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equipment:hotworks:welder [2025/02/20 12:49] – ollieequipment:hotworks:welder [2025/03/04 14:25] (current) – ollie
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 <callout title="PPE Required" type="primary" icon="true"> This equipment requires the use of eye protection and appropriate clothing. </callout> <callout title="PPE Required" type="primary" icon="true"> This equipment requires the use of eye protection and appropriate clothing. </callout>
    
 +Please note, this is a work in progress. Please do not use the welder until inducted - thanks, Ollie
 +Feel free to add to this page, any comments welcome
 +
 +===== Induction =====
 +
 +Prior to using the welder, you must attend an in-person induction. Please post on the forum if you want an induction. Should be starting spring 2025
 +
 +Prior to an induction, please have a quick read through the welder manual, and read this wiki page. There is PPE provided, however the risk assessment requires that inductees bring their own respirator to protect from fumes
 +
 +Induction notes are here - [[equipment:hotworks:welder:induction_notes|]]
 +
 +Please note, the induction only covers the basics and essential safety elements, as well as any hackspace-specific rules. There won't be anything on welding techniques / settings, as there's a myriad of information online. 
 +
 ===== Safety ===== ===== Safety =====
 === Avoiding fire and fumes === === Avoiding fire and fumes ===
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   * Do not weld items which contain surface finishes, which could release flammable or hazardous fumes such as painted or galvanised surfaces.    * Do not weld items which contain surface finishes, which could release flammable or hazardous fumes such as painted or galvanised surfaces. 
   * Keeping workpieces clean can help to minimise sparks and will result in a better weld   * Keeping workpieces clean can help to minimise sparks and will result in a better weld
-  * Make yourself aware of firefighting equipment in the space (eg, fire extinguishers, just outside of the hot works area. Familiarise yourself with where they are, and how you would operate them.+  * Make yourself aware of firefighting equipment in the space (e.g., fire extinguishers, just outside of the hot works area. Familiarise yourself with where they are, and how you would operate them.
   * Have a bucket of sand next to the welding bench, which can quickly and safely extinguish minor flames with minimal cleanup   * Have a bucket of sand next to the welding bench, which can quickly and safely extinguish minor flames with minimal cleanup
   * The roller shutter doors **must** remain open during welding operations, and kept open until fumes have cleared   * The roller shutter doors **must** remain open during welding operations, and kept open until fumes have cleared
-  * Fume extraction **must** be used at all times, and kept on until fumes have cleared. Check fume extractor has not been used for general extraction or hoovering - open the top and ensure there are no flammable items inside (eg sawdust) +  * Fume extraction should be used at all times, and kept on until fumes have cleared. Check fume extractor has not been used for general extraction or hoovering - open the top and ensure there are no flammable items inside (eg sawdust) 
-  * **After welding, you MUST remain in the space for at least 1 hour, checking the area for smouldering items or fires. This is non-negotiable - if you cannot wait the hour, do not weld**+  * **After welding, you MUST remain in the space for at least 1 hour, checking the area for smouldering items or fires. If you cannot wait the hour, do not weld**
  
    
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   * Prior to welding, with the isolator switch turned on, ensure the beacon lights are flashing. These warn other users that welding is being carried out   * Prior to welding, with the isolator switch turned on, ensure the beacon lights are flashing. These warn other users that welding is being carried out
  
-==== PPE ==== + 
 +=== Preventing electric shocks === 
 +  * Check the condition of cables and insulators before turning on the welder 
 +  * Avoid welding in high humidity. Wet clothing, floors, and workpieces increase the risk of electric shocks.  
 +  * Do not attempt to bypass electrical safety equipment, and keep welder covers closed during welding  
 +  * If you have a pacemaker (etc), and only proceed if you've confirmed with your doctor that it’s safe to weld. 
 + 
 + 
 +=== PPE === 
  
