the
equipment in Technical Parameter section in this manual, and read the manual carefully
before using the equipment for the first time. For your own safety and that of your working
environment, please pay particular attention to the safety instructions in the manual and
operate the equipment according to the instructions. For more information on JASIC
products, please contact JASIC Technology, consult an authorized JASIC dealer or visit
JASIC website at www.jasictech.com.
Disclaimer
Shenzhen JASIC Technology Co., Ltd. solemnly promises that this product is manufactured according
to relevant domestic and international standards, and that this product conforms to EN60974-1
International Safety Standard. Patents protect the relevant design scheme and manufacturing technology
adopted in this product.
1. Whilst every effort has been made to ensure that the information contained within this manual is
complete and accurate, no liability can be accepted for any errors or omissions. Please note products are
subject to continual development and may be subject to change without notice.
2. Though contents in this manual have been carefully checked, there may be inaccuracies. Please do not
hesitate contact us in case of any inaccuracy.
3. Do not copy, record, reproduce or transmit the contents of this manual without prior permission from
JASIC.
Manufacturer: Shenzhen JASIC Technology Co. Ltd
Registered Trademark: JASIC
Registered Address: No.3 Qinglan 1st Road, Pingshan District, Shenzhen, Guangdong, China
Postcode: 518118
Tel: [phone] Fax: [phone]
Website: www.jasictech.com E-mail: [e-mail]

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Contents
1. Safety precautions.......................................................................................................................... 6
1.1. General safety..............................................................................................................................6
1.2. Other precautions........................................................................................................................ 9
2. Description of symbols.................................................................................................................10
3. Product overview...........................................................................................................................11
4. Technical parameters................................................................................................................... 12
5. Installation...................................................................................................................................... 14
5.1. External interface description.................................................................................................. 14
5.2. Power installation...................................................................................................................... 15
5.3. MMA electrode holder and earth cable connection..............................................................16
5.4. LIFT TIG welding torch and earth cable connection............................................................ 17
5.5. Wired hand-held remote-control connection (optional)....................................................... 18
(Not optional for standard version without remote control interface)........................................ 18
5.6. Installation of wireless receiver module (optional)............................................................... 18
6. Control panel................................................................................................................................. 20
6.1. Overview..................................................................................................................................... 20
6.2. Display of parameters and error codes..................................................................................21
6.3. Parameter adjustment knob.....................................................................................................21
6.4. Selection of working mode.......................................................................................................21
6.5. Selection of welding electrode diameter for MMA................................................................22
6.6. Selection of MMA parameters................................................................................................. 22
6.7. LIFT TIG mode parameter setting...........................................................................................23
6.8. Protection indicators................................................................................................................. 23
6.9. VRD (Voltage reduction device) function indications...........................................................23
6.10. Barcode display....................................................................................................................... 23
6.11. Restore factory settings..........................................................................................................23
6.12. Wired hand-held remote control (optional)..........................................................................24
6.13. Wireless remote control (optional)........................................................................................24
7. Welding function operation..........................................................................................................25
7.1. MMA operation...........................................................................................................................25
7.2. LIFT TIG operation.................................................................................................................... 29
8. Maintenance.................................................................................................................................. 31
8.1 Power supply maintenance.......................................................................................................31
8.2 Welding torch maintenance...................................................................................................... 32
9. Troubleshooting.............................................................................................................................34
9.1. Common malfunction analysis and solution..........................................................................34
9.2. Alarm and solutions...................................................................................................................37
10. Packaging, transportation, storage and waste disposal.......................................................38
10.1 Transportation requirements...................................................................................................38
10.2 Storage conditions................................................................................................................... 38
10.3 WEEE waste disposal............................................................................................................. 38
Appendix 1: Wiring diagram............................................................................................................ 39
Appendix 2: Exploded view of ARC160 and ARC200................................................................. 40

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Appendix 3: Exploded view of ARC160PFC and ARC200PFC................................................. 43

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For your safety, please read this manual carefully before installing and
operating this JASIC equipment.
Pay extra attention to all content marked with " " .
All operations must be carried out by professional, suitably qualified
persons!

