Miller Electric STi 160 Owner`s manual

Miller Electric STi 160 Owner`s manual
OM-250 147B
2011−04
Processes
Stick (SMAW) Welding
TIG (GTAW) Welding
Description
Arc Welding Power Source
Si 160, STi 160, And STH 160
CE
File: TIG (GTAW)
Visit our website at
www.MillerWelds.com
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.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. 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 can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of
welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
5
6
2-3. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7
7
3-2.
3-3.
3-4.
3-5.
Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
8
8
9
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Remote 6 Receptacle Information (STL And STH Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
11
3-9. Connecting 1-Phase Input Power For 230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls For Si 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Amperage Adjustment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
13
13
4-3. Preparing Unit For Stick Welding (Si Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Controls For STi 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Preparing Unit For Stick Welding (STi Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
15
16
4-6.
4-7.
4-8.
4-9.
Preparing Unit For TIG Welding (STi Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls For STH 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing Unit For Stick Welding (STH Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing Unit For TIG Welding (STH Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
18
19
20
4-10. Gas Connections (STH Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. 2T Or 4T Trigger Mode Settings (STH Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Sequence Controls And Slope Down Settings (STH Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
22
23
4-13. Pulser Control Settings (STH Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Resetting Unit To Factory Default Settings (STi And STH Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
25
4-15. Lift-Arct And HF TIG Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. High Temperature Help Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
26
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST FOR Si MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST FOR STi MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
28
32
34
SECTION 9 − PARTS LIST FOR STH MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
36
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that
the product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
Si 160
STi 160
STH 160
059016011
059016012
059016013
Council Directives:
2006/95/EC Low Voltage
2004/108/EC Electromagnetic Compatibility
Standards:
IEC 60974­1 Arc Welding Equipment ­ Welding Power Sources: edition 3, 2005­07.
IEC 60974­10 Arc Welding Equipment ­ Electromagnetic Compatibility Requirements: edition 2.0, 2007­08.
EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to
electromagnetic fields
(0Hz­300Hz)
EU Signatory:
December 21st , 2010
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ELECTRONIC ENGINEER R&D TECH. SUPPORT
956 142 841
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2010−03
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following 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, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
OM-250 147 Page 1
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. 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 can burn eyes and skin.
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 protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
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.
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 weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety 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 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.
OM-250 147 Page 2
D Wear oil-free protective garments 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 bypass 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.
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 shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect ImplantedMedical 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 can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to 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 guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, 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, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-250 147 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: 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: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-250 147 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
A. Warning! Watch Out! There are possible
hazards as shown by the symbols.
1
Electric shock from welding electrode or
wiring can kill.
1.1 Wear dry insulating gloves. Do not touch
electrode with bare hand. Do not wear wet
or damaged gloves.
1.2 Protect yourself from electric 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 the fumes.
2.2 Use forced ventilation or local exhaust to
remove the fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion or
fire.
3.1 Keep flammables away from welding. Do
not weld near flammables.
3.2 Welding sparks can cause fires. Have a
fire extinguisher nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any closed
containers.
4 Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of filter.
Wear complete body protection.
5 Become trained and read the instructions
before working on the machine or welding.
6 Do not remove or paint over (cover) the
label.
A
1
1.1
3
3.1
3.2
4
2
4.1
2.12.2 2.3
5
6
glk ks;dglkks;d
glks;d
ks;d
fg s;ldfgs;ldfg
k glk
s;ldfg
s;ld
kds;lgkhfsgkds;lgkAslg
kds;lgkgsldgksdlk
slg
A
k
;ld
Asld
S
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
956.142.819-A
OM-250 147 Page 5
2-2. Symbols And Definitions
A
V
Voltage Input
Volts
Increase/Decrease
Of Quantity
Output
Negative
Positive
Gas Input
High Temperature
Direct Current
Percent
Alternating
Current
I1eff
S
Suitable For Areas
Of Increased
Shock Hazard
Amperes
X
U0
Duty Cycle
Rated No Load
Voltage (Average)
Shielded Metal Arc
Welding (SMAW)
Single Phase Static Frequency
Converter-Transformer-Rectifier
U1
I1max
Primary Voltage
Rated Maximum
Supply Current
Hz
Hertz
Line Connection
U2
I2
Conventional Load
Voltage
Rated Welding
Current
Maximum Effective
Supply Current
Remote
Lift-Arc Start
(GTAW)
Gas Tungsten Arc
Welding (GTAW)
Process
TIG (GTAW) Pulse
HF Impulse Starting (GTAW)
On
Off
Look under unit for
label
Initial Slope Time
Final Slope Time
Amps Background
Set-Up
Pre Flow And
Post Flow Time
%
Initial Amps And
Final Amps
Ab
Single Phase
2-3. WEEE Label (For Products Sold Within The EU)
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.
OM-250 147 Page 6
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.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
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 residential locations where the electrical power is provided by the public low
voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
!
This equipment does not comply with IEC 61000−3−12. If it is connected to a public low voltage system, it is the responsibility of
the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment may be connected.
ce-emc 2 2010-10
3-2. Serial Number And Rating Label Location
The serial number and rating information is located on the bottom of the machine. Use the rating labels to determine input power requirements and/or
rated output. CE model rating labels will also display the following symbols: CE, CCC, WEEE, and IEC 60974-1. For future reference, write serial
number in space provided on back cover of this manual.
