AWS J1.2M/J1.2:2016

An American National Standard

Guide to Installation and Maintenance of Resistance Welding Machines

AWS J1.2M/J1.2:2016

An American National Standard

Approved by the American National Standards Institute

August 4, 2016

Guide to Installation and Maintenance of Resistance Welding Machines

1st Edition

Prepared by: American Welding Society (AWS) J1 Committee on Resistance Welding Equipment

Under the Direction of AWS Technical Activities Committee

Approved by AWS Board of Directors

Abstract

This guide provides general instructions for the installation, operation, and maintenance of common types of resistance welding equipment. Generic preventative maintenance schedules and equipment troubleshooting recommendations are provided as an overview of common weld qualification techniques and corrective actions to common weld conditions.

ISBN: 978-0-87171-891-4

©2016 by American Welding Society

All rights reserved Printed in the United States of America

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Statement on the Use of American Welding Society Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by agreement between the contracting parties.

AWS American National Standards are developed through a consensus standards development process that brings together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process and establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or reliance on this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or on behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in any given circumstances. It is assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.

This standard may be superseded by new editions. This standard may also be corrected through publication of amendments or errata, or supplemented by publication of addenda. Information on the latest editions of AWS standards including amendments, errata, and addenda is posted on the AWS web page (www.aws.org). Users should ensure that they have the latest edition, amendments, errata, and addenda.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of any patent or product trade name resulting from the use of this standard.

AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 8669 NW 36 St, # 130, Miami, FL 33166 (see Annex C). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS J1 Committee on Resistance Welding Equipment. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS J1 Committee on Resistance Welding Equipment and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS J1 Committee on Resistance Welding Equipment to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 NW 36 St, # 130, Miami, FL 33166.

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Personnel

AWS J1 Committee on Resistance Welding Equipment

D. C. Sorensen, Chair Entron Controls, LLC

1. B. Hirsch, Vice Chair Unitrol Electronics, Inc.

   1. Babinski, Secretary American Welding Society

D. Beneteau Centerline Ltd.

W. H. Brafford Tuffaloy Products, Inc.

J. D. Dally Standard Resistance Welder Co.

B. Kelly Kelly Welding Solutions P.C.

W. F. Qualls Consultant

N. S. Scotchmer Huys Industries Limited

B. White Jr. Janda Company, Inc.

K. Ymker RoMan Manufacturing

Advisors to the J1 Committee on Resistance Welding Equipment

M. Cubert SpaceX

AWS J1B/TG2 Task Group to Prepare the

Guide to Installation and Maintenance of Resistance Welding Machines

D. Beneteau Centerline Ltd.

M. Cubert SpaceX

J. D. Dally Standard Resistance Welder Co

W. F. Qualls Consultant

D. C. Sorensen Entron Controls, LLC

B. White Jr. Janda Company, Inc.

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Foreword

This foreword is not a part of this standard, but is included for informational purposes only.

The J1 Committee on Resistance Welding Equipment was formed by the American Welding Society in 2005 to establish standards related to the design, construction, calibration, safe operation, and maintenance of resistance welding equipment. This publication is the major product of work done by a Task Group in support of that purpose.

This document is intended to supersede the Resistance Welder Manufacturer’s Association (RWMA) Bulletin 14– Maintenance Manual for Resistance Welding Machines published in 1995. RWMA Bulletin 14 was created to address a need for basic machine maintenance instruction and was intended to help users get the most from their resistance welding equipment. This first edition of this AWS publication, J1.2M/J1.2:201X, Guide to Installation and Maintenance of Resistance Welding Machines, builds on the efforts of the past and reflects input from resistance welding machine manufacturer’s installation and startup experience, updates to various national electrical and fluid power standards, and an understanding of the latest resistance welding machine accessories.

Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS J1 Committee, American Welding Society, 8669 NW 36th St #130, Miami, FL 33166.

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Table of Contents

Page No.

