Nelweld 4000 and 6000Operations and ServiceManualManual Version 1.19June 2008For Control Board Software Versions 2.09 and higher

NELWELD POWER CONTROL UNITLIMITED WARRANTYNelson’s only warranty is that goods being sold will be free from defects in workmanship andmaterial. This warranty is expressly in lieu of other warranties, expressed or implied and whetherstatutory or otherwise, including any implied warranty of merchantability or fitness for aparticular purpose.Nelson’s liability for breach of warranty shall arise only upon return of the defective goods atBuyer’s expense after notice to Nelson of the claimed breach, and shall be limited to furnishing alike quantity of such goods free from such defects or, at Nelson’s option, to refunding thepurchase price (less reasonable depreciation based on actual use); provided, however, that Nelsonwill not accept receipt of equipment returned unless buyer has previously afforded Nelson’spersonnel a reasonable opportunity to inspect and repair said equipment at buyer’s facility orsuch other location as is mutually agreeable. Notice to Nelson must be given within 30 days ofsuch defect or failure and within two (2) years from the date the equipment was delivered orbefore the welding of one million Nelson studs, whichever occurs first. No compensation orreimbursement for transportation costs of any kind will be allowed.Please note that this warranty does not extend beyond the original registered purchaser, and doesnot warrant equipment that has been modified by any party other than Nelson, or equipment thathas been improperly installed, improperly operated, or misused based upon industry standards, orequipment which has not had reasonable and necessary maintenance, or equipment which hasbeen used for operation outside of specifications for the equipment. Nelson shall never be liablefor consequential damages.Nelson reserves the right to make engineering and/or part changes, at any time without notice, asa result of our commitment to continuous improvement.

Nelweld Operations and Service ManualTable of ContentsNELWELD POWER CONTROL UNITLIMITED WARRANTY221.0SAFETY.61.1 SAFETY SYMBOLS61.2 SAFETY CONCERNS71.2.1Safety Advice71.2.2Personnel Training71.2.3Personal Protection Equipment71.2.4Protective Measures at the Worksite71.2.5Safety on the Job81.2.6Electrical Danger91.3 INTENDED USE91.4 GUARANTEE AND LIABILITY91.5 COPYRIGHT102.0INTRODUCTION TO STUD WELDING.122.1 PROCESSES122.2 PRINCIPLES OF THE DRAWN ARC (ELECTRIC ARC) WELDING PROCESS122.3 PRINCIPLES OF THE SHORT CYCLE/GAS ARC WELDING PROCESS122.4 STUD WELDING EQUIPMENT132.5 STUD MATERIALS132.6 STUD WELDING SETUP PARAMETERS132.7 STUD WELDING PRACTICE152.7.1General Guidelines152.7.2Material Selection and Verification172.7.3Operator Training and Qualification182.7.4Visual Weld Inspection192.7.5Physical Weld Inspection202.8 CLOSING COMMENTS213.0INSTALLATION .223.1 TECHNICAL SPECIFICATIONS223.1.1Nelweld Characteristics223.1.2Recommended Input Wire and Fuse Sizes233.1.3Physical Dimensions243.1.4Temperature Ranges243.2 EXTENT OF DELIVERY253.3 EXTENT OF DISPATCH253.4 INSPECTION OF INCOMING MATERIALS253.5 INTERMEDIATE STORAGE253.6 LOCATING THE POWER SOURCE253.7 MOVING THE POWER SOURCE263.8 INPUT CONNECTIONS263.8.1Input Voltage Connection263.8.2Machine Grounding293.8.3Input Fuse and Supply Wire Considerations293.8.4Input Voltage Reconnect Procedure293.9 OUTPUT CONNECTIONS293.9.1Gun Control Cable Connections293.9.2Stud and Work Leads – Stud Negative Applications (straight polarity)303.9.3Stud and Work Leads – Stud Positive Applications (reverse polarity)304.04.14.2OPERATION .31SAFETY PRECAUTIONS31BASIC OPERATION PROCEDURE31-3-

