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Nelweld Operations and Service Manual

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Summary of Contents for 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...

Page 2: ...to inspect and repair said equipment at buyer s facility or such other location as is mutually agreeable Notice to Nelson must be given within 30 days of such defect or failure and within two 2 years...

Page 3: ...7 2 7 3 Operator Training and Qualification 18 2 7 4 Visual Weld Inspection 19 2 7 5 Physical Weld Inspection 20 2 8 CLOSING COMMENTS 21 3 0 INSTALLATION 22 3 1 TECHNICAL SPECIFICATIONS 22 3 1 1 Nelwe...

Page 4: ...37 4 6 21 Stud Feed Weld Success Function 37 4 6 22 Calibration Factor 37 4 6 23 KFL Mode Enable 37 4 6 24 Quick Pilot Arc Mode 37 4 6 25 Output Panel Layout 38 4 6 26 RS 232 Port Cable 38 4 7 CUSTOM...

Page 5: ...65 8 5 WIRING DIAGRAM 67 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 dev...

Page 6: ...Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the Ame...

Page 7: ...manual 1 2 3 Personal Protection Equipment Wearing proper protective equipment is a mandatory stipulation for all operating personnel apprentices and trainees This includes the use of Oil free protect...

Page 8: ...ft check The correct application of all protective equipment All system components for damage All connecting cables for loose contacts and or scorching During normal operation Only use the welding sys...

Page 9: ...o accommodate welding in both the Electric Arc and Short Cycle welding processes The specifications in this operations manual with regard to safe welding testing and qualification practices must be ob...

Page 10: ...improperly trained personnel unsupervised trainee s or unqualified personnel Arbitrary structural alterations to the system Non compliance with the stipulated maintenance intervals 1 5 Copyright The...

Page 11: ...ble should also be on your right side Connect the ground cable to the workpiece as close as possible to the area being welded ELECTRIC SHOCK CAN KILL Do not work next to the welding power source Maint...

Page 12: ...zing the gun solenoid Step B timing out the weld time plunging the stud by de energizing the gun solenoid Step C and turning off the weld current at the end of the weld cycle Step D The fasteners for...

Page 13: ...le or other resistance changes in the weld circuit Compensation for incoming power fluctuations System shutdown in case of variation from the established weld parameters These features have contribute...

Page 14: ...an slow the stud plunge so that there is less than full penetration of the stud into the molten weld pool resulting in less than full weld strength Electric Arc Stud Welding Setups for Mild and Stainl...

Page 15: ...paint galvanizing grease moisture etc While zinc galvanizing is electrically conductive studs should not be welded to a galvanized plate Zinc is a weld contaminant and will cause brittle welds Weld a...

Page 16: ...ith a center ground bolted to the bottom will eliminate or minimize arc blow effects If a welding platen table or surface is used for this purpose it should be kept clean by removing weld splatter wel...

Page 17: ...ilable from Nelson Stud Welding Inc Ceramic ferrules are also available in a wide variety of configurations including but not limited to welding studs to round or rectangular tubing and bars plate or...

Page 18: ...ion stud welding This familiarizes the operators with the general principles of the process proper set up of the equipment weld set up for the studs being used general guidelines and inspection techni...

Page 19: ...and do the stud welding using the WPS guidelines seen in the Stud Qualification Testing chart The welds are then visually inspected tested and certified by the welding supervisor or welding trainer a...

Page 20: ...raightening without approval by the Engineer of Record Torque testing is done to a proof load level slightly lower than the nominal yield of the stud so there is no permanent distortion of the threads...

Page 21: ...les should be checked the necessary adjustments made and the process and operator qualification procedures repeated with satisfactory results before welding continues 2 8 Closing Comments Over one hun...

Page 22: ...300 2100 0 020 1 400 2 750 601 500 725 lb 1 750 601 051 220 380 415 440 3 50 60 Hz 330 kg 300 2100 0 020 1 400 2 750 601 551 725 lb 1 750 601 055 Nelweld 4000 400 VAC CE 3 50 60 Hz 330 kg 300 2100 0 0...

Page 23: ...0 1 4 100 LPS RK 600V RK1 575 60 204 23 3 AWG 6 266 1 4 100 LPS RK 600V RK1 220 50 518 23 3 95mm2 678 1 4 150 LPN RK 250V RK1 or FRN R 250V RK5 380 50 304 23 3 70mm2 397 1 4 100 LPS RK 600V RK1 400 50...

