1、AWS J1.2M/J1.2:2016An American National StandardGuide to Installation and Maintenance of Resistance Welding MachinesAWS J1.2M/J1.2:2016An American National StandardApproved by the American National Standards Institute August 4, 2016Guide to Installation and Maintenance of Resistance Welding Machines
2、1st EditionPrepared by: American Welding Society (AWS) J1 Committee on Resistance Welding EquipmentUnder the Direction of AWS Technical Activities CommitteeApproved by AWS Board of DirectorsAbstractThis guide provides general instructions for the installation, operation, and maintenance of common ty
3、pes 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.iiAWS J1.2M/J1.2:2016ISBN: 978-0-87171-891-42016 by Ameri
4、can Welding SocietyAll rights reservedPrinted in the United States of AmericaPhotocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in any form, including mechanical, photocopying, recording, or otherwise, without the prior written permission of
5、 the copyright owner.Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, or educational classroom use only of specific clients is granted by the American Welding Society provided that the appropriate fee is paid to the Copyright Clear
6、ance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet: .iiiAWS J1.2M/J1.2:2016Statement on the Use of American Welding Society StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS)
7、 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
8、 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 cas
9、es, 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 St
10、andards 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 independ
11、ently 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, directl
12、y 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 oth
13、er 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 determinin
14、g 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 ame
15、ndments 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
16、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 stan
17、dard.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
18、 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 o
19、ffered 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 u
20、nofficial 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,
21、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 A
22、WS J1 Committee on Resistance Welding Equipment and the author of the comments will be informed of the Committees 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 a
23、n 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.ivAWS J1.2M/J1.2:2016This page is intentionally blank.vAWS J1.2
24、M/J1.2:2016PersonnelAWS J1 Committee on Resistance Welding EquipmentD. C. Sorensen, Chair Entron Controls, LLCR. B. Hirsch, Vice Chair Unitrol Electronics, Inc.A. Babinski, Secretary American Welding SocietyD. Beneteau Centerline Ltd.W. H. Brafford Tuffaloy Products, Inc.J. D. Dally Standard Resista
25、nce Welder Co. B. Kelly Kelly Welding Solutions P.C.W. F. Qualls ConsultantN. S. Scotchmer Huys Industries LimitedB. White Jr. Janda Company, Inc.K. Ymker RoMan ManufacturingAdvisors to the J1 Committee on Resistance Welding EquipmentM. Cubert SpaceXAWS J1B/TG2 Task Group to Prepare the Guide to Ins
26、tallation and Maintenance of Resistance Welding MachinesD. Beneteau Centerline Ltd.M. Cubert SpaceX J. D. Dally Standard Resistance Welder Co W. F. Qualls Consultant D. C. Sorensen Entron Controls, LLCB. White Jr. Janda Company, Inc.viAWS J1.2M/J1.2:2016This page is intentionally blank.viiAWS J1.2M/
27、J1.2:2016ForewordThis 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,
28、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 14 Maintenance Manual for Resistance Welding Machines
29、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 Resis
30、tance Welding Machines, builds on the efforts of the past and reflects input from resistance welding machine manufacturers installation and startup experience, updates to various national electrical and fluid power standards, and an understanding of the latest resistance welding machine accessories.
31、 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 36thSt #130, Miami, FL 33166.viiiAWS J1.2M/J1.2:2016This page is intentionally blank.ixAWS J1.2M/J1.2:2016Table of ContentsPage No.1.
32、General Requirements 11.1 Scope . 11.2 Units of Measurement . 11.3 Safety. 12. Normative References . 23. Terms and Definitions . 24. Welding Machine Installation 24.1 Moving 24.2 Unpacking . 24.3 Assembly . 34.4 Setup 34.5 Utility Connection . 34.6 Startup . 55. Maintenance Recommendations 65.1 Coo
33、ling System . 65.2 Electrodes 75.3 Pneumatic System . 85.4 Hydraulic System 105.5 Electrical System . 106. Quality Control . 126.1 Weld Inspection . 126.2 Dimensional Verification . 146.3 Surface Conditions of Spot, Seam, and Projection Welds 147. Preventative Maintenance 167.1 Machine Records . 167
34、.2 Suggested Preventative Maintenance 167.3 Maintenance Procedure . 187.4 Calibration and Verification . 187.5 Removing Equipment from Service 188. Troubleshooting 198.1 Problem: Welding machine does not operate when the initiation device(s) are operated . 198.2 Problem: Resistance welding control g
35、oes through sequence, but electrodes do not close 198.3 Problem: Control initiates but does not complete cycle . 208.4 Problem: The control cycles through as it should, but there is no weld heat 208.5 Problem: Physical problems causing low or no heat at the tips 208.6 Problem: Erratic welds and expu
36、lsion . 218.7 Problem: Welding machine works fine, then welds start to become weaker and weaker . 218.8 Problem: Welding Problems 228.9 Problem: Electrode movement erratic . 22xAWS J1.2M/J1.2:20168.10 Problem: Short life on SCR contactors 228.11 Problem: Poor electrode life 238.12 Problem: Miscellan
37、eous 23Annex A (Informative) Useful Records 25Annex B (Informative) Other Documents on Resistance Welding . 27Annex C (Informative) Requesting an Official Interpretation on an AWS Standard . 29List of AWS Documents from the J1 Committee . 31List of FiguresFigure Page No.1 Proper Water Tube Installat
38、ion 72 Typical Chisel Configuration 131AWS J1.2M/J1.2:2016Guide to Installation and Maintenance of Resistance Welding Machines1. General Requirements1.1 Scope. While resistance welding machines vary considerably in size and complexity, there are basic principles applicable to the installation, opera
39、tion, 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 p
40、recedence. 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 responsibi
41、lity 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 machin
42、e manufacturer, rebuilder, integrator, other organization or individual qualified to make such a determination.1.2 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
43、tables and figures. The measurements may not be exact equivalents; therefore, each system must be used independently.1.3 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 avai
44、lable 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 websiteMaterial or Equipment Manufacturers:(1) Safety Data Sheets supplied by materials ma
45、nufacturers(2) Operating Manuals supplied by equipment manufacturersApplicable Regulatory AgenciesWork 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 do
46、es 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.2AWS
47、 J1.2M/J1.2:20162. Normative ReferencesThe documents listed below are referenced within this publication and are mandatory to the extent specified herein. For undated references, the latest edition of the referenced standard shall apply. For dated references, subsequent amendments to, or revisions o
48、f, any of these publications do not apply.American Welding Society (AWS) standards:AWS A3.0M/A3.0, Standard Welding Terms and DefinitionsAWS J1.1M/J1.1, Specification for Resistance Welding ControlsNational Fire Protection Association (NFPA) standards:NFPA 70, National Electrical CodeNFPA 79, Electr
49、ical Standard for Industrial Machinery3. Terms and DefinitionsAWS A3.0M/A3.0, Standard Welding Terms and Definitions, provides the basis for terms and definitions used herein. However, the following terms and definitions are included below to accommodate usage specific to this document.resistance welding machine. An apparatus incorporating a means for delivering a controlled force and current to perform a resistance welding process.welding machine. See resistance welding machine.user. The individual or company responsible for instructing and directing the personnel w
