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Nelson N1500i Operation And Service Manual

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Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
Stud welding unit N1500i
For Control Board Software 1.06 and higher
Operation and Service Manual
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany

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  • Page 1 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Stud welding unit N1500i For Control Board Software 1.06 and higher Operation and Service Manual Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...

  • Page 2: Table Of Contents

    2.2 Safety notices ....................19 2.3 Intended use ....................24 2.4 Guarantee and liability .................. 25 2.5 Use of original NELSON spare parts ............26 2.6 Copyright ......................26 3. Delivery and Transport ................28 3.1 Extent of delivery ................... 28 3.2 Packing and dispatch ..................
  • Page 3 8.1 Care and cleaning ..................102 8.2 Routine Maintenance ................... 103 9. Drawings and parts lists................. 105 9.1 Explosion drawing Final Assembly N1500i ..........105 9.2 Cover Assembly .................... 108 9.3 Chassis Sub ASM ..................109 9.4 Front panel assembly ..................111 9.5 Horizontal panel assembly ................

  • Page 4: Introduction

    Manual part number: BE 1221 Introduction 1.1 General The operating and service instructions to hand refer to the Nelweld N1500i welding unit. They are intended for operating and service personnel. Trouble-free operation of the Nelweld N1500i welding unit can only be guaranteed with knowledge of the contents of these operating and service instructions.

  • Page 5: Unit Description

    LED display elements. Fault messages are issued, and numerically coded, on the error display. In order to keep the temperature level of the Nelweld N1500i as low as possible the N1500i has two thermostats to monitor internal temperature level. One thermostat is used to turn on the fan automatically when the internal temperature reaches a level.

  • Page 6: Welding Method

    On account of the extremely short weld times the studs can also be welded without ceramic ferrule. To protect the weld pool, particularly with aluminum welds, it is advisable to use inert gas. Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg...

  • Page 7: Operational Sequence

    1.4.1 Welding sequence diagram: 1. Placing 2. Drawing 3. Igniting the 4. Immersing 5. End of welding main arc the welding welding auxiliary stud stud Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg...

  • Page 8: Welding Elements

    • An appropriate ceramic ferrule is required for every stud diameter • For differing ceramic ferrules corresponding ceramic ferrule holders are needed The LFH 000 catalogue offers an overview of the Nelson ceramic ferrule product Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg...

  • Page 9: Material Combinations

    Suitable with Suitable with restrictions b restrictions b restrictions b restrictions b 1.4762 Not suitable 1.4828 Suitable with Suitable with Suitable with restrictions b restrictions b restrictions b 1.4841 welding Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg...
  • Page 10 Vanadium-free Cr-Mo steel with C ≤ 0,35%) Group 5: Highly vanadium-alloyed Cr-Mo-(Ni) steel Group 6: Austenitic steel Group 8: Austenitic ferritic rustproof steel (duplex) Group 10: Pure aluminum ≤ 1% impurities or alloy contents Group 21: Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg...

  • Page 11: Technical Data

    As of: Aug 12.2021 Manual part number: BE 1221 Group 22: Not heatproof alloysNote! Note! Please consult a Nelson expert for material combinations that are not listed in the table and applications where aluminum studs should be welded. 1.8 Technical Data Unit designation/Type:...
  • Page 12 B x H x T (280mm x 460mm x 780mm) Weight: 34Kg/43Kg w/ mains cable Mains plug: CEE (5 pole); 63A at 400V H07RN-F 4G16 (4x16mm 2 ) Mains cable: Length: Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg...
  • Page 13 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 1.8.1 Dimensions 279,5 82,9 177,77 Front Rear Side Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg...
  • Page 14 FFL 100 operating instructions Mains cable for the feeder: on request (220V) Gas hose pipe: 10 m shielding gas hose pipe system (Nelweld N1500i-gun): order no. 67-07-50 Connecting cable (standard): Nelweld N1500i - Workpiece: Earth cable H01N2-D (with 2 earth holders):...
  • Page 15 2/0 Combination Cable-HD Gun 50Ft. 722-000-154 2/0 Combination Cable-SD Gun 50Ft. 722-000-155 2/0 Combination Cable-SD Gun 25Ft. 722-000-156 4/0 Combination Cable-SD Gun 25Ft. 512-387-055 Ethernet patch cable CONTACT NELSON STUD WELDING SALES REPRESENTATIVE FOR AVAILABILITY Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
  • Page 16 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 1.8.4 Guns cable extension incl. control cable Length (m) Cross section (mm 2 ) Part Number / Socket inclusive control cable with BIN 4 67-01-16 / 50...

