IS 4559 : 1993

( Reaffirmed 1999 )

Indian Standard
SINGLE OPERATOR RECTIFIER TYPE
dc ARC WELDING POWER SOURCE -
SPECIFICATION
( Second Revision )

UDC 621’791’75’03

0 BIS 1993

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAPAR MARG
NEW DELHI 110002

September 1993 Price Group 3

Electric Welding Equipment Sectional Committee, ETD 2 1

FOREWORD

This Indian Standard (Second Revision) was adopted by the Bureau of Indian Standards, after
the draft finalized by the Electric Welding Equipment Sectional Cc mmittee had been approved by
the Electrotechnical-Division Council.

This standard was first published in 1968 and this revision has been undertaken to make it up to
A-+,. __A :_,.,..rl_ rL.,..:-&_..:-..rl ___ ...-1.4:-- -,.-4:c,... I^._.__ ^^..--^

This standard deals with rectifier welding power sources incorporating solid state rectifiers.

Rectifier type arc welding power source shall be either with ac/dc output or,~~;hG,“,;,fiutput only.
Thic
-III”
~t~nrlarci
YLU...bU..A
ir ;ntm,Ad
1” aInCIIIVv.3
tn FC\XIP~th-c=later
L” b”.“L .IIW >UI”,
tvne
c_Yyu
nnlw while
“UfiJ **1111v
1’2
A”
AIIIIR
“““Y
.
.
107
,,,
1
1 “pb~“‘c~L‘“”
fr,?
,“I
n:,,n1a
J,LL5LU
operator ac/dc arc welding power source’ deals with the former type.

In preparing this standard, assistance has been derived from the following:
IS0 700-1982 Power sources for manual metal arc welding with covered electrodes and for the
TTr, _Vfi,.POE 1ntnrnnt;nna1
I IU yL”Ubr5.Y. II.L~LIILILI”IIU.
nrn9m;7nt;nn
V,~U.I&Lc&LL”I.
fnr
&“I
Cto”rl~mi;~ot;n”
“LuLIuuIuI~uLIvII.

BS 638 : Part 2 : 1979 Arc welding power sources, equipment and accessories: Part 2
Specification for air cooled power sources for manual metal-arc welding with covered
electrodes and for TIG welding. British Standards Institution.

Pub ‘No. EW 1 : 1983 Electric arc welding power sources. National Electric Manufacturers’
A,,,,.:, r:,, 1TCA

For the purpose of deciding whether a particular requirement of this standard is complied with, the
&..A1 .ViLILJG)
ll‘ull
...I.... ““J~l”lzU
^L..^....,rl “1^_ C1IILLLLkiLG”)
/.,.l-..l,.r,,4 ^___^ ““.:“._ *I.,
GAyIcaaIug
..,.“..1&“1,c.. il +,.“*
L11G IGJUIL LGJL “I
,..,1.,,;,
,.” nmuyom, “L”ll
allall
L,
“CT
..,.....,J‘,rl
l”Ull”CU
,er
VII

in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised)‘. The number
of significant places retained in the rounded off value should be the same as that of the specified
value in this standard.
IS 4559 : 1993

Indian Standard
SINGLE OPERATOR RECTIFIER TYPE
dc ARC WELDING PGWER SOURCE -
SPECIFICATION
( Second Revision )
1 SCOPE engaged continuously for manual metal arc
welding, at the specified load voltage and duty
1.1 This standard lays down the requirements cycle without exceeding the specified temperature-
and tests for single operator arc welding power rise.
sources incorporating solid state rectifiers and
also thyristers and having drooping characteristics. 3.7 Maximum Hand Welding Current

1.2 This standard does not cover ‘constants The maximum welding current for which the arc
potential’ and other special type of arc welding welding power source is calibrated for manual
power sources. metal arc welding at the specified load voltage.