Nelweld Operations and Service Manual4.3 GENERAL DESCRIPTION4.4 RECOMMENDED PROCESSES AND EQUIPMENT4.5 DESIGN FEATURES4.5.1Modular Design4.5.2System Cooling and Thermal Protection4.6 OPERATIONAL FEATURES AND CONTROLS4.6.1Power-up4.6.2Setting the Current4.6.3Current Display4.6.4Setting the Time4.6.5Time Display4.6.6Special Functions4.6.7Setpoints4.6.8Setpoint Programming4.6.9Front Panel Lock4.6.10Status LED Operation4.6.11Fault Icon Indicator4.6.12Weld Counter4.6.13Chuck Stripper4.6.14Lift Check4.6.15Weld Through Deck Mode4.6.16Chuck Saver4.6.17Resetting Default Parameters4.6.18Diagnostic Mode Enable4.6.19Quick Retry Enable4.6.20Loadbank Mode Enable4.6.21Stud Feed Weld Success Function4.6.22Calibration Factor4.6.23KFL Mode Enable4.6.24Quick Pilot Arc Mode4.6.25Output Panel Layout4.6.26RS-232 Port /Cable4.7 CUSTOM ADJUSTMENTS4.7.1Pilot Arc Time Adjustment4.7.2Hot Plunge Time Adjustment4.8 ACCESSORIES4.8.1Caster Kits: User Install4.8.2Gas Valve Control Kit: Tech Install4.8.3Stud Feeder Interface Kit: Tech Install4.8.4Second Output Kit: Tech Install4.8.5RS-232 Port Kit: Tech Install4.8.6Remote Control Kit: Tech Install4.8.7Process Monitoring Kit: Tech Install4.8.8Diagnostic Kit: Tech Install4.8.9Calibration Kit: Tech Install4.9 COMPATIBLE EQUIPMENT4.9.1Two-Wire Controlled Guns4.9.2Three- and Four-Wire Controlled Guns4.9.3Stud Feeding System Interface4.10LIMITATIONS4.10.1Duty Cycle4.10.2Weld Cable 41414141415.0MAINTENANCE. 455.1 SAFETY PRECAUTIONS45ELECTRIC SHOCK CAN KILL455.2 CARE AND CLEANING45-4-

Nelweld Operations and Service Manual5.3MAINTENANCE SCHEDULE456. .46SAFETY PRECAUTIONS46DIAGNOSTIC CODES – TROUBLESHOOTING GUIDE47MACHINE – TROUBLESHOOTING GUIDE487. INFORMATION .52TIMING DIAGRAMS52TIMING DIAGRAM DEFINITIONS53FUNCTION CODE DEFINITIONS55CONTROL FUSES559DECLARATION OF CONFORMITY608. AND PARTS LISTS.59FRONT SECTION59BASE AND SIDE CABINET SECTION61TRANSFORMER AND TOP CABINET SECTION63REAR CABINET SECTION65WIRING DIAGRAM67Notes:Only for EU countriesDo not dispose of Nelson stud welding units and systemcomponents with household waste!Nelson stud welding units and system components are B2Bdevices1 and therefore exclusively designed forcommercial use.We expressly point out that Nelson stud welding units andsystem components must neither be disposed of withhousehold waste nor at municipal collection points!In accordance with the European 2002/96/EC directive onwaste electrical and electronic equipment and withinthe scope of this directive’s translation into nationallaw, Nelson offers the collection and environmentallycompatible disposal of its units and systemcomponents against payment of a fee.Please contact us!-5-

Nelweld Operations and Service Manual1.0SAFETYSafety depends on you. Nelson stud welding power supplies, studs, and equipment are designed and builtwith safety in mind. However, your overall safety can be increased with proper installation, use, andthoughtful operation on your part. Do not install, operate, or repair this equipment without reading thismanual and the safety precautions contained throughout. Most importantly, think before you act, and becareful.1.1 Safety SymbolsThis machine is designed with operator safety as the number one priority. Every effort has been made toprotect the trained operator from injury. Take responsibility for your own safety - please read this entiremanual before operating the equipment to minimize the risk of injury.The safety symbols used in this manual have the following meaning:This attention symbol indicates potentially dangerous situations. It isalways used in connection with one of the additional terms defined below.WARNINGWhen “warning” is indicated, death or serious bodily harm or considerabledamage to property can occur if the corresponding preventative measuresare not taken.DANGERWhen “danger” is indicated, death or serious bodily harm or considerabledamage to property will occur if the corresponding preventative measuresare not taken.CAUTIONWhen “caution” is indicated, important information about the correctmethod of handling the product or special advice directed to the user, isbeing indicated to the reader.This attention symbol indicates that important information about thecorrect method of handling the product or special advice directed to theuser is being indicated to the reader.WARNINGSTUD WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROMPOSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.PACEMAKER WEARERS SHOULD CONSULT WITH THEIR PHYSICIANS BEFOREOPERATING STUD WELDING MACHINERY.Read and understand the following safety highlights. For additional safety information, it is stronglyrecommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1”from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA StandardW117.2-1974.BE SURE THAT ONLY QUALIFIED INDIVIDUALS PERFORM ALL INSTALLATION,OPERATION, MAINTENANCE, AND REPAIR PROCEDURES.-6-

