Related Manuals for Nelson Nelweld 4000
Summary of Contents for Nelson Nelweld 4000
- Page 1 Nelweld 4000 and 6000 Operations and Service Manual Manual Version 1.19 June 2008 For Control Board Software Versions 2.09 and higher...
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Page 2: Nelweld Power Control Unit
Nelson’s liability for breach of warranty shall arise only upon return of the defective goods at Buyer’s expense after notice to Nelson of the claimed breach, and shall be limited to furnishing a like quantity of such goods free from such defects or, at Nelson’s option, to refunding the purchase price (less reasonable depreciation based on actual use);... -
Page 3: Table Of Contents
Nelweld Operations and Service Manual Table of Contents NELWELD POWER CONTROL UNIT LIMITED WARRANTY SAFETY.....................................6 AFETY YMBOLS AFETY ONCERNS 1.2.1 Safety Advice 1.2.2 Personnel Training 1.2.3 Personal Protection Equipment 1.2.4 Protective Measures at the Worksite 1.2.5 Safety on the Job 1.2.6 Electrical Danger NTENDED... - Page 4 Nelweld Operations and Service Manual ENERAL ESCRIPTION ECOMMENDED ROCESSES AND QUIPMENT ESIGN EATURES 4.5.1 Modular Design 4.5.2 System Cooling and Thermal Protection PERATIONAL EATURES AND ONTROLS 4.6.1 Power-up 4.6.2 Setting the Current 4.6.3 Current Display 4.6.4 Setting the Time 4.6.5 Time Display 4.6.6 Special Functions...
- Page 5 ABINET ECTION IRING IAGRAM Notes: Only for EU countries Do not dispose of Nelson stud welding units and system components with household waste! Nelson stud welding units and system components are B2B devices and therefore exclusively designed for commercial use.
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Page 6: Safety Symbols
Nelweld Operations and Service Manual SAFETY Safety depends on you. Nelson stud welding power supplies, studs, and equipment are designed and built with safety in mind. However, your overall safety can be increased with proper installation, use, and thoughtful operation on your part. Do not install, operate, or repair this equipment without reading this manual and the safety precautions contained throughout. -
Page 7: Safety Concerns
Nelweld unit. Knowledge of and careful attention to all safety advice granted in • Oil-free, protective garments covering the this manual is highly advised by Nelson Stud entire body, such as leather gloves, heavy Welding, Inc. -
Page 8: Safety On The Job
Nelweld Operations and Service Manual WARNING As a result of the weld process, strong electromagnetic fields are present during the weld During the welding process, certain exposed cycle. These electromagnetic fields can be parts of the weld gun, such as the stud, dangerous without proper considerations, and chuck, and all parts electrically connected to can:... -
Page 9: Electrical Danger
• The welding unit may only be operated with protective measures must be taken: spare parts and accessories specified in this • The welder must be adequately protected operations manual or by a Nelson technical against electrical dangers by using insulating representative. underlay or intermediary layers, •... -
Page 10: Copyright
• Use of the welding system in residential and The copyright to these operating instructions commercial areas. remains with Nelson Stud Welding, Inc. They • Improper handling of the shielding gas or include the regulations and drawings of a related accessories. - Page 11 Nelweld Operations and Service Manual DANGER ELECTRIC AND WELDING SPARKS MAGNETIC FIELDS CAN CAUSE FIRE OR MAY BE DANGEROUS EXPLOSION Electric current flowing through any current conducting Have a fire extinguisher readily available. • • material causes localized Electric and Magnetic Fields •...
