6207 Jim Snow Way, © P.O, Box 22847, Ch T. J. SNOW COMPANY, INC. ee oe a TJ. SNo South’s Recognized Leader in Resistance Welding ‘7. L “Sim” Snow embarked upon a quest on Apsil 1, 1963, to buitd the South's recognized leader in resistance welding machinery sales and service —T. . Snow Company, Inc Joined in 1973 by his son and now CEO, T-J."*Tom” Snow, J. the ‘company currently ernploys more than 60 highly-skilied professionals and services customers worldwide with its four divisions: New Machin- cry, Used Machinery, Supplies and Service. T. J. Snow stocks more than $1 million worth of competitively priced Resistance Welding supplies including: + Welding Electrodes + Welding Transformers + Welding Controls + Weld Monitoring Equipment + Recirculating Water Cooling Units + Seam Welding Wheels + Accessories + Copper Rod and Bar Stock + Used/Rebuil Guaranteed Welding Transformers and Welding Controls Please See T.J. SNOW, Page 2T. J. SNOW COMPANY, INC. Recognized Leader in Resistance Welding Continued from Page 1 Asexperienced private pilots, our service technicians are xuniquo in the United States. Available 7 days. week, 24- hours # day, 365 daysa year, our technician pilots and company planes can svete caster dovatine and ‘luctuating commercial travel coxpense, We also repair welding transformers and most majer brands of| ‘welding controls at our plant in Chattanooga, “Tenn, at rates that are below factory repair Pee costs. 2 In-plant Resistance ‘Welding Seminars and seminars at TJ. Snow Company are offered by our 7” Service Department. ‘Our Machinery/Roboties Division promotes NEW & USED Single Phase and Three Phase standard machines. Nor- ‘mally 600 are in stock, including: + Bench Type Projection/Spot + Rocker Arm Type Spot + Press Type Projection/Spot * Seam and Flash/Butt Welders. And: NEW & USED Portable Spot Welding Gun Stations. ur standard line of machines include lean, mean, lowfat smulti-gun spot welding machines, a ‘output press-type combination projection a ‘and our newest “Slim Line” design spot and projection. Using standardized components in our CAD systei, Snow | ‘can manufacture more competitively priced machines. To provide our customers with welding systems that are a cost-effective alternative to mamual welding, We also Design & Build: + Single Station and Complex Welding Fixtures and Tooling + Turnkey Robotic Spot and MIG Welding Cells (since 1981) + Dedicated Mig, Tig or Plasma Are welders + Muligun Resistance Welders ‘1.1, Snow Company will Remanufacture from the ground up oustomers” existing machine(s) or offer additional ‘machine(s) with one (1) year. J. Snow Warranty om i ‘materials and workmanship —meeting NEW Machine Specifications. Purchased items carry a pass thru war~ ranty, Remanufactured machines can be turned in 3t0 4 ‘weeks after arriving at our facility. Please send sample paris, part drawings and specifica- tions to us to evaluate and prepare a formal quote. We ‘will go that extra mile to help you with your welding requirements with a sales force that can be in your plant, not just on the phone. Feel free to use our toll-free number for REQ or order- ing, 1-800-NOW-SNOW (800-669-7669) ot FAX your requirements tous at (423) 892-3889. For other inquiries, please call (423) 894-6234.ConTENTS Tid, SHOW sessesrsesssnees Resistance Welding 10 most common variables... Pressure Phase shift heat control ..... Slope .. Transformers & Secondary circuits .. Recommended preventive maintenance... Trouble-Shooting Resistance Welders... Choose the Right Resistance Welder... Buying the ‘Right’ Spot Welder .... Tips to Buy Right Rocker Arm Spot Weldei Set up of Standard Machines. Weld Quality sss Setup Charts .. Glossary .Resistance WELDING Resistance Welding isa high-speed method of joining metals by using pressure and electric heating under accurate control, without the addition of any welding material. ‘The welding force is applied by the welder, eliminating extra tack welds or holding clamps, A Resistance Weld can be made ina fraction of a second. I, The Resistance Welding Process 1. Heat is Developed by the Resistance of the Metal ‘The heat for the weld comes from the resistance of the metal to the passage of current. ‘The pieces are clamped between electrodes at the point where the weld is to be made. A. pulse of current forms the weld 2. The Current Is Controlled Electronically ‘The extent of the heating is determined by the amount of currert and the time it flows. ‘The required heavy amperage is obtained by the use of a transformer with many _ fF» Primary tons and usualy one secondary tra, This cures fed through he Se weld by the clamping electrodes. The time of the curtent flow is best con- Pye electronically. This accurate method can give adjustment of the time of current flow to within 1/120th of a second, so that even the thinnest metals =? can be welded. A wide variety of electronic controls are used for this purpose. When the adjoining metal faces have been melted to form a nugget, the electrodes force thers together into a homogeneous weld. Resistance Welding Pays offin Quantity as well as quality. In addition to achieving a quality weld, with proper control set- tings the welding process can be continued as fast as the ma- terial can be fed into the machine, The machine's productivity depends almost entirely on the speed with which the work is brought to it and taken away. Cooling the work quickly under pressure eliminates distortion and straightening operations. No ‘grinding is necessary to eliminate bead. With controls properly set, there is no buming of the work III. Resistance-Weld any Metals ‘Most metals that are welded in industry can be welded by resistance welding. The process is best applied to light and medium gauges of metal IV. The Resistance Welding Process1. Spot Weld The Spot Weld is the most common of all resistance welds, It is made by clamping the work pieces between two rodlike electrodes connected to a i high-current low-voltage transformer. The current through the metals is localized by the electrodes and the pressure. When the metal has melied, the electrodes force the pieces together. After the current is shut off, the electrodes hold the pieces in place while the weld cools. 2. Projection Weld Projection Welds ate made in much the ame way except ut tho GSR SEES il current is localized through projections, stamped or otherwise processed ‘on one of the pieces before welding. A projection can be a ridge of some length, a small teat, or a number of either. The work pieces are clamped between electrodes of consider- abic area, either flat or formed to fit the work. The current divides equally among all the projections, making welds of even strength. The heating and the pressure continue until the projection is deformed sufficiently to bring the work pieces flat against each other, 3, Seam Weld rotating wheel electrodes. One of the wheels may be replaced with a flat backing electrode which supports the work piece throughout the length of the seam. Thoroughly prossure-tight seams are made in this manner. t ‘A Seam Weld is a line of overlapping spot welds made between Se j Roll Spot Weld ‘A Roll Spot Weld is a line of spot welds made with whee! electrodes, but the welds do not overlap. The strength of the joint produced is equivalent to a row of welds made with spot welder electrodes. Greater speed is attained with the continuous rolling process. Upset Butt Weld ‘An Upset Butt Weld is an adaptation of resistance welding ge-—.