WELDING INDUSTRIES MC101-0 User manual

WELDING INDUSTRIES OF AUSTRALIA
A DIVISION OF WELDING INDUSTRIES LTD
ABN 18 004 547 111
Head Office and International Sales
5 Allan Street, Melrose Park
*South Australia, 5039
Telephone [phone] Facsimile [phone]
www.weldingindustries.com.au
[e-mail]
OWNERS MANUAL
INDURO 165
MODEL MC101-0
05/2002
QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE

Page 2 INDURO 165 OWNERS MANUAL
The information contained in this manual is set out to enable you to properly
maintain your newequipment and ensure that you obtain maximum operating efficiency.
Please ensure that this information is kept in asafeplace for readyreference when
required at anyfuture time.
When requesting spare parts, please quote the model and serial number ofthe
machine and part number ofthe item required. All relevant numbers are shownin lists
contained in this manual. Failure to supplythis information mayresult in unnecessary
delays in supplying the correct parts.
SAFETY
Before this equipment is put into operation, the SAFE PRACTICES section at the
back ofthe manual must be read completely.This will help to avoid possible injurydue to
misuse or improper welding applications.
CONTENTS
Section Page
1 ......................Introduction ........................................................3
2 ......................Receiving ...........................................................4
3 ......................Specifications.....................................................4
4 ......................Power Source Controls ......................................5
5 ......................Operation ...........................................................6
6 ......................Connection to Electrical Mains Power Supply....6
7 ......................MMAWWelding.................................................7
8 ......................GTAWWelding..................................................9
9 ......................General Maintenance.........................................11
10 ....................Fault Finding, No Welding Current.....................11
11 ....................Service Information............................................11
12 ....................Parts List............................................................13
13 ....................Safe Practices....................................................15
FIGURES
Figure Page
1 .......................... Power Source Controls..................................5
2 .......................... Connections for MMAW.................................7
3 .......................... Striking the Arc...............................................8
4 .......................... Cable and Hose Connections for GTAW .......9
5 .......................... Induro 165 Circuit Diagram............................12
6 .......................... Induro 165 Parts Diagram..............................14

INDURO 165 OWNERS MANUAL Page 3
1. INTRODUCTION
MMAW
Manual Metal Arc Welding is aprocess where an arc is struck between aflux-coated
consumables electrode and the work piece. The arc and the weld pool are both shielded
bygases generated bythe fluxcoating ofthe electrode.
The Induro 165 has been designed to be used with 2.0mm, 2.5mm and 3.2mm
diameter electrodes. The smaller are used when welding at lower currents, such as sheet
metal applications. Increasing the electrode diameter permits higher welding currents to
be selected.
WIA manufactures awide range ofmild steel and special purpose electrodes which
cater for home workshop, rural, and industrial requirements. Some popular AUSTARC
electrodes are listed below.The correctlyselected AUSTARC electrode used in
conjunction with your newInduro 165 will influence the qualityof the weld, and the stability
ofthe arc.
Austarc 12P, Classification E4112.
Apopular general purpose electrode used with ease in all positions, vertical up
or down. The smooth forceful arc makes it an ideal electrode for all general mild
steel applications.
Austarc 13S, Classification E4113.
Asmooth running electrode with asoftarc, particularlysuited to light
sheetmetal and smooth mitre fillet welds.
Austarc 16TC, Classification E4816.
Alowhydrogen electrode with good arc stabilityand out-of-position welding
characteristics. This electrode is ideal for medium carbon steels, or steels of
unknown analysis.
Unicord
Ahigh tensile (50tsi), chromium nickel electrode speciallyformulated for joining
all alloysteels and irons, and for tool and die maintenance.
GTAW
Gas Tungsten Arc Welding is awelding process where the arc is struck between a
non-consumable tungsten electrode and the work piece. Aceramic nozzle surrounds the
tungsten electrode and directs aflowofinert gas, usuallyArgon, over the electrode and
the weld zone. Iffiller metal is required, it is hand fed into the welding arc. The DC current
ofthe Induro 165 is suitable for welding most ferrous and non-ferrous metals, but is not
suitable for welding Aluminium for which an AC machine is required.

