Nelson N1500i Fast Start Manual Download Page 1

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Stud welding unit N1500i
Version 1.31 7.June.2013
Manual part number: 729-110-027

Stud welding unit N1500i

Fast Start Manual

For Control Board Firmware Version 1.06 & Higher

(See Nelson representative for full manual)

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

Summary of Contents for N1500i

Page 1: ...29 110 027 Stud welding unit N1500iTM 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 reser...

Page 2: ...rsonnel a reasonable opportunity to inspect and repair said equipment at buyer s facility or such other location as is mutually agreeable Notice to Nelson must be given within 30 days of such defect o...

Page 3: ...ke certain there are no hot sparks or hot metal which could cause a later fire Use fire watchers when necessary 7 For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cuttin...

Page 4: ...Warn others nearby about noise hazard 3 For additional information refer to OSHA Safety Standards 3074 MOVING PARTS CAN CAUSE INJURY Electric fan can start at any time without warning and cause severe...

Page 5: ...3 Specifications 8 2 Control and Display Elements 9 2 1 Front Panel Controls and Displays 10 2 2 Weld Parameters 12 2 2 1 Setting Current and Reading the Current Display 12 2 2 2 Setting the Time and...

Page 6: ...high lying locations such as bridges ladders or plat forms the N1500i must be secured against the risk of falling The Nelweld N1500i must be adequately protected against the intrusi on of liquids It m...

Page 7: ...1 Welding cable connection X2 4 Gas connection input bottle optional 2 Welding cable connection X3 5 Control cable connection X1 3 Gas connection output gun optional 6 input power cable connection Wa...

Page 8: ...z or 400 460VAC 50 60Hz as configured by the re connect internally The 575V unit can not be configured this way See rating plate on the back of the unit 1 2 2 Single Phase Connections Connect to L1 an...

Page 9: ...is how to change input voltage 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 Make sure unit is disconnect...

Page 10: ...Stud welding unit N1500i Version 1 31 7 June 2013 Manual part number 729 110 027 5 Nelson Stud Welding Inc 7900 West Ridge Road Elyria Ohio 44035 USA Voltage Connect Section 575V Not Shown...

Page 11: ...le plug of the gun to the welding cable socket of the N1500i The connection must be secured by a full turn to the right of the wel ding cable plug 1 2 5 Connection of the Control Cable The control cab...

Page 12: ...monitor see section 3 15 to continuously monitor loose connector fault condition in production 1 2 7 Connection of the workpiece When connecting the earth ground terminals attention must be paid to t...

Page 13: ...3 58 7 3 400 460 30 94 75 30 7 5 575 25 75 75 24 7 5 Output on 3 phase input Duty 6 9 12 100 Amps 1500 1200 1000 120 Volts 38 38 38 38 Input Volts Slow Blow Fuse lph Max kVA max lph eff kVA eff 1 Phas...

Page 14: ...Stud welding unit N1500i Version 1 31 7 June 2013 Manual part number 729 110 027 9 Nelson Stud Welding Inc 7900 West Ridge Road Elyria Ohio 44035 USA 2 Control and Display Ele ments...

Page 15: ...trols the input power to the ma chine Upon powering up the internal control soft ware performs a series of diagnostic tests to ensure correct connection and operation of the power source 8 Weld Time S...

Page 16: ...Inc 7900 West Ridge Road Elyria Ohio 44035 USA Weld Tool Icon Gun Coil Green Energized Red Flashing Undetected No Light Detected but not energized Blue Welding in progress light maybe on longer than...

Page 17: ...means the arc shorted early indicating a potential improper gun lift setup When the display shows WAIT when the trigger is pulled it means the rated duty cycle is exceeded during operation or other f...

Page 18: ...ange are listed at 2mm lift andbelow 2 The plunge also needs to be appropiately set 3 When the E009 error appears the lift andplunge should be reviewed 4 If the error is E004 or E007 it generally mean...

Page 19: ...es in text If the stud shorts before the gun coil is de energized adjust weld energy lift current time so that the stud does not short during the weld If the stud shorts after the weld current is shut...

Page 20: ...ention must be paid to the fact that the trial welds are for the most part equivalent to the real conditions in the current production pro cess In obtaining the best welding result the electrical and...