—*y 3 tiple wtoscendsaejonctniiaucietap beat Cae] Cem] clectrode is a clamp that holds one piece. One electrode ‘moves to engage the surfaces to be welded, and current and force are applied, as in spot ‘welding, to heat the joint. When the metal fuses, an upset weld nugget is formed, The electrodes hold the pieces in place while they cool. 6. Flash Butt Weld : - work is held by the same clamp-type clectrodes. However, the heat is Los produced by arcing and by the burning of geseous metal in the atc, The pieces are slowly moved together as the metal is burned away. When properly heated, the pieces are forced together and the current is cut off. The plastic metal and impurities formed by combustion are forced out. Only clean metal is left in the weld. The work coo!s in place in the clamps, as in upset butt welding,Ten Most Common VarIABLES IN Resistance WELDING 1, Current Three basic factors required to produce a weld ate current, pressure, and time. Therefore itis of paramount importance that only a minimumn variation in welding current be tolerated. If insufficient welding current is used, either no weld or a defective weld will result, Iftoo much current is used, the following can occur; excessive heating of the weld, buming, metal expul- sion, indentation, sheet separation, splattering, and burrs. 2. Pressure Pressure is one of the most poorly regulated of the three basic factors but is vitally important in producing consis- tent spot welds. Insufficient pressure will result in weak welds, expulsion, surface burning, and other defects. ‘Too much pressure will result in indentation and — insufficient welding heat because of lowered contact E— resistance. A. Interface Resistance Contact resistance changes according to the amount of pressure applied on the welding area, ‘Contrary to popular belief, if the pressure is increased on the welding area the welding current ‘must be increased proportionately to effect the same amount of heat rise. A simple rule of thumb is: ‘As applied pressure is increased, the resistance dimmin- ishes,requting more curentto produce a weld because of less resistance (which creates heat). Conversely, as applied pressure is diminished, resistance increases, requit- ing less current to weld because of more interface resistance, (which creates the heat). When the interface resistance is dimin. ished becanse of increased pressure, the current is more easily con- ducted between the parts but with considerably less heat effect. 3. Time Weld time is of eritical importance, especialy for light thicknesses of steel, also forthe ‘welding of parts of aluminum, copper, and other high conductivity metals and metals having vvory narrow or critical plastic temperatures, ‘The length of welding time should always be directly coordinated with settings of welding current. For example, if the required amount of welding current necessary to produce a satisfactory weld in a given time is reduced, then the length of weld time must be increased to produce the same heat; conversely, if the welding time is reduced to a shorter period, the amount of current required will be greater,The Human Element ‘The human element is the least consistent variable in spot welding because of the variations encountered in speed, attitude, diligence, capability, carefulness, and many other factors. ‘Though skilled operators have been responsible for producing highly successful products, some of them have produced some of the most misetable specimens imaginable. If parts are carelessly placed in improper position on the machine, if welding is done at the wrong angle, if tips are allowed to mushroom the product is certain to be rejected. On the other hand, if crafismanship is used, perfection in fabrication is not too difficult ‘Though all the remaining nine variables in a welding setup might be perfect, the human clement, because of poor attitude, can destroy perfection in the final result. On the other hand, ‘with the other nine variables at less than maximum efficiency, the human element, with proper skill and attitude, can still produce excellent results. 5 . Machine Characteristics (One of the variables of importance is that group of machine characteristics such as power factor, welders impedence, location of transformer and copper secondaries of the machine, the pressure means, attachments and fixtures; all of which determine the efficiency of the machine and any one of which could contribute to the possibility of variation in production. Although litte can be done to minimize the variables of the machine characteristics after proper installation, the power supply can be kept within a narrow plus or minus range and other disadvantageous factors, such as a low power factor, can be corrected by electrical ‘means, 6. Type and Condition of the Welding Machine ‘The sixth general variable is the type and condition of the welding machine, specifically its physical geometry, the movement of the electrodes, the type, ic. rocker arm, press welder, flash welder, ete. ‘The condition of the bearings, the secondary contact joints, the aligament and rigidity of the machine, the aireylinders, rams, dies, ete., are possible variables which should be minimized from the start by good construction and by vigilant maintenance. 7. Condition of Dies and Electrodes ‘This seventh variable is the one which can be most readily detected and which most readily occurs. Particulat attention should be paid at all times to assure that dies and electrodes are dressed to as neatly original form as possible, and that they ate properly aligned and main- tained, and replaced when wom or damaged so that they are always at the correct height and of the proper size for the particular application Improperly dressed or enlarged electrodes are the cause of a very high percentage of imper- fect spot welds and by its correction will be cured most of the exstwhile evils commonly attributed to spot welding. 8. Condition of Material and Surfaces of Material ‘The eighth variable, which is far to commonly overlooked, is the condition of the metals and the surfaces of the parts to be welded. Such surface conditions as accumulated rust, scale, slag, burrs, oxides, etc., are commonly left uncorrected before welding. Coatings on materials such as zine, tere, etc, are sometimes not compensated for, with disastrous results from sticking or pickup of coatings on electrodes, causing improperly made welds. The wrong type of alloy for tips can add to these difficulties.(Often the welding of air-hardenable steels, dissimilar and unweldable alloys, metals of varying, ‘melting and plastic teraperatures, are attempted on machines not having the special facilities forthe specific job and the result is disappointing. Satisfactory production of resistance welds on metal parts can best be achieved only after such factors as surface condition, coatings, etc., have been carefully taken into account in establishing settings of machines and controls, 9, & 10, Throat Depth and Throat Height The ninth and tenth variables, throat depth and throat height, present two of the most easily correctable conditions, The variables of height and depth directly affect the other factors of current pressure, time, human element, and machine characteristics.NOTESRelative Resistance Values of a Spotweld Inlet Water Tube Electrode Tip Water Return ~~ ~~~ Tip Contact Point — _ Spot Weld — _ R—Interface — [===> R— Material — R—Electrode ~~A Goop Resistance WELD I. AGood Weld = A Proper Combination of Three Variables Pressure + Current + Time 4. The Importance of Pressure A. Tt forces the material to be welded in intimate contact. BB It tends to break through films found on surface layers of the material to be welded C. It presses the sheets to be welded together and restriots the passage of current to this area . It reduces the formation of porosity and cracks in the welded area. E. A substantial pressure maintains a low value of contact resistance between the welding tips and sheers to be welded, reducing the tendency of sticking or alloying of the electrodes to materials being welded. ‘The influence of pressure on the quality of the spot welds is important. The force supplied to the work to be welded, the method of application, as well as the inertia of the moving parts greatly influence the quality ofthe spot weld. ‘The