IS :4804 (Part II)-

1968

Indian Standard

( Reaffirmed 1996 )

SPECIFICATION FOR RESISTANCE WELDING EQUIPMENT

PART II SINGLE-PHASE WELDING .. Third Reprint SEPTEMBER 1991 ( Incorporating
Amendment No. 1 )

ROCKER-ARM MACHINES

SPOT

ULX

621.791.763.1.03

0 Copyright BUREAU
MANAK

1975

OF
9

INDIAN
BAHADUR

STANDARDS
SHAH ZAFAR MARG

BHAVAN.

NEW DELHI 1 loo02

Gr2

December

1968

IS : 4804 ( Part II ) - 1968

luzdian Standard
SPEClFICATION RESlSTANCE WELDING
PART II SINGLE-2edASE vvELD!NG
Electric *SHRI H. Welding Equipment
RAO

FOR EQUIPMENT
SPOT
ETDC
Bangalore

ROCKER-ARM MACWINES
Committee, Represulting
Ltd,

Sectional

21

Chairman
S. NABAYANA Hindustan

Aeronautics

SHRI S. BALASUBRAHMANYAM SHRI A. H. CHAUDHURI SH~I A. V. GHARPUXE SHRI K. 8. SUAH ( Alternate LT-COL B. R. GULAW

Members

Braithwaite & Co ( India ) Ltd, Calcutta Jessop & Co Ltd, CalcutLa Indian Hume Pipe Co Lt)d, Bombay

Ministry of Defence, Production, Poona

Dopartmont

of

Defonce

SRRI B. DESI~~A~~ARI (Alternate ) Malik Electric Works, Bombay: SRRI 8. K. HART SHRI A. K. KHOSI,A Heavy Electr~cals ( India ) Ltd, Bhopal SHRI D. P. GWTA ( Alternate) SHRI B. K. MUKHERJBI~ National Test House, Calcutta SRIZI J. A. MUJ>IYIL Indian Oxygen Ltd, Calcutta SHRI J. C. ACXARYA ( Alternate ) SHRI A. S. NAGARk-ATI Directorate General of Supplies & Disposal% New V. S. KRIPI,AXI SHRI 1). R. T\AaA SHRI T. K. A. IYEa &RI G. T. NIHA~AxI
SHRI

Delhi Board, Ministry of JWlways, Electrodes New Delhi Private Ltd,

Alternate
J.

) )
B. Advani-Oorlikon Bombay

Railway

( Alternate

SHRI J. K. CHANDNA ( Alternate ) Electrical Machine Industries Pvt Ltd, Cnlcut,ta SRRI J. B. PATEL SHRI J. B. Lourx ( Alternate ) SHRI S. G. RAMACHANDIL.~ Kirloskar Electric Co Ltd, Bungalore, SHRI N. 6. SUJ~~LBNNA Alternate ( ) OBFICX 8 STAFF ( UNDER Naval Headquarters, Ministry of Defence, New WATER ) WEAPONS Delhi STAFG OFFICER, XLTXTRTCAI. ENQINEERINQ ( DESIQN ) SHRI P. SUR SHRI P. COO%IAR ( Alternate SHRI Y. S. VENKATF,SWARAN, Director- ( LElec tech )

( Alternate )

Sur Iron & Steel Co Pvt Ltd, Calcutta

)
Director General, IS1

. ( Ex-oficio

Member )

SHRI

Deputy *Chairman for tho meeting

:T. RAJARAMAN Director (Elec tech ), ISI this standard was finalized.

Secrelary

in which

BUREAU

OF

INDIAN

STANDARDS

MANAK BHA~IAN,9 BAHADUR SHAH ZAFhR MAW MIqJi I>!;! .vr I : \ml7

IS:

4804 (RN: TI)- 1968

hdian

Standard
FOR EQUIPMENT
SPOT

SPECIFICATION RESISTANCE WELDING

PART II

SINGLE-PHASE ROCKER-ARM WELDING MACHINES

0. 0.1This

FOREWORD

IndianStandard (Part II) was adopted by the Indian Standards Institution on 4 November 1968, after the draft finalized by the Electric Welding Equipment Sectional Committee had been approved by the Electrotechnical Division Council. 0.2 This part covers single-phase rocker-arm type spot welding machines and designates the electrical ratings together with the mechanical requirements, such as nominal electrode forces, throat depths and clearRequirements for methods of actuation, ance, dimensions of arms, etc. operating speeds, cooling and mechanical and electrical features are also specified. 0.3 This standard, is rmt complete by itself and shall be read in conjunction with IS : 4804 (Part I )-1968*. \ 0.4 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test, shall be rounded off in accordance with IS : 2-1960t. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.

l.SCOPE 1.1This standard

(Part II) covers the essential electrical and mechanical features pertaining to standard sizes of stationary single-phase ac transformer type rocker-arm spot welding machines. It does not include electrical, electronic control equipment. 1.2 This standard clpes not cover portable, rocker-arm resistance welding machines.
*Resistance welding equipment: Part I Single-phase tRules for rounding off numerical values (revised).

fixture

type

or gun type

transformers.

IS : 4804 ( Part

II)

- 1968

2. TERMINOLOGY 2.0 For

apply. 2.1 Spot Welding - Resistance welding in which the welding current is passed through the components of the woskpiece in an area confined by electrodes contacting and applying pressu.re to produce a weld. 2.2 Rocker-Arm Spot Welding Machine -A spot welding machine fitted with one or both arms pivoted to the frame, carrying an electrode holder and electrode and caused to rock about the pivot(s) by means of manual, air or motor operation. 2.3 Throat Depth-The unobstructed work machine from the centre line of the electrodes obstruction of flat work or sheets. 2.4 Throat Clearance-The welding machine between 2.5 Arm - A projecting transmits the electrode unobstructed arms throughout clearance in a welding to the nearest point of work clearance in a spot the throat depth. welding machine which the. welding current. welding directly machine on to the by the to be the purpose of this standard, the following definitions shall

beam of a resistance force and may conduct

2.6 Electrode --A replaceable portion of a resisthnce which transmits current, and usually applies pressure workpiece. 2.7 Nominal Electrode Force the electrodes to the components 2.8 Electrode Holder - A device electrode and conducting current 2.9 Welding Current-The welded at the fused area. The thedretical force of the workpiece. used tc it. for

transmitted holding the parts

mechanically through

current

passing

2.10 Platen - In a resistance welding machine a member with a substantially flat surface to which dies, fixtures, backups or electrode holders are. a:tached and which transmits the electrode force or upsetting force. 3. DESIGN AND PERFORMANCE

3.1 Methods of Actuation - For all machine sizes the methods of actuation shall be manual, pneumatic or motor operated (see Table 1 ), as follows: a)

Manual Actuation -Manual

foot-operated pedal adjustable spring.

acting

actuation through

shall be by means of a a connecting rod and

1s : 4804 ( Part 11) - 1968

b) c)

~wun~ntic

~c~uatiorz -

Pneunxtic

actuation

shall be

by means

ol an z.i:, cyiilI<ler. Motor actuation shall be by means of a through a variable speed device, and/or gear _The arrangement of the means blx, cam and adjustable spring. of actuation shall be such as to provide a variable speed ratio oC approximately 3 to 1 and permit control by a foot-operated

Jlotor Actutrtion I~Io~c)~~ optrating

Cllltf.11.

3.2 Maximum Operating Speeds - Pneumatic welding machines, when working with a 13 mm be capable of opoat.ion at: a) b) 100 strokes aud per minute for throat depths

and motor operated electrode stroke, shall of 450 mm and less, mm. at 50 percent

80 stl~okcs prr minute

for throat

depths

of over 450 in kVA

3.3 Electrical Ratings --The preferred ratings duty cycle shall be 5, 7.5, 10, 15, 30 and 50.

3.4 Nominal Electrode Force -The nominal electrode force when measured at a 300 mm throat depth shall be in accordance with the of electrode forces at other relevant value given in Table 1. Values throat depths shall vary inversely as the throat depth. 3.5 Mechanical

Features Throat
shall

3.5.1

Nominal

Depth

and Clearance
in Table 1.