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1. Safety precautions
1.1. General safety
SAFETY INSTRUCTION
These general safety norms cover both arc welding machines and plasma cutting
machines unless otherwise noted.
It is important that users of this equipment protect yourselves and others from harm or even
death.
The equipment must only be used for the purpose it was designed for. Using it in any other
way could result in damage or injury and in breach of the safety rules.
Only suitably trained and competent persons should use the equipment.
Pacemaker wearers should consult your doctor prior to using this equipment
PPE and workplace safety equipment must be compatible for the application of work
involved.
Always carry out a risk assessment before carrying out any welding or cutting activity
Only qualified personnel should operate this machine!
·Always use the appropriate personal protective equipment.
·Always pay attention to the safety of other persons around the working zone
·Do not carry out any maintenance with the power on the machine
Electric shock——May cause serious injury or even death!
·The equipment should be installed by a qualified person and in accordance
with current standards in operation. It is the users responsibility to ensure that
the equipment is connected to a suitable power supply. Consult with your utility
supplier if required. Do not use the equipment with the covers removed.
·Do not touch live electrical parts or parts, which are electrically charged.
·Turn off all equipment when not in use.
Fumes and gases——May be hazardous to your health.
Locate the equipment in a well-ventilated position and keep your head out of the
fume.
Do not breathe the fume.
Ensure the working zone is well ventilated and provision should be made for
suitable local fume extraction system to be in place.
If ventilation is poor, wear an approved air fed welding helmet or respirator.
Read and understand the Material Safety Data Sheets (MSDS’s) and the
manufacturer’s instructions for metals, consumable, coatings, cleaners and
de-greasers.
Do not work in locations near any de-greasing, cleaning or spraying operations.
Be aware that heat and rays of the arc can react with vapours to form highly
toxic and irritating gases.

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Arc rays——May injure the eyes and burn the skin.
The arc rays from all processes produce intense, visible and invisible (ultraviolet
and infrared) rays that can burn eyes and skin.
·Wear an approved welding helmet fitted with an appropriate shade of filter lens
to protect your face and eyes when working or watching.
·Wear approved safety glasses with side shields under your helmet.
·Never use broken or faulty welding helmets.
·Always ensure there are adequate protective screens or barriers to protect
others from flash, glare and sparks from the working area.
·Ensure that there are adequate warnings that welding or cutting is taking place.
·Wear suitable protective flame resistant clothing, gloves and footwear.
Precautions against fire and explosion
Avoid causing fires due to sparks and hot waste or molten metal.
Ensure that appropriate fire safety devices are available near the welding and
cutting area.
Remove all flammable and combustible materials from the welding, cutting and
surrounding areas.
Do not weld or cut fuel and lubricant containers, even if empty. These must be
carefully cleaned before they can be welded or cut.
Always allow the welded or cut material to cool before touching it or placing it in
contact with combustible or flammable material.
Do not work in atmospheres with high concentrations of combustible fumes,
flammable gases and dust.
Always check the work area half an hour after cutting to make sure that no fires
have begun.
Take care to avoid accidental contact of electrode to metal objects. This could
cause arcs, explosion, overheating or fire.
Risks due to hot material ·
The process will create hot metal, sparks and drips of molten metal, so its very
important to ensure the operator is equipped with full PPE and to always ensure
there are adequate protective screens or barriers to protect others from flash,
glare and sparks from the working area. Hot surfaces will create fires and will
burn any exposed skin.
Always protect your eyes and body. Use the correct welding screen and filter
lens and wear full PPE protective clothing.
Do not touch any hot surfaces or parts bare handed.
Always allow hot surfaces and parts to cool down first before touching or
moving.
If you are required to move hot parts, ensure you use proper tools and insulated
welding gloves (PPE) to prevent burns to your hands and arms.

