Miller Electric Si 160 Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS - READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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1-3. Additional Symbols For Installation, Operation, And Maintenance

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1-4. California Proposition 65 Warnings

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1-5. Principal Safety Standards

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1-6. EMF Information

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SECTION 2

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DEFINITIONS

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2-1. Warning Label Definitions

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2-2. Symbols And Definitions

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2-3. WEEE Label (For Products Sold Within The EU)

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SECTION 3

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SPECIFICATIONS AND INSTALLATION

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3-1. Important Information Regarding CE Products (Sold Within The EU)

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3-2. Serial Number And Rating Label Location

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3-3. Specifications

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3-4. Selecting A Location

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3-5. Volt-Ampere Curves

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3-6. Duty Cycle And Overheating

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3-7. Remote 6 Receptacle Information (STL And STH Models Only)

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3-8. Electrical Service Guide

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3-9. Connecting 1-Phase Input Power For 230 VAC

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3-10. Connecting To 1-Phase Engine Generator

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SECTION 4

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OPERATION

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4-1. Controls For Si 160

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4-2. Amperage Adjustment Control

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4-3. Preparing Unit For Stick Welding (Si Model)

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4-4. Controls For STi 160

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4-5. Preparing Unit For Stick Welding (STi Model)

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4-6. Preparing Unit For TIG Welding (STi Model)

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4-7. Controls For STH 160

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4-8. Preparing Unit For Stick Welding (STH Model)

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4-9. Preparing Unit For TIG Welding (STH Model)

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4-10. Gas Connections (STH Models)

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4-11. 2T Or 4T Trigger Mode Settings (STH Models)

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4-12. Sequence Controls And Slope Down Settings (STH Models)

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4-13. Pulser Control Settings (STH Models)

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4-14. Resetting Unit To Factory Default Settings (STi And STH Models)

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4-15. Lift-Arc

And HF TIG Start Procedures

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SECTION 5

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MAINTENANCE AND TROUBLESHOOTING

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5-1. Routine Maintenance

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5-2. High Temperature Help Display

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5-3. Troubleshooting

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SECTION 6

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ELECTRICAL DIAGRAM

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SECTION 7

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PARTS LIST FOR Si MODELS

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SECTION 8

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PARTS LIST FOR STi MODELS

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SECTION 9

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PARTS LIST FOR STH MODELS

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WARRANTY

Summary of Contents for Si 160

Page 1: ...Visit our website at www MillerWelds com Processes Description TIG GTAW Welding Stick SMAW Welding OM 250 147D 2011 10 Arc Welding Power Source Si 160 STi 160 And STH 160 File TIG GTAW CE...

Page 2: ...ucts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you...

Page 3: ...10 Connecting To 1 Phase Engine Generator 12 SECTION 4 OPERATION 13 4 1 Controls For Si 160 13 4 2 Amperage Adjustment Control 13 4 3 Preparing Unit For Stick Welding Si Model 14 4 4 Controls For STi...

Page 4: ...tage 2004 108 EC Electromagnetic Compatibility Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 2005 07 IEC 60974 10 Arc Welding Equipment Electromagnetic Compatibility Requ...

Page 5: ...r when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage...

Page 6: ...Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent weld...

Page 7: ...panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels cover...

Page 8: ...web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website ww...

Page 9: ...ic shock by insulating yourself from work and ground 1 3 Disconnect input plug or power before working on machine 2 Breathing welding fumes can be hazardous to your health 2 1 Keep your head out of th...

Page 10: ...Rated Maximum Supply Current I2 Rated Welding Current I1eff Maximum Effective Supply Current Remote Lift Arc Start GTAW Gas Tungsten Arc Welding GTAW Process TIG GTAW Pulse HF Impulse Start ing GTAW O...

Page 11: ...At a distance of 1 meter the EMF exposure values were less than 20 of the permissible values B Information On Electromagnetic Compatibility EMC This Class A equipment is not intended for use in resid...

Page 12: ...Volts DC 25 Duty Cycle 30A 7 0 4 8 230 Volts TIG 100A 14 Volts DC 100 Duty Cycle 4 160A 70V 13A 3 0 2 0 160A 16 4 Volts DC 20 Duty Cycle 22A 5 1 3 5 STH 160 230 Volts Stick 100A 24 Volts DC 100 Duty...

Page 13: ...140 150 160 170 180 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 DC AMPERAGE A DC VOLTAGE V 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 DC VOLTAGE V 0 10 20 30 40 5...

Page 14: ...age unit and void warranty 0 50 100 150 200 250 10 100 STICK 50 20 30 TIG DUTY CYCLE WELD AMPERES 3 7 Remote 6 Receptacle Information STL And STH Models Only 6 Socket Socket Information 15 VOLTS DC OU...

Page 15: ...Input Conductor Size In mm2 AWG 4 4 12 4 12 4 12 Max Recommended Input Conductor Length In Meters Feet 24 80 24 80 24 80 Min Grounding Conductor Size In mm2 AWG 4 4 12 4 12 4 12 Reference 2011 Nation...

Page 16: ...urrent Protection Select type and size of over current protection using Section 3 8 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place swit...

