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    Jis C9305

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    Han Win Aung

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    ves eerauo of WM 4433608 0039263 5 me UOC 621.3.025.1 : 621.791.76.037 JAPANESE INDUSTRIAL STANDARD General Rule for Resistance Welding Machines JIS C 9305-15 Translated and Published by Japanese Standards Association Printed in Japan los Copyright by the Japanese Industrial Standards Tue Aug 21 18:10:21 2007 [JIS cx9305 87 mH 4933608 0039264 0 om In the event of any doubt arising, the original Standard in Japanese is to be final authority. Copyright by the Japanese Industrial Standards Tuo Aug 24 18:10:21 2007 JIS Cx9305 87 MM 4933608 003925 2 mm ‘UDC 621.3,025.1:621.791.76.037 JAPANESE INDUSTRIAL STANDARD its General Rule for Resistance C 9305-1987 Welding Machines 1. Scope This Japanese Industrial Standard specifies general rules for the following various single phase a.c. resistance welding machines, hereinafter referred to as the ‘welders", composed of single phase transformers of 50 Hz or 60 Hz and mechanisms for welding force. If other Japanese Industrial Standards or other . specific standards ate provided, however, welders shall comply with the relevant standard(s). Particulars whose numerical values are not specified in any of these standards are subjected to the agreement between the parties concerned. Welders for special use or requiring special requirements may not follow this standard, Control devices except switches in the main circuit are not the subject of this standard. e@ (1) Lap Resistance Welding Machine (a) Spot welding machine (portable spot welding machine is included.) (b) Projection welding machine (©) Seam welding machine (2) Butt Resistance Welding Machine (a) Upset welding machine (b) Flash welding machine Remark: The units and numerical values shown in ( } in this Standard are based on the traditional unit system and are currently the criteria in force, @ x etinitions For the purpose of this Standard the following principal definitions apply: (1) duty cycle The ratio of on-load time to the total period expressed in percentage, when a constant load is intermitted, (2) rated capacity The on-load input power at which the temperature rise ‘Gbuplies withthe relevant provision when @ waldar is loeded at the rated : input voltage of the rated frequency and a duty cycle of 50 %, by adjusting the load. It is expressed in kVA. Applicable Standards and Reference Standards: See page 16. Copyright by the Japanese Industrial Standards ‘Tue Aug 21 15:10:24 2007 SIS #9305 67 MM 4933608 0039265 4 mm 2 C 9305-1987 (3) a) (5) (6) a) (8) (9) (10) ay (12) 3. maximum no-load_input_volt ‘The’ maximum Voltage which can be Spplled oss Input temminasot @ welder maximum on-load_input volta; ‘The across input terminals of a welder ‘When the tated madimum welling current is passed. maximum secondary no-load voltage. ‘The secondary open-circuit. voltage wien the Tated input voltage is spplled to the tap, which can’ produce the maxitwum current, of a welding transformer. maximum short-circuit current The current which flows through the secondary circult when the maximum on-load input voltage of the rated frequency is applied to the tap, which can produce the maximum current, of a welding transformer under standard secondary arrangement and the short-cireuit conditions prepared in accordance with 8.2, ‘maximum welding current ‘The current equal to 90 % of the maximum Thore-circule eument. rated maximum welding current ‘The current nominated on the nameplate ‘Sarvespondlng tS 80 SOF The Thexinum ghort-cfreutt current. rated maximum welding input power It 1s expressed in kVA. The SpOMSRE PONG OF EGE MG"WNOR the tated maximum welding current ls passed. allowable duty cycle at rated maximum welding current The allowable Yaluo"of auty cycle at wilch the apectTied Temperature rise Je complied with when the rated maximum welding current is Intermitted at the rated frequency and the rated input voltage. Provided that the period of intermitting rated maximum welding current 1s 60 sec. rated welding force The guaranteed maximum welding force which acts Snthe weld MMier the standard electrode errangement of a welder. The welding force here referred corresponds to the electrode force for lap welders and to the upset force for butt welders, Provided that, if compressed air is used to generate the welding force, it shall be the guaranteed welding force at the pneumatic pressure of 490 kPa {5 :kgf/om2). hight of working place The hight from the floor to the standard welding position. Standard Service Conditions Welders shall, unless otherwise specified, be used under the following conditions: a @ @) Copyright byt Where the ambient temperature is within the range 0 to 40°C. Indoor Where the altitude does not exceed 1000 m. panese Industrial Standards Tuo Aug 24 15:10:21 2007 {JIS Cx9305 87 MM 4933608 0039267 b 3 © 9305-1987 e 4, Cooling Water 4.1 Temperature of Water The temperature of cooling water used for welders shail not exceed 30°C at thelr inlet ports. 