INSTRUCTIONAL MANUAL

AC Resistance Welding Machine

KIRTI PRESSINGS PVT. LTD.

1

Dear Customer,
KIRTI PRESSINGS PVT LTD thanks you for selecting our machine for your
production requirements.
Our resistance welding machines are designed for very high demand of rigidity and
repeat accuracy. Every part of the machine is now tested and proven successful in
high production volumes. In standard models we have adopted simple controls, rigid
moving parts, minimum throat depth. Providing value for money for years.
Customer feedback is always proving a great opportunity to improve our machines.
Your input regarding improvement or design modifications will allow us to build more
application friendly machines. I request you to help us making better designs.
With this manual we are furnishing installation requirements, operation instructions,
basic fault finding, controller setting examples and information on resistance welding.
We are committed to make latest technologies available to our customers. Please
keep visiting our website for more information and new technology in resistance
welding. www.kirtipressings.com
Thank you once again,
Yours Truly
Ujjwal Bahekar.
Managing Director
Kirti Pressings Pvt Ltd

Table of Contents
I.

Preface and General Safety....................................................................4

i. Introduction............................................................................................4
ii. Safety Information.................................................................................5
iii. Warranty Information............................................................................6
II.
Specifications..........................................................................................7
III. General Dimensions................................................................................8
IV. Unloading The Machine..........................................................................9
V.
Making Installations and Initial Settings...............................................9
VI. Power Connection Requirement...........................................................11
VII. Water Connection Requirement............................................................11
VIII. Powering ON and Test Run...................................................................12
IX. Internal Components of The Machine..................................................17
i. Transformer..........................................................................................17
ii. Thyristor................................................................................................17
iii. Controller..............................................................................................18
X.
Example on Setting Current Monitor....................................................18
XI. Setting Up and Making Resistance Welds...........................................20
i. Welding Electrode................................................................................20
ii. Electrode Installation...........................................................................20
iii. Setting Weld Force..............................................................................20
iv. Electrode Selection.............................................................................21
v. Electrode Material................................................................................21
vi. Electrode Design.................................................................................21
vii. Electrode Alignment...........................................................................22
viii. Electrode Maintenance.......................................................................22
ix. Pressure Settings...............................................................................22
x. Heat Settings.......................................................................................23
xi. Time Setting........................................................................................23
xii. Testing The Weld................................................................................24
XII. Fault Finding.........................................................................................25
XIII. Spare Parts List.....................................................................................31
XIV. Circuit Diagram.....................................................................................32
XV. Standard Starting Parameters For Welding.......................................33
XVI. Contact Details.....................................................................................35

I. Preface and General Safety

i. Introduction:
Thank you for purchasing this KIRTI Product for your production requirement.
Our resistance welding machines are designed for very high demand of rigidity and
repeat accuracy. Every part of the machine is now tested and proven successful in
high production volumes. In standard models we have adopted simple controls, rigid
moving parts, and minimum throat depth. Providing value for money for years.

WARNING
1. Read this instruction manual before using this machine. Be sure to
fully understand the descriptions contained in this instructional manual
before starting operation, inspection or maintenance of this machine.
In particular, the machine must be installed, operated, adjusted and
maintained by trained specialists or qualified personnel as directed in
this instruction manual. If the machine is operated by anyone other
than a trained specialist or other qualified personnel, it can result in
damage to the machine or personal injury. In such case, the
manufacturer of the machine shall be released from al the
responsibility and liability.
2. Any accidents or failures caused by users failing to follow the
instructions contained in this manual shall release the manufacturer of
this machine from all responsibility and liability
3. Keep the instructional manual in a specified place near the machine
as a quick reference tool. Please keep this manual in good condition.
4. When this machine is transferred to another owner, this instruction
manual must be transferred together with the machine.

ii. SAFETY INFORMATION:

This equipment must be used solely for welding operations.
Welding can be harmful to yourself and others.
The user must therefore be educated against the hazards deriving from welding
operations.
Electric shock may be fatal.
Install and earth the welding machine according to the applicable regulations.
Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.
Isolate yourselves from both the earth and the workpiece.

Fumes and gases may be hazardous to your health.

Keep your head away from fumes.
Work in the presence of adequate ventilation, anduse ventilators around the arc to prevent
gases from forming in the work area.

Sparks may injure the eyes ,burn the skin and may cause fire.
Protect your eyes with welding masks fitted with filtered lenses, and protect your body with
appropriate safety garments.
you should also make sure there are no flammable materials in the area, and wear appropriate
protective gaements.
Protect others by installing adequate shields or curtains.

Noise
This machine does not directly produce noise exceeding 80dB,but the welding procedure may
produce noise levels beyond said limit.
Users must therefore implement all precautions required by law.

Explosions
Do not weld in the vicinity of containers under pressure, or in the presence of explosive dust,
gases or fumes.

Eleltromagnetic Compatibility
This must be used solely for professional purposes in an
industrial environment. There may be potential difficulties in ensuring electromagnetic
compatibility in nonindustrial environments.

In case of malfunctions,request assistance from qualified personnel.