  • Page 17: Declaration Of Conformity

    Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany Hereby declare, that the welding unit of type Nelweld N1500i for the welding of studs in keeping with the drawn-arc and short-cycle welding method was developed, constructed and manufactured in accordance with the following EC guidelines: Low voltage 2006/95/EEC •...

  • Page 18: Safety At Work

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Safety at work 2.1 Safety Symbols Safety notices and warnings are made on the one hand for your personal safety and on the other hand for product safety. In these operating instructions they are made to stand out by means of the following safety symbol.

  • Page 19: Safety Notices

    Knowledge of the following safety notices is a prerequisite for safe and correct handling and trouble-free operation of the Nelweld N1500i. In addition, the technical regulations for safe and professional working as well as the generally valid accident prevention regulations have to be observed.
  • Page 20 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Apprentices or personnel receiving on the job training may: • only work with the welding unit under supervision of an experienced person Personal protection equipment (PSA): Welding spatter, arcs and a noise level of 75dB. Consequently, the wearing of the...
  • Page 21 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 A guarantee must be given that a fire extinguisher is to hand at the workplace. Ensure that the workplace is sufficiently ventilated and adequately lit. Symbol Meaning Only weld in rooms/areas, in which no additional hazards due to fire, explosion or moisture can occur.
  • Page 22 Manual part number: BE 1221 Warning! In keeping with standard EN 60974-10 the welding unit N1500i is suited for use in an industrial environment (limit class A). We expressly point out that units of limit class A can cause radio...
  • Page 23 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 • Inform the plant/system personnel about the duration of the malfunction • Secure the welding unit against unintentional restart-up Warning! • Opening the welding unit as well as a work inside the casing may only be carried out by authorized electrical specialists.

  • Page 24: Intended Use

    Observation of the following points falls under intended use: • The N1500i is designed for welding studs according to the drawn-arc and the short-cycle welding methods. • The specifications in these operating instructions with regard to material combinations and the particularities of studs and ceramic ferrules have to be observed.

  • Page 25: Guarantee And Liability

    Alterations to the Nelweld N1500i not authorized by the manufacturer are forbidden. • The Nelweld N1500i is only to be operated with the plant com- ponents listed in. It is not permitted to configure the equipment with that of other manufacturers.

  • Page 26: Use Of Original Nelson Spare Parts

    • Repair by unqualified personnel • Arbitrary structural alterations to the system • Non-observance of the stipulated maintenance intervals The Nelwled N1500i welding unit is only designed for the range of applications, which is specified in on “Intended use”. Note!
  • Page 27 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 The contents of the documentation are protected by copyright. They contain texts and technical drawings that may neither be completely nor partly reproduced or used for competitive purposes or made accessible to third parties without prior authorization.

  • Page 28: Delivery And Transport

    3.5 Storage If the welding unit is not operated immediately after delivery, it must be put into intermediate storage in a secure place. To this end the Nel- weld N1500i has to be sufficiently protected against impurity and moisture. 3.6 Transport In order to avoid damage to the welding unit, the N1500i may only be transported by Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.

  • Page 29: Operating Location

    Seek the assistance of at least one other person when moving or lifting the unit. 3.7 Operating Location The operating location of the N1500i welding unit is restricted to areas of industrial and trading nature. Welding can cause radio interference in residential and commercial areas.
  • Page 30 Manual part number: BE 1221 Warning! In keeping with standard EN 60974-10 the welding unit N1500i is sui- ted for use in an industrial environment (limit class A). We expressely point out that units of limit class A can cause radio interference in residential and commercial areas! Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.