4.2. Quality of Water The electric resistivity of cooling water for thyristors used in the iain GHEITE shall be not less than 8000a-cm and the quality of water shall be similar to that of industrial water. However, the cooling water for thyristors the water cooler of which is insulated is exempted from the above requirement. 4.3 Flow Rate and Pressure of Water The flow rate of cooling water for a welder shall be that marked on the nameplate, and the pressure difference between inlet and outlet ports shall not exceed 69 kPa {0.7 kgf/cm2}. 5. Ratings e@ 5.1 Rated Frequency The rated frequency shall be 50 Hz or 60 Hz. 5.2 Rated Input Voltage The rated input voltage shall be 200 V or 400 V. 5.3 Maximum No-Load Input Voltage The maximum no-load input voltage shall be 230 Vor 460-V when The Fated input. voltage is 200 Vor 400 V, respectively. 5.4 Maximum On-Load Input volte ‘The maximum on-load input voltage shall be iso War 380-V when the rated Tipit voltage is 200 V or 400 V, respectively. 6, Characteristics 6.1 Electrical Characteristics 6.1.1 No-Load Input Power The no-load input power shall not exceed the value obtalned from the Give of rated maximum welding Input, power- S (continuous line) In Fig, 1, when tested in accordance with the method of 8.1. If ‘the maximum welding input power is not clear, however, the reference value shall @ be obtained from the curve of rated capacity-s, (broken line) in the same figure. Copyright by the Japanese Industrial Standards Tue Aug 24 15:10:21 2007 [JIS C#9305 87 mm 4933608 CO392b8 8 mm | 4 c 9305-1987 fig, 1. No-toal tnt Pover ® agi l 33 a4 Ke By oS hi 1 pA on ESET A120 Ae CORA BO e ao ate nina wel tnt BS SP St ayy 6.1.2 Maximum Welding Current The maximum welding current obtained by the method Of 8.5 Shall be within 100 to 110 % of the Tated maximum welding current marked on the nameplate. 6.1.3 Allowable Duty Cycle The allowable duty cycle shall comply with the foliowing fequirement (1) Allowable Duty Cycle at Rated Maximum Welding Current ‘The Flared value of allowable duty oyele a Teted maximum welding current shall satisfy the value calculated as specified in 8.5. (2) Allowable Duty Cycle at Rach Tap of Welding Transformer If the fransformar has tapes the sliowable duty cycle shall sets the values calculated from the following formula: © Allowable duty cycle at each tap (%) = Allowable duty cycle at rated Maximum secondary voltage ai RR eeoonny_ voltage __ maximum welding current * -Seccndary no-load voltage at each tap 6.14 Temperature Rise The temperature rise of welding transformer windings shall Tot exceed the felevant value given in Table 1 when tested by the method of 8.6. ‘The temperature rise of cores or other parts in contact with a winding shall not exceed the appropriate value to the winding given in Table 1. ‘The temperature rise of the parts constituting secondary circuit other than electrodes shall not exceed 60°C. Copyright by the Japanese Industrial Standards ‘Tue Aug 24 15:10:24 2007 UTS C9305 87 MH 4933608 0039265 T mm 5 Unit: °C aroma Class of Ir ot ter cooled type aethod ‘nettod” ereceea te [Stem Samegneter Class B 6 6 70 8 85 80 Class F 105 10 100 As 120 10 7 ‘Class H 130 195 120 40 ee one Remarks 1, Definition of insulation class is based on JIS C 4003. @ 2. ‘The limit of reference ambient temperature for air cooled transformers shall be 40°C, and reference ambinent temperature for water cooled one means the temperature of water at the inlet port * and the mit shall be 30°C. 6.1.5 Withstand Voltage ‘The Insulation of transformer shall withstand the test voltage foF T min without any abnormality when tested by the method of 8.7. 6.2 Mechanical Characteristics 6.2.1 Mechanical Construction Mechanica construction of a welder shall have enough rigidity to endure the welding force, shock caused by welding current, ete. 6.2.2 Height of Working Place The height of working place shall be 900 mm, as a rule. 6.2.3 Maximum Welding Force The electrode force for lap welder or the upset force 10 BHT TaTSGr HRA be ot lose than the rated welding force when @ measured by the method of 89. For the clamping force of butt welder the same requirement applies. 