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Calibration Validation: Rev 1 January 2010 Calibration © TWI LTD 2010
Calibration Validation: Rev 1 January 2010 Calibration © TWI LTD 2010
2 Terminology
BS 7570 defines the terms it uses, such as:
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 the controls are functioning properly.
3 Calibration Frequency
BS 7570 recommends re-calibration/validation at:
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.
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 given, 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.
Voltage
The standard emphasises that for processes where voltage is pre-set (on
constant voltage the power sources) the connection points used for the
voltage meter incorporated into the power source may differ from the arc
voltage, which is the important parameter.
Power
source
2 3
1
7 Wire feeder
4
Arc voltage
5
6
Even if the power source voltage meter 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:
• It is 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 arc.
• For MMA, it is 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
a change from an air 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 return cable at point 6.
The Standard gives guidance about minimising any drop in line voltage by
ensuring that the:
The Standard gives data for line voltage drops (DC voltage) according to
current, cable cross-section and length (for both copper and aluminium
cables).
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.