Page 21: ...00 25 8 SC Studs 6 0 M6 7 mm 700 25 9 SC Studs 6 0 M6 7 mm 700 25 0 SC Studs 6 0 M6 7 mm 700 25 The duty cycle limits for the Nelweld N1500i can be seen in the Stud Weld Rate table below If the duty c...

Page 22: ...awn arc stud 7 16 675 420 6 Drawn arc stud 1 2 800 550 7 Drawn arc stud 5 8 1200 670 8 Drawn arc stud 3 4 1500 840 9 Drawn arc stud 3 4 1500 840 0 Drawn arc stud 3 4 1500 840 Preset bank 2 is loaded s...

Page 23: ...tud Size Current Amps Time msec Lift in Plunge in 1 3 16 5mm 300 15 062 125 2 1 4 6mm 400 17 062 125 3 5 16 8mm 450 25 062 125 4 3 8 10mm 500 33 062 125 5 7 16 11mm 625 42 062 125 6 1 2 13mm 750 55 06...

Page 24: ...t On Time F21 User Counter F25 Software Versions F26 Restore Factory Defaults F30 Short Cycle Mode F31 Drop Time To Toggle Full List Simple List Press and hold the F key until the display reads Full F...

Page 25: ...x F5 Stud Expert Mode Material MILD STEEL STAINLESS STEEL ALUMINUM MILD STEEL x F6 Stud Expert Mode Process STUD WELD STUD WELD x F7 Calibration Values 700 to 850 750 Clock cycles Used by manufacturin...

Page 26: ...rs Mode 3 Same as mode 2 except user can toggle between presets and can not change the value of presets Mode 4 Same as mode 3 except user can vary the time and current by the percentage as set by F57...

Page 27: ...ch F codes change automatically F31 Drop Time 0 to 100 35 ms This is a drop time measurementfunction THAT DOES AN ACTUAL WELD If F48 Drop Time Configuration is in either Manual or Auto mode the measur...

Page 28: ...n the weld is out of tolerance F37 Pulse Cleaning Enable OFF ON OFF X When enabled the weld current will pulse high current and low current before the weld F38 Pulse Cleaning Threshold Voltage 0 00 to...

Page 29: ...state MAX_CURRENT will depend on the power unit model N1500i or N800i and power input 3 phase or single phase F48 Drop Time Configuration Manual Auto or Average Manual X In Manual mode F31 Drop Time F...

Page 30: ...nsidered acceptable If out of tolerance an E016 error will be generated F57 Lock Mode 4 Adjustment Percentage 1 to 20 10 Percentage the user may adjust the front panel time and current from the preset...

Page 31: ...fter the number of pecks is performed When zero pecking is disabled F64 Fieldbus Selection OFF Van Rob Ford GM OFF X For automated systems select the appropriate fieldbus selection to determine the IO...

Page 32: ...OR VOLTAGE IM BALANCE The capacitors could not be balanced for some unknown reason The difference between the caps is greater than 10 usually around 30V Remove the upgrade to v1 02 software See troubl...

Page 33: ...1 UNIT TOO HOT PLEASE WAIT The thermal sensor was tripped This er ror will disappear when the sensor resets Thermal sensor on output PCB heatsink has been ac tivated Wait for it to cool down See troub...

Page 34: ...ESS LOCK TO CLEAR The measured cable connector voltage drop was out of tolerance from the target setting Check the cables and connections Loose connection in weld circuit See troubleshooting E017 PILO...

Page 35: ...es 100ms 5ms Limits Stud Expertstuds Limits presets to 100ms max weld time F30 Short Cycle 1 Drawn Arc Mode OFF 12ms 20ms Metric Values 1000ms Limits Stud Expert studs Limits 100ms presets to 100ms mi...

Page 36: ...great If the gun is a Heavy Duty gun it is equipped with Tranquil Arc Back out the clear plastic plunge dampener housing to decrease the free travel Weld appears cold Time setting or current set ting...

Page 37: ...e free travel Mechanical bind in gun Manually depress chuck adaptor and release Chuck adaptor must return to the full out position rapidly without binding If necessary disassemble and clean thegun On...

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