Miller Si 160, Si 160 PFC Owner's Manual

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

CE

Visit our website at

www.MillerWelds.com

File: TIG (GTAW)

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.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

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.

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

1-1. Symbol Usage 1.......................................................................

1-2. Arc Welding Hazards 1.................................................................

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

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − DEFINITIONS 5..................................................................

2-1. Additional Safety Symbols And Definitions 5................................................

2-2. Miscellaneous Symbols And Definitions 6..................................................

SECTION 3 − SPECIFICATIONS AND INSTALLATION 7...........................................

3-1. Important Information Regarding CE Products (Sold Within The EU) 7..........................

3-2. Serial Number And Rating Label Location 7................................................

3-3. IP Rating 7............................................................................

3-4. Specifications 8........................................................................

3-5. Selecting A Location 8..................................................................

3-6. Volt-Ampere Curves 9..................................................................

3-7. Duty Cycle And Overheating 10...........................................................

3-8. Remote 6 Receptacle Information (STi Model Only) 10........................................

3-9. Electrical Service Guide 11...............................................................

3-10. Connecting 1-Phase Input Power 12.......................................................

3-11. Connecting To 1-Phase Engine Generator w/230 Volt Output 13................................

SECTION 4 − OPERATION 14...................................................................

4-1. Controls (Si Models) 14..................................................................

4-2. Amperage Adjustment Control 14..........................................................

4-3. Preparing Unit For Stick Welding (Si Models) 15.............................................

4-4. Controls For STi 160 16..................................................................

4-5. Preparing Unit For Stick Welding (STi Model) 17.............................................

4-6. Preparing Unit For TIG Welding (STi Model) 18..............................................

4-7. Resetting Unit To Factory Default Settings (STi Model Only) 19.................................

4-8. Lift-ArctAnd HF TIG Start Procedures 19..................................................

SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 20.......................................

5-1. Routine Maintenance 20.................................................................

5-2. High Temperature Help Display 20.........................................................

5-3. Troubleshooting 21......................................................................

SECTION 6 − ELECTRICAL DIAGRAM 22........................................................

SECTION 7 − PARTS LIST FOR Si MODELS 26...................................................

SECTION 8 − PARTS LIST FOR STi MODELS 28..................................................

SECTION 9 − PARTS LIST FOR Si PFC MODELS 30...............................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

ITW Welding 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 059016011

Si 160 PFC 059016016

STi 160 059016012

Council Directives:

 2006/95/EC Low Voltage

 2004/108/EC Electromagnetic Compatibility

 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

 IEC 609741 Arc Welding Equipment  Welding Power Sources: edition 3, 200507.

 IEC 6097410 Arc Welding Equipment  Electromagnetic Compatibility Requirements: edition 2.0, 200708.

 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
(0Hz300Hz)

EU Signatory:

January 2nd , 2013

___________________________________________________________________________________

Massimigliano Lavarini Date of Declaration

ELECTRONIC ENGINEER R&D TECH. SUPPORT

956 172 003

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2011−10

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.

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 follow-

ing 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, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

. 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.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in
use.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

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 equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-261 767 Page 1

FUMES AND GASES can be hazardous.

)

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

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 op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

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

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

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 by-

pass them.

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

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

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

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

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 containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

D Do not weld where the atmosphere 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.

OM-261 767 Page 2

workpiece, and hot equipment can cause fires and

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

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE 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.

Compressed 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, mechani-

cal 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 compressed 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 num-

ber 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.

OVERUSE can cause OVERHEATING

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.

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.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

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.

H.F. RADIATION can cause interference.

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.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.
D 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.

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 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.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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-261 767 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.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], 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 Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

1-6. EMF Information

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.

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: [phone], 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: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-

try, 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: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.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: [phone], website:
www.cdc.gov/NIOSH).

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, restrict access for passers−by or conduct 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.

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.

OM-261 767 Page 4

SECTION 2 − DEFINITIONS

2-1. Additional Safety Symbols And Definitions

Warning! Watch Out! There are possible hazards as shown by the symbols.

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Protect yourself from electric shock by insulating yourself from work and ground.

Safe1 2012−05

Safe2 2012−05

Safe3 2012−05

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Keep flammables away from welding. Do not weld near flammables.

