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Nelweld Operations and Service Manual

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Sales and Service Information

North America Sales Offices and Warehouses

Subsidiaries

International

Atlanta

1520 Pine Log Road
Suite 6
Conyers, GA 30012
Phone: 800.635.9353

Boston

114 Union Street
Holden, MA 01520-2549
Phone: 800.635.9353

*Chicago

9008 S. Thomas Avenue
Bridgeview, IL 60455
708.430.3770
Phone: 800.635.9353
Fax: 708.430.3975

*Dallas

2211 Century Center Blvd.
Suite 105
Irving, TX 75062
Phone: 972.721.9055

800.635.9353

Fax: 972.438.7883

Denver

P.O. Box 2470
Parker, CO 80134
Phone: 800.635.9353

**Elyria

7900 West Ridge Road
P.O. Box 4019
Elyria, OH 44036-2019
Phone: 440.329.0400
Fax: 440.329.0521

Houston

214 Schooner Drive
Freeport, TX 77087
Phone: 800.635.9353

Indianapolis

17767 Sun Park Drive
Westfield, IN 46074
Phone: 800.635.9353

Kansas City

8600 W. 95

Street

Suite 104
Overland Park, KS 66212
Phone: 800.635.9353

*Los Angeles

20621B East Valley Blvd.
Walnut, CA 91789-2731
Phone: 909.468.2105

800.635.9353

Fax: 909.468.2112

Mexico

Matilde Marquez No. 61-M
Col. Penon de los Banos
Del. Venustiano Carranza
C.P. 15520 Mexico D.F.
52.55.26432282
800.635.9353
Fax:  52.55.26432286

Milwaukee

Unit LL #1
11400 W. Bluemound Road
Wauwatosa, WI 53226-4049
Phone: 800.635.9353

Nashville

2114 Rogers Lane
Lebanon, TN 37087-7382
Phone: 800.635.9353

*Philadelphia

260 Boot Road
Downingtown, PA 19335
Phone: 610.873.0012

800.635.9353

Fax: 610.873.2550

Pittsburgh

5213 Broadlea Drive
Pittsburgh, PA 15236-2606
Phone: 800.635.9353

Richmond

2907 Semmes Avenue
Richmond, VA 23225
Phone: 800.635.9353

*San Francisco

23765 Foley Street
Hayward, CA 94545
510.293.0660
Phone: 800.635.9353
Fax: 510.293.0677

Seattle – Export

406 – 26

Ave. Place

Milton, WA 98354
Phone: 253.874.3524
Fax: 253.874.5748

Tampa – Export

P.O. Box 3990
Seminole, FL 33775
727.596.9600
Fax: 727.593.3494

Tampa – US

9401 Ayleshire Place
Riverview, FL 33569
Phone: 800.635.9353

*Toronto

6199A Danville Rd.
Mississauga, Ontario
Canada L5T 2H7
Phone: 905.795.8277

800.635.9353

905.795.8275

Tulsa

6104 East 32

Street

Suite 100
Tulsa, OK 74135
Phone: 800.635.9353

Warren

52 Casale Dr., Street
Warren, NJ 07059
Phone: 800.635.9353

Winston-Salem

P.O. Box 5339
Winston-Salem, NC 27113
Phone: 800.635.9353

England

Nelson U.K. Ltd.
47-49 Edison Rd.
Rabans Lane Ind’l Estate
Aylesbury HP19 8TE, UK
Phone: 44.1296.433500
Fax: 44.1296.487930

France

Nelson Frances S.A.S.
Z. 1 du Chemin Vert
8 rue de l’Angoumois
F-95100 Argenteuil, France
Phone: 33.1.3411.9400
Fax: 33.1.3411.2033

Germany

Nelson Germany

Mailing Address

Postfach 40 20
58272 Gevelsberg
Germany

Shipping Address

Flurstrasse 7-19
58285 Gevelsberg
Germany

Phone: 49.2332.661.0
Fax: 49.2332.661.165

Italy

Nelson Italy
Via Miraflores, 20
Nichelino, (TO) I-10042
Italy
Phone: 39.011.6059238
Fax: 39.011.6059230

Middle East & Asia/Pacific

7900 West Ridge Rd.
P.O. Box 4019
Elyria, OH  44036-2019
Phone:  440.329.0400
Fax:  440.329.0597

World Wide Web:

www.NelsonStudWelding.com

E-mail:

[email protected]

Central & South America

P.O. Box 3990
Seminole, FL 33775
USA
Phone: 727.596.9600
Fax: 727.593.3494

For Distributors in specific areas
call: 440.329.0400

General Offices

7900 West Ridge Road
P.O. Box 4019
Elyria, OH  44036-2019
Phone:  440.329.0400
Fax:  440.329.0521

World Wide Web:

www.NelsonStudWelding.com

E-mail:

[email protected]

Printed in USA IDD 6-01
* Warehouse
** Manufacturing Facility

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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