2 REFERENCES 3.8 Minimum Hand Welding Current

2.1 The Indian Standards listed in Annex A are The minimum welding current for which the arc
necessary adjuncts to this standard. welding power source is calibrated for manual
metal arc welding at the specified load voltage.
3 TERM[NOLOGY
3.9 Minimum Automatic Welding Current
3.0 For the purpose of this standard, the
following definitions shall apply. The minimum welding current for which the arc
welding power source is calibrated for automatic
3.1 Load Characteristics or semiautomatic metal-arc welding at the
specified load voltage.
The specified relationship between load voltage
and load current of arc welding power source.
3.10 Maximum Continuous Automatic Welding
3.2 Manual Metal-Arc Welding ( Hand Welding) Current

Metal-arc welding with consumable electrodes The maximum welding current which the arc
not exceeding 460 mm in lengthand applied by welding power source is capable of delivering for
the operator without automatic or semiautomatic continuous operation on automatic or semiauto-
means of replacement. matic arc welding at the specified load voltage
and drlty cycle without exceeding the specified
3.3 Semiautomatic Arc Welding temperature-rise.

Metal-arc welding in which the arc length is 3.11 Open Circuit Voltage
automatically controlled but the positioning of
the arc is manual. The voltage between the output terminals of the
arc welding power source when no current is
3.4 Automatic Arc Welding flowing in the we~lding circuit.

Metal-arc welding in which the arc length and NOTE--This does not include superimposed high
the travel of the electrodes or the work pieces are frequency voltage and voltage derived from low
voltage safety device.
automatically controlled.

3.5 Duty Cycle 3.12 Load Voltage

The ratio of time during which the output side The voltage between the output terminals of the
of the arc welding power source is loaded, to the arc welding power source when a specified
total elapsed time, the primary side being current is flowing.
energized throughout.
3.13 Rating
3.6 Maximum Continuous Hand Welding Current
A statement of operating parameters assigned to
The maximum welding currents which the welding the arc welding power source by the manufacturer
power source is capable of delivering when under specified conditions.

1
IS 4559 : 1993

3.14 Type Tests the total duration of each cycle shall be 5 minutes
comprising of a period, 3 minutes of load
Tests made on an arc welding power source which followed by a period, 2 minutes of no-load
is representative of other arc welding power operation.
sources to demonstrate that they comply with
specified requirements. 4.5.1 The rated duty cycle at maximum conti-
nuous automatic welding current shall be taken
NOTE - An arc welding power source is considered as 100 percent. Duty cycles other than 100
to be representative of others if it is identical in rating
and construction.
percent shall be a matter of agreement between
the purchaser and thesupplier.
3.15 Routine Tests
4.5.2 The rated duty cycle at maximum con-
Tests carried out on each arc welding power source tinuous semiautomatic welding shall be a matter
to check requirements which are likely to vary of agreement between the purchaser and the
during production. supplier.

4 RATING 4.6 Tolerance on Open-Circuit Voltage

The permissible tolerance for the open-circuit
4.1 Rated Input Voltage
voltage(s) shall be f5 percent subject to
The preferred rated input voltage shall be 415 V. limitation given in 4.3.

NOTE - Tn case of a rectifier tyne arc welding power 5 NORMAL SERVICE CONDITIONS
source suitable for 415 volts, supply should be taken
either from two lines or three lines of three phase 5.1 This standard applies to rectifier type arc
supply denending upon whether the power source is
designed for connection to two or three lines of a welding power sources operating under the
three phase system. following normal service conditions ( see
also 11.7.3 ):
4.2 Rated Frequency 40°C
a) Reference-ambient temperature
The rated frequency shall be 50 Hz. b) Altitude not exceeding 1000 m

4.3 Rated Open-Circuit Voltage 6 DESIGN AND CONSTRUCTION

The open-circuit voltage of the arc welding power 6.1 The rectifier assembly shall be isolated from
source shall not exceed 100 V. the mains supply by a double wound transformer.
Output terminals shall be insulated from the
NOTE - Where it is required to control the open-
circuit voltage for safety purposes, suitahle ssf:ty enclosure and shall be suitably protected against
devices may be incorporated to bring down voltage to accidental or inadvertent contact.
the desired value.
6.2 Monocrystalline rectifiers shall be of adequate
4.4 Rated Current current carrying capacity and able to withstand,
with surge devices, if fitted, transient voltages
The rectifier type arc welding power source shall likely to occur from arc welding and allied pro-
be rated at current and duty cycles corresponding cesses. These rectifiers shall comply with
to maximum continuous hand welding current. IS 3895 : 1966.
Preferred current ratings shall be:
150, 200, 300, 400, 500, 600, 900 and 1 200 A. 6.3 Polycrystalline rectifiers ( metal rectifiers )
shall comply with IS 251 I : 1963, except for the
4.4.1 Minimmm Hand Welding Current voltage test which shall be in accordance with 11.8
of this standard
The minimum hand welding current shall not be
more than 20 percent of the rated current at the 6.4 The arc welding power source shall be
specified load voltage. capable ~of:

4.4.2 Minimum Automatic Welding Current a) withstanding the full specified supply
voltage without the necessity for reforming
It shall be a matter of agreement between the the rectifier cells by the application of
purchaser and the supplier. reduced voltage; and

4.4.3 Maximum Hand Welding Current b) withstanding an ac voltage instantaneously

applied and maintained for 5 minutes
The maximum hand welding current shall not which is 10 percent higher than the voltage
exceed 1’35 times the rated current at the appropriate to the selected preliminary
specified load voltage. voltage tapping. It shall also be able to
4.5 Duty Cycle withstand repeated switching off of the ac
supply at the same excess voltage when
The rated duty cycle at maximum continuous the dc output terminals are not connected
hand welding current shall be taken as 60 percent; to an external load.

2
IS 4559 : 1993

6.5 Frame and Enclosure 7.3 The capacitor shall-be so connected that it is
switched off with the arc welding power source.
The arc welding power source shall be so manu-
factured that it has the strength and rigidity 8 CONTROL AND PROTECTIVE DEVICES
necessary to withstand rough usage. It shall be
provided with an enclosure or tank which shall 8.1 If a switch, controller or circuit breaker is
enclose all live metal parts other than a flexible employed in the rectifier type arc welding power
supply cord or cable and output terminals. source, it shall be suitable for the particular
apphcation and shall conform to the relevant
6.5.1 The enclosure or tank shall -be so con- Indian Standard(s).
structed as to exclude vertically falling water or
dirt in case of a drawbar being provided, the same 8.2 Contacts of all regulating taps, if provided,
should be suitably locked. shall be such as to make positive contact between
moving and stationary contacts. Visual indicator
6.5.2 The enclosure of the tank shall be provided shall -be provided to indicate the current setting.
with suitable lifting lugs. In case of oil-immersed
power sources, an oil level indicator and a drain 8.3 Remote Control Devices
plug shall also be provided.
Remote control devices, if provided, shall not
6.5.3 In case of a portable arc welding machine operate at voltages exceeding 110 V. For supply
the wheels used shall be either of cast iron, solid to the control circuits, power shall be taken from
rubber type or a IJHMWPE (ultra high molecular a winding electrically isolated from the supply
weight ,polyethylene ). mains.

6.6 Earthing
9 PERFORMANCE
Two earthing terminals shall be provided for two
separate and distinct connections to earth of all 9.1 The arc welding power source shall be
metallic parts which are not intended to carry capable of operating continuously delivering
current. Earthing terminals shall be suitably maximum continuous hand welding current at
protected against corrosion and shall be metalli- the specified duty cycle without overheating.
cally clean. Earthing terminals shall be marked
indelibly with the symbol & 9.2 Indication and Accuracy

The arc welding power source shall carry a means

6.7 Protection Against Corrosion of indicating the load current which takes into
All metallic parts and surfaces of the assembly account the relationship between conventional
shall be suitably protected against corrosion. load voltage and conventional welding current as
given in Table 1. The accuracy of this indication
7 CAPACITORS shall be within f 10 percent of true value unless
the maximum output current exceeds ten times
7.1 Capacitors may be used to improve the power the minimum output current. In this case, the
factor to approximately 0‘85 lagging at 50 percent accuracy at minimum current shall be:
of the maximum continuous hand welding current
Z max
at the specified load voltage ( see Table 1 ). f m percent

