Nelson N1500i Fast Start Manual
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Nelson N1500i Fast Start Manual

Stud welding unit
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Stud welding unit N1500i
Version 1.31 7.June.2013
Manual part number: 729-110-027
Stud welding unit N1500i
TM
Fast Start Manual
For Control Board Firmware Version 1.06 & Higher
(See Nelson representative for full manual)
Copyright © 2013 Nelson Stud Welding, Inc. All rights reserved.
Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA

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  • Page 1 Fast Start Manual For Control Board Firmware Version 1.06 & Higher (See Nelson representative for full manual) Copyright © 2013 Nelson Stud Welding, Inc. All rights reserved. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 2 INVERTER LIMITED WARRANTY Nelson’s only warranty is that goods being sold will be free from defects in workmanship and material. This warranty is expressly in lieu of other warranties, expressed or implied and whether statutory or otherwise, including any implied warranty of merchantability or fitness for a particular purpose.
  • 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 © 2013 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. © 2013 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 5: Table Of Contents

    3.1 How to Access Full List ................19 3.2 Diagnostic Error Codes ................27 3.2.1 Notes on which F codes change automatically ........30 3.3 Weld Process Problems ................31 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg Germany...

  • Page 6: Connection And Installation

    With the exception of the input power cable all the connecting elements are arranged in a functional manner on the front plate of the N1500i. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 7 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! Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 8: Input Connection

    • Reconnect instructions for selecting the input voltage still applies whether using 1 phase or 3 phase operation. • Isolate and securely tape L2 (red wire). Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 9: Change Input Voltage (Reconnect)

    - Move lead #200 at small aux. block per graphic for desired voltage. - Move jumper and lead # 14 on large terminal block per graphic for desired voltage. (See photo next page.) Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 10 Stud welding unit N1500i Version 1.31 7.June.2013 Manual part number: 729-110-027 Voltage Connect Section *575V Not Shown Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 11: Connection Of The Welding Cable

    Pin 4: Start button of the gun (-) The connection must be secured by “screwing on” the control cable plug! Control Cable Connection (X1) Silver Pin: White Wire Brass Pin: Black Wire Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 12: Connection Of The Ground Cable

    (pipelines, shipbuilding, etc.). 3. Place the earth ground terminals if possible at the same distance from the point of welding when two ground clamps are used. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 13: Specifications

    Operating Temperature: -20 to +40 Degrees C Unit Length: 28in (71cm) Storage Temperature: -40 to +60 Degrees c Width: 10.7in (27cm) Efficiency at rated output: 88% Open - Circuit Voltage: 75V Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 14: Control And Display Elements

    Stud welding unit N1500i Version 1.31 7.June.2013 Manual part number: 729-110-027 2 Control and Display Ele- ments Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 15: Front Panel Controls And Displays

    UPPER display. It can be changed using the + and – arrow keys to the right of the current display in one (1) amp increments. 1. Explanations see next page Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 16 No Light = Detected but not energized Blue - Welding Contact Detect in progress (Green) (light maybe “on” longer than actual weld time Good/Bad Weld for animation) Indicator (Green/Red) Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 17: Weld Parameters

    When this is the case, the display does not chan- ge during or after a weld. However, if an error condition occurs, the Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 18: Lift Distance And Plunge Distance Parameters

    (shock absorber). Simply go to F31, and shoot a stud. The actual gun speed is measured and the actual drop time is saved in F31. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 19: Weld Parameter Presets

    To do so, first select the desired time and current settings using the corresponding Up/Down arrow. Then press and hold the desired preset key for 4 seconds. The preset values Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 20: Recommended Weld Parameters

    Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 21: Weld Parameters And Settings

    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 att- empted, a “Wait” prompt will be displayed. “Wait” will disappear when the unit is ready for another weld.
  • Page 22 Bank 1 is loaded when a 4 - wire gun interface is used. Note: The preset bank may be selected manually using Function Code F44. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 23: Parameters For Short - Cycle Procedure

    Nelweld 1500i 3/16” 0.15 1/4” 0.17 5/16” 0.25 3/8” 10mm 0.33 7/16” 11mm 0.42 1/2” 13mm 0.55 5/8” 16mm 0.67 1100 3/4” 19mm 0.84 1400 Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 24: Operational Function Codes & Error Code

    The inverter will remember the setting during power-down. Please see operators manual for the full F code list. Note: Press and hold F key for at least 8 seconds to show whole F Code List. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 25 NORMAL OPEN AFTER CONTACT BREAK, AFTER CONTACT When to get the signal. This only applies when stud Stud Feed Style AFTER WELD BREAK feed is enabled. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 26 While in this F code, press and hold the time-down Restore Factory Defaults BUTTON DOWN BUTTON button to reset all F codes to default. Scroll Speed 100 to 500 Controls text scrolling speed Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 27 'Lock' key + the desired preset key at the same time. tP=Pilot Time (ms) For the main preset (no preset), use the 'Lock' key + Pass\Fail indicator the time-down arrow key. Cable Resistance (milliohms) Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 28 ABORT code, Capacitor # Phases the power unit is at the maximum output in voltage imbalance, or Duty Cycle and current, PWM AVG will be 100%. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 29 5 to 1000 1000 current (F50 current). Pulse Weld Low Time 5 to 1000 1000 This is the time the weld will deliver the low current. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 30 Press and hold the gun Gun as Remote OFF ON trigger 2 seconds beyond the lift check to increment presets within a preset bank. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 31 0 to 4 Factory use only. Other features: • To enter/exit demo mode, press 1,2, and 3 simultaneously. This will disable welding and flash LEDs. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 32: Diagnostic Error Codes

    On boot-up only, after closing the charge from one or more switch boards. E007 INPUT VOLTAGE TO LOW relay, the caps have 10 seconds to get the proper voltage. -See troubleshooting- Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 33 E014 NO STUD HIT DETECTION clear error. fore the main current is turned off. If it is not detected, this error will occur. -See troubleshooting- Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 34 1 of 3 reasons. WAIT ON UPPER DISPLAY 2. Switch board out of calibration AND CYCLE OR CAP ON -See troubleshooting- 3. Switch board malfunction LOWER DISPLAY Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 35: Notes On Which F Codes Change Automatically

    100ms 1000ms 100ms presets to 100ms min weld time. Mode = OFF English Values) Sud Feed Enable = ON For firmware version 1.06 and higher. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

  • Page 36: Weld Process Problems

    Plunge is measured by the amount of stud protruding beyond the bottom edge of the ferrule. Ensure proper Too much plunge. plunge settings are being used, and correct, if necessary. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...
  • Page 37 F48 to “auto” or “average” to match the welder and gun seamlessly. Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA...

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