OM-250 147 Page 7
3-3. Specifications
Input Power
Model
Single-Phase
AC
230 Volts
Stick
Si 160
Rated Welding
Output
Welding
Amperage
Range
Max
OCV DC
(Uo)
100A @ 24 Volts DC,
100% Duty Cycle
150A @ 26 Volts DC,
25% Duty Cycle
15−150A
230 Volts
Stick
STi 160
150A @ 16 Volts DC,
25% Duty Cycle
15−150A
4−150A
230 Volts
Stick
STH 160
160A @ 16.4 Volts DC,
20% Duty Cycle
4−160A
4−150A
160A @ 16.4 Volts DC,
20% Duty Cycle
4−160A
7.0/4.8
5.2 Kg
(11.5 lb)
L = 380 mm
W = 145 mm
H = 245 mm
13A
3.0/2.0
21A
4.8/3.2
20A
4.5/2.8
30A
7.0/4.8
6.0 Kg
(13.2 lb)
L = 380 mm
W = 145 mm
H = 245 mm
13A
3.0/2.0
22A
5.1/3.5
20A
4.5/2.8
30A
7.0/4.8
6.0 Kg
(13.2 lb)
L = 380 mm
W = 145 mm
H = 245 mm
13A
3.0/2.0
22A
5.1/3.5
70V
100A @ 14 Volts DC,
100% Duty Cycle
230 Volts TIG
30A
70V
100A @ 24 Volts DC,
100% Duty Cycle
150A @ 26 Volts DC,
25% Duty Cycle
4.5/2.8
Dimensions
70V
100A @ 14 Volts DC,
100% Duty Cycle
230 Volts TIG
20A
Weight
85V
100A @ 24 Volts DC,
100% Duty Cycle
150A @ 26 Volts DC,
25% Duty Cycle
KVA/KW @
Duty Cycle
85V
100A @ 14 Volts DC,
100% Duty Cycle
230 Volts TIG
Amperes Input At Rated
Load Output,
50/60Hz,
Single-Phase
70V
3-4. Selecting A Location
Airflow Distance
Requirements
1
!
Do not move or operate unit
where it could tip.
1
Line Disconnect Device
Locate unit near correct input
power supply.
2
2
460 mm
(18 in.)
460 mm
(18 in.)
OM-250 147 Page 8
Welding Power Source
Shoulder Strap
Use strap to lift unit.
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
956142809_1-6_B
3-5. Volt-Ampere Curves
Volt-ampere curves show minimum and
maximum voltage and amperage output
capabilities of welding power source.
Curves of other settings fall between
curves shown.
Si 160 Max Output − 150 A; Si 160 Min Output − 15 A
DC VOLTAGE (V)
100
95
90
85
80
75
70
65
60
Stick Max
55
50
45
40
35
30
25
20
15
10
5
0
Stick Min
0
10
20
30
40
50
60
70
80
90 100 110
DC AMPERAGE (A)
120 130 140
150 160 170
180
DC VOLTAGE (V)
Sti 160 And STH 160 Max Output − 160 A; Sti 160 And STH 160 Min Output − 4 A
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
Stick/TIG Max
Stick/TIG Min
TIG
0
10
20
30
40
50
60
70
80
90 100 110 120 130 140 150 160
STICK
170 180 190
DC AMPERAGE (A)
OM-250 147 Page 9
3-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes 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 amperage or duty cycle before starting to
weld again.
250
WELD AMPERES
200
NOTICE − Exceeding duty cycle can
damage unit and void warranty.
TIG
150
STICK
100
50
0
10
2030
50
100
% DUTY CYCLE
3-7. Remote 6 Receptacle Information (STL And STH Models Only)
6
Socket
Socket Information
1
Contactor control +13.8 volts DC.
2
Contact closure to 1 completes contactor control
circuit and enables output when Lift-Arc TIG remote is selected.
3
Output to remote control; +10 volts DC output to
remote control.
4
0 to +10 volts DC input command signal from
remote control.
5
Remote control circuit common.
6
Chassis common.
15 VOLTS DC
OUTPUT
CONTACTOR
REMOTE
OUTPUT
CONTROL
CHASSIS
OM-250 147 Page 10
3-8. Electrical Service Guide
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
Si 160
Sti 160
STH 160
230
230
230
30
30
30
Time-Delay Fuses 2
35
35
35
3
45
45
45
Input Voltage (V)
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes
Normal Operating Fuses
1
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)
Min Input Conductor Size In
Reference: 2008 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-250 147 Page 11
3-9. Connecting 1-Phase Input Power For 230 VAC
1
!
Installation must
meet all
National and Local Codes − have
only qualified persons make this
installation.
!
Disconnect and lockout/tagout
input power before connecting
input conductors from unit.
!
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
1
Black And White Input Conductor
(L1 And L2)
Green Or Green/Yellow Grounding
Conductor
Input Power Cord.
Disconnect Device (switch shown in
the OFF position)
Disconnect Device Grounding
Terminal
Disconnect Device Line Terminals
=GND/PE
Earth Ground
5
7
2
3
4
4
5
6
L1
L2
2
6
1
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to
disconnect device line terminals.
7
3
Over-Current 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 switch in the On position.
Tools Needed:
956142809_1-6_B / 956142809_2-6_B
OM-250 147 Page 12
SECTION 4 − OPERATION
4-1. Controls For Si 160
3
6
1
2
4
5
956142809_3-6_D
!
1
Weld output terminals are energized Light comes on if unit overheats. Welding can 5 Negative Weld Output Receptacle
when power is On and Ready Light resume when unit has cooled (see Section
3-6).
