AWS J1.1M/J1.1:2013

An American National Standard

Specification for Resistance Welding Controls

AWS J1.1M/J1.1:2013

An American National Standard

Approved by American National Standards Institute

July 29, 2013

Specification for Resistance Welding Controls

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 standard provides nomenclature pertaining to the design, construction, and programming of resistance welding controls. Standard calibration and performance parameters as well as labeling and documentation requirements are also outlined. The purpose is to promote standardization, safety, and proper application of resistance welding controls.

AWS J1.1M/J1.1:2013

ISBN-13: 978-0-87171-842-6

©2013 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 D). 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 required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS J1Committee 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.

Personnel

AWS J1 Committee on Resistance Welding Equipment

D.C. Sorenson, Chair ENTRON Controls LLC

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

E.H. Abrams, 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 PC

W.F. Qualls Consultant

N.S. Scotchmer Huys Industries Limited

B. White Jr. Janda Company

K. Ymker RoMan Manufacturing, Inc.

Advisors to the J1 Committee on Resistance Welding Equipment

M. Cubert Sciaky, Inc.

AWS J1/TG1 Task Group to Prepare the Specification for Resistance Welding Controls

D. Beneteau Chair Centerline Ltd

J.P. Derdeyn Techno Control Cybernetic Inc.

P.W. Fischer Automation International Inc.

R.B. Hirsch Unitrol Electronic Inc.

B. Kelly Kelly Welding Solutions PC

D.C. Sorenson ENTRON Controls LLC

T. Sparschu tms Solutions

J. Stanway BF ENTRON LLC

L.B. Wright Matuschek Welding Products Inc.

Foreword

This foreword is not a part of AWS J1.1M/J1.1:2013, Specification for Resistance Welding Controls, 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 Manufacturers’ Association (RWMA) Bulletin 5 – Resistance Welding Control Standard published in 1994. RWMA Bulletin 5 had superseded the National Electrical Manufacturers Association (NEMA) document ICS-5:1979 of the same name. This document therefore perpetuates a long legacy to promote standardization, safety, and proper application of resistance welding controls.

The Resistance Welder Manufacturers’ Association amalgamated with the American Welding Society in 2005. The RWMA Committee of the American Welding Society continues to promote the application and advancement of the resistance welding process. The guidance and support of the RWMA Committee has contributed to the successful execution of this document.

This first edition of this AWS publication, J1.1M/J1.1:2013, Specification for Resistance Welding Controls, builds on the efforts of the past and provides considerable revisions throughout. Control function definitions and label examples have been enhanced. Many design prescriptive requirements have been removed. Inverter technology has been added.

Your comments for improving J1.1M/J1.1:2013, Specification for Resistance Welding Controls are welcome. Submit comments to the Managing Director, Technical Services Division, American Welding Society, 8669 NW 36th Street,

#130, Miami, FL 33166; telephone (305)443-9353; fax (305) 443-5951; e-mail info@aws.org; or via the AWS web site

<https://www.aws.org>.

Table of Contents

Page No.

1. Scope and Applicability 1

2. Normative References 1

3. Terms and Definitions 2

4. Control Nomenclature 3

   1. Control Types 3

   2. Special Purpose Control Configurations 3

   3. Control Components 4

   4. Control Operation 5

   5. Control Functions 7

   6. Fault Classifications 11

5. Interface Connections 12

   1. Emergency Stop 12

   2. External Weld/No Weld 13

   3. Initiation Input (s) 13

   4. Pressure Switch Connections 13

   5. Fault Signaling 13

6. Identification and Labeling 13

   1. Control Equipment Rating and Identification Plates 13

   2. Terminal Markings for Power 14

   3. Terminal Markings for Control 14

   4. Precautionary Labels 14

7. Performance 16

   1. General 16

   2. Emergency Stop 17

   3. Protection Against Spurious Operation 17

   4. Automatic Voltage Compensation (Single Phase) 17

   5. Constant Current 17

   6. Heat Control 17

   7. Constant Power 17

   8. Constant Voltage 18

   9. Manual Transgun Control 18

8. Performance Tests 18

   1. Downslope Test 18

   2. Initiation Test 18

   3. Upslope Calibration 18

9. Documentation 19

   1. Contents 19

   2. Format 19

AWS J1.1M/J1.1:2013

Annex A (Normative) Weld Sequences 21

Annex B (Informative) Example Precautionary Labels 27

1. DANGER: Voltage And Flash Hazard Label 27

2. DANGER: Hazardous Voltage From One Or More Sources 27

3. DANGER: Earth Ground Required 28

4. DANGER: Stored Energy Hazardous Voltage 28

5. DANGER: Stored Energy Discharge-Hazardous Voltage 28

6. WARNING: Hazardous Voltage From One or More Sources 29

7. WARNING: Flash Hazard Do Not Disassemble 29

8. WARNING: Stored Energy Hazardous Voltage 29

9. WARNING: Stored Energy Discharge-Hazardous Voltage 30

10. CAUTION: Water Hose Burst Hazard 30

Annex C (Informative) Other Documents on Resistance Welding 31

Annex D (Informative) Guidelines for Preparation of Technical Inquiries for

AWS Technical Committees 33

List of Tables

Table Page No.

1 Control Group Terminal Markings 15

List of Figures

Figure Page No.

1. Alternate Polarity Weld Current 5

2. Unipolarity Weld Current 7

3. Slope Current 10

1. Waveform Example of a Repeating Pulse Weld Schedule 21

2. Example of a Pulsation Weld Schedule 22

3. Waveform Example of a Pulsation Weld Schedule with Preweld and Postweld Functions 22

4. Example of a Single Pulse Weld Schedule with Preweld and Postweld Functions 23

5. Simplified Example of a Pulsation Weld Schedule Incorporating Preweld and Postweld Functions 23

6. Simplified Example of a Single Pulse Weld Schedule with Preweld and Postweld Functions 24

7. Simplified Example of a Single Pulse Weld Schedule with Preweld Compression 24

8. Simplified Example of a Roll Spot Weld Schedule 25

9. Simplified Example of a Continuous Seam Weld Schedule 25

10. Waveform Example of Frequency Converter Waveforms 26

Specification for Resistance Welding Controls

1. Scope and Applicability

   1. Scope. This standard provides nomenclature pertaining to the design, construction, and programming of resistance welding controls. Standard calibration and performance parameters as well as labeling and documentation requirements are also outlined. As there are many available resistance welding control types, configurations, sizes and models, not every part of this standard may apply in every case. This document does not supersede regulations, codes and standards relating to electrical and electronic circuit design or implementation. The purpose is to promote standardization, safety, and proper application of resistance welding controls.

   2. Units of Measure. 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. Material Safety Data Sheets supplied by materials manufacturers

         2. Operating Manuals supplied by equipment manufacturers Applicable Regulatory Agencies

         
         

2. Normative References

The following standards contain provisions, which, through reference in this text, constitute mandatory provisions of this AWS Standard. For undated references, the latest edition of the referenced standard shall apply. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply.

American Welding Society (AWS) document1

AWS A3.0M/A3.0, Standard Welding Terms and Definitions; Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying

1 AWS standards are published by the American Welding Society, 8669 NW 36th St, #130, Miami, FL, 33166.