Page 4 INDURO 165 OWNERS MANUAL
2. RECEIVING
Check the equipment received against the shipping invoice to make sure the
shipment is complete and undamaged. Ifanydamage has occurred in transit, please
immediatelynotifyyour supplier.
The INDURO 165 package contains:
§ Induro 165 Inverter Power Source
§ (This) Owners Manual
Optional additional items for Induro 165:
Arc Lead Kit - 3m............................................................................ AA58-0/3
Includes:• 3 metre welding lead with electrode holder
• 3 metre work lead with clamp
TIG + Arc Lead Kit..........................................................................AA59-0/3
Includes:• 3 metre welding lead with electrode holder
• 3 metre work lead with clamp
• 3m TIG torch with starter kit & adaptor
• argon flowgauge regulator
3. SPECIFICATIONS
PrimaryVoltage........................................ 240 Volts AC, +/- 10%, 50/60 Hz
Maximum PrimaryDemand.........................................................32.5 Amps
Rated Input Current.....................................................................20.5 Amps
Welding Current Range ..........................................................5 - 165 Amps
DutyCycle.....................................................165 Amps @ 40% DutyCycle
Open Circuit Voltage.................................................................57 Volts DC
......................................................................with VRD operated – 11.2vdc
Mass ..................................................................................................4.8 Kg
This power source comes with a15 amp plug fitted, however ifthe unit is to be used
at full working current and dutycycle capability,a20 amp plug should be fitted and the
unit connected to a 20 amp mains power outlet.
IMPORTANT NOTICE
WARRANTY MAY BE VOIDED IF EQUIPMENTIS POWERED FROM AN
UNSUITABLE ENGINE DRIVEN GENERATOR.
Anygenerator used to power this equipment must haveaminimum capacityof 6,000
watts continuous and must incorporate output voltage regulation.
Generators without voltage regulation must have a capacityofat least 16,000 watts.

INDURO 165 OWNERS MANUAL Page 5
4. POWER SOURCE CONTROLS
FIGURE 1. POWER SOURCE CONTROLS
i. CURRENT CONTROL
This control sets the output current level ofthe power source within the range
5 - 165 Amps. Rotate the knob clockwise to increase the output current.
ii. FREQUENCY CONTROL
Varies the frequencyofthe pulses from 0.5Hzto 100Hz(ie 0.5 to 100 pulses per
second).
iii. DUTY CYCLE
Varies the dutycycle ofthe pulse current from 10% to 90%
iv. WELD MODE
Press this button to step between Stick Mode, TIG Mode & Pulse TIG Mode
v. STICK MODE
This LED is illuminated when Stick Mode (Manual Metal Arc Welding) is selected.
vi. TIG MODE
This LED is illuminated when TIG Mode (Gas Tungsten Arc Welding) is selected.
vii. PULSE TIG MODE
This LED is illuminated when Pulse TIG (Pulse Gas Tungsten Arc Welding) Mode is
selected.
viii. OVER TEMPERATURE INDICATOR
This LED is illuminated ifanyinternal thermal protection devices have operated.
ix. VRD SAFE MODE INDICATOR
When lit steadily,this LED indicates that the voltage across the output terminals will
be reduced to a safe level within 0.2 seconds after welding stops (full safe mode).
This LED blinks to indicate that the voltage across the output terminals will be
reduced to a safe level 5 seconds after welding stops (tack welding mode).
POWER ON/OFF SWITCH (located on the rear panel)
In the OFF position, this switch isolates the power source from the mains power
supply.
The fan will continue to rotate for approximately5seconds after the unit is turned off
until the stored energyin the unit’s power supplyis consumed.

