Miller STi 160 Owner's Manual
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Miller STi 160 Owner's Manual

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Si 160, STi 160, And STH 160
OM-250 147F
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
CE
File: TIG (GTAW)
2013−01

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  • Page 1 OM-250 147F 2013−01 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Arc Welding Power Source Si 160, STi 160, And STH 160 File: TIG (GTAW) Visit our website at www.MillerWelds.com...
  • Page 2 From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    ..........4-4. Controls For STi 160 .
  • Page 4 Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number Si 160 059016011 STi 160 059016012 STH 160 059016013 Council Directives:  2006/95/EC Low Voltage.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Definitions

    SECTION 2 − DEFINITIONS 2-1. Additional Safety Symbols And Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. Safe2 2012−05 Protect yourself from electric shock by insulating yourself from work and ground.

  • Page 10: Miscellaneous Symbols And Definitions

    Do not weld on drums or any closed containers. Safe16 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility. Contact your local recycling office or your local distributor for further information. Safe37 2012−05 Wear hat and safety glasses.

  • Page 11: Section 3 − Specifications And Installation

    SECTION 3 − SPECIFICATIONS AND INSTALLATION 3-1. Important Information Regarding CE Products (Sold Within The EU) A. Information On Electromagnetic Fields (EMF) This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

  • Page 12: Specifications

    4−150A Stick 150A @ 26 Volts DC, 7.0/4.8 25% Duty Cycle L = 380 mm 6.0 Kg STi 160 W = 145 mm (13.2 lb) 100A @ 14 Volts DC, H = 245 mm 3.0/2.0 100% Duty Cycle 230 Volts TIG 4−160A...

  • Page 13: Volt-Ampere Curves

    120 130 140 150 160 170 90 100 110 DC AMPERAGE (A) Sti 160 And STH 160 Max Output − 160 A; Sti 160 And STH 160 Min Output − 4 A Stick/TIG Max Stick/TIG Min STICK 90 100 110 120 130 140 150 160...

  • Page 14: Duty Cycle And Overheating

    3-7. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, output stops, the Overtemperature Light comes On, and the cooling fan runs. Wait fifteen minutes for unit to cool. Reduce am- perage or duty cycle before starting to weld again.

  • Page 15: Electrical Service Guide

    In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and 630.12. Si 160 Sti 160 STH 160 Input Voltage (V) Input Amperes (A) At Rated Output...

  • Page 16: Connecting 1-Phase Input Power

    3-10. Connecting 1-Phase Input Power =GND/PE Earth Ground Tools Needed: input4 2012−05 − Ref. 803 766-C / 956142809_1-6_B / 956142809_2-6_B OM-250 147 Page 12...

  • Page 17: Connecting To 1-Phase Engine Generator W/230 Volt Output

    3-10. Connecting 1-Phase Input Power (Continued) Installation must meet all National and VAC without removing cover to relink the Black And White Input Conductor (L1 Local Codes − have only qualified per- power source. And L2) sons make this installation. Green Or Green/Yellow Grounding NOTICE −...

  • Page 18: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls For Si 160 956142809_3-6_D Weld output terminals are energized Light comes on if unit overheats. Welding can Negative Weld Output Receptacle when power is On and Ready Light resume when unit has cooled (see Section (LED) is lit.

  • Page 19: Preparing Unit For Stick Welding (Si Model)

    4-3. Preparing Unit For Stick Welding (Si Model) Weld output terminals are energized when power is On, and Ready Light is lit. Positive Weld Output Receptacle Connect electrode cable to this re- ceptacle. Negative Weld Output Receptacle Connect work cable to this recep- tacle.

  • Page 20: Controls For Sti 160

    4-4. Controls For STi 160 8 8 8 956142809_3-6_D Weld output terminals are energized For Stick welding, connect electrode cable to remote control and by the Amperage/ when power is On, and Ready Light is this receptacle. For TIG welding, connect work Set-up Adjustment control.

  • Page 21: Preparing Unit For Stick Welding (Sti Model)

    4-5. Preparing Unit For Stick Welding (STi Model) =Light Flashing =Light Off =Light On =Light Flashing If Voltage Reduction Device Is On Process Selection Set-Up Menu Press And Release Press And Hold Weld output terminals are ener- ceed as follows: Example: If preset amperage is 90 amps, gized when power is On, and 0% = 90 amps, 50% = 135 amps.

  • Page 22: Preparing Unit For Tig Welding (Sti Model)

    4-6. Preparing Unit For TIG Welding (STi Model) =Light Flashing =Light Off =Light On =Light Flashing If Voltage Reduction Device Is On Process Selection Set-Up Menu Press And Release Press And Hold Weld output terminals are ener- and then the factory default setting of 50 switch.

  • Page 23: Controls For Sth 160

    4-7. Controls For STH 160 8 8 8 956142809_3-6_D Weld output terminals are energized Negative Weld Output Receptacle 10 Power Switch when power is On, and Ready Light is Place switch in On (I) position to turn unit on. For Stick welding, connect work cable to this lit.

  • Page 24: Preparing Unit For Stick Welding (Sth Model)

    4-8. Preparing Unit For Stick Welding (STH Model) =Light Flashing =Light Off =Light On =Light Flashing If Voltage Reduction Device Is On Process Selection Set-Up Menu Press And Release Press And Hold Weld output terminals are ener- ceed as follows: Example: If preset amperage is 90 amps, gized when power is On, and 0% = 90 amps, 50% = 135 amps.

