Nelson N1500i Operating Manual
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Nelson N1500i Operating Manual

Facs stud welding system
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Operating the N1500i FACS Stud
Welding System
Operations Manual
(729-110-053)
For Dot Matrix Units Software Version 1.00 and later
These instructions are for experienced operators. If you are not fully familiar with
the principles of operation and safe practices for arc welding equipment, we urge you
to read AWS SP -"Safe Practices" available from the American Welding Society. Do not
permit untrained persons to install, operate or maintain this equipment. Do not
attempt to install or operate this equipment until you have read and fully
understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety section before
utilizing this equipment. .
Part No. 729-110-053 V.1.03
© 2018 Nelson Stud Welding, Inc. All rights reserved.

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  • Page 1 If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety section before utilizing this equipment. . Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 2 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...
  • Page 3 For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding Processes,” available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 4 Keep hands, hair, loose clothing, and tools away from moving parts. Reinstall panels or guards and close doors when servicing is finished and before reenergizing welder. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 5: Table Of Contents

    3.4.1 Maximum Weld Cable Length ..................29 3.4.2 Maximum Output & Rated Output................. 30 3.4.3 Energy Consumption ...................... 30 3.4.4 Supply Cable Lengths ....................31 3.5 N1500i Weld Cycle Timing ....................32 Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 6 5.1 Care and Cleaning ........................ 53 5.2 Routine Maintenance ......................54 6. Drawings and parts lists ..................55 6.1 Explosion drawing Final Assembly N1500i ..............55 6.1.1 Parts List Final Assembly N1500i ................. 56 6.2 Cover Assembly ........................57 6.2.1 Parts list cover assembly ....................57 6.3 Chassis Sub ASM .........................
  • Page 7 8.3.17 Additional Warning - WAIT is on upper display and CYCLE or CAP is on lower display ..........................82 9. Wiring Diagram Nelweld N1500i ..............83 10. Spare Parts List for N1500i ................85 Contact Information ....................86 Part No. 729-110-053 V.1.03...

  • Page 8: Connection And Installation

    When working in elevated locations, such as bridges, ladders or platforms the N1500i must be secured against the risk of falling. The N1500i must be adequately protected against the intrusion of liquids. It may not be installed on liquid-bearing pipelines.
  • Page 9 2.Welding cable connection (+) X3 4. Input power cable connection Warning! Prior to any connection work the Nelweld N1500i welding unit must be switched off. The input power switch of the unit must be in the >>0<< position! Part No. 729-110-053 V.1.03...

  • Page 10: 1Input Connection

    N1500i FACS Manual 1.2.1Input Connection Warning! The N1500i may be operated with an input power voltage of 200- 230VAC/50/60Hz or 400-460VAC/50/60Hz as configured by the reconnect terminal blocks internally. The 575V unit cannot be configured this way. See rating plate on the back of the unit.

  • Page 11: Change Input Voltage (Reconnect)

    1.2.3 Change Input Voltage (Reconnect) Warning! The diagram below shows the jumper positions needed for various input voltages (230V/460V or 230V/460V/575V) on the N1500i with internal reconnect. Re-wiring is needed on both the small “aux. block” and the big terminal block.
  • Page 12 Jumper & Lead 460 VAC Connection 230 VAC Connection Jumper is installed between 1 and 2 on large terminal block (small terminal block, lead moves to end position) Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 13: Connection Of The Welding Cable

    N1500i FACS Manual 1.2.4 Connection of the Gun Weld Cable Connection of the welding cable of the gun is effected by means of the welding cable socket of the N1500i which is marked with the gun symbol. Gun Weld Cable Connection (X2) Connect the welding cable plug of the gun to the welding cable socket of the N1500i.

  • Page 14: Connection Of The Shielding Gas

    1.2.7 Connection of the shielding gas (Option) Prerequisites: The Nelweld N1500i has an optional shielding gas valve combination kit that can be factory or field installed. The connected weld gun needs to be equipped with the optional special equipment for shielding gas.
  • Page 15 Should the gas tubes be removed by pressing/pulling the release ring, the self-sealing coupler sockets prevent any shielding gas from escaping. Warning! Note! Use Nelson gas foot to save gas consumption. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 16: Connection Of The Workpiece

    Note! Prior to connecting the workpiece ground terminals, the following advice on avoiding arc blowing should be observed. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 17: Arc Blowing Effect

