WIA MC100-0 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 145
MODEL MC100-0
05/2002
QUALITY WELDING PRODUCTS, SYSTEMS AND SERVICE

Page 2 INDURO 145 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 145 Circuit Diagram............................12
6 .......................... Induro 145 Parts Diagram..............................14

INDURO 145 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 145 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 145 will influence the qualityofthe weld, and the
stabilityofthe 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 145 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 145 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 145 package contains:
§ Induro 145 Inverter Power Source
§ (This) Owners Manual
Optional additional items for Induro 145:
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..............................................................28 Amp
Rated Input Current.......................................................................16.5 Amp
Welding Current Range ..........................................................5 - 145 Amps
DutyCycle.......................................... 145 Amps @ 25.8v, 35% 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 and the unit must be connected
to a 15 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 145 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 - 145 Amps. Rotate the knob clockwise to increase the output current.
ii. WELD MODE
Press this button to step between Stick Mode, TIG Mode & Pulse TIG Mode
iii. STICK MODE
This LED is illuminated when Stick Mode (Manual Metal Arc Welding) is selected.
iv. TIG MODE
This LED is illuminated when TIG Mode (Gas Tungsten Arc Welding) is selected.
v. PULSE TIG MODE
This LED is illuminated when Pulse TIG (Pulse Gas Tungsten Arc Welding) Mode is
selected.
vi. OVER TEMPERATURE INDICATOR
This LED is illuminated ifanyinternal thermal protection devices have operated.
vii. 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 145 OWNERS MANUAL
5. OPERATION
SAFE MODE
The Induro 145 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 then 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 145 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
145 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 145 is supplied with a 15 Amp Heavy Duty mains power supplycable.
This cable must onlybe connected to acorrectlyinstalled 15 Amp GPO (General Purpose
Outlet). The plug and GPO are both identified byawide Earth pin, which is intended to
prevent the plug being inserted into astandard 10 Amp GPO. Ifit becomes necessaryto
replace the mains power supplycable, use onlya cable with equivalent current rating.
The recommended SupplyCircuit Breaker rating is 25 Amps.
Ifit is necessaryto use an extension power supplycable, ensure that it is rated for a
minimum of15 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 145 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 145 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 145 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 145 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 145 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 145 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 145 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
Use Pulse TIG mode when TIG welding thin materials. The welding current is
generated in aseries ofpulses at apreset frequencyand duration. This pulsing action
controls the heat input to the material, while still providing ahigh enough current to
achieve weld penetration.
Toselect Pulse TIG Mode, press the Weld Mode button until the Pulse TIG Mode
LED is lit. The Induro 145 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.

INDURO 145 OWNERS MANUAL Page 11
9. GENERAL MAINTENANCE
Before removing the machine cover, ENSURE that the unit is disconnected fromthe
mains power supply. When the unit is energised LETHAL VOLTAGES are present on the
electrical components enclosed.
The Induro 145 turns the cooling fan off when it is not required to reduce dust
intake. However care should be taken to prevent excessivedust and dirt entering the
welding power source. Itis recommended that at regular intervals, according to the
prevailing conditions, the machine covers be removed and anyaccumulated dust be
removed bythe use ofdry, lowpressure compressed air.
10. FAULT FINDING, NO WELDING CURRENT
Check:
• That mains supplyis available at the INDURO 145 power source. At least one ofthe
keypad LED’s should be lit. Ifnot, test that the power point works byplugging in
another appliance.
• That the welding and work leads are connected securelyto the output sockets at the
front ofthe machine.
• For continuityofthe work lead, work clamp and electrode holder. Loose connections
can prevent proper flowofthe welding current.
The INDURO 145 welding power source incorporates an in built protection device
which will trip ifthe unit is overloaded. In this event, the machine will not deliver welding
current, and the red Over Temp LED will be illuminated. Ifthe thermal overload protection
device has been tripped, leavethe machine energised with the fan running to achievethe
maximum cooling rate.
Ifequipment failure is suspected, forward the unit to your nearest authorised WIA
qualified service agent. To find out your nearest qualified service agent call 1300 300 884.
11. SERVICE INFORMATION
NOTE that the following information is intended for use by Qualified Service Personnel.
When the unit is energised LETHAL VOLTAGES are present on the electrical and
electronic components. It is not intended that persons without suitable training and
knowledge attempt to performservice tasks on the components of this welder.
The electrical components ofthe equipment are shownin the circuit diagram below.
The INDURO 145 is an inverter type design, where the mains supplyis first rectified,
filtered, then chopped to ahigh frequencybefore being applied to the welding transformer.
The output ofthis transformer is rectified to form the welding output ofthe machine.