(LED) is lit.
For Stick welding, connect work cable to this
receptacle.
3 Amperage Adjustment Control
Ready Light (LED)
Light comes on approximately two seconds after power switch is placed in On (I) position if
Stick has been selected. The light indicates
that the unit is energized and ready for welding.
2 High Temperature Light (LED)
See Section 4-2.
4
Positive Weld Output Receptacle
6
Power Switch
For Stick welding, connect electrode cable to Place switch in On (I) position to turn unit on.
this receptacle.
Place switch in Off (0) position to turn unit off.
4-2. Amperage Adjustment Control
1
Amperage Adjustment Control
Rotate knob clockwise to increase
amperage (Min − Max).
1
OM-250 147 Page 13
4-3. Preparing Unit For Stick Welding (Si Model)
5
3
!
Weld output terminals are
energized when power is On,
and Ready Light is lit.
1
Positive Weld Output
Receptacle
Connect electrode cable to this receptacle.
2
Negative Weld Output
Receptacle
Connect work cable to this receptacle.
4
3
Power Switch
Place switch in On (I) position.
4
1
2
Ready Light (LED)
Allow time for unit to complete its
start up cycle. Light comes on
approximately two seconds after
power switch is placed in On (I) position. The light indicates that the
unit is energized and ready for
welding.
5 Amperage Adjustment Control
Set amperage, see Section 4-2.
956142809_3-6_D
Notes
OM-250 147 Page 14
4-4. Controls For STi 160
2
13
1
11
888
9
10
8
12
4
5
3
6
7
956142809_3-6_D
!
remote control and by the Amperage/
Weld output terminals are energized For Stick welding, connect electrode cable to
Set-up Adjustment control.
when power is On, and Ready Light is this receptacle. For TIG welding, connect work
cable to this receptacle.
lit.
9 Ammeter And Parameter Display (Meter)
6 Negative Weld Output Receptacle
1 Ready Light (LED)
Meter displays actual amperage while welding.
Light comes on approximately two seconds af- For Stick welding, connect work cable to this Meter also displays preset parameters for any
ter power switch is placed in On (I) position. receptacle. For TIG welding, connect torch to of the following: time, set-up, and overheating
alarm.
The light indicates that the unit is energized and this receptacle.
ready for welding.
10 Power Switch
7 Remote Control Receptacle
2 High Temperature Light (LED)
Connect remote control to receptacle (see Place switch in On (I) position to turn unit on.
Light comes on if unit overheats. Welding can Section 3-7). For TIG and Stick welding, output Place switch in Off (0) position to turn unit off.
resume when unit has cooled (see Section may be adjusted from min to max of the front Upon power up, unit will recall and display the
3-6).
last welding procedure, or factory default propanel setting with the remote control.
cedure (see Section 4-14).
3 Amperage/Set-Up Adjustment Control
8 Remote Control Pixel
Use control to adjust welding amperage and Pixel flashes when a remote control is connec- 11 Stick Welding Light (LED)
change values while in the set-up mode.
See Section 4-5).
ted to the remote control receptacle.
4 Process/Set-Up Selector Switch
12 TIG Lift Arc Start Light (LED)
. When a foot or finger remote control is conSee Section 4-5 and/or 4-6
nected , remote trigger is not enabled. Only See Section 4-6).
5 Positive Weld Output Receptacle
amperage adjustment is controlled by the 13 Set-Up Light (LED)
OM-250 147 Page 15
4-5. Preparing Unit For Stick Welding (STi Model)
5
=Light Off
*
=Light Flashing
=Light On
=Light Flashing If Voltage Reduction Device Is On
Process Selection
Set-Up Menu
4
*
8
9
7
1
3
2
6
Press And Release
!
1
2
3
4
5
6
7
8
9
Weld output terminals are energized when power is On, and
Ready Light is lit.
Positive Weld Output Terminal
Remote Control Receptacle
Negative Weld Output Terminal
Amperage/Set-Up Adjustment
Control
Ammeter And Parameter Display
(Meter)
Process/Set-Up Selector Switch
Stick Welding Light ( LED)
Ready Light (LED)
Set-Up Light ( LED)
Prepare unit for Stick welding as follows:
Connect electrode holder to positive
weld output receptacle.
Connect work clamp to negative weld
output terminal.
If desired, connect an optional remote
control to the remote control receptacle
to remotely control weld amperage.
Turn power on. Allow time for unit to complete its start up cycle.
Press and release Amperage/Set-Up
Adjustment control to select Stick welding and light corresponding LED. Display
meter displays ARC for three seconds
and then the factory default setting of 80
amperes.
Voltage Reduction Setting
To change voltage reduction setting, proceed as follows:
OM-250 147 Page 16
Press And Hold
Press and hold Process/Set-Up Adjustment Control to enter set-up mode.
Upon entry, the Set-Up light begins to
flash, and the display meter displays
VRD.
Voltage Reduction default is Off. Use
Amperage/Set-Up Adjustment control to
enable or turn setting On.
When Voltage Reduction is enabled,
Stick Welding light flashes continuously.
VRD is set to 20 volts
. Unit will automatically exit the set-up
menu if no activity is detected for
more than three seconds. Press and
hold Process/Set-Up Adjustment
control to re-enter set-up mode.
Hot Start Setting
Use Hot Start to increase output amperage 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 release Process/Set-Up Selector switch.