nature and change of the contact resistance during welding is a complex phenomenon, involving such factors as the physical properties of the surface films, persistence of the pressure application, the variations of the physical properties of the metal itself and the film surfaces in relation to the elevated temperature, [As the pressure is increased, the contact resistance decreases, In accordance with the heat formula for a given condition of the materials being welded, this decrease in resistance will require a greater amount of heat in the same time interval. Therefore, the deorease in resis- tance, with increased pressure, does demand more current to achieve the result of a good weld. It might appear desirable to Decrease the pressure and thus increase the resistance enabling the use of a lower current consumption, However, the use ofa low pressure below the specified amount is conducive to several undesirable problems. It may cause sparking and sticking between the electrodes and sheets resulting in rapid clectrode deterioration and an unsatisfactory appearance of the spot weld, Also, it may not produce sufficient forging pressure to prevent porosity or cracks in the weld area. Another factor is the lower tensile strength of the weld. The spot welding of low carbon steels has many variables and is dependent upon the thickness of the thinnest outside piece. The changes in electrode force, weld time, and weld current are quite large. For instance, the welding of a standard piece of SAE 10-10 low eazbon mild stee!, 032" thick, requires a net electrode force of 400 Ibs, with ¢ recommended weld time of 8 cycles and a welding secondary current of 8,000 amps. The minimum weld spacing again is quite important, with a recommended spacing minimum of 1/2” for the 032" mild steel. As an objective comparison, a piece of .109" thick 1010 mild steel requires 1,600 Ibs. of net electrode force and a weld time of 23 cycles. The welding current increases to 17,500 secondary amps.From this, it is seen that a good weld must consist of changes in current, time, and pressure as the material thickness increases or decreases. Any attcmpt for a compromise on any of the thrce variables will result in something less than what might be desirable for a sound, struc~ turel weld. From the Above, it Proves the Equation: Pressure+ Current + Time = A Class (High Strength) Weld AIR CYLINDER PRESSURE CHART AIR CYLINDER DIAMETER PSI 35 4 im 6 oe 8 9 10 i 12 | 50 60 80 (9S 100) 490) ee eee 565 10 95 125 160 195 280 385 500 640 780 1130 15 145 190 240 295 425 580 755 955 1180 1700 20 190 250 320 390 565 770 1005 1275 1570 2270 25 240 310 400 490 705 960 1260 1590 1965 2835. 30 290 370 480 590 850 1155 1510 1910 2355 3400 35 335 440 S60 685 990 1350 1760 2230 2750 3960 40 385 500 640 785 1190 1540 2010 2550 3140 4530 45 430 560 715 885 1270 1730 2260 2865 3535 5100 50 480 625 795 980 1410 1925 2515 3180 3930 5650 55 530 690 875 1080 1550 2120 2770 3500 4325 6230 60 580 750 955 1175 1695 2310 3020 3820 4715 6800 65 625 810 1035 1275 1830 2500 3270 4140 5110 7350 70 765 875 1115 1370 1975 2700 3520 4450 5500 7930 75 720 940 1195 1470 2120 2830 3770 4775 5890 8500, 80 710 1000 1270 1570 2260 3080 4020 5100 6280 9050 85 815 1060 1355 1670 2400 3270 4270 5400 6670 9620 90 865 1125 1430 1765 2540 3460 4525 5725 7065 10200 95 910 1190 1515 1860 2680 3655 4780 6050 7460 10750 100 960 1250 1595 1960 2820 3850 5040 6360 7655 11300Puase SHirt Heat ContTROoL I. Control ‘Heat’ or Welding Current 1. SCR Contactor ‘The SCR contactor is basically used as a switch to tum welding current “on” and “ofl.” SUICON CONTROLLED RECTIFIER (SCH) CONTACTOR IL, Fundamentals 1, Coil Voltage When the armature coil of a two pole generator is revolved, a voltage is induced in the coil that will rise from 0 to a maximum value, then decrease to zera again during the positive half cycle ‘As soon as voltage diminishes to a zero value again, the direction of the voltage is versed. Itrises again to the same maxinem value and falls to zero during the negative half-eycle just as this occurred curing the positive half-cycle. There are 360 degrees (line 2-B), fo one complete cycle and in 60 eycle operation, this sequence is generated 60 times each second. This configuration is known as a Sine Wave and is used to represent an altemating voltage or current. 2, Electronic Heat Control ‘An electronic heat control is a “phase shift network" that controls the voltage wave, By applying a small voltage between the SCR’s gate and cathode the SCR is gated on and | vwill pass weld current . The point the SCR fies determines the amount of heat that witl ‘pase through the weld. This selected point will occur during the positive half cycle of the voltage wave, and exactly 180 degrees later in the negative half eycle of each complete | cycle of weld. SCR ring 9IIL. Slope Control Slope control is another type of heat control. It can be up-stope, down-slope, or up-down slope and it isan automatic electronic control that gradually builds up or gradually de- creases the amount of current, or “heat,” applied to a weld through the phase shifting of the firing tubes, ee 1, Slope Control Uses A. High Carbon Steel This can be especially advantageous when welding high carbon steel as it allows the ‘weld to cool slowly, thereby eliminating brittleness and cracking. B. Galvanized Steel Another use for this type of control is in the welding of galvanized steels. A slow buildup of heat (up-slope) allows the zinc to melt and flow away from the electrodes. erent care oat Goncrted trough workpneovitiouthest pecan 2. Slope Control Advantages |A. Less power required due to lower electrode forces that means less indentation and better appearance of welds. B. Less tip pickup due to less flashing. C. Longer electrode life due to lower forces and low pickup. D. Less material cleaning required due to Low initial heat that burns off impurities. E. Less critical welding schedules because of consistency of heat action through up-down slope contro.Simplified Diagram of a Welding Circuit Typical Transformer ConfigurationMultiple Gun Connections with Dual Secondary Fixture-TypeTransformer (4) Welding Guns the’ a Transformer Indirect Multiple Spot Welding (2) Welding Guns Cables ‘Transformer Direct Spot Welding (2) Welding Gunsoe Push-Pull Multiple Spot Welding (4) Welding Guns Transformer ~~ Shunt Die Series Multiple Spot WeldingFuse & Wire Sizes ror Spot WELDERS 230 - 240 Volt 575-600 Volt 460-480 Volt Sg [a= | [Maat [reese] a 10 40 6 20 8 20 8 15 60 ae 25 8 30 8 20 80 2 35 8 40 6 30 125 2/0 50 6 60 4 40 175 4/0 70 4 80 2 50 200 300 MCM. 90, - 100 0 75 300 400 MCM 125 20 150 3/0 100 400 600 MCM 150 3/0 200 40 125 500 (2) 300 MCM. 200 250 MCM 250 300 MCM. 150 600 (2) 400 MCM. 250 300 MCM 300 400 MCM 200 | 800 |@soomcm] 300 | 400Mcm | 400 | 300MCM 250 1000 | (2) 600 MCM. 400 500 MCM 500 600 MCM 300 1200 | (2) 500 MCM 500 600 MCM 600 750 MCM 400 800 500 1200 Am Increase of 10 percent for each 25 feet beyond 100 feet of ino Note: Use This Information as a Guideline Only. fine wit is recommended.STANDARD PRODUCTION TEST PROCEDURE FoR Resistance WELDING TRANSFORMERS I. Dielectric Test 1. Insulation Resistance (Megger Test) ‘The following miniraum insulation resistance should be obtained for new or used trans- formers. The measurement should be made with a 500 ot 1000 volt Megger and the transformer windings should be at room temperature (approximately 20C). A, 220 Volt Transformers Primary to ground 5 MEGOHMS Primary to secondary 5 MEGOHMS B, 460 Volt Transformer Primary to ground 6 MEGOHMS Primary to secondary 6 MEGOHMS C, 575 Volt Transformers Primary to ground 6.5 MEGOHMS Primary to secondary 6.5 MEGOHMS Dirt accumulation, moisture in the insulation and age of the insulation have a degrading 4 on the insulation resistance. Therefore, on used transformers, the windings should be cleaned and dried out before the Megger Test