    The polarity in the illustration refers to ferromagnetic materials. When welding aluminum, attention must be paid to reverse polarity. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 18: Connection Diagram Short-Cycle And Drawn Arc Welding

    N1500i FACS Manual 1.4 Connection Diagram Short-Cycle and Drawn Arc Welding Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 19 N1500i FACS Manual THREE PHASE CONNECTION BLACK (L1) WHITE (L2) RED (L3) GREEN (GND) Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 20: Additional Cautions

    N1500i FACS Manual 1.5 Additional Cautions SELECT SUITABLE LOCATION The N1500i will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life and reliable operation. The machine must be located where there is free circulation of clean air such that air movement in the back, out the sides and bottom will not be restricted.

  • Page 21: Specifications

    Storage Temperature: -40 to +60 Degrees c Width: 10.7in (27cm) Efficiency at rated output: 88% Max Lift Height 0.098” (2.5mm) @ +/- Open - Circuit Voltage: 75V 10% rated voltage Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 22: Generator Sizing

    N1500i FACS Manual 1.7 Generator Sizing Generator Sizing The N1500i may be supplied with a generator with the following characteristics: •Full Power 1500A - For 1500A weld current using more than 25 ft 4/0 weld cable: Use a 100kW (125 kVA) with at least +/- 1.5% regulation from no-load to full-load, and less than 5% THD wave form distortion to get the full output current.

  • Page 23: Facs Dot Matrix User Interface

    N1500i FACS Manual 2. FACS Dot Matrix User Interface Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 24 UPPER display. It can be changed using the + and – Diameter Display arrow keys to the right of the current display in one (1) amp increments. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 25: Operation

    9. Lay out the welding and workpiece ground cable without loops or snarls to minimize unwanted electromagnetic effects. 10. Check the settings of the N1500i welding unit, and the setup of the connected gun. 11. During the brief stud welding process, maintain the position of the weld gun and the workpiece.

  • Page 26: Basic Procedure

    N1500i FACS Manual 3.2 Basic Setup Procedure Setting up the N1500i unit is very easy, once the proper electrical connections and gun connections are established: 1. Turn the main power switch on the front of the unit to the “on”...

  • Page 27: Weld Parameters

    3.3.2 Setting the Weld Time and Reading the Weld Time Display The time setting is shown on the front panel lower display. It can be Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 28: Lift Distance And Plunge Distance Parameters

    6. If the lift capability is marginal, i.e. it lifts a low lift height, but fails to lift at slightly higher lift height, then consult your Nelson Rep. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 29: Calibrate The Gun Drop Time F31

    To select a preset, simply press key 1, 2, 3, 4, 5, 6, 7, 8, 9, 0. When a Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 30: Recommended Weld Parameters

    Nelson cannot assume any responsibility for updating or correcting the welding advice or guide values, once they have been given. Nor does the provision of information create, expand or alter any warranty with respect to the sale of our products.

  • Page 31: Weld Parameters And Settings

    3.3.7 Weld Parameters and Settings Note! Weld parameters and settings below are developed using Nelson equipment and Nelson studs. It is recommended to use fasteners from one manufacturer (Nelson studs) to ensure weld consistency and compatibility. Factory Preset Weld Settings (Drawn Arc)

  • Page 32: Parameters For Short Cycle Procedure

    .187 3.3.9 Parameter for drawn arc procedure The duty cycle limits for the Nelweld N1500i can be seen in the Stud Weld Rate table below. If the duty cycle is exceeded, and a weld is attempted, a “Wait” prompt will be displayed. “Wait” will disappear when the unit is ready for another weld.
  • Page 33 There are conditions that will filter the table for selection, or reveal only a subset of the table to the user. • In the case of the N1500i, studs requiring more than 1500A of weld current will not appear in the list for selection.
  • Page 34 Drawn Arc 7/16" Pitch Base 630, 350, 340, 610, Drawn Arc 7/16" Full Base 720, 400, 380, 730, Drawn Arc 7/16” Pulse 375, 675, 375, 675, Drawn Arc Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 35: Performing A Lift Check

    (Continue holding the trigger for 2 more seconds) • The gun will lift for 2 seconds then release. During the 2 seconds, a manual measurement may be taken. Warning! check. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 36: Rating Charts

    N1500i FACS Manual 3.4 Rating Charts 3.4.1 Maximum Weld Cable Length Check with Nelson representative for a weld cable length calculator Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 37: Maximum Output & Rated Output

