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General| Brand | Nelson |
|---|---|
| Model | ALPHA 850 |
| Category | Welding System |
| Language | English |
Manual overview for ALPHA 850 users, covering safe and reliable operation. Information valid as of July 2021.
Details ALPHA 850 capabilities, including drawn arc/short cycle processes, automatic/manual guns, and thyristor copper bar operation.
Explains drawn arc and short cycle drawn arc processes, stud preparation, use of ceramic rings (CF), and shielding gas (SG).
Illustrates the stud welding steps: placing stud, auxiliary arc, main arc, immersion, and end of weld, with weld time ranges.
Lists stud types (SC, DA) and bolts for short cycle and drawn arc processes, based on dimensions and standards.
Describes ceramic rings' function in centering the arc and shaping the weld bead, and notes requirements for matching rings and holders.
Presents tested material combinations for welding, indicating suitability for force transfer or heat transfer according to EN ISO standards.
Provides detailed technical specifications for the ALPHA 850, including input voltage, power, current range, dimensions, and environmental limits.
EU Declaration of Conformity for ALPHA 850, confirming compliance with Machinery and EMC Directives, and listing used harmonized standards.
Explains safety symbols and hazard terms (Danger, Warning, Caution) used in the manual to ensure user safety.
Covers informal safety instructions, personnel training requirements, and mandatory personal safety equipment for operating the ALPHA 850.
Defines the ALPHA 850's intended use for specific stud welding processes (BH 100, BH 10) in industrial/commercial sectors.
Outlines conditions voiding warranty and liability, including unintended use, improper operation, or unauthorized modifications.
States copyright protection for the documentation, prohibiting unauthorized reproduction, use, or communication of its content.
Lists the components included with the ALPHA 850 welding device: the unit itself and the operating manual.
Specifies acceptable locations for the ALPHA 850, restricting use to industrial/commercial areas and prohibiting outdoor use in bad weather.
Provides guidelines for setting up the ALPHA 850, including level placement, vibration-free surface, ventilation clearance, and fluid protection.
Details safe connection of the power cable to a tested earth conductor socket, emphasizing electro-technical personnel involvement.
Explains connecting the welding cable to socket X20 for standard manual stud loading and automatic stud loading systems.
Describes connecting the control cable to the 4-pin or 7-pin socket for manual or automatic welding gun control.
Details connecting the earth cable plug to socket X21 for weld current return, emphasizing secure connection and cable routing.
Guides on connecting earth clamps to the workpiece, ensuring direct contact and optimal placement for preventing arc blow.
Identifies front panel controls: Power switch, Weld current/time potentiometers, and Operating mode selector switch.
Explains the function of LED indicators on the ALPHA 850 for status, faults, and process feedback, aiding in troubleshooting.
Lists the four internal fuses (F1-F4) for control circuits, their ratings, response behavior, and the main power unit fuse.
Provides essential pre-welding instructions: material suitability, workpiece prep, and checking settings for good weld joints.
Details setting electrical (current/time) and mechanical (lift/stick out) parameters on the gun and device for optimal weld results.
Outlines quality checks: normal work inspection (10 studs), simplified inspection (3 studs), and ongoing production monitoring.
Describes visual weld inspection for drawn arc process, identifying defects like constriction, undercut, and low weld bead, with corrective actions.
Details visual inspection for short cycle drawn arc process, covering defects like incomplete weld diameter and uneven bead, with corrective actions.
Provides guidance on cleaning the ALPHA 850, emphasizing safety switch-off, appropriate cleaning agents, and frequency.
Recommends daily, 3-monthly, and annual maintenance intervals for the ALPHA 850, including visual inspections and professional checks.
Instructs on safe repair procedures for the ALPHA 850, requiring switch-off, authorized personnel, and use of standard tools.
Provides a systematic troubleshooting guide for ALPHA 850 power supply and gun function issues, with possible causes and checks.
Offers guidance on proper disposal of ALPHA 850 components, aligning with environmental protection and waste management regulations.
Lists and defines technical abbreviations used in the ALPHA 850 operating manual for clarity and reference.
Lists bibliographic sources, standards, and regulations referenced in the ALPHA 850 operating manual for further information.
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