is made. 2. High Potential Test (HIPOT Test) “The Hipot testis a destructive test and therefore should be applied only if required, New Transformers Primary to secondary 1500 RMS Volts, 60 Hertz Primary to ground 1500 RMS Volt, 60 Hertz Secondary to ground 1000 RMS Volt, 60 Hertz ‘Used Transformers Primary to secondary 600 RMS Volt, 60 Hertz, Primary to ground 600 RMS Volt, 60 Hertz,IL. Open Circuit Test (Secondaries Open) 1, Secondary Voltage netgize the primary of the transformer with the name plate primary voltage and measure the secondary voltage on cach tap. The test should be started on the lowest tap and higher taps measure in succession. The low and high tap voltages should closely corre- spond to those shown on the name plate. Any deviation of the applied primary voltage to the name plate primary voltage will change the secondary voltage in the satne proportion. III, Water Flow and Leak Tests 1. Flow Test Connect transformer to a water supply and adjust flow to the water flow shown on the ‘name plate (generally | GPM.) Measure the pressure at the In and Out water connec- tions. The pressure differential should not exceed 7 PSL 2, Leak Test The transformer must withstand 100 PSI without leaking, ‘This test ean be performed with water filled secondaries pressurized to 100 PSI ifall cooling passages are exposed to enable visual inspection for leaks. If cooling circuits cannot be visually inspected, pressur- ize the water passages with 100 PSI air pressure and close off the air supply. A pressure gauge installed into the closed water circuit must maintain the original pressure for at Jeast 10 minutes. It is important that the water connections, shut off valves, et. are absolutely leak-tight 10 avoid erroneous results,TRANSFORMER SECONDARY VoLTaGeE VS PRIMARY Turns at Primary Vottace or 220 59125: bo 46 47886 256° 126 1745” 166 1.325 47 469 87 253 127 1.73 167 1315 \ ME 458 88 25. PS 172. 168 1.31 49 449° 89 92.475 129. 1.705 169. 1.30 reso leg Toasts a 1 sum cpmTRANSFORMER SECONDARY VOLTAGE VS. PRIMARY Turns AT Primary Vottace or 440 2: 2 2.59 218 4b 10.72 “#2 10.48 2 #257 214 7 43 10.24 BUD ALG SAP CAPS OAS 215120459258 1,705 4410.0 5.06 130: 3.384 193 2.54 216 259 17 By. 9.76 5.0 1313.36 Bd 2.53 2EF 2.025 260 1.692 “46 “9-56 BO °4.95° 132 G.334" 175 “DSI 218 92.02 261 1.685 42. 9.38 489 133 3.31 176 2.5 219: 2.01 262 1.68 48 9.16 484 134 3.28 177 2485 220 2.0 263 1.673 4985 ATB > 139° 3:26 178 12476 221 1.99". 264 1,666 50 8.8 4.74 1363.23 199 2.455 222 198 265 1.66 “ST 8.66 468 137 3.21 180 244 223 1.97 266 1.655 528.46 B64 138 SABE! 181 QAR 224.965 267 1.648TRANSFORMERS / SECONDARIES I, Transformers 1, Construction 2, Tap Leads — Secondary Voltage 3, Insulation A. New Transformers 1500 V Hi-Pot B. Used Transformers 600 V Hi-Pot 4. Transformer Secondary Connections A. Fixture Transformers Series/Parallel vs. Voltage B, Machine Transformers Pad Sizes II. SECONDARIES 1. Copper Size A. Water Cooled B. Air Cooled 2. Laminated Shunts 3. Secondary Connections ‘A. Joint Condition B. Impedance Changesfox £2 ~ NOUS. 1 ue Roan eyes ainer ae : o3n YAWYOASNVHL SdAL FYNLXIS Bekina_ccrntners eet eaNOTESRECOMMENDED PREVENTIVE MAINTENANCE For RESISTANCE WELDERS Caution — all appropriate lockout or other safely procedures should be strictly followed during any maintenance being performed on these machi I. Tooling Proper water: Water should be clean and free from contaminants, flow should be adequate and temperature should be appropriate for the application. Repair any leaks, ‘Tip condition: Tip condition should be monitored continuously and the tips should be maintained in as nearly alike-new condition as possible. Contact area: All contact areas should be kept clean and frce of corrosion with all connections made up tightly. IL, Transformer “Water: Water should be clean and fiee from contaminants, flow should be adequate and temperature should be appropriate to cool the transformer. Repair any leaks. Tap switch: Must be kept clean with all connections tight. The wiper(s) and contacts showld have enough tension to make a good electrical connection without being so tight thatthe tap switch is difficult to operate. Grounds: All ground connections and/or ground reactors should be kept in good and undam- aged condition and connected to a good earth ground. III. Secondary Insulation: One half (either the upper or lower depending on the particular welder) of the ‘copper secondary should be insulated from the machine frame while the other half should be grounded to the frame. The insulation must be maintained in an undamaged condition and free foils or other contamination which could lessen its insulating capability. Clean joints: All joints and connections between sections of the copper secondary must be kept clean and tight for good electrical conductivity. The use of any components or sealing materials which could block the flow of current must be avoided. Any corrosion or other contaminations in these connections must be removed periodically. Water: All the water tubes and hoses must be kept in good condition and an adequate supplyof clean, cool water provided for proper cooling of the secondary copper. Tighten: Periodically all bolts, holders, adapters, etc., should be checked for tightness to ensure that a good current path is maintained, IV. Air system Filter: The air flter/water-trap should be kept clean and drained as needed for good operation. Frequent draining may be necessary if the welder is operated in an environment with high humidity conditions, Regulator: The air pressure regulator should be observed for consistent operation and should bbe provided with a gauge to indicate the pressure setting of the regulator. Oiler: The oiler (lubricator) must be kept in good operating condition and adjusted properly. An. adequate supply of light oil for lubrication of the air eylinder(S) and valve(s) must be main- tained in it. Approximately one drop of oil delivered per twenty times the machine is eycled should be sufficient Cylinder: All seals and wipers should be kept in good condition and any leaks corrected promptly. Any equipment connected to the cylinder such as flow controls or quick exhaust valves should also be checked for proper operation. Cylinder shafts and walls should not be damaged in any way. The eylinder should operate smoothly while extending or retracting. Valves: All air valves should be Kept clean and all air and electrical connections in good condition. Mufflers should be in place for operator protection, Air leaks: The entire system should be checked for leaks on a periodic basis. This check should inelude inspection of the valves, hoses, fittings, flow controls, cylinder(s), filter(s) regulator(s}, lnbrieator(s), gouges, pressure switch(es), etc V. Control SCR or ignitron tbes: The scr or ignitron tube contactor should be checked for loose connec- tions and should be Kept clean and dry. Failure to weld ot excessive noise (transformer rattle) while welding could be indicative of a contactor failure. Alltiming: The control timing functions (squeeze, weld, hold, and off) should be operated throughout their ranges to verify that they are functioning and responding properly. (While ‘checking the weld timing, the heat control should be adjusted toa low setting.) Heat control: The heat control (percent current) may be checked — although rather crudely — by making gross changes in its settings, then sample welding and observing if the zesponse ‘was correct. More precise checking can be done by the use of a weld scope or a weld checker which can read the actual secondary current developed when the welder is fired. Such an instrument can detect the small changes in current which should be the result of incremental changes in the heat coutrol setting. ‘Water: As with the other components which ate water cooled, the control (specifically the 11 Se Conn * esac len Tig aaacontactor) requires an