    1300 1500 amps amps 3.4.3 Energy Consumption Inverters can realize significant electricity saving over its life time. Use the following online calculator to compute the savings: http://www.nelsonstud.com/calculator/energy.html Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 38: Supply Cable Lengths

    This table is based on a 1500 Amp output. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 39: N1500I Weld Cycle Timing

    N1500i FACS Manual 3.5 N1500i Weld Cycle Timing This section explains how the N1500i controls weld current, timing, and the weld gun. It further explains what factors affect drop time. For short cycle welding, the gun drop time and plunge time are critical components in the weld timing, so they must be configured, understood, and used correctly to get the optimum results.
  • Page 40 Front Panel Time + Plunge short circuit on-time (F2) = 50ms+50ms=100ms, but the arc would exist only during the Actual Weld Time, or 50ms. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 41 Touching Work The resulting Actual Weld Time is 20ms. The stud would still take 30ms to drop, but the main current and main arc would only be 20ms. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 42: Drop Time Variables

    6. Inspect and clean gun housing and related parts – replace parts as needed. Debris in this housing will resist travel. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 43: Inspection And Testing Of The Weld

    The test results must be recorded in the production log. Warning! atisfactory! 1. See the following pages for information on visual inspection Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 44 • Weld flash single-sided. Corrective measures: Eliminate blowing effect by applying corrective measures described in Section 1.3. 1. EN ISO 14555: „Welding Arc stud welding of metallic materials“ (2006) Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 45 Corrective measures: Decrease weld time and weld cur- rent, adjust plunge distance and/or damping. 1. EN ISO 14555: „Welding Arc stud welding of metallic materials“ (2006) Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 46: Weld Process Monitor

    F32 is refreshed after each weld, and no weld history is recorded. To save actual signals for all welds in production permanently as record keeping, contact Nelson for Nelware™ PC software. 3.8.2 Set up weld monitor tolerance Two tolerances must be configured: F34 gun drop time tolerance and F35 weld energy tolerance.
  • Page 47 'LOCK' key. Enter a password that will be used to both unlock the unit and also will allow welding to resume if a failed weld occurs. Press 'LOCK' again as the Enter key. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 48 If any weld settings are to be changed or F code configurations are to be accessed, the unit must be unlocked before doing so. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 49: Operational Function Codes & Error Codes

    Stud Feed on Air To feed a stud even when triggering the gun while not OFF ON Trigger welding. This only applies when stud feed is enabled. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 50 This Drop Time 0 to 100 value changes automatically depending on F30 (short cycle mode) and the gun interface installed in the unit. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 51 Diagnostic Data # Phases imbalance, or Duty Cycle current, PWM AVG will be 100%. Output Board 700 to 1300 1000 Used by manufacturing. Do not change. Calibration Offset Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 52 20 to 25 This is the time the weld will deliver the low current. Factory Only 95-105 Input Board Gain Factory Only Input Board Offset 700-1300 1000 Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 53: Diagnostic Error Codes

    10 seconds to get E007 INPUT VOLTAGE TO LOW -See troubleshooting- the proper voltage. On-board control PCB failure PRIMARY OVERCURRENT E008 A primary overcurrent occurred. ERROR -See troubleshooting- Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 54 If E014 NO STUD HIT DETECTION it is not detected, this error will occur. -See troubleshooting- Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 55 WAIT ON UPPER DISPLAY 1 of 3 reasons. AND CYCLE OR CAP ON 2. Switch board out of calibration -See troubleshooting- LOWER DISPLAY 3. Switch board malfunction Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 56: Weld Process Problems

    Plunge is measured by the amount of stud protruding beyond the bottom edge of the ferrule. Consult Section 2.6 Too much plunge. to ensure proper plunge settings are being used, and correct, if necessary. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 57 V1.06 or higher. without plunger dampener ,it is recommended to set F48 to “auto” or “average” to match welder seamlessly. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 58: Maintenance

    • Do not use aggressive solvents, alcoholic agents, or combustible liquids for the cleaning work. • The case of the Nelweld N1500i should be wiped down with a dry cloth. Rating plate and safety warnings must be very legible.