6.2.4 Adjustable Range of Welding Force The welding force shall be continuously eayaseable fe over {ho Tange of 30 to 100 % of the rated welding force, when measured by the method of 8.9. ‘ 6.2.5 Rigidity of Welder The rigidity of a welder shall be tested as follows: (1) Spot Welder The rigidity of a spot welder is specified by the Sefiection of upper frame or upper arm, the deflection of lower arm, and the skid between upper and lower électrodes, and the measuring method shall comply with 8.10.1 (2) Projection Welder The rigidity of a projection welder is specified Bytes parallelism between the upper alld jower platens when the electrode force is applied, and the measuring method shall comply @ with 8.10.2. ——— Copyright by the Japanese industrial Standards ‘Tue Aug 24 15:10:21 2007 JTS Cx9305 67 MH 4933608 0039270 & a 6 C 9305-1987 (3) Seam Welder The rigidity of a seam welder is specified by the deflection of upper frame or upper arm, the deflection of lower arm, and the skid between upper and lower electrodes, and the measuring method shall comply with 8.10.3, (4) Butt Welder ‘The rigidity of a butt welder is specified by the angle made by axes of both test steel rods clamped on the electrodes, which 1s caused by the deflection between the fixed and movable stands, and the measuring method shall comply with 8.10.4, 6.2.6 Mechanical Accuracy of Projection Welder — ‘The mechanical accuracy of a projection welder Is-spocifiod by the-paralelim of upper ond tower platen surfaces, verticality of upper platen motion, and parallelism between upper and lower platens when the lower platen is moved, and the measuring method shall comply with 8.11. 6.2.7 Cooling Water Piping System The cross-sectional area of piping shall be enough to pass the cooling water indicated on the nameplate at a pressure e difference between inlet and outlet ports not exceeding 69 kPa (0.7 kgf/cm?}. The parts used for this cooling system shall withstand the hydraulic pressure of 290 kPa (3 kgt/em?}. 6.2.8 Compressed Air Piping System The pneumatic pressure of compressod ait Used Tor Weldsts shall be 460 kPa (6 kgt/om?}, as standard, and the parts used for this pneumatic system shall withstand the pneumatic pressure of 690 kPa (7 kgt/om2), 7. Safety 7.1 Cooling Water Piping The cooling water system of a welder which accommodates TiyistaTs aid requires cooling water shall comply with the following requirements: (1) Metallic parts with a length 50 mm or more along the water flow shall be provided at the inlet and outlet ports and they shall be electrically connected with the welder body. (2) Im a'welder of such construction that the parts on which the input e voltage being applied, like thyristors, are directly coolded by water, rubber or PVC hoses of good insulation shall be used in the piping for such circults. 7.2 Switch in Main Current Circuit When a switch for main current circuit is provided Ina welder body, If shall not be easily accessed. 7.3. Barth Terminal Any welder containing secondary circuit in its body shall provide an earth terminal capable of connecting an earthing wire of 14 mm2 cross-sectional area, and instruction for earthing shall be attached on its conspicuous place. 7.4 Voltage of Control Power Source and Voltage of Operating Circuit The voltage of eitel power source Shall be so, 100 £10 Vy B00 DV OF 400 240 V. ‘The nominal voltage of the circult for a foot switch’or the starting circuits which are directly operated by an operator shall not exceed 25 V, as a rule, If the voltage overs the said voltage, an electric shock preventive device shall’ be provided. However, the voltage shall not exceed 100 V even if the protection is e@ provided. Copyright by the Japanese industrial Standards Tuo Aug 24 15:10:21 2007 VIS #9305 87 Ml 4933608 003927) 6 mm 7 ¢ 9305-1987 e 7.5 Operation of Projection Welder For a projection welder equipped with platens, ete dentable” to provide a ea Safety device such as both-hand operated switch. 