adoquate supply of clean cooling watet. Both supply and return hoses as well as any jumper hoses mast be at least 18" (eighteen inches) long. There must be no leaks and the cooling water should not be so cold that it causes condensation on the contactor orother electrical or electronic components. VI. Mechanical Ram: Check the ram and slides or rollers for smooth operation and minimal side play. Lubri- cate and adjust as necessary. Verify the proper operation of any fast follow-up device(s) such as springs or diaphragm cylinders, Bushings: Check for wear and looseness or excessive play in bushings or bearings at any hinge points — particularly on rocker arm-type welders. Lubricate and adjust or replace as | necessary, Heads: Searn welder heads require regular (daily) checks for proper lubrication with the ‘correct grease or oil. Do not over lubricate. Keep welding wheels tight and clean and cool, zt VII. Electrical Connections: All connections must be kept clean and tight and free of foreign matter and Debris. Fuses: All fuses should be checked to determine that they are not blown, that they are of the proper size and rating, and that they are ftee of corrosion. ‘Wires: Check placement of wires and wiring hamesses to be certain that no wiring is chafing ‘or rubbing against anything which might cause damage. Also check for frayed or burned insulation Clean: Keep both the interior and the exterior of the welding control clean. Carefully blow out the interior with clean, dry air to remove any accumulations of dust, ete. Blow off and/or wipe down the exterior as needed. Do not allow tools, parts, sag, dir, trash, etc. to accumulate on orn the welder or the welding control. The welding control enclosure is not a locker for storage of any items other than the appropriate wiring diagrams and operating manual. WATER QUALITY Cooling water requirements for trouble-free operation and reduced maintenance, + Resistivity greater than 2000 ohms-CM @ 25 degrees C. + pH between 7 and 8 (neutral or slightly alkaline). + Mineral content to be not more than 20 ppm, chlorides. + 10. ppm, nitrates; 100 ppm, sulfate, + Total solids content not more than 250 ppt. + Total hardness (as caleium carbonate) not more than 250 ppm. een ng gM Sim mannRECOMMENDED PREVENTIVE MAINTENANCE FOR RESISTANCE WELDERS Frequency Daily TOOLING Weekly Monthly Six Mo's ‘Annually Proper Water xx Tip condition As Needed Contact Area XX TRANSFORMER| Water XX [Tap Switch [Ground xX SECONDARY [insulation [Clean Joints Water fFigiten AIR SYSTEM Filter Regulator xx Oiler ICylinder Valves eb [Air leaks XX CONTROL, [Ser or Tubes Timing, XX [Heat Control Water Xx MECHANICAL Ram ae [Bushing Heads XX ELECTRICAL [Connections [Fuses XX, Wires xX (Clean XXNOTESTrousie-SHooTING RESISTANCE WELDERS At THE Root OF THE PROBLEM I. Air System 1. Valves? 2, Regulator, Filter, Oiler, ete.? 3. Cylinder (Packing, “o” Rings, Seals, ete)? 4, Pressure Switches, Limit Switches, etc.? IL, Welding Control 2 1. Tioning Funct 2. Firing Signals? 3. Inputs (Foot Pedal, Palm Buttons, PLC's, et 4, Outputs (Valve, Relays, Voliages, ete.)? III. Transformer 1. Tap Switch? 2. Windings? 3. Secondary Connections? IV. Electrodes 1. Correct Material for Job 2. Properly Dressed, or Cleaned? 3. Correctly Lined Up? 4, Water Tubes Properly Installed? 5, Proper Water Flow? Trous_e SHOOTING RESISTANCE WELDING EquIPMENT Warnine!! 1, Find out if there is power to the welder, and ensure that al fuses are good After it is found that the power and fuses are good, proceed as outlined below. 1, Localize the Problem to Specific Welder Process of Elimination A. Isolate the Problem Consider the welding machine as five sections. Valuable production, time can be lost ‘working in the wrong section. The five sections are: 1. Welding Control 2. Pressure System (Hydraulic/Pneumatic, ote.)3. Transformer (Primary/Secondary). 4, Electrodes’ Tooling 5. Material used in the product. B, Do Not Proceed Unless the Control Functions Correctly 1, Control Power, 2. Initiation operating correctly. 3. Control has a proper weld schedule. 4. Control has timing functions ora schedule. 5. Voltage to valve when initiated 6. Emergency Stop open or closed. 7. Pressure Switch set correctly. C. Check the Air System 1. Air supply to the Welder. 2. Filter, Regular, and Oiler are functioning properly 3. Solenoid Valve operating, correct voltage to coil 4, Pressure Cylinder packing holding pressure or leaking air. 5, Flow Controls set. 6. Clean and dry air supply is highly recommended. D. Welding Transformer and the Secondary Welding loop This is the main path for the current flow through the material that isto be welded. A problem here can cause major problems that are often overlooked. 1. Tap Switch on correct setting. 2. Tap Switch making good connections at each setting. 3. All transformer leads are tight t tap switch and in the contactor cabinet. 4, All secondary connections are clean and tight. The secondary joint should either be silver plated or have copper lube applied for better conduction of the heavy ‘curtent required on the secondary side. E, Tooling and Electrodes 1. Tooling and/or electrodes should be lined up properly and feveled as necessary for proper fit-up to the part being welded 2. Spot Welding tips need to be kept at a constant size and shape to make welds on a consistent basis, Tip condition is one of the most neglected of al the factors that cause bad or inconsistent welds. 3. Proper water cooling for the electrodes or tooling is essential for making good quality welds. Without proper cooling, electrode life is shortened and weld quality deteriorates very rapidly. F. Materials Material plays a very important part in achieving acceptable welds. Some materials may not be up to the standards that are required to make good quality welds, Not all ‘materials are consistent in the elements used in their manufacturing. High carbon steels can be hard to weld. Galvanized coatings can vary in thickness, in the qualityRESISTANCE WELDER PROBLEM SOLVING FLOW SHEET Does the thing work?aye 20003 A SONDOM TOUNOS PHD OULCOHD HGHOLY ( saa doos. [ (aoviase 7 7 els a RENIN, waVRIOASNVeL vl | usngossnval | a j SSNs Hy 0D MONE BOvIgR NaS aT it wR RVONODAS il TERSTS SN pasa] L_ 2a a SONDIDVE BOVLIOA 7 | 2 map T a jounos |e uve | 1004 eM 1 a FOvR sounos |pajon.yay qi a1qissog uoy -pruapuy awog mBuang ra MOT [\ 1e38ny Prat auog 21069 Bunmnsodg fo bug nk O40 PIPAA dAISSIOXT WO Wau PIAL UQ 204021 PIAA uno0g kay uowoniapuy owog Moin 183mg ary UO Haun) PIAA ho ao.04 Pron poonpey wally Bupnapy 21042 play fo Burmasag 1y 99401 PIOAA AAISSOONG PaIoDAUIDy SapousD215 pIIny jpous piayy 01 Yous ‘DIEM, Soposjoayiz uoisyndcg, Jponfing pun (Ausouog) poroy} fo sso] aaissooxg U Bienes rm apK Sunerdg Jo pug y SUL PIAA 04g 21049 pag fo pus ay 2240 IPA AAISS99XG aly Plead PP saan PIAA sapousely «opuy) i prey fo sso] HO 240d PIPAL 2on.p apounva)q ID Daly uayopy 91969 Plan JO PUL IV STET, PAA MOUS UO waar PIAL 4O 9040s1 PIAL ups juauing, YM SHADIS, BuiysDjet pay ~1Suaquy pallq Suyvapy 91042 prom Jo Suuurseg iy 20407 PPA WOPYyNsUT UOHRLIVA 99.10] PPAA iparovuey saponsaig — |peaowoy aox07 prawt | sanunuoy aou0y pray | dois MOLD PRAM sanuyjuor a2d0s1 Pap, | |_| ie |_| [ea aun, (e810) aun, (08.0,7) Suns out (2810) progy a1 Jo pusy PIOH Jo pug PIOH Jo app WILL, PIAA JO PUT e SOnUHUO) Wen] PIA | sang mauny pag | Mauny Peg ON |sopanaajy woomsag puaroyy 7 SanunBUOD 20404 DIAM \sanuyuor ao4oxg pjagy| Penddy 224021 pj24t 9198p Jo HIG OUT, PIA JO APPHAL | oUILy, proay urdos duIL, az9anbg [_] L_J soIpedoy qysnog sapor ~9918 SUIpiOM, Es IpAD Suyessdg [eULIONparonajay sapousoaly Suryooag ‘Buyjong | ‘Gusouog so88nyy pany dope apa Jo pug y cous (oso) PIO Juoraynsuy Ho waning PP aouog PIAA Of wee ‘MOT xf aans| “sag 10 aU, a D PIOH Jus!UIMsUy PaIDUuaY SPOOL uossyndesy 04 lang” wBuang 400g uouvuapuy avapy aaysoiog pen | aan A | apX2 BuyerodG Jo pug ry OWE, PIPAA BUOY Paddony