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equipment:hotworks:welder [2025/03/04 13:08] – ollieequipment:hotworks:welder [2025/04/19 15:25] (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+Please only use the equipment and materials covered in the induction. Please do not use your own equipment. The welding / hot works area is a trial, to prove to our insurers etc that we can have a hot works area without burning the hackspace down 
 ===== Induction ===== ===== Induction =====
  
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 Prior to an induction, please have a quick read through the welder manual, and read this wiki page.  Prior to an induction, please have a quick read through the welder manual, and read this wiki page. 
  
-Induction notes are here - + 
 + 
 +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.  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. 
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   * 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. 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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   * 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]]   * 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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 ===Welder=== ===Welder===
  
-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 Hackspace welder is a Clarke MIG160EN
  
 Link to manual - [[https://www.clarkeservice.co.uk/manuals/mig_welders/MIG160EN_Mig_Welder_REV_8.pdf]] 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__
 +
 +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 not 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. As mentioned above, this welding setup should be seen as a trial, so please do not try to alter the equipment.
 +
 +
 +__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=== ===Fume extractor===
  
-The fume extractor is an Extractability Protectavac by Weldability. It must be used at all times during welding, to help keep fume levels low+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/]] 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] [photos to be added here at a later date, to show instructions for operation and maintenance]
  
 +This extractor is intended only for welding use, and not general extraction / cleaning tasks. However prior to welding, empty the contents of the extractor into the general waste bin, **before** starting any welding activity
  
-=== Gas vs Gasless welding=== +===Avoiding bin fires=== 
-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+The standard general waste dustbin potentially contain flammable materials, and therefore care must be taken to avoid invertedly disposing of hot embers, sparks etc, where they could later ignite. Placing hot items in the normal bin poses a fire risk 
 + 
 +Therefore, a separate "welding dustbin" is provided. It is a standard steel dustbin without a bin liner, so is generally fireproof. Is solely for disposal of any waste which may be hot and pose a fire risk. For example, arisings from sweeping up, after welding.  
 + 
 +Signage attempts to prevent its use as a normal bin, but experience shows signage is ignored, so there may be flammable items already in the bin. Before starting any welding tasks, empty the dustbin into the general waste bin.  
 + 
 +Using this bin acts as a stop-gap, allowing time for any hot objects to cool down. 
  
  
 +===== Consumables =====
 +The following items will be stored in the welder, as consumables
  
 +  * 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. [[https://www.ebay.co.uk/itm/326371887307]] or similar
 +  * Welding torch shroud. [[https://www.ebay.co.uk/itm/387634952855]] or similar
  
  • equipment/hotworks/welder.1741093698
  • Last modified: 8 weeks ago
  • by ollie