CALIBRATION

LABORATORY

WELDING MACHINE
TITLE : WELDING MACHINE VALIDATION PROCEDURE

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REVISION RECORD SHEET

NOTES

i) Revisions after Rev. 0 are denoted by a vertical line in the left hand margin
against the revised text, with the revision number displayed next to the revision
line as shown on the left.

ii) Revision numbers are A, B, C, etc. up to the issue for management approval
and implementation, which is Rev. 0. Subsequent revisions shall be 1, 2, 3,
etc.

No. Date Description of Revision Prepared Review Approved

Issued for approval &

0 01-Jan-2019
implementation

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TITLE : WELDING MACHINE VALIDATION PROCEDURE

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Table of Contents

S/No. Description Page No.

1.0 Purpose 4

2.0 Scope 4

3.0 Reference 4

4.0 Definitions 4

5.0 Responsibilities 4

6.0 General Guidelines 5

7.0 Validation Procedure 5

8.0 Records 7

9.0 Attachments 7

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TITLE : WELDING MACHINE VALIDATION PROCEDURE

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1.0 PURPOSE
1.1 The purpose of this work instruction is to ensure that standard practices /
methods of validation are followed to obtain reproducible and comparable
results and this document shall be revised as and when required to meet
specific requirements of the project to become a project specific work
instruction.

2.0 SCOPE
2.1 This work instruction is applicable for Calibration Laboratory to carryout
validation of welding machine at Lab. temperature as per applicable
international standards/methods.

3.0 REFERENCE
3.1 Documents used:
 OH & SM - Occupational Health & Safety Manual
 BS EN 50504 - Validation of Arc Welding Equipment
3.2 Welding Load Bank
3.3 Tachometer

4.0 DEFINITIONS
4.1 Monitoring and Measuring Equipment - equipment that are used to provide
evidence of conformity of product to determined requirements.
4.2 Validation - All the operations for the purpose of demonstrating that an item of
welding equipment or a welding system conforms to the operating
specification for that welding equipment or system.
4.3 Wire Feed Speed - The rate of delivery of a consumable welding filler wire or
rod to the welding arc.
4.4 UUT - Unit Under Test (Welding machines & wire feeders)

5.0 RESPONSIBILITIES
5.1 All the Operators/Technicians perfoming the validation shall be trained by
ATS.
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TITLE : WELDING MACHINE VALIDATION PROCEDURE

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6.0 GENERAL GUIDELINES

6.1 All welding equipment shall be validated in accordance with this procedure
and relevant international standards.
6.2 The technician who is performing the validation should have sufficient
knowledge and previous experience in this field.
6.3 Principle of operation
6.4 The welding power load bank is generally used for validation of welding
equipment.
6.5 The welding power load bank is designed to load test by means of constant
resistive load for the output of transformer-type, engine or motor driven
generator welding power sources.

7.0 VALIDATION PROCEDURE

7.1 The validation condition such as ambient temperature and relative humidity
should be measured to ensure that it is within the power source and test
instrumentation rating.
7.2 The UUT to be validated with reference to the Standard constant resistive
Load bank.
7.3 Damage/ loose connection in the UUT, if any shall be rectified. Start the UUT
and allow for initial warm up 10 to 15 minutes.

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TITLE : WELDING MACHINE VALIDATION PROCEDURE

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7.4 Note down the validation conditions (Temperature & Humidity) in the
Validation Data sheet with a certified Dew point Meter.
7.5 Connect the reference True RMS digital Multimeter across the UUT output
terminals and measure the OCV (open circuit voltage/ Rated no load voltage
U0). Record/ note down the OCV/ U0 value in the Validation Data sheet.
7.6 Power on the load bank and allow for initial warm up 10 to 15 minutes.
7.7 Check the load bank selector switch positions are in the minimum marking.
7.8 Connect the UUT to the constant resistive load bank with proper copper cable
connectors and fasten them properly.
7.9 Confirm that no load is applied and check for the zero reading in the UUT
display. Now the setup is ready for validation.
7.10 Set the required current value in the UUT, apply the required load and
maintain the conventional load voltage (U2) as per the manufacturer
specification or between 20 to 35 volts.
7.11 Always switch off / stop the UUT before changing the Load value from load
bank.
7.12 Minimum three set of readings of the UUT and tabulate them in the validation
Data sheet. The linearity of the UUT to be checked in both the directions for
increasing and decreasing loads.
7.13 Accuracy of the UUT will be determined according to the manufacturer
Specification/Standard.
7.14 Switch off / stop the UUT and the load bank and remove all connections
safely.
7.15 The accuracy level for validation of all welding equipment (standard grades)
shall be followed as indicated below:

S.No. Description Accuracy (rdg)

1 Current ±10%
2 Rated no-load voltage ±5%
3 Wire feed speed ±10%

7.16 In case of not meeting the accuracy, the welding equipment or wire feeder
shall be repaired / adjusted to bring the instrument within the accuracy limit.

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TITLE : WELDING MACHINE VALIDATION PROCEDURE

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8.0 RECORDS
8.1 Measurement/reading shall be recorded in the appropriate Check
List/Formats given the Attachment.
8.2 The test report should contain the following information as minimum.
 Client/Customer Name
 Instrument Manufacturer, Make, Model, Range, Serial No & Accuracy
 Test results

9.0 ATTACHMENT

S.No Format No. Description

1 L4-CAL-E-11 Welding Machine

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