Do not dispose of electrical equipment together with normal waste.
This machine is protected by a thermostat, which prevents the machine from
operating if the allowable temperatures are exceeded. In this condition the display
will show the error
5

iii. Warranty Information

II. Specifications:
Rated Power at 50% Duty Cycle
Secondary Voltage
Welding Current Maximum
Control Type
Time Setting Least Count
Throat Depth
Arm Gap Maximum
Electrode Force
Maximum Strokes Per
Second(No weld)
Free Air Consumption for 100
Spots 25mm stroke 1bar
Cooling Water Pressure
Required
Cooling Water Flow Rate Per
Minute
Power Supply
Main Supply Fuse Rating
Delayed Fuse
Supply Cable Required
Dimensions
Weight

50kVA
6v,8v,9v
13.5kA
Secondary Feedback type
DSP Based
1 Cycle
300mm
300mm
150~470kg
6
250 liters
2kg/cm2
9liters/minute
415v 50Hz 2Phase
150A
150A
50mm2 Aluminium/70mm2
Copper
900mm x 430mm x 1742mm
515kg

III. General Dimensions

212

1030

953

1530

1742

1742

258

430

900

Side View

Front View

IV. Unloading of the machine

For unloading eyebolts are provided at top of the machine.
Use proper hook to unload the machine. For more safety use wire rope . Assume 800kgunloading weight while choosing unloading equipment.
Caution. The weight of the machine is concentrated at upper portion. This may cause machine
to topple if handled manually and carelessly. Use crane for unloading and placing the machine at
place. Due care should be taken for possibility of toppling.

V. Making installations and initial settings

Remove packing covers

Install machine at place.

Check for transit damages

Machine on long distance transport comes with protection to controller. REMOVE THIS
COVER BY UNBOLTING FOUR SCREWS. This cover is not part of the machine. Please
remove this after installation.

Tower lamp is packed in this cage. UNPACK THE TOWER LAMP and screw it at the
location at top of the machine. Two wires coming from tower lamp are marked (ERROR).
Generally the packing is done by retaining the connection.

Locate the mark press

and turn
To fix

Fix the FRL unit

Connect tube

Air preparation unit is packed in box and located inside the machine body. Unpack the
FRL unit, Unscrew the bolts at left side of the machine Fix the FRL. Tubing is to be fitted
at out of the FRL. Do this by placing the tube by little pressing against the connector. The
air pressure switch if supplied with machine is to be connected by two wires. These
connections are to be made on N.C. terminals of the switch. (N.O. terminal screw is
removed on dispatch)

Fix pressure guage

Connect wires to NC
contact of pressure
switch

Connect Factory air supply (minimum pressure 5~6 bar) to FRL unit

Fill the lubricator by 32 grade lubrication oil

Machine foundation is not generally required, If needed, expansion bolt fixing can be done
at the holes provided.

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VI. Power connection Requirement

Two phase connection with 35mm square copper single core multistrand cable is required
for better performance. Lower cable thickness will effect less current drawn at secondary
and heating of cables voltage drop in primary.
Minimum100 amp MCCB is required for isolating the machine.

VII. Water connection Requirement

Cooing water is most important input to the machine. Please do not take welds from the machine
if water connection is not provided. Air tower cooling is recommended for the machine cooling
water.
Like all cooling systems HARD WATER IS NOT GOOD FOR LIFE OF THE MACHINE. If you are
using hard water please treat it with softeners. Using hard water as machine coolant will
drastically reduce life of Transformer and Thyristor. These are high value spares.
The cooling arrangement should be capable to take away heat from the water. Cooling tower is
best in performance. Underground tank of 4000 Liters can serve alternate to one machine.
Water at output should be less than 5 degree above room temperature. This can be adjusted by
allowing more water flow through the machine.

CONNECT ONLY TWO PHASES OF 415V A.C. MAINS LINE AS INDICATED OPENING
BACK PANEL OF THE MACHINE.

Connect supply
two phase 440v
by 30mm sq
copper cable

Connect only two phases. (Phase 1 and phase 2)

Connect water inlet and water outlet as indicated. Connections are to be made at nipples
provided right bottom at back of machine.
Insure proper flow of cooling water so that out water should not exceed 10 deg above
ambient. it is advisable to out water in free tunnel or dia 2 inch pipe gravity return.
Never operate machine without cooling water this may damage costly thyristor assemblies.
Connect equipment to proper earth.
Connect air line to the point provided at FRL unit

11

VIII. Powering ON and Test Run

Before making supply 'on' please check and confirm following again.
1. Ensure the 440v supply is connected to the machine.
2. Check water input and output connection are made. Inspect visually for leakage . Stop
leakages if any.
3. Inspect air connection for leakage. adjust pressure setting to 3~4 kg/cm^ as per job
requirements
4. Insure electrode gap and fitment of electrodes

After insuring proper connections make supply on. Check power supply voltage
by multimeter this should not be below 400v.

Check controller power supply by multimeter this should be 220v. There are taps
provided on 440 to 220v isolation transformer to adjust this voltage
Make controller ON by accessing On/Off switch located at back of the controller.

CAUTION:
PLEASE REPLACE PROTECTIVE COVER AFTER CONNECTIONS OR
MAITANANCE OF THE CONTROLLER. THERE IS ELECTRIC SHOCK
HAZARD AS HIGH VOLTAGE TERMINALS MAY BE ACCIDENTALY
TOUCHED.

12

Always insure this

protective cover closed.
Hazard of accidental
touching to high voltage
points if kept open.

Weld power
LED indicate
presense of
phase 1 and
phase 2

Ready LED :
indicate machine
is in weld mode
and ready to
weld.

W.POWER

READY

START

STEP END

CAUTION

ERROR

Never attempt to open

controller lid when weld
power LED on front
panel is glowing or
without insuring
complete power to
Controller On Off
switch makes controller
On or OFF but 440v is
always live and
connected unless Main
power is off.