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Page 12: Introduction To Stud Welding
Nelweld Operations and Service Manual INTRODUCTION TO STUD WELDING • The trigger is then depressed to start the fully 2.1 Processes controlled automatic sequence. This sequence consists of initiating the weld current, lifting There are two main stud welding processes that the stud to create an arc by energizing the gun can be accomplished by the Nelweld series of solenoid (Step B), timing out the weld time,... -
Page 13: Stud Welding Equipment
Nelweld Operations and Service Manual Rather, the studs have a machined, slightly • System shutdown in case of variation from tapered point through which the welding current the established weld parameters. passes. These features have contributed greatly to simplified weld set up and increased weld quality The weld pocket that is formed during Short of current stud welding power supplies. - Page 14 Nelweld Operations and Service Manual If no gap exists, the current will not create On some base materials, longer times and sufficient heat to melt the metal. Short lift reduced amperage improves the ductility of may allow molten metal to bridge the arc-gap, the weld zone.
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Page 15: Stud Welding Practice
Nelweld Operations and Service Manual zinc galvanizing is electrically conductive, studs Weld Settings table specifies should not be welded to a galvanized plate. Zinc recommended weld settings. It should be noted is a weld contaminant and will cause brittle that these settings are only suggested starting welds. - Page 16 Nelweld Operations and Service Manual Figure 2-2 shows typical ground and edge effect electrical contact and current flow. It may take patterns due to arc blow. These effects are less some time and trials to establish a good a current noticeable where large masses of steel are present flow path...
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Page 17: Material Selection And Verification
There are spark retention 2.7.2 Material Selection and Verification accessories available from Nelson Stud Welding, Studs are made from steel supplied to the Nelson Inc. Stud Welding, Inc. by quality, approved steel suppliers. -
Page 18: Operator Training And Qualification
(CMTR) for each heat and diameter of general guidelines and inspection techniques. steel supplied. These mill test reports certify Highly skilled representatives of Nelson Stud compliance to welding code specified material Welding, Inc. can provide both written and visual... -
Page 19: Visual Weld Inspection
Nelweld Operations and Service Manual equipment, settings, welding cables and ceramic quality certification agencies, or other interested ferrules to be used in production welding. parties. All ten studs of each diameter and position to be 2.7.4 Visual Weld Inspection qualified must be tensile and/or bend and/or A proper relationship between the Lift, Plunge, torque tested to failure. -
Page 20: Physical Weld Inspection
Nelweld Operations and Service Manual stud so there is no permanent distortion of the • Burn through the base material. threads. Torque test proof load requirements are In most arc welding processes the weld fillet found in AWS D1.1, D1.5, or D1.6. The test studs metal comes from the addition of filler metal may be used in production. -
Page 21: Closing Comments
Nelweld Operations and Service Manual repaired with a hand weld by adding a minimum fillet weld as required in the Weld Flash Size table. The repair weld shall extend at least 3/8" beyond each end of the discontinuities being repaired. If any of the studs bend tested fail the test or if there is continued and frequent evidence of insufficient stud burn off, production must be... -
Page 22: Installation
3 φ 60Hz 2100 0.020 1.400 330 kg 750-601-501 725 lb 750-601-000 230/460/575VAC 3 φ 60Hz 2100 0.020 1.400 330 kg 750-601-500 Nelweld 4000 50/60 725 lb 750-601-051 220/380/415/440 3 φ 2100 0.020 1.400 330 kg 750-601-551 50/60 725 lb... -
Page 23: Recommended Input Wire And Fuse Sizes
(Amps) (Super Lag) Current Time 208/60 488/6.7% LPN-RK(250V)RK1 230/60 442/6.7% LPN-RK(250V)RK1 460/60 224/6.7% AWG 6 LPS-RK(600V)RK1 575/60 181/6.7% AWG 6 LPS-RK(600V)RK1 Nelweld 4000 220/50 461/6.7% 95mm LPN-RK(250V)RK1 380/50 270/6.7% 70mm LPS-RK(600V)RK1 400/50 257/6.7% 70mm LPS-RK(600V)RK1 415/50 248/6.7% 70mm LPS-RK(600V)RK1 440/50 234/6.7%... -
