1

Introduction
BS 7570 - Code of practice for validation of arc welding equipment 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 the output meters provide accurate
readings
The Standard refers to two grades of equipment - standard grade and
precision grade.
Standard grade equipment is suitable for manual and semi-automatic
welding processes.
Precision grade equipment is 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.
Thus, when considering welding equipment, those that have output meters
for welding parameters (current, voltage, travel speed, etc.) can be
calibrated by checking the meter reading with a more accurate measuring
device and adjusting the readings appropriately.
Equipment that does not have output meters (some power sources for
MMA, MIG/MAG) cannot be calibrated but they can be validated, that is to
make checks to see that the controls are functioning properly.

Rev 1 January 2010

Calibration of Welding Equipment
Copyright TWI Ltd 2010

Calibration Frequency
BS 7570 recommends re-calibration/validation at:
Yearly intervals (following an initial consistency test at 3 monthly
intervals) for standard grade equipment
Six monthly intervals for precision grade equipment.
However, the Standard also recommends that re-calibration/validation may
be necessary more frequently. Factors that need to be considered are:

Equipment manufacturers recommendations

Users requirements
If the equipment has been repaired re-calibration should always be
carried out
If there is reason to believe the performance of the equipment has
deteriorated

Instruments for Calibration

Instruments used for calibration should:
Be calibrated by a recognised calibrator - using standards that are
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 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.

Rev 1 January 2010

Calibration of Welding Equipment
Copyright TWI Ltd 2010

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 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
voltmeter 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 voltmeter should be
positioned as near as practical to the arc.
This is illustrated by the figure at the end of this section, which shows the
power source voltage meter connected across points 1 and 7.
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 voltmeter is connected across points 3 and 7
(which it may be) the meter reading would not take account of any
significant voltage drops in the return cable - section 6-7.
The magnitude of any voltage drops in the welding circuit will depend on
cable diameter, length and temperature and the Standard emphasises the
following:
It is desirable to measure the true arc voltage between points 4-5 but for
some welding processes it is not practical to measure arc voltage so
close to the arc
For MMA, it is possible to take a voltage reading relatively close to the arc
by connecting one terminal of the voltmeter through the cable sheath as
close as ~2m from the arc and connect the other terminal to the
workpiece (or to earth)
For MIG/MAG the nearest practical connection points have to be 3-5 but
a change from an air-cooled to a water-cooled torch or vice-versa may
have a significant affect on the measured voltage
Voltage drops between points 5-6 will be insignificant if there is a good
connection of the return cable at point 6.
Rev 1 January 2010
Calibration of Welding Equipment
Copyright TWI Ltd 2010

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
The current-return connector is suitably rated and is firmly attached and
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 cable 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 be 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 tachogenerator, may be appropriate.

Rev 1 January 2010

Calibration of Welding Equipment
Copyright TWI Ltd 2010

Power
Source

2
Wire Feeder

4
arc voltage {

5
6

An example of a welding circuit (for MIG/MAG)

Rev 1 January 2010

Calibration of Welding Equipment
Copyright TWI Ltd 2010