Nelson Nelweld Operating Manual

Nelweld 4000 and 6000
Operations and Service

Manual
Manual Version 1.19

June 2008
For Control Board Software Versions 2.09 and higher

NELWELD POWER CONTROL UNIT
LIMITED WARRANTY
Nelson’s only warranty is that goods being sold will be free from defects in workmanship and
material. This warranty is expressly in lieu of other warranties, expressed or implied and whether
statutory or otherwise, including any implied warranty of merchantability or fitness for a
particular purpose.
Nelson’s liability for breach of warranty shall arise only upon return of the defective goods at
Buyer’s expense after notice to Nelson of the claimed breach, and shall be limited to furnishing a
like quantity of such goods free from such defects or, at Nelson’s option, to refunding the
purchase price (less reasonable depreciation based on actual use); provided, however, that Nelson
will not accept receipt of equipment returned unless buyer has previously afforded Nelson’s
personnel a reasonable opportunity 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 from the date the equipment was delivered or
before the welding of one million Nelson studs, whichever occurs first. No compensation or
reimbursement for transportation costs of any kind will be allowed.
Please note that this warranty does not extend beyond the original registered purchaser, and does
not warrant equipment that has been modified by any party other than Nelson, or equipment that
has been improperly installed, improperly operated, or misused based upon industry standards, or
equipment which has not had reasonable and necessary maintenance, or equipment which has
been used for operation outside of specifications for the equipment. Nelson shall never be liable
for consequential damages.
Nelson reserves the right to make engineering and/or part changes, at any time without notice, as
a result of our commitment to continuous improvement.
Nelweld Operations and Service Manual
Table of Contents
NELWELD POWER CONTROL UNIT 2
LIMITED WARRANTY 2
1.0 SAFETY.............................................................................................................................................................................6
1.1 SAFETY SYMBOLS 6
1.2 SAFETY CONCERNS 7
1.2.1 Safety Advice 7
1.2.2 Personnel Training 7
1.2.3 Personal Protection Equipment 7
1.2.4 Protective Measures at the Worksite 7
1.2.5 Safety on the Job 8
1.2.6 Electrical Danger 9
1.3 INTENDED USE 9
1.4 GUARANTEE AND LIABILITY 9
1.5 COPYRIGHT 10
2.0 INTRODUCTION TO STUD WELDING....................................................................................................................12
2.1 PROCESSES 12
2.2 PRINCIPLES OF THE DRAWN ARC (ELECTRIC ARC) WELDING PROCESS 12
2.3 PRINCIPLES OF THE SHORT CYCLE/GAS ARC WELDING PROCESS 12
2.4 STUD WELDING EQUIPMENT 13
2.5 STUD MATERIALS 13
2.6 STUD WELDING SETUP PARAMETERS 13
2.7 STUD WELDING PRACTICE 15
2.7.1 General Guidelines 15
2.7.2 Material Selection and Verification 17
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 Nelweld Characteristics 22
3.1.2 Recommended Input Wire and Fuse Sizes 23
3.1.3 Physical Dimensions 24
3.1.4 Temperature Ranges 24
3.2 EXTENT OF DELIVERY 25
3.3 EXTENT OF DISPATCH 25
3.4 INSPECTION OF INCOMING MATERIALS 25
3.5 INTERMEDIATE STORAGE 25
3.6 LOCATING THE POWER SOURCE 25
3.7 MOVING THE POWER SOURCE 26
3.8 INPUT CONNECTIONS 26
3.8.1 Input Voltage Connection 26
3.8.2 Machine Grounding 29
3.8.3 Input Fuse and Supply Wire Considerations 29
3.8.4 Input Voltage Reconnect Procedure 29
3.9 OUTPUT CONNECTIONS 29
3.9.1 Gun Control Cable Connections 29
3.9.2 Stud and Work Leads – Stud Negative Applications (straight polarity) 30
3.9.3 Stud and Work Leads – Stud Positive Applications (reverse polarity) 30
4.0 OPERATION ..................................................................................................................................................................31
4.1 SAFETY PRECAUTIONS 31
4.2 BASIC OPERATION PROCEDURE 31
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4.3 GENERAL DESCRIPTION 32
4.4 RECOMMENDED PROCESSES AND EQUIPMENT 32
4.5 DESIGN FEATURES 32
4.5.1 Modular Design 32
4.5.2 System Cooling and Thermal Protection 32
4.6 OPERATIONAL FEATURES AND CONTROLS 32
4.6.1 Power-up 32
4.6.2 Setting the Current 33
4.6.3 Current Display 33
4.6.4 Setting the Time 33
4.6.5 Time Display 34
4.6.6 Special Functions 34
4.6.7 Setpoints 34
4.6.8 Setpoint Programming 34
4.6.9 Front Panel Lock 34
4.6.10 Status LED Operation 35
4.6.11 Fault Icon Indicator 35
4.6.12 Weld Counter 35
4.6.13 Chuck Stripper 35
4.6.14 Lift Check 36
4.6.15 Weld Through Deck Mode 36
4.6.16 Chuck Saver 36
4.6.17 Resetting Default Parameters 37
4.6.18 Diagnostic Mode Enable 37
4.6.19 Quick Retry Enable 37
4.6.20 Loadbank Mode Enable 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 ADJUSTMENTS 38
4.7.1 Pilot Arc Time Adjustment 38
4.7.2 Hot Plunge Time Adjustment 38
4.8 ACCESSORIES 38
4.8.1 Caster Kits: User Install 38
4.8.2 Gas Valve Control Kit: Tech Install 38
4.8.3 Stud Feeder Interface Kit: Tech Install 39
4.8.4 Second Output Kit: Tech Install 39
4.8.5 RS-232 Port Kit: Tech Install 39
4.8.6 Remote Control Kit: Tech Install 39
4.8.7 Process Monitoring Kit: Tech Install 40
4.8.8 Diagnostic Kit: Tech Install 40
4.8.9 Calibration Kit: Tech Install 40
4.9 COMPATIBLE EQUIPMENT 41
4.9.1 Two-Wire Controlled Guns 41
4.9.2 Three- and Four-Wire Controlled Guns 41
4.9.3 Stud Feeding System Interface 41
4.10 LIMITATIONS 41
4.10.1 Duty Cycle 41
4.10.2 Weld Cable Length 41
5.0 MAINTENANCE............................................................................................................................................................ 45
ELECTRIC SHOCK CAN KILL 45
5.2 CARE AND CLEANING 45
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5.3 MAINTENANCE SCHEDULE 45
6.0 TROUBLESHOOTING .................................................................................................................................................46
6.2 DIAGNOSTIC CODES – TROUBLESHOOTING GUIDE 47
6.3 MACHINE – TROUBLESHOOTING GUIDE 48
7.0 MISCELLANEOUS INFORMATION .........................................................................................................................52
7.1 TIMING DIAGRAMS 52
7.2 TIMING DIAGRAM DEFINITIONS 53
7.3 FUNCTION CODE DEFINITIONS 55
7.4 CONTROL FUSES 559
7.5 DECLARATION OF CONFORMITY 60
8.0 DIAGRAMS AND PARTS LISTS.................................................................................................................................59
8.1 FRONT SECTION 59
8.2 BASE AND SIDE CABINET SECTION 61
8.3 TRANSFORMER AND TOP CABINET SECTION 63
8.4 REAR CABINET SECTION 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

devices1 and therefore exclusively designed for
commercial use.
We expressly point out that Nelson stud welding units and

system components must neither be disposed of with
household waste nor at municipal collection points!
In accordance with the European 2002/96/EC directive on

waste electrical and electronic equipment and within
the scope of this directive’s translation into national
law, Nelson offers the collection and environmentally-
compatible disposal of its units and system
components against payment of a fee.
Please contact us!
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1.0 SAFETY
Safety depends on you. Nelson stud welding power supplies, studs, and equipment are designed and built
with safety in mind. However, your overall safety can be increased with proper installation, use, and
thoughtful operation on your part. Do not install, operate, or repair this equipment without reading this
manual and the safety precautions contained throughout. Most importantly, think before you act, and be
careful.
1.1 Safety Symbols
This machine is designed with operator safety as the number one priority. Every effort has been made to
protect the trained operator from injury. Take responsibility for your own safety - please read this entire
manual 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 is

always used in connection with one of the additional terms defined below.
When “warning” is indicated, death or serious bodily harm or considerable
WARNING damage to property can occur if the corresponding preventative measures
are not taken.
When “danger” is indicated, death or serious bodily harm or considerable
DANGER damage to property will occur if the corresponding preventative measures
are not taken.
When “caution” is indicated, important information about the correct

CAUTION method of handling the product or special advice directed to the user, is
being indicated to the reader.
This attention symbol indicates that important information about the
correct method of handling the product or special advice directed to the
user is being indicated to the reader.
WARNING
STUD WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM
POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH THEIR PHYSICIANS BEFORE
OPERATING STUD WELDING MACHINERY.
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 American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974.
BE SURE THAT ONLY QUALIFIED INDIVIDUALS PERFORM ALL INSTALLATION,
OPERATION, MAINTENANCE, AND REPAIR PROCEDURES.
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1.2.3 Personal Protection Equipment
1.2 Safety Concerns
Wearing proper protective equipment is a
Safety should be one of the utmost concerns for mandatory stipulation for all operating personnel,
each user of a Nelweld unit. Knowledge of and apprentices, and trainees. This includes the use
careful attention to all safety advice granted in of:
this manual is highly advised by Nelson Stud • Oil-free, protective garments covering the
Welding, Inc. entire body, such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap
Observing all safety warnings and advice is a over your hair (for downhand and vertical
prerequisite for safe and correct handling and welding),
trouble-free operation of the Nelweld series of
• Welder’s protective glasses with a protective
stud welding power supplies.
filter,
1.2.1 Safety Advice • Helmet, when welding overhead,
Operating instructions must always be kept at the • Ear protection is recommended, but not
place the Nelweld unit is used. The ability to required.
quickly consult the manual is highly • During welding, exposed metallic parts of the
recommended to all Nelweld users. weld gun, such as the stud, chuck, and all
parts electrically connected to these parts, are
Safety signs, stickers, etc. must remain attached current-carrying. To reduce the risk of
to the Nelweld unit at all times. They should accidental electrocution, do not wear
remain free from dirt and be kept in legible conductive jewelry, like rings, watches, or
condition. chains.
1.2.2 Personnel Training 1.2.4 Protective Measures at the Worksite
All operating personnel of the Nelweld power The workplace must be of such a nature that
supply series must: people in the vicinity are adequately protected
• Be instructed in handling welding appliances, from the harmful effects of optical radiation and
• Have had training and possess authorization generated heat. Space limiters and protective
to perform stud welding, screens must be placed in such a way that the
• Know and follow the contents of this reflection and permeability of any radiation are
operations manual. avoided as much as possible.
All electrical repair personnel must: Combustible and flammable materials must be
• Have had training that qualifies them to carry removed from the welding zone. A guarantee
out repairs on the Nelweld unit, must be given that a fire extinguisher is on hand
• Be entitled to operate electrical circuits and on the premise, and within easy reach of the
appliances in accordance with safety operator. Only weld in areas or rooms where
engineering standards. adequate ventilation of weld gases is possible,
and where there are no fire, smoke, or explosion
Apprentices, or personnel receiving on-the-job hazards. In the event that such a location cannot
training, must: be used or such conditions cannot be avoided,
• Work with the welding system only under the consult an authorized welding supervisor or fire
supervision of an experienced specialist, safety officer prior to welding.
• Know and follow the contents of this Ensure that the workspace is adequately lit.
operations manual.
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As a result of the weld process, strong WARNING

electromagnetic fields are present during the weld
cycle. These electromagnetic fields can be During the welding process, certain exposed
dangerous without proper considerations, and parts of the weld gun, such as the stud,
can: chuck, and all parts electrically connected to
• Interfere with any cardiac pacemakers, them are current carrying.
resulting in a life-threatening situation for Do not touch these parts during the
pacemaker wearers, welding cycle!
• Damage or hamper the use of both electrical
Wear no electrically conductive jewelry
lines and electronic appliances,
while welding, such as rings, watches, or
• Irrevocably erase magnetic data carriers chains.
(computer memory),
• Magnetize and damage watches or similar Welding units of this output class can cause
digital devices. radio interference in residential and
commercial areas.
While the strongest electromagnetic fields are
present around the Nelweld power supply, fields After every work shift:
also emanate from the welding cables. Proper • Switch the welding unit off and remove the
precautions should be taken near the cables as main power plug,
well. • Secure and label the welding unit to prevent
Both the work and ground welding cables should unauthorized use,
be laid out in as straight a manner as possible, and • Ensure that the stipulated maintenance
with sufficient clearance from other electrical intervals are observed, as seen in Section 5.3.
equipment. This is particularly applicable when In case of malfunction:
welding on building sites and on special • Switch the welding unit off and remove the
installations. If in doubt, consult the respective main plug.
equipment manufacturers. • Secure and label the welding unit to prevent
It is the operator’s obligation to ensure that the unauthorized restart,
worksite is in accordance with the standards set • After repair, the operability of the welding
forth in this manual. power supply must be guaranteed.
1.2.5 Safety on the Job WARNING
Before every work shift, check:
Only a qualified electrician should perform
• The correct application of all protective
equipment, any work inside the unit’s casing. Any work
done should be made in accordance with all
• All system components for damage, local and national electrical codes.
• All connecting cables for loose contacts
and/or scorching. Failure to do so may result in bodily injury
or death.
During normal operation:
• Only use the welding system when it is in a
technically perfect condition,
• Refrain from any manner of working that is
not safe.
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• The specifications in this operations manual,
1.2.6 Electrical Danger with regard to safe welding, testing, and
When working with any electrical device, it is a qualification practices, must be observed.
good idea to ensure that a safe working • Care should be used when operating a
environment is present at all times. Such a safe Nelweld power supply in residential or
environment is not present when: commercial areas, as damage to external
• In confined spaces with electrically electrical and electronic devices may be
conductive walls, caused by electromagnetic interference
• The work area/room is wet, damp, extremely generated by the welding arc.
dry, or hot, • Nelweld units may only be configured with
• Freedom of movement on electrically those unit components that are specified
conductive parts is restricted (i.e. metallic throughout this operations manual, or by a
ladders, scaffolding, mounting rails, floor Nelson customer service or technical
plates), representative. Configuration with
• Working conditions entail being in a confined components manufactured or distributed by
space between or on electrically conductive other manufacturers, or other arbitrary
parts. structural alterations to the system, are not
allowed.
Under these working conditions, the following • The welding unit may only be operated with
protective measures must be taken: spare parts and accessories specified in this
• The welder must be adequately protected operations manual or by a Nelson technical
against electrical dangers by using insulating representative.
underlay or intermediary layers, • The specified maintenance and inspection
• Any insulating materials used must be applied routines, as well as replacing worn
in such a way that touching conductive parts, components, have to be implicitly observed.
damp walls, and damp flooring is eliminated, • Nelweld units must never be used to attempt
• If the use of insulating materials is not pipe thawing.
possible due to an increase in danger, such as
risk of falling or special room conditions, Furthermore, the observance of general and
work must at least be done in dry, undamaged particular safety advice throughout this operations
working clothes. manual, as well as relevant accident prevention
regulations, falls under intended use.
1.3 Intended Use Usage exceeding the limits set forth in this
manual are inadmissible and possibly dangerous.
The relevant standards and accident prevention The manufacturer is not liable for damage
regulations were taken into account when resulting hereof; the operator alone bears the risk.
developing the Nelweld series of stud welding
power supplies. The welding unit was built 1.4 Guarantee and Liability
according to the latest technological
developments and is operationally reliable. Guarantee and liability claims in cases of physical
Despite this, dangers can originate from a injury and property damage are excluded if they
Nelweld power supply if it is operated by are due to one or more of the specified reasons
untrained people or not used as intended. below:
• The Nelweld stud welding power supply line • Non-intended use of the Nelweld welding
is designed to accommodate welding in both unit,
the Electric Arc and Short Cycle welding • Non-compliance with the operating
processes. instructions of the Nelweld unit.
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• Non-compliance with the operating • Non-compliance with the stipulated
instructions for the system components. maintenance intervals.
• Improper startup, operation, and maintenance
of the system. 1.5 Copyright
• Use of the welding system in residential and
The copyright to these operating instructions
commercial areas.
remains with Nelson Stud Welding, Inc. They
• Improper handling of the shielding gas or include the regulations and drawings of a
related accessories. technical nature, which, completely or partially,
• Use in damp, flammable, and potentially may neither be copied nor used for purposes of
dangerous surroundings. competition or communication to others. Failure
• Startup in cases of improperly mounted or to comply to this without prior authorization is
implemented protective devices or repair strictly prohibited.
work.
Nelson Stud Welding, Inc.
• Startup by improperly trained personnel, P.O. Box 4019
unsupervised trainee(s), or unqualified 7900 West Ridge Road
personnel. Elyria, OH 44036-2019
• Arbitrary structural alterations to the system. Telephone: (440) 329-0400
Fax: (440) 329-0521
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DANGER
ELECTRIC AND WELDING SPARKS