Page 24: Physical Dimensions
Nelweld Operations and Service Manual 3.1.3 Physical Dimensions Nelweld 4000 Nelweld 6000 Shown with Single Gun Configuration Shown with Double Gun Configuration Physical Dimensions (excluding handles and side bumpers) Machine Height Width Depth Weight 32 in (813 mm) with legs 24 in (610 mm) 33.5 in... -
Page 25: Extent Of Delivery
Failure to observe these precautions can delivery. Any possible transport damage and/or result in excessive operating temperatures and missing parts must immediately be made known frequent, unanticipated shutdowns. to Nelson Stud Welding, Inc. or the authorized forwarding company. - 25 -... -
Page 26: Moving The Power Source
Nelweld Operations and Service Manual 3.7 Moving the Power Source 3.8 Input Connections This equipment been designed WARNING portability. Nelweld models are supplied from the factory with legs in the four corners of the Only a qualified electrician should connect base. - Page 27 Nelweld Operations and Service Manual FOR 3000 & 4000 18" (457mm) MODELS, ADD 18” TO THESE WIRE LENGTHS 12" (305mm) CRIMP ON WIRE LUG - 3/8" (9MM) DIAMETER HOLE 1" (25.4mm) ATTACH TO GROUND WIRE - ONE REQUIRED GREEN WIRE (GROUND) (GREEN/YELLOW WIRE FOR CE UNITS) L1, L2 AND L3 CONNECTIONS FIRMLY ATTACH THREE POWER LEADS, AS SHOWN.
- Page 28 4 60 V O L T S 575 V O LTS N elso n S tu d Weld ing , In c. Nelson Stud Welding, Inc. Reorder Number 724-569-100 Figure 3-5: Link connections for 208/230/460/575 V model. (Systems shipped after April 2006).
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Page 29: Machine Grounding
Nelweld Operations and Service Manual Figure 3-6: Link connections for 220/380/415/440 V model 220 V O LT S 4 15 V O L T S 380 V O LT S 4 40 V O L T S Nelso n Stud W elding, Inc. Reord er Num ber to a different voltage, remove the left side case side panel, with respect to the front of the... -
Page 30: Stud And Work Leads - Stud Negative Applications (Straight Polarity)
Nelweld Operations and Service Manual 3.9.2 Stud and Work Leads – Stud Negative Applications (straight polarity) Most welding applications run with the stud being negative (-). For these applications, connect the stud gun weld cable to the gun connector on the power source output panel marked with a gun symbol. -
Page 31: Operation
Nelweld Operations and Service Manual OPERATION 4.1 Safety Precautions WELDING SPARKS can cause fire or FUMES AND GASES can be dangerous. explosion. • • Keep your head Keep flammable away from fumes. material away. • • Use ventilation or Do not weld on exhaust fans to containers that have remove fumes from... -
Page 32: General Description
Nelson recommends using original Nelson guns, output is disabled, and the operator is notified by feeders, and genuine Nelson studs to insure the a fault indicator and warning code displayed on highest quality welded stud solution. Nelson, as the front panel. -
Page 33: Setting The Current
4.6.7 4.6.9 4.6.6 4.6.11 4.6.5 4.6.4 Nelweld Maximum Settings Current (amps) Time (seconds) Power source Nelweld 4000 2100 0.020 1.400 Nelweld 6000 2500 0.020 1.500 conditions where it is not possible for the power 4.6.2 Setting the Current source to deliver the desired current, a warning The current setting is displayed on the front panel light will light on the front panel display. -
Page 34: Time Display
Nelweld Operations and Service Manual 4.6.5 Time Display and current are displayed on the front panel, and the LED on the selected preset key lights. The time display is used to display both the desired time setting and the actual weld time. In 4.6.8 Setpoint Programming normal operating modes, the desired setting and Nelweld users are not restricted to pre-... -
Page 35: Status Led Operation
• Contact LED – this LED is on whenever the particularly useful for studs with short chuck stud chucked in the gun is in contact with the engagement, such as Nelson’s capped grounding work. lug studs. 4.6.11 Fault Icon Indicator... -
Page 36: Lift Check
Nelweld Operations and Service Manual cool, and is represented by t on the “Timing function F13. It has a default value of 2000 Diagrams” in Section 7.1 of this guide. It is milliseconds (2.000 seconds) when lift check is set using special function F42 and has a enabled. -
