Nelweld Operations and Service Manual
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6.3 Machine – Troubleshooting Guide
Problems Occurring at Startup / Bootup
Problem
Possible cause
Solution
Input fuse or circuit breaker open
Check customer-provided fuse or circuit breaker
Reconnect panel, it may be wired
incorrectly.
Refer to
Section 3.5.4
of this guide and check
connections.
Nothing happens when the
machine is turned ON.
Internal Power Source Problem
Contact your qualified Nelson Technical Service
Representative.
Machine starts up, but a strange,
electrical noise is heard
Jumpers are not set properly
See
Section 3.8.1
for proper jumper settings.
Machine starts up, but there is an
error code displayed immediately
afterward.
Refer to
Diagnostic Code
list.
Welding cannot be done until error is corrected.
Correct error, if possible. Otherwise, contact your
qualified Nelson Technical Service Representative.
Gun LED on front panel flashes.
No gun connected to the power
supply on startup.
Connect stud welding gun to the Master (right, with
respect to the front of the machine) gun input.
Weld settings were not retained
from previous setting.
EEPROM Error (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 is
not, there is no electrical contact between the stud
and workpiece. Ensure that there is no rust, scale,
oil, water, residue, paint, galvanization, etc. present
on the stud or workpiece, per
Section 2.7.1.
Improper ground connection.
Ensure that the workpiece is properly grounded. No
weld cycle will take place if there is not a
continuous circuit from the power supply, through
the workpiece, and back.
Insufficient gun lift
Perform a Lift Check, as specified in
Section
4.5.14
. Consult
Section 2.6
to ensure proper lift
settings are being used. Correct the lift to the proper
setting if the lift is improperly set.
Cable / connectors broken
Test weld cables and connectors to ensure
consistent conductivity through the length of the
cable during bending. If testing indicates a broken
cable or connector, replace cables and/or
connectors.
No pilot arc voltage is detected
(E009)
A short was detected after the pilot arc time
expired. Check gun for shorts.
Welding gun lifts, but no weld
takes place.
Gun malfunction
The lifting mechanism may be binding, preventing
the gun from lifting properly. Repair the lifting
mechanism.
Содержание Nelweld 4000
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 61: ...Nelweld Operations and Service Manual 61 8 2 Base and Side Cabinet Section...
Страница 65: ...Nelweld Operations and Service Manual 65 8 4 Rear Cabinet Section...
Страница 67: ...Nelweld Operations and Service Manual 67 8 5 Wiring Diagram...