WALINY PIAA UO 224024 PIAL veay PIAA we jaye fo ssoT uot uopuly davoy ~ vody uaxjoyy pooag SUIT], POH Jo SunmnBag [4D PIO JO pug IW PULL PIAA Su0TT Pawar Spohr} yBuaug \ PIAA MOT azig 1088nyy pus, 9195 Sunexodg Jo puss 1y OUI, PIAA 4104S paddorg 1uasin plays uQ 20404 Play, smog 01 J pauoig isn jas8ny post | | pIoH Jo Suluuisog 9104) PIAA JO PU 1¥ SWELL PRPAA 04S 20402] PAM MOT 40 aT payddy iuauny pian 440M OF sapoaoayy fo Suyous uo Buippay yo38inp PIE Mout jouowy fo ssoy moyg syands | owny, azaonbg ayy 0 UAaPyyNsUy UOHVLAIVA JUL], apADPRITOLDY SOPOT PROUD THOT PI | IO MORIN PAT UIT PEA a 40 20404 PRU (0940. PIAL sug 01 jem| fod sued AU ©1 PaPIOAL suy 31 sopon| Reel ERE) og Coy Sa83nN ~2ar] ‘euoqyy uo Sapo, PIA Tews smoaQ| ey ase 09 wBuieng Suysel soponsorg ied mario ung uo dp 91a i ] { "heyy paw [ (ory, 281051) (ony, 98103) ee apg Jo pug, PION JO pug PIOH Jo OPP SUL PIeAA JO PUTT SanuyjUoy 2240.4 PIA OWL PIAA JO OLPPHAL yoy sueg st yoiong o1 suraig soponoayg, sepuy, PR Sanuuyjuog 2010.1 PIAA SULT PIAA UTBog, yprqu0g PRN 0} [RIO ysoreay, ysnony, peg yuormy payddy 2040, pio Sepodaayy waaniag jpLainpy aut, azaanbg apa Jo res — I Gm eponseg nes orn justoryng i ae ie, [\" wane ee PIAA UO dp 314 [BIO 100g JO AIACxoosinG THE RicHt Resistance WELDER Rosistance welding looks too simple to be true; in fact, it's almost like magic! Properly applied, it's the fastest, strongest and least expensive method of joining metal. A properly made spot weld will not shear or break in the fused zone; instead, the base metal will tear around the weld. As with most machinery investments, there are many choices on today’s market, and all of them will produce & weld of some sort. But just as you would not choose a pickup truck to haul a ten ton Joad, neither should you expect a light duty resistance welder to perform properly under heavy duty condi- tions. THROAT DEPTH . Wrong Welder Costly Mistake “SPANG RAG OF PARTS tr you choose the wrong machine —oruse te wrong welding — £ sear 4 schedule — you and your compeny may be in for BIG trouble. Companies have lost thousands of dollars due to improperly made spot {J welds. For example, an appliance plant was producing $4,000 in serap per ‘week off one machine due to bad spot welds on galvanized metal, and that Joss had been going on for months. Another company, a military contrac: tor, had to scrap $60,000 worth of aluminum missile wings because ‘the spot welds would not meet government specs. Automotive plants have had to do recalls, and welding engineers have lost their jobs cue to had resistance ‘welds, and as a company that works inthis field daily, T.J. Snow recognizes that its preventable with alittle knowledge and training E> : resistance welder that will successfully make a particular weld, but there IS usually just one machine yyy _t1-Laver THIN THICK ‘that is more RIGHT for that application than any other. The responsible vendor will ask all the right questions and make recommendations based upon the customer's welding application. Resistance welder buyers can get into trouble if they fail to ask the right questions or read the fine print in « welder manufacturer’s literature. Although most reputable welder mamufactur- crs are members of the RWMA, and meet that group's minimum standards for machines as published in Bulletin 16, thee isa growing influx of light duty foreign-made welders (and now some domestic copies) that do not meet specs. 1. Comparing Welders ‘The light-duty machines are often entry-level spot welders designed to be very attractively priced, and although the KVA ratings and welding capacities may sound similar to more, expensive machines, the buyer should BEWARE. Comparing resistance welder ma- chines just by looking at the KVVA rating is a poor method, unless duty cycle, secondary amperage output and forge force ratings are included. ‘VA size of a welder is a thermal rating, and KVA does not do the welding -- Theamperage and force does. Welders that meet RWMA standards must have KVA ratings stated at 50% duty cycle, whereas another welder with similar sounding specs may have ‘a KVA rated at a much lower duty cycle. Just as engine horsepower ratings can be cited at difforont RPMS, resistance welding machine manufacturers have a Way to inflate their ratings, if desired. A machine rated 100 KVA at 50 percent duty cycle may also be rated 141 KVA at 25 percent duty eycle and 224 KVA at 10 percent duty cycle. Thus, the KVA rating can be inflated by citing a smaller duty cycle inthe fine print, or omitting the duty cycle specification altogether! Some of the lower priced machines being sold today specify the KVA rating at duty cycles as low a 10 percent. The machines may be adequate for some small job shops welding low-speed, light-gauge applications, but do not expect them to operate to RWMA standards! 2. Short Circuit Current ‘Another performance measure for resistance welders is the mexinum available SHORT CIRCUIT CURRENT (amperage). RWMA standards specify the proper short-circuit current based on 50 percent duty cycle, escraescn aurmgecton Racrroos maRcrO Note: Short circuit ratings can be inflated by citing sy tee eS “peak” instead of “RMS” (root-mean-squared, or aver- Wz io ba ae age), current oulpu, yet its the RMS current that does the AS welding, and RMS figures are used in welding charts. crow, coma, owt iio =e Se IIL, Types of Resistance Welders i ay Asyoumightexpect there are vaious subgroups underthe == SE above headings: SPOT WELDERS can be categorized as Rocker Am, Vertical Action Press Type, Bench Type, and Portable Gun ‘Type. PROJECTION WELDERS are press type machines with ‘T-slotted platens. Some are combination projection and spot welders, with both platens and arms. Although most Projec- tion Welders are floor mounted, a few are bench type. SEAM WELDERS can be configured as circumferential (circular) or longitudinal, Some ate combination machines and can be used either way. FLASH WELDERS AND BUTT WELDERS are similar machines with different control systems. Also, Flash Welders uswally have a larger Kva rating than Butt Welders and are designed for heavier jobs. A. Three Basic Elements 1, The Mechanical System The MECHANICAL SYSTEM consists of a rigid steel frame and the means for applying the necessary weld force or pressure. Most resistance welders today are air operated. sine Mn aS * sion canoe2. The Electrical System : E Aaa ‘The ELECTRICAL SYSTEM consists of the ‘machine’s primary disconnect switch, control con- \ yvuyy tractor, welding transformer, transformer tap switeh, and secondary circuit (including electrodes, electrode holders ["""™") ie and arms), that conduct the euttent through the work ae pieces, Soeciegg tn atte The Control System <2 ‘The CONTROL SYSTEM initiates, a regulates and times the duration of the current flow. Controls also sequence the overall operation of the machine functions of Squeeze, Weld, Hold, Off and Repeat. i ‘The Phase Shift Heat Control function allows the opera- tor to fine tune whatever current magnitude is selected with the transformer tap switch. Computer chips, with their programmable functions, have invaded resistance welder controls just as they have all other areas of our lives, and the customer now has the advantage of having basically all available control options, such as Preheat, Up ‘Slope, Pulsation, etc. available as needed for 2 specific application. B. Systems Unchanged EP ‘The mechanical and electrical systems of Resistance welders have remained ‘basically unchanged for the pest 50 years, except for the sad fact that many brands are now being made lighter and cheaper, but, as is the ease with almost all industrial machin- as ery, the control systems are changing almost daily. C. Projection Welder j cree os i Bet ‘The PROJECTION WELDER, with i’ large flat copper T-slotted i Platens, is ideally suited for making multiple projection welds, such as Veet] ‘on small to medium size