Nelweld Operations and Service Manual1.2.31.2 Safety ConcernsPersonal Protection EquipmentSafety signs, stickers, etc. must remain attachedto the Nelweld unit at all times. They shouldremain free from dirt and be kept in legiblecondition.Wearing proper protective equipment is amandatory stipulation for all operating personnel,apprentices, and trainees. This includes the useof: Oil-free, protective garments covering theentire body, such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a capover your hair (for downhand and verticalwelding), Welder’s protective glasses with a protectivefilter, Helmet, when welding overhead, Ear protection is recommended, but notrequired. During welding, exposed metallic parts of theweld gun, such as the stud, chuck, and allparts electrically connected to these parts, arecurrent-carrying. To reduce the risk ofaccidental electrocution, do not wearconductive jewelry, like rings, watches, orchains. should be one of the utmost concerns foreach user of a Nelweld unit. Knowledge of andcareful attention to all safety advice granted inthis manual is highly advised by Nelson StudWelding, Inc.Observing all safety warnings and advice is aprerequisite for safe and correct handling andtrouble-free operation of the Nelweld series ofstud welding power supplies.1.2.1Safety AdviceOperating instructions must always be kept at theplace the Nelweld unit is used. The ability toquickly consult the manual is highlyrecommended to all Nelweld users.Personnel TrainingProtective Measures at the WorksiteAll operating personnel of the Nelweld powersupply series must: Be instructed in handling welding appliances, Have had training and possess authorizationto perform stud welding, Know and follow the contents of thisoperations manual.The workplace must be of such a nature thatpeople in the vicinity are adequately protectedfrom the harmful effects of optical radiation andgenerated heat. Space limiters and protectivescreens must be placed in such a way that thereflection and permeability of any radiation areavoided as much as possible.All electrical repair personnel must: Have had training that qualifies them to carryout repairs on the Nelweld unit, Be entitled to operate electrical circuits andappliances in accordance with safetyengineering standards.Combustible and flammable materials must beremoved from the welding zone. A guaranteemust be given that a fire extinguisher is on handon the premise, and within easy reach of theoperator. Only weld in areas or rooms whereadequate ventilation of weld gases is possible,and where there are no fire, smoke, or explosionhazards. In the event that such a location cannotbe used or such conditions cannot be avoided,consult an authorized welding supervisor or firesafety officer prior to welding.Apprentices, or personnel receiving on-the-jobtraining, must: Work with the welding system only under thesupervision of an experienced specialist, Know and follow the contents of thisoperations manual.Ensure that the workspace is adequately lit.-7-

Nelweld Operations and Service ManualAs a result of the weld process, strongelectromagnetic fields are present during the weldcycle. These electromagnetic fields can bedangerous without proper considerations, andcan: Interfere with any cardiac pacemakers,resulting in a life-threatening situation forpacemaker wearers, Damage or hamper the use of both electricallines and electronic appliances, Irrevocably erase magnetic data carriers(computer memory), Magnetize and damage watches or similardigital devices.While the strongest electromagnetic fields arepresent around the Nelweld power supply, fieldsalso emanate from the welding cables. Properprecautions should be taken near the cables aswell.Both the work and ground welding cables shouldbe laid out in as straight a manner as possible, andwith sufficient clearance from other electricalequipment. This is particularly applicable whenwelding on building sites and on specialinstallations. If i