The Set-Up light will continue to flash.
The display meter will display HS.
Use the Amperage/Set-Up Adjustment
control to change amperage from 0 to 50
percent of the preset amperage value,
with 15 percent being the default value.
The maximum Hot Start amperage value
is 150 amps.
Example: If preset amperage is 90 amps,
0% = 90 amps, 50% = 135 amps.
Arc Force Setting:
Use Arc Force to increase short-circuit
amperage at low arc voltage. Set at 0 for
normal welding amperage. Turn control
clockwise to increase short-circuit amperage.
To change Arc Force setting, proceed as
follows:
While in the set-up menu, press and release the Process/Set-Up Selector
switch. The Set-Up light continues to
flash.
Use the Amperage/Set-Up Adjustment
control to change amperage from 0 to 50
percent of the preset amperage value,
with 15 percent being the default value.
The maximum Arc Force setting is 150
amps.
Example: If preset amperage is 90 amps,
0% = 90 amps, 50% = 135 amps.
Anti Stick
Anti Stick prevents the electrode from
sticking while welding.
This function is automatically active while
using the Stick welding process. Anti
Stick increases amperage when arc
voltage is below ten volts for more than
two seconds.
. The
amperage range while Stick
welding is from 4 to 150 amps.
4-6. Preparing Unit For TIG Welding (STi Model)
5
=Light Off
*
=Light Flashing
=Light On
=Light Flashing If Voltage Reduction Device Is On
Process Selection
Set-Up Menu
4
8
*
7
9
1
3
2
6
Press And Release
!
Weld output terminals are energized when power is On, and
Ready Light is lit.
1 Positive Weld Output Terminal
2 Remote Control Receptacle
3 Negative Weld Output Terminal
4 Amperage/Set-Up Adjustment
Control
5 Ammeter And Parameter Display
(Meter)
6 Process/Set-Up Selector Switch
7 TIG Welding Light (LED)
8 Ready Light (LED)
9 Set-Up Light ( LED)
Prepare unit for TIG welding as follows:
Connect electrode holder to negative
weld output receptacle.
Connect work clamp to positive weld output terminal.
If desired, connect a remote control to the
remote control receptacle.
Turn power on. Allow time for unit to complete its start up cycle.
Press and release Amperage/Set-Up
Adjustment control to select TIG welding
and light corresponding LED. Display
meter displays TIG for three seconds
Press And Hold
and then the factory default setting of 50
amperes.
Voltage Reduction Setting
To change voltage reduction setting, proceed as follows:
Press and hold Amperage/Set-Up Adjustment Control to enter set-up mode.
Upon entry, the Set-Up light begins to
flash, and the display meter displays
VRD.
Voltage Reduction default is Off. Use
Amperage/Set-Up Adjustment 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 the set-up
menu if no activity is detected for
more than three seconds. Press and
hold Amperage/Set-Up Adjustment
control to re-enter set-up mode.
Slope Down Setting
switch. The Set-up light continues to
flash.
The display meter will display SL.
Use the Amperage/Set-Up Adjustment
control to reduce amperage over a set
period of time (0−10 seconds) at the end
of the weld. The default setting is 0
seconds.
Application:
Slope Down should be used while TIG
welding materials that are crack sensitive, and/or the operator wants to eliminate the crater at the end of the weld.
Anti Stick
Anti Stick prevents the electrode from
sticking while welding.
This function is automatically active while
using the TIG welding process. Anti Stick
increases amperage when arc voltage is
below four volts for more than two
seconds.
. The
amperage range while TIG
welding is from 4 to 160 amps.
To change Slope Down setting, proceed
as follows:
While in the set-up menu, press and release the Process/Set-Up Selector
OM-250 147 Page 17
4-7. Controls For STH 160
2
13
8
3
888
1
11
12
14
15
9
8
10
17
16
4
5
6
7
956142809_3-6_D
!
Negative Weld Output Receptacle
10 Power Switch
For Stick welding, connect work cable to this Place switch in On (I) position to turn unit on.
receptacle. For TIG welding, connect torch to Place switch in Off (0) position to turn unit off.
Upon power up, unit will recall and display the
this receptacle.
last welding procedure, or factory default pro7 Remote Control Receptacle
cedure (see Section 4-14).
Connect remote control to receptacle (see
11 TIG HF Start Light (LED)
Section 3-7). For TIG and Stick welding, output
may be adjusted from min to max of the front See Section 4-15.
panel setting with the remote control.
12 TIG Lift Arc Start Light (LED)
. When a foot or finger remote control is con- See Section 4-15).
nected , remote trigger is enabled only in 13 Set-Up Light (LED)
the TIG mode. Amperage adjustment is 14 Stick Welding Light (LED)
controlled by the remote control and AmSee section 4-8.
perage/Set-up adjustment control.
15 Sequencer Parameters Switch
8 Remote Control Pixel
See Section 4-12.
See Section 4-2.
Pixel flashes when a remote control is connec16 Pulse Control Switch
4 Process/Set-Up Selector Switch
ted to the remote control receptacle.
See Section 4-8 and/or 4-9.
9 Ammeter And Parameter Display (Meter) See Section 4-13.
5 Positive Weld Output Receptacle
Meter displays actual amperage while welding. 17 Gas In Fitting
For Stick welding, connect electrode cable to Meter also displays preset parameters for any Connect hose from shielding gas supply reguthis receptacle. For TIG welding, connect work of the following: time, set-up, and overheating lator/flowmeter to gas in fitting. Fitting has ⅝-18
cable to this receptacle.
alarm.
right-hand threads. See Section 4-10.