Page 37: Resetting Default Parameters
Nelweld Operations and Service Manual 4.6.17 Resetting Default Parameters main current. When this function is disabled, the signal will be given after every weld attempt. To reset all controllable functions, to default When this function is enabled, the signal will be conditions, select special function F44 and press given after every successful weld. -
Page 38: Output Panel Layout
This section specifies options that are available Weld Cable Connector Connector for use with Nelweld units. Nelson Factory Trained Personnel should install the kits where specified. Where a connection to a computer is required, an RS-232 port must be either factory or field-installed. -
Page 39: Stud Feeder Interface Kit: Tech Install
Stud Feed Interface Kit. With this kit installed, computer or laptop. An RS-232 port is necessary an isolated contact is provided to trigger the stud for any additional Nelson software kits (Nelware feeding device. kits) that require communication between the To install this kit, a connector assembly is added Nelweld unit and a computer. -
Page 40: Process Monitoring Kit: Tech Install
Nelweld Operations and Service Manual Software to be installed on the user’s personal computer. 4.8.7 Process Monitoring Kit: Tech Install The Process Monitoring Kit allows the use of a personal computer or laptop to keep track of preset and actual weld parameters to meet QS- 9000 and ISO 9000 requirements. -
Page 41: Compatible Equipment
Thus if welding with 200 feet of gun cable and Nelweld power sources are compatible with all 200 feet of ground cable, then the total cable existing Nelson stud welding guns with three- and length is 400 feet. four-wire control with the use of a converter. - Page 42 Parameters listed are those used during testing, and should be used only when considering weld duty cycle Stud Size Time Current Weld Rate (studs per minute) (sec) (in) (mm) Nelweld 4000 Nelweld 6000 3/16” 0.15 Unlimited Unlimited 1/4” 0.17 Unlimited 5/16”...
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Page 45: Maintenance
Every 6 months • Circuit boards* electrical repair personnel. • Electrical connections and components* General overhaul of the Nelweld unit by Nelson Factory General maintenance to verify that the Every 5 years Trained personnel. machine is functioning properly. -
Page 46: Troubleshooting
6.1 Safety Precautions WARNING Service and Repair should only be performed by Nelson Stud Welding, Inc. Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 47: Diagnostic Codes - Troubleshooting Guide
Nelweld Operations and Service Manual 6.2 Diagnostic codes – Troubleshooting Guide The diagnostic codes can be accessed via the F1 Special Function Mode. The E codes can be scrolled with the up/down keys next to the LED Display. The error codes are erased when the unit is shut off. Diagnostic Description Recommended Action... -
Page 48: Machine - Troubleshooting Guide
Refer to Section 3.5.4 of this guide and check Nothing happens when the incorrectly. connections. machine is turned ON. Contact your qualified Nelson Technical Service Internal Power Source Problem Representative. Machine starts up, but a strange, Jumpers are not set properly See Section 3.8.1 for proper jumper settings. - Page 49 (3) that might have blown. Those fuses are located on the Pilot Arc PCB. If there are further problems, contact your qualified Nelson Technical Service Representative, If in dual gun operation, another Wait for the other welder to finish the cycle, and welder may be attempting to weld retrigger.
- Page 50 Nelweld Operations and Service Manual Weld Quality Problems Problem Possible cause Solution Adjust calibration value (F114) until correct current Calibration value is incorrect is achieved. Check the stud burn-off. If the burn-off is much greater than what is typical for that diameter stud, the time and current settings may not be correct.
- Page 51 Nelweld Operations and Service Manual Weld Quality Problems Problem Possible cause Solution Plunge is measured by the amount of stud protruding beyond the bottom edge of the ferrule. Plunge is too short. Consult Section 2.6 to ensure proper plunge settings are being used, and correct, if necessary.