MAGNETIC FIELDS CAN CAUSE FIRE OR
MAY BE DANGEROUS EXPLOSION
• Electric current flowing through any current conducting • Have a fire extinguisher readily available.
material causes localized Electric and Magnetic Fields • Remove fire hazards from the welding area. If this is
(EMF). Welding causes EMF around welding cables and not possible, cover them to prevent the welding sparks
welding machines. from starting a fire. Remember that welding sparks
• EMF may interfere with some pacemakers. Welders and hot materials from welding can easily go through
having a pacemaker should consult his or her physician small cracks and openings to adjacent areas. Avoid
before welding. welding near hydraulic lines.
• Exposure to EMF generated while welding may have • Sparks and spatter are thrown from the welding arc.
other additional health risks. These effects are currently Wear oil free protective garments such as leather
unknown, but are under investigation. gloves, heavy shirt, cuffless trousers, high shoes, and
• All welders should use the following procedures in a cap over your hair. Always wear safety glasses with
order to minimize exposure to EMF from the welding side shields when in a welding area.
circuit:
Route the gun and ground cables together and
secure them together with tape, when possible.
Never coil the gun cable around your body.
Do not place your body between the gun and ground
cables. If the gun is on your right side, the ground ELECTRIC SHOCK
cable should also be on your right side. CAN KILL
Connect the ground cable to the workpiece as close
as possible to the area being welded.
Do not work next to the welding power source.
Maintain at least 3 feet between you and the • The gun and ground circuits are electrically live, or
welding power source. “hot,” when the welder is powered and the gun trigger
is pressed. Do not touch these “hot” parts with your
bare skin or wet clothing.
• Wear dry, hole-free gloves to insulate hands. Insulate
yourself from work and ground circuits using dry
ARC RAYS CAN BURN
insulation. Make certain the insulation is large
enough to cover the full area of physical contact
between you and the work and ground circuits.
• Use a face/eye shield with the proper filter and cover • Ground the workpiece to be welded to a good
plates to protect your eyes from sparks and the rays of electrical (earth) ground using the ground cable.
the arc when welding or observing open arc welding. • Always be sure the ground cable maintains a solid
Faceshield and filter lenses should conform to ANSI electrical connection with the metal being welded. The
Z87. I standards. connection should be as close as possible to the area
• Use suitable clothing made from durable flame-resistant being welded.
material to protect you. Any assistants should dress to • Maintain the welding gun(s), work clamps, welding
the same standard as the primary welder. cables, and welding machine so that they are in good,
safe operating condition. Replace any damaged
• Protect other nearby personnel with suitable, non-
insulation.
flammable screening and/or warn them not to watch the
arc or expose themselves to the arc rays, hot spatter or
newly welded metal.
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2.0 INTRODUCTION TO STUD WELDING
2.1 Processes • The trigger is then depressed to start the fully

controlled automatic sequence. This sequence
There are two main stud welding processes that consists of initiating the weld current, lifting
can be accomplished by the Nelweld series of the stud to create an arc by energizing the gun
power supplies: solenoid (Step B), timing out the weld time,
plunging the stud by de-energizing the gun
• Drawn Arc (Electric Arc) solenoid (Step C), and turning off the weld
• Short Cycle/Gas Arc current at the end of the weld cycle. (Step D)
Each process is a bit different, and is intended for The fasteners for electric arc stud welding have a
different applications. Thus, it is important to special shape and flux on the end of the stud that
choose the correct process for your needs. is to be welded. This flux initiates, improves
starting, and stabilizes the welding arc, and
2.2 Principles of the Drawn Arc (Electric
deoxidizes the molten weld metal for a sound,
Arc) Welding Process
void free weld zone producing a full penetration
weld which is strong enough to develop the full
Electric Arc stud welding involves the same
stud strength.
electrical, mechanical, and metallurgical
principles as any other arc welding process. In The ceramic ferrule confines the weld arc and
stud welding, the power source and stud welding heat to a specific area of the base material and
control system are set to control the amperage holds the molten metal in place to provide the
flow (current) and the duration (time) of arcing. uniform weld flash. The term flash is used
The weld gun has a trigger circuit to initiate the instead of fillet since the weld zone is made up of
weld and a lifting mechanism to draw the stud a mixture of material melted from the end of the
away from the base material and initiate the stud and from the base plate material rather than
welding arc. The gun accessories include a chuck from a filler material as is used in other welding
to hold the stud and a ferrule grip to hold the processes.
ceramic ferrule, which is also called an arc shield.
2.3 Principles of the Short Cycle/Gas Arc
Welding Process
In the Short Cycle stud welding process, a

welding power source provides a continuous
A B C D welding current. Both welding current and time
Figure 2-1: Stud welding sequence of operations are important factors when welding using the
Short Cycle process, as in the Electric Arc
The sequence of operations to make a stud weld process. Typically, the welding time varies from
are as follows: 10-100 milliseconds (0.01 – 0.1 seconds), and the
current varies from 300 to 1800A, depending on
• A stud and ferrule are loaded into the chuck the size of the stud. Shielding gas may be used as
and grip. a welding aid in place of ceramic ferrules.
• The gun is positioned against the base The welding cycle proceeds in a manner that is
material taking up the plunge, or stud length very similar to the Electric Arc process. However,
available for burn off against the gun spring unlike the Electric Arc process, the studs used do
pressure. (Step A) not have a flux load in the tip of the stud. The
speed of the process renders a flux load obsolete.
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Rather, the studs have a machined, slightly • System shutdown in case of variation from
tapered point through which the welding current the established weld parameters.
passes. These features have contributed greatly to
The weld pocket that is formed during Short simplified weld set up and increased weld quality
Cycle welding is not very deep, making it ideal of current stud welding power supplies.
for welding to thin base materials. In another example, the change in the welding
Additionally, since the process can utilize gun plunge dampener from a potentially erratic
shielding gases, it is suitable for welding a wider pneumatic weld plunge dampener to a very
variety of metals, and attaching studs of greater reliable, self contained, sealed hydraulic plunge
diameter. The use of a shielding gas during the dampener control has been another significant
Short Cycle welding process defines the Gas Arc contribution to weld quality.
welding process. The gas provides an inert
atmosphere in which highly reactive metals can 2.5 Stud Materials
be welded safely.
Stud materials and base materials must be
Examples of the applications covered by both compatible with the stud welding process.
Short Cycle and Gas Arc welding include Suppliers of both materials can provide physical
welding aluminum; copper, nickel, or chrome- and chemical certification on the products they
plated material; stainless steel; magnesium; and supply and these should be requested when orders
even titanium. are placed, if needed.
2.4 Stud Welding Equipment Studs of all styles are available in low carbon
steel and various stainless steel grades. Most
Stud welding was developed and has been in commonly, Mild Steel Grades 1010 through 1020
continuous use for over 60 years. During that and 18-8 Stainless Steel are used as stud
time there have been many improvements in the materials.
equipment used in the process, but the principles
remain the same. D.C. power is passed from a 2.6 Stud Welding Setup Parameters
stud welding control system that is set to provide
Full strength stud welding results can be obtained
the time and current necessary to weld the stud,
by understanding the following settings or
and the lifting of the gun.
adjustments, and how they relate to weld quality.
In past years, the power was supplied by power
sources separated from the control system such as • Plunge is the amount of stud that protrudes
motor generators, transformer rectifiers or battery beyond the ferrule. This portion of the stud
banks. length is available to be “burned off”, or
melted, to develop the weld flash. Long or
The evolution in the stud welding industry in excessive plunge may cause excessive splatter
recent years has been from mechanical to solid and high or uneven fillet formation. Plunge is
state welding equipment with closed loop a physical measurement set and measured
controls. Incorporation of solid-state electronics with the stud and ceramic ferrule in place on
into stud welding units has facilitated: the stud gun.
• Verification to measure both the weld time
• Lift is the distance the gun pulls the stud away
and current
from the base material. Lift is essential to the
• Compensation for weld cable or other stud weld process since is creates an air gap
resistance changes in the weld circuit. which the current must bridge. The current
• Compensation for incoming power flow across the resistance of this gap creates
fluctuations the heat to melt the stud and base material.
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If no gap exists, the current will not create
On some base materials, longer times and
sufficient heat to melt the metal. Short lift
reduced amperage improves the ductility of
may allow molten metal to bridge the arc-gap,
the weld zone.
resulting in cold welds. Excessively long lift
increases the chance of having arc blow and • Amperage is the current from the power
welds that are bonded on only one side of the source that flows through the weld arc.
fillet. Lift is set on the stud gun and is Increasing the amperage increases the weld
measured physically when the weld cycle is heat. As with the time setting, a higher
initiated. Note that this should be set and amperage setting is needed for larger stud
measured by placing the stud and ferrule on a sizes. Amperage is set on the stud welding
non-conductive surface and initiating the weld control system current setting indicator.
cycle so that an actual molten weld is not • Alignment is centering the stud in the ceramic
made while lift is being measured. ferrule so that the stud does not contact the
• Time is the normal duration of the weld. On ceramic ferrule during the lift and plunge,
thin base material, shorter than normal time which may cause friction or binding between
and higher amperage can be used to achieve the stud and ferrule. Binding can slow the
sufficient heat, and still prevent melting stud plunge so that there is less than full
through the base material. penetration of the stud into the molten weld
pool resulting in less than full weld strength.
Electric Arc Stud Welding Setups for Mild and Stainless Steel Studs Welded and Base Materials
Diameter Area Downhand Welding Overhead Welding Vertical Welding
(in) (mm) (in2) Amp Sec Lift Plunge Amp Sec Lift Plunge Amp Sec Lift Plunge
3/16 4.8 0.0276 300 0.15 0.062 0.093 300 0.15 0.062 0.125 300 0.15 0.062 0.125
1/4 6.4 0.0491 450 0.20 0.062 0.093 450 0.17 0.062 0.125 450 0.17 0.062 0.125
5/16 7.9 0.0767 550 0.25 0.062 0.125 500 0.25 0.062 0.125 500 0.25 0.062 0.125
3/8 9.5 0.1105 650 0.35 0.062 0.125 550 0.33 0.062 0.125 600 0.33 0.062 0.125
7/16 11.1 0.1503 700 0.45 0.062 0.125 675 0.42 0.062 0.125 750 0.33 0.062 0.125
1/2 12.7 0.1964 850 0.55 0.062 0.125 800 0.55 0.062 0.125 875 0.47 0.062 0.125
5/8 15.9 0.3068 1200 0.70 0.062 0.187 1200 0.67 0.093 0.187 1275 0.60 0.062 0.187
3/4 19.1 0.4418 1500 0.90 0.093 0.187 1500 0.84 0.093 0.187 1700 0.73 0.093 0.187
7/8 22.2 0.6013 1750 1.10 0.125 0.250 1700 1.00 0.125 0.250 Not Recommended
1 25.4 0.7854 2000 1.40 0.125 0.250 2050 1.40 0.125 0.250 Not Recommended
Short Cycle Welding Setups for Mild and

Stainless Steel Studs and Base Materials
Diameter Area All welding positions
in mm (in2) Amp Sec Lift Plunge
0.156 4 0.019 400 0.060 0.040 0.062
0.198 5 0.031 500 0.070 0.050 0.062
0.237 6 0.044 600 0.080 0.050 0.062
0.276 7 0.060 650 0.090 0.062 0.062
0.315 8 0.078 700 0.100 0.062 0.080
0.354 9 0.098 800 0.120 0.062 0.100
0.394 10 0.122 900 0.150 0.070 0.100
0.471 12 0.174 1100 0.180 0.080 0.120
- 14 -
The Weld Settings table specifies the zinc galvanizing is electrically conductive, studs
recommended weld settings. It should be noted should not be welded to a galvanized plate. Zinc
that these settings are only suggested starting is a weld contaminant and will cause brittle
points for obtaining a final set up which is then welds. Weld and ground spots can be cleaned
verified by visual inspection, after weld very quickly by spot grinding with an abrasive
measurement and physical testing. Other factors wheel, wire brush or wheel, drill bur, end mill, or
such as grounding of the welding system, base other similar device. It should be noted that solid
plate composition, ambient temperature, cable grinding wheels or abrasive discs do not remove
connections, etc. can influence the weld settings. zinc plating very well, but usually just result in
the grinding disc or wheel filling with zinc and
Stud manufacturers are required to qualify their then merely spreading the zinc plating around
studs’ weld base diameters by tests with currents making the weld spot look shiny and clean but
at plus or minus 10% from optimum (except in allowing enough zinc to remain in the weld area
the case of 7/8”and 1” diameters which are plus to still cause welding problems. Use of open pore
or minus 5%), an indication of the variability that abrasive disc or a grinding wheel is preferable
can occur under actual welding conditions. This when removing galvanizing.
quantification helps ensure that the settings listed
above are a good starting point for most welding Galvanizing: Galvanizing should be done after
applications. the base plate has been stud welded. If
galvanizing is done prior to welding, the effects
2.7 Stud Welding Practice of hydrogen embrittlement should be considered
when hot dip galvanizing is used. Hydrogen
embrittlement can have several points of origin
2.7.1 General Guidelines
that can cause serious brittleness in the weld or in
In stud welding as in other welding and the stud shank when studs are bent with a very
fabricating methods, there are some general tight bend diameter.
guidelines to consider when determining the
Other causes are improper pickling of the finished
basics of good practice. Among these are:
weld plate either by pickling too long or not
Weld Plate Thickness: A plate thickness that is at rinsing thoroughly after pickling, plating too long
least 1/3 of the stud shank diameter will develop or at too high a temperature. It can also occur
the full steel tensile and shear capacity of the when the stud is very high strength in comparison
stud. The weld base plate will, however, undergo with the base plate material strength.
distortion and bending in many cases, leading to a
Edge Distance: Studs welded near an edge should
change in the stud diameter/plate thickness ratio,
be placed no closer to a free edge of a base plate
when high loads are applied which are not
than the diameter of the stud plus 1/8” to the edge
satisfactory in many cases.
of the stud base. This distance should preferably
Weld Plate Cleanliness: The most applicable rule be not less than 1” to 1-1/2 “ from a free edge or
is that the area where the stud is to be welded edges. Special ferrules should be used in
(weld spot) should be as clean as possible to situations where studs are welded closer than this
eliminate welding problems. The spot where the requirement or on the edge of a plate or bar.
ground clamp(s) are to be fastened should also be
Grounding/Arc Blow: Edge distance (above) and
cleaned on both sides of the plate so a good
ground placement can influence weld quality due
current path is established. Normally, a light rust
to arc blow. That is, the welding arc is
or light mill scale is not detrimental. Heavy mill
electromagnetically deflected away from the
scale or heavy, flaky rust should be removed as
grounding point or toward the larger mass of the
should any deleterious coating such as heavy oil,
base plate configuration being welded.
paint, galvanizing, grease, moisture etc. While
- 15 -
Figure 2-2 shows typical ground and edge effect electrical contact and current flow. It may take
patterns due to arc blow. These effects are less some time and trials to establish a good a current
noticeable where large masses of steel are present flow path for your typical base plate
such as in large beams, but relatively small configuration, but the end result is a significant
embedment plates can present difficulties. increase in weld quality and consistency and
Typically, there is a lack of weld fillet on the lower rejections and repair costs.
periphery of the stud opposite the arc blow
Weld Cables: It is not recommended to leave
direction that can adversely affect weld strength
combination or ground cables in a circular or
and quality.
coiled fashion during unit operation. Failure to
For example, a welding platen table may be place cables as recommended below may result in
grounded at all 4 corners by 4 separate ground poor weld quality and the development of
cables bolted to the table and joined to the dangerous electromagnetic fields.
welding system single ground wire by a bolted
connection. This in essence turns the entire CAUTION
platen into a grounded mass and arc blow on a
small plate set onto the table is minimized. On
longer, rectangular plates a double ground (one at
each end on opposite edges of the plate provides a
good current flow pattern.
The ground connection does not have to
be a screw type “C” clamp, but can be fast
action spring clamps or lever action hold
down clamps mounted to the welding table and
connected to the stud welding system ground
cable(s).
Ceramic Ferrules: These are also termed ceramic