stampings, utilizing special tooling that mounts Sai] on the platens. As asidelight, itis very important to design some i ‘means of weld pressure equalization into projection welding tooling, cence) ‘especially as the tooling wears ies Vertical Action Seam Welder iS 8 Press Type an Projection Welder When to choose a SEAM WELDER might seem faicly ~ ‘obvious, such as when you need to have an air or liquid tight ea joint in a metal par, but there are other uses for these machines, such . as Roll Spot Welding. a 10-Spucroer nage A few clever fabricators are using a seam welder for high speed spot welding by incorpo- rating one or more machines into a roll forming line, setting the controls on intermittent, and making evenly spaced spot welds at the same time and speed as the roll formedshapes come off the Tine. A.pocionane clang ters {Ehpny Ting as altar Pan von Sloe eins Caent E, Flash and Butt Weiders " eb Flash and Butt Welders are almost world unto themselves when compared to other forms of resistance welding. Except for machines to butt and tee weld VV \wire for appliance racks and store displays, you usually don’t see these are very specialized, such as making automotive wheel rims, and are beyond the scope of this presentation. F. Single Phase Vs. Three Phase Welders Most people purchasing their first Resistance Welder naturally assume that these machines, like large motors, are all wired for three phase power. In fact, ‘most auction brochures will describe a spot welder as a 220 or 440 volt “three a phase” machine, when it’s actually Single Phase. The fact that many resis- tance welders are wired into a three phase disconnect further confses the average person, but opening the box will usually reveal that only two of the stb anes three legs are in use! Probably 95 percent of all resistance welders in use “e-tymyannin today operate off Single Phase Power, ene Although offering a very desirable high amperage secondary output that is almost like DC, a Three Phase Frequency Convertor Resistance Welder is almost three times as expen~ sive as a comparable single phase machine. Therefore, these types of machines are mostly used when there’s almost no other choice, such as when you need to weld alumi- rum to Military or Aircraft Specifications, or when you are faced with some sort of high amperage application, such as the ring protection welding of spuds to tanks. protner wot Pressure Important Ein SrRKE [A very important variable is Pressure. RWMA specifications state the maximum forging force that should be available from each resistance welding machine frame size, Most rocker arma spot welders are rated in frame sizes 1, 2 and 3. An air-operated Size 3 rocker arm should produce 2,000 pounds of weld force at 80 PSI vwith 12" arms installed. ‘Most press welders are made in frame sizes 00 through 4, Most press welders in “Size 00 and 0” frames are small bench-top. ‘Although not entirely accurate for all throat depths, remember that an RWMA Size I machine will produce approximately 1 ton (2,000 pounds) maximum weld force in a short (12”) throat configuration. A size 2 frame with a 12” throat will produce 2 tons of force. Due to structural considerations, RWMA specs allow force ratings to be reduced as the throat depths are increased. ‘The welding force produced by a press welder is easily computed from the diameter ofits air cylinder and the air fine pressure, but rocker arm machines are entirely different. Extending the arm length (throat depth) of a rocker arm has a dramatic effect on the ‘maximum weld force available, since the welding force decreases as arm lengths areincreased. Therefore, a deep-throat rocker arm welder not specifically designed to have arms of that length will have less force available than many “Class A” welding specs require. This will reduce the weld strength, especially ifthe fit-up of the parts is Tess than ideal and a portion of the weld force is consumed just overcoming the “spring-back” of the metal as the parts are forced into intimate contact prior to weld. H. Examine Weld Application Begin by examining the welding application, and don’t force a welder to do a jab its not designed to do. Document the metal alloy and thickness... What weld strength will be required? What production rate? Will the job run long enough to justify an investment in higher speed machinery? Cheek the applicable RWMA or AWS welding chart — but remember, the settings shown are just a starting point, and not usually the actual weld schedule you will use. By learning the basies of resistance welding, and checking that you have the right machine and that itis properly maintained, you can adjust and optimize your own welding sched- ules as needed to make consistently good welds — day in and day out. IV. Desirable Features for All Resistance Welders L 1, Water Cooling In addition to having water cooled electrodes and holders, any resistance welder used in heavy duty production work should have water cooling circuits for the welder trans- former und secondary, plus the welder control contactor. A growing trend is to have a self-contained water chiller and recirculator dedicated to each machine or group of machines. Built-In Disconnect Switch ‘A built-in and interlocked disconnect switch is now often required to meet OSHA regulations. But regardless of regulations, itis important for the operator to have easy and quick access to a switch that turns the entire machine and control on and off. This switeh should be properly sized and should either be a circuit breaker or equipped with fuses. Properly Sized Copper Secondary Conductors Resistance Welders need! a heavy duty copper secondary conductor loop to operate under production conditions without overheating. Due to the high price of copper, thisis, ‘where some of the newer, less expensive designs are getting short changed. Properly Designed and Rated Transformer ‘The best (and most expensive) resistance welding transformers are stacked core, water cooled units, with cast copper secondaries. Some low-end transformers, especially in the smaller KVA ratings, are not water cooled. Some of these also have the laminated shunt of the welder running through the transformer core and serving as the secondary. 1. Sr Cg ne “ reson Wen T5. Adequate Secondary Voltage Secondary voltage is the “pressure” that pushes the welding current (secondary amper- age) out through the arms. Think of water going through a Tong garden hose. Water volume is not much good without water pressure. The farther the work is from the transformer, and the more square inches of space that are contained in the secondary Joop, the higher the secondary voltage must be to overcome the welder’s impedance and resistance and deliver the amps (weld hest) to the work piece. Buyine THE ‘RicHt’ Spot WELDER ‘Although the buying process is complicated by price differences that are difficult to under- stand and justify, purchasing the wrong spot welding machine can be an expensive mistake. I. Avoid Recalls Many recalls were traced to improperly made spot welds, and sad to say, the Resis- tance Spot Welding process sometimies got the blame. A properly made spot weld will not sheat ot break in the fused zone; instead, the base metal will tear around the weld. In adition to strength, spot welding offers speed and cost-effectiveness that no other ‘metal-joining method can match, II. RWMA Guidelines The average metal fabricator or welding engineer can determine the right welding machine and get the most for their money by following Resistance Welder Manufacturers’ Association's guidelines. Consult the charts published by RWMA or the American Welding Society to determine the ‘optimum welding current and electrode force for your application. 1. RWMA Charts awa Some charts have multiple sets of specifications for Classes A, B and C spot welds. t's best to use the Class A specs whenever possible. Note that these charts do not specily a “KVA’ rating for welding ench metal thickness, although the KVA rating is often used to compare Resistance Spot Welding machines. 