  • Page 59: Routine Maintenance

    (Nygogel 760G from Nye Lubricants) to all PCB connectors prior to reconnecting. This forms a corrosion\moisture barrier that will protect the contacts for reliable operation. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 60: Drawings And Parts Lists

    N1500i FACS Manual 6. Drawings and parts lists 6.1 Final Assembly N1500i Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 61: Parts List Final Assembly N1500I

    CABLE,PRIMARY POWER,N1500i 750-651-101 HORIZONTAL SHELF, 1500I FACS 724-569-013 LABEL, TRASH CAN, CE,ROHS 87-07-86 LABEL,HIGH VOLTAGE SYMBOL 724-572-001 DECAL,RATING INFO,N1500i,400-480V 724-576-015 DECAL, MADE IN USA, NCD+ 750-615-201 COVER,RED,N550c,STD Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 62: Cover Assembly

    COVER 87-09-35 LABEL, CARDIAC PACEMAKER 724-485-012 LABEL,TWO PERSON LIFT,ROHS 724-569-000 DECAL,WARNING 724-572-004 DECAL,LIFTING INSTRUCTION 87-05-19 LABEL, POWER PLUG BEFORE OPEN 724-569-004 DECAL,NELSON LOGO 724-572-021 DECAL, SIDE, N1500i Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 63: Chassis Sub Asm

    SCREW, M4 X 70 PHMS 524-005-284 WASHER, FENDER, M4, SS 524-005-153 NUT, M4, WITH NYLON INSERT 717-140-010 GROMMET, RUBBER 86-44-38 OR CABLE GLAND 721-313-001 FAN CABLE 86-44-39 STRAIN RELIEF NUT Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 64: Front Panel Assemblies

    FRONT CONNECTOR PANEL, DINSE/HUBBELL 714-166-099 DINSE,FEMALE,PANEL MOUNT,MEDIUM SKT 714-174-004 CONNECTOR,3 PIN,FEMALE PANEL 724-572-012 LABEL,CON,PANEL,N1500i,FACS,DINSE/HUBBELL 750-652-113 PANEL, DOT MATRIX DISPLAY 750-649-065 PCB ASM,USER PANEL,N1500i FACS,DOT MATRIX 750-610-327 BUSBAR,GUN,N1500i 701-142-003 TRANSDUCER,CURRENT,600A NOM Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 65: Horizontal Panel Assembly

    750-610-022 INPUT PCB ASM 714-028-004 CABLE BUSHING,SNAP,26MM ID 700-149-021 POWER SUPPLY, AS-DC 24V 714-028-005 CABLE BUSHING,SNAP,19MM ID 708-143-003 FUSE HOLDER 715-039-001 W, Sp SLOW-BLOW FUSE, 1.5A, 600V Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 66: Vertical Panel Assembly

    PLATE,3 PHASE BRIDGE,N1500i FACS 701-175-000 INPUT BRIDGE,215A,3PH,1600VAC 708-149-000 TERMINAL BLOCK, LARGE, 3 POS 750-610-055 PCB,SWTCH ASM W/THML,N15i,ROHS 708-150-000 TERMINAL BLOCK, SMALL, 3 POS 723-242-021 C.T. SUB ASM 750-610-206 VERTICAL CHASSIS Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 67: Facs Board Set

    7.1 Dot Matrix User Interface Dot Matrix Connections CAN Bus \ 24V supply CAN Bus \ 24V supply Address jumper Product variant Product type jumper JTAG (programming) Debug Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 68: Output Smps

    J2 CAN Bus \ 24V supply J3 Address jumper J4 CTs, gate drives, input analog signals J5 Pilot output, relay drivers, capacitor sensing J8 JTAG (programming) J9 Debug Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 69: Gun Interface

    J12 CAN Bus \ 24V supply J13 Address jumper J14 Product Type J15 Product Variant J16 Gun Trigger, Gun Coil, Gun AC input J18 JTAG (programming) J19 Debug Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 70: Sensing Monitor

    Thermal input, current sense input, phase sensing, capacitor V-F inputs, contact sensing, single phase sensing, analog output, weld terminal voltage input J27 Battery voltage sense, case ground sense J28 JTAG (programming) J29 Debug Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 71: Troubleshooting

    Step 2. SOLUTION RECOMMENDED • This column provides a course of action for the Possible Cause, generally it states to contact your local Nelson Authorized Field Service Facility. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 72: Problems / Possible Cause / Solution

    Warning! If for any reason you do not understand the test procedures or are unable to person the tests/repairs safely, contact your Local Nelson Authorized Field Service Facility for technical troubleshooting assistance before you proceed. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 73: Welding Problems

    Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to person the tests/repairs safely, contact your Local Nelson Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

