Jasic MIG160PFC User manual

Copyright©2022 Shenzhen JASIC Technology Co., Ltd.
MIG160PFC/MIG160
MIG200PFC/MIG200
MIG250PFC/MIG250
IGBT INVERTER WELDER

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Congratulations on choosing 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 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. The relevant design scheme and manufacturing technology adopted in this
product are protected by patents.
1. While every effort has been made to ensure that the information contained in this manual is accurate
and complete, no liability will be accepted for any errors or omissions dueto theoperation not according to
this manual.
2. JASIC reserves the right to change the manual at any time without prior notice.
3. Though contents in this manual have been carefully checked, there might be inaccuracies. Please
contact us in case of inaccuracy.
4. 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: sale[email protected]

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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.............................................................................................................12
4. Technical parameters.......................................................................................................14
5. Installation .......................................................................................................................17
5.1. External interface description .......................................................................................18
5.2. Power installation..........................................................................................................20
5.3. MIG welding torch and earth cable connection.............................................................21
5.4. MMA electrode holder and earth cable connection.......................................................23
5.5. Lift TIG welding torch and earth cable connection........................................................24
5.6. Wired handheld remote controller / foot pedal controller connection (optional)............25
5.7. Installation of wireless receiver module (optional) ........................................................25
6. Control panel...................................................................................................................26
6.1. Overview.......................................................................................................................26
6.2. Barcode display............................................................................................................32
6.3. Restore factory settings................................................................................................32
6.4. Welding engineer mode functions.................................................................................34
7. Welding function operation..............................................................................................36
7.1. MIG operation...............................................................................................................36
7.2. MMA operation .............................................................................................................42
7.3. Lift TIG operation..........................................................................................................44
7.4. Standby ........................................................................................................................46
7.5. Functions and use of wireless/wired remote controller.................................................46
8. Maintenance....................................................................................................................47
8.1. Power supply maintenance...........................................................................................47
9. Troubleshooting...............................................................................................................48
9.1. Common malfunction analysis and solution..................................................................48
9.2. Alarm and solutions ......................................................................................................51
9.3. Common MIG malfunction............................................................................................52
10. Packaging, transportation, storage and waste disposal.................................................53
10.1. Transportation requirements.......................................................................................53
10.2. Storage conditions......................................................................................................53
10.3. Waste disposal ...........................................................................................................53
11. After-sales service..........................................................................................................54
11.1. Warranty card .............................................................................................................54
11.2. Maintenance ...............................................................................................................54
Appendixes..........................................................................................................................55
Appendix 1: Wiring diagram.................................................................................................55
Appendix 2: List of common spare parts..............................................................................59
Appendix 3 Packaging and parts.........................................................................................69

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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 user's 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 it's 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 surfacesand parts to cool down first before touching ormoving.
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.
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.

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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 minimize 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
Warning! Read the Manual
Electric shock risk warning
WEEE tag
Current unit "A"
Wire feed speed unit "m/min"
Thickness of welding base metal "mm"
Voltage unit "V"
Inductance of MIG/arc force of MMA
MIG burn back time unit "ms"
Overheat protection indicator
Overcurrent protection indicator
VRD function indicator
MMA mode
MIG mode
Lift TIG mode
Welding mode switching
Mixed gas welding (80% argon + 20% CO2) of carbon steel
Mixed gas welding (80% argon + 20% CO2) of flux-cored carbon steel
Self-shielded welding of carbon steel
100% argon shielding of aluminum magnesium alloy
Mixed gas welding (98% argon + 2% CO2) of stainless steel
Welding type selection: welding base metal and gas

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Welding wire diameter
MIG/Lift TIG 2T operation
MIG/Lift TIG 4T operation
MIG push torch
MIG spool torch
Other function switching
Remote controller
MIG synergic function
Inching wire feeding function
Gas check function