7.6 Operating Console Operating console(s) to operate a welder shall be located Stra plave easily accessed by hand of an operator standing on the working position. Thé components used for starting the machine shall be 80 constructed and arranged that the machine or the apparatus shall not start contrary to the intension of the operator, 7.7. Fail-Safe Device Such part of the device operated by fluid like compressed air or liquid that has possiblity to come close to the operator shall be so designed that the movement in harmful direction to the operator will not occur : when the pressure of the fluid falls owing to current-off or other accident, However, slow movement caused by leakage of fluid is exempted from the above requirement, @ rest ant cateuttion 8.1 No-Load Input Power Test ‘The no-load input power shall be measured by applying the Tated Input Voltage of the rated frequency to the tap of welding transformer which can produce the maximum current. 8.2 Maximum short-Circuit Current Test _ ‘The maximum short-circuit current test shall be carfied out as follows: Prepare the standard arrangement of secondary circuit of a welder, short-circuit the both electrodes in accordance with the appropriate procedure given below, apply a voltage not less than 1/3 of the rated input, voltage at the rated frequency to the input side tap of the welding transformer which can produce the maximum secondary current, and measure the primary current fs. Measure the exciting current 1% at the same voltage while the output terminals are opened, and obtain the measured value of the maximum short-circuit current. fe from the following formula. When the switch in main current circuit is a ignitron or a thyristor, carry out the measurement under such condition that the static switch is not phase controlled using an appropriate method, hams LOX GEXA where fig: measured value of maximum short-circult current Et maximum on-load input voltage (refer to 5.4) 1+ input terminal voltage at the measurement of Fin a: winding ratio of welding transformer Calculate the primary current Js when the maximum short-circuit current is following through secondary side from the following formu Copyright by the Tue Aug 24 15: [IS cx9305 87 me 4933608 0039272 T me 8 C 9308-1987 (1) Spot Welder ‘The upper electrode and lower electrode. with specified e Slectfode Tbe shall be directly short-circuited by applying the rated welding force, under the standard throat dimensions. (2) Projection Welder An auxiliary copper rod having a length equal to” the standard platen specing and enough cross-sectional area not. to become overheated shall be placed vertically on the centre of the lower platen, The upper platen and lower platen shall be short-circuited by applying the rated welding force to the upper platen, while the standard throat dimensions are kept. (3) Seam Welder _The upper electrode and lower electrode shall be directly short-circuited by the specified roller electrodes for applying the rated welding force, under the standard throat. dimensions. (4) Butt Welder ‘The electrode on fixed stand and electrode on movable stand shall be directly short-circuited by clamping a copper rod or plate having enough cross-sectional area not to become overheated at both electrodes, under the standard electrode arrangement. e@ 8.3 Calculation of Maximum Welding Current The maximum welding current JA) shall be calculated from t imum short-olrouit current fe obtained from the test of 8.2 by the afd of following formula: Ioy= haa X0.9 8.4 Calculation of Rated Maximum Welding Input Power ‘The rated maximum welding Taput poWSr shall ‘be caleulated Tom Cie primary current ‘he obtained from the test of 8.2 by the aid of the following formula, and expressed in kVA. Rated maximum welding input power = isxa.0x-#x rated input voltage where at rated maximum welding current 8.5 Calculation of Allowable Duty Cycle at Rated Maximum Wel Current ‘The al iowable duty cycle at rated wadimum fe duty cycle at rated maximum welt Sy ae anaes ‘shal ‘calculated from the following formula: e Allowable duty cycle at rated maximum welding current (%) : Rated capacity . Rated maximum welding input power ) *°? 