Validation Instructions

Kemppi Oy
CONTENTS

1. READ THIS FIRST ...................................................................................................................................... 1

2. GENERAL .................................................................................................................................................... 1
3. MEASURING INSTRUMENTS .................................................................................................................... 1
4. NOMINAL CURVE CALCULATION ............................................................................................................. 2
4.1. Nominal curve for TIG mode ..................................................................................................................... 2
4.2. Nominal curve for MMA mode................................................................................................................... 2
4.3. Nominal curve for MIG/MAG mode: .......................................................................................................... 3
5. VALIDATION ERROR RANGE.................................................................................................................... 3
5.1. Terms and meanings: ............................................................................................................................... 3
5.2. Voltage and current set value limits .......................................................................................................... 4
5.3. Display error limits ..................................................................................................................................... 4
5.4. Wire feeder error range ............................................................................................................................. 4
6. VALIDATION PROCEDURE ....................................................................................................................... 5
6.1. Preparations .............................................................................................................................................. 5
6.2. Power source validating process .............................................................................................................. 5
6.3. Wire feeder validation process .................................................................................................................. 6
6.4. Gas and water flow ................................................................................................................................... 6
6.5. Certificate .................................................................................................................................................. 6
6.6. Labels ........................................................................................................................................................ 6

Kemppi Oy
Validation instructions Version 1.0 19.7.2019

1. READ THIS FIRST

100VDC or higher are inside the machine

Before removing any covers or commencing any testing or measurement disconnect the power source
from the mains voltage

Dangerous DC voltage may still exist after the removal of the input voltage. Machine discharges the
voltage while it is turned off, but it is always better to ensure this by measuring the voltage

Wait at least one minute for the capacitors to become discharged.

Digital multimeters (later DMM) may give different values depending the specifications they have. For
example diode measuring values may vary between the DMM models. In this manual Fluke 179 DMM is
used.

The device may be repaired only by a person legally authorized to perform electric work.

2. GENERAL

This manual holds the instructions to do a successful validation. Validation must be done at least once in
a year for standard grade and twice for precision grade. Customer may demand more frequent validation
process.

Validation must be done after the repair work and new label must be put in to the machine.

2.1. Terms

Calibration: Measuring and recording the errors that measuring instruments have.

Validation: Accepting or discarding the machine according to measurements and determined errors.

3. MEASURING INSTRUMENTS

To execute calibration several equipment is needed. Measuring instruments Following values must be
measured: voltage, current, wire feed speed gas flow and water flow.

• Voltage measuring: accurate digital multimeter (e.g. Fluke 179)

• For current measuring: clamp meter or shunt + digital multimeter
• Wire feed speed: tachometer or tape measure and stopwatch
• Gas and water cooler flow: no need to measure but check that flow is ok

For calibration measurement load bank is needed as well. There is no big difference if the load is manual
or automatic. Only requirements are that it must be adjustable and accept welding voltage and current
range up to 500 amps.

Calibration must be done with annually calibrated equipment that are at least 2 times more accurate than
equipment under validation.

1
Kemppi Oy
Validation instructions Version 1.0 19.7.2019

4. NOMINAL CURVE CALCULATION

Measuring machines output values and comparing them to display values must be done in certain way.
Current to voltage (MMA and TIG) or voltage to current (MIG/MAG) has relation that is called nominal
curve. Idea is that curve is standardized and results can always be compared to earlier ones during the
machine life cycle.

Notice that nominal curve minimum point is limited higher that many modern welding machines can
reach. This is the reason why examples are giving suggested minimum point for each welding process.

4.1. Nominal curve for TIG mode

Nominal voltage determination in TIG mode:

   ∗ 0,04 10

So if using 300A TIG machine current and voltage values should be following in maximum.

    300 ∗ 0,04 10  22

Minimum point is determined to 15A in practice, because going below that point voltage stays almost
constant but current goes to zero according to formula. In practice machine can go lower values. Good
compromise it to select 15A minimum current and voltage will be 10,6V.

   15 ∗ 0,04 10  10,6

Maximum setting can be done according to machine maximum output current value.

4.2. Nominal curve for MMA mode

Nominal voltage determination in MMA mode:

   ∗ 0,04 20

If using 300A MMA welding machine voltage will be 32V:

    300 ∗ 0,04 20  32

Also in MMA mode 15A is good current value for minimum. Voltage will be 20,6V:

   15 ∗ 0,04 20  20,6

2
Kemppi Oy
Validation instructions Version 1.0 19.7.2019

4.3. Nominal curve for MIG/MAG mode:

MIG/MAG mode is CV type and instead of adjusting current voltage is adjusted. But still power sources
are ranged by current it is better to determine output values in function of current:

   ∗ 0,05 14

Maximum setting can be determined normally according to machine output voltage and current. For
example 300A machine output voltage will be 29V:

    300 ∗ 0,05 14  29

Minimum setting is better to select again above machine’s real minimum value. Nominal curve formula
cannot give values below 14V but modern inverters can actually weld below that point. 20A is good value
to start with an voltage will be 15V:

   20 ∗ 0,05 14  15

5. VALIDATION ERROR RANGE

The error limits are determined for standard grade (appendix 1). If precision grade is required see
appendix 2.

Following examples describes standard grade power source and wire feeder validation.

5.1. Terms and meanings:

- Set value: The value that is set by welding machine user interface, i.e. machine is asking some
voltage (CV) or current (CC) output
- Display value: The display reading that is shown
- Measured value (called sometimes true value or real value): The value that measuring instrument
measures in the welding machine output. This is the value where set value and display value are
compared.

