Miller Si 160 Owner's Manual
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Miller Si 160 Owner's Manual

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www.MillerWelds.com
Si 160, Si 160 PFC, And STi 160
OM-261 767A
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-261 767A 2013−01 Processes Stick (SMAW) Welding TIG (GTAW) Welding Description Arc Welding Power Source Si 160, Si 160 PFC, And STi 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

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 4: Declaration Of Conformity

    Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number Si 160 059016011 Si 160 PFC 059016016 STi 160 059016012 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

    At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values. B. Information On Electromagnetic Compatibility (EMC) For Si 160 And STi 160 Models 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.

  • Page 12: Specifications

    Stick 150A @ 26 Volts DC, 7.0/4.8 25% Duty Cycle L = 380 mm 5.2 Kg W = 145 mm Si 160 (11.5 lb) 100A @ 14 Volts DC, H = 245 mm 3.0/2.0 100% Duty Cycle 230 Volts TIG 15−150A...

  • Page 13: Volt-Ampere Curves

    3-6. Volt-Ampere Curves Volt-ampere curves show minimum Si160MaxOutput − 150A;Si160MinOutput − and maximum voltage and amper- age output capabilities of welding power source. Curves of other set- tings fall between curves shown. Stick Max StickMin 100 110 130 140 150 160 170 180 DC Amperage (A) Si160PFCMaxOutput −...

  • 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 STi 160 PCF...

  • Page 16: Connecting 1-Phase Input Power

    3-10. Connecting 1-Phase Input Power =GND/PE Earth Ground Tools Needed: input4 2012−05 − 956172002_3-A / 956172002_4-A OM-261 767 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 necting unit to an engine generator. Connect green or green/yellow grounding Local Codes − have only qualified per- conductor to disconnect device grounding See rating label on unit and check input volt- sons make this installation.

  • Page 18: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls (Si Models) 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 Models)

    4-3. Preparing Unit For Stick Welding (Si Models) 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: Resetting Unit To Factory Default Settings (Sti Model Only)

    4-7. Resetting Unit To Factory Default Settings (STi Model Only) 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 24: 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 25: 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 26: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 956 142810-A Figure 6-1. Circuit Diagram For Si 160 OM-261 767 Page 22...
  • Page 27 956 142811-C Figure 6-2. Circuit Diagram For STi 160 OM-261 767 Page 23...
  • Page 28 956 172001-A Figure 6-3. Circuit Diagram For Si 160 PFC OM-261 767 Page 24...
  • Page 29 Notes OM-261 767 Page 25...

  • Page 30: 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 31 Dia. Part Mkgs. Description Quantity 7-1. Main Assembly For Si 160 (Continued) ....156005158 Bracket, pcb assy support ........

  • Page 32: 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 33 Item Dia. Part Mkgs. Description Quantity 8-1. Main Assembly For STi 160 (Continued) ..057084160 Circuit Board, Pwm ..........

  • Page 34: Section 9 − Parts List For Si Pfc Models

    SECTION 9 − PARTS LIST FOR Si PFC MODELS Hardware is common and not available unless listed. 956172002_2-A Figure 9-1. Main Assembly For Si 160 PFC Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly For Si 160 PFC .
  • Page 35 Part Item Mkgs. Description Quantity Figure 9-1. Main Assembly For Si 160 PFC (Continued) ....057014275 Cable, Power w/Plug ..........
  • Page 36 Notes...
  • Page 37 Notes...
  • Page 38 Notes...
  • Page 39 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 40 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 160 pfc059016011059016016059016012

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