Start light : glows at

pressing of start switch
. This light should be
off when foot switch is
not pressed

13

KA window1
Current 1,2,3 buttons: Sets
current values to W1 , W2, W3
respectively.
Monitor window 2
Monitor on off :
ON : current drawn
in cycle is displayed
in KA window 1and
its %on set value in
monitor window 2
OFF displays
setting values in
window1
To start controller:
Make sure weld power LED at top left is glowing. This light indicated the presence of phase 1
and phase 2. If this light is off please check input connection of F1 and F2.
Make the controller on by reaching out on-off switch situated at back of the controller.
Controller with run through initial checks, showing 333 222 111 at all windows.
Select schedule 01 if not already selected.
Put some values in welding parameters.
To do so
Press PROG/OPER values in some digit will be blinking now.
Use curser < > to move blinking digit to squeeze window.
By pressing + - select value for this field (say 18) .
Move curser for next position by pressing >.
Select (00) for weld1 ,(0) for cool1, (0) for slope 1,
Select ( 12 ) for weld2 . This field indicates welding duration for main welding time,
Select (00) for cool2 , (00) for wled2 ,(0) for slope 2 ,
Put value ( 08) in hold , this sets hold time for welding operation.
Put value (00) in OFF(pulse ) window. IF you select (00) machine will run in single cycle, for
repeat cycle select value = pause you need between to weld cycles .( 10 = 200 msec pause
before starting next repeat cycle.)
Select valve (1) . If output valve is connected to valve 1..Refer manual.
Press PROG/OPER AGAIN THE BLINKING WILL STOP . THIS COMPLETES SETTING
OF TIMING CYCLE.

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(YOU CAN TRY PRESSING PROG /OPER BUTTON AT ANY POSITION IF YOU PRESS IS
THE SETTING DIGIT WILL BLINK AND IF YOU PRESS IF AGAIN THE BLINKING WILL
STOP INDICATING THE VALUE IS SAVED)
Look for Curr1 curr2, curr3 buttons. The value in current window is corresponding to switch
selected. The selected switch will glow.
Press curr 2 LED will glow on this switch--Enter value of secondary current required for welding.
To do this press prog/ oper button bring curser in the window, select ( 08.0) and again press
prog / oper button.
This means for weld 2 parameter you are selecting 8.0 Kilo Amp. As secondary current.
Never select value beyond 15 KA. (Depends on machine capacity)
Look for mode switch. By repeated pressing values in MODE window will change. Select
mode (6). Press PROG/OPER button bring the blinking digit to DATA window by pressing
>. Select maximum current ( 030.0) (differs from machine capacity) press prog/ oper again.
NOW the panel is ready for weld.
Check for air pressure ---set it to 3.5 ~ 4.2 bar
Pressure can be adjusted by lifting black knob upward and rotating
clockwise will increase the pressure. Pressing the knob down can
lock the set value.
It gets latched in one position.

Check for electrodes and its alignment.

Both electrodes should be in vertical plane.
CHECK FOR WELD BUTTON. This should be off for initial trials.
Confirm pressing WELD switch. The LED glowing shows welding on.
KEEP EVERY THING OFF THE ELECTRODES. TAKE CARE FOR NO BODY PART WILL
COME IN BETWEEN THE ELECTRODES.
Press foot switch electrodes should come down and go up completing the cycle.
If every thing is OK till this step. Make weld on by pressing weld
Switch. SOME MACHINES HAVE EXTERNAL WELD/ NO WELD SWITCH.

15

-Put parts in the machine. Cycle the machine by pressing foot switch.
Welding current should flow and the value of this current flown will be indicated in
CURRENT window. (Monitor display switch should be on )
If there is error error LED will glow. You can reset the condition by pressing error reset
check for the reason referring manual.

PUT COMPONENT BETWEEN ELECTRODES; TAKE A DRY RUN.

TOGGLE WELD/ NO WELD SWITCH TO WELD POSITION.
NOW YOU ARE READY FOR WELD. ON PRESSING FOOT SWITCH WELDING WILL BE
OPERATIVE.
ADJUST WELDING PARAMETERS TO SUIT THE COMPONENT.

FOR machines installed with pressure switch interlock : If the controller cycle is
stopping at 'squeez please check air pressure or setting of air pressure and
pressure swich. Machine will only operate if pressure set on pressure switch
available .

This completes settings of the controller.

*Remember that exact parameters can only be decided by few trials.
*All parameters (except ENERGY for W1, W2 & W3) are in terms of
Cycles, where 1 CYCLE = 20 milliseconds (1cycle of 50 Hz mains).

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IX. Important components in the machine

i. Transformer:
Transformer is the heart of the machine.
The transformers comes in various ratings i.e. 25 KVA, 35 KVA,
50 KVA, 100 KVA etc. KVA = Kilo Volt Ampere.
It indicates maximum current X voltage delivered at out put for welding. Typically secondary
welding current is of the order of 10 KA (Kilo- Amp) to 20 KA for most of the applications.
Primary side of the controller is connected to 440V AC between two phases. The One phase is
connected directly and other through thyristor, the electric regulator.
The power can be made available at different tap levels.
You can change the tap located at back side. Keeping common terminal at place change upper
terminal lug.
There is thermistor switch located at bottom of the transformer it is connected to controller. It
shuts off welding in case of overheating.
The transformer is water cooled. The water flows from the secondary coil .It takes away most of
the heat generated.
Caution:
ALWAYS PAY ATTENTION TO COOLING OF THE TRANSFORMER. TAKE IMMEDIATE
ACTIONS IF THERE IS GENERATION OF OVERHEAT WITH IN ANY PART OF THE
MACHINE.

ii. Thyristor
Thyristor controls energy to be dissipated through the part to be welded. It does it as per control
signal received from the electronic controller.
This is very delicate device. It can get short or open like any electronic gadget. Please take care
in proper earth of the machine. The variaster is attached across the terminal protects it form over
voltage spike. In such case this variaster get
fused.
Care should be taken in connecting terminals
G1 G2 K1 K2
The wire is soldered to the terminal with
identification ferrules
In case of rewiring confirm four times is the
wires are connected at G1 G2 K1 K2 of the
controller.
The device is cooled by heat sink. Water is
always flowing through it. For safety the water
path is made series with transformer. In case of
rise in water temperature, thermo error is
generated in controller.