Page 12 INDURO 145 OWNERS MANUAL
FIGURE 5. INDURO 145 CIRCUIT DIAGRAM

INDURO 145 OWNERS MANUAL Page 13
12. PARTS LIST
Item #....Qty ....... Part #...................Description
1............1 ........... MC100-48............Upper Case
2............1 ........... MC100-55............Sticker Set for Upper Case
(not illustrated, contains all labels and decal)
3............1 ........... MC100-47............Lower Case
4............1 ........... MC100-45............Cooling Fan Assembly
5............1 ........... CP101-0/17 .........Fan Grille
6............1 ........... MC100-53............Shoulder Strap
7............1 ........... CP38-50/8 ...........On/Off Switch
8............1 ........... MC100-37............On/Off Switch Sealing Boot
9............2 ........... SA140-0/2............Output Socket, 25mm Dinsel
10..........1 ........... MC100-30............15A PrimarySupplyCable & 15 A Plug
11..........1 ........... M0004..................PrimaryCable Grip
12..........1 ........... M0005..................PrimaryCable Nut
13..........1 ........... MC100-10N .........Power Control PCB
includes....1 ........... E0010 ..................Relay
14..........1 ........... MC100-11N .........Front Panel Control PCB
includes 1 ........... CP34-36/2 ...........Current Adjustment Potentiometer
15..........1 ........... MC100-54............Current Adjustment Knob
16..........1 ........... MC100-43............Thermistor Assembly
17..........1 ........... D0018..................Input Rectifier, 50A, 240V
18..........4 ........... D0019..................MOSFET
19..........1 ........... L0008...................Planar Transformer
20..........1 ........... D0017..................Dual Output Rectifier Module
21..........2 ........... L0006...................Toroid, Amorphous Metal
22..........1 ........... MC100-5..............Shunt resistor Assembly
23..........6 ........... NSS316WP.........Speed Nut

Page 14 INDURO 145 OWNERS MANUAL
6
7
8
10
11
12
13
1
15
14
21
22
16
18
20
17
19
5
23
4
3
9
FIGURE 6. INDURO 145 PARTS DIAGRAM

INDURO 145 OWNERS MANUAL Page 15
13. SAFE PRACTICES
These notes are provided in the interests ofimproving operator safety.Theyshould
be considered onlyas abasic guide to SafeWorking Habits. Afull list ofStandards
pertaining to industryis available from the Standards Association of Australia, also various
State ElectricityAuthorities, Departments ofLabour and Industryor Mines Department
and other Local Health or SafetyInspection Authorities mayhaveadditional requirements.
WTIA Technical Note TN7-98 also provides acomprehensiveguide to safepractices in
welding.
EYE PROTECTION
NEVER LOOK ATAN ARC WITHOUTPROTECTION. Wear afull face helmet, with
an appropriate shade filter lens protected byclear cover glass. This is aMUSTfor anyarc
process to protect the eyes from radiant energyand flying sparks etc.. Replace the cover
glass when it is broken, pitted, or spattered.
Recommended shade filter lens.
Amps TIG MMAW MIG Pulsed MIG
0-100................. 10.............. 9................ 10.............. 12-13
100-150............. 11.............. 10.............. 10.............. 12-13
150-200............. 12.............. 10-11......... 11-12......... 12-13
200-300............. 13.............. 11.............. 12-13......... 12-13
300-400............. 14.............. 12.............. 13.............. 14
400-500............. -- ............... 13.............. 14.............. 14
500 +................. -- ............... -- ............... 14.............. 14
BURN PROTECTION.
The welding arc is intense and visiblybright. Its radiation can damage eyes,
penetrate lightweight clothing, reflect from light-coloured surfaces, and burn the skin and
eyes. Burns resulting from gas-shielded arcs resemble acute sunburn, but can be more
severe and painful.
Wear protectiveclothing - leather or heat resistant gloves, hat, and safety-toe boots.
Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entryofsparks
and slag.
Avoid oilyor greasyclothing. Aspark mayignite them. Hot metal such as electrode
stubs and work pieces should never be handled without gloves.
Ear plugs should be worn when welding in overhead positions or in a confined space.
A hard hat should be worn when others are working overhead.
Flammable hair preparations should not be used bypersons intending to weld or cut.