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Page 52: Miscellaneous Information
Nelweld Operations and Service Manual Miscellaneous Information 7.1 Timing Diagrams Weld sequence and air trigger for lift check Contact Gun Trigger Gas Valve Pilot Arc Main Arc Gun Coil Feed Signal Contact Lost Feed Signal After Weld Feed Signal Contact Lost* Feed Signal After Weld* Welding... -
Page 53: Timing Diagram Definitions
Nelweld Operations and Service Manual Chuck stripper and chuck saver operation Contact Gun Trigger Gas Valve Pilot Arc Main Arc Gun Coil Feed Signal Contact Lost Feed Signal After Weld Feed Signal Contact Lost* Feed Signal After Weld* Chuck Welding Welding Saver Chuck... - Page 54 20 ms Weld time as set on the user interface. It Set on front panel starts when the main current is turned on Nelweld 4000 max. 1.4 sec and ends when the gun coil is shut off. Nelweld 6000 max.
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Page 55: Function Code Definitions
Nelweld Operations and Service Manual 7.3 Function Code Definitions Default Minimum Maximum Description Units Zero state One state Comments Value Value Value Scrolls through error codes of Error Display E--- E001 E018 active errors Only Nelweld 6000 can enable Weld Through Deck disabled enabled this option... - Page 56 Nelweld Operations and Service Manual Default Minimum Maximum Description Units Zero state One state Comments Value Value Value Enable to allow preset selections F111 Preset-Enabled Lock Mode disabled enabled while locked. Enable to allow for supply of F112 Loadbank Mode Enable disabled enabled weld current through a fixed...
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Page 57: Control Fuses 559
Nelweld Operations and Service Manual 7.4 Control Fuses There are cartridge type fuses in the Nelweld that should only clear if the unit is abused or damaged (overvoltage, circuit board damage, wiring faults,etc). Designator Type Case Part Number Protects Location in Nelweld 4A,250V, 715-060-003... -
Page 58: Declaration Of Conformity
Nelweld Operations and Service Manual 7.5 Declaration of Conformity - 58 -... -
Page 59: Diagrams And Parts Lists
Nelweld Operations and Service Manual Diagrams and Parts Lists 8.1 Front Section * Not shown - 59 -... - Page 60 Nelweld Operations and Service Manual - 60 -...
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Page 61: Base And Side Cabinet Section
Nelweld Operations and Service Manual 8.2 Base and Side Cabinet Section - 61 -... - Page 62 Nelweld Operations and Service Manual - 62 -...
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Page 63: Transformer And Top Cabinet Section
Nelweld Operations and Service Manual Transformer and Top Cabinet Section * European units only ** Alternate is used on European units. See parts list. - 63 -... - Page 64 Nelweld Operations and Service Manual - 64 -...
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Page 65: Rear Cabinet Section
Nelweld Operations and Service Manual 8.4 Rear Cabinet Section - 65 -... - Page 66 Nelweld Operations and Service Manual - 66 -...
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Page 67: Wiring Diagram
Nelweld Operations and Service Manual 8.5 Wiring Diagram - 67 -... - Page 68 *San Francisco England Middle East & Asia/Pacific 1520 Pine Log Road 8600 W. 95 Street 23765 Foley Street Nelson U.K. Ltd. 7900 West Ridge Rd. Suite 6 Suite 104 Hayward, CA 94545 47-49 Edison Rd. P.O. Box 4019 Conyers, GA 30012 Overland Park, KS 66212 510.293.0660...
- Page 69 Nelweld Operations and Service Manual This manual is Nelson part #750-599-100 If replacement or additional manuals are needed, please use this part number when ordering. Nelson Stud Welding, Inc. 7900 West Ridge Road P.O. Box 4019 Elyria, OH 44036-2019 TEL: 440-329-0400 FAX: 440-329-0521 www.NelsonStudWelding.com...