Page 6 INDURO 165 OWNERS MANUAL
5. OPERATION
SAFE MODE
The Induro 165 incorporates aVoltage Reduction Device. This device is designed to
improveoperator safetybyreducing the voltage across the welding leads to asafelevel
whenever the machine is not welding.
There are two safe modes:
• Full safe – the output drops to asafevoltage 0.2 seconds after welding stops.
The output switches back to the welding voltage when the resistance from the
electrode to the workpiece falls below200 ohms.
The Green VRD SafeLED is continuouslylit to indicate when the unit is in Full Safe
mode.
• Tack Weld Mode – the output drops to a safe voltage 5 seconds after welding stops.
The output then switches back to the welding voltage when the resistance from the
electrode to the workpiece falls below200 ohms. This mode should onlybe selected if
performing a series ofshort welds in succession, and difficultyis experienced in
starting the arc.
The Green VRD Safe LED blinks to indicate when the unit is in Tack Weld Mode.
This mode should onlybe selected when working in an “environment without
increased hazard ofelectric shock.” For further information, refer WTIA Tech Note 7.
Toselect Tack Weld Mode, press the Weld Mode button three times immediatelyafter
turning on the machine. The Induro defaults to Full Safe Mode each time it is switched on.
SLEEP MODE
The Induro 165 goes into “sleep mode” when not used for more than 10 minutes. This is a
lowpower consumption mode which includes shutting down the fan.
As soon as the operator attempts to strike an arc or ifanybutton is pressed, the Induro
165 automatically“wakes up” in the mode in which it was last used.
Sleep mode is indicated bythe currentlyselected weld mode LED blinking slowly,with all
other LEDs being off.
6. CONNECTION TO ELECTRICAL MAINS POWER SUPPLY
The INDURO 165 is supplied with a3metre, 20 Amp Heavy Duty(30/0.25) PVC
mains power supplycable. This cable must at minimum be connected to acorrectly
installed 15 Amp GPO (General Purpose Outlet). The plug and GPO are both identified by
awide Earth pin, which is intended to prevent the plug being inserted into a standard 10
Amp GPO. Ifit becomes necessaryto replace the mains power supplycable, use onlya
cable with equivalent current rating.
The recommended Circuit Breaker rating is 25 Amps.
Ifit is necessaryto use an extension power supplycable, ensure that it is rated for a
minimum of20 Amps. Voltage drop which will occur over long lengths ofcable will reduce
the maximum welding current available from the equipment.
As noted previously,it is not recommended that the INDURO 165 be powered from
small engine-driven generator sets unless theyhaveadequate voltage regulation due to
the peaks ofsupplyvoltage which can occur with some equipment ofthis type. Excessive
voltage peaks can damage the circuits ofthe welder.

INDURO 165 OWNERS MANUAL Page 7
7. MMAW WELDING
A. CONNECTION FOR MMAW WELDING
It is important to select the electrode polarityin accordance with the manufacturers
recommendations for that electrode. Most common electrodes are operated with the
electrode at positive polarity, as illustrated in Figure 2.
FIGURE 2. CONNECTIONS FOR MMAW, ELECTRODE POSITIVE

Page 8 INDURO 165 OWNERS MANUAL
B. MMAW OPERATION
Be certain that you are wearing suitable protectiveclothing, gloves etc. and that you
are working in anon-hazardous area. Ifnecessary,refer again to the SAFE PRACTICES
section ofthis manual.
Connect the Work Clamp to the work piece. Place the desired electrode in the
Electrode Holder.
Turn on the power switch located on the rear panel. Wait approx5seconds as the
unit goes through its initiation sequence.
Press the Weld Mode button until the Stick Mode LED is lit. The Induro 165 keeps
the last mode used in memory,so this step is onlynecessarywhen using adifferent mode
to that used last.
Select an appropriate welding current for the electrode diameter bysetting the knob
on the machine front panel. WIA AUSTARC electrodes will give the best results.
Tostrike the arc, drag the end ofthe electrode along the work piece as ifstriking a
match. As the arc initiates, liftthe electrode slightlyaway,aiming to establish an arc length
ofapproximately3mm.
As the electrode end is consumed, feed the electrode into the arc in order to
maintain arc length. As ageneral rule, the arc should be held as short as possible while
still giving stable burn off and good weld appearance. An arc which is too long cause an
unwieldyflowofmetal with arough weld appearance and reduced penetration. An arc too
short leads to anarrowweld deposit and “stuttery”arc characteristics, and the electrode is
liable to freeze onto the work piece.
As the solidified weld deposit forms, movethe end ofthe electrode slowlyalong the
weld path, aiming to maintain apool ofmolten weld metal behind the arc. Decreasing this
rate oftravel will result in awider weld deposit, and similarlyincreasing it will narrowthe
weld deposit.
Alwaysfill the crater which tends to form at the end ofaweld deposit, bypausing
momentarilybefore withdrawing the electrode to break the arc. Unfilled craters are apoint
ofweakness, and can lead to weld cracking.
FIGURE 3. STRIKING THE ARC