17

iii. Controller
This machine uses AK 54, a current feedback controller.
This controller sense current flowing in secondary of the machine and with feedback it corrects
the variation if any by controlling thyristor current. More facilities are available with this unit.
Refer manual to know more about facilities provided.
The current sensing coil is located at secondary of the transformer just behind the Bakelite
cover.
The best use of the controller can be done by using its current monitoring system. This system
can instantly give alarm at the faulty spot.

X. Example on using current monitor.

While using current monitor you need to feed upper and lower limit to the controller. This can be
done as under:
Example:
Suppose your part requires 10 KA current for 8 cycle .
And your setting is as under
30
00
sq
Weld1
And
0
10
Curr1
Curr2

0
Co1

0
Sl1

8
We2

0
Co2

0
We3

0
Sl2

5
hold

0
off

0
Curr3

(Insure you are putting value in curr2, this can be done by pressing curr2 button and insuring the
led over the button is glowing. Also insure values in curr1 and curr3 by pressing respective
buttons. If there is value in weld 1 , it corresponds to curr1 ; value in weld2 and weld3
corrosponds to curr2 and curr3 respectively. If you put some value in weld1 and 0 in curr1 this
will result in error)
This setting means you need 10 KA current for good part.
Press MONITOR DISPLAY button, insure the LED on the button is glowing.
Monitor display ON will give you actual current flown during the process this value will be
displayed at window immediately above the curr2 button; Its percentage over set value of
current will be displayed at the window above monitor display button.
Observe actual current flown, displayed in the window, and its percentage over set value (10KA)
If the % difference is better than +/- 5%, your setting time is OK (else try to increase weld time).
Make destructive test and confirm parameters OK for weld strength. After getting OK result move
for next step.
Calculate 10 % less of the set value (i.e. 9 KA)
Set 09.0 KA in curr2 window.
Make a weld.
Observe actual current drawn.
Make destructive test for weld strength.

18

If the test is ok,

We can conclude 9KA current is also OK for making good weld.
If you get test fails, Increase default value and repeat the procedure or insure your self, by trial
and error correct lower value of current.
Accordingly set upper value. And calculate safe % of upper limt.
In this example Now we have
9 KA as lower limit. ( 10% lower)
10 KA set value
10.5 KA as upper limit (5% high )
Now we can set upper and lower limit on controller monitor.
Push prog button
Push lower limit button (- % limit)
Enter 10
Push upper limit ( +% limit)
Enter 05
Push prog again
Take weld.
Now the controller is programmed for upper and lower limits.
It will give alarm (error output) at the instant the actual current fall beyond the go nogo limit.
Pressing error reset button can reset error alarm.
There are other few other errors related to setting and maintenance of the controller. Please
read the error no. Details from the manual page 36.
We can also use other powerful function built in .
Like
Electrode wear compensation
Multiple program calling
Interlocking with other inputs.
Computer interfacing for data download
Please refer FORWEL AK54 manual for details supplied with this booklet.

19

XI. Setting Up and Making Resistance Welds

Given there mutiple variable in resistance welding, the key is to identify each of your variables
and minimize their change. When changing any one variable you must consider the influence on
the remaining variables. A reduction in time can increase demand for current, and a reduction in
force will decrease demand for current to reach welding temperatures. Document all changes
and develop history of tests you make in developing your weld schedule.
Precise control over welding temperature is vital in resistance welding operations. The primary
variables affecting weld formation are heat, time, and pressure. Resistance welding equipment is
designed to, 1) provide current, 2) exercise precise control over time and current and 3) supply a
forging pressure with rapid follow-up. The following profile addresses important variables and
steps to follow in making a resistance weld. This introductory summary is followed by a
procedural analysis, which discusses each of these steps in greater detail

i. Welding Electrodes
Select the proper electrode material or materials for metals being welded
Determine electrode geometry. If a standard shape electrode is not suitable for your operation
an electrode should be designed to properly address the part/electrode interface The final
electrode design should be easy to change with sufficient to access for maintenance.

ii. Electrode Installation

Install the electrodes into electrode holders, and align. Electrode holders are typically adjustable
for both vertical and rotational positioning. Careful attention should be taken to ensure that the
alignment is correct and. Electrode alignment should produce an even footprint, allow for the
easy insertion and removal of the parts, plus provide access to clean the electrode on the
machine. In some cases electrode geometry in critical and will require cleaning off site.

iii. Setting Weld Force

Make sure the power source is shutdown and set electrode force using an electrode force
gauge. Most weld heads have an indicator that typical displays some nonlinear reference to the
force and should not be mistaken as actual force values. The use of a electrode force gauge is
recommended
Place the parts between the electrodes; actuate the top electrode to meet the parts. Carefully
check to see that proper contact is being made. Determine if the effects of the pressure alone
causes any serious deflection of the electrodes and or deformation to the parts.
Turn the power on and set the heat control to low amplitude and time settings. Begin by
gradually increasing the values to produce the required temperatures to form the weld .If the
maximum power settings are reached before a proper weld is obtained; gradually decrease the
pressure between successive trials. This procedure will increase the contact resistance between
the parts and increase the temperatures generated at the interface. (Note: A minimum amount of
electrode force is required to stabilize the contact resistance between the electrodes and the
parts). If the force is to low electrode sticking and expulsion of molten material will result.
The settings you begin your study with are not as important as the documentation of the
changes made and their respective results. To minimize the complications in developing a weld
schedule do not attempt to change more than one variable at the same time. Evaluate each weld
for the strength and requirements of your particular application . Once the parameters have been
determined fully document the process variables and publish in your manufacturing records.