  • Page 31: Connection And Installation

    The load-carrying capacity of the floor space should be at least double the weight of the welding unit. When working in high-lying locations, such as bridges, ladders or plat- forms the N1500i must be secured against the risk of falling.
  • Page 32 Gas connection input Mains cable connection Warning! Prior to any connection work the Nelweld N1500i welding unit must be switched off. The mains switch of the unit must be in the >>0<< position! Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
  • Page 33 Manual part number: BE 1221 4.2.1 Connection of the Input Voltage Before the Nelweld N1500i welding unit is connected to the supply voltage the following connecting criteria must be observed. • The CEE plug of the input power cable may only be connected to appropriately designed input power socket outlets •...
  • Page 34 Symbol Connection 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. It must be noted that procedurally safe operation of the system can only be guaranteed when NS 40-B or NS 40 SL guns are connected.
  • Page 35 The welding current return takes place via the earth ground cable, which must be connected as follows to the earth ground cable socket of the Nelweld N1500i. Earth Ground Cable Connection (X3) Connect the earth ground cable plug into the proper socket of the Nel- weld N1500i.
  • Page 36 Manual part number: BE 1221 4.2.5 Connection of the shielding gas Prerequisites: • The Nelweld N1500i has an optional shielding gase valve combination kit that can be factory or feild installed. • The connected weld gun has already been equipped with the optional special equipment for shielding gas.

  • Page 37: Arc Blowing Effect

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Warning! Prior to commencing work the shielding gas tubes must be checked for leaks! 4.2.6 Connection of the workpiece As standard, the earth ground cable is equipped with two earth ground terminals which have to be connected to the workpiece.
  • Page 38 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Magnetic blowing effect: • Deviation of the arc as a result of the influence of magnetic or electromagnetic fields. The possibilities of reducing the thermal blowing effect are limited. They are restricted to precise centering of the stud and chuck.
  • Page 39 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Note! • The polarity in the illustration refers to ferromagnetic materials. When welding aluminum attention must be paid to reverse polarity • More remedial measures can be found to the standard EN ISO 14555.

  • Page 40: Connection Diagram Short-Cycle And Drawn Arc Welding

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 4.4 Connection Diagram Short-Cycle and Drawn Arc Welding 63A CEE connector Mains connection Note: This is a general 400V AC / 50Hz connection diagram and is to be used along with...

  • Page 41: Connection Diagram Shielding Gas

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 4.5 Connection Diagram Shielding Gas Note: This is a general connection diagram and is to be used along 63A CEE connector with previous connection instruc- tions as connector locations will...

  • Page 42: Additional Cautions

    4.6 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 43 • A power cord is provided and wired into the machine. Follow the power cord connection instructions. TROUBLESHOOTING WITH COVER OFF • Do not remove plexiglass. Unlike other welders, N1500i heat- sinks have HIGH VOLTAGE. Caution! Incorrect connection may result in equipment damage!

  • Page 44: Control And Display Elements

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Control and Display Elements 5.1 Front Panel Controls and Displays Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...
  • Page 45 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Pos. Designation Description Time/Current Mode Enables Time/Current weld parameter selection Setup selection by stud diameter and other Stud Expert Mode process parameter such as weld position Function Mode...
  • Page 46 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Weld Tool Icon glows green when Gun Coil button is pressed Green = Energized Red (Flashing) = Undetected Trigger Detect Weld Cycle Detect Contact Detect (Green or Red)

  • Page 47: Operation

    9. Always lay out the welding and earth cable without any snarls. Electromagnetic influences can thus be largely avoided. 10. Check the settings of the N1500i welding unit and of the connected gun that you require for the welding task.

