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Nelweld Operations and Service Manual

 

 

 

- 37 -

 

4.6.17  Resetting Default Parameters 

To  reset  all  controllable  functions,  to  default 
conditions,  select  special  function  F44  and  press 
and  hold  the  time  minus  key  until  system  resets. 
This  function  resets  the  preset  setpoints,  as  well 
as the user weld counter. 

4.6.18  Diagnostic Mode Enable 

To  help  determine  the  cause  of  a  problem 
welding,  enable  diagnostic  mode  using  special 
function  F66.    When  this  function  is  enabled,  a 
flashing indicator on the control panel allows the 
user to see that an error occurred.  This error can 
then  be  examined  by  interrogating  special 
function  F1.  (See  diagnostic  codes  in  the 
troubleshooting guide).  

4.6.19  Quick Retry Enable 

To truncate the gun lift time on a misfire, enable 
special  function  F26.  When  this  function  is 
disabled, the gun will lift for the entire weld time 
even on a misfire.   

Special function F26 is particularly useful 
in  Weld  Though  Deck  applications  in 
which  high  weld  time  settings  are 

typically  used.  For  this  reason,  special  function 
F26  is  automatically  enabled  or  disabled  when 
Weld  Through  Deck  is  enabled  or  disabled. 

The 

‘Quick  Retry  Enable’  state  may  still  be 
overridden after being automatically changed. 

4.6.20  Loadbank Mode Enable 

The  Loadbank  Mode  Enable  function  provides  a 
means  of  supplying  weld  power  through  a 
loadbank by bypassing some logical checks (such 
as pilot arc voltage and contact latch states).  This 
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  this  function  for  normal  welding  by 
setting its value to zero. 

4.6.21  Stud Feed Weld Success Function 

The  ‘Stud  Feed  Weld  Success  Function’  allows 
the  stud  feed  control  to  give  the  stud  feed  signal 
only after completing the weld cycle with the full 

main current.  When this function is disabled, the 
signal  will  be  given  after  every  weld  attempt.  
When  this  function  is  enabled,  the  signal  will  be 
given  after  every  successful  weld.    Weld  errors 
such as pilot arc errors (E009 or E010) and shunt 
errors (E012) can be flagged using this function. 

 

Note:  F25  (Feed  Signal  Air  Trigger  Enable)  is 
overridden by this function. 

4.6.22  Calibration Factor 

The  Calibration  Factor  allows  for  offset 
adjustment  of  the  output  current.    For  example, 
the Nelweld may be set to deliver 500A, but it is 
proven  to  deliver  only  490A.  The  calibration 
factor  may  be  adjusted  in  the  positive  direction 
until  the  Nelweld  is  proven  to  deliver  exactly 
500A. 

4.6.23  KFL Mode Enable 

In  the  default  state  (disabled,  or  zero),  the  gun 
drive  circuit  is  set  to  drive  a  handgun.    When 
enabled,  the  KFL  mode  boosts  the  gun  drive 
supply  as  needed  by  the  KFL  gun.    Enable  this 
function only when using the KFL gun. 

4.6.24  Quick Pilot Arc Mode 

In  the  default  state  (disabled,  or  zero),  the  pilot 
arc  time  duration  is  as  set  with  special  function 
F4.  When enabled (or one), main current begins 
as  soon  as  the  pilot  arc  is  established,  thus 
truncating the pilot arc time duration. 

Содержание Nelweld 4000

Страница 1: ...Nelweld 4000 and 6000 Operations and Service Manual Manual Version 1 19 June 2008 For Control Board Software Versions 2 09 and higher...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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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