20

iv. Electrode Selection

Electrodes can be in the form of a rod, plate or incorporated into a special fixture. Electrode
materials are specific alloys designed for a range of conductivity and hardness. RWMA stands
for, Resistance Welders Manufacturing Association and they have identified a range of alloys.
RWMA2, 3... can be also be referred to as Class 2, 3... Also, some materials are identified with a
"Mallory" number. Your selection is based on the alloys ability to withstand the specific demands
of you application.
Electrodes simultaneously, conduct electrical current to the weld site, and conduct thermal
energy away. In welding resistive materials a conductive electrode pulls heat away from
electrode / part interface, ensuring welding temperatures are only achieved at the parts interface.
Welding temperatures develop at different rates depending on a materials mass and/or
composition. Keep in mind, when welding dissimilar materials, heat generates at different rates,
and two different electrode alloys may be required. To control the even heat generation in both
parts, electrodes of varying conductivity and or shape are used. For example, a larger diameter
or more conductive electrode allows surplus heat to exit from a thinner material while a heavier
part reaches welding temperatures. This is referred to as Heat Balance. Changes in electrode
material and geometry are used to ensure good heat balance.
Fundamental electrode selection calls for a conductive electrode when welding resistive
materials; and resistive electrodes when welding conductive materials. . The parts mass and
composition are used as guidelines in the proper selection of the electrode material.

v. Electrode Material
Copper is a commonly used electrode material due to its high electrical and thermal conductivity.
To withstand the welding environment, copper is alloyed with other elements. For example,
copper strengthened by the addition of aluminum oxide particles offers higher wear resistance
than traditional Copper-Chromium welding alloys. Oxygen-free copper should be avoided, due to
their low tensile and yield strength at elevated temperatures electrode deform quickly.
Established standards for welding alloys by the Resistance Welders Manufacturers' Association
(RWMA) include a range of copper and refractory alloys. Some of the most common alloys used
are: RWMA Class 2 - Copper-Chromium Alloy used to weld resistive materials; RWMA Class 3 Copper-Cobalt-Beryllium Alloy has the same general applications as the RWMA Class 2, but this
material sacrifices conductivity for increased hardness; RWMA Class 11 - Copper-Tungsten
Alloy is used in applications where high electrode force and conductivity are required; RWMA
Class 13 - Tungsten. Class 13 materials are used for conductive alloys; RWMA Class 11 or
Molybdenum electrodes are similar in conductivity to RWMA 13 materials, but Class 11 materials
are easier to machine. In summary, always fabricate the electrodes using a resistance welding
alloy.

vi. Electrode Design

When designing electrodes, consider ease of manufacturing, replacement, and maintenance.
Electrode design is governed by part thickness, composition, shape, size and the required weld
size. Electrode geometry establishes current density in the weld site. The force applied by the
weld head on the electrode influences current density in the weld site. The electrodes also
maintain intimate contact between the materials and provide a forging action during the
formation of the weld. Concurrently, they dissipate heat from the weld site, preventing surface
fusion between the electrode and the parts.

21

The electrode face is directly above the point of fusion, and this area is subject to repeated
exposure to high temperature and pressure. If electrodes overheats and begins to fuse with the
materials being welded, consider increasing the electrode force, diameter, conductivity or use
water cooled electrodes.
Another important factor in determining electrode shape is accessibility to the weld site. The
weld site does not always allow for a basic straight shank electrode design. Limited access may
require offset, or angled electrodes. With offset electrodes, ensure the electrode diameter is
sufficient to transmit the required pressure and current without distortion.
When changes to electrode design and material fail to produce desired results projection welding
techniques may offer a solution. A projection or dimple formed, typically in the thinner part,
focuses welding current to assist in issues with heat balance or great difference in parts mass.

vii. Electrode Alignment

The preferred electrode alignment is vertically opposed because is force exerted is one of simple
compression. Careful attention to electrode alignment is important; if the centers are not aligned,
the net effective tip area is reduced. When electrode tips are not parallel the pressure and
current is confined to a fraction of the designed area, and destruction to both the electrodes and
the parts is likely.

viii. Electrode Maintenance

Electrode tips will eventually become pitted or spattered with weld material. They require
periodic maintenance to reshape and/or clean the welding surface. Often, files are used as a
maintenance tool for cleaning. This not recommended, files easily alter shape and surface finish
of the electrode. A preferred electrode maintenance material is emery paper. Specially shaped
electrodes must be cleaned and dressed with consideration given to retaining original contours.
Standard flat-tip electrodes of equal dimension can be reshaped very simply as follows:
Choose an emery paper of #400 to #600 grit. Fold the paper so that abrasive surfaces are
exposed. Hold the emery paper between the electrodes and carefully bring the electrodes
together so that both tips are in light contact with the emery paper.
Rotate emery paper in circles between the tips, or pull it in alternating directions. Continue this
polishing operation until both tips are clean and smooth and are in good contact with each other.
A small dental mirror provides easy inspection. Care should be taken to keep the plane of the
emery paper horizontal and perpendicular to the long axis of the electrodes. Commercially
available emery cleaning disk adhere emery paper on heavy paper disk. Keep in mind the paper
backing is soft, and electrodes will tend to form a radius by simply spinning these disk between
electrodes. If you electrode are of different size, a ridged substrate between the emery paper is
recommended. In some cases ceramic is used to clean electrodes.
Remove emery paper and metal by products from the tips with either a brush, or flush with
alcohol. Adding a small amount of alcohol to emery paper before cleaning operation can
minimize the accumulation of cleaning by products on the tips and weld station.

ix. Pressure Settings

Electrode pressure forces the materials to be welded into good contact with each other before,
during, and after welding. The effect on the weld is a forging action. The electrode pressure is

22

indicated on the weld head and graduated in relative units. For precise work, a force gauge
indicating actual pressure obtained is recommended. The pressure should be high enough to
render the surfaces of the materials uniform in electrical resistance. Forces set to low can cause
dramatic changes in current density and may be evident by pitting of the electrode surfaces.
Pressure should not be confused with "follow-up." Follow-up is the ability of the welding head to
follow the minute expansion and contraction of the weld during heating and cooling. This action
maintains a constant forging action during the manufacture of the weld and insures consistent
weld uniformity. Low-inertia and friction are important to providing rapid follow-up during a weld,
and are feature of a good weld head design.