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3. Product overview
MIG160/MIG200 series MIG250 series
This series are digital multi-process inverter DC MIG welders featuring advanced technology
with excellent performance. They can be used to weld carbon steel, low-alloy steel, aluminum
magnesium alloy and stainless steel, etc. The MIG mode of the welder features preset wire
feed speed and welding voltage. The welders also have a built-in "Synergic" expert
parameter library for welding wires of different diameters under different shielding gases and
base metals. After setting the welding wire diameter, shielding gases and base metal through
the panel, the operator sets one of the welding current, wire feed speed and plate thickness,
and the welder automatically finds the corresponding welding voltage to achieve good
welding results. With adjustable arc-force in MMA and torch-control Lift TIG modes, these
welders have wider applications.
These inverter welders support DC MIG, DC MMA and Lift TIG welding modes and can be
widely used to weld various metals. The unique electrical structure and zoning diversion-type
air passage design inside the machine increases the heat dissipation efficiency, thus
improving its duty cycle. Benefitting from the unique air passage design, the machine
effectively prevents damage to the power device and control circuits from dust drawn in by
the fan, thus greatly improving its reliability.
The main functions include:
◆Three welding modes: MIG, MMA and Lift TIG.
◆In MIG mode, preset the wire feed speed, welding voltage, welding inductance and burn
back time.
◆Supports selection of gas check, inching wire feeding and wire diameter.
◆"Synergic" function: The welder automatically matches the parameters according to the
welding wire diameter, gas and base metal after setting the current, wire feed speed, and
plate thickness, making it easier to use.
◆Can be equipped with a digital/analog push torch or analog spool torch.
◆In MMA mode, preset the current and arc force, making the current adjustment more

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accurate.
◆Anti-stick function: Prevents the welding electrode from sticking to the work piece during
welding.
◆MMA hot start function: Makes MMA arc ignition easier and more reliable.
◆Lift TIG is controlled by the welding torch.
◆On-demand fan: Prolongs the life span of fan and reduces accumulation of dust inside the
machine.
◆Parameters are automatically saved before shutdown, and the settings are restored after
starting again.
◆Factory settings parameter restore function.
◆Standby function: In MIG and Lift TIG mode, the machine automatically enters standby
state if it is not used for a long time.
◆Optional wired handheld remote controller and wireless remote controller.(Not optional for
standard version which has no remote control interface)

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4. Technical parameters
Item
Unit
MIG160/MIG200/MIG250 Parameters
Model
/
MIG250
MIG200
MIG160
Input voltage
VAC
AC230V±15%
AC230V±15%
AC230V±15%
Input frequency
Hz
50/60
50/60
50/60
Rated input current
(AC230V)
A
46.3@MIG
33.5@TIG
41.3@MMA
46@MIG
32@TIG
36@MMA
46@MIG
26@TIG
29@MMA
Rated input power
(AC230V)
kVA
10.51@MIG
9.08@TIG
10.15@MMA
8.85@MIG
7.53@TIG
8.81@MMA
7.28@MIG
5.98@TIG
7.26@MMA
Output current range
(MIG)
V
11~30
11~28
11~26
Wire feed speed
range (MIG)
m/min
2~18
2~15
2~14
Output current range
(MIG)
A
30~250
30~200
30~160
Output current range
(Lift TIG)
A
5~250
5~200
5~160
Output current range
(MMA)
A
20~220
20~180
20~140
Arc force range
A
0~60, 30 by default
0~60, 30 by default
0~60, 30 by default
Hot start current
range
A
60
60
60
No-load voltage
V
60
60
60
VRD voltage
V
10.5
10.1
10.1
Rated working
voltage
V
26.5@MIG
20@TIG
28.8@MMA
24@MIG
18@TIG
27.2@MMA
22@MIG
16.4@TIG
25.6@MMA
Efficiency (%)
/
85.74%@MIG
83.67%@TIG
87.44%@MMA
81.39%@MIG
80.51%%@TIG
85.49%@MMA
83.6%@MIG
81.2% @TIG
85.7%@MMA
Duty cycle (%)
/
30%@MIG
30%@TIG
30%@MMA
30%@MIG
30%@TIG
30%@MMA
30%@MIG
30%@TIG
30%@MMA

