Nelson ArcCharger N550C DOMESTIC Operation Manual
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Nelson ArcCharger N550C DOMESTIC Operation Manual

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OPERATING THE
DOMESTIC & EXPORT
Operations Manual
For Software Version 1.03
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. 729-110-040 Rev. 1.41 | June 2016
© 2016 Nelson Stud Welding, Inc. All Rights Reserved.

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Summary of Contents for Nelson ArcCharger N550C DOMESTIC

  • 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. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 2 N550c Arc Charger™ 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 Prevention in Use of Cutting and Welding Processes,” available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 4 Keep all safety devices and cabinet covers in position and in good repair. Use equipment only for its intended purpose. Do not modify it in any manner. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 5: Table Of Contents

    Setting Time & Reading Time Display ................28 5.3.3 Lift Distance & Plunge Distance Diameters ..............28 5.3.4 Calibrate Gun Drop Time F31 ..................28 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 6 Routine Maintenance ....................53 Explosion Drawing Domestic/Export N550c Final Assembly ........54 7.3.1 Parts List N550c Final Assembly .................. 55 Nelweld N550c Wiring Diagram ................58 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 7 Domestic Wiring Diagram ...................58 Export Wiring Diagram ....................58 Domestic Short Cycle Wiring Diagram ................60 Export Short Cycle Wiring Diagram ................62 Contact Information ....................64 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 8: Introduction

    If studs are welded under inert gas, a tapered welding tip is preferred. The tranquil arc plunge dampener option should not be used with this process. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 9: Operational Sequence

     For differing ceramic ferrules, corresponding ceramic ferrule holders are needed. The Nelson Stud Welding catalog offers an overview of the Nelson ceramic ferrule product range. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 10: N550C Arc Charger™ Technical Data

    *Input current is a function of the weld rate, which is largely dependent upon the user application. Adjustments to charge current are described later within this document. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 11: Dimensions

    1.5.1 Dimensions Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 12: Delivery & Transport

    Inspection of Incoming Materials Each Nelson welder is rigorously tested prior to shipment, and includes a copy of the testing protocol. On arrival, the welding unit must be checked for damage as well as for the completeness of the parts within the extent of delivery.

  • Page 13: Transport

    The unit may also tip over causing injury. Lie the unit back down horizontally after transporting if using the wheel kit. Welding Position Transport Position Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 14: Operating Location

    .063″ (1.6 mm) thick, which should extend not less than 5.9″ (150 mm) beyond the equipment on all sides. Incorrect connection may result in equipment damage. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 15: Connection & Installation

    (1 m) to existing heat sources must be observed. Attention must be paid to the fact that the ventilation slits on the unit casing are kept free. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 16: Connection

    Prior to any connection work, the Nelweld N550c Arc Charger welding unit must be switched off. The input power switch of the unit must be in the >>0<< position Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 17: Input Power Connection

    NCD+ circuit boards, particularly when sharing the same work piece. For more information please consult your local Nelson service support. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 18 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 19: Connection Of Welding Cable

    Prior to any connection work, the Arc Charger welding unit must be switched off and the input power switch must be in the >>0<< position. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 20: Connection Of Work Piece

    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. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 21 The polarity in the illustrations provided refers to ferromagnetic materials. When welding aluminum, reverse polarity is normally used. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 22: Short-Cycle & Drawn Arc Welding Connection Diagram

    .063″ (1.6 mm) thick, which should extend not less than 5.9″ (150 mm) beyond the equipment on all sides. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 23 Ensure the capacitors have been discharged prior to working on the power unit. Incorrect connection may result in equipment damage. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 24: Control & Display Elements

    Control & Display Elements Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 25: Front Panel Controls & Displays

    The CURRENT setting is displayed on the front panel UPPER display. It can be changed using the + and – arrow keys to the right of the current display in one (1) amp increments. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 26 Figure 2 Weld Tool Icon Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 27: Operation

    Capacitive Discharge process. 12. Straight polarity (negative stud, positive work) should be used for most stud welding applications. See recommendations for specific applications for exceptions. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 28: Basic Procedure

    This condition may occur when using high currents with small or excessively long weld cables. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 29: Setting Time & Reading Time Display

    If you accidentally recall a preset, F31 value can be changed to the value associated with the preset. Check F31. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 30: Weld Parameter Presets

    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

    5.3.7 Weld Parameters and Settings 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) Stud Size ...

  • Page 32: Stud Expert

    7 mm Pitch Base 0.200 7 mm Full Base 0.230 7 mm MP(F) M8 0.300 5/16" Pitch Base 0.230 5/16" Full Base 0.260 5/16” Pulse 0.400 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 33: Rating Charts

    8 mm MR M10,S8 0.300 5.4 Rating Charts 5.4.1 Maximum Weld Cable Length Check with Nelson representative for a Weld Cable Length calculator. NOTE: Cable lengths described in the chart (Figure 6) assume weld times shown in the chart text. Longer weld times may not...

  • Page 34: Maximum Welding Output Voltage

    5.4.2 Maximum Welding Output Voltage Check with Nelson representative for a Weld Cable Length calculator. Nelweld N550c Rated Output Voltage (Figure 7) is 40V. 5.4.3 Supply Cable Lengths Based on 3% drop and maximum 7% below nominal at mains connection during weld.