  • Page 48: Basic Procedure

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Note! If welding on one workpiece with several welding units cannot be avoided, it is not recommended to weld simultaneously 6.2 Basic Procedure The process to begin welding using a Nelweld unit is very easy, once the proper electrical connections and gun connections are established: •...
  • Page 49 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.3.1 Setting Current and Reading the Current Display The current setting is the current setting during a weld, and can be viewed in the front panel’s upper display. It can be changed using Up/ Down arrow keys to the right of the current display in one (1) amp increments.
  • Page 50 5. Check input voltage from unit control panel using F18 and read capacitor voltage. 6. If the lift capability is marginal, i.e. it lifts a low lift height, but fails to lift at slightly higher lift height, consult your Nelson Rep. 6.3.4 Calibrate the gun drop time F31 It is recommended to calibrate the gun so that the welder understands the gun drop time and delivers the precise main arc time programmed.
  • Page 51 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.3.5 Weld Parameter Presets The power source has ten available preset configurations. Each of the- se is assigned a time and current setting for commonly welded stud sizes. To select a preset, simply press key 1, 2, 3, 4, 5, 6, 7, 8, 9, 0.
  • Page 52 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Note! The weld parameters in the tables and in Stud Expert are provided as is, without warranty of any kind, either expressed or implied, including, but not limited to, the implied warranties of merchantability and fitness for a particular application.
  • Page 53 SC-Studs [6.0 M6] 7 mm 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. If the unit reaches an abnormally high temperature, a failsafe thermal sensor will protect the unit and display E011.
  • Page 54 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Factory Preset Weld Settings (Drawn Arc) ∅ Preset Nelson Stud Type Stud Size Current (Amps) Time (MS) IS-Studs 3 mm IS-Studs 4 mm IS-Studs 5 mm SD6, MR M8, S6...
  • Page 55 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Drawn arc stud 3/4” 1500 Drawn arc stud 3/4” 1500 • Preset bank 2 is loaded (such that presets 0-9 are as described above) when in short cycle mode.
  • Page 56 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.3.8 Parameters for short - cycle procedure Note! The following parameters are only starting points (guide values) which must be adjusted to specific application conditions (base material, work piece surface condition, weld position, gun type, weld circuit inductance and grounding etc.).
  • Page 57 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.3.9 Parameter for drawn - arc procedure Drawn Arc Welding Time Lift Plunge Diameter ∅ Stud Type Current (A) Lift (mm) Plunge (mm) Welds/min (msec) (mm) (mm)
  • Page 58 English, only diameters in inches are available. If unit is set to both, then both will be available for selection. • In the case of the N1500i, studs requiring >800A will not appear in the list for selection.
  • Page 59 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Process standard standard aluminium aluminium 4mm SC-Bolzen M4 500, 500, Short Cycle 5mm Pitch Base 290, 140, 150, 240, Drawn Arc 5mm Full Base 320, 160, 170,...
  • Page 60 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 1standard tstandard 1aluminium taluminium Process 8mm SC-Bolzen M8 700, 700, Short Cycle 8mm WTOP M8 1250, 1250, Short Cycle 8mm ATC M8 920, 920, Short Cycle 3/8" Pitch Base...
  • Page 61 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Process standard standard aluminium aluminium 1/2" Full Base 840, 480, 450, 890, Drawn Arc 1/2” Pulse 450, 850, 450, 850, Drawn Arc 13mm Pitch Base 750, 420,...

  • Page 62: Rating Charts

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 • Pull and hold down the trigger. The gun will lift and release for the programmed weld time. (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.
  • Page 63 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Check with Nelson representative for a Weld Cable Length calculator 6.4.2 Energy Consumption Inverters can realize significent electricity saving over its life time. Use the following online calculator to compute the savings: http://www.nelsonstud.com/calcutator/energy.html...
  • Page 64 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 400-460 Vac Up To X feet (M) AWG Cable (mm2) 60 (18.288) 10 (6) 100 (30.48) 8 (10) 190 (57.912) 6 (13.3) 300 (91.44) 4 (21.2) 480 (146.304) 2 (33.6)

  • Page 65: N1500I Weld Cycle Timing

    Here are the relevant settings for welding on the N1500i: • F31 – Drop time. Use this function to measure \ configure the drop time of the gun.
  • Page 66 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 The Actual Weld Time is the time from the start of the main current to the time that the stud hits the workpiece. Under normal conditions, it will be equivalent to the Front Panel Time.
  • Page 67 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...