INDURO 165 OWNERS MANUAL Page 9
8. GTAW WELDING
A. CONNECTION FOR GTAW WELDING
For GTAW,the torch is connected electrode negative. Figure 3illustrates the correct
connection ofthe welding torch and gas supply.Welding grade Argon is the shielding gas
most commonlyused for DC GTAWwelding.
Before initial use ofthe welding torch, allowgas to purge the torch and hoses for 5
minutes at approximately10 litres/min. For welding purposes, the gas flowrate should be
set in the range 2 - 5 litres/min.
Tungsten electrodes for DC GTAW should be 1 - 2% Thoriated or Witstar. This type
will provide the best arc initiation, arc stabilityand tip shape retention characteristics.
Thoriated electrodes can be recognised byared coded end. The tungsten electrode is
ground to apoint, with the grinding marks pointing towards the tip. For welding currents
less than 20 amps, the included angle ofthe point should be 30o,for currents greater than
20 amps, the recommended angle is 60o.When set in the torch, the tungsten should
protrude 6mm from the ceramic gas nozzle.
FIGURE 4. CABLE AND HOSE CONNECTIONS FOR GTAW

Page 10 INDURO 165 OWNERS MANUAL
B. GTAW OPERATION
Connect the Work Clamp to the work piece.
Turn on the power switch located on the rear panel. Wait approx5seconds as the
unit goes through its initiation sequence.
Press the Weld Mode button until the TIG Mode LED is lit. The Induro 165 keeps the
last mode used in memory,so this step is onlynecessarywhen using adifferent mode to
that used last.
Select an appropriate welding current for the job bysetting the knob on the machine
front panel.
Toinitiate the arc, the tungsten electrode should be touched onto the work piece,
then lifted in asmooth movement to establish an arc length slightlylarger than the
diameter ofthe electrode. When the arc is stable, it can be transferred to the work piece.
Use ofacopper striking plate can be used to avoid electrode contamination. The
electrode can also be contaminated bycontact with the filler rod. Acontaminated
electrode produces an unstable arc.
C. PULSE GTAW OPERATION
When Pulse TIG Mode is used, the welding current is generated in aseries of
pulses. This pulsing action controls the heat input to the material, while still providing a
high enough current to achieveweld penetration. Both the frequencyand duration ofthe
welding current pulses maybe varied on the Induro 165.
The frequencycontrol sets the pulses per second. Alowfrequencysetting can be
used to assist the operator to produce auniform weld when the hand fed electrode is
advanced in time with each pulse. High frequencysettings tend to make the arc more
directional, and mayassist in producing a small fillet weld in thin materials.
The pulse % control sets the percentage ofpulse time in each cycle. Higher settings
produce a hotter weld.
Toselect Pulse TIG Mode, press the Weld Mode button until the Pulse TIG Mode
LED is lit. The Induro 165 keeps the last mode used in memory,so this step is only
necessarywhen using a different mode to that used last.
Select an appropriate welding current for the job bysetting the knob on the machine
front panel.
Initiate the arc in the same manner as that described above.