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Noise——Excessive noise may be harmful to hearing
·Protect your ears by ear shields or other hearing protectors.
·Give warning to nearby personnel that noise may be potentially
hazardous to hearing.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the operation of
pacemakers or electronically controlled medical equipment.
Wearers of vital electronic equipment should consult their physician before
beginning any arc welding, cutting, gouging or spot welding operations.
Do not go near welding equipment with any sensitive electronic equipment as
the magnetic fields may cause damage.
Keep the torch cable and work return cable as close to each other as possible
throughout their length, this can help minimise your exposure to harmful
magnetic fields.
Do not wrap the cables around the body.
Protection from moving parts
When the machine is in operation keep away from moving parts such as motors
and fans.
Moving parts, such as the fan, may cut fingers and hands and snag garments.
Protections and coverings may be removed for maintenance and controls only
by qualified personnel after first disconnecting the power supply cable.
Replace the coverings and protections and close all doors when the intervention
is finished and before starting the equipment.
Take care to avoid getting fingers trapped when loading and feeding wire during
set up and operation.
When feeding wire be careful to avoid pointing it at other people or towards your
body.
Always ensure machine covers and protective devices are in operation.
Troubleshooting
Before the machines are dispatched from the factory, they have already been
checked thoroughly. The machine should not be tampered with or altered.
Maintenance must be carried out carefully. If any wire becomes loose or is
misplaced, it maybe potentially dangerous to user!
Only professional maintenance personnel should repair the machine!
Ensure the power is disconnected before working on the machine. Always wait
5 minutes after power switch off before removing the panels.
If you still do not fully understand or cannot solve the problem after reading the
instructions in this manual, you should contact the supplier or JASIC's service
center immediately for professional help.

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1.2. Other precautions
Warning! Location
The machine should be located in a suitable position and environment. Care
should be taken to avoid moisture, dust, steam, oil or corrosive gases. Place
on a secure level surface and ensure that there is adequate clearance
around the machine to ensure natural airflow.
Warning! The handle or strap on the machine is only suitable for manual
lifting of the machine. If mechanical equipment such as crane is used to lift
the machine, please ensure the machine is secured with suitable lifting
equipment.
Warning!
Input connection
Before connecting the machine, you should ensure that the correct supply is
available. Details of the machine requirements can be found on the data
plate of the machine or in the technical parameters shown in the manual. The
equipment should be connected by a suitably qualified competent person.
Always ensure the equipment has a proper grounding.
Never connect the machine to the mains supply with the panels removed.
1) When the operator's movement is limited by the surroundings (for example, the operator
can only bend his knees, barefoot, or lie down during operation), the operator shall practice
proper insulation and avoid direct contact with conductive parts on the equipment.
2) Do not use the machine in closed containers in narrow spaces where conductive
components cannot be removed.
3) Do not use the machine in humid environments where the operator is prone to the risk of
electric shock.
4) Do not use the machine in sunlight or rain, and no water or rainwater shall seep into the
machine.
5) Do not perform gas shielded welding in an environment with strong air flow.
6) Avoid welding or cutting in dusty area or environment with corrosive chemical gas.
7) The ambient temperature must be between-10° C and 40°C during operation and
between-25°C and 50°C during storage.
8) Welding or cutting shall be carried out in a relatively dry environment, and the air humidity
shall not exceed 90%.
9) The inclination of the machine shall not exceed 10°.
10) Ensure that the input power supply voltage does not exceed 15% of the rated voltage of
the machine.
11)Beware of falling when welding or cutting at heights.

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2. Description of symbols
Read this operation manual carefully before use。
Warning in operation。
Single-phase static frequency converter-transformer rectifier。
Symbol of single-phase AC power supply and rated frequency。
Can be used in the environment which has high risk of electric shock.
IP Degree of protection, such as IP23S.
U1Rated AC input voltage (with tolerance ±15%)
I1max Rated maximum input current
I1eff Maximum effective input current
XDuty cycle The ratio of given duration time/the full-cycle time
Note1: This ratio shall be within 0~1, and can be indicated by percentage.
Note2: In this standard, the full-cycle time is 10 min.
For example, if the duty cycle is 60%, the load-applying time shall be 6 min and the following
no-load time shall be 4min.
U0No-load voltage, Open circuit voltage of secondary winding.
U2Load voltage
HInsulation class
It’s forbidden to dispose electric waste with other ordinary waste. Please take care
of our environment.
Electric shock risk warning
Current unit "A"
Overheat protection indicator
Overcurrent protection indicator
VRD function indicator
MMA mode
LIFT TIG mode
Selection of welding electrode diameter for MMA

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MMA current
Hot start current of MMA
Arc force of MMA
Welding mode switching
Other function switching
Wireless indication
Remote control
Pairing of wireless remote controller
3. Product overview
This is a digital inverter DC manual welder featuring advanced technology which provides
excellent performance. It provides stable DC arc and can weld carbon steel, low alloy steel,
stainless steel and other materials. Moreover, it offers adjustable Hot start and Arc force
functions. It is a durable machine with a wide range of applications.
With DC MMA and LIFT TIG processes, it can be widely used in precise welding of an
extensive range of materials. The unique electrical structure and air passage design inside
the machine increases the dissipation of heat generated by power devices, thus improving
the duty cycle of the machine. Benefitting from the unique air passage, the equipment can
effectively prevent damage to power devices and control circuits from dust drawn in by the
fan, thus greatly improving the reliability of the equipment.
The main functions are:
Two welding processes: DC MMA and LIFT TIG.
Current settings, Arc force and Hot start current are displayed for more accurate
adjustment.

