Section 22

Calibration

Rev 2 April 2013

Calibration
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22

Calibration

22.1

Introduction
BS 7570 - 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:

22.2

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.

Terminology
BS 7570 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.

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Calibration
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22.3

Calibration frequency
BS 7570 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:

22.4

Equipment manufacturers recommendations.

Users 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.

Instruments for calibration

Instruments used for calibration should:

22.5

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.

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

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Calibration
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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 the figure which shows the power source voltage meter
connected across points 1 and 7.
Power
source

77

Arc voltage

Wire feeder

55

6
6
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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Calibration
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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.

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