x. Heat Settings
Always start with low weld current and time settings and work up to the optimum weld results.
Power supplies provide several output options including: multiple pulses, off time, upslope, down
slope and polarity. A standard technique used to displace plating and or oxides is to use a dual
pulse weld where a lower amplitude first pulse is followed by a higher amplitude second pulse.
Off time settings are used to cool or quench the weld between pulses. Upslope feature gradually
increase or decrease current into the parts, and is beneficial when welding materials that are
sensitive to heating and cooling rates. Polarity settings, positive and negative are used to
appoint a specific direction to current flow through the parts.
Requirements of the materials being welded determine what methods of heating are necessary.
Keep in mind, heat loses by conduction into surrounding parts and electrodes, as well as
radiation into the surrounding air. These losses are essentially non-controllable, increasing with
increases in total time. At some period during an extended welding interval, the radiation losses
will equal the heat input, thus stopping further temperature rise.
Factors affecting the amount of heat being generated by a given weld current for a unit of time
are:
1. The electrical resistance of the materials being welded
2. The electrical resistance of the electrode materials
3. The contact resistance between the parts as determined by surface conditions, scale, welding
pressure, etc.
4. The contact resistance between the electrodes and parts as determined by surface conditions,
area of electrode contact and welding pressure.

xi. Time Settings

Generated welding temperatures is a linear function of time. Heat may be affected either by a
change of current or by a change of time. Finite values of time are required before any weld is
formed. The exact minimum length depends upon current magnitudes, material thickness and
composition. If weld time is to short now weld will form, regardless of the increase in current.

xii. Testing the Weld

The most reliable test of weld quality is its strength compared with the strength of the materials
joined. A very simple and practical test is described below:
After joining two pieces of sheet metal with one spot weld, peel them apart. If one of the two
pieces fails or has a hole in it the weld should have adequate strength. If a hole pulled in one of

23

the materials has a diameter at least twice the thickness of the thinner material the weld is
probably as strong as can be obtained.

Note, the above information has no mention of the variables regarding materials being welded.
There is plenty to say about material variables, but for now just remember variables left unmonitored can shut your production down. A change in vendor or materials should be closely
monitored to ensure optimum welding results.

What Next?
You now have some basic information to assist you in your welding operations. If it is helpful to
you please let us know.

24

XIII. FAULT FINDING:

Problem 1---Welding Machine Is Dead
One common indicator of this problem is no light or displays are working on the welding control.
A simple test with a voltmeter at the incoming power source to the welding control should show if
power is coming into the box.
Dont measure from one power line to the cabinet ground or the conduit. This can give false
readings because voltage runs through the welding transformer and shows a reading to the
cabinet metal, even if one side of the power line is dead.
If power is present, check the welding control for small power fuses, making sure that power is
turned off to the equipment before removing fuses for testing.
Check for continuity on these fuses.
If the fuses are fine, power can be turned on and the voltage into the control measured.
Ensure the reading is a normal 440 volts across phases and 220 V betn neutral and phases.
Make these measurements at controller and machine terminals.
Any blown fuses should be replaced with ones of exactly the same type and rating. These fuses
are selected by the manufacturer to protect the electronic components.

Problem 2---Control Has Lights but Will Not Cycle

If closing the foot (or hand) initiation switch does not elicit an action, the most common cause is
a bad switch.
Check this switch electrically by multimeter. Or shorting link.
The fact that a switch mechanically closes does not guarantee that the welding control will cycle.
Switches are designed for high-current switching (amps). Welding control uses low voltage and
very low current (milliamps) for initiation. Over a period of time, the contacts inside a switch can
form a very thin oxide layer that block conduction of electricity.
To check this unwire the initiation switch and replace it with another switch. If the machine then
operates, the problem is solved.

Problem 3---Machine Cycles, but Tips Do Not Close

If the machine cycles but the welding electrodes will not close; it could be the result of a bad air
solenoid or a non-electrical problem, such as insufficient air to the system.
check that sufficient air pressure (typically 2.5 ~3 Kg/cm sq minimum) is shown on the air
regulator's gauge.
If air pressure is present, the solenoid valve that operates the machine's cylinder with a manual
operating screw., operate it to see if the cylinder operates. If it does not close the welding
electrodes, the solenoid valve should be replaced.
If the manual operator works in this test, the problem might be in the solenoid valve coil or the
welding control valve drive circuit. To check these, locate the terminals on the welding control
that provides voltage to the welding solenoid valve.
controls uses 220 volts AC to operate the solenoid coil, the solenoid valve coil's nameplate
should be checked to confirm this. With the equipment initiated, control's output terminals for
voltage when the system has been initiated.

25

If voltage is present and the valve does not operate, the test should be repeated on wires at the
coil end. If voltage still is present and the valve still does not operate, the valve coil should be
replaced.
If no voltage is present, output fuses for the control's valve terminal should be checked. If these
are all right, the problem probably lies in the control.

