CALIBRATING MODERN WELDING POWER SOURCES –

NECESSITY OR NECESSARY EVIL?

Thomas Reithofer, voestalpine Böhler Welding GmbH
Ewald Jantscher, STJ Schweißtechnik Jantscher
Andrea Pierobon, voestalpine Böhler Welding Selco S.l.r.
Gerhard Posch, voestalpine Böhler Welding GmbH

INTRODUCTION
When we refuel our cars, we all rely on the fact that the 50 litres On modern welding machines, which consist of highly complex
shown on the pump display is the actual amount we get in the electronic components including integrated measuring
tank – rather than, say, only 48 litres – although everyone knows instruments, the current and voltage levels can simply be read
and accepts that the mechanical components such as pumps, from the display. But is the information displayed correct and/
electric motors and valves are subject to a certain degree of or does the accuracy of the readings and the figures displayed
variability due to manufacturing tolerances and general wear. alter over time?
In the case of a petrol pump, however, periodical calibration
of the fuel delivery system, identifiable by the presence of a This article briefly explains the causes in electrical engineering
testing inspectorate sticker, ensures that we actually get what terms for possible variations in the readings, elucidates the
it says on the display. requirements of the applicable standards, and discusses the
technical necessity and the “calibration” of the power source.
But how is that question dealt with when it comes to welding
and welding power sources? The “fuel” for welding is the welding
current and voltage provided by the power source. Since the
current and voltage, along with the welding speed, have a A BRIEF EXCURSION INTO THE WORLD OF TECHNICAL
fundamental influence on the welding process as well as on the STANDARDS
properties of the weld seam, they are also defined as quality- In welding, ensuring compliance with precise measurement and
related parameters in the welding procedure specification display tolerances is not only essential for obtaining optimum
(WPS), and compliance with them is an essential requirement welding results but also largely governed by technical standards.
for weld quality. EN1090, for example, demands internal production control at

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the factory and, therefore, monitoring of compliance with the For that reason, it makes sense to always have an electrical
specified welding parameters as well. If one works according safety inspection by authorised persons carried out immediately
to that standard, regular calibration of the welding power before calibrating the equipment. Accordingly, it is also important
sources is a fundamental requirement for quality control in to be familiar with the currently applicable welding equipment
order to be certain that the figures displayed on the machine standards that relate to electrical safety. We offer a brief overview
match the actual levels in play. below.

Therefore, the “calibration” of welding power sources is an

important quality-related aspect that should be taken into
account in any welding shop. For metalworking businesses STANDARDS THAT DEFINE ELECTRICAL SAFETY AND THE
certified to the EN ISO 9000 series of standards, it is even CALIBRATION OF POWER SOURCES
compulsory. Another important aspect is the possible economic Welding power sources operate with high electrical currents
implications, such as in connection with product liability issues. and voltages and, therefore, pose a high level of potential
electrical danger. Accordingly, manufacturers must comply with
But just as important as regular calibration is the technical the strict electrical engineering standards when developing
safety inspection of the power sources. Practice shows that the such products and guarantee that in practical use the welding
obligatory safety inspection of welding power sources leads to power source poses no danger to the welder during normal use
the “disqualification” of welding power sources much more when in proper working order. That is a fundamental reason
frequently than calibration does. In roughly 40% of the safety that argues for the use of high-quality power sources designed
inspections carried out, the machines reveal serious defects for industrial/commercial use even by private individuals.
such as damaged plugs or cables, damaged sockets or burnt
earth connections. Although such defects are essentially Figure 1 provides an overview of the essential standards for
unrelated to the results of a calibration, they should nevertheless welding power sources. The full versions of the standards can
always be rectified first before any calibration process is started. be obtained from the national standards institutions.