---Nominal

throat

depths

and clearances

be as given
the throat

NOTE-- Although a rang:e of dimenaious

neceswrily mean that within that range.

is shown in Table 1, this does not depths and clearances are infinitely variable

3.5.2 Arms, Electrode rocker-arms and electrode The size and taper

Holders
holders

and

Electrodes
shall

shall be as given

The diameters in Table 1. in Table 1.

of

of electrodes

be as given

3.5.3 Lower Arm Horizontal Adjustment -The minimum horizontal adjustment of the lower arm for all machine sizes shall be 12.5 mm on either size of the centre-line of the platen. 3.5.4 machine

Electrode
a) b)

Opening -

sizes shall be:

The

minimum actuated or motor

electrode

opening and machines. depth, change

for all

38 mm for manually 32 mm for pneumatic

machines, actuated

The openings ar based on a 300 mm throat electrode openings bein,% directly proportional to the depth from 300 mm. 4

with other in throat

TABLE

1 MECHANICAL

STANDARDS FOR ROCKER-ARht WELDING MACHINES 3.1, 3.4, 3.5.1 and 3.5.2)

TYPE

Sl=OT

(Clauses RATINQ kVS AT 50PERCENT DUTY CYCLE NOMINAL THROAT CLEARANCE w-7 Min Max

ROCKERARM DIA

ELECTRODEHOLDER FOR MORSE TAPER ,_--~_-_P-, Morse Length * ,----A----~ Taper No. Lower Dia. tipper

ELECTKODEHOLDER FOR ISO TAPER ~------h---~ Length IS0 r____h_ -- _~ Taper L,ower Dia

upper
(10)

NOMINAL ELECTRODE Foncn AT 30 cm THROAT URPTH* r- .__.h.~.___ Manual Pneumaoperatic/ tion Mok3r

NOXIN AL THROAT
hPTH

ClpX.SL(1)
kVA -@2) mm (3) mm 5 75 10 15 30 50 32 38 38 51 64 64 100 100 100 125 160 150 (4) mm 200 200 200 350 380 380 (5) 1 1 1 2 2 2 (6) mm 150 150 150 200 200 200 (7) mm 200 200 200 300 300 300 (8) mm 19 19 25 25 25 31,5 13 13 13 16 16 16 150 150 150 200 200 200

(9)

mm

(11) mm 200 200 200 300 300 300

(12) mm 19 19 25 25 25 31,5

(13) kgf 50 65 100 135 200 250

tion (14) -

kg f

(15)
cm

VI

55 85 110 250 400 500

20, 30, 20430 40 20, 30, 30446, io 30, 46, 60, 76, 91 30, 46, 60, 76, 91 3 ** $ x h q m z z ti

Ratings below 6 kVA have NOTE no data on force, tapers, etc. *Nominal electrode

not been included aince short-circuit

current data is not

available.

There is also

machines, and

for pneumatically force values are based on jair line supply pressure of 56 kg/cm* operators force on the foot pedal of 30 kgf in the case of manually operated machines.

operated

I z
%

IS : 4804 ( Part II ) - 1968

The electrodes machine shall be so adjusted that at the end of the stroke are together and the arms are horizontal and parallel. the shall

3.6 Accessories for Pneumatic include the following: a) b) c) d) e) Simple air strainer, regulating ) pressure valves Air line lubricator, Air pressure Air ( welding A,ir speed

Actuation

-Air-line

accessories

valve, gauge, and cushions ( optional). cooling, having or air cylinder

control

3.7 Water Cooling - When machines are provided with water they shall be in accordance with the following requirements:

a) b) cl 4 e)
3.8

A minimum of one circuit shall be provided a rating up to and including 30 LVA; A minimum of two circuits having a rating of 50 kVA, cooled type; A suitable machines; A suitable visual inlet drain

for machines

shall be provided if the transformer shall and be

for machines is of the water with all

manifold

provided

shall be pro;ided;

Where a machine have flow adjusting

has more than one cooling circuit valves for each cooling circuit.