arc shields. Ferrules serve several functions.
• Contain the pool of molten metal and form it
into the fillet (flash) formed around the stud
periphery.
• Control to a great extent the amount of arc
Figure 2-2: Effect of (A) welding near an edge, and (B) brightness seen and the quantity of sparks
ground connection on the distortion of magnetic field.
expelled during the weld.
Frequently, a copper or steel plate larger than the • They are designed with specific vent patterns
base plate to be welded with a center ground so that when the arc is initiated, the flux in the
bolted to the bottom will eliminate or minimize end of the stud is consumed and deoxidizes
arc blow effects. If a welding platen, table, or the weld zone. Weld gasses are expelled
surface is used for this purpose, it should be kept through the vents, thus preventing oxygen
clean by removing weld splatter, weld berries and from entering the weld area.
ferrule pieces so that the surface contacts the • Style variations allow welds in many
weld plate cleanly and evenly to assure good positions and to plate edges, corners, etc.
- 16 -
It is important to keep the ferrules dry. If they tubing and bars, plate or bar edges, channels, and
absorb a great deal of moisture, heat from the struts.
weld instantly turns the moisture into steam, Welding Stainless Steel Studs to Carbon Steel
which may cause the ferrule to shatter. If the Base Plates: Full strength welds are made when
ferrule shatters, molten metal will be forcefully standard carbon steel studs are welded to either
ejected from the weld zone, leading to dangerous approved stainless steel base or carbon steel plate
situation for the operator. A very porous and materials. Similarly, welds made with stainless
weak weld would then result. steel studs to stainless steel or carbon steel base
Ferrule cartons are marked with a warning that plate materials develop full stud steel capacity in
they contain silica, a possible health hazard. tension or shear. However, in cases where
Since the ferrules are made from “green” fireclay stainless steel studs are welded to carbon steel
ceramic with binders, and fired at high plates, and are to be subject to repetitive or cyclic
temperature, there is no free silica material at loads, stress corrosion failure in the weld can
inhalable sizes released during the weld. If occur.
simply broken free of the weld, they are basically It is good practice to specify that the stainless
an inert, inorganic material, such as fired studs to be used in such conditions are either
aggregate or rock, and may be disposed of easily annealed after manufacture or made from
and safely. It would take an extensive amount of annealed-in-process stainless steel with a
ferrule breakage or grinding to produce sufficient hardness less than 90 on the Rockwell B scale, in
loose powder to reach any inhalable level the finished condition. This minimizes the chance
dangerous to the stud welding operator or those of weld failures.
nearby.
Stud Welding In Adverse Weather
Position Welding: Studs of all weld base Conditions: Studs should not be welded
configurations and diameters from minimum to when the base plate temperature is below
maximum available can be easily welded in the 0º F (-18º C), or when the surface of the base
downhand position. As a general rule, studs up to plate is wet, frost covered, or exposed to falling
and including 3/4” diameter can be welded to the rain or snow. Additionally, it is not
weld plate vertical position with consistent, full recommended to use stud welding equipment in
strength results. Special ceramic ferrules are used environments where falling rain or snow, or
with studs 5/8” and above when welding to the standing water are present.
plate vertical position. There is a special ceramic
ferrule for welding 7/8” diameter studs in the A brittle failure by impact testing at low
vertical position, but welding this diameter stud temperatures in the weld or in the base metal is
requires very carefully controlled conditions. quite common. Tension and shear tests done at
Studs larger than 7/8” cannot be welded in the temperatures below -40º F (-40º C) on studs
vertical position. welded at that temperature showed no loss in
strength of the stud weld. It is the impact testing
Welding overhead can also be done with all stud that causes weld failure. Whenever possible
diameters. Naturally, the overhead position welding and testing studs at low temperature
causes an increased amount of welding sparks to welding should be avoided.
fall during welding and suitable operator
protection is needed. There are spark retention 2.7.2 Material Selection and Verification
accessories available from Nelson Stud Welding, Studs are made from steel supplied to the Nelson
Inc. Stud Welding, Inc. by quality, approved steel
Ceramic ferrules are also available in a wide suppliers. Quality assurance procedures
variety of configurations, including but not established at the manufacturing facility require
limited to, welding studs to round or rectangular that the steel supplier provide certified mill test
- 17 -
reports (CMTR) for each heat and diameter of general guidelines and inspection techniques.
steel supplied. These mill test reports certify Highly skilled representatives of Nelson Stud
compliance to welding code specified material Welding, Inc. can provide both written and visual
grades and chemistry, and are available from the materials as part of a complete program
stud manufacturer as part of their certification concluding in formal qualification of both the
package on every shipment of studs made when operators and the stud welding process.
requested at the time of purchase. Process Qualification: Stud welding is a
At the time of manufacture, studs are also tested prequalified process, unique among the many
to determine that their mechanical properties are welding processes due to the many millions of
in compliance with welding code requirements. studs that have been successfully welded with the
A certificate of compliance (COC) for each stud process.
shipment can be made at the time of shipment, When studs are welded in the downhand
certifying chemical and physical property position to approved base plate materials,
compliance to customer or engineering only two (2) studs are required to be
specifications sent with the stud purchase order. welded and tested. The test consists of both a
COC’s can certify compliance with steel visual inspection and a physical inspection by
specifications, such as: bending the studs 30º from the vertical position
• ASTM – A108 by hammering on the unwelded end or bending
• ASTM – A276 with a pipe or other bending device.
• AWS D1.1, Structural Welding Code – Steel
• AWS D1.6, Structural Welding Code – Stainless Steel If the bend test and visual inspection are both
• Canadian Welding Bureau W59 – Welded Steel satisfactory, both the process and the operator are
Construction considered qualified for those stud diameters
• International Standards Organization ISO –13918 welded downhand as long as there are no process
Welding Studs and Ceramic Ferrules for Arc Stud changes. Such changes include those made in the
Welding, etc.
studs, settings, equipment, welding cables,
Similarly, the weld plate fabricator should require ceramic ferrules, or from an approved to a non-
certified mill test reports from its vendors on steel approved base material qualified by the test. The
purchased for use as base materials in its welding two-stud test is required at the start of every
operations to verify compliance to welding code production period such a shift change or operator
approved materials. Stud manufacturers are change, and if any process changes are made.
required by welding codes to weld test and
qualify their weld base diameters and materials. Stud Qualification Testing
No. of Studs to
Along with the stud certificates of compliance Welding Procedure
be Tested
and material certified test reports for both studs • Downhand, standard welding
and weld plates, the stud weld base qualifications configuration 2
• To approved base plate
should be kept on file at the weld plate fabricators • Special welding position
location to verify compliance with quality • Welding through metal deck 10
programs and welding codes. • To non-approved base plate material
2.7.3 Operator Training and Qualification Studs welded to a non-approved base plate
material, in the vertical or overhead position, to
Operator Training: Introductory training of the fillet or heel of an angle, etc., must be
operators in the stud welding process is the first application qualification approved by welding ten
step in successful production stud welding. This (10) of each of the stud styles and diameters to be
familiarizes the operators with the general used in production in the position(s) and base
principles of the process, proper set up of the materials to be used in production with the same
equipment, weld set up for the studs being used,
- 18 -
equipment, settings, welding cables and ceramic quality certification agencies, or other interested
ferrules to be used in production welding. parties.
All ten studs of each diameter and position to be 2.7.4 Visual Weld Inspection
qualified must be tensile and/or bend and/or
torque tested to failure. They must also meet A proper relationship between the Lift, Plunge,
visual inspection requirements. Failure must be in Time, and Amperage is needed to obtain good
the stud shank or in the base plate material, not in weld results. The length reduction or burn-off and
the weld for all studs tested. the weld fillet appearance are determined by the
weld settings. Visual weld inspection consists of
Note that failure is allowed in the base plate interpreting the appearance of the weld flash, and
material, given certain conditions. This provision is normally very accurate if certain guidelines are
is acceptable when it is known that the base plate followed.
material may be of a composition, strength or
thickness that will not fully develop the strength
of the stud weld, but the strength and weld results
are acceptable for the end use intended. Such a
failure is not acceptable in the case of embedment
plates used for structural connections or for
A B C
attachments requiring full strength and ductility.
The successful completion of the application
qualification tests qualifies both the operator and
the process.
Documentation of the qualification of the
operator and the stud welding process should be D E F
part of the overall records of the plate fabrication
Figure 2-3: Visual Weld Quality
facility. This can be done by first establishing a A Satisfactory weld with good flash formation
Welding Procedure Specification (WPS) and B Stud in which plunge is too short
Procedure Qualification Record (PQR) for the C Hang-up during plunge – possible ferrule/stud binding
D Poor vertical alignment
stud diameters, equipment, settings, cable lengths, E Stud weld made with insufficient heat
welding positions, weld plate materials and F Stud weld made with excessive heat
ceramic ferrules that are to be used in the welding A good weld is characterized by:
operation. • Even flash formation.
• A shiny, bluish hue to the flash surface.
Once the welding procedure specifications are
• A slight flow or bend of flash metal into the base
completed and documented, the operators trained material.
in stud welding should be tested. They should set • Good flash height.
up and do the stud welding using the WPS • Consistent after-weld length.
guidelines, seen in the Stud Qualification Testing • Full “wetting” – flash around the stud periphery
chart. The welds are then visually inspected, A cold weld, which requires more time and/or amperage, is
tested, and certified by the welding supervisor or indicated by:
welding trainer, and the operator is certified by • Low flash height.
name using the same form as a Welder • Incomplete flash formation.
• A dull gray cast to the flash surface.
Qualification Record (WQR).
• Stringers of flash metal forming "spider legs."
These records should be retained, along with A hot weld made with too much time and/or amperage is
material certifications and production inspection distinguished by:
records, as part of the documentation files for • Excessive splatter.
review by customers, the engineer of record, • A washed-out flash.
• Undercutting of the stud.
- 19 -
• Burn through the base material. stud so there is no permanent distortion of the
In most arc welding processes the weld fillet threads. Torque test proof load requirements are
metal comes from the addition of filler metal found in AWS D1.1, D1.5, or D1.6. The test studs
from a stick electrode or a spool of welding wire. may be used in production.
In stud welding a portion of the stud itself is the The stud welding operator is responsible for pre-
source of the weld metal. The length of the stud production set up and testing. The operator shall
that is melted to develop the flash is called burn- weld two studs to a production weld plate or to a
off, and is defined as the difference in length piece of material similar to the weld plate in
between a welded stud and its original length. material composition and within 25% of the
The length reduction or burn-off is a very good production weld plate thickness.
gauge of weld quality, since the burn-off is Inspections during production are also the
determined by the weld settings of time, current, responsibility of the operator. Pre-production and
lift, and plunge. Proper burn-off also indicates production inspection test results should be
that there was no bind or hang-up during the recorded and approved by the welding supervisor.
plunge motion of the gun. Any unsatisfactory pre-production and/or
The most convenient method of checking production inspections and tests should be
burn-off is to stand an unwelded stud brought to the welding supervisor’s attention and
upside down (load end up) next to a corrections made, accompanied by additional
welded stud to compare the length difference. tests with fully satisfactory inspection and test
After weld height can also be checked with a results before proceeding with further welding.
sliding carpenter’s level/square tool. The Stud At regular intervals during production welding,
Burnoff Length table shows typical burn-off the studs welded after the last testing interval
length reductions when welding to bare plate of should have the ceramic ferrules removed and
sufficient thickness. should be visually inspected. If the visual
Stud Burn-Off Lengths inspection shows a full periphery weld flash,
(not including flux load) without undercut, and satisfactory after weld
Stud Diameter Length Reduction length, welding may continue. If the visual
3/16” through 1/2” 1/8”
inspection shows a lack of flash or insufficient
(5mm through 12mm) (3mm) weld burn off, the questionable studs should be
5/8” through 7/8” 3/16” marked and appropriate supervisory personnel
(16mm through 22mm) (5mm) notified.
1” and over 1/4”
(25mm and over) (6mm)
Minimum Weld Flash Size
2.7.5 Physical Weld Inspection Stud Diameter Weld Flash Size
Two studs should be welded according to 3/16” through 7/16” 3/16”
qualified settings during pre-production testing. (5mm through 11mm) (5mm)
Following satisfactory visual inspection, they are 1/2” 1/4”
(12mm) (6mm)
bent 30º or torque tested in the case of threaded 5/8” through 7/8” 5/16”
studs. This procedure should also be followed if (16mm through 22mm) (8mm)
there is any change of operator or any change in 1” and over 3/8”
equipment, position, settings, etc. Studs that are (25mm and over) (10mm)
bent may be straightened to the original axis. In accordance with codes, contract documents or
Studs should not be heated during bending or quality assurance inspection criteria, studs
straightening without approval by the Engineer of without a full peripheral flash, but with a
Record. Torque testing is done to a proof load satisfactory after weld length may be bent 15º in
level slightly lower than the nominal yield of the the direction opposite the lack of flash, or
- 20 -
repaired with a hand weld by adding a minimum
fillet weld as required in the Weld Flash Size
table. The repair weld shall extend at least 3/8"
beyond each end of the discontinuities being
repaired.
If any of the studs bend tested fail the test or if
there is continued and frequent evidence of
insufficient stud burn off, production must be
halted and appropriate supervisory personnel
notified. The welding variables 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 hundred million studs of all types are

welded throughout the world each year. Stud
welding is a long recognized and practiced
welding method.
If the method is employed properly using suitable
equipment and qualified settings with trained
operating personnel, approved studs and base
plate materials and appropriate quality assurance
and inspection procedures, it is reasonable to
expect that 100% of all welds made will develop
full strength and full quality.
- 21 -
3.0 INSTALLATION
3.1 Technical Specifications
3.1.1 Nelweld Characteristics

Weld
Weld Time
Standard Input Unit Current Number
Machine (seconds) Part Number
Voltage/Frequency Weight (amps) of Guns
Min Max Min Max
208/230/460/575 725 lb 1 750-601-001
3 φ 60Hz 300 2100 0.020 1.400
VAC 330 kg 2 750-601-501
725 lb 1 750-601-000
230/460/575VAC 3 φ 60Hz 300 2100 0.020 1.400
330 kg 2 750-601-500
Nelweld 4000
50/60 725 lb 1 750-601-051
220/380/415/440 3φ 300 2100 0.020 1.400
Hz 330 kg 2 750-601-551
50/60 725 lb 1 750-601-055
400 VAC (CE) 3φ 300 2100 0.020 1.400
Hz 330 kg 2 750-601-555
208/230/460/575 1050 lb 1 750-600-001
3 φ 60Hz 300 2500 0.020 1.500
VAC 480 kg 2 750-600-501
1050 lb 1 750-600-000
230/460/575VAC 3 φ 60Hz 300 2500 0.020 1.500
480 kg 2 750-600-500
Nelweld 6000
50/60 1050 lb 1 750-600-051
220/380/415/440 3φ 300 2500 0.020 1.500
Hz 480 kg 2 750-600-551
50/60 1050 lb 1 750-600-055
400 VAC (CE) 3φ 300 2500 0.020 1.500
Hz 480 kg 2 750-600-555
- 22 -
3.1.2 Recommended Input Wire and Fuse Sizes