Page 16 INDURO 145 OWNERS MANUAL
TOXIC FUME PREVENTION.
Adequate ventilation with air is essential. Severe discomfort, illness or death can
result from fumes, vapours, heat, or oxygen depletion that welding or cutting mayproduce.
NEVER ventilate with oxygen.
Lead, cadmium, zinc, mercury,and beryllium bearing and similar materials when
welded or cut mayproduce harmful concentrations of toxic fumes. Adequate local exhaust
ventilation must be used, or each person in the area as well as the operator must wear an
air-supplied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit fumes should not be heated
unless coating is removed from the work surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in aconfined space onlywhile it is being ventilated and, ifnecessary,while
wearing air-supplied respirator.
Vapours from chlorinated solvents can be decomposed bythe heat ofthe arc (or
flame) to form PHOSGENE, ahighlytoxic gas, and lung and eyeirritating products. The
ultra-violet (radiant) energyofthe arc can also decompose trichlorethylene and
perchlorethylene vapours to form phosgene. Do not weld or cut where solvent vapours
can be drawninto the welding or cutting atmosphere or where the radiant energycan
penetrate to atmospheres containing even minute amounts oftrichlorethylene or
percholorethylene.
FIRE AND EXPLOSION PREVENTION.
Be aware that flying sparks or falling slag can pass through cracks, along pipes,
through windowsor doors, and through wall or floor openings, out ofsight ofthe operator.
Sparks and slag can travel up to 10 metres from the arc.
Keep equipment clean and operable, free ofoil, grease, and (in electrical parts) of
metallic particles that can cause short circuits.
Ifcombustibles are present in the work area, do NOTweld or cut. Movethe work if
practicable, to an area free ofcombustibles. Avoid paint sprayrooms, dip tanks, storage
areas, ventilators. Ifthe work can not be moved, movecombustibles at least 10 metres
awayout ofreach ofsparks and heat; or protect against ignition with suitable and snug-
fitting fire-resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on or cut.
Walls, ceilings, and floor near work should be protected byheat-resistant covers or
shields.

INDURO 145 OWNERS MANUAL Page 17
Aperson acting as Fire Watcher must be standing bywith suitable fire extinguishing
equipment during and for some time after welding or cutting if;
§ Combustibles (including building construction) are within 10 metres.
§ Combustibles are further than 10 metres but can be ignited bysparks.
§ Openings (concealed or visible) in floors or walls within 10 metres mayexpose
combustibles to sparks.
§ Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by
radiant or conducted heat.
After work is done, check that area is free ofsparks, glowing embers, and flames.
Anytank or drum which has contained combustibles can produce flammable vapours
when heated. Such acontainer must never be welded on or cut, unless it has first been
cleaned as described in AS.1674-1974, the S.A.A. Cutting and Welding SafetyCode. This
includes athorough steam or caustic cleaning (or asolvent or water washing, depending
on the combustible's solubility), followed bypurging and inerting with nitrogen or carbon
dioxide, and using protectiveequipment as recommended in AS.1674-1974. Water-filling
just belowworking level maysubstitute for inerting.
Hollowcastings or containers must be vented before welding or cutting. Theycan
explode. Never weld or cut where the air maycontain flammable dust, gas, or liquid
vapours.
SHOCK PREVENTION.
Exposed conductors or other bare metal in the welding circuit, or ungrounded
electricallyaliveequipment can fatallyshock aperson whose bodybecomes aconductor.
Ensure that the machine is correctlyconnected and earthed. Ifunsure havemachine
installed byaqualified electrician. On mobile or portable equipment, regularlyinspect
condition oftrailing power leads and connecting plugs. Repair or replace damaged leads.
Fullyinsulated electrode holders should be used. Do not use holders with protruding
screws. Fullyinsulated lock-type connectors should be used to join welding cable lengths.
Terminals and other exposed parts ofelectrical units should have insulated knobs or
covers secured before operation.