Difference between revisions of "Marshall Dynabolt 250 Amp AC/DC Tig Welding Set"

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{{EquipmentInfobox
 
{{EquipmentInfobox
 
|name=Marshall Dynabolt Tig Welding Set
 
|name=Marshall Dynabolt Tig Welding Set
|image=Hackspace_Unknown.png
+
|image=Marshall Dynabolt welder.jpg
 
|model=Marshall Dynabolt 250 Amp AC/DC Tig Welding Set
 
|model=Marshall Dynabolt 250 Amp AC/DC Tig Welding Set
 
|category=Equipment <!-- Main category. Please leave alone to keep item in this category -->
 
|category=Equipment <!-- Main category. Please leave alone to keep item in this category -->
 
|subcat=Metalworking<!-- Sub-category if one exists. Please check main listing to see other categories contained within the main one -->
 
|subcat=Metalworking<!-- Sub-category if one exists. Please check main listing to see other categories contained within the main one -->
|status=Good working order
+
|status=Under construction
|consumables=Argon gas, welding tips, filler rods
+
|consumables=Argon gas, welding tips, gas lenses, filler rods
 
|accessories=Foot pedal, welding torch
 
|accessories=Foot pedal, welding torch
 
|reqtraining=yes
 
|reqtraining=yes
Line 12: Line 12:
 
|owner=Hackpace
 
|owner=Hackpace
 
|origin=Bought through pledge in Jan 2015
 
|origin=Bought through pledge in Jan 2015
|location=Basement, Workshop
+
|location=Metal Workshop
|maintainers=Des, TGreer, Dean, Liam
+
|maintainers=Tim, Des, Dean, Liam  
 
}}
 
}}
 
Marshall Dynabolt 250 Amp AC/DC Tig Welding Set, used for accurate welding of steel, stainless steel, aluminium and alloys.
 
Marshall Dynabolt 250 Amp AC/DC Tig Welding Set, used for accurate welding of steel, stainless steel, aluminium and alloys.
  
This machine requires training and experience in basic welding techniques before use.  
+
This machine requires training and experience in stick and MIG welding techniques before use.  
  
 
If you want to quickly weld mild steel please consider using the stick welder.
 
If you want to quickly weld mild steel please consider using the stick welder.
Line 24: Line 24:
  
 
http://www.lincolnelectric.com/en-gb/support/welding-solutions/Pages/aluminum-faqs-detail.aspx
 
