Nelson Nelweld 6000 - Table of Contents

Nelweld Operations and Service Manual
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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