Safe5 2012−05

Safe6 2012−05

Safe8 2012−05

Safe10 2012−05

Safe12 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Do not remove or paint over (cover) the label.

Safe14 2012−05

Safe20 2012−05

OM-261 767 Page 5

Do not weld on drums or any closed containers.

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.

2-2. Miscellaneous Symbols And Definitions

A

Amperes Voltage Input

Safe16 2012−05

Safe37 2012−05

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

Become trained and read the instructions before working on the
machine or welding.

Safe40 2012−05

S

Suitable For Areas

Of Increased

Shock Hazard

Shielded Metal Arc

Welding (SMAW)

I

1eff

V

Volts

Output Negative Positive

Gas Input High Temperature Direct Current Line Connection

Percent

Alternating

Current

Maximum Effective

Supply Current

Process Single Phase Set-Up On

Off

X

U

Increase/Decrease

Of Quantity

Duty Cycle

Rated No Load

Voltage (Average) I

0

Remote

Look under unit for

label

U

1

1max

Primary Voltage

Rated Maximum

Supply Current

Lift-Arc Start

(GTAW)

Single Phase Static Frequency

Converter-Transformer-Rectifier

Hz

Conventional Load

U

I

2

2

Voltage

Rated Welding

Current

Gas Tungsten Arc

Welding (GTAW)

Hertz

OM-261 767 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 The EMF assessment on this equipment was conducted at 0.5 meter.
S 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. There can 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 2011-09

C. Information On Electromagnetic Compatibility (EMC) For Si 160 PFC Model

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 can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con­ducted as well as radiated disturbances.

This equipment complies with IEC 61000-3-12.

ce-emc 4 2011-09

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.

3-3. IP Rating

IP Rating: 23S. This equipment is designed for outdoor use. It may be stored, but is not intended to be used outside during precipitation unless
sheltered. Operating Temperature Range: 14F (-10 C) to 104 F (40 C). Ratings were developed at an ambient temperature of 20 C to 25 C.

OM-261 767 Page 7

3-4. Specifications

Model

Si 160

Si 160

PFC

STi 160

Input Power

Single-Phase

AC

230 Volts

Stick

230 Volts TIG

230 Volts

Stick

230 Volts TIG

230 Volts

Stick

230 Volts TIG

Rated Welding

Output

100A @ 24 Volts DC,

100% Duty Cycle

150A @ 26 Volts DC,

25% Duty Cycle

100A @ 14 Volts DC,

100% Duty Cycle

150A @ 16 Volts DC,

25% Duty Cycle

100A @ 24 Volts DC,

100% Duty Cycle

150A @ 26 Volts DC,

25% Duty Cycle

100A @ 14 Volts DC,

100% Duty Cycle

160A @ 16.4 Volts DC,

20% Duty Cycle

100A @ 24 Volts DC,

100% Duty Cycle

150A @ 26 Volts DC,

25% Duty Cycle

100A @ 14 Volts DC,

100% Duty Cycle

160A @ 16.4 Volts DC,

20% Duty Cycle

Welding

Amperage

Range

15−150A 85V

15−150A 85V

4−150A 70V

4−160A 70V

4−150A 70V

4−160A 70V

OCV DC

Max

(Uo)

Amperes In-

put At Rated

Load Output,

50/60Hz,

Single-Phase

20A 4.5/2.8

30A 7.0/4.8

13A 3.0/2.0

21A 4.8/3.2

13.7A 3.1/2.8

22.1A 5.0/4.8

13A 3.0/2.0

22A 5.1/3.5

20A 4.5/2.8

30A 7.0/4.8

13A 3.0/2.0

22A 5.1/3.5

KVA/KW At

Duty Cycle

Weight

5.2 Kg

(11.5 lb)

6.2 Kg

(13.7 lb)

6.0 Kg

(13.2 lb)

Dimensions

(mm)

L = 380 mm

W = 145 mm

H = 245 mm

L = 380 mm

W = 145 mm

H = 245 mm

L = 380 mm

W = 145 mm

H = 245 mm

3-5. Selecting A Location

Airflow Distance
Requirements

2

460 mm

(18 in.)

OM-261 767 Page 8

1

460 mm

(18 in.)

Do not move or operate unit
where it could tip.

1 Line Disconnect Device
Locate unit near correct input

power supply.
2 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.

956172002_3-A