Page 17: ...overheats Welding can resume when unit has cooled see Section 3 6 3 Amperage Adjustment Control See Section 4 2 4 Positive Weld Output Receptacle For Stick welding connect electrode cable to this rece...

Page 18: ...ve Weld Output Receptacle Connect work cable to this recep tacle 3 Power Switch Place switch in On I position 4 Ready Light LED Allow time for unit to complete its start up cycle Light comes on approx...

Page 19: ...l Receptacle Connect remote control to receptacle see Section3 7 For TIG and Stick welding output may be adjusted from min to max of the front panel setting with the remote control 8 Remote Control Pi...

Page 20: ...ss Set Up Adjustment control to re enter set up mode Hot Start Setting Use Hot Start to increase output amper age at the start of a weld to help prevent electrode sticking To change Hot Start setting...

Page 21: ...is Off Use Amperage Set UpAdjustment control to enable or turn setting On When Voltage Reduction is enabled TIG Welding light flashes continuously VRD is set to 20 volts Unit will automatically exit...

Page 22: ...of the front panel setting with the remote control When a foot or finger remote control is con nected remote trigger is enabled only in the TIG mode Amperage adjustment is controlled by the remote co...

Page 23: ...control to re enter set up mode Hot Start Setting Use Hot Start to increase output amper age at the start of a weld to help prevent electrode sticking To change Hot Start setting proceed as follows Wh...

Page 24: ...eceptacle Turn power on Allow time for unit to com plete its start up cycle Press and release Amperage Set Up Adjustmentcontrol to select TIG welding and light corresponding LED Display meter displays...

Page 25: ...Flow Adjust Typical flow rate is 15 CFH cubic feet per hour 7 1 liters per minute Make sure flow adjust is closed when opening cylinder to avoid damage to the flowmeter 4 Gas In Fitting Connect hose...

Page 26: ...ity is de tected for more than three seconds Press and hold Pro cess Set Up Adjustment con trol to re enter set up mode While in the set up mode to change between 2T and 4T proceed as fol lows Press a...

Page 27: ...Default is 40 percent min 10 percent or minimum value set during initial set up max 90 percent or maximum value set dur ing initial set up 7 Slope Up Time Use control select amount of time that it ta...

Page 28: ...k amperage is the highest welding amperage allowed to occur in the pulse cycle Weld penetration varies directly with peak amperage The default value 50 A 8 Background Current Ab Use Background Amps co...

Page 29: ...electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present be fore tungsten electrode touches workpiece only a low sensing voltage is present between electrode and wor...

Page 30: ...ervice clean monthly Blow out inside Direct airflow through front and back louvers Do not remove case when blowing out inside of unit 5 2 High Temperature Help Display 1 High Temperature Light LED 2 M...

Page 31: ...not operating Unit not warmed up enough to require fan cooling Check for and remove anything blocking fan movement Have Factory Authorized Service Agent check fan motor and control circuitry Stick wel...

Page 32: ...OM 250 147 Page 28 SECTION 6 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram For Si 160 956 142810 A...

Page 33: ...OM 250 147 Page 29 956 142811 C Figure 6 2 Circuit Diagram For STi 160...

Page 34: ...OM 250 147 Page 30 Figure 6 3 Circuit Diagram For STH 160 956 142812 D...

Page 35: ...OM 250 147 Page 31 Notes...

Page 36: ...M5 8x12 Soc Hd torx Stl Pld Sems Piloted 1 8 000208498 Receptacle Twist Lock Power 1 9 000208612 Receptacle Twist Lock Power Gas 1 10 156005157 Plate Front Upper Pcb Support 1 11 156118074 Panel Fron...

Page 37: ...lder Ground Clamp Cable set 3mt 1 27 156033037 Cover switch 1 When ordering a component originally displaying a precautionary label the label should also be ordered Optional To maintain the factory or...

Page 38: ...x Stl Pld Sems Piloted 1 8 000208498 Receptacle Twist Lock Power 1 9 000208612 Receptacle Twist Lock Power Gas 1 10 156005160 Plate Front Upper Pcb Support 1 11 156118074 Panel Front 1 12 FM1 FM2 0561...

Page 39: ...1 28 058066079 Electrode Holder Ground Clamp Cable Set 3mt 1 When ordering a component originally displaying a precautionary label the label should also be ordered Optional To maintain the factory ori...

Page 40: ...X 12 Soc Hd torx Stl Pld Sems Piloted 1 8 000208498 Receptacle Twist Lock Power 1 9 000208612 Receptacle Twist Lock Power Gas 1 10 PC4 057084161 Circuit Board Led Switch 1 11 156118074 Panel Front 1...

Page 41: ...fmr HF 1 31 056001007 Shaft M10 32 F M5x75 1 32 156005163 Plate Front Upper Pcb Support 1 33 156033037 Cover Switch 1 34 058066079 Electrode Holder Ground Clamp Cable Set 3mt 1 When ordering a compone...

Page 42: ...Notes...

Page 43: ...ystems Hydramate 1 and 2 Water Coolant Systems USA Models Non Integrated Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Co...

Page 44: ...ountry Zip Postal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding S...

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