  • Page 68: Drop Time Variables

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Since [20ms – 30ms] < 0, the, the gun coil is released prior to starting the main current. So the weld profile would look like this: Main current time...

  • Page 69: Inspection And Testing Of The Weld

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Temperature: As temperatures rise, dampeners have less of an impact. They allow the stud to fall nearly 65% faster at 90 degrees F than at 0 degrees F.
  • Page 70 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 welded and the following tests carried out on them: • Visual inspection (all studs • Bending test (5 studs) • Macro section (2 studs) The test results must be documented and attached to the quality docu- mentation.
  • Page 71 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 technological tests would go beyond the scope of these operating and service instructions. See EN ISO 145551 for detailed information in this regard. Image Descriptipn 1. Perfect weld Even flash weld ring, no perceptible errors.
  • Page 72 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.7.2 “Drawn-arc-method“ - Visual inspection Inspection and testing of the weld is restricted in these operating and service instructions to the visual inspection of welds. A description of the mechanical and technological tests would go beyond the scope of these operating and service instructions.

  • Page 73: 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.
  • Page 74 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 To clear a target stored in a preset, exit F mode by selecting I\t mode, then press both the Lock button and the desired preset button simultaneously.
  • Page 75 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Use: The unit is now locked and ready to weld. When a weld is out of tolerance, the unit will flash the red triangle icon and display 'WELD ERROR - ENTER PASSWORD'.

  • Page 76: Plunge Current

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 This is a medium level security mode, whereby the user must select a Lock Mode 4: password to lock the unit. Changes may be made to the weld settings by use of the presets and by adjusting the time / current by a predetermined range.
  • Page 77 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 The same weld made with standard method (plunge current is the same as the main arc current) is shown below for comparison: F46 = OFF (Disabled) By default plunge current is disabled. *Patent Pending...

  • Page 78: Pulse Welding (In Main Current)

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.10 Pulse Welding (in main current) The welder normally welds with a constant DC current during main arc. For some applications, it is desirable to pulse the main current. Potential benefits are the ability...

  • Page 79: Pulse Cleaning (During The Beginning Of Main Arc Stage)

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.11 Pulse Cleaning (during the beginning of main arc stage) The welder normally outputs a constant low current in pilot arc to draw an arc before turning on the main arc for welding. In some applications, it is desirable to have very high and narrow pulses in the beginning of main arc stage before engaging full main arc.

  • Page 80: Password Reset

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.12 Password Reset If the password is forgotten, it can be reset or removed. Turn the power off, press and hold the F key and the Time-Down key, and turn the power back on. Keep the keys pressed until the display reads 'OK'.

  • Page 81: Chuck Change Indicator

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.16 Chuck Change Indicator A user programmable weld counter counts down and turns the chuck change indicator ON when it reaches zero. Refer to F29 code in Section 4 Operation Fuction Codes and Error Codes.

  • Page 82: F Code F61 - Pulse Cleaning Contaminant To Be Cleaned

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 6.18 F Code F61 - Pulse Cleaning Contaminant to be Cleaned F61 has possible values of Zinc or Galvanized to Primer Paint, Oil or Oxide. The default value is set to Primer Paint. This function is used to designate how the pulse cleaning function will determine to abort pulsing and begin the main arc.