STANDARD DESIGNATION BRIEF DESCRIPTION

» A European standard implemented in the various countries with corresponding prefix (e.g.
EN IEC 60974:2018 DIN, OVE, etc.)
Arc welding equipment » Subdivided according to subsystems (e.g. power sources, liquid cooling systems, etc.)
» Individual parts are identified by a dash followed by part number

» Applies to welding power sources for arc welding and related processes for commercial
EN IEC 60974-1:2018 use that have a power supply voltage up to 1000V, are battery-operated or mechanically
Arc welding equipment – Part 1: driven.
Welding power sources » Deals with safety and performance requirements for the construction of welding power
sources and during regular maintenance or repair

OVE EN IEC 60974-1:2019

Arc welding equipment – Part 1: » Current edition of Austrian version of relevant standard EN IEC 60974-1
Welding power sources

DIN EN IEC 60974-1:2018; VDE

0544-1:2018 » Current edition of German version of relevant standard EN IEC 60974-1
Arc welding equipment Part 1: Wel- » Corresponds to VDE 0544-1:2018
ding power sources

DIN EN IEC 60974-14:2019; VDE

» Applies to checking the performance of arc welding equipment built according to the safety
0544-1:2019
requirements of IEC 60974-1
Arc welding equipment Part 14: Ca-
» Currently applicable and replaces DIN EN 50504:2009; VDE 0544-50:2009
libration, validation and consistency
» All national standards that conflict with this standard must be withdrawn by 23/11/2021
testing

DIN EN 50504:2009; VDE 0544- » This (old) standard laid down validation procedures for arc welding equipment.
50:2009 » This standard has been withdrawn and replaced by DIN EN IEC 90974-14:2019; VDE 0544-
Validation of arc welding equipment 14:2019

Figure 1: Overview of essential standards for welding power sources (source: own presentation)

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MEANING AND DEFINITION OF CALIBRATION
The standard “OVE EN IEC 60974-14 Arc welding equipment NECESSITY AND BENEFITS OF CALIBRATION
– Part 14: Calibration, validation and consistency testing” defines Modern power sources are now highly complex electronic
not only “calibration” but also “validation”. components (Fig. 2) and are essentially supplied in calibrated
condition. The calibration interval specified by the manufacturer
Calibration: and/or in the standards (usually one year) should always be
“Activities for determining the relationship existing between a complied with. Due to a variety of environmental effects and
DISPLAYED VALUE and a REFERENCE VALUE under defined natural ageing processes of various electronic components
conditions” such as capacitors (there are large differences according to
design in this area) and, to a lesser extent, resistors and coils
Validation: (oxidation, diffusion, etc.), parameters may begin to drift from
“Activities for the purpose of verifying that a SET VALUE matches the set values.
the REFERENCE VALUE (within defined limits)”
When a welding power source starts to drift noticeably and,
especially, by how much depends on the ambient conditions
In practice, that means that in the case of welding power sources (temperature fluctuations, humidity, dust exposure, etc.), partly
without an integrated measuring instrument and display, i.e. on the load on the machine (frequent use in the upper power
“old” systems, the procedure carried out is validation, which range, frequent changing of the settings, etc.), but most
means basically checking whether welding parameters can still particularly on the quality of the electronic components fitted.
be correctly set. In the case of “modern” power sources with
integrated measuring instruments and displays, on the other Experience shows that, overall, roughly 3-5% of older-generation
hand, the procedure carried out is calibration. In such cases, welding power sources (without digital control systems) that are
calibration means comparing the readings displayed with the tested in the course of standard annual calibration procedures
actual reference values. Since most power sources now have return values outside the specified limits and, therefore, should
digital displays, calibration is the most frequently used verification not continue to be used for welding processes that are subject
procedure in practice. In many cases, however, both calibration to a technical standard. In such cases, the machines should be
and validation are carried out, which although allowed according readjusted or repaired by qualified persons or directly by the
to the standard, is not necessary for power sources with a digital manufacturer. In the case of modern inverter power sources,
display. Since the two processes are very similar, the two terms unacceptable drift levels occur only in isolated exceptional
are also frequently confused and incorrectly used. cases (<0.5%), even after many years of use.