Page 24: ...0 kg 34 in 865 mm with legs 28 in 710 mm Nelweld 6000 39 6 in 1005 mm with casters 31 in 786 mm over handles 35 5 in 900 mm 1050 lbs 480 kg 3 1 4 Temperature Ranges Operating Temperature Range 32 F to...

Page 25: ...unit is not operated immediately after delivery it must be put into storage in a secure location The location must sufficiently protect the unit from dust and moisture and maintain the appropriate sto...

Page 26: ...may be strung through either two or four handles If the handles need to be removed the screws holding the handles in place must be retorqued to 25 ft lbs otherwise handle failure may result when lift...

Page 27: ...ND GREEN YELLOW WIRE FOR CE UNITS FOR 3000 4000 MODELS ADD 18 TO THESE WIRE LENGTHS Connect L1 L2 and L3 to the top of the front mounted disconnect switch Connect the ground lead to the stud provided...

Page 28: ...l 2006 460 VO LTS 230 VO LTS 208 VO LTS Nelson Stud Welding Inc Figure 3 4 Link connections for 230 460 575 V model Systems shipped prior to April 2006 575 VOLTS 460 VOLTS 230 VOLTS Reorder Number 724...

Page 29: ...hut offs from welder inrush currents even if the machine is not being used at high currents 3 8 4 Input Voltage Reconnect Procedure Welders with transformers that have primary voltage taps rated for 4...

Page 30: ...e connection may result in unsatisfactory welding performance 3 9 3 Stud and Work Leads Stud Positive Applications reverse polarity When positive stud polarity is required such as in some galvanized a...

Page 31: ...er gun lift Lock the unit if desired Perform test welds to verify the correct welding settings After establishing proper setup production welding may begin Keep your head away from fumes Use ventilati...

Page 32: ...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 env...

Page 33: ...t display in one 1 amp increments In normal operating modes the desired setting and the actual current will be the same In this situation the display does not change during or after a weld However in...

Page 34: ...ix available setpoint configurations Each of these is assigned a time and current setting for commonly welded stud sizes To select a setpoint simply press key 1 2 3 4 5 or 6 When a setpoint is selecte...

Page 35: ...all the welds performed since the last time the counter was reset This weld counter is displayed using special functions F31 F32 and F33 To reset the user weld counter press and hold the time display...

Page 36: ...heck is enabled Lift Check Hold Time this time is represented by t8 on the Timing Diagrams in the Section 7 1 of this guide It can be adjusted using special function F13 It has a default value of 2000...

Page 37: ...is is primarily used for the purpose of calibration because the loadbank is a stable load When this function is enabled the gun coil will not lift Enable this function by setting F112 to one Disable t...

Page 38: ...for this parameter is 50 milliseconds 0 050 seconds For some applications with very slow or very fast gun operation it may be desirable to change this time setting The Plunge Time can be adjusted usi...

Page 39: ...The default setting for this function is normally open Feed Signal Style the feed signal can be set to occur after the weld is completed after weld or after contact to the welded stud is lost contact...

Page 40: ...computer 4 8 8 Diagnostic Kit Tech Install This kit allows the use of a personal computer to setup and troubleshoot the Nelweld unit for more demanding applications The kit includes Nelware Diagnostic...

Page 41: ...lding guns with three and four wire control with the use of a converter 4 9 3 Stud Feeding System Interface With the Stud Feeder Interface Kit installed the power source can trigger any feeding device...

Page 42: ...sec Current A Nelweld 4000 Nelweld 6000 3 16 5mm 0 15 300 Unlimited Unlimited 1 4 6mm 0 17 450 50 Unlimited 5 16 8mm 0 25 500 40 Unlimited 3 8 10mm 0 33 550 22 Unlimited 1 2 13mm 0 55 800 19 30 5 8 16...

Page 43: ...0 80 90 100 110 120 130 140 150 160 170 180 190 200 Cable Length ft or m including ground cable Current amps feet meters 4 0 0000 120mm 2 95mm 2 3 0 000 85mm 2 2 0 00 70mm 2 1 0 0 50mm 2 Example Desir...

Page 44: ...90 100 110 120 130 140 150 160 170 180 190 200 Cable Length ft or m including ground cable Current amps feet meters 4 0 0000 120mm 2 95mm 2 3 0 000 85mm 2 2 0 00 70mm 2 1 0 0 50mm 2 Example Desired cu...

Page 45: ...ectrical connections should be done only by proper electrical repair personnel Impurities inside the welding unit such as metallic dust must be wiped off or blown out In case of contact with liquids t...

Page 46: ...listing that best describes the symptom that the machine is exhibiting Step 2 PERFORM EXTERNAL INTERNAL TESTS The second column labeled Possible Cause lists the obvious external possibilities that ma...