1. General Requirements 1

   1. Scope 1

   2. Units of Measurement 1

   3. Safety 1

2. Normative References 2

3. Terms and Definitions 2

4. Welding Machine Installation 2

   1. Moving 2

   2. Unpacking 2

   3. Assembly 3

   4. Setup 3

   5. Utility Connection 3

   6. Startup 5

5. Maintenance Recommendations 6

   1. Cooling System 6

   2. Electrodes 7

   3. Pneumatic System 8

   4. Hydraulic System 10

   5. Electrical System 10

6. Quality Control 12

   1. Weld Inspection 12

   2. Dimensional Verification 14

   3. Surface Conditions of Spot, Seam, and Projection Welds 14

7. Preventative Maintenance 16

   1. Machine Records 16

   2. Suggested Preventative Maintenance 16

   3. Maintenance Procedure 18

   4. Calibration and Verification 18

   5. Removing Equipment from Service 18

8. Troubleshooting 19

   1. Problem: Welding machine does not operate when the initiation device(s) are operated 19

   2. Problem: Resistance welding control goes through sequence, but electrodes do not close 19

   3. Problem: Control initiates but does not complete cycle 20

   4. Problem: The control cycles through as it should, but there is no weld heat 20

   5. Problem: Physical problems causing low or no heat at the tips 20

   6. Problem: Erratic welds and expulsion 21

   7. Problem: Welding machine works fine, then welds start to become weaker and weaker 21

   8. Problem: Welding Problems 22

   9. Problem: Electrode movement erratic 22

   10. Problem: Short life on SCR contactors 22

   11. Problem: Poor electrode life 23

   12. Problem: Miscellaneous 23

Annex A (Informative) Useful Records 25

Annex B (Informative) Other Documents on Resistance Welding 27

Annex C (Informative) Requesting an Official Interpretation on an AWS Standard 29

List of AWS Documents from the J1 Committee 31

List of Figures

Figure Page No.

1. Proper Water Tube Installation 7

2. Typical Chisel Configuration 13

Guide to Installation and Maintenance of Resistance Welding Machines

1. General Requirements

   1. Scope. While resistance welding machines vary considerably in size and complexity, there are basic principles applicable to the installation, operation, maintenance, and troubleshooting. This document is intended to provide basic information to the users of the resistance welding equipment to supplement the instructions and recommendations of the equipment manufacturer. Where there is conflict, the equipment manufacturers’ document shall take precedence. Although this guide is not written with mandatory requirements, mandatory language, such as the use of “shall,” will be found in those portions of the document where failure to follow the instructions or procedures could produce inferior, misleading, or unsafe results.

      It is the responsibility of the resistance welding equipment user to ensure the equipment conforms to relevant electrical, mechanical, and operating safety standards.

      Further assistance relating to interpretation or applicability of any of the suggestions outlined in this guide shall be obtained from the original machine manufacturer, rebuilder, integrator, other organization or individual qualified to make such a determination.

   2. Units of Measurement. This standard makes use of both the International System of Units (SI) and U.S. Customary units. The latter are shown within brackets [ ] or in appropriate columns in tables and figures. The measurements may not be exact equivalents; therefore, each system must be used independently.

   3. Safety. Safety issues and concerns are addressed in this standard, although health issues and concerns are beyond the scope of this standard.

      Safety and health information is available from the following sources: American Welding Society:

      1. ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes

      2. AWS Safety and Health Fact Sheets

      3. Other safety and health information on the AWS website Material or Equipment Manufacturers:

1. Safety Data Sheets supplied by materials manufacturers

2. Operating Manuals supplied by equipment manufacturers Applicable Regulatory Agencies

Work performed in accordance with this standard may involve the use of materials that have been deemed hazardous, and may involve operations or equipment that may cause injury or death. This standard does not purport to address all safety and health risks that may be encountered. The user of this standard should establish an appropriate safety program to address such risks as well as to meet applicable regulatory requirements. ANSI Z49.1 should be considered when developing the safety program.