Section 22

Calibration
22 Calibration
22.1 Introduction
BS EN 50504 - Code of practice for validation of arc welding equipment, is a
standard that gives guidance to:

 Manufacturers about the accuracy required from output meters fitted to

welding equipment to show welding current, voltage, etc.
 End users who need to ensure that output meters provide accurate
readings.

The Standard refers to two grades of equipment, standard and precision:

 Standard: Suitable for manual and semi-automatic welding processes.

 Precision: Intended for mechanised or automatic welding because there is

usually a need for greater precision for all welding variables as well as the
prospect of the equipment being used for higher duty cycle welding.

22.2 Terminology
BS EN 50504 defines the terms it uses, such as:

Calibration Operations for the purpose of determining the magnitude of errors of a

measuring instrument, etc.
Validation Operations for the purpose of demonstrating that an item of welding
equipment, or a welding system, conforms to the operating specification
for that equipment or system.
Accuracy Closeness of an observed quantity to the defined, or true, value.

When considering welding equipment, those with 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 can be validated to see the controls are
functioning properly.

22.3 Calibration frequency

BS EN 50504 recommends re-calibration/validation at:

 Yearly intervals (following an initial consistency test at three monthly

intervals) for standard grade equipment.
 Six monthly intervals for precision grade equipment.

The Standard also recommends that re-calibration/validation may be necessary

more frequently. Factors that need to be considered are:

 Equipment manufacturer’s recommendations.

 User’s requirements.
 If the equipment has been repaired re-calibration should always be carried
out.
 If there is a reason to believe the performance of the equipment has
deteriorated.

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22.4 Instruments for calibration
Instruments used for calibration should:

 Be calibrated by a recognised calibrator using standards traceable to a

national standard.
 Be at least twice and preferably five times more accurate than the accuracy
required for the grade of equipment.
 For precision grade equipment it will be necessary to use instruments with
much greater precision must be used for checking output meters.

22.5 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.

To obtain an accurate measure of arc voltage, the voltage meter should be

positioned as near as practical to the arc.

This is illustrated by Figure 22.1 which shows the power source voltage meter
connected across points 1 and 7.

WIS5-90516b
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 Power
source

2 3
77 1 Wire
feeder

4
Arc voltage
{ 5
5
6
6

Figure 22.1 A welding circuit (for MIG/MAG).

However because there will be some voltage drops in sections 1-2, 3-4 and 6-7
due to connection points introducing extra resistance into the circuit, the
voltage meter reading on the power source will tend to give a higher reading
than the true arc voltage.

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.

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 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 effect 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:

 Current return cable is as short as practical and is heavy, low resistance,

cable.
 Current/return connector is suitably rated and firmly attached so does not
overheat due to high resistance.

The Standard gives data for line voltage drops (DC voltage) according to
current, cable cross-section and length (for both copper and aluminium cables).

Wire feed speed

For constant voltage (self-adjusting arc) processes such as MIG/MAG the
standard recognises that calibration of the wire feeder is generally not needed
because it is linked to current.

If calibration is required it is recommended that the time is measured (in

seconds) for ~1m of wire to be delivered (using a stopwatch or an electronic
timer). The length of wire should then be measured (with a steel rule) to an
accuracy of 1mm and the feed speed calculated.

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. Most of the standard
devices can be checked using a stopwatch and measuring rule but more
sophisticated equipment, such as a tacho-generator, may be appropriate.

WIS5-90516b
Calibration 22-4 Copyright © TWI Ltd