Nevertheless, it is advisable to perform

regular checks even on modern power
sources, especially to ensure the
e q u i p m e nt co m p l i e s w i t h t h e
specifications of the WPS and the
standard. Machines should in any case
always be calibrated after any major
servicing or repairs.

PERMISSIBLE TOLERANCES FOR

CALIBRATION
The maximum permissible tolerances
for current, voltage and wire feed rate
are specified in each case in OVE EN
IEC 60974-14, with a distinction being
made between “standard class” and
“precision class” with reference to EN
IEC 60974-1. Thus, the tolerance for
current for standard-class welding
equipment with digital measurement
and display units is +/- 2.5% of the
maximum rating for the welding current
specified on the rating plate.

Figure 2: Design of a modern welding power source (source: voestalpine Böhler Welding) In the case of a 500A system, that

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would be +/- 12.5 A. By comparison, the permissible tolerance
for precision-class equipment is +/- 1%, i.e. as little as +/- 5 A.
With lower-power systems the permissible tolerances are
accordingly smaller.

For special applications, it may also be necessary to calibrate

other components of a welding system where specified by the
WPS or the power source manufacturer.

Key
a SET VALUE 1 Voltage
NECESSARY CAPABILITIES OF THE CALIBRATORS b DISPLAYED VALUE 2 Current
c REFERENCE VALUE 3 Wire feed rate
As a fundamental principle, calibration and validation of power
d Standard load or arc load
sources should only be carried out by an expert. According to
OVE EN IEC 60974 -14, that is a person who “can show proof Figure 4: Example configuration for a calibration process (source:
of suitable qualifications, appropriate experience and adequate OVE EN IEC 60974-14)
training in relation to welding and measurement technology,
and knowledge regarding possible electrical hazards and the The measurements must be performed using calibrated
necessary safety measures”. instruments that ensure sufficient resolution of the measured
variable (at least two and a half times more precise than specified
by the verification class concerned). In addition, the power
sources must be placed under standardised loads (normal load)
METHODS FOR CALIBRATING WELDING POWER SOURCES according to the process during the measurements.
In general, all common types of power source for arc welding All relevant parameters and measurement results must be fully
(GMAW, SAW, SMAW, FCAW, GTAW) are calibrated/validated. recorded and documented in a corresponding report.
The calibration/validation process is basically defined by the
standard. Since modern power sources generally have integrated If a standardised calibration device as offered by a number of
calibration software (usually accessible via the Service menu) reputable manufacturers is used, the calibration process can
and professional service and maintenance technicians almost be performed relatively quickly and easily. In such cases,
exclusively use purpose-designed calibration equipment and specialised software solutions simplify not only the generation
software in practice, calibration is almost always done in that of reports but also set the parameters specified in the standard,
way today. such as current, voltage and wire feed rate, along with the
permissible tolerances in each case and the number of
Calibration in direct current mode is sufficient in many cases. measurement points required. The loads required in each case
The specifications of the standard in each case are summarised can be implemented with the aid of the resistive loads integrated
in Figure 3. in the calibration device. Figure 5 shows a possible set-up for
calibration.

A revolution counter is generally used to check the wire feed

rates. In that case, the wire feed rate is mathematically calculated
from the speed of rotation measured on the wire feeder. An
alternative method would be a travel/time measurement using
a stop-watch and tape measure followed by mathematical
calculation of the feed rate.

Every measurement must be documented accordingly. If the

measured values established in each case are acceptable
according to the specifications of the standard, the fact is
documented accordingly in the “calibration report” for the
machine concerned. The machine is also provided with a sticker
indicating the same.