Page 47: ...r E008 Gun Coil Open Check gun coil wiring and related circuit wiring E009 Gun Lift Error A short was detected after the pilot arc time expired Check gun E010 Shunt Signal Open No pilot arc current de...

Page 48: ...E005 Replace the main control board Mechanical Problems Occurring During Welding Problem Possible cause Solution No contact between stud and workpiece Verify that the green Contact LED is lit If it i...

Page 49: ...trigger not released after last weld Trigger may be stuck or the control cable may be shorted in the closed position This will be indicated by a lit Trigger LED on the front panel Physically release o...

Page 50: ...eck the stud burn off If the burn off is much less than what is typical for that diameter stud the time and current settings may not be correct Consult Section 2 6 to ensure proper current and time se...

Page 51: ...a Heavy Duty gun it is equipped with Tranquil Arc Back out the clear plastic plunge dampener housing to increase the free travel Mechanical bind in gun Manually depress chuck adaptor and release Chuck...

Page 52: ...Signal After Weld Gun Coil Contact t7 Feed Signal Contact Lost Feed Signal After Weld Welding Air Trigger Weld sequence and air trigger for lift check t8 t1 t2 t3 t4 t5 Gas Valve Gun Trigger Main Arc...

Page 53: ...a gas shield is present before starting an arc If another weld is started while gas is flowing due to the postflow timer the preflow is aborted and the weld starts immediately Function F15 When Gas O...

Page 54: ...active low 1 active high Function F23 Sets Feed Signal Style default option 0 contact loss 1 after weld t7 Feed Signal Pulse Width When the Nelweld unit controls the operation of a stud feeding unit...

Page 55: ...ime on misfire F31 User Weld Counter millions 0 0 999 Resettable user weld counter millions F32 User Weld Counter thousands 0 0 999 Resettable user weld counter thousands F33 User Weld Counter hundred...

Page 56: ...e to allow for supply of weld current through a fixed resistive load F113 Stud Feed Weld Success Enable 0 0 1 disabled enabled Enable to suppress stud feed signal under all conditions other than a suc...

Page 57: ...4A 250V Slow Blow 3AG 715 060 003 F4 Gun supply In pilot arc board See picture 1 F5 and F6 2A 250V Slow Blow 3AG 715 060 004 F5 Fan Supply F6 Control supply In pilot arc board See picture 1 F1 4A 250V...

Page 58: ...Nelweld Operations and Service Manual 58 7 5 Declaration of Conformity...

Page 59: ...Nelweld Operations and Service Manual 59 8 0 Diagrams and Parts Lists 8 1 Front Section Not shown...

Page 60: ...4 Power supply 20W 12V 12V 5V 1 1 729 011 200 Weld cable bridge to shunt output 1 pos 5000 6000 2 2 720 544 001 Switch disconnect 3000 4000 1 1 709 261 000 Weld cable bridge to shunt output 2 pos 3000...

Page 61: ...Nelweld Operations and Service Manual 61 8 2 Base and Side Cabinet Section...

Page 62: ...6000 1 1 750 600 210 E3 Cabinet bumper end cap 5000 6000 2 2 750 600 212 E4 Side bumper attachment hardware rivet push type 8 8 729 098 000 Right side cabinet panel 3000 4000 1 1 750 601 206 Right sid...

Page 63: ...Nelweld Operations and Service Manual 63 Transformer and Top Cabinet Section European units only Alternate is used on European units See parts list...

Page 64: ...dware washer 8mm spring lock 2 4 524 005 082 D11 Cable mounting harrdware washer 10mm locking 3 3 524 005 083 I5 Single dual lead mounting hardware nut M8 hex 2 4 524 002 218 D12 Cable mounting hardwa...

Page 65: ...Nelweld Operations and Service Manual 65 8 4 Rear Cabinet Section...

Page 66: ...2 2 729 096 010 A6 Wiring harness 5000 6000 1 1 723 241 021 Pilot arc resistor 2 resistor assembly 1 0 705 001 007 Pilot arc resistor 3 resistor assembly 0 1 705 001 006 A8 Ground braid for SCR Power...

Page 67: ...Nelweld Operations and Service Manual 67 8 5 Wiring Diagram...

Page 68: ...eet Hayward CA 94545 510 293 0660 Phone 800 635 9353 Fax 510 293 0677 Seattle Export 406 26th Ave Place Milton WA 98354 Phone 253 874 3524 Fax 253 874 5748 Tampa Export P O Box 3990 Seminole FL 33775...

Page 69: ...s 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 4...

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