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INDURO 165 OWNERS MANUAL 

Page 3 

1. INTRODUCTION 

 
MMAW 

 

Manual Metal Arc Welding is a process where an arc is struck between a flux-coated 

consumables electrode and the work piece. The arc and the weld pool are both shielded 
by gases generated by the flux coating of the 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 a wide range of mild steel and special purpose electrodes which 

cater  for  home  workshop,  rural,  and  industrial  requirements.  Some  popular  AUSTARC 
electrodes  are  listed  below.  The  correctly  selected  AUSTARC  electrode  used  in 
conjunction with your new Induro 165 will influence the quality of the weld, and the stability 
of the arc. 

 

Austarc 12P, Classification E4112. 

A popular 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. 

A  smooth  running  electrode  with  a  soft  arc,  particularly  suited  to  light 
sheetmetal and smooth mitre fillet welds. 

 

Austarc 16TC, Classification E4816. 

A  low  hydrogen  electrode  with  good  arc  stability  and  out-of-position  welding 
characteristics.  This  electrode  is  ideal  for  medium  carbon  steels,  or  steels  of 
unknown analysis. 

 

Unicord 

A high tensile (50tsi), chromium nickel electrode specially formulated for joining 
all alloy steels and irons, and for tool and die maintenance.  

 

GTAW 

 

Gas  Tungsten Arc Welding is a welding process where the arc is struck between a 

non-consumable tungsten electrode and the work piece. A ceramic nozzle surrounds the 
tungsten  electrode  and  directs  a  flow  of  inert  gas,  usually  Argon,  over  the  electrode and 
the weld zone. If filler metal is required, it is hand fed into the welding arc. The DC current 
of  the  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.  

Summary of Contents for MC101-0

Page 1: ...111 Head Office and International Sales 5 Allan Street Melrose Park South Australia 5039 Telephone 08 8276 6494 Facsimile 08 8276 6327 www weldingindustries com au info weldingindustries com au OWNERS MANUAL INDURO 165 MODEL MC101 0 05 2002 QUALITY WELDING PRODUCTS SYSTEMS AND SERVICE ...

Page 2: ... in supplying the correct parts SAFETY Before this equipment is put into operation the SAFE PRACTICES section at the back of the manual must be read completely This will help to avoid possible injury due 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 Su...

Page 3: ...ed 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 A smooth running electrode with a soft arc particularly suited to light sheetmetal and smooth mitre fillet welds Austarc 16TC Classification E4816 A low hydrogen electrode with good arc stability and out of position welding c...

Page 4: ... regulator 3 SPECIFICATIONS Primary Voltage 240 Volts AC 10 50 60 Hz Maximum Primary Demand 32 5 Amps Rated Input Current 20 5 Amps Welding Current Range 5 165 Amps Duty Cycle 165 Amps 40 Duty Cycle Open Circuit Voltage 57 Volts DC with VRD operated 11 2v dc Mass 4 8 Kg This power source comes with a 15 amp plug fitted however if the unit is to be used at full working current and duty cycle capabi...

Page 5: ...c 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 if any internal 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...

Page 6: ...s switched on SLEEP MODE The Induro 165 goes into sleep mode when not used for more than 10 minutes This is a low power consumption mode which includes shutting down the fan As soon as the operator attempts to strike an arc or if any button is pressed the Induro 165 automatically wakes up in the mode in which it was last used Sleep mode is indicated by the currently selected weld mode LED blinking...

Page 7: ...NG It is important to select the electrode polarity in 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: ...s the arc initiates lift the electrode slightly away aiming to establish an arc length of approximately 3mm As the electrode end is consumed feed the electrode into the arc in order to maintain arc length As a general 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 unwieldy flow of metal with a rough wel...

Page 9: ...w rate 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 stability and tip shape retention characteristics Thoriated electrodes can be recognised by a red coded end The tungsten electrode is ground to a point with the grinding marks pointing towards the tip For welding currents less than 2...

Page 10: ...le arc C PULSE GTAW OPERATION When Pulse TIG Mode is used the welding current is generated in a series of pulses This pulsing action controls the heat input to the material while still providing a high enough current to achieve weld penetration Both the frequency and duration of the welding current pulses may be varied on the Induro 165 The frequency control sets the pulses per second A low freque...

Page 11: ... 165 power source At least one of the key pad LED s should be lit If not test that the power point works by plugging in another appliance That the welding and work leads are connected securely to the output sockets at the front of the machine For continuity of the work lead work clamp and electrode holder Loose connections can prevent proper flow of the welding current The INDURO 165 welding power...

Page 12: ...Page 12 INDURO 165 OWNERS MANUAL FIGURE5 INDURO 165 PARTS DIAGRAM 6 7 8 10 11 12 13 1 15 16 14 22 23 17 19 21 18 20 5 24 4 3 9 ...

Page 13: ...1 MC101 30 20A Supply Cable 15 A Plug 11 1 M0004 Primary Cable Grip 12 1 M0005 Primary Cable Nut 13 1 MC101 10N Power Control PCB includes 1 E0010 Relay 14 1 MC101 11N Front Panel Control PCB includes 1 CP34 36 2 Current Adjustment Potentiometer 2 R0018 Pulse Adjustment Potentiometer 15 1 MC100 54 Current Adjustment Knob 16 2 E10016 Pulse Adjustment Knob 17 1 MC100 43 Thermistor Assembly 18 2 D001...

Page 14: ... that persons without suitable training and knowledge attempt to perform service tasks on the components of this welder The electrical components of the equipment are shown in the circuit diagram below The INDURO 165 is an inverter type design where the mains supply is first rectified filtered then chopped to a high frequency before being applied to the welding transformer The output of this trans...

Page 15: ...INDURO 165 OWNERS MANUAL Page 15 FIGURE 6 INDURO 165 CIRCUIT DIAGRAM ...

Page 16: ...oken 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 visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from light coloured surfaces and burn th...

Page 17: ...ant energy of the arc can also decompose trichlorethylene and perchlorethylene vapours to form phosgene Do not weld or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichlorethylene or percholorethylene FIRE AND EXPLOSION PREVENTION Be aware that flying sparks or falling slag ...

Page 18: ... depending on the combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective equipment as recommended in AS 1674 1974 Water filling just below working level may substitute for inerting Hollow castings or containers must be vented before welding or cutting They can explode Never weld or cut where the air may contain flammable dust gas or liquid va...

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