Figure 3: Operating modes for calibration (source: based on OVE

It is essential that any defects that are identified in the course
EN IEC 60974-14)
of the safety inspection that is usually carried out in conjunction
with calibration are rectified immediately before the calibration
A basic set-up for the calibration process is illustrated in Figure process. Fundamentally, however, it should be in the interests
4. Power source manufacturers may specify different test of every single business, and especially the welders, to eliminate
configurations for their products. any such risks without delay as soon as they are discovered.

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Figure 5: Calibration of a welding power source using a calibrator (source:
Schweisstechnik Jantscher)

ECONOMIC ASPECTS
When procuring welding power sources one should in any case
be aware of the safety and quality features and also consider
from the outset what the associated service concept is to look SUMMARY
like (what service is required, who can provide it, how often will Welding power sources fundamentally pose a high potential
a service be required, etc.). Furthermore, welding power source electrical danger due to the high welding currents and voltages.
manufacturers can significantly influence the quality and safety Nevertheless, the risk is reduced to a minimum by compliance
of a system by various means such as the use of high-quality with current electrical engineering standards right from the
electronic components and comprehensive quality controls. development stage and the use of high-quality electrical
That is why, at voestalpine Böhler Welding for example, every components, especially in the case of systems intended for
circuit board in a welding power source is manufactured on the commercial use. Reputable power source manufacturers and
in-house PCB production line in Cittadella, Italy, checked by a professional service technicians can provide more detailed
3-stage quality assurance process and sensitive electronic expert advice on the subject.
components are protected by an extra coating of lacquer. What To ensure work is carried out in accordance with the applicable
is more, every single power source is put through a static and standards, regular calibration of welding power sources, generally
dynamic end-of-line test before shipping. once a year, is necessary, even though modern power sources
very rarely show any unacceptable divergence from the specified
For metalworking businesses that have several welding power values. In practice, however, it has been shown that annual
sources, an economic efficiency analysis of calibration per se inspections frequently reveal safety-related defects on the
definitely makes sense. Depending on the welding machine welding power sources that could certainly pose a danger to
and its condition, the work involved in the technical safety the welder. For that reason alone, it is an obvious step to have
inspection and calibration/validation should be estimated at the inspections regularly performed and documented by qualified
approx. one hour’s labour for a service technician and assistant. service technicians, even if it may not appear necessary for
But if one weighs those costs against the risks and quantifies high-quality welding power sources at first sight. Only in that
the possible losses of production, quality deficiencies, product way is it possible to sustainably ensure that all health-and-safety
liability issues and health-and-safety aspects, it quite quickly and quality-related aspects are complied with, which in turn
becomes clear that such regular (usually annual) outlays are contributes to the safety of the welder, customer satisfaction
absolutely worth the expense. and financial success.

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BIBLIOGRAPHY AUTHORS

OEV EN IEC 60974-1: 2019, Lichtbogenschweißeinrich-tungen DI Thomas Reithofer,

- Teil 1: Schweißstromquellen (IEC 60974-1:2017) Vice President Global Equipment
Services & Digital Solutions at
OEV EN IEC 60974-14: 2019, Lichtbogenschweißein-richtungen voestalpine Böhler Welding
GmbH
– Teil 14: Kalibrierung, Validierung und Konsis-tenzprüfung
(IEC 60974-14:2018)

Plaßmann W, Schultz D; Handbuch Elektrotechnik – Grundlagen

und Anwendungen für Elektrotechniker (6. Aufl.); Springer
Vieweg Verlag

voestalpine Böhler Welding GmbH; Maintenance Manual –

Ewald Jantscher, IWT;
Calibration and Validation (Rev. A); 2020
Chief Executive and Proprietor
STJ Schweißtechnik Jantscher

This original article was published in the magazine ÖGS Schweiss-

und Prüftechnik in November 2020 firstly.

DI Andrea Pierobon, EWF/EWT;

Equipment Service Manager at
voestalpine Böhler Welding Selco
S.l.r.

DI Dr. Gerhard Posch, IWE;

Vice President Knowledge & Data
Management at voestalpine
Böhler Welding GmbH

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