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OM-260311 Page 2

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D

Keep your head out of the fumes. Do not breathe the fumes.

D

Ventilate the work area and/or use local forced ventilation at the arc

to remove welding fumes and gases. The recommended way to

determine adequate ventilation is to sample for the composition

and quantity of fumes and gases to which personnel are exposed.

D

If ventilation is poor, wear an approved air-supplied respirator.

D

Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

D

Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D

Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D

Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

D

Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and

sparks when welding or watching (see ANSI Z49.1 and Z87.1

listed in Safety Standards).

D

Wear approved safety glasses with side shields under your

helmet.

D

Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D

Wear body protection made from durable, flame

resistant mate-

rial (leather, heavy cotton, wool). Body protection includes

oil-free clothing such as leather gloves, heavy shirt, cuffless

trousers, high shoes, and a cap.

ARC RAYS can burn eyes and skin.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D

Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D

Do not weld where flying sparks can strike flammable material.

D

Protect yourself and others from flying sparks and hot metal.

D

Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D

Watch for fire, and keep a fire extinguisher nearby.

D

Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D

Do not cut or weld on tire rims or wheels. Tires can explode if heat-

ed. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

D

Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are

properly prepared according to AWS F4.1 and AWS A6.0 (see

Safety Standards).

D

Do not weld where the atmosphere can 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 welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire

hazards.

D

Do not use welder to thaw frozen pipes.

D

Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D

Wear body protection made from durable, flame

resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high

shoes, and a cap.

D

Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D

After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D

Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D

Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D

Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT can injure eyes.

D

Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D

Wear approved safety glasses with side

shields even under your welding helmet.

 BUILDUP OF GAS can injure or kill.

D

Shut off compressed gas supply when not in use.

D

Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.

D

Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D

Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding,  spot

welding, gouging, plasma arc cutting, or induction heating

operations.

Noise from some processes or equipment can

damage hearing.

D

Wear approved ear protection if noise lev-

el is high.

NOISE can damage hearing.

Summary of Contents for STH 160

Page 1: ...ription TIG GTAW Welding Stick SMAW Welding OM 260311E 2019 03 Arc Welding Power Source STH 160 And STH 160 L File TIG GTAW CE For product information Owner s Manual translations and more visit www Mi...

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: ...ating 12 SECTION 4 INSTALLATION 12 4 1 Remote 6 Receptacle Information 12 4 2 Weld Output Terminals And Selecting Cable Sizes 13 4 3 Weld Output Terminals 13 4 4 Electrical Service Guide 14 4 5 Connec...

Page 4: ......

Page 5: ...06 95 EC Low Voltage 2004 108 EC Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipment Standards IEC 60974 1 2012 Arc W...

Page 6: ...l exposure is below the Exposure Limit Values ELVs YES NO for health effects at the standardized configurations if NO specific required minimum distances apply Occupational exposure is below the Expos...

Page 7: ...electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneelin...

Page 8: ...ot possible tightly cover them with approved covers D Do not weld where flying sparks can strike flammable material D Protect yourself and others from flying sparks and hot metal D Be alert that weldi...

Page 9: ...o move unit be sure forks are long enough to extend beyond opposite side of unit D Keep equipment cables and cords away from moving vehicles when working from an aerial location D Follow the guideline...

Page 10: ...George Carter Way Suite 103 Chantilly VA 20151 phone 703 788 2700 website www cga net com Safety in Welding Cutting and Allied Processes CSA Standard W117 2 from Canadian Standards Association Standar...

Page 11: ...tion Safe37 2017 04 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2017 04 Protect yourself from electric shock by insulating yourself from wo...

Page 12: ...ses Use ear protection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Safe38 2012 05 Become trained and read the instructions before working on t...

Page 13: ...rent Line Connection Percent X Duty Cycle U1 Primary Voltage I2 Rated Welding Current I1eff Maximum Effective Supply Current Remote U2 Conventional Load Voltage Alternating Current U0 Rated No Load Vo...

Page 14: ...n on con necting input power This equipment will deliver rated output at an ambient air temperature up to 104 F 40 C Model Input Power Single Phase AC Rated Welding Output Welding Amperage Range Max O...

Page 15: ...supply system There can be potential difficulties in ensuring electromagnetic compatibility in those locations due to con ducted as well as radiated disturbances This equipment does not comply with IE...

Page 16: ...here gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 1 Line Disconnect Device Locate unit near correct input power supply Movement Location And Airflow 1 18 in 460 mm 18...

Page 17: ...STH 160 L Max Output 160 A STH 160 L Min Output 4 A 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 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 Stic...

Page 18: ...ranty 0 50 100 150 200 250 10 100 STH 160 STICK 50 20 30 DUTY CYCLE WELD AMPERES STH 160 L STICK STH 160 STH 160 L TIG SECTION 4 INSTALLATION 4 1 Remote 6 Receptacle Information 6 Socket Socket Inform...

Page 19: ...Cycle mm2 AWG 10 100 Duty Cycle mm2 AWG 100 20 4 20 4 20 4 30 3 35 2 50 1 60 1 0 60 1 0 150 30 3 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 95 3 0 200 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 120 4 0 Thi...

Page 20: ...perating Fuses 3 Min Input Conductor Size In AWG mm2 4 10 6 14 2 5 Max Recommended Input Conductor Length In Feet Meters 124 38 66 20 Min Grounding Conductor Size In AWG mm2 4 10 6 14 2 5 Reference 20...

Page 21: ...OM 260311 Page 15 4 5 Connecting 1 Phase Input Power For 230 VAC Tools Needed 956142809_1 6_B 956142809_2 6_B 2 1 L1 L2 1 GND PE Earth Ground 6 5 3 4 7...

Page 22: ...nd L2 to dis connect device line terminals 7 Over Current Protection Select type and size of over current protec tion using Section 4 4 fused disconnect switch shown Close and secure door on disconnec...

Page 23: ...in to max 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...

Page 24: ...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 While in the set up menu press and...

Page 25: ...le Connect work clamp to positive weld out put terminal If desired connect a remote control to the remote control receptacle Turn power on Allow time for unit to com plete its start up cycle Press and...

Page 26: ...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 27: ...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 and hold...

Page 28: ...lt 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 takes to...

Page 29: ...rage 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 control...

Page 30: ...t control or hand control Hold electrode to workpiece for 1 2 seconds and slowly lift electrode Arc is formed when electrode is lifted Normal open circuit voltage is not present be fore tungsten elect...

Page 31: ...OM 260311 Page 25 SECTION 6 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram For STH 160 And STH 160 L 956142812 D...

Page 32: ...1 7 244862 Screw M5 8 x 12 Soc Hd torx Stl Pld Sems Piloted 1 8 208498 Receptacle Twist Lock Power 1 9 208612 Receptacle Twist Lock Power Gas 1 10 PC4 057084161 Circuit Board Led Switch 1 11 15611807...

Page 33: ...er 1 29 PC6 057084164 Circuit Board Filter 1 30 058021155 Xfmr 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...

Page 34: ...Notes 229895 MATERIAL THICKNESS GAUGE...

Page 35: ...or for a minimum of one year whichever is greater Induction Heating Power Sources Coolers and Electronic Controls Recorders Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Contro...

Page 36: ...ry 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 Suppl...

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