http://www.lincolnelectric.com/en-gb/support/welding-solutions/Pages/aluminum-faqs-detail.aspx
 +
 +
How to assemble to TIG torch with picture is here
 +
 +
http://welders.tokentools.com.au/tig-torch-assembly/
 +
 +
Electrode Thickness, Amperage and Argon Gas Flow Settings can be obtained here
 +
 +
http://www.millerwelds.com/products/gunstorches/tig-torches/helpmechoose/
 +
 +
Filler Materials for aluminium here
 +
 +
http://www.lincolnelectric.com/en-us/support/welding-how-to/Pages/tig-welding-aluminum-detail.aspx
 +
 +
--------------------------------------------------------------------------------------------------------
 +
Update WIP
 +
 +
TIG (Tungsten Inert Gas) welding is particularly useful for aluminium, It uses an electrode nozzle with a fixed (should be permanent, but they do wear) tungsten tip where a plasma 'flame' is created (started with a high-voltage / high frequency starter) and used to heat the filler wire and joint. The nozzle allows a flow of inert shield gas around the working area, reducing slag creation and (particularly important with aluminium) oxidation.
 +
 +
The '''TIG welder''' is a 'stick' welder - the electrode / nozzle is held in one hand, and the filler wire applied with the other.
 +
 +
==Shield gas ==
 +
For the TIG we use a [http://www.boconline.co.uk/en/products-and-supply/industrial-gases/inert-gases/pureshield-argon/pureshield-argon.html Pureshield Argon].<br/>
 +
 +
==Capacity and rating ==
 +
[[File:Tig Welder Rating Plate.jpeg|thumb|400px|Rating Plate]]
 +
The Tig welder has a large range
 +
 +
Power is from a 63 amp socket, on the highest setting the Tig could draw more current than this
 +
 +
<br clear=all>
 +
 +
==Controls==
 +
[[File:TIGWelderFrontPanel.JPG|250px]]<br clear=all>
 +
Details on the front panel controls
 +
{| class="wikitable"
 +
|-
 +
! Name
 +
! Picture
 +
! Description
 +
|-
 +
| Main On Off Switch || [[File:TIGWelderOn Off Switch.JPG|200px]] || Main switch on the welder, remember to turn off the welder as much as possible in-between setting up for welds
 +
|-
 +
| DC+ AC DC- selector || [[File:TIGWelderDC+ AC DC- Switch.JPG|200px]] || '''Do not change this setting with the main power switch ON.'''<br/> This selector has three positions that control the mode of the welder<br/>
 +
* DC- (DCEN), DC Electrode Negative, used for Steel TIG
 +
* AC, used for Aluminium TIG
 +
* DC+ (DCEP), DC Electrode Positive, used for Arc
 +
|-
 +
| Working power range selector || [[File:TIGWelderWorkingPowerRange.JPG|200px]] ||  '''Do not change this setting with the main power switch ON.''' <br/>There are three possible working ranges, low, medium and high. Each has a slightly different range for DC or AC
 +
{|
 +
! Position
 +
! AC
 +
! DC
 +
|-
 +
| Up || 140-310 || 125-310
 +
|-
 +
| Middle || 40-165 || 40-190
 +
|-
 +
| Down || 10-45 || 10-55
 +
|}
 +
 +
|-
 +
| Percentage power dial || [[File:TIGWelderPercentagePowerWithinRange.JPG|200px]] || Main power control dial, used to fine tune the amp control of the welder. <br/>This dial acts as a percentage of the current selected range.
 +
|-
 +
|Remote control enable||[[File:TIGWelderRemoteAmpageControlSwitch KEEPswitchedOFF.JPG|200px]] || Used to enable remote current control when a foot control is installed.<br/> '''Until we have a remote foot pedal this should be left in the OFF position.'''
 +
|-
 +
| High Frequency control || [[File:TIGWelderHF OnAtStrike Off Continous Switch.JPG|200px]] || Controls the high frequency generation of the welder, this switch has three positions and each has a set use.<br/>
 +
*Up (IO) High frequency start, use this for DC TIG welding (Steels)
 +
*Middle (O) Off used for Stick welding
 +
*Down (I) On, used to AC TIG welding (Aluminum)
 +
|-
 +
| Remote trigger enable || [[File:TIGWelderTorchSwitchEnable TIG-on STICKoff.JPG|200px]] || '''This should be left in the ON position.''' <br/> Used to enable the remote trigger, only place in OFF position when doing Arc welding
 +
|-
 +
| Gas overrun timer || [[File:TIGWelderGasOverrunTimer.JPG|200px]] || Controls how long after arc cut off the gas will run for. <br/> Outer scale is tungsten width, inner scale is time in seconds
 +
|}
 +
 +
==Tungsten and collets==
 +
We have a selection of the following tungsten tips and collets to fit
 +
{| class="wikitable"
 +
!Size
 +
! Color band
 +
! Grade
 +
! Used for
 +
! Notes
 +
|-
 +
| 1.6mm ||style="background-color: red;"|Red  || 2% Thoriated || DCEN Steel || Slightly radioactive! Do not sharpen without wearing a dust mask.
 +
|-
 +
| 2.4mm ||style="background-color: red;"| Red || 2% Thoriated || DCEN Steel || Slightly radioactive! Do not sharpen without wearing a dust mask.
 +
|-
 +
| 1.6mm ||style="background-color: white;"| White || Zirconaited|| AC Aluminium ||
 +
|-
 +
| 2.4mm ||style="background-color: white;"| White || Zirconaited || AC Aluminium ||
 +
|-
 +
| 1.6mm ||style="background-color: gold;"| Gold || 1.5% Lanthanated || AC or DCEN, All rounder Steel or Aluminium ||
 +
|-
 +
| 2.4mm ||style="background-color: gold;"| Gold || 1.5% Lanthanated|| AC or DCEN, All rounded Steel or Aluminium ||
 +
|-
 +
|}
 +
 +
Tungsten electrodes come in a a range of different grades/types, each performs differently and have their own uses.<br/>
 +
They are marked with a colour band at one end, do not grind this off!<br/>
 +
The following was borrowed from [http://weldingweb.com/archive/index.php/t-57759.html here]
 +
 +
ZIRCONIATED Tungsten Color Code WHITE or BROWN, are best suited for AC Tig welding applications.<br/>
 +
Zirconiated, White, AC Welding applications. Better start up than Pure Tungsten, Balls up well and has a more stable arc than Pure Tungsten. Better current carrying capacity and high resistance to contamination during welding.
 +
 +
LANTHANATED Tungsten Color Code BLACK, GOLD or BLUE, is suitable for AC & DC welding applications.<br/>
 +
Lanthanated, Black, AWS Class EWLA-1.5, AC & DC welding applications. Non-Radioactive Good arc characteristics in ac/dc applications. Applications: carbon & stainless steel, nickel alloys and titanium.
 +
 +
CERIATED Tungsten Color Code GREY or ORANGE, are best suited for low amperage DC welding applications.<br/>
 +
Ceriated, Grey, An excellent alternative to Thoriated tungsten especially in low amperage welding. Takes 10% less current to start and has a very stable arc.
 +
 +
PURE Tungsten Color Coded GREEN, are best suited for AC Tig welding applications.<br/>
 +
Pure Tungsten, Green, AWS Class EWP, AC welding applications. Least expensive of all electrodes. Applications: aluminum and magnesium alloys.
 +
 +
THORIATED Tungsten Color Code RED, YELLOW, MAUVE or ORANGE, is best suited for DC Tig welding applications.<br/>
 +
2% Thoriated, Red, AWS Class EWTH-2, DC welding applications. The most common type of electrode used today. Applications: carbon & stainless steel, nickel alloys and titanium.
 +
 +
===Grinding tip shapes===
 +
Do not grind the end with the color band!
 +
 +
=== Training ===
 +
https://wiki.london.hackspace.org.uk/view/Welding_Training
 +
 +
==Power supply ==
 +
A 63A plug and socket connection is used, with a pushbutton on/off control station and no-volt release.<br/>
 +
RFID control of access will be installed shortly.
 +
 +
==Tig welding tips==
 +
Random collection of useful links
 +
* http://www.mig-welding.co.uk/tig-technique.htm
 +
* http://www.millerwelds.com/resources/improving-your-skills/tig/
 +
* http://www.mig-welding.co.uk/tig-calculator.htm
 +
* http://www.gowelding.org/TIG_Welding.html

