Nelweld Operations and Service Manual
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Weld Quality Problems
Problem Possible cause Solution
Plunge is too short.
Plunge is measured by the amount of stud
protruding beyond the bottom edge of the ferrule.
Consult Section 2.6 to ensure proper plunge settings
are being used, and correct, if necessary.
Mechanical bind in accessories or
ferrule.
Position the foot or ferrule grip of the gun so that
the stud is centered in the ferrule opening. If the
stud is off-center, it can restrict the plunging motion
of the stud during welding.
Time setting or current setting is
too high.
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.
Consult Section 2.6 to ensure proper current and
time settings are being used. Correct the settings
and perform weld inspections as described in
Sections 2.7.4 and 2.7.5.
Plunge dampening is too great.
If the gun is a Heavy Duty gun, it is equipped with
Tranquil Arc
®
. Back out the clear plastic plunge
dampener housing to increase the free travel.
Mechanical bind in gun.
Manually depress chuck adaptor and release. Chuck
adaptor must return to the full out position rapidly
without binding. If necessary, disassemble and clean
the gun.
On Heavy Duty guns, ensure that the weld cable is
centered between the legs and does not rub on them.
Base material contamination.
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,
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.
Stud “hangs-up” during the weld.
Incorrect ferrule.
Ensure that the ferrule being used is the proper
ferrule for the stud size and application.
Problems Occurring During Shutdown
Problem Possible cause Solution
Broken switch. Replace main power switch.
Machine does not shut down
when the power is turned off at
the main power switch.
Switch contacts broken and/or
shorted.
Replace switch contacts.
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