Table 1 Welding Current and and the accuracy at maximum current shall be
Welding Load Voltage f IO percent, with the accuracy varying linearly
( Clauses 7.1, 9.2 and 11.5 ) between these two values.
Welding Current Welding LFd Voltage Whatever the method of regulation, the difference
A
between the indicated currents corresponding to
(1) (2) two successive positions of the setting device
150 26 shall in no case exceed 15 percent of the higher
200 28 of the two indicated currents.
300 32
NOTES
400 36
500 40 1 Subject to agreement between the purchaser and the
manufacturer, scales graduated to indicate the current
600 and above 44 under other than conventional load voltages may be
NOTE - *[he above load voltages are based on the fitted for specific purpose.
formula U - 20 + 0’04 I, where U is the load voltage
and I is the load current. This formula is applicable 2 In exceptional cases where because of the design of
to all welding currents up to 600 A. the welding equipment ( for example, devices with
dual control ), it is impracticable to obtain a graduat-
ed scale for currents for conventional load voltage, it
is recommended that the manufacturer provide on the
7.2 The capacitor, if provided as part of the arc equipment, an ammeter of class index 2’5 [ see IS 1248
welding power source, shall conform to ( Part 2 ) : 1983 1, properly damped, to in&ate the
IS 2834 : 1986. weldmg current.

3
IS 4559:1993
10 MARKLNG source which, in essential detail, is representative
of the one being purchased ( see 3.14 ) are
10.1 The following information shall be given on furnished; the purchaser may accept these as
the rating plate: evidence of ‘type test’ instead of actual tests.
Type tests and their sequence shall be as follows:
a) Indication of the source of manufacture;
a) Insulation resistance test ( 11.2 ),
b) Reference to this Indian Standard, that is,
Ref to IS 4559 : 1993; b) Over voltage test ( 11.3 ),
c) Type and manufacturer’s serial number; c) Open-circuit voltage test ( 11.4 ),
d) Range of welding current, minimum and d) Load characteristic test ( 11.5 ),
maximum; e) Short-circuit test f 11.6 ),
e) Maximum continuous hand welding f) Temperture-rise test ( 11.7 ),
current;
g) High voltage test ( 11.8 ), and
f) Maximum continuous automatic welding
h) Insulation resistance test ( repeated )
current;
( 11.2 ).
g) Duty cycle at maximum current;
h) Input current at rated output at 60 percent 11.1.2 Routine Tests
duty;
j) Rated input voltage, frequency and number The routine tests and their sequence shall be as
of phases; follows:
k) Open circuit voltage, minimum and a) Insulation resistance test ( 11.2 ),
maximum;
b) Open-circuit voltage test ( 11.4 ),
m) Type of cooling;
c) Load characteristic test ( 11.5 ),
n) Mass;
d) Short-circuit test ( 11.6 )
p) Class of insulation;
e) High voltage test ( 11.8 ), and
q) Country of manufacture; and
f) Insulation resistance test ( repeated )
r) A warning worded as follows: ( 11.2 ).
WARNING : Currents in excess of the
following are for inter- 11.1.2.1 A certificate of routine tests shall be
mittent use only: furnished by the manufacturer which shall show
For hand welding that each of the arc welding power source has
. . . . . . . . . . . . Amperes been subjected to the tests specified in 11.1.2 and
For automatic welding that it complies with the requirements specified in
. . . . . . . . . . . . . Amperes this standard for these tests and that each of
the arc welding power source has been found to
10.2 Arc welding power sources shall be fitted be sound electrically and mechanically and is in
with a current calibration chart. working order in all particulars.

10.3 The polarity of the output terminals shall II .2 Insulation Resistance Test
be marked in relation to the polarity in the
following manner: For the purpose of this test, the rectifier cells
shall be short-circuited on both the ac and dc
a) Positive terminals as ‘+‘, and sides while remaining connected to the trans-
b) Negative terminals as ‘--‘. former. Protective or filter devices or capacitors
shall be disconnected or short-circuited as desired.
In case a polarity changeover switch is provided,
the polarities marked are for straight connections 11.2.1 The insulation resistance before and after
only. high voltage test shall be not less than 2 meg-
ohms. The insulation resistance shall be measured
10.4 The arc welding power source may also be with dc voltage of about 500 V applied for a
marked with the Standard Mark. sufficient time for the reading of the indicator to
become practically steady, such voltage being
11 TESTS taken from an independent source or generated
in the measuring instruments.
11.1 Tests shall be made to prove compliance
with all the requirements of this standard. 1 I .3 Over Voltage Test

11.1.1 7jpe Tests An over voltage test shall be made as specified

in 6.4 followed by repeated switching off of the
These tests may be made by mutual agreement ac supply, 50 times, at the same excess voltage
between the purchaser and the supplier and if when the dc output terminals are not connected
the records of type tests on arc welding power to an external load.