8,6 Temperature Test The temperature test shall be carried out on welder transtoringF windlngs OF others In accordance with the following. Items: (1) Loading Method The output side of welder shall be loaded or Stort-alreilted. es appropriate, ‘Then the welder stall be continuously loaded until the temperature is almost stabilized, by applying an input voltage of the rated frequency, which produces the thermally equivalent continous current, to the primary side tap which can pass the maximum current, However, loading period need not exceed 4h. ‘The thermally equivalent continuous current shall be calculated from the following formula: Copyright by the Japanese industrial Standards Tue Aug 24 15:10:21 2007 ‘UTS Cx9305 8? Mm 4933608 0039273 1 a 9 C 9305-1987 @ Rated capacity Thermally equivalent continuous current = ———— POY _ x very Rated input voltage For water cooled welders, water of the specified flow rate on the nameplate shall be passed through the certain cooling system, (2) Method for Measuring Temperature of Winding and Secondary Conductor othe temperature oF primary winding shall be measured by roststance method, and the temperature of secondary winding shall be measured by thermometer method at a point where the temperature is considered maximum, in direct contact with the conductor. ‘The temperature of secondary conductor shall be measured by a thermometer. (3) Determination of Ambient Temperature For alr cooled transformers, the amblent temperature shall be tiesbured by a thermometer placed at an’ appriopriate point around the welder to be tested at a height approximately equal to one half of the hight of welder and 1 to 2 e@ meters apart from the welder. For water cooled transformers, the temperature of water shall be measured at the inlet port or in the water supply source close to the inlet port by a thermometer. If the ambient temperature varies during the temperature test, the mean value of the temperatures recorded every 30 minutes during the latter half of the total test period shall be taken, 8.7 Withstand Voltage Test A substantially sinusoidal voltage of 2 £ + 1000 V in terits oF the matinumt Voltage CE) which is induced in the primary winding when the rated input voltage is applied on the tap which gives the maximum current at a frequency of 50 Hz or 60 Hz shall be applied to the transformer, immediately after the temperature test, between the primary circuit, and the secondary circuit and the iron core connected together. However, the minimum voltage shall be 1500 V, and as regards welders providing switches in their main circuit, these switches and attached electrical components may be disconnected from ‘the main circult or the cooling water circuit for these switches may be removed at this test. 8.8 Mechanical Construction and Height of Working Place Welders shall be 8.9 Tests for Maximum Welding Force and Adjustable Range of Welding Force The dee ee ee aS aoe ore eee force caus Eween both fes, when compréssed alr! pneumatic pressure 490 kPa (5 kgf/cm?) or fluid of the specified pressure is fed under the standard electrode arrangement of the welder, shall be measured by a spring balance or by other means, ‘The adjustable range of welding force shall be obtained by measuring the welding force in the same way by adjusting the pressure control valve. 8.10 Test for Rigidity of Welder 8.10.1 Spot Welder —_Rigidity test of spot welders shall be made as follows: Copyright by the Japanese Industrial Standards, ‘Tue Aug 21 15:10:24 2007 [uIS ¢#9305 87 mm 4533608 0035274 3 mm: 10 © 9305-1987 (1) Upper Frame Deflection Test The deflection of the front end part of upper frame sl e Measured by a dial gauge @ as shown in Fig. 2, while the electrodes of the welder are so adjusted that the standard throat dimensions appear. when the electrode force 1s applied, and the pnoumatic pressure is so adjusted that the rated welding force is obtained. ‘The distance between the measuring point and the front wall of the welder body shall be the standard throat depth, This measurement, however, Is not carried out for rocker arm type one. (2) Lower Arm Deflection Test The deflection of lower atm shall be measured by 4 dial gauge @ as shown in Fig. 2, under the same conditions as those specified in the above item (1). (3) Electrode Skid Test The electrodes shall be adjusted so that the alectrodes become the upper A=0, the central A= B, and tho lower ‘2=0 positions in Fig. 3, and the standard throat dimensions appear when the electrode force is applied, The sliding plate as shown in the same figure shall be inserted between the upper electrode and e@ lower electrode, The skid between the upper and the lower electrodes shall be measured by @ dial gauge at the above three electrode positions. In this procedure, the radius of curvature of the electrode Used shall be 50 mm, and the total thickness of the sliding plate shall not exceed 30 mm, For welders having an arm length of exceeding 600 mm, the skid botween the upper and lower electrodes in perpendicular direction to the arm shall also be measured in the same manner. Fig. 2. “Measurement of Fig. 3, Measurement