Validation is done in two different steps:

1. Welding machine set value is compared to measured values

2. Welding machine display value or values is/are compared to measured values

Both of these have different error limits and they can be determined by certain rules.

According to EN 50504 only one is required to be recorded but it is suggested to record both.

3
Kemppi Oy
Validation instructions Version 1.0 19.7.2019

5.2. Voltage and current set value limits

When machine is set to certain current or voltage set value (only one can be selected and another is
determined by set load) machine’s real output value is compared to this value.

• In the range of 0-25% of voltage and current set value error can be ±2,5% of maximum setting
• In the range of 25-100% of voltage and current set value error can be ±10% of true value
(measured value)

Example 1:

400A MMA welding machine

- MMA is constant current so set value is current
- In 0-100A (0-25%) range set value error limit is 2,5% from 400A = 10A and is fixed throughout the
range
- In 100-400A (25-100%) range set value error limit is 10% of value that is measured at the
moment i.e. 250A set value can have 25A error and 400A set value can have 40A error

Example 2:

300A MIG/MAG welding machine

- MIG/MAG is constant voltage so set value is voltage
- In this example machine voltage range is 12-32V
- 0-25% of maximum setting is 0-8V so machine cannot reach this range
- 25-100% is 8-32V so voltage set value error can be 10% of true value i.e. set value 20V can have
error 2V and 32V can have error 3,2V

5.3. Display error limits

Displays have different error limits depending if they are voltage or current meters.
- Current display may have maximum error of ±2,5% of maximum welding current
- Voltage display may have maximum error of ±2,5% of no load voltage (OCV)

Example 3:

300A MMA welding machine with OCV 80V

- Current display may differ 300 ∗ 0,025  ±7,5 (fixed) from true measured value
- Voltage display may differ 80 ∗ 0,025  ±2 (fixed) from true measured value

5.4. Wire feeder error range

For both set value and display value error range is same. According to EN 50504 only one is required to
be recorded but it is suggested to record both.

- Standard grade error range is ±10% of the true value

- Precision grade error range is ±2,5% of the true value

4
Kemppi Oy
Validation instructions Version 1.0 19.7.2019

Example 4:

Standard grade wire feeder

- 5m/min setting error range is ±0,5m/min

6. VALIDATION PROCEDURE

6.1. Preparations

• Welding machine must be switched off and connected to load.

• Multimeter should be connected to as close as possible to welding machine output terminals.
Easiest way is to put them through welding cable insulator
• Clamp meter can be put around the one of the welding cables. If shunt is used multimeter is
needed to read shunt values.
• Switch off all features that may modify display from their original values (current, voltage or wire
feed speed).
• Check and record machines welding current and voltage range and OCV voltage.
• Calculate and determine error limits to each value that will be validated
• Determine 5 welding current steps from minimum to maximum. Notice the minimum setting
determination that was discussed earlier.
• Calculate voltages for current steps according to nominal curve calculation.
• Measure environment temperature and mains supply voltage
• Determine and record if standard or precision grade is used

6.2. Power source validating process

1. Switch on the machine

2. Set minimum value
3. Switch on the load
4. Set machine to 4T if TIG or MIG/MAG machine
5. Press trigger if TIG or MIG/MAG machine
6. Adjust load so that nominal voltage is reached (MMA and TIG) or current is in required level
(MIG/MAG)
7. Record both measured values and display values
8. Set next value and adjust load so that nominal curve rule is coming true.
9. Repeat step 7-8 as long as five different set values are gone through
10. Press the trigger (if TIG or MIG/MAG) and switch off the load.
11. Repeat steps 2-10 but set values are selected in order from maximum to minimum
12. Once every value is measured twice (from min to max and max to min) calculate mean values of
each display value and measured value.
13. Check if values are inside the error range

5
Kemppi Oy
Validation instructions Version 1.0 19.7.2019

6.3. Wire feeder validation process

1. Set wire feed speed set value to minimum

2. Trigger the machine and record measured wire feed speed (use tachometer or run wire 6
seconds and multiply by 10 and measure bur measuring tape)
3. Set next set value and repeat steps 2-3.
4. Once all the 5 steps are tested repeat the test from maximum to minimum in same set value
points. Records the results
5. Calculate mean values of measurements
6. Compare values to previous validation and check that they are still close enough

6.4. Gas and water flow

1. Check that water is flowing through the system and record PASS or FAILED
2. Check that gas is flowing through the system and record PASS or FAILED

6.5. Certificate

Certificate must hold the following information:

- Name and address of the validating authority
- Welding machine type (power source, feeder)
- Model and brand of welding machine
- Serial number of the welding machine
- Ambient temperature
- Supply voltage
- Welding machine type (MMA,TIG,MIG/MAG)
- Validation equipment names and models
- Grade of validation (standard or precision)
- Range of the validation, measurement records (can be in attachment)
- Result of validation: passed or failed
- Date
- Signature or mark of the inspector

6.6. Labels

Passed label must hold following information:

- Passed
- If precision grade validation, it must be mentioned “PRECISION GRADE”
- Date
- Date of expiry of validation
- Inspectors ID or name
- Brand, model and serial number of the welding machine

Failed label
- Failed
- Date
- Inspectors name or ID
- Brand, model and serial number of the welding machine

6
Kemppi Oy
Validation instructions Version 1.0 19.7.2019

APPENDIX 1

7
Kemppi Oy
Validation instructions Version 1.0 19.7.2019

APPENDIX 2

8
Kemppi Oy