  • Page 83: Function Codes

    As of: June 06.2012 Manual part number: BE 1221 Function Codes NOTE! Contact the factory or Nelson representative if F25 shows a different version for F code info not in the table below. The table below is for firmware version 1.05 only Description...
  • Page 84 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes Stud Expert Mode DOWNHAND, DOWN position VERTICAL, HAND Stud Expert Mode MILD STEEL, MILD material STAINLESS, STEEL Stud Expert Mode...
  • Page 85 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes NORMAL Stud feed normal NORMAL This only applies when stud feed is enabled. CLOSED, NOR- le- vel OPEN MAL OPEN...
  • Page 86 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes Mode 1: Use the lock key to toggle blocking on all keys - no password protec- tion. Mode 2: Use the lock key to enter a password, lock key as ‘enter’. From there, all keys are blocked until you press lock again.
  • Page 87 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes Lets user select which units are dis- played as stud sizes while in F24 Stud Expert Mode English, Metric oder English Stud Ex- pert mode.
  • Page 88 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes This is a drop time measurement func- tion THAT DOES AN ACTUAL WELD. If F48 (Drop Time Configurati- on) is in either Manual or Auto mode, the measurement taken during the weld (while viewing this function) will be stored in this function and used in weld timing.
  • Page 89 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes Turn this on to disable welding when a weld is out of specified weld F33 Disable Welding on energy/ drop range. Flashes ‘WELD ERROR!’ and requires a password...
  • Page 90 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes Pulse Cleaning Time Time to remove from the main weld time per pulse done prior to the to Subtract for Each 0 to 500 weld.
  • Page 91 Amps the plunge state. MAX_CURRENT will depend on the power unit model (N1500i or N800i) and power input (3 phase or single phase) In Manual mode, F31 (drop time func- tion) is the only way to configure the drop time. In Auto mode, F31 automa- tically gets a new value taken...
  • Page 92 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes F52 Pulse Weld Low 1000 This is the time the weld will deliver the low current (F50 current). Time Enable this to continue delivering weld current beyond the time settings...
  • Page 93 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes F58 Keep Gun Lift En- Keeps the lifted after the weld for 5 se- conds for the purpose of OFF ON able troubleshoo- ting applications.
  • Page 94 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 code Description Possible Values Default Unit Notes For automated systems, select the ap- propriate fieldbus selection to OFF, Van Rob, F64 Fieldbus Selection deter- mine the IO map and sequence of signals. For standard mode, Ford, GM disable this F code.

  • Page 95: Error Codes

    Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Error Codes Fatal – meaning you have to power down Error Number Error Display What this really means to reset. Otherwise, Likely problem you weld again to reset.
  • Page 96 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Fatal – meaning you have to power down Error Number Error Display What this really means to reset. Otherwise, Likely problem you weld again to reset. The control sensed that the...
  • Page 97 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Fatal – meaning you have to power down Error Number Error Display What this really means to reset. Otherwise, Likely problem you weld again to reset. The thermal sensor was...
  • Page 98 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Fatal – meaning you have to power down Error Number Error Display What this really means to reset. Otherwise, Likely problem you weld again to reset. If the unit is delivering 95%...
  • Page 99 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Fatal – meaning you have to power down Error Number Error Display What this really means to reset. Otherwise, Likely problem you weld again to reset. The configurations of the...
  • Page 100 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 7.1.1 Notes on which F codes change automatically 4-Wire Gun Interfaces F2 - Plunge F30 - Short weld weld Action Result F31 - Drop TIme Short Circuit...

  • Page 101: Weld Process Problems

    Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Weld Process Problems Problem Possible Cause Solution Check the stud burn-off. If the burn-off is much greater than what is typical for that Time setting or diameter stud, the time and current settings may not be correct. Consult Section 2.6 current setting is too to ensure proper current and time settings are being used.
  • Page 102 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Problem Possible Cause Solution Check the stud burn-off. If the burn-off is much less than what is typical for that Time setting or current diameter stud, the time and current settings may not be correct. Consult Section 2.6 setting is too low.
  • Page 103 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Problem Possible Cause Solution ® Plunge dampening is If the gun is a Heavy Duty gun, it is equipped with Tranquil Arc . Screw in the clear plastic too little.
  • Page 104 Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 Contamination of the base plate or stud may cause the arc to become erratic. Ensure that Base material the- re is no rust, scale, oil, water, residue, paint, galvanization, etc. present between the contamination.

  • Page 105: Maintenance

    • Neither aggressive or alcoholic agents nor combustible liquids may be used for the cleaning work. • The unit casing of the Nelweld N1500i must be wiped down with a dry cloth. Type plate and safety advice must be very legible.