Problem 4---Welding Electrodes Close, but No Weld Occurs

If the welding electrodes close but no weld occurs, one of the following maintenance tips may be
appropriate.
Controller Key lock switch is in set mode, make controller keys at proper position for
welding.
i.e. keylock sw at run mode . It was observed on overturning this switch (if it is loose ); causes
wire soldered to sw broken .
energy setting at weld 2 is not selected or selected very low. Check schedule and put
appropriate values.
Problem in Machine's Secondary. By far, the most common cause of this condition can be
found in the machine's secondary circuit.
It is not uncommon for welding electrodes not to touch the part after they have been adjusted or
after new ones have been installed. The welding machine should be adjusted so that at least 10
mm more travel (over travel) is available after the electrodes have touched.
Another very common problem occurs when someone has wrapped Teflon tape around the
electrode shank to stop water leaks. This certainly stops the leak, but, unfortunately, it also
electrically insulates the electrode.
A good way to test the secondary of the welding machine is to first turn off the power. Then, with
the electrodes open, the continuity between the top and bottom electrodes should be checked.
If the secondary is working, the measurement should be about 1 ohm or less. If the reading is
high, go across each mechanical junction of the welding machine secondary until a high value is
found.
Heavily used spot-welding machines commonly have oxidized connections. If this is the case,
the connection should be opened and the surfaces cleaned with a fine abrasive and polished.
The use of coarse abrasives will make the problem worse a few years down the road.
Terminal connection pads are plated. These junctions are conducting thousands of amps.
Secondary connections should be tightened fully, and questionable bolts always should be
replaced.
NO-WELD Switch Problem controller NO-WELD switch should be in weld position to initiate
weld.

Problem 5---Major Metal Expulsion When Electrodes Close

Major metal expulsion occurring just as the welding electrodes touch, blowing copper and metal
sparks , is another common resistance welding equipment problem.
Often, the welding electrodes will even "weld" together. In this case, one of the following
problems may be responsible.
1.The welding machine was fired too soon.
Expulsion usually occurs because too little time is allowed for the required welding force
between the welding electrodes to be achieved before welding current starts to flow. In this case,
the electrodes close "live" and act like an arc-welding machine.
ensure that the squeeze time set in the program is long enough. This squeeze time is set in
halfcycles (1half cycle = 1/120 second).

26

This setting is directly proportional to initial distance between top and bottom electrodes more is
distance, more should be squeeze time.
2.Leaking welding cylinder.
Expulsion also can occur if the welding machine's air cylinder has a large internal cup seal leak,
which prevents the cylinder from producing the required welding force.
Welding with very low force causes major expulsion and electrode sticking. If the cylinder has
this internal leak, air comes out of the solenoid valve's exhaust port when the welding electrodes
are closed.

Problem 6---Welding Electrode Meltdown

If the electrodes close "live," weld together, and continue heating until they have been reduced
to a molten glob, the operator probably has pulled the disconnect before calling maintenance.
There are two possible causes for an electrode meltdown.
Values of weld time and energy selected very high. Recheck schedule parameters.
Transformer grounding. One possible cause of welding electrode meltdown is a welding
transformer with a primary winding that has become shorted to the welding machine case. While
this is a fairly unusual condition, it can happen.
A resistance welding control switches voltage only on one side of the power line. The other side
of the power line goes directly to the welding transformer.
To test for this condition, the technician first should turn the power off and then remove the wire
going from the silicon-controlled rectifier (SCR) contactor to the welder transformer, and then
insulate the end of that wire.
With the power then turned on, a weld sequence should be attempted. If the problem still occurs,
the transformer should be checked and probably replaced.
SCR contactor shorted. A more common problem is a shorted SCR contactor. This device
actually is two SCRs mounted in a single water- or air-cooled assembly.
SCR contactors normally operate for long periods without problems, but they can fail.
Unfortunately, 99 times out of 100, they fail in the shorted condition.
SCR contactors fail either because of excessive internal heat or because of a high-voltage spike
across the device.
Excessive internal heat can occur when the SCR contactor is not being cooled properly. On a
water-cooled SCR contactor, the flow of cooling water through the SCR heat sink should be at
least a 20 liters per minute. If there is a restriction or if the back pressure on the return hose is
too high, water will not flow properly.
High voltage can happen when lightning strikes an outside power line or when the welding
machine is run with excessive expulsion for a long period. A properly sized SCR contactor
should have a voltage rating of at least three and a half times the line voltage.
There is a metal oxide varister (MOV) installed across the SCR contactor to clamp high-voltage
spikes around the switch. When an SCR contactor is replaced, this MOV also should be
replaced as preventive maintenance.
The SCR contactor is used as a solid-state switch to pass electricity to the welding transformer
when the weld is made. At all other times, it should be an open switch. If the SCR contactor is
shorted, electricity flows through the welding transformer constantly.

27

Shorted SCR contactor test. If the technician suspects that the SCR contactor has shorted, a
voltage meter can be installed across the two large power terminals. When power is turned on to
the control, the line voltage should be present across these points (unless the control has an
isolation contactor installed).
If the line voltage cannot be read at these points, the technician should turn the power off to the
control and disconnect the wire going to the welding transformer. With the power still off
continuity across the same two terminals should be measured.
If the SCR is shorted, it will read about 1 ohm. If the SCR is not shorted, the reading will be
1,000 ohms or more. This usually is a reading of other components, such as snubbers, that are
installed across the SCR contactor.