Weld output terminals are energized
when power is On, and Ready Light is
lit.
1 Ready Light (LED)
Light comes on approximately two seconds after power switch is placed in On (I) position if
Lift-Arct or Stick has been selected. The light
indicates that the unit is energized and ready
for welding.
2 High Temperature Light (LED)
Light comes on if unit overheats. Welding can
resume when unit has cooled.
3 Amperage/Set-Up Adjustment Control
Use control to adjust welding amperage and
change values while in the set-up menu.
OM-250 147 Page 18
6
4-8. Preparing Unit For Stick Welding (STH Model)
5
=Light Off
*
=Light Flashing
=Light On
=Light Flashing If Voltage Reduction Device Is On
Process Selection
Set-Up Menu
4
8
9
1
*
3
2
7
6
Press And Release
!
1
2
3
4
5
6
7
8
9
Press And Hold
Weld output terminals are energized when power is On, and
Ready Light is lit.
ceed as follows:
Positive Weld Output Terminal
Remote Control Receptacle
Negative Weld Output Terminal
Amperage/Set-Up Adjustment
Control
Ammeter And Parameter Display
(Meter)
Process/Set-Up Selector Switch
Stick Welding Light ( LED)
Ready Light (LED)
Set-Up Light (LED)
Upon entry, the Set-Up light begins to
flash, and the display meter displays
VRD.
Prepare unit for Stick welding as follows:
Press and hold Process/Set-Up Adjustment Control to enter set-up mode.
Voltage Reduction default is Off. Use
Amperage/Set-Up Adjustment control to
enable or turn setting On.
When Voltage Reduction is enabled,
Stick Welding light flashes continuously.
VRD is set to 20 volts.
. Unit will automatically exit the set-up
menu if no activity is detected for
more than three seconds. Press and
hold Process/Set-Up Adjustment
control to re-enter set-up mode.
Connect electrode holder to positive
weld output receptacle.
Hot Start Setting
Connect work clamp to negative weld
output terminal.
Use Hot Start to increase output amperage at the start of a weld to help prevent
electrode sticking.
If desired, connect a remote control to the
remote control receptacle.
Turn power on. Allow time for unit to complete its start up cycle.
Press and release Process/Set-Up Adjustment control to select Stick welding
and light corresponding LED. Display
meter displays ARC for three seconds
and then the factory default setting of 80
amperes.
Voltage Reduction Setting
To change voltage reduction setting, pro-
To change Hot Start setting, proceed as
follows:
While in the set-up menu, press and release Process/Set-Up Selector switch.
The Set-up light continues to flash.
The display meter will display HS.
Use the Amperage/Set-Up Adjustment
control to change amperage from 0 to 50
percent of the preset amperage value,
with 15 percent being the default value.
The maximum Hot Start amperage value
is 150 amps.
Example: If preset amperage is 90 amps,
0% = 90 amps, 50% = 135 amps.
Arc Force Setting:
Use Arc Force to increase short-circuit
amperage at low arc voltage. Set at 0 for
normal welding amperage. Turn control
clockwise to increase short-circuit amperage.
To change Arc Force setting, proceed as
follows:
While in the set-up menu, press and release the Process/Set-Up Selector
switch. The Set-Up light continues to
flash.
Use the Amperage/Set-Up Adjustment
control to change amperage from 0 to 50
percent of the preset amperage value,
with 15 percent being the default value.
The maximum Arc Force setting is 150
amps.
Example: If preset amperage is 90 amps,
0% = 90 amps, 50% = 135 amps.
Anti Stick
Anti Stick prevents the electrode from
sticking while welding.
This function is automatically active while
using the Stick welding process. Anti
Stick increases amperage when arc
voltage is below ten volts for more than
two seconds.
. The
amperage range while Stick
welding is from 4 to 150 amps.
OM-250 147 Page 19
4-9. Preparing Unit For TIG Welding (STH Model)
5
=Light Off
*
=Light Flashing
=Light On
=Light Flashing If Voltage Reduction Device Is On
Process Selection
Set-Up Menu
4
8
*
9
1
3
2
7
6
Press And Release
1
Press And Hold
Positive Weld Output Terminal
Prepare unit for TIG welding as follows:
Anti Stick
2
Remote Control Receptacle
Connect electrode holder to negative
weld output receptacle.
Anti Stick prevents the electrode from
sticking while welding.
3
Negative Weld Output Terminal
4
Amperage/Set-Up Adjustment
Control
Connect work clamp to positive weld output terminal.
5
Ammeter And Parameter Display
(Meter)
If desired, connect a remote control to the
remote control receptacle.
This function is automatically active while
using the TIG welding process. Anti Stick
increases amperage when arc voltage is
below four volts for more than two
seconds.
Turn power on. Allow time for unit to complete its start up cycle.
. The
6
Process/Set-Up Selector Switch
7
TIG Welding Light (LED)
8
Ready Light (LED)
9
Set-Up Light (LED)
OM-250 147 Page 20
Press and release Amperage/Set-Up
Adjustment control to select TIG welding
and light corresponding LED. Display
meter displays TIG for three seconds
and then the factory default setting of 50
amperes.
amperage range while TIG
welding is from 4 to 160 amps.
4-10. Gas Connections (STH Models)
1
2
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.
3
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.