Fuse or Breaker
Input Input Portable Size Fuse
Recommended
Machine Voltage / Current/ Power Specifications2 Rating
Fuse
Frequency Duty Cycle Cable1 (Amps)
Current Time (Super Lag)
208/60 488/6.7% 3/0 601 1.0 150 LPN-RK(250V)RK1
230/60 442/6.7% 3/0 544 1.0 150 LPN-RK(250V)RK1
460/60 224/6.7% AWG 6 275 1.0 100 LPS-RK(600V)RK1
575/60 181/6.7% AWG 6 222 1.0 100 LPS-RK(600V)RK1
Nelweld 4000 220/50 461/6.7% 95mm2 568 1.0 150 LPN-RK(250V)RK1
380/50 270/6.7% 70mm2 332 1.0 100 LPS-RK(600V)RK1
400/50 257/6.7% 70mm2 316 1.0 125 LPS-RK(600V)RK1
415/50 248/6.7% 70mm2 305 1.0 100 LPS-RK(600V)RK1
440/50 234/6.7% 70mm2 288 1.0 100 LPS-RK(600V)RK1
LPN-RK(250V)RK1
208/60 547/23.3% 250 MCM 717 1.4 150
or FRN-R(250V)RK5
LPN-RK(250V)RK1
230/60 496/23.3% 3/0 649 1.4 150
or FRN-R(250V)RK5
460/60 253/23.3% 1/0 330 1.4 100 LPS-RK(600V)RK1
575/60 204/23.3% AWG 6 266 1.4 100 LPS-RK(600V)RK1
Nelweld 6000 LPN-RK(250V)RK1
220/50 518/23.3% 95mm2 678 1.4 150
or FRN-R(250V)RK5
380/50 304/23.3% 70mm2 397 1.4 100 LPS-RK(600V)RK1
400/50 289/12% # 70mm2 378 1.4 125 LPS-RK(600V)RK1
415/50 279/23.3% 70mm2 364 1.4 100 LPS-RK(600V)RK1
440/50 264/23.3% 70mm2 344 1.4 100 LPS-RK(600V)RK1
1
Four (4) conductor, 600V - 90°C
2 Fuse should break for currents greater than those listed and/or times longer than those listed. Additionally, ensure that the
fuse or breaker is compatible with the listed voltage and maximum instantaneous current.
# For CE-marked, 400V, 50/60Hz units, duty cycle is reduced by 50% due to temperature/rating limits imposed by EN60974-12.
* Please consult local standards.
CAUTION
Verify that all fuses or circuit breakers are suitable for the electrical load applied. Failure to comply
with the recommended input fuse sizes and warnings can result in damage to the Nelweld unit.
Fuses are always preferred over circuit breakers due to the high inrush current
(on the order of 1300A for 1-2 cycles)
- 23 -
3.1.3 Physical Dimensions
Nelweld 4000 Nelweld 6000

Shown with Single Gun Configuration Shown with Double Gun Configuration
Physical Dimensions
(excluding handles and side bumpers)
Machine Height Width Depth Weight
32 in (813 mm) with legs 24 in (610 mm) 33.5 in 725 lbs
Nelweld 4000
35.3 in (897 mm) with casters 27 in (686 mm) over handles (850 mm) (330 kg)
34 in (865 mm) with legs 28 in (710 mm) 35.5 in 1050 lbs
Nelweld 6000
39.6 in (1005 mm) with casters 31 in (786 mm) over handles (900 mm) (480 kg)
3.1.4 Temperature Ranges

Operating Temperature Range 32°F to 104°F 0°C to 40°C
Storage Temperature Range -58°F to 185°F -50°C to 85°C
3.1.5 Enclosure Safety Rating IP23
Suitable for Outdoor Use Yes

Protection from Precipitation Safe in wind-blown rain up to 60 degrees from vertical
Protection from Ingress of Objects Objects with 12.5 mm minimum diameter can not enter
Protection from Access by User Human finger can not touch hazardous parts
- 24 -
3.5 Intermediate Storage
CAUTION
ELECTRIC SHOCK If a Nelweld welding unit is not operated
CAN KILL
immediately after delivery, it must be put into
• Only qualified
personnel should
storage in a secure location. The location must
perform this sufficiently protect the unit from dust and
installation. moisture, and maintain the appropriate storage
• Turn the input power temperature, seen in Section 3.1.4, -58°F to
OFF at the disconnect 185°F.
switch or fuse box
before working on
this equipment.
3.6 Locating the Power Source
• Turn the power switch on the Nelweld power The primary concerns when finding an
source to “OFF” before connecting or
disconnecting output cables or other equipment.
appropriate location for a Nelweld unit are
• Do not touch electrically “hot” parts. safety and cooling ability.
• Always connect the Nelweld power source’s The unit must be located on a horizontal,
grounding terminal (located on the welder base
near the reconnect panel) to a good electrical earth
vibration-free, non-slip floor space. The unit
ground. may topple over if it is tilted more than 10
degrees. Nelweld units cannot be stacked.
3.2 Extent of Delivery The load-carrying capacity of the floor space
should be equivalent to at least double the
Included in the extent of delivery of a Nelweld weight of the welding unit. Additionally, the
power supply are the following unit location should provide proper protection
components: against the intrusion of liquid, and should not be
• One (1) Nelweld welding unit, as specified located on pipelines.
at the time of order,
Place the welder where clean cooling air can
• One (1) set of operating instructions,
freely circulate into the machine through the
“Nelweld 4000 and 6000 Operations and
front louvers and out through the case rear vent.
Service Manual”
Make sure the unit is not placed up against a
3.3 Extent of Dispatch wall such that the rear vent is blocked. A
clearance of 3 feet (1 m) should be allowed
Unless otherwise agreed, the type of packing between the Nelweld unit and any other
complies with HPE Regulations, which were obstruction.
laid down by the Federal Association of Entry of dirt, dust, or any foreign material that
Wooden Materials, Pallets, and Export Packing. can be drawn into the power source should be
kept at a minimum. To help minimize
3.4 Inspection of Incoming Materials contamination, the power source is designed
with an on-demand cooling fan. This internal
The operability of welding units are tested prior fan remains off until cooling is required. Use of
to dispatch. On arrival, the welding unit has to filters on the air intake to prevent dirt from
be checked for damage, as well as for the building up restricts airflow. Do not use such
completeness of the parts within the extent of filters. Failure to observe these precautions can
delivery. Any possible transport damage and/or result in excessive operating temperatures and
missing parts must immediately be made known frequent, unanticipated shutdowns.
to Nelson Stud Welding, Inc. or the authorized
forwarding company.
- 25 -
3.7 Moving the Power Source 3.8 Input Connections
This equipment has been designed for

portability. Nelweld models are supplied from WARNING
the factory with legs in the four corners of the
Only a qualified electrician should connect
base. This allows a forklift to lift these
the input leads to the power source.
machines from their front or the side for easy
Connections should be made in accordance
relocation. There are also Caster Kits available,
with all local and national electrical codes,
which take the place of the stationary legs, for
following the connection diagram located on
those requiring continuous mobility. Once
the inside of the reconnect/input access
positioned, the swivel casters should be locked
panel of the machine.
to prevent accidental movement.
Failure to do so may result in bodily
The main cable is not a structural member, and
injury or death.
must not be used as a handle during transport.
All Nelweld power sources have side 3.8.1 Input Voltage Connection
handles that can be used to help move a The power switch on the front panel should be
power unit with a Caster Kit installed. turned to the off position before making any
These are also designed to allow hoisting by power connections. Connections should be
using a fabric slings, each at least 39” long and made in accordance with all local and national
having a load-carrying capacity of 1100 lbs (500 electrical codes, following the connection
kg), strung diagonally through opposite corner diagram in Figure 3-2.
handles, as shown in Figure 3-1. The sling may
be strung through either two or four handles. If Use a three-phase supply line. Remove the left
the handles need to be removed, the screws side case side panel, with respect to the front of
holding the handles in place must be retorqued the machine. A 2½ inch (63.5 mm) diameter
to 25 ft-lbs, otherwise handle failure may result hole for the input supply is located on the lower
when lifting the unit. left of the rear cabinet panel.
Figure 3-1: Proper hoisting technique of a Nelweld power

supply using two handles.
- 26 -
FOR 3000 & 4000 18" (457mm)

MODELS, ADD 18” TO
THESE WIRE LENGTHS
12" (305mm)
1" (25.4mm)
CRIMP ON WIRE LUG - 3/8" (9MM) DIAMETER HOLE
ATTACH TO GROUND WIRE - ONE REQUIRED
GREEN WIRE (GROUND)

(GREEN/YELLOW WIRE FOR CE UNITS)
L1, L2 AND L3 CONNECTIONS

FIRMLY ATTACH THREE POWER LEADS, AS SHOWN.
COLOR AND POSITIONS IS NOT CRITICAL.
ENSURE THAT NO UNINSULATED WIRE IS
EXPOSED.
GROUND CONNECTION
FIRMLY ATTACH GREEN WIRE TO THE GROUNDING
STUD, AS SHOWN. (GREEN/YELLOW FOR CE UNITS)
VERIFY THAT LUG IS PROPERLY CRIMPED AND THAT

CONNECTION IS SECURE.
CABLE TO PRIMARY POWER
Figure 3-2: Connecting the input power cables
Connect L1, L2 and L3 to the top of the front

mounted disconnect switch. Connect the
ground lead to the stud provided on the cabinet
floor.
Ensure that the transformer jumper links are
appropriately connected for the input line
voltage being supplied, as shown in Figures 3-3,
3-4, and 3-5. Removing the upper case panel
and handles are not required in order to change
jumper settings, and is not recommended.
WARNING
When changing jumper links, DO NOT
OVERTIGHTEN NUTS, otherwise,
damage may occur to the Nelweld unit.
Additionally, do not lubricate the posts,

nuts, or jumpers.
- 27 -
Figure 3-4: Link connections for 230/460/575 V model.

Figure 3-3: Link connections for 208/230/460 V model
(Systems shipped prior to April 2006.) (Systems shipped prior to April 2006)
2 08 V O L T S 230 V O LTS
2 30 V O L T S 460 V O LTS
4 60 V O L T S
575 V O LTS
N elso n S tu d Weld ing , In c.

Nelson Stud Welding, Inc. Reorder Number 724-569-100
Figure 3-5: Link connections for 208/230/460/575 V model. (Systems shipped after April 2006).
- 28 -
Figure 3-6: Link connections for 220/380/415/440 V model
220 V O LT S 4 15 V O L T S
2 6 2 6 2 6
2 6 2 6 2 6
3 3 3
3 3 3
1 1 1 1 1 1
5 5 5
5 5 5
4 4 4 4 4 4
380 V O LT S 4 40 V O L T S
2 6 2 6 2 6 2 6 2 6 2 6
3 3 3 3 3 3
1 1 1 1 1 1
5 5 5 5 5 5
4 4 4 4 4 4
Nelso n Stud W elding, Inc. Reord er Num ber
to a different voltage, remove the left side case

side panel, with respect to the front of the
3.8.2 Machine Grounding machine, and refer to the reconnect instructions
The frame of the welder must be grounded. A located on the decal attached to the machine
ground stud marked with the symbol is floor in front of the transformer, or as shown in
located on the cabinet floor for this purpose. Do Figures 3-3, 3-4, 3-5, and 3.6. Welders with
not connect this external ground lead to a stud transformers rated at 400 VAC, 50 Hz are not
that already has an internal ground lead reconnectable, and thus are shipped wired at 400
connected to it. Consult your local and national VAC.
electrical codes for proper grounding methods.
3.9 Output Connections
3.8.3 Input Fuse and Supply Wire
Considerations Use the largest welding and ground cables
Refer to the Technical Specifications at the suitable for the job. For large studs and/or long
beginning of this Installation section for cable runs, 4/0 copper wire cables are preferred.
recommended fuse and wire sizes. Fuse the Voltage drops can become excessive, leading to
input circuit with the recommended super lag poor welding characteristics if undersized
fuse or delay type breakers (also called “inverse welding cables are used.
time” or “thermal/magnetic” circuit breakers). To avoid interference problems with other
Choose input and grounding wire size according equipment and achieve the best possible results,
to local or national electrical codes. Using fuses • Route all cables directly to the work and
or circuit breakers smaller than recommended gun.
may result in inappropriate shut-offs from • Avoid excessive lengths
welder inrush currents, even if the machine is
• Bundle the gun and ground cables together
not being used at high currents.
where practical
3.8.4 Input Voltage Reconnect Procedure • Do not coil excess cable.
Welders with transformers that have primary 3.9.1 Gun Control Cable Connections
voltage taps rated for 460VAC/60Hz or
440VAC/50 Hz will be shipped wired for these Connect the control cable between the gun and
voltages respectively. To move this connection the power source output panel connector marked
with a gun symbol.
- 29 -
3.9.2 Stud and Work Leads – Stud Negative
Applications (straight polarity)
Most welding applications run with the stud
being negative (-). For these applications,
connect the stud gun weld cable to the gun
connector on the power source output panel
marked with a gun symbol. A grounding cable
must be run from the positive (+) power source
output panel connector to the work piece. The
work piece connection must be firm and secure.
Excessive voltage drops at the work piece
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 applications,
install as above, except reverse the
output connections at the power source, namely,
with the stud gun weld cable to the positive (+)
connector and grounding cable to the negative
(-) connector marked with a gun symbol.
CAUTION
“Stud positive” applications should only be
attempted with single gun machines. The
power source is not designed to operate two
outputs with one or both guns operating in
the “stud positive” mode.
Failure to observe this precaution may
result in a dangerous welding situation.
- 30 -
4.0 OPERATION
4.1 Safety Precautions
FUMES AND GASES can be dangerous. WELDING SPARKS can cause fire or
explosion.
• Keep your head • Keep flammable
away from fumes. material away.
• Use ventilation or • Do not weld on
exhaust fans to containers that have
remove fumes from held combustibles.
the breathing zone. • Always wear safety
glasses when welding.
ELECTRIC SHOCK can kill. ARC RAYS can burn.

• Do not touch • Wear eye, ear, and
electrically live parts body protection.
with skin or wet
clothing.
• Protect those near the
welding area by
• Insulate yourself from posting caution signs
work and ground. and/or non-flammable
• Always wear dry, screening.
insulating gloves
• Maintain solid electrical
connections.
Observe additional Safety Guidelines detailed throughout this manual.
4.2 Basic Operation Procedure • Save any setpoints, if desired.

• Adjust other settings by accessing the proper
The process to begin welding using a Nelweld function.
unit is very easy. Once the proper electrical • Perform a lift check to verify proper gun lift.
connections and gun connections are established: • Lock the unit, if desired.
• Turn the main power switch on the front of • Perform test welds to verify the correct
the unit to the “on” position. Wait for the unit welding settings.
to complete its startup sequence. After establishing proper setup, production
• Set the desired current and time settings. welding may begin.
- 31 -
4.3 General Description 4.5.2 System Cooling and Thermal

Protection
The Nelweld welding systems are high This power source is designed to effectively
performance, digitally controlled transformer- manage heat generated by the power source and
rectifier power sources, capable of welding a vast inherent to its working environment. Built-in
array of weld studs over a myriad of applications. fans are used to pull cool air into the case front,
When equipped with a compatible Nelson stud through the machine, and out the case rear. A
welding gun and appropriate accessories, they can thermostat controls these fans so that they only
support manual, gas arc, and automated stud operate when necessary to keep the machine
welding processes to meet the most stringent within the allowed temperature range.
requirements.
The power source also has thermostats built-in to
4.4 Recommended Processes and monitor the temperature of critical internal
Equipment components. If any of these temperatures
exceeds its maximum allowed value, machine
Nelson recommends using original Nelson guns, output is disabled, and the operator is notified by
feeders, and genuine Nelson studs to insure the a fault indicator and warning code displayed on
highest quality welded stud solution. Nelson, as the front panel. The system remains in the
the inventor and industry leader in stud welding, disabled state until the temperature is reduced to
recognizes the importance of taking a systems an acceptable level.
approach to avoiding and resolving stud welding
problems. Only by using original Nelson WARNING
products and equipment for all aspects of the
system can we guarantee the best possible weld Keep all body parts away from the cooling fan.
results. The fan may start without warning, causing
bodily injury to hands, arms, or any other body
4.5 Design Features parts that are in contact with the fan blades.
Do not service or repair the cooling fan while
4.5.1 Modular Design the power is connected.
This product line is designed in a modular Failure to do so may result in
fashion, which leads to many customer benefits: bodily injury or death.
• Allows for easy upgrades as customer
requirements change. For example, a single 4.6 Operational Features and Controls
gun unit can be field-upgraded to a dual gun
system using a Second Output Kit. 4.6.1 Power-up
• Modular design approach leads to the highest The main switch controls the input power to the
value offering: the customer pays only for the machine. Upon powering up, the internal control
options that are desired. software performs a series of diagnostic tests to
• Most field-installed options are ensure correct connection and operation of the
interchangeable between each power source power source. The unit also displays the current
size. software version and model designation during
the power up routine. Once the startup routine is
• The common design of the product line
complete, the time and current settings are
minimizes the required equipment training
reported on the corresponding front panel
and aids in troubleshooting.
displays. The unit is now ready to weld.
- 32 -
4.6.3 4.6.2
4.6.10
4.6.7
4.6.9
4.6.6
4.6.11 4.6.5 4.6.4
Nelweld Maximum Settings