Latest revision as of 22:20, 6 February 2020

Marshall Dynabolt Tig Welding Set
Marshall Dynabolt welder.jpg
Model Marshall Dynabolt 250 Amp AC/DC Tig Welding Set
Sub-category Metalworking
Status Under construction
Last updated 6 February 2020 22:20:56
Consumables Argon gas, welding tips, gas lenses, filler rods
Accessories Foot pedal, welding torch
Training requirement yes
ACnode no
Owner Hackpace
Origin Bought through pledge in Jan 2015
Location Metal Workshop
Maintainers Tim, Des, Dean, Liam

Marshall Dynabolt 250 Amp AC/DC Tig Welding Set, used for accurate welding of steel, stainless steel, aluminium and alloys.

This machine requires training and experience in stick and MIG welding techniques before use.

If you want to quickly weld mild steel please consider using the stick welder.

A good intro to welding with aluminium can be found here..

http://www.lincolnelectric.com/en-gb/support/welding-solutions/Pages/aluminum-faqs-detail.aspx

How to assemble to TIG torch with picture is here

http://welders.tokentools.com.au/tig-torch-assembly/

Electrode Thickness, Amperage and Argon Gas Flow Settings can be obtained here

http://www.millerwelds.com/products/gunstorches/tig-torches/helpmechoose/

Filler Materials for aluminium here

http://www.lincolnelectric.com/en-us/support/welding-how-to/Pages/tig-welding-aluminum-detail.aspx


Update WIP

TIG (Tungsten Inert Gas) welding is particularly useful for aluminium, It uses an electrode nozzle with a fixed (should be permanent, but they do wear) tungsten tip where a plasma 'flame' is created (started with a high-voltage / high frequency starter) and used to heat the filler wire and joint. The nozzle allows a flow of inert shield gas around the working area, reducing slag creation and (particularly important with aluminium) oxidation.

The TIG welder is a 'stick' welder - the electrode / nozzle is held in one hand, and the filler wire applied with the other.