2
3
4
1
Gas In Fitting
Connect hose from shielding gas
supply regulator/flowmeter to gas in
fitting. Fitting has 5/8-18 right-hand
threads.
5
Gas Out Fitting
Connect shielding gas hose from
torch to gas out fitting. Fitting has
3/8-19 BSPP right-hand threads.
4
5
956142809_3-6_D
OM-250 147 Page 21
4-11. 2T Or 4T Trigger Mode Settings (STH Models)
1
5
2
3
4
5
6
6
7
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
4
7
3
2T and 4T are used with the TIG
process. Select TIG process according to Section 4-9.
2
. Unit will automatically exit the
set-up menu if no activity is detected for more than three
seconds. Press and hold Process/Set-Up Adjustment control to re-enter set-up mode.
1
While in the set-up mode, to change
between 2T and 4T proceed as follows:
Press and hold the Process/Set-Up
Selector switch until Set-Up light
begins to flash and meter displays
2T.
Rotate Amperage/Set-Up Adjustment control to switch between 2T
and 4t.
Current (A)
Remote 2T Trigger Operation
Main Amps
Final Slope
Postflow
Preflow
P
Time
R
Current (A)
Remote 4T Trigger Operation
Main Amps
Initial Slope
Final Slope
Initial Amps
Final Amps
Postflow
Time
Preflow
P
OM-250 147 Page 22
R
P
R
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.
1
2
2
1
3
3
4
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 parameters, press and release the Sequencer Parameters switch. Selected
parameter will be displayed on the
meter and the corresponding LED
lights.
Turn Amperage/Set-Up Adjustment control to change value of selected parameter. Value selected is
displayed on the meter.
5
4
Preflow Time
Use control to set length of time gas
flows before arc initiation. Default is
0.2 seconds (min=0s, max=2.0s).
6
Initial Current
Use control to set a starting amperage that is different from the weld
amperage. Default is 40 percent.
(min=10 percent or minimum value
set during initial set-up, max=90
percent or maximum value set during initial set-up).
7
Slope Up Time
Use control select amount of time
that it takes to slope up/down from
initial amperage to weld amperage.
To disable, set to 0. Default =1.0
second. (min=0s, max=10s).
8
Slope Down Time
Use control to select amount of time
that it takes to slope up/down from
weld amperage to final amperage.
To disable, set to 0. Default =2.0
seconds. (min=0s, max=10s).
Application::
Slope Down Time should be used
while TIG welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
9
7
5
8
6
9
Pulse Control
See Section 4-13
10
Final Current
Use control to select amperage to
which weld amperage has sloped
up/down to. Default is 30 percent.
(min=10 percent or minimum value
set during initial set-up, max=90
percent or maximum value set during initial set-up).
10 Post Flow Time
Use control to set length of time gas
flows after welding stops to protect
weld puddle.
OM-250 147 Page 23
4-13. Pulser Control Settings (STH Models)
Pulsing is only available while using
a TIG process.
Select TIG process according to
Section 4-9.
1
2
2
1
3
3
4
5
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
switch. Selected parameter will be
displayed on the meter and corresponding LED lights.
5
Turn Amperage/Set-Up Adjustment control to change value of selected parameter. Value selected is
displayed on the meter.
4
6
Duty Cycle (%)
Use control to control weld puddle
cooling. Default is 50 percent
(min=0.1 percent, max=90 percent).
7
Peak Current
Peak amperage is set using the
Amperage/Set-Up Adjustment control. Peak 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 control to
set the low pulse of the weld amperage, which cools the weld puddle
and affects overall heat input. Background Current is set as a percentage of peak amperage. Default is
40 percent (min=10 percent,
max=90 percent).
9
Pulse Frequency (Hz)
Pulse Frequency controls weld
bead appearance. Default=60Hz
(min=0.4 Hz, max=300Hz).
Application:
7
%
6
Ab
8
9
OM-250 147 Page 24
HZ
Pulsing refers to the alternating
raising and lowering of the weld output at a specific rate. The raised
portions of the weld output are controlled in width, height, and frequency, forming pulses of weld output.
These pulses and the lower amperage level between them (called the
background current) alternately
heat and cool the molten weld
puddle. The combined effect gives
the operator better control of penetration, bead width, crowning, undercutting, and heat input.
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.
1
2
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).
Factory default settings are now restored.
2
1
956142809_3-6_D
4-15. Lift-Arct And HF TIG Start Procedures
Lift-Arc Start
When Lift-Arc button light is On, start arc as
follows:
Lift-Arc Start Method
1
“Touch”
1−2
Seconds
2
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at
weld start point, enable output and shielding
gas with torch trigger, foot 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 before tungsten electrode touches workpiece;
only a low sensing voltage is present between
electrode and workpiece. The solid-state output contactor does not energize until after
electrode is touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting contaminated.
Application:
Lift-Arc is used for the DCEN or AC GTAW
process when HF Start method is not permitted, or to replace the scratch method.
HF Start
Do NOT Strike Like A Match!
When HF Start button light is On, start arc as
follows:
High frequency turns on to help start arc when
output is enabled. High frequency turns off
when arc is started, and turns on whenever
arc is broken to help restart arc.
Application:
HF start is used for the DCEN GTAW process
when a non-contact arc starting method is
required.
OM-250 147 Page 25
SECTION 5 − MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
!
Disconnect power before maintaining.
. Maintain more often during severe conditions.
