Sign In
Upload
Download
Table of Contents
Contents
Add to my manuals
Delete from my manuals
Share
URL of this page:
HTML Link:
Bookmark this page
Add
Manual will be automatically added to "My Manuals"
Print this page
×
Bookmark added
×
Added to my manuals
Manuals
Brands
Nelson Manuals
Welding System
Nelweld 4000
Operation and service manual
Nelson Nelweld 4000 Operation And Service Manual
Hide thumbs
1
2
Table Of Contents
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
page
of
69
Go
/
69
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Nelweld Power Control Unit
Limited Warranty
Table of Contents
1 0 Safety
Safety Symbols
Safety Concerns
Safety Advice
Personnel Training
Personal Protection Equipment
Protective Measures at the Worksite
Safety on the Job
Electrical Danger
Intended Use
Guarantee and Liability
Copyright
2 Introduction to Stud Welding
Processes
Principles of the Drawn Arc (Electric Arc) Welding Process
Principles of the Short Cycle/Gas Arc Welding Process
Stud Welding Equipment
Stud Materials
Stud Welding Setup Parameters
Stud Welding Practice
General Guidelines
Material Selection and Verification
Operator Training and Qualification
Visual Weld Inspection
Physical Weld Inspection
Closing Comments
3 Installation
Technical Specifications
Nelweld Characteristics
Recommended Input Wire and Fuse Sizes
Physical Dimensions
Temperature Ranges
Extent of Delivery
Extent of Dispatch
Inspection of Incoming Materials
Intermediate Storage
Locating the Power Source
Moving the Power Source
Input Connections
Input Voltage Connection
Machine Grounding
Input Fuse and Supply Wire Considerations
Input Voltage Reconnect Procedure
Output Connections
Gun Control Cable Connections
Stud and Work Leads - Stud Negative Applications (Straight Polarity)
Stud and Work Leads - Stud Positive Applications (Reverse Polarity)
4 Operation
Safety Precautions
Basic Operation Procedure
General Description
Recommended Processes and Equipment
Design Features
Modular Design
System Cooling and Thermal Protection
Operational Features and Controls
Power-Up
Setting the Current
Current Display
Setting the Time
Time Display
Special Functions
Setpoints
Setpoint Programming
Front Panel Lock
Status LED Operation
Fault Icon Indicator
Weld Counter
Chuck Stripper
Lift Check
Weld through Deck Mode
Chuck Saver
Resetting Default Parameters
Diagnostic Mode Enable
Quick Retry Enable
Loadbank Mode Enable
Stud Feed Weld Success Function
Calibration Factor
KFL Mode Enable
Quick Pilot Arc Mode
Output Panel Layout
RS-232 Port /Cable
Custom Adjustments
Pilot Arc Time Adjustment
Hot Plunge Time Adjustment
Accessories
Caster Kits: User Install
Gas Valve Control Kit: Tech Install
Stud Feeder Interface Kit: Tech Install
Second Output Kit: Tech Install
RS-232 Port Kit: Tech Install
Remote Control Kit: Tech Install
Process Monitoring Kit: Tech Install
Diagnostic Kit: Tech Install
Calibration Kit: Tech Install
Compatible Equipment
Two-Wire Controlled Guns
Three- and Four-Wire Controlled Guns
Stud Feeding System Interface
Limitations
Duty Cycle
Weld Cable Length
5 Maintenance
Safety Precautions
Electric Shock Can Kill
Care and Cleaning
Maintenance Schedule
6 Troubleshooting
Safety Precautions
Diagnostic Codes - Troubleshooting Guide
Machine - Troubleshooting Guide
7 Miscellaneous Information
Timing Diagrams
Timing Diagram Definitions
Function Code Definitions
Control Fuses 559
Declaration of Conformity
8 Diagrams and Parts Lists
Front Section
Base and Side Cabinet Section
Transformer and Top Cabinet Section
Rear Cabinet Section
Wiring Diagram
Advertisement
Quick Links
1
Stud Welding Setup Parameters
2
Diagnostic Codes - Troubleshooting Guide
Download this manual
Nelweld 4000 and 6000
Operations and Service
Manual
Manual Version 1.19
June 2008
For Control Board Software Versions 2.09 and higher
Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Table of Contents
Troubleshooting
TROUBLESHOOTING
46
DIAGNOSTIC CODES - TROUBLESHOOTING GUIDE
47
MACHINE - TROUBLESHOOTING GUIDE
48
Need help?
Do you have a question about the Nelweld 4000 and is the answer not in the manual?
Ask a question
Questions and answers
Related Manuals for Nelson Nelweld 4000
Welding System Nelson Nelweld 6000 Operation And Service Manual
(69 pages)
Welding System Nelson N1500i Operating Manual
Facs stud welding system (91 pages)
Welding System Nelson NS20A Instruction And Maintenance Manual
Heavy duty floating lift welding guns (19 pages)
Welding System Nelson N1500i Operation And Service Manual
Stud welding unit (150 pages)
Welding System Nelson NCD+ Auto-Gap Gun Instruction & Maintenance Manual
(29 pages)
Welding System Nelson NCD+ 1000T Operation Manual
Operating the capacitor discharge stud welding unit (35 pages)
Welding System Nelson NCD+ Instruction & Maintenance Manual
Contact gun (33 pages)
Welding System Nelson INTRA 2100 Operating Manual
Stud welding unit (68 pages)
Welding System Nelson N800iTM Operation And Service Manual
Stud welding unit (142 pages)
Welding System Nelson NS-40 Instruction And Maintenance Manual
Standard duty floating lift welding guns (18 pages)
Welding System Nelson ALPHA 850 Operating Manual
Stud welding unit (65 pages)
Welding System Nelson ArcCharger N550C DOMESTIC Operation Manual
(65 pages)
Welding System Nelson NCD+ 3200 Operation Manual
Capacitor discharge stud welding unit (32 pages)
Welding System Nelson N1500i Fast Start Manual
Stud welding unit (37 pages)
This manual is also suitable for:
Nelweld 6000
Table of Contents
Save PDF
Print
Rename the bookmark
Delete bookmark?
Delete from my manuals?
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL
Need help?
Do you have a question about the Nelweld 4000 and is the answer not in the manual?
Questions and answers