of Arm Deflection Electrode Skid ® : I q Needle roller siding plate e Copyright by the Japanese Industrial Standards Tue Aug 24 15:10:21 2007 7 VES C¥9305 87 MH 4933608 0039275 5 mm ity © 9305-1987 e 8.10.2 Projection Welder The surface of lower platen shall be placed on sts standard positon, ‘and the copper rod shown in Table 2 shall be placed on the centre of the lower platen. ‘The difference in parallelism of the’ surface of upper platen, when the upper platen is lowered by its own weight onto the copper rod (at no-load) and when the rated welding force is applied, shall be measured in accordance with the method of 8.11 (2), and the difference between the reading at no-load and the reading at on-load shall’ be obtained. Table 2. Dimension of Rod Units_mm Platen No. Diameter of rod Length of rod c lou 30 2 ee a Equal to standard e ag Fy platen spacing au 60 Remark: Platen No, is based on JIS C 9307. 8.10.3 Seam Welder ‘The measurement shall be carried out by the same method as that specified in 8.10.1. However, it is enough to measure the skid between upper and lower electrodes at one point with the specified electrode dimensions. 8.10.4 Butt Welder A steel rod having a cross-sectional area corresponding to the maximum welding ability of a welder shall be clamped in each of the electrodes on the fixed stand and movable stand so that the standard electrode spacing appears, as shown in Fig. 4, ‘The end of one steel rod shall have a spherical surface with the radius of curvature of 100 mm. A gauge plate 4 (mm) long shall be attached to each of the above steel rod as shown in the figure. The deviation of distance between the two gauge plates when the rated welding force @ is applica between the both electrodes, shall be measured, and the inclination & shall be obtained from the following formula. The gauge plates shall be attached {in the direction which is likely to cause the maximum value of b~ by. 1000 where fy: distance between gauge plates at no-load hy: distance between gauge plates at rated welding force Copyright by the Japanese Industrial Standards Tue Aug 24 15:10:21 2007 12 UIS Cx9305 87 MMH 4933408 OO34927b 7 mm | © 9305-1987 Fig, 4. Measuring Method of Deflection of Butt Welder Feces SE mere on, Unit: mm {— Gauge plato Rina Bo Z ae | 8.11 Mechanical Accuracy Test of Projection Welder The mechanical accuracy test of a projection welder shall be made as follows: a) (ay (b) (ce (2) Measuring apparatus The measuring apparatus to be used for the items @}1e Ca) shall be as follows: ‘The accuracy of indication of the test indicator shall be within 0.003 mm over the service range. If dial gauges are used, they shall be the gauges specified in JIS B 7503 of JIS B 7509. The straightedges specified as special grade in Table 1 of JIS B 7514 shall be used. ‘The aquares specified as special yrade:in\‘Table 2 of JIS B 7626 shall e used. Parallelism of Surfaces of Upper and Lower Platens The upper platen Biull ‘be placed at Tis Toweet-end position, the Tower platen shall be in its standard position, and a straightedge shall be placed on the upper surface of lower platen perpendicular to the welder body, as shown in Fig. 6. A dial gauge shall be placed on the straightedge with its gauge part in contact with the lower surface of upper platen and moved along the straightedge (measuring line), ‘The maximum difference between the gauge readings at 3 points Le. at the centre and both edges (positions 15 mm from the both ends are excluded) on the measuring line shall be taken as the measured value. ‘The measuring points shall be 6 points in right and left, front and rear directions of D-E-F and H-E-B as shown in Fig. 5. For welders whose lower platen is so designed that the inclination in right and left direction is adjusted at every time when the platen is moved upwards or downwards, the measurement shall be made along the front and rear direction only. ‘At the thme of measuring, compressed air in the pressure cylinder shall be completely exhausted. Copyright by the Japanese Industrial Standards Tue Aug 24 18:10:21 2007 JIS Cx93DS 87 MM 4933608 0039277 9 a 13 C 9305-1987 Fig, 5. Measuring Points for Accuracy Fig. 6. Measuring Method of Parallelism of Inspection of Platen Upper and Lower Platen Surfaces = Unit: mm ee Toe end st Ue 28 pao Ay ft 7 [Ke wee a ote a eee “ESE Tp evar my (3) Squarencess of Upper Platen's Motion A straightedge shall be placed Site tpper sitfece of lower platen, a square

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