4
IS 4559 : 1993

11.4 Open-Circuit Voltage Test 11.7.1.1 The load should -be a non-inductive
resistance at appropriate load voltage. A tolerance
With the input side connected to the rated input of f 10 percent shall be allowed on the value of
voltage and output side open-circuited, the open- this load voltage.
circuit voltage shall be measured.
11.7.1.2 Test shall be made at the rated -input
11.5 Load Characteristic Test voltage.

For the purpose of this test, the input side of the 11.7.1.3 Arc welding power sources suitable for
arc welding power source shall be connected to hand welding shall be tested for temperature-rise
rated input voltage and the output terminals shall at a current equal to the maximum continuous
be connected to a variable resistive load. The hand welding current and at the duty cycle equal
associated load currents and load voltages shall to 60 percent.
be as given in Table 1.
11.7.1.4 Arc welding power sources suitable for
11.6 Short-Circuit Test both semiautomatic and automatic welding shall
be tested for temperature-rise at a current equal
Steady short-circuit current at maximum setting to the maximum continuous automatic welding
within the range specified shall not be more than current and at a duty cycle equal to 100 percent.
200 percent of the welding current corresponding
to this setting. Under short-circuit conditions,
11.7.1.5 The temperature-rise test shall continue
the voltage between output terminals shall not until steady tnaximum temperature is obtained.
exceed 3 volts. If the temperature-rise does not vary by more
NOTE - Care shall be taken to ensure that this test than 2”C/h, it is considered that steady
does not-take more than 10 seconds. temperature has been achieved.

-11.7 Temperature-Rise Test 11.7.2 When measured in accordance with

IS 9678 : 1980, the temperature-rise shall not
11.7.1 Test Con&lions exceed the limits specified in Table 2.

Table 2 Limits of Permissible Temperature-Rise

( Clause 11.7.2 )

SI No. Parts Class A Class E Class B Class F Class H

Insulation Insulation Insulation Insulation Insulation
T R
"C 0: 0; "C 0: 0: 0: 0% .g 0:
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (J2)
i) Windings 55 60 65 15 70 80 85 100 105 125
ii) Oil 50 - - - - _ - - - -
iii) Uninsulated parts includ- The temperature-rise shall in no case reach such a value that there is risk
ing cores not in contact of injury to any insulation material on adjacent parts or to the welding.
with insulated windings plant in any respect

NOTES
1 T = by thermometer.
R = by resistance.
2 The numerical values quoted for classes F and H should be considered as tentative only and may be -revised
and use when more practical experience is available. If Class C insulation is used, the temperature-rise shall be
a matter of agreement between the purchaser and the supplier.
3 For details of classes of insulation, see IS 1271 : 1985.
IS 4559 : 1993

11.7.3 For ambient temperature exceeding 4O’C b) For the complete unit except as for (c)
or altitude more than 1 000 m or both, the below, 1 500 volts; and
derating factor shall be subject to agreement
between the purchaser and the surmlier. c) For all auxiliary circuits not exceeding
110 volts to earth, 1 000 volts.
11.8 High Voltage Test
11.8.4 The appropriate voltage, obtained from a
For the purpose of this test, rectifier cells shall be separate source, shall be applied for 60 seconds
short-circuited on either or both the ac and dc to each winding in turn, between the winding
sides while remaining connected to the trans- under test and the remaining windings, core,
former. Protective or filter devices or capacitors frame and tank or casing of the transformer,
shall be disconnected or short-circuited as desired. connected together and to earth.