Current (amps) Time (seconds)
Power source
Min Max Min Max
Nelweld 4000 300 2100 0.020 1.400
Nelweld 6000 300 2500 0.020 1.500
4.6.2 Setting the Current conditions where it is not possible for the power
The current setting is displayed on the front panel source to deliver the desired current, a warning
upper display. It can be changed using the + and light will light on the front panel display. This
– keys to the right of the current display in one typically occurs when using high currents with
(1) amp increments. As each of these keys small or excessively long weld cables.
remains pressed, the current setting will increase 4.6.4 Setting the Time
or decrease at a faster rate.
The time setting is displayed on the front panel
4.6.3 Current Display lower display. It can be changed using the + and
The current setting is the current setting during a – keys to the right of the time display in one (1)
weld, and can be viewed in the front panel’s millisecond (0.001 second) increments. As each
upper display. It can be changed using the + and of these keys remains pressed, the time setting
– keys to the right of the current display in one will increase or decrease at a faster rate. This
(1) amp increments. In normal operating modes, time is represented by t4 on the “Timing
Diagrams” in the Section 7.1 of this guide.
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
- 33 -
4.6.5 Time Display and current are displayed on the front panel, and
The time display is used to display both the the LED on the selected preset key lights.
desired time setting and the actual weld time. In 4.6.8 Setpoint Programming
normal operating modes, the desired setting and
the actual weld time will be the same. When this Nelweld users are not restricted to pre-
is the case, the display does not change during or programmed setpoints, but may save more usable
after a weld. However, if an error condition weld settings. To do so, first select the desired
occurs, the proper error code will be displayed on time and current settings using the corresponding
the front panel display. This will typically + and – keys. Then press and hold the desired
happen if a weld is aborted early. preset key for 4 seconds. When the green LED of
the preset button being pressed turns ON, the
Please note that when the current and time selected preset has been successfully
are specified, the actual current and time programmed.
delivered during the weld cycle are
accurate to 3% of the specified value. Only when Factory Set Preset Weld Settings
the specified value is beyond this tolerance will Time Current
Preset Stud Size
the current and/or time displays show a different (seconds) (amps)
value. 1 3/16” (5mm) 0.150 300
2 1/4” (6mm) 0.200 450
4.6.6 Special Functions 3 5/16” (8mm) 0.250 550
4 3/8” (10mm) 0.350 650
The power source has several special functions as 5 1/2” (12mm) 0.550 850
described throughout this manual. These are 6 5/8” (16mm) 0.700 1200
accessed by pressing the function, or “F”, key
4.6.9 Front Panel Lock
followed by a numeric function code. When
accessing the special functions, the LED on the The front panel has a lockout feature that
function button will light and the upper display prevents any changes from being made to the
will show “F” followed by the function code. All front panel settings. The power source is shipped
of the preset button LED’s are OFF when in the with the lock disabled. Before using the lock
Special Function mode since they now act as a function, it must be enabled using special
keypad for entering the function codes. Scrolling function F45. The default combination for the
through the function codes can also be lock is 1-2-3-4.
accomplished by using the + and – keys to the To lock the control panel, press the LOCK key
right of the function code display. The lower followed by a 4-digit combination, as determined
display shows the current status or current value by the operator. Combinations of numbers that
of the selected function. When in the special are less than four (4) digits cannot be used to
function mode, the selected machine output is lock the front panel. Enter the combination into
disabled. Note: as tabulated in Section 7.3, the memory by pressing the LOCK key again. This
special function codes are sequentially numbered will cause the LOCK key’s closed-lock-icon LED
using only digits 1 through 6. to turn ON.
4.6.7 Setpoints To unlock the control panel, press the LOCK key
The power source has six available setpoint followed by the previously entered combination,
configurations. Each of these is assigned a time and the LOCK key again. The LOCK key’s
and current setting for commonly welded stud open-lock-icon LED turns ON indicating that the
sizes. To select a setpoint, simply press key 1, 2, panel is now unlocked. In case a combination is
3, 4, 5, or 6. When a setpoint is selected, its time forgotten, a supervisory combination will work to
unlock the panel. The supervisory combination
- 34 -
can be changed using special function code F46, a counter is displayed using special functions
function only accessible after entering the F31, F32, and F33.
supervisory locking password. The default value To reset the user weld counter, press and
for the supervisory password is also 1-2-3-4. hold the time display’s down arrow for
When locked, the LED on the LOCK key’s three seconds while viewing F31, F32, or
closed-lock icon is illuminated, the displays read F33.
time and current but adjustments cannot be made. • System Weld Counter – The system weld
Most of the special functions can still be viewed counter keeps track of all the welds performed
in the locked mode, however, they cannot be during the life of the power source. It cannot
modified. When unlocked, the open lock icon be reset without the aid of special software,
LED is lit indicating that setpoints and special available only in the factory.
function parameters may be modified. This weld counter is displayed using special
The preset-enabled lock function provides a functions F34, F35, and F36. It does not roll
different type of lock function where, while the over this number but simply displays this
control panel is locked, any of the 6 presets may maximum value for the remainder of the life
be selected, but not modified, by the operator. of the power source.
This feature is enabled by using special function In the weld counters, F31 and F34 display
F111 millions, F32 and F35 display thousands, and F33
and F36 display hundreds of welds. This is done
4.6.10 Status LED Operation because the displays cannot show more than four
The control panel has three green LED’s on the digits at one time. So, if the user’s weld counter
gun diagram and function as follows: shows F31 as 128, F32 as 932, and F33 as 067,
then 128,932,067 welds have been performed
• Gun Coil LED – this LED is on whenever the
since this counter was last reset. Each counter,
gun coil is energized. This LED will blink if
user and system, is shipped set to zero and can
there is no gun connection detected. It will
record up to one billion welds.
blink and the Fault Icon will illuminate if the
gun coil is shorted. 4.6.13 Chuck Stripper
• Trigger LED – this LED is on whenever the The power source model features a chuck stripper
gun trigger is pulled or whenever the unit is
option, which makes it easier for the operator to
welding.
pull the gun off of a welded stud. This feature is
• Contact LED – this LED is on whenever the particularly useful for studs with short chuck
stud chucked in the gun is in contact with the engagement, such as Nelson’s capped grounding
work. lug studs.
4.6.11 Fault Icon Indicator When in this operating mode, after a weld is
This indicator turns ON when a fault condition completed, the gun coil is energized a second
occurs. Please refer to the troubleshooting time. This pulls (strips) the chuck from the
section of this guide for fault condition welded stud. By default, the chuck stripper
descriptions and resolution. function is disabled, but can be enabled using
special function F41.
4.6.12 Weld Counter The chuck stripper has two adjustable time
The power source has two weld counters – one parameters associated with it:
resettable and one non-resettable: • Chuck stripper delay time – After a weld is
• User Weld Counter – The User Weld Counter completed, this is the delay time before the
keeps track of all the welds performed since gun coil is energized the second time. The
the last time the counter was reset. This weld delay time allows the weld to solidify and
- 35 -
cool, and is represented by t9 on the “Timing function F13. It has a default value of 2000
Diagrams” in Section 7.1 of this guide. It is milliseconds (2.000 seconds) when lift check is
set using special function F42 and has a enabled.
default value of 200 milliseconds (0.200 For safety reasons, once in the lift check mode,
seconds). machine output is disabled and no voltage is
• Chuck stripper hold time – This is the length present in the gun. Ensure that there is no contact
of time that the gun coil is energized during between current-carrying gun components and a
the chuck stripping process. It is represented grounded workpiece when initiating a lift check.
by t10 on the “Timing Diagrams” in Section
7.1 of this guide. The hold time is set using To disable the lift check option, change the value
special function F43 and has a default value of special function F11 to 0.
of 50 milliseconds (0.050 seconds). 4.6.15 Weld Through Deck Mode
4.6.14 Lift Check The Nelweld power sources can be optimized to
The power source features a lift check function perform the weld-through-deck process by
that allows the gun lift distance to be quickly using special function F2. When enabled,
verified and to simplify lift adjustment. the plunge time is extended to 180
milliseconds (0.180 seconds) and the maximum
To perform a lift check, first load a stud and weld time is increased to 2.5 seconds. The
ferrule into the gun with the proper plunge setting Nelweld 6000 is shipped with the weld through
for welding. Then, press the stud against an deck mode disabled.
insulating workpiece, namely wood or similar
non-conductive surface. Pull and hold the gun 4.6.16 Chuck Saver
trigger. The gun will energize for the weld time The chuck saver circuit prevents damage to the
set on the front panel. Continue to hold the gun chuck after a weld is performed. This feature can
trigger. After the lift check delay time, the gun be disabled by adjusting special function F56.
coil will energize a second time and remain
energized for the time specified by the user. This When special function F56 is enabled: After a
second energizing time is the lift check hold time. weld is completed, the power source requires that
When the gun lifts during the second time, a scale electrical contact with the workpiece is broken
may be placed next to the stud to measure the lift. before it allows the next weld to be initiated.
Therefore, if the gun trigger is pulled a second
If a non-conductive workpiece is not time after a weld is complete, but contact has not
available, the gun may be air triggered, been broken to the welded stud, then the second
and pressed against any surface only after trigger pull is ignored.
the first gun lift.
When special function F56 is disabled: After a
The lift check function times outlined above are weld is completed, the power source does not
adjusted as follows: require that electrical contact with the workpiece
• Lift Check Delay Time – this time is is broken before it allows the next weld to be
represented by t6 on the “Timing Diagrams” initiated. Therefore, if the first weld attempt did
in Section 7.1 of this guide. It can be adjusted not complete, a second attempt can be made
using special function F12. It has a default without breaking contact between the stud and
value of 2000 milliseconds (2.000 seconds) workpiece. This function should be used
when lift check is enabled. carefully as it is possible to weld the chuck to the
Lift Check Hold Time – this time is represented stud if a second weld is attempted after the first
by t8 on the “Timing Diagrams” in the Section 7.1 weld was successful.
of this guide. It can be adjusted using special
- 36 -
4.6.17 Resetting Default Parameters main current. When this function is disabled, the
signal will be given after every weld attempt.
To reset all controllable functions, to default
When this function is enabled, the signal will be
conditions, select special function F44 and press
given after every successful weld. Weld errors
and hold the time minus key until system resets.
such as pilot arc errors (E009 or E010) and shunt
This function resets the preset setpoints, as well
errors (E012) can be flagged using this function.
as the user weld counter.
4.6.18 Diagnostic Mode Enable Note: F25 (Feed Signal Air Trigger Enable) is
To help determine the cause of a problem overridden by this function.
welding, enable diagnostic mode using special 4.6.22 Calibration Factor
function F66. When this function is enabled, a
The Calibration Factor allows for offset
flashing indicator on the control panel allows the
adjustment of the output current. For example,
user to see that an error occurred. This error can
the Nelweld may be set to deliver 500A, but it is
then be examined by interrogating special
proven to deliver only 490A. The calibration
function F1. (See diagnostic codes in the
factor may be adjusted in the positive direction
troubleshooting guide).
until the Nelweld is proven to deliver exactly
4.6.19 Quick Retry Enable 500A.
To truncate the gun lift time on a misfire, enable 4.6.23 KFL Mode Enable
special function F26. When this function is In the default state (disabled, or zero), the gun
disabled, the gun will lift for the entire weld time drive circuit is set to drive a handgun. When
even on a misfire. enabled, the KFL mode boosts the gun drive
Special function F26 is particularly useful supply as needed by the KFL gun. Enable this
in Weld Though Deck applications in function only when using the KFL gun.
which high weld time settings are
4.6.24 Quick Pilot Arc Mode
typically used. For this reason, special function
F26 is automatically enabled or disabled when In the default state (disabled, or zero), the pilot
Weld Through Deck is enabled or disabled. The arc time duration is as set with special function
‘Quick Retry Enable’ state may still be F4. When enabled (or one), main current begins
overridden after being automatically changed. as soon as the pilot arc is established, thus
truncating the pilot arc time duration.
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
- 37 -
4.7.2 Hot Plunge Time Adjustment
4.6.25 Output Panel Layout Hot plunge time is defined as the time main
current is on after the gun coil is shut off. It is
represented by t5 on the “Timing Diagrams” in
the Section 7.1 of this guide. The factory default
setting for this parameter is 50 milliseconds
(0.050 seconds). For some applications with very
slow or very fast gun operation, it may be
Gun Control Gun Weld desirable to change this time setting. The Plunge
Connector Cable Time can be adjusted using special function F3.
Connector
4.8 Accessories
RS-232 Workpiece
Communications Weld Cable This section specifies options that are available
Connector Connector for use with Nelweld units. Nelson Factory
Trained Personnel should install the kits where
specified. Where a connection to a computer is
required, an RS-232 port must be either factory or
4.6.26 RS-232 Port /Cable field-installed. If Nelson software must be
installed on the computer as part of the kit, the
This port is accessed through the connector
computer must meet the minimum specifications
shown on the output panel. It allows for
set forth in the PC Requirements table. When
connection between the welder and a personal
ordering kits, consult the part numbers listed in
computer or laptop, and is necessary for the use
the Nelweld Accessory and Kit Numbers table.
of any additional Nelson software kits (Nelware
kits). 4.8.1 Caster Kits: User Install
The isolated RS-232 interface cable that connects The Nelweld power supplies are shipped from the
the welder to the computer is sold separately. The factory with legs installed on the base. If unit
user can extend this cable up to 25 feet. With the mobility is a requirement, customer-installed
use of additional hardware, this distance is Caster Kits are available. The front casters swivel
virtually unlimited. to allow lateral motion while rear casters are
stationary. Each swivel caster is equipped with a
4.7 Custom Adjustments brake to prevent movement once the unit is
located in the desired position.
4.7.1 Pilot Arc Time Adjustment
To install, unbolt the legs, place the casters over
Pilot Arc Time is defined as the time the pilot arc the holes, and reattach the bolts. Opening the
is turned on before main current flows and is cabinet is unnecessary.
represented by t3 on the “Timing Diagrams” in
the Section 7.1 of this guide. The factory default 4.8.2 Gas Valve Control Kit: Tech Install
setting for this parameter is 50 milliseconds The Nelweld units are designed to control a gas
(0.050 seconds). For some applications, it may be valve using the Gas Valve Control Kit. One kit is
desirable to change this time setting. The Pilot required per unit output. This kit may be either
Arc Time can be adjusted using special function installed by Nelson Factory Trained Personnel or
F4. by the customer.
- 38 -
By default, the power source is shipped with the lost (“contact loss”). “After weld” is used for
gas valve control disabled. Special function F14 very high speed applications, while “contact
must be used to enable the gas valve option. loss” is typical for most other applications.
Special function F23 adjusts this parameter,
There are two adjustable parameters associated
which has a default setting of “contact loss.”
with the gas valve control:
• Feed Signal Pulse Width – this time is
• Gas Valve Preflow Time – after the trigger is
pulled, the gas valve is energized for a short represented by t7 on the “Timing Diagrams”
in Section 7.1 of this guide. It can be adjusted
period of time before the weld is initiated.
This allows the gas line to be purged of air as required by using special function F24, and
has a default value of 10 milliseconds (0.010
and to ensure adequate shielding. This time is
represented by t1 on the “Timing Diagrams” seconds). A value from 100 to 500
in Section 7.1 of this guide. It can be adjusted milliseconds (0.100 to 0.500 seconds) is
recommended.
using special function F15, and has a default
value of 500 milliseconds (0.500 seconds). 4.8.4 Second Output Kit: Tech Install
• Gas Valve Postflow Time – after a weld is
Nelweld power supplies can accommodate
completed, the gas valve continues to be
welding by up to two users. Units that are
energized for a short period of time to
manufactured as single gun units may be
maintain the gas shield while the weld metal
converted to dual gun units through the
solidifies and cools. This time is represented
installation of a Second Output Kit. This kit
by t2 on the “Timing Diagrams” in Section 7.1
consists of a control panel, an output panel, a
of this guide. It can be adjusted by using
bridge assembly, and associated wiring and
special function F16, and has a default value
hardware.
of 500 milliseconds (0.500 seconds).
Part numbers for Second Output Kits are listed in
4.8.3 Stud Feeder Interface Kit: Tech Install the Nelweld Accessory and Kit Numbers table.
All Nelweld models are capable of interfacing
4.8.5 RS-232 Port Kit: Tech Install
with an external stud feeding device using the
Stud Feed Interface Kit. With this kit installed, This kit allows for interface between a personal
an isolated contact is provided to trigger the stud computer or laptop. An RS-232 port is necessary
feeding device. for any additional Nelson software kits (Nelware
kits) that require communication between the
To install this kit, a connector assembly is added
Nelweld unit and a computer. The kit is only
as part of a replacement output panel, and a
needed for units that do not have a factory-
wiring harness is simply plugged into the existing
installed RS-232 port.
SCR Power PC board. Special function F21 must
be used to enable the control of a stud feeder. The kit consists of a front panel socket assembly,
a drilling template, and a 10-foot (3.0 meter) long
There are three adjustable parameters associated isolated RS-232 interface cable. The user can
with the stud feed option: extend this cable up to 25 feet. With the use of
• Feed Signal Level – using special function additional hardware, this distance is virtually
code F22, the feed signal level can be unlimited.
selected, allowing “normally open” or
“normally closed” operation. The default 4.8.6 Remote Control Kit: Tech Install
setting for this function is “normally open.” The Remote Control Kit allows the use of a
• Feed Signal Style – the feed signal can be set computer to emulate the front panel interface to
to occur after the weld is completed (“after provide remote operation of the power source.
weld”) or after contact to the welded stud is This kit includes Nelware Remote Control
- 39 -
Software to be installed on the user’s personal
computer.
4.8.7 Process Monitoring Kit: Tech Install
The Process Monitoring Kit allows the use of a
personal computer or laptop to keep track of
preset and actual weld parameters to meet QS-
9000 and ISO 9000 requirements. The kit
includes Nelware Process Monitoring Software to
be installed on the user’s 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 Software to be installed on
the user’s computer.
4.8.9 Calibration Kit: Tech Install
This kit allows the use of a personal computer for
calibration of the power source. The kit includes
Nelware Calibration Software to be installed on
the user’s computer, and other hardware.
PC Requirements
Component Minimum
Processor 200 MHz
RAM 32 MB
Video 800 x 600 VGA
Operating System Windows 95/98/NT 4.0
- 40 -
Nelweld Accessory and Kit Numbers Output Type Isolated Contact