2. KVA Resistance Spot Welding machines have always been rated in KVA (a thermal rating), which can be stated in different ways depending on the percent duty cycle specified. The KVA rating of RWMA standard machines is based on a 50 percent duty cycle, but not all RW machine manufacturers hold to these standards. As an example, a machine rated at 100 KVA at 50 percent duty cycle may also be rated 141 KVA at 25 percent duty cycle or 224 KVA at 10 percent duty cycle, Thus, the KVA rating can be inflated by citing « shorter duty cycle inthe fine print, or omitting the duty cycle reference completely.3. Short-Circuit Current RWMA standards specify the short-circuit current based on the machine size, KYA rating ‘and throat dimensions, along with the allowable duty eycle when operated under short-circuited conditions. To comply with this standard, a RW machine must have ‘adequate copper sections in the secondary loop, well-designed water cooling, and the KYA rating of the welding transformer based on a 50 percent duty cycle, NOTE: The short-circuit current can be inflated by listing “peak” instead of “RMS” (root-mean-square) current. It is the RMS or effective current on which weld schedules are based to produce acceptable welds. 4, Lower Priced Macl ‘Some lower-priced and imported machines specify the KYA rating at a 10 percent duty cycle. This is adequate for job shops with low speed, light-gauge applications, but do not expect them to perform to RWMA specifications. When replacing a Resistance Welding ‘machine, verify all specifications match the original machine's, orreliable welds may not result Weld Force ‘Weld force is the other part of the Resistance Welding equation that must be considered by the welding engineer. Basically, the spot welding machine is a sophisticated device used to heat and forge metal together. The force applied to the weld area is critical to the ‘weld’s strength. A point to consider is that all machines of equal KVA rating may not offer equal weld force. Most modern production Resistance Welding machines are ‘operated with air cylinders of varions diameters that apply the weld foree either directly (vertical-action press-type machine) or through a lever mechanism (rocker arm types). 5. 6. Press-Type Welders ‘The force produced by a press-type machine is easily computed from the diameter of its air cylinder and the air pressure applied. Rocker Arm Welders Rocker arm machines are entirely different. Extending the arm length (throat depth) of a rocker arm has a dramatic effect on the 3 ‘maximum welding force available, since the welding force i ‘decreases in the same ratio as the throat depth increases. Therefore, a deep-throat rocker arm not specifically designed to have arms of that length will not produce the force and will adversely affect weld strength. This is particularly true if part fit-up is Jess than ideal, and a portion of the weld force is consumed just overcoming the spring back of the meta to force the parts into intimate contact. NOTE: RWMA specifications specify the maxireum force expected from each spot welding ‘machine frame size for both rocker arm and press types. The nonconforming, light-duty models on the market today cannot compete with heavier duty models. III. Performance Mother Nature cannot he fooled. It still takes the proper welding force and welding current 0 do a specific welding job. Be aware, also, that manufacturers of lower quality models some- times cite Class B or Class C specifications to make theit machines appear 1o give higher performance. Be guided by the Class A specificationsA. Example Weld RWMA specifies for welding 18-gauge (0.048-in.) mild steel, Class A weld settings of 10,300 secondary amps, 650 Ib of force, and a weld time of 12 cycles. Since one cycle equals 1/60 of a second, 12 cycles equals 1/5 of a second. This results in an attractive, low-marking spot weld with an average tensile shear strength of 1820 Ib. Class C welds can be accomplished on the same metal by using only 6100 weld amps, 205 Tb of force, and a whopping weld time of 42 cycles, which is almost 1/4 of a second. The Class C weld is much less attractive due to the incrcased heat-affected zone caused by the long weld time and the average tensile shear strength drops 12 pereent to 1600 Ib. Buying a resistance spot welding machine is the same as buying most things — you pay your money and you take your choice. But, it pays to make an informed choice. {This information was drawn from an article by RWMA Member Thomas J. Snow, Jr, Z J. Snow Company, Inc., Chattanooga, Tenn. printed by RWMA. WELDER nt A ee I, Advantages of Rocker Arm Design a i ae 1. Price i i i | Rocker Arms are often the least expensive type of Resistance ‘Welder to buy, since a longer throat depth does not significantly increase the price of the machine. Rocker arms are what people think of when they hear the phrase SPOT WELDER. Accessibility with the ‘The arms and tips are out in the clear and can teach into most pars, especi addition of offset or angled holders and tips. 3. Wide Electrode Opening ‘The Rocker Arm design lends itself to applications where the part must be loaded into the throat 4. Versatility Rocker Arms can be used for many spot welding applications. Arms and holders can be interchanged as needed. High Speed Rocker Arms can usually weld faster than any other type of spot welder, They can be used like a sewing machine.Il. Disadvantages of Rocker Arm Design 4. Electrode Skidding TThe arcing motion of the upper arm can be minimized through proper machine adjustment, but never eliminated entirely. 2. Not Suited for Projection Welding ‘The arcing motion of the upper arm makes Rocker Arms unsuitable for Projection ‘Welding applications, since pressure will not be applied equally to all points. 3. Low Electrode Force ‘The maximum electrode force available decreases as the arm length is increased, III. Rocker Arm Design Differences Since T. J. Snow Company stocks and sells all brands of used spot welders, we have a unique perspective on the various differences in design. Most rocker arm designs over the years have had the rocker mechanism exposed for easy maintenance, Some brands enclose this in @ rectangular metal or fiberglass housing to avoid pinch points. This is probably a good idea, and it provides a good place to store tools, but in over 30 years of dealing in rocker arm spot welders, we have never heard of anyone being hurtin the rocker mechanism. Another difference from brand to brand is the designer’s choice of flat face plate or a round column lower secondary connection. We like the flat face plate better, since, over the years of use, it is easier to maintain intimate contact between two large flat copper surfaces as op- posed to two radii Despite this, the round column design is more prevalent, perhaps because iti less expensive 10 build and is able to be swiveled from side to side. This feature can come in handy when using offset electrode holders, Just remember to really tighten the connections after any adjustments are mace to avoid oxidation and arcing, Tue ABC's oF Spot WELDING I. Specifications : ‘Some welding charts for mild stee! have multiple sets # | of specifications, for Class A, B and C spot welds. Ws best to use Class A weld spees wherever possible, since those settings take the least time, wes > > yield the most strength, and offer the least distortion. *—* "alien, : ‘A resistance welder salesman should size a machine srur viet seein ane "acne to weld your application to Class A specs. Forexample, in choosing a welder to join two pieces of 18 gauge low carbon steel, the chart in RWMA’s Fourth Edition Resistance Welding Manual recommends Class A settings of 10,300 secondary amps, 650 pounds of forging foree, 1 be Coma *