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
= Repair
l = Replace
Every
3
Months
nl Labels
~ Weld Terminals
n l Gas Hoses
Every
3
Months
n lCables And Cords
Every
6
Months
!
Do not remove case when blowing out inside of unit.
Blow out inside. Direct airflow through front and back louvers.
~:During heavy service, clean monthly.
5-2. High Temperature Help Display
1
2
2
1
-- -
High Temperature Light (LED)
Meter Help Display
When unit over heats, High Temperature
light turns on and unit emits an audible
beep. The meter displays three dashes as
shown. Unit shuts down and fans run until
temperature drops within normal operating range (see Section 3-6).
NOTICE − Wait at least four minutes before checking to see if temperature is within normal operating range.
956142809_3-6_D
OM-250 147 Page 26
5-3. Troubleshooting
Trouble
No weld output; unit completely inoperative; ready light (LED) Off.
Remedy
Place line disconnect switch in On position (see Section 3-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-9).
Check for proper input power connections (see Sections 3-8 and 3-9).
No weld output; high temperature light
(LED) On.
Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 3-6).
Reduce duty cycle or amperage.
Check and correct blocked/poor airflow to unit (see Section 3-9).
Erratic or improper welding arc or output.
Use proper size and type of weld cable (see your Distributor).
Clean and tighten weld connections.
Check electrode polarity and reverse if necessary; check and correct poor connections to workpiece.
Fan 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 welding problems: Hard starts; Use proper type and size of electrode.
poor welding characteristics; unusual
Check electrode polarity and reverse if necessary; check and correct poor connections.
spattering.
Make sure a remote control is not connected.
TIG welding problems: Wandering arc; Use proper type and size of tungsten.
hard starts; poor welding characterisUse properly prepared tungsten.
tics; spattering problems.
Check electrode polarity and reverse if necessary.
TIG welding problems: Tungsten elec- Shield weld zone from drafts.
trode oxidizing and not remaining bright
Check for correct type shielding gas.
after welding.
Check and tighten gas fittings.
Check electrode polarity and reverse if necessary.
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-250 147 Page 27
SECTION 6 − ELECTRICAL DIAGRAM
956 142810-A
Figure 6-1. Circuit Diagram For Si 160
OM-250 147 Page 28
956 142811-B
Figure 6-2. Circuit Diagram For STi 160
OM-250 147 Page 29
956 142812-C
Figure 6-3. Circuit Diagram For STH 160
OM-250 147 Page 30
Notes
OM-250 147 Page 31
SECTION 7 − PARTS LIST FOR Si MODELS
. Hardware is common and
not available unless listed.
3
2
1
4
19
17
23
16
21
25
24
20
12
10
5
18
11
23
27
26
15
13
14
12
22
6
7
8
9
956 142809_4-6_D
Figure 7-1. Main Assembly For Si 160
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
7-1. Main Assembly For Si 160
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1 . . . PC1 . . . . 057084156
2 . . . . . . . . . . . . 756033051
3 . . . . . . . . . . . . 956142819
4 . . . . . . . . . . . +156121043
5 . . . . . . . . . . . . 356029228
6 . . . . . . . . . . . . 000193920
7 . . . . . . . . . . . . 000244862
8 . . . . . . . . . . . . 000208498
9 . . . . . . . . . . . . 000208612
10 . . . . . . . . . . . 156005157
11 . . . . . . . . . . . . 156118074
12 FM1,FM2 . 056126080
13 . . PC2 . . . . 057084157
14 . . . . . . . . . . +156006070
15 . . . . . . . . . . . 057116002
16 . . . . . . . . . . . 156118075
17 . . . . . . . . . . +056052011
18 . . . . . . . . . . . 356029230
19 . . . . . . . . . . . 656089045
20 . . . S1 . . . . 056067277
21 . . . . . . . . . . . 057014232
22 . . . . . . . . . . . 000208497
23 . . . . . . . . . . . 000208558
24 . . . . . . . . . . . 156005159
OM-250 147 Page 32
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Kit, PCB Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M5− 8x12 Soc Hd−torx Stl Pld Sems Piloted . . . . . . . . . . . . . . . . .
Receptacle, Twist Lock Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, Twist Lock Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, Front Upper Pcb Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, W/Leads And Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board,Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strap, Shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, Rear Power Switch/Cable Support . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, 16a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M8−1.2 13mm Hex 8,3 Mm T Semi Cone Washer . . . . . . . . . . . . . . .
Term, Friction 250x0,32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Pcb Assy Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
7-1. Main Assembly For Si 160 (Continued)
. . . 25 . . . . . . . . . . . 156005158 . Bracket, pcb assy support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . *058066079 . Electrode holder/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 original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 147 Page 33
SECTION 8 − PARTS LIST FOR STi MODELS
. Hardware is common and
not available unless listed.
3
19
1
2
4
18
17
16
21
23
20
25
24
27
26
28
12
15
13
11
14
10
5
12
6
7
8
9
22
956142809_5-6_F
Figure 8-1. Main Assembly For STi 160
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
8-1. Main Assembly For STi 160
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1 . . . PC1 . . . . 057084158
2 . . . . . . . . . . . . 756033051
3 . . . . . . . . . . . . 956142819
4 . . . . . . . . . . . +156121043
5 . . . . . . . . . . . . 356029229
6 . . . . . . . . . . . . 000193920
7 . . . . . . . . . . . . 000244862
8 . . . . . . . . . . . . 000208498
9 . . . . . . . . . . . . 000208612
10 . . . . . . . . . . . 156005160
11 . . . . . . . . . . . . 156118074
12 FM1,FM2 . 056126080
13 . . PC3 . . . . 057084159
14 . . . . . . . . . . +156006070
15 . . . . . . . . . . . 057116002
16 . . . . . . . . . . . 156118075
17 . . . . . . . . . . +056052011
18 . . . . . . . . . . . 356029230
19 . . . . . . . . . . . 656089045
20 . . . S1 . . . . 056067277
21 . . . . . . . . . . . 057014232
22 . . . . . . . . . . . 000208497
23 . . . . . . . . . . . 000208558
24 . . . . . . . . . . . 156005159
25 . . . . . . . . . . . 156005161
OM-250 147 Page 34
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.