Open Circuit Voltage Max 250VAC, 220VDC
Model Part .40A @ 125VAC
Kit Name Rated Resistive Loads
Number Number 2.0A @ 30VDC
Caster Kit, 6” 4000 512-387-000 .20A @ 125VAC
Caster Kit, 8” 6000 512-387-001 Rated Inductive Loads
1.0A @ 30VDC
Gas Valve Control Kit All 512-387-015 Max Operating Current - 3A (AC)
Stud Feeder Interface Kit All 512-387-040 Resistive 3A (DC)
Second Output Kit 4000 512-387-010 Max Operating Current - 1.50A (AC)
Second Output Kit 6000 512-387-011 Inductive 1.50A (DC)
RS-232 Port Kit All 512-387-020 Max Switching Capacity -
50VA, 60W
Nelware Remote Control Kit All Contact Nelson Resistive
Nelware Process Monitoring Kit All Contact Nelson Max Switching Capacity -
25VA, 30W
Nelware Diagnostic Kit All Contact Nelson Inductive
Nelware Calibration Kit All Contact Nelson
Isolated RS-232 Cable All 721-310-009 4.10 Limitations
4.9 Compatible Equipment
4.10.1 Duty Cycle
4.9.1 Two-Wire Controlled Guns The duty cycle limits for the Nelweld 3000, 4000,
5000, and 6000 can be seen in the Stud Weld Rate
The Nelweld power supply line is compatible table.
with two-wire welding guns employing Nelweld
Lift Technology. 4.10.2 Weld Cable Length
The diameter and length of the weld cable limit
Part the amount of current that can be supplied to the
Nelweld Gun Description stud welding arc. For best performance, use the
Number
Standard Duty, Drawn Arc – NS40, two-wire 751-692-000 largest diameter cable, only use as much cable
Short Cycle – NS40SC, two-wire 751-695-000 length as needed, bundle the gun and ground
Heavy Duty – NS20AHD, two wire 751-693-000 cables together where practical, and do not coil
Note that a three pin connector is used excess cable.
even though welding guns only use two The following graphs define cable length limits
wires. for each machine in the product line.
4.9.2 Three- and Four-Wire Controlled Guns The total weld length includes the work lead.
Nelweld power sources are compatible with all Thus if welding with 200 feet of gun cable and
existing Nelson stud welding guns with three- and 200 feet of ground cable, then the total cable
four-wire control with the use of a converter. length is 400 feet.
4.9.3 Stud Feeding System Interface

With the Stud Feeder Interface Kit installed, the
power source can trigger any feeding device
whose trigger requirements meet the following
specifications:
- 41 -
Stud Weld Rate

Parameters listed are those used during testing, and should be used only when considering weld duty cycle
Stud Size Time Current Weld Rate (studs per minute)
(in) (mm) (sec) (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” 16mm 0.67 1200 15 25*
3/4” 19mm 0.84 1500 12 20*
7/8” 22mm 1.00 1700 4 13*
1” 25mm 1.40 2000 10*
* For CE-marked, 400V, 50/60Hz units, stud weld rates are reduced by 50% due to temperature rating
limits imposed by EN60974-12.
- 42 -
Maximum Cable Length: Nelweld 4000
2100
Note: Some
1950 4/O cable is
107sqmm,
1800 which falls
between the
1650
95sqmm and
120sqmm
1500
2
4/0 (0000), 120mm
1350
Example: 2
1200 95mm
Current (amps)
Desired current = 1500 A 2
3/0 (000), 85mm
1050
Maximum Weld Cable Length:
2
2 2/0 (00), 70mm
1/0, 50mm : 228 ft (68 m)
2
900 2/0, 70mm : 327 ft (96m)
3/0, 85mm2 : 393 ft (119m)
95mm2 : 440 ft (134m) 2
750 1/0 (0), 50mm
4/0, 120mm2 : 558 ft (170m)
600
10 33 66 98 131 164 197 230 262 295 328 361 394 427 459 492 525 558 591 623 656 feet
3 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 meters
Cable Length (ft or m), including ground cable
- 43 -
- 44 -
Maximum Cable Length: Nelweld 6000 Note: Some
2500 4/O cable is
107sqmm,
which falls
2250 between the
95sqmm and
120sqmm
2000
1750 2
4/0 (0000), 120mm
1500 2
95mm
Example:
3/0 (000),
2
Current (amps)
1250 Desired current = 1750 A 85mm
2
Maximum Weld Cable Length: 2/0 (00), 70mm
1/0, 50mm2: 255 ft (77 m)
1000 2/0, 70mm2: 361 ft (120m)
2
3/0, 85mm : 440 ft (133m) 2
2 1/0 (0), 50mm
95mm : 492 ft (150m)
750 4/0, 120mm2: 623 ft (190m)
500
10 33 66 98 131 164 197 230 262 295 328 361 394 427 459 492 525 558 591 623 656 feet
3 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 meters
Cable Length (ft or m), including ground cable

5.0 MAINTENANCE
ELECTRIC SHOCK CAN KILL

• Turn the input power OFF at the disconnect switch or fuse box
before working on this equipment.
• Turn the Power switch on the Nelweld power source “OFF” before
connecting or disconnecting output cable or other equipment.
• Do not touch electrically hot parts.
5.2 Care and Cleaning
The stud welding unit requires no special care. See operating instructions for the necessary cleaning work
for welding guns or any attached peripherals.
The cleaning or maintenance specified in this chapter is necessary for the proper functioning of any
Nelweld unit. Please observe the following specifications when performing any maintenance duties:
• Aggressive, combustible, or alcohol-based solvents should not be used for cleaning work.
• Exterior cleaning should be done using a dry cloth and leave any safety or warning stickers legible.
• Cleaning the unit is required in accordance with the operating conditions and degree of soiling.
Cleaning any electrical 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, the Nelweld unit must be shut down immediately and repaired by a
Local Authorized Nelson Field Service Facility.
5.3 Maintenance Schedule

Maintenance
Suggested Tasks Notes
Interval
Visual inspection of the outside of the unit casing, including:
• Welding cables, control cables, and hoses
Any task marked with an asterisk (*)
• Inspect lifting handles, ensuring they are secure and tight
Daily should only be carried out by proper
• Main plug and cable* electrical repair personnel.
• Display and control elements*
• Connecting sockets and plugs*
Blow out the machine using a low-pressure air stream,
Weekly
including the intake louvers, rear vent, and cooling channels.
Visual inspection inside the unit casing, including:
Any task marked with an asterisk (*)
• Wiring*
Every 6 months should only be carried out by proper
• Circuit boards* electrical repair personnel.
• Electrical connections and components*
General overhaul of the Nelweld unit by Nelson Factory General maintenance to verify that the
Every 5 years
Trained personnel. machine is functioning properly.
- 45 -
6.0 TROUBLESHOOTING
WARNING
Service and Repair should only be performed by Nelson Stud Welding, Inc. Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician
and machine operator and will invalidate your factory warranty. For your safety and to avoid
Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
CAUTION
This Troubleshooting Guide is provided to help you locate and remedy possible problems with
machine setup or operation. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “Problem”. This
column describes possible symptoms that the machine may exhibit. Find the 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 may contribute to the machine symptom. Perform
these tests/checks in the order listed. Many “Solutions” can be verified without removing the case
cover. However, more thorough investigation may require examination of the inner machine contents.
Use extreme caution when repairing any component within the case, and follow all safety guidelines
set forth in this manual.
Step 3. SEEK PROFESSIONAL ASSISTANCE. If you have exhausted all of the recommended tests
in Step 2, consult your Local Authorized Nelson Field Service Facility.
WARNING
If for any reason you do not understand the test procedures or are unable to
perform the tests/repairs safely, contact your LOCAL AUTHORIZED NELSON
FIELD SERVICE FACILITY for assistance before you proceed.
1-800-NEL-WELD (1-800-635-9353)
- 46 -
6.2 Diagnostic codes – Troubleshooting Guide
The diagnostic codes can be accessed via the F1 Special Function Mode. The E codes can be scrolled with
the up/down keys next to the LED Display. The error codes are erased when the unit is shut off.
Diagnostic
Description Recommended Action
Code
E001 Line Frequency Error Invalid frequency detected. Ensure the proper line frequency is being used.
Phase B or C (with respect to Phase A) was not detected. Ensure that all input power
E002 Missing Phase
phases are present.
E005 EEPROM Failure Main Control PCB failure.
Dual Output
E006 Check harness connections between control PCB’s.
Communications Error
Gun Coil or Gun Cable Check gun coil wiring, or gun control cable for broken insulation or water immersion
E007
Shorted to Work of a gun control connector.
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 detected and/or the arc current went out. Check shunt wiring.
E012 Time Control Fault Main weld arc went out. Clean surface or change weld parameters.
Welding is disabled until the unit’s welding power supply cools to an acceptable level.
This code will display automatically with or without F1 diagnostic mode enabled.
High Temperature
E015 This error will occur if the pilot arc board is unable to supply 15VDC. The 15VDC
Fault
supply exists if two green LEDs on the pilot arc board are lit. If they are not lit,
replace the pilot arc board(s).
E016 SCR Shorted Check shunt wiring. Replace defective SCR.
Weld was outside of specified tolerance. Only valid for Process Monitor users. See
E017 Weld Quality Error
the Nelware users manual for details.
E018 Security Error An incorrect security code was passed to the Nelweld through the RS-232 port.
- 47 -
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
Nothing happens when the Reconnect panel, it may be wired Refer to Section 3.5.4 of this guide and check
machine is turned ON. incorrectly. connections.
Contact your qualified Nelson Technical Service
Internal Power Source Problem
Representative.
Machine starts up, but a strange,
Jumpers are not set properly See Section 3.8.1 for proper jumper settings.
electrical noise is heard
Machine starts up, but there is an Welding cannot be done until error is corrected.
error code displayed immediately Refer to Diagnostic Code list. Correct error, if possible. Otherwise, contact your
afterward. qualified Nelson Technical Service Representative.
No gun connected to the power Connect stud welding gun to the Master (right, with
Gun LED on front panel flashes.
supply on startup. respect to the front of the machine) gun input.
Weld settings were not retained
EEPROM Error (E005) Replace the main control board.
from previous setting.
Mechanical Problems Occurring During Welding

Verify that the green “Contact” LED is lit. If it is

not, there is no electrical contact between the stud
No contact between stud and
and workpiece. Ensure that there is no rust, scale,
workpiece.
oil, water, residue, paint, galvanization, etc. present
on the stud or workpiece, per Section 2.7.1.
Ensure that the workpiece is properly grounded. No
weld cycle will take place if there is not a
Improper ground connection.
continuous circuit from the power supply, through
the workpiece, and back.
Perform a Lift Check, as specified in Section
4.5.14. Consult Section 2.6 to ensure proper lift
Welding gun lifts, but no weld Insufficient gun lift
settings are being used. Correct the lift to the proper
takes place. setting if the lift is improperly set.
Test weld cables and connectors to ensure
consistent conductivity through the length of the
Cable / connectors broken cable during bending. If testing indicates a broken
cable or connector, replace cables and/or
connectors.
No pilot arc voltage is detected A short was detected after the pilot arc time
(E009) expired. Check gun for shorts.
The lifting mechanism may be binding, preventing
Gun malfunction the gun from lifting properly. Repair the lifting
mechanism.
- 48 -
Mechanical Problems Occurring During Welding

Check shunt wiring for faults.

If no problems are found, verify that the pilot arc
board is functioning. When the board is functioning
properly, two green LED’s, D6 and D12, should be
Welding gun lifts, but no weld No pilot arc current is detected illuminated. If either is not illuminated, check for
takes place (continued). (E010) loose cables connected to the board. Also, check
and replace any fuses (3) that might have blown.
Those fuses are located on the Pilot Arc PCB.
If there are further problems, contact your qualified
Nelson Technical Service Representative,
If in dual gun operation, another
Wait for the other welder to finish the cycle, and
welder may be attempting to weld
retrigger.
at the same time.
If the coil is shorted, yellow LED D2 on the control
Shorted gun coil (E007) board will be illuminated. Correct the short. Unit
power must be reset for this error to be corrected.
Welding gun does not lift when
the trigger is pulled. Locate the break in the coil circuit. Check all lines
Open gun coil (E008) between the gun coil and the power PCB board for
loose connections or broken lines.
Trigger may be stuck or the control cable may be
Gun trigger not released after last shorted in the closed position. This will be
weld. indicated by a lit “Trigger” LED on the front panel.
Physically release or disconnect the trigger.
Wait for the other welder to finish the cycle, and
Another welder is welding.
retrigger.
Master control board (right) cannot communicate
Second weld gun does not fire with the slave control board (left) if the wiring
Wiring harness disconnected.
when welding in dual-gun mode. harness is disconnected. Ensure that the harness
runs between the Master JP3 and Slave JP3.
Board communication problem. Error displays on the Master front panel display
(E006) (right). Replace control board(s).
Verify that application is within the duty cycle
Duty cycle exceeded limits provided in the Section 4.9.1 of this guide. If
the duty cycle is exceeded, reduce weld rate.
Move power source to allow room for airflow out
Output louvers blocked
of the cabinet rear.
Unit goes into thermal shutdown Remove obstruction from louvers on the cabinet
Input louvers blocked
repeatedly and/or often. front.
A faulty thermal switch may generate excessively
Thermal switch may be faulty
low trip-off temperatures. Replace thermal switch.
Excessive contaminates inside Blow out machine as indicated in the Section 5.2 of
machine are preventing proper this guide. Move machine away from the source of
cooling the contamination.
- 49 -
Weld Quality Problems

Adjust calibration value (F114) until correct current

Calibration value is incorrect
is achieved.
Check the stud burn-off. If the burn-off is much
greater than what is typical for that diameter stud,
the time and current settings may not be correct.
Time setting or current setting is
Consult Section 2.6 to ensure proper current and
too high.
time settings are being used. Reduce the current
setting and perform weld inspections as described in
Sections 2.7.4, and 2.7.5.
Weld appears “hot.” Plunge is measured by the amount of stud
protruding beyond the bottom edge of the ferrule.
Plunge is too short.
Consult Section 2.6 to ensure proper plunge settings
are being used, and correct, if necessary.
Ensure that the ferrule being used in the welding
Incorrect ferrule. process is the proper ferrule for the stud size and
application.
If the gun is a Heavy Duty gun, it is equipped with
Plunge dampening is too great. Tranquil Arc®. Back out the clear plastic plunge
dampener housing to decrease the free travel.
Check 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
Time setting or current setting is Section 2.6 to ensure proper current and time
too low. settings are being used.
Correct the settings and perform weld inspections as
described in Sections 2.7.4 and 2.7.5.
Ensure that the ferrule being used in the welding
Incorrect ferrule. process is the proper ferrule for the stud size and
application.
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
Insufficient gun lift. the lift is improperly set.
Weld appears “cold.”
Perform weld inspections as described in Sections
2.7.4 and 2.7.5.
Perform a Lift Check, as specified in Section 4.5.14,
several times. Consult Section 2.6 to ensure proper
Inconsistent gun lift.
lift settings are being used. If lift results are
inconsistent, disassemble and clean the gun.
Plunge is measured by the amount of stud
Too much plunge.
Plunge dampening is too little. Tranquil Arc®. Screw in the clear plastic plunge
dampener housing to decrease the free travel.
- 50 -
Weld Quality Problems