Shield gas

For the TIG we use a Pureshield Argon.

Capacity and rating

The Tig welder has a large range

Power is from a 63 amp socket, on the highest setting the Tig could draw more current than this


Controls

250px
Details on the front panel controls

Name Picture Description
Main On Off Switch 200px Main switch on the welder, remember to turn off the welder as much as possible in-between setting up for welds
DC+ AC DC- selector 200px Do not change this setting with the main power switch ON.
This selector has three positions that control the mode of the welder
  • DC- (DCEN), DC Electrode Negative, used for Steel TIG
  • AC, used for Aluminium TIG
  • DC+ (DCEP), DC Electrode Positive, used for Arc
Working power range selector 200px Do not change this setting with the main power switch ON.
There are three possible working ranges, low, medium and high. Each has a slightly different range for DC or AC
Position AC DC
Up 140-310 125-310
Middle 40-165 40-190
Down 10-45 10-55
Percentage power dial 200px Main power control dial, used to fine tune the amp control of the welder.
This dial acts as a percentage of the current selected range.
Remote control enable 200px Used to enable remote current control when a foot control is installed.
Until we have a remote foot pedal this should be left in the OFF position.
High Frequency control 200px Controls the high frequency generation of the welder, this switch has three positions and each has a set use.
  • Up (IO) High frequency start, use this for DC TIG welding (Steels)
  • Middle (O) Off used for Stick welding
  • Down (I) On, used to AC TIG welding (Aluminum)
Remote trigger enable 200px This should be left in the ON position.
Used to enable the remote trigger, only place in OFF position when doing Arc welding
Gas overrun timer 200px Controls how long after arc cut off the gas will run for.
Outer scale is tungsten width, inner scale is time in seconds

Tungsten and collets

We have a selection of the following tungsten tips and collets to fit

Size Color band Grade Used for Notes
1.6mm Red 2% Thoriated DCEN Steel Slightly radioactive! Do not sharpen without wearing a dust mask.
2.4mm Red 2% Thoriated DCEN Steel Slightly radioactive! Do not sharpen without wearing a dust mask.
1.6mm White Zirconaited AC Aluminium
2.4mm White Zirconaited AC Aluminium
1.6mm Gold 1.5% Lanthanated AC or DCEN, All rounder Steel or Aluminium
2.4mm Gold 1.5% Lanthanated AC or DCEN, All rounded Steel or Aluminium

Tungsten electrodes come in a a range of different grades/types, each performs differently and have their own uses.
They are marked with a colour band at one end, do not grind this off!
The following was borrowed from here

ZIRCONIATED Tungsten Color Code WHITE or BROWN, are best suited for AC Tig welding applications.
Zirconiated, White, AC Welding applications. Better start up than Pure Tungsten, Balls up well and has a more stable arc than Pure Tungsten. Better current carrying capacity and high resistance to contamination during welding.

LANTHANATED Tungsten Color Code BLACK, GOLD or BLUE, is suitable for AC & DC welding applications.
Lanthanated, Black, AWS Class EWLA-1.5, AC & DC welding applications. Non-Radioactive Good arc characteristics in ac/dc applications. Applications: carbon & stainless steel, nickel alloys and titanium.

CERIATED Tungsten Color Code GREY or ORANGE, are best suited for low amperage DC welding applications.
Ceriated, Grey, An excellent alternative to Thoriated tungsten especially in low amperage welding. Takes 10% less current to start and has a very stable arc.

PURE Tungsten Color Coded GREEN, are best suited for AC Tig welding applications.
Pure Tungsten, Green, AWS Class EWP, AC welding applications. Least expensive of all electrodes. Applications: aluminum and magnesium alloys.

THORIATED Tungsten Color Code RED, YELLOW, MAUVE or ORANGE, is best suited for DC Tig welding applications.
2% Thoriated, Red, AWS Class EWTH-2, DC welding applications. The most common type of electrode used today. Applications: carbon & stainless steel, nickel alloys and titanium.

Grinding tip shapes

Do not grind the end with the color band!

Training

https://wiki.london.hackspace.org.uk/view/Welding_Training

Power supply

A 63A plug and socket connection is used, with a pushbutton on/off control station and no-volt release.
RFID control of access will be installed shortly.

Tig welding tips

Random collection of useful links