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Power factor
/
0.73@MIG
0.66@TIG
0.72@MMA
0.65@MIG
0.59@TIG
0.65@MMA
0.58@MIG
0.54@TIG
0.58@MMA
Insulation class
/
H
H
H
Protection class
/
IP23S
IP23S
IP23S
Dimensions L*W*H
mm
700*280*511
565*220*415
565*220*415
Net weight
Kg
24@ plus
15@ plus
15@ plus
23.7@ standard
14.7@ standard
14.5@ standard
Overall total weight
Kg
31.3@ plus
20.7@ plus
20.7@ plus
30@ standard
19.9@ standard
19.7@ standard
Idle state power
W
<50
<50
<50
Characteristics
/
CC/CV
CC/CV
CC/CV
Pollution level
/
Grade 3
Grade 3
Grade 3
Item
Unit
MIG160PFC/MIG200PFC/MIG250PFC Parameters
Model
/
MIG250PFC
MIG200PFC
MIG160PFC
Input voltage
VAC
AC230V±15%
AC230V±15%
AC230V±15%
Input frequency
Hz
50/60
50/60
50/60
Rated input current
(AC230V)
A
43.7@MIG
26.6@TIG
31.9@MMA
38.3@MIG
19.1@TIG
25@MMA
33@MIG
14.4@TIG
18.5@MMA
Rated input current
(AC115V)
A
38.7@MIG
28.9@TIG
33@MMA
41.8@MIG
23.7@TIG
28.5@MMA
37.5@MIG
16.4@TIG
25.3@MMA
Rated input power
(AC230V)
kVA
7.84@MIG
6.07@TIG
7.34@MMA
5.74@MIG
4.43@TIG
5.77@MMA
4.22@MIG
3.23@TIG
4.19@MMA
Rated input power
(AC115V)
kVA
4.32@MIG
3.31@TIG
3.75@MMA
3.68@MIG
2.79@TIG
3.28@MMA
2.98@MIG
1.79@TIG
2.26@MMA

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Output voltage range
(MIG)
V
11~30@230V
11~25@115V
11~28@230V
11~24@115V
11~26@230V
11~22@115V
Wire feed speed range
(MIG)
m/min
2~18@230V
2~13@115V
2~15@230V
2~13@115V
2~14@230V
2~11@115V
Output current range
(MIG)
A
30~250@230V
30~160@115V
30~200@230V
30~140@115V
30~160@230V
30~120@115V
Output current range
(TIG)
A
5~250@230V
5~160@115V
5~200@230V
5~140@115V
5~160@230V
5~100@115V
Output current range
(MMA)
A
20~220@230V
20~125@115V
20~180@230V
20~110@115V
20~140@230V
20~100@115V
Arc force range
A
0~100
0~100
0~100
Hot start current range
A
0~60, 30 by default
0~60, 30 by default
0~60, 30 by default
No-load voltage
V
65
67
67
VRD voltage
V
10.1
10.1
10.1
Rated working voltage
V
26.5@MIG
20@TIG
28.8@MMA
24@MIG
18@TIG
27.2@MMA
22@MIG
16.4@TIG
25.6@MMA
Efficiency (%)
(230V)
/
84.88@230V MIG
83.97@230V MMA
82.8@230V TIG
83.86@230V MIG
85.46@230V MMA
81.72@230V TIG
84.03@230V MIG
85.88@230V MMA
81.69@230V TIG
Efficiency (%)
(115V)
/
81.55@115V MIG
83.57@115V MMA
79.6@115V TIG
80.24@115V MIG
82.50@115V MMA
78.36@115V TIG
80.65@115V MIG
82.91@115V MMA
78.32@115V TIG
Duty cycle (%)
/
30@MIG
30@TIG
30@MMA
25@MIG
25@TIG
25@MMA
30@MIG
30@TIG
30@MMA
Power factor
/
0.99
0.99
0.99
Insulation class
/
H
H
H
Protection class
/
IP23S
IP23S
IP23S
Dimensions L*W*H
mm
700*280*511
565*220*415
565*220*415
Net weight
Kg
25.5@ plus
16@ plus
16@ plus
25.2@ standard
15.7@ standard
15.5@ standard

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Overall total weight
Kg
32.8@ plus
21.8@ plus
21.8@ plus
31.2@ standard
21@ standard
20.8@ standard
Idle state power
W
<50
<50
<50
Characteristics
/
CC/CV
CC/CV
CC/CV
Pollution level
/
Grade 3
Grade 3
Grade 3
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.

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5.1. External interface description
MIG160/MIG160PFC/MIG200/MIG200PFC series
(Front panel view) (Rear panel view)
a. Power switch
b. Input power cord
c. Inlet nozzle of gas valve
d. Positive polarity
e. Negative polarity
f. Central socket
g. Polarity changeover connector
h. 9-pin aviation socket (optional)
i. Wireless receiver module (optional)

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MIG250/MIG250PFC series
(Front panel view) (Rear panel view)
a. Power switch
b. Input power cord
c. Inlet nozzle of gas valve
d. Positive polarity
e. Negative polarity
f. Central socket
g. Polarity changeover connector
h. 9-pin aviation socket (optional)
i. Wireless receiver module (optional)

Page 20
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) Ensure the input voltage value is within the specified input voltage range.
2) Ensure that the power switch 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.)
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.