1 Introduction BS 7570 - Code of practice for validation of are welding equipment — a standard that gives guidance to: * Manufacturers about the accuracy required from output meters fitted to welding equipment to show welding current, voltage, ete * End users who need to ensure that the output meters provide accurate readings The Standard refers to two grades of equipment - standard grade and precision grade. ‘Standard grade equipment is suitable for manual and semi-automatic welding processes, Precision grade equipment is intended for mechanised or automatic welding because there is usually a need for greater precision for all welding Variables as well as the prospect of the equipment being used for higher ‘duty cycle’ welding. 2 Terminology BS 7570 defines the terms it uses - such as: Calibration: Operations for the purpose of determining the magnitude of errors of a measuring instrument, etc. Validation: Operations for the purpose of demonstrating that an item of welding equipment, or a welding system, conforms to the operating specification for that equipment or system, Accuracy: Closeness of an observed quantity tothe defined, or true, value Thus, when considering welding equipment, those that have output meters for welding parameters (current, voltage, travel speed, etc.) can be calibrated by checking the meter reading with a more accurate measuring device ~ and adjusting the readings appropriately. Equipment that does not have output meters (some power sources for MMA, MIG/MAG) cannot be calibrated but they can be validated, that is to make checks to see that the controls are functioning properly. C&iercton of Welding Equipment OWT wees Copy TH LODO CLM SiS aoe3 Calibration Frequency BS 7570 recommends re-calibration/validation at: © Yearly intervals (following an initial consistency test at 3_ monthly intervals) for standard grade equipment © Six monthly intervals for precision grade equipment. However, the Standard also recommends that re-calibration/validation may be necessary more frequently. Factors that need to be considered are: «Equipment manufacturer's recommendations User's requirements If the equipment has been repaired re-calibration should always be carried out © If there is reason to believe the performance of the equipment has deteriorated 4 Instruments for Calibration Instruments used for calibration should: © Be calibrated by a recognised calibrator - using standards that are traceable to a national standard © Be at least twice, and preferably five times, more accurate than the ‘accuracy required for the grade of equipment + For precision grade equipment it will be necessary to use instruments with much greater precision for checking output meters. 5 Calibration Methods The Standard gives details about the characteristics of power source types, how many readings should be taken for each parameter and guidance on precautions that may be necessary. Rev { January 2010 Calibraion of Welding Equipment WI wono ceurne Copyright © TW Lid 2010 CMT cite reso.00%For the main welding parameters, recommendations from the Standard are. as follows: Current: Details are given about the instrumentation requirements and how to measure pulsed current but there are requirements specified, or recommendations made, about where in the circuit current measurements should be made. The implication is that current can be measured at any position in the circuit ~ the value should be the same. Voltag The standard emphasises that for processes where voltage is pre-set (on constant voltage the power sources) the connection points used for the voltmeter incorporated into the power source may differ from the arc voltage, which is the important parameter. To obtain an accurate measure of arc voltage, the voltmeter should be positioned as near as practical to the arc, This is illustrated by the figure at the end of this section, which shows the Power source voltage meter connected across points 1 and 7. However, because there will be some voltage drops in sections 1-2, 3-4 and 6-7 due to connection points introducing extra resistance into the circuit, the voltage meter reading on the power source will lend to give a higher reading then the true arc voltage. Even if the power source voltmeter is connected across points 3 and 7 (which it may be) the meter reading would not take account of any significant voltage drops in the return cable - section 6-7. ‘The magnitude of any voltage drops in the welding circuit will depend on cable diameter, length and temperature and the Standard emphasises the following: * Itis desirable to measure the true arc voltage between points 4-5 but for some welding processes it is not practical to measure arc voltage so close to the are * For MMA, itis possible to take a voltage reading relatively close to the arc by connecting one terminal of the voltmeter through the cable sheath as close as ~2m from the arc and connect the other terminal to the workpiece (or to earth) * For MIG/MAG the nearest practical connection points have to be 3-5 but 8 change from an air-cooled to a water-cooled torch or vice-versa may have a significant affect on the measured voltage * Voltage drops between points 5-6 will be insignificant if there is a good connection of the retumn cable at point 6. Rev January 2070 von een Calibration of Welding Equipment OYE resco Copyright® TAIL 2010, WLM teenThe Standard gives guidance about minimising any drop in line voltage by ensuring that: ‘* The current retum cable is as short as practical and is heavy, low resistance, cable * The current-return connector is suitably rated and is firmly attached and so does not overheat due to high resistance The standard gives data for line voltage drops (DC voltage) according to current, cable cross section and cable length (for both copper and aluminium cables). Wire feed speed For constant voltage (self-adjusting arc) processes such as MIG/MAG the standard recognises that calibration of the wire feeder is generally not needed because itis linked to current. If calibration is required, it is recommended that the time be measured (in seconds) for ~1m of wire to be delivered (using a stopwatch or an electronic. timer). The length of wire should then be measured (with a steel rule) to an accuracy of 1mm and the feed speed calculated. Travel speed Welding manipulators, such as rotators and robotic manipulators, as well as the more conventional linear travel carriages, influence heat input and other properties of a weld and should be checked at intervals. Most of the standard devices can be checked using a stopwatch and measuring rule, but more sophisticated equipment, such as a tacho- generator, may be appropriate. mimayaD Cctercion of Weling Equipment ape pert Copyricnt © TWI Ltd 2010 ‘ona TECHNOLOGYWire Feeder are voltage { ‘An example of a welding circuit (for MIG/MAG) Rev 1 January 2010 ~ ay Calibration of Welding Equipment EWI vom Sotuhtenats Copyright © TWILtd 2010 CLM ‘sre e.001