Jasic JM-160C Operator'S Manual Download Page 36

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www.jasic.co.uk

Wilkinson Star Limited

Shield Drive

Wardley Industrial Estate

Worsley

Manchester

M28 2WD

+44 (0)161 793 8127

April 2020 Issue 3

Summary of Contents for JM-160C

Page 1: ...Operator Manual MIG Series MIG 160 JM 160C MIG 200 JM 200C MIG 200 PFC JM 200PFC ...

Page 2: ...anty purposes and to ensure you get the correct information should you require assistance or spare parts Date purchased ________________________________________ From where ________________________________________ Serial number ________________________________________ The serial number is normally located on the top or underside of the machine and will begin with AA For further information on your ...

Page 3: ...lators 7 RF declaration 8 LF declaration 8 Materials and their disposal 8 Product Overview 9 Technical Specifications 10 Description of Controls 11 Installation 13 Operation 15 Guide to MMA Welding 17 MMA Welding Problems 21 Guide to MIG Welding 22 MIG Welding Problems 27 MIG Welding Torch 29 Maintenance 30 Service Schedule Record 30 Troubleshooting 31 EC Declaration of Conformity 32 WEEE Disposal...

Page 4: ...e and overheating Never use worn damaged under sized or poorly jointed cables Insulate yourself from work and earth using dry insulating mats or covers big enough to prevent any physical contact Never touch the electrode if you are in contact with the work piece return Do not wrap cables over your body Ensure that you take additional safety precautions when you are welding in electrically hazardou...

Page 5: ...ulty welding helmets Always ensure there are adequate protective screens or barriers to protect others from flash glare and sparks from the welding area Ensure that there are adequate warnings that welding or cutting is taking place Wear suitable protective flame resistant clothing gloves and footwear Check and be sure the area is safe and clear of inflammable material before carrying out any weld...

Page 6: ...the the welding fume Ensure the welding 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 airfed 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 weld in location...

Page 7: ...eated by high currents may affect the operation of pacemakers or elec tronically 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 re...

Page 8: ...ry current from the power supply network high power systems affect the quality of power provided by the network Consequently connection restrictions or maximum impedance requirements permitted by the network at the public network connection point must be applied to these systems In this case the installer or the user is responsible for ensuring the equipment can be connected consulting the electri...

Page 9: ...warm and comfortable to hold Jasic MIG 160C 200C and 200PFC Product Features Compact size lightweight and modern design 40Khz inverter MIG and MMA welding functions are available The JM 160C and JM 200C are single phase 230V AC input machines The JM 200PFC is a single phase wide voltage machine capable of operating on input voltages of between 95V 265V AC The JM 200PFC has inbuilt advanced energy ...

Page 10: ...60HZ Rated input power kVA 5 9 8 115V 4 2 230V 5 8 Rated input current Imax A 31 35 6 35 6 Rated input current Ieff A 15 2 21 115V 20 1 230V 14 8 Welding current range A MIG 30 160 MMA 10 160 MIG 30 200 MMA 10 200 115V MIG 30 140 115V MMA 10 140 230V MIG 30 200 230V MMA 10 200 No load voltage V 65 65 65 Rated duty cycle 40 C MIG 160A 35 MMA 160A 35 MIG 200A 35 MMA 200A 35 115V MIG 140A 35 115V MMA...

Page 11: ...control dial 8 Voltage control dial 9 MIG MMA mode selector switch Rear view Jasic MIG 160C 200C and 200PFC 10 Power switch The ON OFF mains switch for the machine 11 Gas inlet connection The gas inlet that allows you to connect the gas supply from the gas regulator 12 Cooling fans The entry for the air to access the cooling fans 13 Input cable gland The entry for the mains power cable ...

Page 12: ...bly Holds the upper drive roll in place which applies pressure to the welding wire onto the grooved drive roller 8 Drive roll tensioner Allows the correct amount of tension to be applied to the top roller to ensure good feed of the wire through the MIG torch Front control panel view Jasic MIG 160C 200C and 200PFC A Power LED Indicates that power is present at the machine and that the power switch ...

Page 13: ...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 Output connections Electrode polarity In general when using manual arc welding electrodes the electrode holder is connected to the positiv...

Page 14: ...which will affect wire feeding Press the wire inch button to thread the wire out of the torch through the contact tip You are now ready to start MIG welding Gasless self shielded MIG welding Insert the welding torch into the Euro connector for torch in MIG output socket on the front panel of the machine and tighten it Insert the work return cable plug C into the output terminal of the welding mach...

Page 15: ...nd on cooling forms a slag covering to protect the weld from contamination When the electrode is moved along the work piece at the correct speed the metal core deposits a uniformed layer called the weld bead After connecting the welding leads as detailed you will need to switch the power switch on the back panel to ON Select the MIG MMA by switching to the MMA welding mode There is now open circui...

Page 16: ...ED on and the fans are running Switch the MMA MIG switch to MIG mode ensuring the standard spool gun switch is set to standard Open the gas valve of the cylinder and adjust the gas regulator to obtain the desired flow rate Adjust the voltage control knob in MIG and wire feed speed control knob in MIG on the front panel of the machine to get the correct welding voltage and welding current Operate t...

Page 17: ...ross rather than to or from your body The electrode holder lead should always be clear of any obstruction so that you can move your arm freely along as the electrode burns down Some elders prefer to have the welding lead over their shoulder this allows greater freedom of movement and can reduce the weight from your hand Always inspect your welding equipment welding cables and electrode holder befo...

Page 18: ...on as the electrode contacts the work piece The welder should always ensure a good connection of the work clamp The nearer the clamp is placed to the welding area the better When the arc is struck the distance between the end of the electrode and the work will determine the arc voltage and also affect the weld characteristic As a guide the arc length for electrodes up to 3 2mm diameter should be a...