  • Page 25: Preparing Unit For Tig Welding (Sth Model)

    4-9. Preparing Unit For TIG Welding (STH Model) =Light Flashing =Light Off =Light On =Light Flashing If Voltage Reduction Device Is On Process Selection Set-Up Menu Press And Release Press And Hold Positive Weld Output Terminal Prepare unit for TIG welding as follows: Anti Stick Anti Stick prevents the electrode from Connect electrode holder to negative...

  • Page 26: Gas Connections (Sth Models)

    4-10. Gas Connections (STH Models) Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. Regulator/Flowmeter Install so face is vertical. Flow Adjust Typical flow rate is 15 CFH (cubic feet per hour) (7.1 liters per minute).

  • Page 27: Or 4T Trigger Mode Settings (Sth Models)

    4-11. 2T Or 4T Trigger Mode Settings (STH Models) Process/Set-Up Selector Switch TIG HF Start TIG Lift Arc Start Light (LED) Ready Light (LED) Set-Up Light (LED) Ammeter And Parameter Display (Meter) Amperage/Set-Up Adjustment Control 2T and 4T are used with the TIG process.

  • Page 28: Sequence Controls And Slope Down Settings (Sth Models)

    4-12. Sequence Controls And Slope Down Settings (STH Models) Sequencing is only available while using a TIG process. Select TIG process according to Section 4-9. Sequencer Control LEDs Ammeter And Parameter Display (Meter) Amperage/Set-Up Adjustment Control Sequencer Parameters Switch To enter Sequencer Control set-up mode and scroll through paramet- ers, press and release the Sequen- cer Parameters switch.

  • Page 29: Pulser Control Settings (Sth Models)

    4-13. Pulser Control Settings (STH Models) Pulsing is only available while using a TIG process. Select TIG process according to Section 4-9. Pulser LEDs Ammeter And Parameter Display (Meter) Amperage/Set-Up Adjustment Control Pulser Control Switch Pulser Light (LED) Pulser light is on when pulser is on. To enter Pulser set-up mode and scroll through parameters, press and release the Pulser Control...

  • Page 30: Resetting Unit To Factory Default Settings (Sti And Sth Models)

    4-14. Resetting Unit To Factory Default Settings (STi And STH Models) This procedure will delete all operator specified parameters, and recall all factory parameters. Process/Set-up Switch Power Switch Turn unit off. Turn unit on while pressing and holding Process/Set-up switch; wait for a beep signal (about two seconds).

  • Page 31: Section 5 − Maintenance And Troubleshooting

    SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. n = Check Z = Change ~ = Clean = Repair l = Replace * To be done by Factory Authorized Service Agent Every Months ~ Weld Terminals...

  • Page 32: Troubleshooting

    5-3. Troubleshooting Trouble Remedy Place line disconnect switch in On position (see Section 3-10). No weld output; unit completely inop- erative; ready light (LED) Off. Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-10). Check for proper input power connections (see Sections 3-9 and 3-10). Unit overheated causing thermal shutdown.

  • Page 33: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 956 142810-A Figure 6-1. Circuit Diagram For Si 160 OM-250 147 Page 29...
  • Page 34 956 142811-C Figure 6-2. Circuit Diagram For STi 160 OM-250 147 Page 30...
  • Page 35 Figure 6-3. Circuit Diagram For STH 160 956 142812-D OM-250 147 Page 31...

  • Page 36: Section 7 − Parts List For Si Models

    SECTION 7 − PARTS LIST FOR Si MODELS Hardware is common and not available unless listed. 956 142809_4-6_D Figure 7-1. Main Assembly For Si 160 Item Dia. Part Mkgs. Description Quantity 7-1. Main Assembly For Si 160 ..
  • Page 37 Item Dia. Part Mkgs. Description Quantity 7-1. Main Assembly For Si 160 (Continued) ....156005158 Bracket, pcb assy support .........

  • Page 38: Section 8 − Parts List For Sti Models

    SECTION 8 − PARTS LIST FOR STi MODELS Hardware is common and not available unless listed. 956142809_5-6_F Figure 8-1. Main Assembly For STi 160 Item Dia. Part Mkgs. Description Quantity 8-1. Main Assembly For STi 160 ..
  • Page 39 Dia. Part Mkgs. Description Quantity 8-1. Main Assembly For STi 160 (Continued) ..057084160 Circuit Board, Pwm ..........

  • Page 40: Section 9 − Parts List For Sth Models

    SECTION 9 − PARTS LIST FOR STH MODELS Hardware is common and not available unless listed. 956142809_6-6_F Figure 9-1. Main Assembly For STH 160 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly For STH 160 ..
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly For STH 160 (Continued) ..057084160 Circuit Board, Pwm ..........
  • Page 42 Notes...
  • Page 43 Effective January 1, 2013 (Equipment with a serial number preface of MD or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions 90 Days —...
  • Page 44 File a claim for loss or damage during Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 shipment. email: miller@itw−welding.it For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2013 Miller Electric Mfg. Co. 2013−01...

This manual is also suitable for:

Si 160Sth 160

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