11.8.1 As type test, this test shall be applied at 11.8.5 The test shall be commenced at a voltage
the conclusion of the temperature-rise test. not greater than one-third of the test value, and
shall be increased to the specified value as rapidly
11.8.2 The test shall be made with a single-phase as is consistent with its magnitude being indicated
alternating voltage as nearly as possible of sine- by the measuring instrument. At the end of the
wave from and of any convenient frequency test, the voltage shall be reduced rapidly tvless
between 40 and 60 Hz. than one-third of its full value before switching
Off.
11.8.3 The rms nor peak value of the applied
voltages shall be measured. The rms value shall NOTE - This test should not be carried out when
the insulation resistance value is below 2 megohms.
be as follows:

a) For the transformer alone when tested prior 11.8.5 If this test is required to be repeated, the
to inclusion in the complete unit, 2 000 test voltage levels shall be reduced to 75 percent
volts; of the original values.

ANNEX A
( %lause 2.1 )
LIST OF REFERRED [ND-IAN STANDARDS

IS No. Title IS No. Title

1248 Direct acting indicating 2511 : 1963 Polycrystalline semiconductor

( Part 2) : 1983 analogue electrical measuring rectifier stacks
instruments and their accesso- 2834 : 1986 Shunt capacitors for power
ries: Part 2 Ammeters and systems ( second revision )
voltmeters ( second revision ) 3895 : 1966 Monocrystalline semiconduc-
tor rectifier cells and stacks
1271 : 1985 Thermal evaluation and classi- 9678 : 1980 Methods of measuring tempe-
fication of electrical insulation rature-rise of electrical
(first revision ) equipment
I I
Standard Mark

The use of the Standard Mark is governed by the provisions ofthe Bureau ofIndian
Standards Act. 1986 and the Rules and Regulations made thereunder. The Standard Mark on
products covered by an Indian Standard conveys the assurance that they have been produced
to comply with the requirements of that standard under a well defined system of inspection,
testing and quality control which is devised and supervised by BIS and operated by the
producer. Standard marked products are also continuously checked by BIS for conformity
to that standard as a further safeguard. Details of conditions under which a licence for the
use of the Standard Mark may be granted to manufacturers or producers may be obtained
from the Bureau of Indian Standards.
Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.

Copyright

BIS has the copyright of all its publications. No part of these publications may be reproduced in
any form without the prior permission in writing of BIS. This does not preclude the free use, in the
course of implementing the standard, of necessary details, such as symbols and sizes, type or grade
designations. Enquiries relating to copyright be addressed to the Director ( Publications ), BIS.

Review of Iudiau Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also
reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no
changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of
Indian Standards should ascertain that they are in possession of the latest amendments or edition by
referring to the latest issue of ‘BIS Handbook’ and ‘Standards Monthly Additions’. Comments on this
Jndian Standard may be sent to BIS giving the following reference:

Dot : No. ETD 21 ( 3575 )

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

-.-

BUREAU OF INDJAN STANDARDS

Headquarters:

Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002

Telephones : 331 01 31, 331 13 75 Telegrams : Manaksanstha
( Common to all Offices )

Regional Offices: Telephone

Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg 331 01 31

NEW DELHI 110002 331 13 75

Eastern : l/14 C. T. T. Scheme VII M, V. I. P. Road, Maniktola 37 84 99, 37 85 61

CALCUTTA 700054 37 86 26, 37 86 62

Northern : SC0 445-446, Sector 35-C, CHANDIGARH 160036 53 38 43, 53 16 40

53 23 84

MADRAS 600113 235 02 16, 235 04 42

Southern : C. I. T. Campus, IV Cross Road, { 235 15 19, 235 23 15
Western : Manakalaya, E9 MIDC, Marol, Andheri ( East ) t 632 92
78 91,
95, 632 78 92
58
BOMBAY 400093

Branches : AHMADABAD. BANGALORE. BHOPAL. BHUBANESHWAR. COIMBATORE.

FARJDABAD. GHAZIABAD. GUWAHATI. HYDERABAD. JAIPUR. KANPUR.
LUCKNOW. PATNA. THIRUVANANTHAPURAM.

Printed at Printrade, New DelhiJndia