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Anti-stick function: prevents the welding electrode from sticking to the work piece
during welding.
Synergic function: the current is set automatically to match the selected electrode
diameter, making the welder easier to use
MMA Hot start function: makes MMA arc ignition easier and more reliable.
On-demand fan: prolongs the life span of fan and reduce the accumulation of dust
inside the machine.
Arc ignition function: HF TIG ignition with provide reliable arc ignition.
Parameters are automatically saved before shutdown, and the settings are restored
after starting again.
Parameters factory restore.
Wired hand-held remote control and wireless remote control are optional. (Not optional
for standard version which has no remote control interface)
4. Technical parameters
Item
Unit
Parameters
Model
/
ARC200PFC
ARC160PFC
ARC200
ARC160
Input voltage
VAC
AC95~265V
AC95~265V
AC230V±15%
AC230V±15%
Input frequency
Hz
50/60
50/60
50/60
50/60
Rated input
current
(AC230V)
A
19.6@TIG
29.7@MMA
14@TIG
22.6@MMA
27@TIG
39@MMA
24@TIG
33@MMA
Rated input
current
(AC115V)
A
27.2@TIG
31.2@MMA
23.3@TIG
28.7@MMA
/
/
Rated input
power
(AC230V)
kVA
4.5@TIG
6.8@MMA
3.2@TIG
5@MMA
6.2@TIG
9@MMA
5.5@TIG
7.6@MMA
Rated input
power
(AC115V)
kVA
3.1@TIG
3.6@MMA
2.7@TIG
3.3@MMA
/
/
Welding current
range (TIG)
(AC230V)
A
10～200
10～160
10～200
10～160
Welding current
range (MMA)
(AC230V)
A
20～200
20～160
20～200
20～160
Welding current
range (TIG)
(AC115V)
A
10～160
10～120
/
/

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Welding current
range (MMA)
(AC115V)
A
20～120
20～110
/
/
Welding voltage
range (TIG)
(AC230V)
V
10.4～18
10.4～16.4
10.4～18
10.4～16.4
Welding voltage
range (MMA)
(AC230V)
V
20.4～28
20.4～26.4
20.4～28
20.4～26.4
Welding voltage
range (TIG)
(AC115V)
V
10.4～16.4
10.4～14.8
/
/
Welding voltage
range (MMA)
(AC115V)
V
20.4～24.8
20.4～24.4
/
/
Arc force range
A
0～60
0～60
0～60
0～60
Hot start current
range
A
0～60
0～60
0～60
0～60
No-load voltage
V
78
78
62
62
VRD voltage
V
11
11
11
11
Arc start mode
Contact arc start
Contact arc start
Contact arc start
Contact arc start
Duty cycle (%)
%
TIG: 200@25%
MMA: 200@25%
TIG: 160@25%
MMA: 160@25%
TIG: 200@25%
MMA: 200@25%
TIG: 160@25%
MMA: 160@25%
Power factor
0.99
0.99
0.72
0.64
Insulation class
H
H
H
H
Protection class
IP23S
IP23S
IP23S
IP23S
Dimensions
L*W*H
mm
413*150*311
413*150*311
375*131*252
375*131*252
Net weight
Kg
7.2
7.2
5.5
5.5
Overall total
weight
Kg
9.0
9.0
6.5
6.5
Power supply
efficiency (at
maximum input
current)
%
85
86
86
86.5
Idle state power
W
47
38.2
26
22.6
Characteristic
CC
CC
CC
CC
Pollution level
Level 3
Level 3
Level 3
Level 3