Plunge is measured by the amount of stud

Plunge is too short.
Position the foot or ferrule grip of the gun so that
Mechanical bind in accessories or the stud is centered in the ferrule opening. If the
ferrule. stud is off-center, it can restrict the plunging motion
of the stud during welding.
Check the stud burn-off. If the burn-off is much
greater than what is typical for that diameter stud,
the time and current settings may not be correct.
Time setting or current setting is
Consult Section 2.6 to ensure proper current and
too high.
time settings are being used. Correct the settings
and perform weld inspections as described in
Sections 2.7.4 and 2.7.5.
Stud “hangs-up” during the weld. Plunge dampening is too great. Tranquil Arc®. Back out the clear plastic plunge
dampener housing to increase the free travel.
Manually depress chuck adaptor and release. Chuck
adaptor must return to the full out position rapidly
without binding. If necessary, disassemble and clean
Mechanical bind in gun. the gun.
On Heavy Duty guns, ensure that the weld cable is
centered between the legs and does not rub on them.
Contamination of the base plate or stud may cause
the arc to become erratic. Ensure that there is no
rust, scale, oil, water, residue, paint, galvanization,
Base material contamination. etc. present between the stud and the workpiece.
Welding to a clean plate can help diagnose if there
is any foreign substance on the base material or
studs.
Ensure that the ferrule being used is the proper
Incorrect ferrule.
ferrule for the stud size and application.
Problems Occurring During Shutdown

Machine does not shut down Broken switch. Replace main power switch.
when the power is turned off at Switch contacts broken and/or
the main power switch. Replace switch contacts.
shorted.
- 51 -
7.0 Miscellaneous Information
7.1 Timing Diagrams
Weld sequence and air trigger for lift check
Contact
Gun Trigger
Gas Valve
t1 t2 t2
Pilot Arc
t3
Main Arc
t4 t5
Gun Coil
t7 t4 t6 t8
Feed Signal
Contact Lost
t7 t7
Feed Signal
After Weld
Feed Signal
Contact Lost*
Feed Signal
After Weld*
Welding Air Trigger
Starting a weld during gas postflow
Contact
Gun Trigger
Gas Valve
t1 t2 t2
Pilot Arc
t3 t3
Main Arc
t4 t5 t4 t5
Gun Coil
Feed Signal
Contact Lost
Feed Signal
After Weld
Feed Signal
Contact Lost*
Feed Signal
After Weld*
Welding Welding Idle
- 52 -
Chuck stripper and chuck saver operation
Contact
Gun Trigger
Gas Valve
t1 t2 t1 t2
Pilot Arc
t3 t3
Main Arc
t4 t5 t4 t5
Gun Coil
t9 t10 t9 t10
Feed Signal
Contact Lost
Feed Signal
After Weld
Feed Signal
Contact Lost*
Feed Signal
After Weld*
Chuck
Welding Welding
Saver
Chuck Chuck
Stripper Stripper
7.2 Timing Diagram Definitions
Symbol Description Controlling Function Values

Gas Preflow Time
After the gun trigger is closed, the gas valve Function F14 default 0 (off)
is turned on for the preflow time before the Enables/Disables Gas
Option option 1 (on)
gun is lifted and before the pilot arc is turned
on. This allows time for the air to purge
t1 from the gas line to insure that a gas shield
is present before starting an arc.
Function F15 default 500 ms
If another weld is started while gas is flowing When Gas Option is Enabled, minimum 0 ms
due to the postflow timer, the preflow is Sets Preflow Time maximum 5000 ms
aborted and the weld starts immediately.
Gas Postflow Time Function F14 default 0 (off)

Enables/Disables Gas Option option 1 (on)
After the weld is complete, the gas valve is
t2 held on for the postflow time. This provides Function F16 default 500 ms
a gas shield while the weld solidifies and When Gas Option is Enabled, minimum 0 ms
begins to cools. Sets Postflow Time maximum 5000 ms
Pilot Arc Time

When the gun trigger is closed, the gun coil default 50 ms
is energized and the pilot arc is turned on. Function F4
t3 After the pilot arc time expires, the main arc Sets Pilot Arc Time
minimum 10 ms
maximum 100 ms
is turned on. This allows the gun time to lift
before main current flows.
- 53 -
Symbol Description Controlling Function Values

Weld Time default
minimum 20 ms
Weld time as set on the user interface. It .
starts when the main current is turned on Set on front panel
Nelweld 4000 max. 1.4 sec
t4 and ends when the gun coil is shut off. .
Nelweld 6000 max. 1.5 sec
Function F2 Nelweld 6000 max.,
Enables/Disables Weld 2.5 sec
Through Deck mode if enabled (F2 is 1)
Hot Plunge Time default 50 ms
Function F3 minimum 50 ms
The time that the main current is on after Sets Plunge Time
maximum 250 ms
t5 the gun coil is shut off.
Function F2 Nelweld 6000 default,
Enables/Disables Weld 180 ms
Through Deck mode if enabled (F2 is 1)
Lift Check Delay Time
Function F11 default 1 (on)
When the gun is air triggered, the gun coil is Enables/Disables Lift Check option 0 (off)
energized for the weld time. After it is shut
t6 off and the trigger remains pressed, the lift
check delay timer starts. Once it expires, default 2000 ms
the gun coil is energized a second time to Function F12 minimum 100 ms
allow gun lift verification and adjustment. Sets Lift Check Delay Time
maximum 9999 ms
t7 Feed Signal Pulse Width Function F22 default 0 (active low)

Sets Feed Signal Level option 1 (active high)
When the Nelweld unit controls the
operation of a stud feeding unit, the pulse Function F23 default 0 (contact loss)
width is the amount of time the feeder’s Sets Feed Signal Style option 1 (after weld)
shutter is open, allowing a stud to drop
from the feeder into the gun. default 10 ms
Function F24 minimum 10 ms
Sets Feed Signal Pulse Width
maximum 500 ms
t8 Lift Check Hold Time
Function F11 default 1 (on)
During lift check, after the gun coil is Enables/Disables Lift Check option 0 (off)
energized a second time, it remains
default 2000 ms
energized for the lift check hold time. Function F13 minimum 10 ms
This eases lift check and adjustment. Sets Lift Check Hold Time
maximum 9999 ms
t9 Chuck Stripper Delay Time Function F41
Enables/Disables Chuck
default 0 (off)
After the main current is shut off, the Stripper Function option 1 (on)
chuck stripper delay occurs before
Function F42 default 200 ms
turning on the gun coil a second time to
Sets Chuck Stripper Delay minimum 10 ms
pull the chuck off of the welded stud. Time maximum 2000 ms
t10 Chuck Stripper Hold Time Function F41 default 0 (off)
Enables/Disables Chuck
This defines how long the gun coil is Stripper Function option 1 (on)
energized during the chuck stripping default 50 ms
operation. Function F43 minimum 10 ms
Sets Chuck Stripper Hold Time
maximum 500 ms
- 54 -
7.3 Function Code Definitions

Default Minimum Maximum
Description Units Zero state One state Comments
Value Value Value
Scrolls through error codes of
F1 Error Display E--- E001 E018
active errors
Only Nelweld 6000 can enable
F2 Weld Through Deck 0 0 1 disabled enabled
this option
Default changes to 0.180 if weld
F3 Plunge Time 0.050 0.050 0.250 sec
through deck enabled.
F4 Pilot Arc Time 0.050 0.010 0.100 sec
Disables output capability when
F5 Prevent Welding if Error 0 0 1 disabled enabled
weld-related error occurs.
Generator or power grid
F6 Input Power Detection Scheme 0 0 1 autodetect generator
detection
F11 Lift Check Enable 1 0 1 disabled enabled
F12 Lift Check Delay Time 2000 500 9999 sec
F13 Lift Check Hold Time 2000 500 9999 sec
F14 Gas Valve Enable 0 0 1 disabled enabled
F15 Gas Valve Preflow Time 0.500 0 5.000 sec
F16 Gas Valve Postflow Time 0.500 0 5.000 sec
F21 Feed Signal Enable 0 0 1 disabled enabled
F22 Feed Signal Level 0 0 1 active low active high
F23 Feed Signal Style 0 0 1 contact loss after weld
F24 Feed Signal Pulse Width 0.010 0.010 0.500 sec
Stud feed on air trigger.
F25 Feed Signal Air Trigger Enable 1 0 1 disabled enabled
Overridden if F21 is disabled.
Truncates gun lift time on
F26 Quick Retry Enable 0 0 1 disabled enabled
misfire.
Resettable user weld counter -
F31 User Weld Counter (millions) 0 0 999
millions
F32 User Weld Counter (thousands) 0 0 999
thousands
F33 User Weld Counter (hundreds) 0 0 999
hundreds
Non-resettable total weld
F34 Total Weld Counter (millions) 0 0 999
counter - millions
F35 Total Weld Counter (thousands) 0 0 999
counter - thousands
F36 Total Weld Counter (hundreds) 0 0 999
counter - hundreds
F41 Chuck Stripper Enable 0 0 1 disabled enabled
F42 Chuck Stripper Delay Time 0.200 0.010 2.000 sec
F43 Chuck Stripper Hold Time 0.050 0.010 0.500 sec
F44 Reset to Factory Defaults FAC Reset all non-preset parameters
F45 Front Panel Lock Enable 0 0 1 disabled enabled
F46 Supervisor’s Lock Combination 1234 1111 6666 Password must be 4 digits.
Read only - Nelweld model
F51 Model Number 4000 2000 6000
number (2000-6000)
Read only - Updates every 5
F52 Line Frequency 60.0 40.0 70.0
sec.
F53 Software Version X.XX Read only
Month and day the software was
F54 Software Installation Month/Day mmdd
installed as mmdd
Year software was installed as
F55 Software Installation Year yyyy
yyyy
Allows multiple weld attempts
F56 Chuck Saver Enable 1 0 1 disabled enabled
without breaking contact
F61 Factory Use 750 0 1000
F62 Factory Use ABC ABC ACB
F65 Factory Use 20 20 20 x
Enable for troubleshooting weld
F66 Diagnostic Mode Enable 0 0 1 disabled enabled
problems
- 55 -
Default Minimum Maximum
Description Units Zero state One state Comments
Value Value Value
Enable to allow preset selections
F111 Preset-Enabled Lock Mode 0 0 1 disabled enabled
while locked.
Enable to allow for supply of
F112 Loadbank Mode Enable 0 0 1 disabled enabled weld current through a fixed
resistive load.
Enable to suppress stud feed
F113 Stud Feed Weld Success Enable 0 0 1 disabled enabled signal under all conditions other
than a successful weld.
Offset adjustment factor for
F114 Calibration Factor 0 -200 +200
calibrating the Nelweld
Enable only when using a KFL
F115 KFL Mode Enable 0 0 1 disabled enabled
gun.
Enable to fire main arc as soon
F116 Quick Pilot Arc Mode 1 0 1 disabled enabled
as pilot arc is established.
- 56 -
7.4 Control Fuses

There are cartridge type fuses in the Nelweld that should only clear if the unit is abused or damaged
(overvoltage, circuit board damage, wiring faults,etc).
Designator Type Case Part Number Protects Location in

Nelweld
F4 4A,250V, 3AG 715-060-003 F4: Gun In pilot arc
Slow supply. board – See
Blow picture 1
F5 and F6 2A,250V, 3AG 715-060-004 F5: Fan In pilot arc
Slow Supply board – See
Blow F6: Control picture 1
supply.
F1* 4A,250V, 3AG 715-060-003 F1 Gun Wiring harness
Slow Supply from pilot arc
Blow PCB – See
picture 2
F2 2.5A, 5mm x 715-060-002 F2 Control In control
250V, 20mm Supply power supply
Fast mounted to the
front panel –
See picture 3
*400V units only
Picture 1. F4, F5, and F6 Picture 2. F1*
Picture 3. F2
- 57 -
7.5 Declaration of Conformity
- 58 -
8.0 Diagrams and Parts Lists

8.1 Front Section
* Not shown
- 59 -
- 60 -
Quantity Quantity Part
Label Description Part Number Label Description
1 Gun 2 Gun 1 Gun 2 Gun Number
Case front panel, 3000/4000 1 1 750-601-201 C10 Shunt mounting hardware, washer 10mm flat 2 2 524-005-147
B1
Case front panel, 5000/6000 1 1 750-600-203 C11 Shunt mounting hardware, washer 10mm locking 2 2 524-005-083
Louver Panel, 3000/4000 1 1 750-601-202 C12 Shunt mounting hardware, nut M10 x 15. Hex 2 2 524-005-174
B2
Louver Panel, 5000/6000 1 1 750-600-204 C13 Shunt mounting hardware, M10 x 50 screw 1 1 524-005-211
B3 Blank output panel, single output units only 1 1 750-600-216 C14 Shunt mounting hardware, washer 10mm flat 1 1 524-005-147
B4 Cover plate mounting hardware, nut M5 keps 4 4 524-005-204 C15 Shunt mounting hardware, washer 10mm lock 1 1 524-005-083
B5 Cover plate mounting hardware, washer 5mm flat 4 4 524-005-118 C16 Shunt mounting hardware, nut M10 x 15, hex 1 1 524-005-174
B6 Frount louver mounting hardware, nut M5 keps 4 4 524-005-204 C17 Shunt standoff, insulated 1 1 729-100-000
B7 Frount louver mounting hardware, washer 5mm flat 4 4 524-005-118 C18 Shunt standoff mounting hardware, screw M8 x 38 1 1 542-002-220
B8 Blank display panel, single output units only 1 1 750-600-218 C19 Shunt standoff mounting hardware, washer 8mm spring lock 1 1 524-005-082
B9 Display panel gasket 2 2 750-600-219 C20 Shunt standoff mounting hardware, washer 8mm flat 1 1 524-005-183
B10 Display panel mounting hardware, screw M4 x 12 12 12 524-005-212 Shunt harness, output 1 1 1 723-241-013
C21
B11 Power suply shield - - 750-600-205 Shunt harness, output 2 0 1 723-241-018
B12 Power supply mounting hardware, spacer 6mm x 8mm 4 4 729-099-000 Weld cable, bridge to shunt, output 1, pos, 3000 1 1 720-544-101
B13 Power supply mounting hardware, nut M3 keps 8 8 542-005-208 Weld cable, bridge to shunt, output 1, pos, 4000 1 1 720-544-001
B14 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
C23
Switch disconnect, 3000/4000 1 1 709-261-000 Weld cable, bridge to shunt, output 2, pos, 3000 0 1 720-544-103
B15 Switch disconnect, 5000/6000, 230/460/575V 1 1 709-261-010 Weld cable, bridge to shunt, output 2, pos, 4000 0 1 720-544-003
Switch disconnect, 5000/6000, 208/230/460V 1 1 709-261-020 Weld cable, bridge to shunt, output 2, pos, 5000/6000 0 2 720-544-003
Output panel, 3000 1 2 750-602-201 Weld cable, Dinse to bridge, output 1, neg, 3000 1 1 720-544-102
C1
Output panel, 4000/5000/6000 1 2 750-600-215 Weld cable, Dinse to bridge, output 1, neg, 4000 1 1 720-544-002
Frount louver mounting hardware, nut M5 keps 4 4 524-005-204 Weld cable, Dinse to bridge, output 1, neg,5000/6000 2 2 720-544-002
C2 C24
Frount louver mounting hardware, washer 5mm flat 4 4 524-005-118 Weld cable, Dinse to bridge, output 2, neg, 3000 0 1 720-544-104
C3 Control cable connector, 3-pin 1 2 714-174-004 Weld cable, Dinse to bridge, output 2, neg, 4000 0 1 720-544-004
C4 Control cable connector mounting hardware, M3 x 10 screw 2 4 524-005-127 Weld cable, Dinse to bridge, output 2, neg, 5000/6000 0 2 720-544-004
C5 Control cable connector mounting hardware, nut M3 keps 2 4 524-005-208 C25 RS-232 Assembly 1 2 721-310-003
Dinse connector, female 500A, 3000 2 4 714-166-099 G1 Front panel display 1 2 750-591-001
C6
Dinse connector, female 600A, 4000/5000/6000 2 4 714-166-100 H1 Front panel display decal 1 2 724-569-600
C7 Shunt 1 1 729-097-000 H3 Nelson Stud Welding nameplate 1 1 724-569-003