Problem 7---Loud Transformer Growling, Saturation

A properly operating welding transformer has a smooth humming sound when welding. If,
however, the operating sound suddenly changes dramatically, the system has a problem.
When this occurs, continued use of the machine can cause permanent damage to the welding
transformer and the SCR contactor. Under this condition, line fuses sometimes blow or circuit
breakers open. Also, welds that are produced will be very weak or might not stick at all.
This problem often occurs when the welding transformer is operated in an unbalanced condition
in which the AC that flows into the transformer is more in one polarity than the other.
The difference produces a direct-current component in the welding transformer and causes the
transformer to go into the saturation condition. When this happens, the primary current (line
current) will jump from hundreds of amps to thousands. This excessively high amperage can
cause the power wires feeding the machine to slap within their conduit.
SCR Problem. One cause of saturation can be a bad SCR contactor. This is quite rare, but it
can happen. In this case, only one polarity of the line voltage is conducted.
The SCR contactor actually is an assembly of two individual SCR elements installed back-toback. One of the SCR elements conducts the positive side of the AC line, and the second
conducts the negative side.
If all are working correctly, these SCR elements are fired alternately at the same timing (relative
to the line voltage frequency) to provide balanced AC to the welding transformer. However, if
only one of the SCR elements operates, the welding transformer saturates quickly.
Take following steps to test operation on both sides of an SCR contactor that has been removed
from the welding control:
1. Connect two 1.5-volt batteries in series with a 3-volt flashlight bulb across the SCR contactor.
2. Touch the gate wire from either SCR to the + side of the battery pack as shown. Note that the
gate wire is connected to the center of each individual SCR. If the light does not turn on, connect
the gate wire from the remaining SCR to the + side of the battery pack. The SCR should stay on.
Once the light is on, remove voltage from the gate wire. The SCR should stay on.
3. Momentarily touch a wire from one side of the SCR contactor to the other, and the light will
become very bright. Remove this wire and the light should go out.
Now, reverse the battery pack/lamp wires to the SCR contactor and repeat the same test with
the remaining SCR gate wires.
If both sides check out properly, the SCR is operational.
Control Problem. A second cause of saturation is an improperly operating welding control.
Controls synchronize firing of the SCR contactor to the line voltage frequency. If the circuitry is
not operating properly, weld transformer saturation occurs.
Also, controllers have fuses on the SCR firing circuits. check these fuses and replace them if
they are blown. Additionally, firing wires (gate and cathode wires) coming from the SCR

28

contactor to the control should be checked to ensure that they are connected properly and
tightened.
Another cause is minimum firing angle setting is put too high so as to overlap with next welding
cycle.
The procedure to set min firing angle is given in the manual but please be very careful as this is
a system setting and should be done under instruction of manufacturer. and is not required to
change unless the controller is changed or used for other machine.

29

Fault

Observation

Controller not cycle

on pressing
footswitch and no
cylinder movement

Controller display off No control power. Fuse Replace fuse

blown off

W.power LED off

Possible reason

Isolation control
transformer faulty

Replace

No power 440 V

restore

Controller display on No input signal/ faulty

'ready LED ' do not foot switch
lit after pressing FS
Ready LED lits on
pressing foot sw

Possible solution

Check foot switch /

connections

Solenoid coil bad or no Check solenoid coil

supply to solenoid
power supply; change
solenoid coil
Air pressure insufficient Check /restore air supply

Controller cycles on Cylinder goes back

pressing foot switch ; after removing foot
cylinder operates but switch signal
no welding

Insufficient pressing
duration

Press foot swich for

longer

Wrong input signal

connection to 1st start

Contact electrician ,
check input to start1 *

Cylinder stops at
sueeze,
Squeez data
disappears .

Interlock hold, pressure Adjust input pressure and

switch setting ;
pressure switch setting, if
pressure switch faulty other interlock is provided
,check the interlock.

Cylinder operate
normally ; no error;
no welding ; ready
LED not on

Weld no weld switch off Check external weld no

weld ; and weld no weld
switch on controller ,
.

Error 21 on
controller

short link 12~13 open

Connect short link

Several resons
possible

Check error list and

cause in controller
manual

Improper contact due

to rust, carbon

Observe for heating;

Clean secondary
contacts

Teflon tape in electrode

Phase1 , k1 mismatch
if controller rewired/
reinstalled

Remove teflon if put on

electrodes of water
leakage ; use taper
reamer to clean taper
Contact expert electrician
interchange ph1;ph2*

30

XIV. Spare parts List

Sr.N Item
o.

Specification

Make

Control Transformer

440 V in, 230v, 25V out

Kirti

Lower Electrode

SK 3430

Upper Electrode

SK 0003

Linear bearings

LME 50 UU

THK

Copper Flexible

75mm Width X 350 Length

Kirti

Pneumatic Connectors/ tube

Push in Type

Festo , SMC

Electrode Holder

Asia Automotive
SK1215 250 OR 300 LENGTH. Ph-02532350165

FRL Unit

FRC 1/2 "

Coil for valve

MSFW 230 (4540)

Festo

10 Pneumatic Valve

MFH 5 1/4 p no. 6211

Festo

11 MOV variaster

420 V

Kirti

12 Thyristor assembly

504 Water Cooled Assembly

Rectifier
House,Mumbai

13 Digital weld controller

AK54 V 230V

Forwel Kirti

14 Transformer

50 Kva

Kirti

Asia
Automotive,
Nasik
Asia
Automotive,
Nasik

Janatics

31

XV. Circuit Diagram

Circuit Diagram

32

33

1
1.5
2
1
1.5
2
3
2

M6
M6
M6
M8
M8
M8
M8
M10

M6

Lower
Sheet
(mm)
0.8

Nut

3~3.5
3~3.5
3~3.5
3.5~4
4~4.5
4~4.5
4~5
4~5

2.5~3
20~25
20~25
20~25
25~30
25~30
25~30
25~30
25~30

20~25
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
5~7
5~7
6~8
6~8
6~8
8~10
8~10
8~10

4~6
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
8~12
10~14
10~14
12~15
8~15
12~17
12~17
12~20

4~6

0
0
0
0
0
0
0
0

Pressure Squeeze Weld1

Cool1
Slope1 Weld2 Cool2
Weld3
Slope2 Hold
Curr1
(Kgf)
(Cycles) (Cycles) (Cycles) (Cycles) (cycles) (cycles) (Cycles) (Cycles) (Cycles) (kA)

Standard Starting Parameters For Nut Projection Welding

7.5~
9.5
8~10
8~10
10~12
10~12
10~12
12~14
12~14
12~15

Curr2
(kA)

0
0
0
0
0
0
0
0

Curr3
(kA)

34

KIRTI PRESSINGS PVT. LTD.

W-35,MIDC Waluj,Aurangabad,Maharashtra,431136,India.
Website: http://www.kirtipressings.com
email: info@kirtipressings.com
Tel: +91-240-2554596/555502
Fax: +91-240-2551233
35