it shall

Electrical

Features

3.8.1 Voltage adjustment shall be obtained through a plug or link arrangement or tap change switch of not less than 6 steps, providing a minimum open circuit secondary voltage which shall be 55 to 65 percent of the maximum open circuit voltage.
3.8.2 Initiating Control-The switch shall not exceed 110 volts.
rated qapacity.
NOTE This stipulation

nominal

voltage
to small

on

any

initiating
30 kVA

is not applicable

machines

below

3.8.3 Test for Rating (Maximum Conventional Power ai 50 Percent secondary circuit of the transformer shall be short Duty Cycle ) -The

The temperature-rise test circuited in the. manner described in 3.8.4. shall then be carried out in accordance with the method described in clause 7.6 of IS : 4804 ( Part I )-1968*.

l Sp0CifiC8tiOn transformers.

for

resistsnce

welding

equipment:

Pert

Single-phase

IS : 4804 ( Part II ) - 1968 3.8.4 Short-Circuit Conditions - A copper rod shall be substituted for the two electrode holders and this shall be clamped securely in the top and bottom arms to produce the required short-circuit. The arms of the machine shall be adjusted to produce the throat clearance and throat depth as specified in the name plate.
3.8.5

Short -Circuit

Secondary

Current

3.8.5.1 The short-circuit secondary current when determined in the relevant manner described in IS : 4804 (Part I )-1968* with the throat clearance and the throat depth as specified in Table 2, shall comply with the minimum values given therein.
TABLE 2 THROAT DEPTH, CLEARANCE AND SHORT-CIRCUIT CURRENT
THROAT DEPTH THROAT CLEARANOE

MINIMUM

TRANSFORMER RATING AT 50 PEIICENT DUTY CYCLE

MINIMUM SHORTCraonIT CURBSENT

(1)
kVA 6

(2)
cm

(3) mm 150

(4) kA 63 i:;

20 30 40 20 30 40 20 30 40 30 46 60 30 46 60 76 91 30 46 60 76 91

7.5

160

;:; 6.4 9.0 ;:; 9.0 81 7.2

01

150

15

30

200

171 140 12.2 108 9.6 22.5 189 162 14.4 13.1

60

200

*Specification transformers.

for

resistance

welding

equipment:

Part

Sihgle-phase

IS : 4804 ( Part II) - 1968

3.8.5.2 The transformer shall be capable of operating at no less than 4 percent duty cycle at the indicated short-circuit current without exceeding the temperature rise specified in IS : 4804 ( Part I )-1968.
NOTE - For the purpose of compliance with this clause, compute the duty cycle in accordance with-the formula given IS : 4804 ( Part. I )-lYBt;*, PO being taken as the product of the circuit current in kA a,nd the maximum open-circuit seconda,ry

it shall suffice to in clause 4.3.1 in minimum, shortvo!tage.

4. MARKING 4.1 Name Plate -The following information indelibly marked on the name plate: shall be Iegibly and

f,

The name of the manufactureaand/or trade-mark; Manufacturers type and serial number; The number of this Indian Standard [Ref IS : 4804 ( Part II )]; Maxirnurn conventional power in kilo volt amperes at 50 percent duty cycle; Maximum short-circuit power, Pm in kVA; Maximum short-circuit secondary current in amperes; 9) Supply voltage and frequency; h) Maximum and minimum open circuit secondary volts; 3 Class of insulation; k) Litres per minute, cooling water ( where applicable ); m) Maximum electrode force, in kgf ( where applicable ); h) Maximum throat depth; throat clearance; P) Maximum 4 Air pressure, in kgf/cm2 range ( where applicable ); r) Water pressure, in kgf/cm2 range (where applicable ); s) Maximum temperature of input cooling water; and t) Country of manufacture; Ll) Weight of the equipment. The __
Mark.

4.1.1 fication

_welding

machine

may also be marked

with

the

ISI Certi-

NOTE -The use of the ISI Certification Mark is governed by the provisions of the Indian Standards Institution ( Certification Marks ) Act and the Rules and Regulations made thereunder. The IS1 Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well-defined system of inspection, testing and quality control which is devised and supervised by IS1 and operated by the producer. ISI marked products are also continuously checked by ISI for .conformity to that standard as a Details of conditions under winch a licence for the use of the ISI further safeguard. Certification Mark may be granted to manufacturers or processors, may be obtained from the Indian Standards Institution. *Specification transformers. for

resistance

welding

equipment:

Part

Single-phase

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