  • Page 74: E001 Shorted Control Cable-Fix Control Cable And/Or Gun

    13VDC (1ms during a weld, or 20ms while idle), this error will be displayed and if welding, the weld will stop immediately. +15VDC and ground is located at U15 pin 3 and TP14, respectively, of FACS output SMPS board. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 75 Likely items to check in order from most likely to least: • Switch board(s) • FACS Input board • Wiring to the FACS Input board. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 76: E003 Capacitor Voltage Imbalance

    This will happen if the current sensing fails for any reason (wiring, power supply, etc.), but is most likely caused by the arc actually popping out. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 77: E005 Regulation Error - Short Circuit

    >15ms, it will abort the weld and display this error. This will happen if the current sensing fails for any reason (wiring, power supply, etc.). Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 78: E006 Input Voltage Too High

    / opens and watches the primary voltage closely. If the voltage is sensed to be a damaging level (>470VDC on the capacitor banks - J1 on each switch board of the N1500i, J1, J4), the relays are turned off and this error is displayed. They system must be powered down and examined/ fixed prior to anything else.

  • Page 79: E007 Input Voltage Too Low

    (<225VDC on the capacitor banks” - J1 on each switch board of the N1500i, J1, J4 of the N800i), the unit will re- main in this state. The system must be powered down and examined/ fixed prior to anything else.
  • Page 80 5. If the V-F signal is in a range of (2314Hz and 4529Hz or 250V - 470V) and when first powered up, you still get this error, replace the FACS input board. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 81: E008 Primary Overcurrent Error

    If the error is consistent, check that the workpiece is directly clamped to the output of the unit. Check for a small burn mark on the workpiece. If the mark is not there, replace the pilot arc board. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 82: E010 Capacitor Voltage Could Not Be Read

    Fatal, meaning you have to power down to continue welding >> No Acknowledge, meaning the error will exist as long as the unit is powered on. (Note, welding can continue while the error exists) >> No Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 83: E012 Short Circuit-Check Gun Lift Setting

    If this occurs during the plunge time, the error is not displayed, but the weld is aborted - as this is expected to happen during plunge time. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 84: E013 Weld Failed - Out Of Tolerance

    1. Change the weld setup as appropriate. 2. Configure new target. To do this, select F32 and hold the lock button. 3. Adjust tolerance (weld energy F35 or drop time F34) Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 85: E014 Warning - Cold Plunge - Stud Hit After Current Was Shut Off

    40V). This error is generated if the arc voltage exceeds 60V, representing a condition where the pilot arc blew out. For this condition, check surface conditions and clean the workpiece of any ferrule dust or debris. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 86: E018 Warning - Drop Time Is Too Long For Short Cycle

    40ms. The Maximum time the pilot arc will stay on is 40ms, so it is possible the arc will go out before the main arc starts. For consistent welds, reconfigure the drop time and\or front panel time to satisfy the equation. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 87: Additional Warning - Wait Is On Upper Display And Cycle Or Cap Is On Lower Display

    Step 1: Check Switch Board Calibration: Switch boards generate a signal representing the capacitor voltage for the FACS input board. Step 2: Switch Board Malfunction: If re-calibration of the switch board fails, exchange the switch board. Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 88: Wiring Diagram Nelweld N1500I

    N1500i FACS Manual 9. Wiring Diagram Nelweld N1500i For 575 units: move the #200 wire, add the #203 wire, and change the rating plate to PN 724-574-00 Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.
  • Page 89 N1500i FACS Manual For 575 units: move the #200 wire, add the #203 wire, and change the rating plate to PN 724-574-000 Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 90: Spare Parts List For N1500I

    Pilot Arc Board 750-649-065 Dot Matrix User Interface 750-649-035 SMPS Output Board 750-649-045 Input Sensing Board 750-649-040 Gun Interface Board 701-175-000 3 Phase Bridge Rectifier 750-610-034 Output Rectifier Board Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

  • Page 91: Contact Information

    Elyria, OH 44036-2019 USA Phone: 440.329.0400 Fax: 440.329.0526 World Wide Web: NelsonStudWelding.com E-mail: Nelson.Sales@NelsonStud.com Italy Nelson Stud Welding Via Miraflores, 20 Nichelino, (TO) I-10042 Italy Phone:39.011.6059238 Fax: 39.011.6050015 Part No. 729-110-053 V.1.03 © 2018 Nelson Stud Welding, Inc. All rights reserved.

This manual is also suitable for:

N800i

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