Nelson Nelweld 4000, Operation And Service Manual

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Nelweld Operations and Service Manual
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4.3 General Description
The Nelweld welding systems are high
performance, digitally controlled transformer-
rectifier power sources, capable of welding a vast
array of weld studs over a myriad of applications.
When equipped with a compatible Nelson stud
welding gun and appropriate accessories, they can
support manual, gas arc, and automated stud
welding processes to meet the most stringent
requirements.
4.4 Recommended Processes and
Equipment
Nelson recommends using original Nelson guns,
feeders, and genuine Nelson studs to insure the
highest quality welded stud solution. Nelson, as
the inventor and industry leader in stud welding,
recognizes the importance of taking a systems
approach to avoiding and resolving stud welding
problems. Only by using original Nelson
products and equipment for all aspects of the
system can we guarantee the best possible weld
results.
4.5 Design Features
4.5.1 Modular Design
This product line is designed in a modular
fashion, which leads to many customer benefits:
• Allows for easy upgrades as customer
requirements change. For example, a single
gun unit can be field-upgraded to a dual gun
system using a Second Output Kit.
• Modular design approach leads to the highest
value offering:
the customer pays only for the
options that are desired.
• Most field-installed options are
interchangeable between each power source
size.
•
The common design of the product line
minimizes the required equipment training
and aids in troubleshooting.
4.5.2 System Cooling and Thermal
Protection
This power source is designed to effectively
manage heat generated by the power source and
inherent to its working environment. Built-in
fans are used to pull cool air into the case front,
through the machine, and out the case rear. A
thermostat controls these fans so that they only
operate when necessary to keep the machine
within the allowed temperature range.
The power source also has thermostats built-in to
monitor the temperature of critical internal
components. If any of these temperatures
exceeds its maximum allowed value, machine
output is disabled, and the operator is notified by
a fault indicator and warning code displayed on
the front panel. The system remains in the
disabled state until the temperature is reduced to
an acceptable level.
WARNING
Keep all body parts away from the cooling fan.
The fan may start without warning, causing
bodily injury to hands, arms, or any other body
parts that are in contact with the fan blades.
Do not service or repair the cooling fan while
the power is connected.
Failure to do so may result in
bodily injury or death.
4.6 Operational Features and Controls
4.6.1 Power-up
The main switch controls the input power to the
machine. Upon powering up, the internal control
software performs a series of diagnostic tests to
ensure correct connection and operation of the
power source. The unit also displays the current
software version and model designation during
the power up routine. Once the startup routine is
complete, the time and current settings are
reported on the corresponding front panel
displays. The unit is now ready to weld.