 The following PPE must be used  The following PPE must be used 
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   * Gauntlets   * Gauntlets
   * Fire-proof long sleeve clothing (e.g. overalls)   * Fire-proof long sleeve clothing (e.g. overalls)
-  * Welding hood or mask- +  * Welding hood or mask. There are three hanging up, just outside the hot works area. Link to manual [[https://www.clarkeservice.co.uk/manuals/welding_accessories/PG4_Headshield_Iss_3.pdf]]
   * Closed footwear   * Closed footwear
 +  * The risk assessment also specifies a respirator, to protect from fumes
  
 These are the minimum requirements. You may also need additional PPE for other related tasks, such as eye protection when using an angle grinder.  These are the minimum requirements. You may also need additional PPE for other related tasks, such as eye protection when using an angle grinder. 
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-==== Equipment ====+===== Equipment =====
  
-The Hackspace welder is a Clarke MIG160EN, with an adjustable welding current between 30 and 150 Amps. This is enough to weld 5mm mild steel, and to blow holes through thinner stuff. +The welder is stored on the lower shelf of the welding table, in the hot works area, next to the roller shutter doors. Also on the table are a few welding accessories such as a pair of MIG pliers and a chipping hammer
  
-Link to manual - [[https://www.clarkeservice.co.uk/manuals/mig_welders/MIG160EN_Mig_Welder_REV_8.pdf]]+===Welder===
  
-The welder is stored on the lower shelf of the welding table, in the hot works area, next to the roller shutter doors. Also on the table are a few welding accessories such as a pair of mig pliers and a chipping hammer+The Hackspace welder is a Clarke MIG160EN
  
 +Link to manual - [[https://www.clarkeservice.co.uk/manuals/mig_welders/MIG160EN_Mig_Welder_REV_8.pdf]]
  
 +__Welder settings__
  
 +Review the manual for a table showing recommended gas settings. Additional trial and error will be required to get the right setting.
  
  
-=== Gas vs Gasless welding===+__Gas vs Gasless welding__ 
 The welder is designed for both gas MIG and Gasless welding, however in the Hackspace all welding shall be the gasless type. This uses wire with a flux core to prevent oxidisation and contamination of the weld pool. The welder is designed for both gas MIG and Gasless welding, however in the Hackspace all welding shall be the gasless type. This uses wire with a flux core to prevent oxidisation and contamination of the weld pool.
 Whilst the welder can operate as a standard MIG (ie with Gas) the Hackspace does permit compressed cylinders. The risk assessment for the welding has not considered the use of shielding gas, so for the foreseeable, all welding shall be gasless Whilst the welder can operate as a standard MIG (ie with Gas) the Hackspace does permit compressed cylinders. The risk assessment for the welding has not considered the use of shielding gas, so for the foreseeable, all welding shall be gasless
  
  
 +__Welder polarity__
 +
 +The welder should remain in the "no gas" configuration. The torch is connected to the negative terminal (-ve), with the earthing cable connected to the positive (+ve) terminal.
 +
 +__Loading wire__
 +
 +The welder manual explains this best, however it will be shown in the induction
 +
 +===Fume extractor===
 +
 +The fume extractor is an Extractability Protectavac by Weldability. It should be used at all times during welding, to help keep fume levels low
 +Link to product page - [[https://www.weldability-sif.com/products/extractability/ext1vacmax230/]]
 +
 +[photos to be added here at a later date, to show instructions for operation and maintenance]
 +
 +
 +
 +===== Consumables =====
 +The following items will be proposed, for inclusion on the consumable list. Wire and tips will be required frequently, however torch shrouds shouldn't need replacement often
 +//For the time being, I'll provide wire and tips, just to get inductions started - Ollie//
  
 +  * Welding wire. Flux cored "gasless" wire, 0.8mm diameter, 0.45kg reel. [[https://www.toolstation.com/sip-mig-gasless-flux-cord-welding-wire/p13760]] or similar
 +  * Welding torch tips. 0.8mm diameter, pack of 5. [[https://www.toolstation.com/sip-mig-contact-tips-08mm/p96874]] or similar
 +  * Welding torch shroud. [[https://www.toolstation.com/sip-conical-mig-shrouds/p11948]] or similar
  
  • equipment/hotworks/welder.1740055748
  • Last modified: 3 weeks ago
  • by ollie