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5. Installation
Warning! All connections shall be made with the power supply is turned off.
Warning! Electric shock may cause death; after power failure, there is still a
high voltage on the equipment, do not touch the live parts on the equipment.
Warning! Incorrect input voltage may damage the equipment.
Warning! This product meets the requirements of Class A equipment in EMC
requirements and is not to be connected to a residential low-voltage power
supply grid.
5.1. External interface description
(Front panel view) (Rear panel view)
a. Power switch
b. Input power cord
c. Output positive polarity
d. Output negative polarity
e. Wired hand-held remote control (optional) (Not optional for standard version which has
no remote control interface)
f. Wireless remote control (optional) (Not optional for standard version which has no remote
control interface)

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5.2. Power installation
Warning! The electrical connection of equipment shall be carried out by
suitably qualified personnel.
Warning! All connections shall be made after the power supply is off.
Warning! Incorrect voltage may damage the equipment.
1) Test with multi-meter to ensure the input voltage value is within the specified input
voltage range.
2) Ensure that the power switch of the welder is turned off.
3) Connect the input power cord to the input terminal or plug the power cord into the
corresponding socket (if any) and ensure a good contact.
4) Ground the power supply well. (As shown in the diagram, the European plug has a
grounding terminal, so no additional grounding is required.)
(Wiring diagram)
NOTE!
If the input cable needs to be extended, please use a cable with larger cross-sectional
area to reduce the voltage drop, 3x2.5mm2or more is recommended.

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5.3. MMA electrode holder and earth cable connection
(Wiring diagram)
Pay attention to the polarity of wiring before MMA welding. Generally, there are two
connection methods of DC welder: DCEN and DCEP connection.
DCEN: the welding electrode holder is connected to the negative polarity, and the workpiece
is connected to the positive polarity.
DCEP: the electrode holder is connected to the positive polarity, and the workpiece is
connected to the negative polarity.
The operator can choose DCEN based on the base metal and welding electrode. Generally
speaking, DCEP is recommended for basic electrodes (i.e., electrode connected to the
positive polarity), while no special provisions are made for acid electrodes.
1) Ensure that the power switch of the welder is turned off.
2) Insert the cable plug with welding electrode holder into the corresponding socket under
the front panel of the welder and tighten it clockwise.
3) Insert the cable plug with earth clamp into the corresponding socket under the front panel
of the welder and tighten it clockwise.
NOTE! If you want to use long secondary cables (electrode holder and earth cable),
you must ensure that the cross-sectional area of the cable is increased appropriately
in order to reduce the voltage drop due to the cable length.

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5.4. LIFT TIG welding torch and earth cable connection
1) Ensure that the power switch is turned off.
2) Insert the cable plug with the earth clamp into the positive socket on the front panel of the
welder and tighten it clockwise.
3) Insert the cable plug of the welding torch into the corresponding negative socket on the
front panel of the welder and tighten it clockwise.
Note! The positive and negative polarities should not be reversed as this will prevent
normal welding operation.
4) Connect the shield gas pipe input end of the welding torch to the output gas connection of
the gas pressure regulator and secure it firmly with a clamp.
(Wiring diagram)
NOTE! If you want to use long secondary cables (TIG torch and earth cable), you must
ensure that the cross-sectional area of the cable is increased appropriately in order to
reduce the voltage drop due to the cable length.

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5.5. Wired hand-held remote-control connection (optional)
(Not optional for standard version without remote control interface)
(Wiring diagram)
Insert the 3-pin aviation plug of the hand-held remote controller directly into the
corresponding remote socket of the machine.
NOTE: Please check that the machine supports wired hand-held remote control
before installation.
5.6. Installation of wireless receiver module (optional)
(Not optional for standard version without remote control interface)

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(Installation drawing)
1) Remove the plug shown in above left drawing,and refit into the space the wireless
receiver module shown in above right drawing.
2) Remove the screws on the left side cover of the machine.
3) Remove the buckle inside the front panel of the machine and pull out the plug.
卡扣
4) Insert the wireless receiver module to the front panel, and then connect the connection
line of the receiver module to the CN5 socket on the main board.
NOTE: Please check that the machine supports wired hand-held remote control
before installation.

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6. Control panel
6.1. Overview
a. Parameter and error code display
b. Protection indicator
c. Operation mode selector
d. electrode diameter selector
e. VRD function indicator
f. Parameter adjustment knob
g. MMA parameter selection
h. Remote control enable (optional) (The standard version does not have the key and the
indicator will not be on during working)