  • Page 35: N550C Weld Cycle Timing

    See below. Under normal conditions, critical times and events throughout the main current time can be described in the following weld profile. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 36 For example: Front Panel Time = 20 ms Drop Time (F31) = 30 ms Plunge short circuit on-time (F2) = 100 ms Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 37: Drop Time Variables

    These factors can change the timing of the weld short circuit. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 38: Inspection And Testing Of The Weld

    Bending test (all studs) The test results must be documented and attached to the quality documentation. See the following pages for information on visual inspection Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 39: Short Cycle Method - Visual Inspection

    Corrective measures: Reduce weld time or increase weld current, weld in shielding gas. EN ISO 14555: Welding Arc stud welding of metallic materials (2006) Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 40: Drawn Arc Method - Visual Inspection

    Stud adjust plunge distance and/or damping. too short. EN ISO 14555: Welding Arc stud welding of metallic materials (2006) Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 41: 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. 5.8.2 Setup Good Weld Target To save target without preset association (i.e.

  • Page 42: Operational Function Codes & Error Codes

    Loadbank Enable testing. Lock Mode 1 to 1 Mode 1: Use lock key to toggle blocking on all keys - no password protection. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 43 Pulse Weld High 100 to 800 lower of the two currents during the Current weld. (The front panel current setting will be the high current). Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 44 ESA Mode: Fixed at 75% International Mode: Max 90% * These F Codes will only appear and apply to short cycle power units. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 45: Diagnostic Error Codes

    Low cable inductance. Increase cable inductance, using a longer ground cable (#1AWG, 25 (#722-000- 124) or 2/O AWG, 25 (#722-000-151) combo cables), to eliminate faulty welds. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 46 Incorrect wiring from overtemp thermostat to control board. Inspect wiring. Measure ~22VDC while open, near 0VDC while closed.  Overtemp Thermostat sensor failed. Replace sensor.  Faulty wiring connection. Replace wiring. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 47 Faulty charge IGBT. Replace charge IGBT.  Failure of the control board. Replace control board.  Failure of the power supply board. Replace power supply board. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 48: Additional Warning - Rebooting/Tripping Of Gfci

    Unit will reboot having not charged. This allows the operator to make F67 changes. Once ready, power system down, then back up to charge normally. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 49: Additional Warning - First Charge Is Slow

    Slippage of the foot will lead to a faster drop time. 6. Inspect and clean gun housing and related parts. Replace parts as needed. Debris in the housing will resist travel. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 50: Weld Quality Problems

    Correct the lift to the proper setting if the lift is improperly set. Perform weld inspections as described in Inspection and Testing of the Weld. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 51 Correct the settings and perform weld inspections as described in Inspection and Testing of the Weld. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 52 Go to F31 and perform of position welding, or welding into angle iron. programmed calibration. weld time set- point. No error code displayed. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 53: Maintenance

    Blowing down the welding unit with air pressure is not recommended due to the risk of injury to lungs and eyes. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 54: Routine Maintenance

    760G from Nye Lubricants) to all PCB connectors prior to reconnecting. This forms a corrosion\moisture barrier that will protect the contacts for reliable operations. Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 55: Explosion Drawing Domestic/Export N550C Final Assembly

    Arc Charger N550c Manual | Explosion Drawing Domestic/Export N550c Final Assembly Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 56: Parts List N550C Final Assembly

    SCREW, PHMS, M4 x 16 SS WASHER, FLAT, M4 SS 524-005-120 524-005-344 SCREW, PHMS, M4 x 8 BLACK SS ROD, THREADED, M6 x 210 SS 524-005-345 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 57 NUT, M8 SS 1.5’ TAPE, THERMAL 103-479-000 524-005-356 SCREW, M3 X 10 PHMS SS 524-005-301 WASHER, LOCK, M3, SS PCB ASM, BUS VOLTAGE INDICATOR 750-615-008 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 58 LABEL, TRASH CAN, CE, RoHS 724-577-006 LABEL, CHOPPER DIAGRAM, N550c PCB, ASM, ARC CHARGER AUMOTATED 750-615-021 ACCESSORY 724-485-016 LABEL, TIP OVER HAZARD * Short –cycle units only Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 59: Nelweld N550C Wiring Diagram

    Arc Charger N550c Manual | Nelweld N550c Wiring Diagram Nelweld N550c Wiring Diagram Domestic Wiring Diagram Export Wiring Diagram Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 60 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 61: Domestic Short Cycle Wiring Diagram

    Domestic Short Cycle Wiring Diagram Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 62 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 63: Export Short Cycle Wiring Diagram

    Export Short Cycle Wiring Diagram Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.
  • Page 64 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

  • Page 65: Contact Information

    Phone: 440.329.0400 Italy Fax: 440.329.0597 Nelson Italy World Wide Web: NelsonStudWelding.com Via Miraflores, 20 E-mail: Nelson.Sales@NelsonStud.com Nichelino, (TO) I-10042 Italy Phone:39.011.6059238 Fax: 39.011.6059230 Part No. 729-110-040 Rev. 1.41 | June 2016 © 2016 Nelson Stud Welding, Inc. All Rights Reserved.

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