  • Page 106: Routine Maintenance

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Warning! Opening the welding unit as well cleaning inside the unit may only be carried out by an authorized electrical specialist! Blowing down the welding unit with air pressure is expressly forbid-...
  • Page 107 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 • Output terminals Examine capacitors for leakage or oozing. Replace boards if needed. 1. Examine the sheet metal case for dents or breakage. Repair the case as required.

  • Page 108: Drawings And Parts Lists

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Drawings and parts lists Explosion drawing Final Assembly N1500i Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...

  • Page 109: Chassis Sub Asm

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 9.1.1 Parts List Final Assembly N1500i Item Part Number Comment Description CHASSIS SUB ASM 750-610-435 USER INTERFACE PCBASM 750-610-083 FRONT PANEL ASM 750-610-433 CENTER, VERTICAL SUB ASM...
  • Page 110 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Item Part Number Comment Description SPACER, 10 X 4.3 X 5MM 729-114-015 MAIN POWER SWITCH 709-256-015 W, Sp WASHER, 4MM LOCK, SS 524-005-303 SPACER, 10 X 4.3 X 50MM 729-114-017 SCREW, M4 X 0.7 X 55MM PHCRMS...
  • Page 111 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Cover Assembly TORQUE NUT TO 4 N-M (35-40 IN-Lbs) 9.2.1 Parts list cover assembly Item Part Number Comment Description 729-114-001 HANDLE ASSEMBLY 750-610-245 COVER, CE 524-005-147 WASHER, M10...
  • Page 112 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 Chassis Sub ASM Note! Rotate strain relief 30 degrees clockwise to have access to the screws Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...
  • Page 113 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 9.3.1 Parts list chassis sub ASM Item Part Number Comment Description 750-610-321 CHASSIS 717-512-013 W, Sp 86-44-38 STRAIN RELIEF 524-005-292 SCREW, M4 X 70 PHMS, SS 729-022-008...

  • Page 114: Front Panel Assembly

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 9.4 Front panel assembly Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...
  • Page 115 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 9.4.1 Parts list Front front assembly Item Part Number Comment Description 750-610-343 FRONT CONNECTOR PANEL 750-610-327 BUSS TERMINAL GUN 750-610-326 BUSS TERMINAL WORK HARNESS TRIGGER CONN. 4 WIRE...

  • Page 116: Horizontal Panel Assembly

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 9.5 Horizontal panel assembly Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...
  • Page 117 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 9.5.1 Parts list Horizontal panels assembly Item Part Number Comment Description 750-610-347 HORIZONTAL CHASSIS 750-610-233 3 PHASE BRIDGE SUPPORT PLATE 750-610-022 INPUT PCB ASM 66-08-80 FILTER ASM...

  • Page 118: Vertical Panel Sub Assembly

    Stud welding unit N1500i As of: June 06.2012 Manual part number: BE 1221 9.6 Vertical panel sub assembly Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...
  • Page 119 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 9.6.1 Parts list Vertical panel sub assembly Item Part Number Comment Description 750-610-206 VERTICAL CHASSIS 750-610-033 OUTPUT RECTIFIER PCB ASM, POHS 750-610-062 PILOT ARC PCB ASM, ROHS...

  • Page 120: Troubleshooting

    10.Troubleshooting 10.1 How to use Troubleshooting guide Warning! Service and Repair should only be performed by Nelson Factory Trained Personnel. Unauthorized repairs performed on this equipment my 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.
  • Page 121 Manual part number: BE 1221 Note! If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Nelson Authorized Field Service Facility. Replace Plexiglas after service! Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...

  • Page 122: Problems / Possible Cause / Solution

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.2 Problems / Possible Cause / Solution Problems Possible Cause Solution Major physical or • Contact your local authorized electrical damage is evident when the Nelson Field Service Facility for...