Page 19: ...uit quickly lift up about 2 4mm and arc will be ignited This method is difficult to master Scratch technique Drag the electrode and scratch the work piece as if striking a match Scratching the electrode may cause the arc to burn along the scratch path so care should be taken to scratch in the weld zone When the arc is struck adopt the correct welding position Electrode positioning Horizontal or fl...

Page 20: ...ectrode 1 The electrode feeding to the molten pool along axis 2 The electrode swing right and left 3 The electrode moving in the weld direction The operator can choose the manipulation of electrode based on welding joint welding position electrode spec welding current and operation skill etc Weld characteristics A good weld bead should exhibit the following characteristics 1 Uniform weld bead 2 Go...

Page 21: ... speed Ensure the arc is on the leading edge of the weld puddle Porosity Small holes or cavities on the surface or within the weld material Work piece dirty Electrode is damp Arc length is excessive Remove all contaminant from the material i e oil grease rust moisture prior to welding Replace or dry the electrode Reduce the arc length Excessive penetration The weld metal is below the surface level...

Page 22: ...rom contamination which also enhances the arc The MIG MAG process can be used to weld a wide variety of materials and is normally used in the horizontal position but can be used in vertical or overhead with the correct selection of machine wires and current In addition it can be used to weld at long distances from the power source subject to the correct cable sizing It is the dominant process used...

Page 23: ... CO welding Gases such as oxygen and carbon dioxide were added and are active constituents to the inert gas to improve the welding performance Although the MAG process is in common use today it is still referred to as MIG welding although technically this is not correct The process began to prove itself as an alternative to stick electrode MMA and TIG GTAW offering high productivity and deposition...

Page 24: ... positive This means that the majority of the heat is in the electrode wire Certain special wires may require the polarity to be reversed i e electrode wire negative polarity Always consult the manufacturer s data sheet for the best operating parameters The voltage is often referred to as the heat setting This will be altered dependent on the material type thickness gas type joint type and positio...

Page 25: ...lding process are When welding try to use an electrode stick out the distance between the weld and the contact tip of around 6 8mm When welding thin materials try and use smaller MIG wire diameters and for thicker materials use thicker wires Make sure you select the correct MIG wire type for the material to be welded Ensure the MIG welding gun has the correct sized contact tip and type of liner Al...

Page 26: ...26 MIG Set Up Guide Please Note This information is intended to act as a guide only MIG WELDING GUIDE ...

Page 27: ...lding tip Readjust the upper feed pressure Increase the pressure to eliminate burn back to tip Decrease pressure to eliminate bird nesting Replace torch liner Replace wire Check and replace welding tip No operation when the torch switch is operated Torch switch faulty Fuse blown Faulty PCB inside the equipment Check the torch switch continuity and replace if faulty Check fuses and replace if neces...

Page 28: ...prior to welding Irregular weld bead and shape Incorrect voltage wire feed settings If it s convex voltage is too low and if it s concave then voltage is too high Insufficient or excessive heat input Wire is wandering Incorrect shielding gas Adjust voltage and or wire feed speed Adjust the wire feed speed dial or the voltage control Replace contact tip Check and change the shielding gas as require...

Page 29: ...29 MIG WELDING TORCH JM 160C JM 200C and JM 200PFC MIG Welding Torch Air Cooled Model T150 Rating 180A Co2 150A Mixed Gases 60 Duty Cycle EN60974 7 Wire Size 0 6mm to 1 0mm ...

Page 30: ...it 5 minutes after power switch off before opening the case SERVICE SCHEDULE RECORD Period Maintenance item Daily examination Check the condition of the machine mains cables welding cables and connections Check for any warnings LEDs and machine operation Monthly examination Disconnect from the mains supply and wait for at least 5 minutes before removing the cover Check internal connections and tig...

Page 31: ... automatically after the welding machine is cooled Check incoming mains supply to ensure it is within 230V 15 Wire feed motor does not rotate when the Wire feed speed maybe set to zero MIG torch trigger switch is depressed Check supply to wire feed motor Motor PCB may be faulty Welding current reduces when welding Poor work lead connection to the work piece TIG electrode melts when arc is struck T...

Page 32: ...erials Do not dispose of the equipment with normal waste The European Directive 2002 96 EC on Waste Electrical and Electronic Equipment states the electrical equipment that has reached its end of life must be collected separately and returned to an environmentally compatible recycling facility Jasic has a relevant recycling system which is compliant and registered in the UK with the environment ag...

Page 33: ...he scope of the warranty Defects due to natural wear and tear Failure to observe the operating and maintenance instructions Connection to an incorrect or faulty mains supply Overloading during use Any modifications that are made to the product without the prior written consent Software errors due incorrect operation Any repairs that are carried out using non approved spare parts Any transport or s...

Page 34: ...Jasic HD True Colour Auto Darkening Welding Helmet SSARG2G Single Stage 2 Gauge Argon Regulator WTLHK2 2m Gas Hose and Quick Gas Connecter 10048354 V Groove 0 6mm 0 8mm 10048356 V Groove 0 8mm 1 0mm 10048347 V Groove 1 0mm 1 2mm B6200ZZ Flat Pressure Roll 10048338 Knurled 0 8mm 1 0mm FCW 10048352 U Groove 0 6mm 0 8mm 10048349 U Groove 0 8mm 1 0mm 10048353 U Groove 1 0mm 1 2mm Jasic Auto Darkening ...

Page 35: ...35 SCHEMATIC ...

Page 36: ...www jasic co uk Wilkinson Star Limited Shield Drive Wardley Industrial Estate Worsley Manchester UK M28 2WD 44 0 161 793 8127 April 2020 Issue 3 ...

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