Shunt bracket, 3000 1 1 750-602-202 H4 Weld data decal 1 1 724-569-007
C8
Shunt bracket. 4000/5000/6000 1 1 750-600-217 J1 Case front panel mounting bolt 4 4 524-005-218
C9 Shunt mounting hardware, screw M10 x 50 2 2 524-005-211 DC power supply harness, single gun 1 0 723-241-000
K1
DC power supply harness, dual gun 0 1 723-241-010
8.2 Base and Side Cabinet Section
- 61 -
8.3
- 62 -
Quantity
Label Description Part Number
1 Gun 2 Gun
Cabinet base panel, 3000/4000 1 1 750-601-100
D1
Cabinet base panel, 5000/6000 1 1 750-600-100
D2 Ground stud connection hardware, nut M8 x 1.25 hex 1 1 524-005-054
D3 Ground stud connection hardware, washer 8mm locking 1 1 524-005-082
D4 Ground stud connection hardware, washer 8mm flat 1 1 524-005-143
D17 Protected earth ground decal 1 1 724-569-005
Left side cabinet panel, 3000/4000 1 1 750-601-205
E1
Left side cabinet panel, 5000/6000 1 1 750-600-208
Left side case bumper, 3000/4000 1 1 750-601-207
E2
Left side case bumper, 5000/6000 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
F1
Right side cabinet panel, 5000/6000 1 1 750-600-209
Right side cabinet bumper, 3000/4000 1 1 750-601-207
F2
Right side cabinet bumper, 5000/6000 1 1 750-600-211
N2 Voltage selection decal 1 1 724-569-100
Caster kit 6", 3000/4000 opt opt 512-387-000
582-387-000
N3
Caster kit 8" 5000/6000 opt opt 512-387-001
582-387-001
N4 Cabinet base leg 4 4 750-600-201
N5 Leg attachment hardware, bolt M10 x 20 16 16 524-005-145
N6 Leg attachment hardware, washer 10mm locking 16 16 524-005-083
N7 Leg attachment hardware, washer 10mm flat 16 16 524-005-147
Transformer and Top Cabinet Section
**
* European units only

** Alternate is used on European units. See parts list.
- 63 -
- 64 -
Quantity Quantity Part
Label Description Part Number Label Description
1 Gun 2 Gun 1 Gun 2 Gun Number
C10 Transformer mounting hardware, washer 10mm flat 4 4 524-005-147 G8 Pilot Arc PCB mounting hardware, spacer 4 8 750-600-224
C11 Transformer mounting hardware, washer 10mm locking 4 4 524-005-038 G9 Pilot Arc PCB mounting hardware, nut M5 keps 4 8 524-005-204
C12 Transformer mounting hardware, nut M10 x 15. Hex 4 4 524-008-078 G10 Pilot Arc PCB mounting hardware, washer 5mm flat 4 8 524-005-118
C22 Control connector to SCR Power PCB 1 2 723-241-007 G11 SCR Power PCB 1 2 750-592-001
Alternate control connector to SCR Power PCB with filter (on
C22 1 2 723-241-026 G12 SCR Power PCB mounting hardware, screw M5 x 16 5 10 524-005-136
European units only)
D5 Transformer mounting angle iron 2 2 729-105-000 G13 SCR Power PCB mounting hardware, screw slot adapter 5 10 750-600-222
Bridge assembly, 1 output, 3000/4000 1 0 750-601-107 G14 SCR Power PCB mounting hardware, mounting bracket 5 10 750-600-225
Bridge assembly, 2 output, 3000/4000 0 1 750-601-108 G15 SCR Power PCB mounting hardware, washer M5 fender x 20 5 10 524-005-217
D6
Bridge assembly, 1 output, 5000/6000 1 0 750-600-107 G16 SCR Power PCB mounitng hardware, nut M5 keps 5 10 524-005-204
Bridge assembly, 2 output 5000/6000 0 1 750-600-108 G27 SCR Power PCB mounting hardware, screw M5 x 16 5 10 524-005-214
Bridge mounting hardware, screw M6 x 25, 3000/4000 4 4 524-002-315 G18 SCR Power PCB mounting hardware, nut M5 keps 5 10 524-005-204
D7
Bridge mounting hardware, screw M8 x 38, 5000/6000 4 4 524-002-424 H2 Decal, Nelson logo 2 2 724-569-004
Bridge mounting hardware, nut M6 x 1 hex 4 4 524-001-277 I1 Anode lead hardware, single lead, screw M8 x 40, 3000/4000 2 4 524-002-126
D8
Bridge mounting hardware, nut M8 x 1.25 hex 4 4 524-001-276 Anode lead hardware, dual lead, screw M8 x 40, 5000/6000 2 4 524-002-532
Cable, Transformer to Bridge, 3000 3 3 720-544-100 I2 Dual anode lead mounting hardware, cable lug spacer 1 2 750-600-223
D9
Cable, Transformer to Bridge, 4000/5000/6000 3 3 720-544-000 I3 Single/dual lead mounting hardware, washer 8mm flat 2 4 524-005-143
D10 Cable mounting hardware, screw M10 x 25 3 3 524-005-203 I4 Single/dual lead mounting hardware, 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 hardware, nut M10 x 1.5 hex 3 3 524-005-078 I6 Cathode lead hardware, single lead, screw M8 x 40, 3000/4000 2 4 524-002-126
D13 Cable mounting hardware, screw M8 x 20 6 6 524-002-126 Cathode lead hardware, dual lead, screw M8 x 40, 5000/6000 2 4 524-002-220
D14 Cable mounting hardware, nut M8 x 1.25 hex 6 6 524-002-218 I7 Single/dual lead mounting hardware, washer 8mm flat 2 4 524-005-143
D15 Cable mounting hardware, washer 8mm spring locking 6 6 524-005-082 I8 Single/dual lead mounting hardware, washer 8mm spring lock 2 4 524-005-082
D16 Cable mounting hardware, washer 8mm flat 6 6 524-005-143 I9 Single/dual lead mounting hardware, nut M8 hex 2 4 524-002-218
D18 Choke coil 1 2 700-141-000 K2 Cable, 50-pin, SCR Power PCB to Control 1 2 723-241-003
D19 Choke coil mounting hardware, bolt M10 x 90 hex head 1 2 524-001-274 K3 Cable, 50-pin, SCR Power PCB to Pilot Arc PCB 1 2 723-241-008
D20 Choke coil mounting hardware, washer 10mm flat 1 2 524-002-021 K4 Wiring harness, pilot arc 1 1 723-241-009
D21 Choke coil mounting hardware, washer 10mm spring locking 1 2 524-002-020 K5 Cable, pilot arc to ground 1 2 723-241-015
D22 Choke coil mounting hardware, nut M10 x 1.5 1 2 524-002-019 K9 Wiring harness, pilot arc to third phase 1 2 723-241-016
D23 Choke coil mounting hardware, shoulder bushing 1 2 527-002-041 L1 Cabinet top panel, 3000/4000 1 1 750-601-208
D24 Line Filter (on European units only) 1 2 750-600-250 Cabinet top panel, 5000/6000 1 1 750-600-213
G4 Gap pad, thermally conductive 1 2 729-106-030 L2 Lifting handle 4 4 750-600-214
G5 Pilot Arc PCB 1 2 750-593-000 L3 Lifting handle mounting hardware, M10 x 20 12 12 524-005-207
G6 Pilot Arc PCB mounting hardware, screw M5 x 30 4 8 524-005-213
G7 Pilot Arc PCB mounting hardware, screw slot adapter 4 8 750-600-222
709-080-001 (Thermo switch N.O. 37 deg C) for fan Note: Most wire harnesses are stocked in kits 723-241-300 (dual gun
709-080-002 (Thermo switch N.C. 102 deg C) for SCR overtemp. harness kit and 723-241-301 (single gun harness kit). For European
kits: 723-241-302 (dual gun harness kit) and 723-241-303 (single gun
harness kit).
8.4 Rear Cabinet Section
- 65 -
- 66 -
Quantity
Label Description Part Number
1 Gun 2 Gun
Cabinet rear panel, 3000/4000 1 1 750-601-203
A1
Cabinet rear panel, 5000/6000 1 1 750-600-206
Plenum, small single fan, 3000 1 1 750-602-200
A2 Plenum, large single fan, 4000 1 1 750-601-204
Plenum, dual fan, 5000/6000 1 1 750-600-207
A3 Plenum assembly hardware, nut M5 keps 7 7 524-005-204
A4 Plenum assembly hardware, washer 5mm flat 7 7 524-005-118
Fan, small, 3000 1 1 729-096-010
A5 Fan, large, 4000 1 1 729-096-000
Fan small, 5000/6000 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
A7
Pilot arc resistor, 3 resistor assembly 0 1 705-001-006
A8 Ground braid for SCR Power PCB 1 2 723-241-012
A9 Grommet, push type 3 3 717-140-002
Fan mounting hardware, screw, 3000 4 4 524-001-273
A10 Fan mounting hardware, screw, 4000 4 4 524-001-272
Fan mounting hardware, screw, 5000/6000 4 4 524-001-273
Fan mounting hardware, washer, 3000 4 4 524-002-123
A11 Fan mounting hardware, washer, 4000 4 4 524-002-033
Fan mounting hardware, washer, 5000/6000 4 4 524-002-123
J1 Case rear panel mounting bolt 4 4 524-005-218

8.5 Wiring Diagram
- 67 -
Sales and Service Information
North America Sales Offices and Warehouses Subsidiaries International

Atlanta Kansas City *San Francisco England Middle East & Asia/Pacific
1520 Pine Log Road 8600 W. 95th Street 23765 Foley Street Nelson U.K. Ltd. 7900 West Ridge Rd.
Suite 6 Suite 104 Hayward, CA 94545 47-49 Edison Rd. P.O. Box 4019
Conyers, GA 30012 Overland Park, KS 66212 510.293.0660 Rabans Lane Ind’l Estate Elyria, OH 44036-2019
Phone: 800.635.9353 Phone: 800.635.9353 Phone: 800.635.9353 Aylesbury HP19 8TE, UK Phone: 440.329.0400
Fax: 510.293.0677 Phone: 44.1296.433500 Fax: 440.329.0597
Boston *Los Angeles Fax: 44.1296.487930 World Wide Web:
114 Union Street 20621B East Valley Blvd. Seattle – Export www.NelsonStudWelding.com
Holden, MA 01520-2549 Walnut, CA 91789-2731 406 – 26th Ave. Place France
Phone: 800.635.9353 Phone: 909.468.2105 Milton, WA 98354 Nelson Frances S.A.S. E-mail:
800.635.9353 Phone: 253.874.3524 Z. 1 du Chemin Vert Nelson.Sales@NelsonStud.com
*Chicago Fax: 909.468.2112 Fax: 253.874.5748 8 rue de l’Angoumois
9008 S. Thomas Avenue F-95100 Argenteuil, France Central & South America
Bridgeview, IL 60455 Mexico Tampa – Export Phone: 33.1.3411.9400 P.O. Box 3990
708.430.3770 Matilde Marquez No. 61-M P.O. Box 3990 Fax: 33.1.3411.2033 Seminole, FL 33775
Phone: 800.635.9353 Col. Penon de los Banos Seminole, FL 33775 USA
Fax: 708.430.3975 Del. Venustiano Carranza 727.596.9600 Germany Phone: 727.596.9600
C.P. 15520 Mexico D.F. Fax: 727.593.3494 Nelson Germany Fax: 727.593.3494
*Dallas 52.55.26432282 Mailing Address
2211 Century Center Blvd. 800.635.9353 Tampa – US Postfach 40 20
Suite 105 Fax: 52.55.26432286 9401 Ayleshire Place 58272 Gevelsberg
Irving, TX 75062 Riverview, FL 33569 Germany
Phone: 972.721.9055 Phone: 800.635.9353
Shipping Address For Distributors in specific areas
800.635.9353 Milwaukee
Flurstrasse 7-19 call: 440.329.0400
Fax: 972.438.7883 Unit LL #1 *Toronto
58285 Gevelsberg
11400 W. Bluemound Road 6199A Danville Rd.
Germany
Denver Wauwatosa, WI 53226-4049 Mississauga, Ontario
P.O. Box 2470 Phone: 800.635.9353 Canada L5T 2H7 Phone: 49.2332.661.0
Parker, CO 80134 Phone: 905.795.8277 Fax: 49.2332.661.165
Phone: 800.635.9353 Nashville 800.635.9353
2114 Rogers Lane 905.795.8275 Italy
**Elyria Lebanon, TN 37087-7382 Nelson Italy
7900 West Ridge Road Phone: 800.635.9353 Tulsa Via Miraflores, 20
P.O. Box 4019 6104 East 32nd Street Nichelino, (TO) I-10042
Elyria, OH 44036-2019 *Philadelphia Suite 100 Italy
Phone: 440.329.0400 260 Boot Road Tulsa, OK 74135 Phone: 39.011.6059238
Fax: 440.329.0521 Downingtown, PA 19335 Phone: 800.635.9353 Fax: 39.011.6059230
Phone: 610.873.0012 General Offices
Houston 800.635.9353 Warren 7900 West Ridge Road
214 Schooner Drive Fax: 610.873.2550 52 Casale Dr., Street P.O. Box 4019
Freeport, TX 77087 Warren, NJ 07059 Elyria, OH 44036-2019
Phone: 800.635.9353 Pittsburgh Phone: 800.635.9353 Phone: 440.329.0400
5213 Broadlea Drive Fax: 440.329.0521
Indianapolis Pittsburgh, PA 15236-2606 Winston-Salem
World Wide Web:
17767 Sun Park Drive Phone: 800.635.9353 P.O. Box 5339
www.NelsonStudWelding.com
Westfield, IN 46074 Winston-Salem, NC 27113
Phone: 800.635.9353 Richmond Phone: 800.635.9353 E-mail:
2907 Semmes Avenue Nelson.Sales@NelsonStud.com
Richmond, VA 23225
Phone: 800.635.9353
Printed in USA IDD 6-01

* Warehouse
** Manufacturing Facility
- 68 -
This manual is 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: 440-329-0400
FAX: 440-329-0521
www.NelsonStudWelding.com
- 69 -

Nelson Nelweld Operating Manual

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Nelweld 4000 and 6000

Operations and Service

Manual Version 1.19

For Control Board Software Versions 2.09 and higher

Only for EU countries

Do not dispose of Nelson stud welding units and system

Nelson stud welding units and system components are B2B

We expressly point out that Nelson stud welding units and

In accordance with the European 2002/96/EC directive on

Please contact us!

1.1 Safety Symbols

This attention symbol indicates potentially dangerous situations. It is

When “caution” is indicated, important information about the correct

As a result of the weld process, strong WARNING

ELECTRIC AND WELDING SPARKS

2.0 INTRODUCTION TO STUD WELDING

2.1 Processes • The trigger is then depressed to start the fully

In the Short Cycle stud welding process, a

Short Cycle Welding Setups for Mild and

Ceramic Ferrules: These are also termed ceramic

2.8 Closing Comments

Over one hundred million studs of all types are

3.1 Technical Specifications

3.1.1 Nelweld Characteristics

3.1.2 Recommended Input Wire and Fuse Sizes

Nelweld 4000 Nelweld 6000

3.1.4 Temperature Ranges

3.1.5 Enclosure Safety Rating IP23

Suitable for Outdoor Use Yes

3.7 Moving the Power Source 3.8 Input Connections

This equipment has been designed for

Figure 3-1: Proper hoisting technique of a Nelweld power

FOR 3000 & 4000 18" (457mm)

GREEN WIRE (GROUND)

L1, L2 AND L3 CONNECTIONS

VERIFY THAT LUG IS PROPERLY CRIMPED AND THAT

CABLE TO PRIMARY POWER

Figure 3-2: Connecting the input power cables

Connect L1, L2 and L3 to the top of the front

Additionally, do not lubricate the posts,

Figure 3-4: Link connections for 230/460/575 V model.

N elso n S tu d Weld ing , In c.

Figure 3-6: Link connections for 220/380/415/440 V model

to a different voltage, remove the left side case

4.1 Safety Precautions

ELECTRIC SHOCK can kill. ARC RAYS can burn.

Observe additional Safety Guidelines detailed throughout this manual.

4.2 Basic Operation Procedure • Save any setpoints, if desired.

4.3 General Description 4.5.2 System Cooling and Thermal

4.6.11 4.6.5 4.6.4

Nelweld Maximum Settings

Nelweld Accessory and Kit Numbers Output Type Isolated Contact

4.9.3 Stud Feeding System Interface

Stud Weld Rate

Cable Length (ft or m), including ground cable

Cable Length (ft or m), including ground cable

5.1 Safety Precautions

ELECTRIC SHOCK CAN KILL

5.2 Care and Cleaning