  • Page 123: Welding Problems

    As of: Aug 12.2021 Manual part number: BE 1221 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 124 Opening the welding unit as well as work inside the casing may only be carried out by authorized electrical specialists! Prior to any work on the N1500i the welding unit must be switched off. The master switch of the welding unit must be in the „0“ position! 10.3.1 E001 Shorted Control Cable-Fix Control Cable and/or...
  • Page 125 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.2 E002 Primary Voltage Dip too Low-Check Primary Voltage Primary Voltage Dip Too Low E002 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 126 If the voltage is dipping, check the primary and secondary of the aux transformer while at idle and during weld. If the primary is dipping, move N1500i to a stiffer supply. If the secondary is dip- ping but primary is not, replace aux transformer. If neither dips, replace power supply board.
  • Page 127 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.3 E003 Capacitor Voltage Imbalance Capacitor Voltage Imbalance E003 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 128 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.4 E004 Regulation Error-Arc Went Out Regulation Error- Arc Went Out E004 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 129 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.5 E005 Regulation Error - Short circuit Regulation Error- Short E005 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 130 (>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. The system must be powered down and examined/ fixed prior to anything else.
  • Page 131 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 from there. You'll have to get past this error to tune the voltage readings correctly, which will involve some power down/up cycles. 3. Broken connection from control board to the switch board in V-F circuit. Check control board JP1 pins 1,9 for one pair, 2, 10 for the other.
  • Page 132 (<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. That is, no welding can be done in this state.
  • Page 133 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 way of the full scale and tune from there. You'll have to get past this error to tune the voltage readings correctly, which will involve some power down/up cycles.
  • Page 134 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.8 E008 Primary Overcurrent Error Primary Overcurrent Error E008 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 135 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.9 E009 Could Not Establish Pilot Arc Could Not Establish Pilot Arc E009 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 136 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.10 E010 Capacitor Voltage Could Not Be Read Capacitor Voltage Could Not Be Read E010 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 137 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.11 E011 Unit Too Hot-Please Wait Unit Too Hot - Please Wait E011 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 138 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.12 E012 Short Circuit-Check Gun Lift Setting Short Circuit- Check Gun Lift Setting E012 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 139 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.13 E013 Weld Failed - Out of Tolerance Weld Failed - Out of Tolerance E013 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 140 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.14 E014Warning-ColdPlunge-StudHitAfterCurrent Shut Off Cold Plunge - Stud Hit After Current E014 Was Shut Off Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 141 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.15 E015 Warning - Near Maximum Welding Output Capacity Warning - Near Maximum Welding E015 Output Capacity Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 142 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.16 E016 Warning - Check Weld Cables and Connectors - Press lock to clear Warning - Check Weld Cables and E016 Connectors Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 143 Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.3.17 E017 Warning - Pilot Blew Out Warning - Pilot Blew Out E017 Fatal, meaning you have to power down to continue welding Acknowledge, meaning the error will exist as long as the unit is powered on.
  • Page 144 2. Switch board is out of calibration 3. Switch board malfunctioned • If lower display reads “CYCLE”, Check Duty Cycle: The N1500I is reated at 9% • If lower display reads “CAP”, Step 1:Check Switch Board Calibration: Switch boards generate a signal rep- resenting the capacitor voltage for the control board.

  • Page 145: Wiring Diagram Nelweld N1500I

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 10.4 Wiring Diagram Nelweld N1500i Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany...

  • Page 146: Annex

    Disposal of the Nelweld N1500i Disposal of the Nelweld N1500i in an orderly and as pollution-free as possible manner can be ensured by complying with the measures stated below. You are thus making an important contribution towards environmental protection and waste management.

  • Page 147: Disposal In Accordance With The European Directive

    11.2 Disposal in accordance with the European directive 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.
  • Page 148 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 environ- mentally-compatible disposal of its units and system components against payment of a fee.

  • Page 149: Abbreviations

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 11.3 Abbreviations The abbreviations used in this documentation in alphabetical order: AlMg Aluminum- Magnesium alloy AF type of cooling Fan (forced-air cooling) Ceramic ferrule Chromium German Standards Institute...

  • Page 150: Literature

    Stud welding unit N1500i As of: Aug 12.2021 Manual part number: BE 1221 11.4 Literature ISO/TR 15608: Welding - Guidelines for a metallic material grouping system (2000) EN 60529: Degrees of protection provided by enclosures (IP-Code) (2000) EN 60974-1: Arc welding equipment...

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