Essential for Industrial Manufacturing Sites: TK6500 Arc Welding Machine AC-DC Power Calibrator

The Importance of Arc Welding Machines Calibration

In industrial manufacturing, arc welding machines play a crucial role in metal joining processes, with their performance directly impacting weld quality and safety. These machines function as welding power sources, supplying controlled output voltage and current to initiate and sustain an electric arc between the electrode and the workpiece.

To ensure reliable welding performance, the AC and DC outputs of these power sources must be regularly calibrated. However, in many facilities, this critical verification step is often overlooked or performed with inadequate instruments, leading to compromised weld quality, increased safety risks, and potential non-compliance with international standards.

Standards such as IEC 60974-1 and IEC 60974-4 require welding power sources to undergo regular testing and verification. Similarly, ANSI/AWS C4.1 (USA) and JIS B 8815 (Japan) outline rigorous performance testing procedures and stress the importance of traceable calibration for welding output parameters. Unfortunately, traditional tools such as handheld multimeters or resistive load banks often fall short in terms of accuracy, stability, and on-site applicability.

Additionally, conventional calibration methods frequently involve disassembling the built-in voltmeters and ammeters of the welder's power supply, making the process cumbersome and inefficient, especially for on-site or batch testing scenarios.

To address these challenges, TK6500 Arc Welding Machine AC-DC Power Calibrator offers a highly accurate and convenient solution for on-site calibration. Designed specifically for welding machines, TK6500 Electric Welding Machine AC-DC Power Calibrator enables calibration of internal ammeters and voltmeters without the need for disassembly, significantly improving efficiency. It supports both AC and DC power measurements, with a maximum current capacity of up to 3 kA. Users can choose between two accuracy classes—Class 0.05 and Class 0.1—to meet various calibration requirements.

Key Features and Specifications of TK6500 Arc Welding Machine AC-DC Power Calibrator

• AC and DC voltage measurement range: 5 V to 180 V (optional extension up to 500 V)

• AC and DC current through-center measurement range: 10 A to 3 kA

• Frequency range (F): DC and 40 Hz to 1 kHz

• Voltage and current accuracy classes: 0.05 and 0.1

• Harmonic measurement capability

• USB interface for data export

Wide Range of Current Measurement

• TK6500 Arc Welding Machine AC-DC Power Calibrator adopts the method of measuring the current through the core, which can reduce the wiring work of the current loop and improve the work efficiency.

• The wide range measurement capability can cover the calibration of the commonly used AC and DC arc welding machine power supply, and the user can choose different specifications of current sensors (500  A/ 1 kA/ 2 kA/ 3kA) according to the needs, such a combination. It is beneficial to reduce the size and volume of the host, and the choice of lightweight sensor is more convenient to carry to the field for calibration work.

Power Analysis and Trend Visualization

• Visual Display Of The Measured Power: The measured voltage and current measurement results are displayed at the same time

• Power Trend Test: Curve the power over time in real time during the test cycle.

• Power Stability Analysis: calculate the maximum (MAX), minimum value (min), and peak-peak value of the measured electricity ( P-P ), mean ( Avg ) , standard deviation ( S .dev ) , divergence ( Div ), etc.

Tablet-Based Remote Operation (Optional)

• Problems in on-site calibration: In industrial settings, the welding machine under test is often placed on an elevated platform while the standard equipment (TK6500 main unit + load) remains on the ground, as shown in Figure (b). Under such conditions, it is difficult to simultaneously record the readings of both the welding machine and the standard calibrator, causing inconvenience in the calibration process.

• Solution: An optional tablet accessory is provided, which can communicate with TK6500 arc welding machine AC-DC power calibrator main unit in real time via WiFi. The user can use the tablet to photograph the readings of the welding machine under test, while the system automatically records the corresponding standard calibrator readings at the exact moment of the photo, facilitating subsequent data processing.

• Additional tablet functions: The tablet also displays measurement waveforms, harmonic spectra, and trend charts,      enabling analysis of multiple harmonic contents and statistical calculations of parameters such as maximum, minimum, average, and RMS values—all of which characterize the stability of the welding power source.

As industries increasingly demand higher welding quality and stricter compliance with international standards, the need for reliable, efficient, and traceable calibration solutions has become more urgent than ever. TK6500 Arc Welding Machine AC-DC Power Calibrator provides a practical answer to these challenges. With its high accuracy, wide measurement range, user-friendly features, and support for non-invasive, on-site verification, TK6500 Arc Welding Machine AC-DC Power Calibrator streamlines the calibration process while minimizing disruption to operations. Whether for routine inspections or large-scale batch testing, it empowers quality control teams to ensure that welding power sources consistently meet performance and safety standards.

For more information or to discuss how TK6500 can support your calibration needs, please feel free to contact us.