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.
.
Kit, PCB Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M5− 8 X 12 Soc Hd−torx Stl Pld Sems Piloted . . . . . . . . . . . . . . . .
Receptacle, Twist Lock Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, Twist Lock Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, Front Upper Pcb Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, W/Leads And Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board,Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strap, Shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, Rear Power Switch/Cable Support . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, 16a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M8−1.2 13mm Hex 8.3 Mm T Semi Cone Washer . . . . . . . . . . . . . . .
Term, Friction 250 X 0.32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, PCB Assy Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, PCB Assy Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
8-1. Main Assembly For STi 160 (Continued)
. . . 26 . . PC2 . . . . 057084160 . Circuit Board, Pwm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . 156033037 . Cover Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 147 Page 35
SECTION 9 − PARTS LIST FOR STH MODELS
. Hardware is common and
not available unless listed.
3
1
2
19
4
17
18
16
23
24
12
23
32
10
5
21
31
26
13
20 33
15
14
11
34
27
12
28
29
6
8
7
22
30
9
25
956142809_6-6_F
Figure 9-1. Main Assembly For STH 160
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly For STH 160
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1 . . . PC1 . . . . 057084158
2 . . . . . . . . . . . . 756033051
3 . . . . . . . . . . . . 956142819
4 . . . . . . . . . . . +156121043
5 . . . . . . . . . . . . 356029231
6 . . . . . . . . . . . . 000193920
7 . . . . . . . . . . . . 000244862
8 . . . . . . . . . . . . 000208498
9 . . . . . . . . . . . . 000208612
10 . . PC4 . . . . 057084161
11 . . . . . . . . . . . . 156118074
12 FM1,FM2 . 056126080
13 . . PC3 . . . . 057084162
14 . . . . . . . . . . +156006070
15 . . . . . . . . . . . 057116002
16 . . . . . . . . . . . 156118075
17 . . . . . . . . . . . 056052011
18 . . . . . . . . . . . 356029232
19 . . . . . . . . . . . 656089045
20 . . . S1 . . . . 056067277
21 . . . . . . . . . . . 057014232
22 . . . . . . . . . . . 000208497
23 . . . . . . . . . . . 000208558
24 . . . . . . . . . . . 156005159
25 . . . . . . . . . . . 156005162
OM-250 147 Page 36
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.
.
.
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.
Kit, PDB Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M5− 8 X 12 Soc Hd−torx Stl Pld Sems Piloted . . . . . . . . . . . . . . . .
Receptacle, Twist Lock Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, Twist Lock Power/Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, Led Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, W/Leads And Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board,Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strap, Shoulder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, Rear Power Switch/Cable Support . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, 16a 250vac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, M8−1.2 13mm Hex 8,3 Mm T Semi Cone Washer . . . . . . . . . . . . . . .
Term, Friction 250 X 0.32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, PCB Assy Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, PDB Assy Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly For STH 160 (Continued)
...
...
...
...
...
...
...
...
...
26
27
28
29
30
31
32
33
34
. . PC2 . . . . 057084160
. . GS1 . . . . 056061069
. . PC5 . . . . 057084163
. . PC6 . . . . 057084164
. . . . . . . . . . . 058021155
. . . . . . . . . . . 056001007
. . . . . . . . . . . 156005163
. . . . . . . . . . . 156033037
. . . . . . . . . . *058066079
.
.
.
.
.
.
.
.
.
Circuit Board, Pwm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, Gas Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, Arc Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Xfmr, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, M10/32 F M5x75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, Front Upper Pcb Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrode Holder/Ground Clamp Cable Set, 3mt . . . . . . . . . . . . . . . . . . . . .
+
When ordering a component originally displaying a precautionary label, the label should also be ordered.
*
Optional.
1
1
1
1
1
1
1
1
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-250 147 Page 37
Notes
Effective January 1, 2011
(Equipment with a serial number preface of MB 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
below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
eighteen months after the equipment is shipped to an
International distributor.
1.
5 Years Parts — 3 Years Labor
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 171
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
HF Units
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
2 Years — Parts
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
Automatic Motion Devices
Field Options
(NOTE: Field options are covered under True Blue
for the remaining warranty period of the product they
are installed in, 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 Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water Coolant Systems (Hydramate 1 and 2)
Water
Coolant
Systems
(USA
Models,
Non-Integrated)
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
6.
90 Days — Parts
*
*
*
*
*
*
*
Accessory (Kits)
Canvas Covers
Induction Heating Coils and Blankets
MIG Guns
Remote Controls
Replacement Parts (No Labor)
Spoolmate Spoolguns
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at ITW Welding Products
Group Europe or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
milan_warr 2011−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
Country
Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Products Italy S.r.l.
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
 2011 Miller Electric Mfg. Co. 2011−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: [email protected]−welding.it
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