Nelson N1500i Operating Manual Download

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Part No. 729-110-053 V.1.03

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. .

Summary of Contents for N1500i

Page 1: ...les 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 o...

Page 2: ...ed Nelson s personnel 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...

Page 3: ...rk area to make 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...

Page 4: ...el is high 2 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...

Page 5: ...erator Sizing 15 2 FACS Dot Matrix User Interface 16 3 Operation 18 3 1 Advice on Stud Welding 18 3 2 Basic Procedure 19 3 3 Weld Parameters 20 3 3 1 Setting Current and Reading the Current Display 20...

Page 6: ...ance 53 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...

Page 7: ...008 Primary Overcurrent Error 76 8 3 9 E009 Could Not Establish Pilot Arc 76 8 3 10 E010 Capacitor Voltage Could Not Be Read 77 8 3 11 E011 Unit Too Hot Please Wait 77 8 3 12 E012 Short Circuit Check...

Page 8: ...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 In ord...

Page 9: ...hts reserved 1 Welding cable connection X2 3 Control cable connection X1 2 Welding cable connection X3 4 Input power cable connection Warning Prior to any connection work the Nelweld N1500i welding un...

Page 10: ...by the reconnect terminal blocks internally The 575V unit cannot be configured this way See rating plate on the back of the unit 1 2 2 Single Phase Connections Connect to L1 and L3 of the input line s...

Page 11: ...r 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 Make sure unit is disconnected fro...

Page 12: ...2018 Nelson Stud Welding Inc All rights reserved Voltage Connect Section 575V Not Shown Jumper Lead 460 VAC Connection 230 VAC Connection Jumper is installed between 1 and 2 on large terminal block s...

Page 13: ...g cable socket of the N1500i The connection must be secured by a full clockwise turn of the welding cable plug 1 2 5 Connection of the Control Cable The female control cable socket acceptsthe malecont...

Page 14: ...e ground cable socket of the Nelweld N1500i Workpiece Weld Cable Connection X3 Use cable resistance monitor see section 3 15 to continuously monitor loose connector fault condition in production 1 2 7...

Page 15: ...the coupler plug to lock it into place Connection of the gun The tubing system to the weld gun or to the feeder must be connected to the coupler socket The tubing system with coupler plug optional mus...

Page 16: ...s pipelines etc may not be used as current conductors unless they are themselves the workpiece to be welded 2 The welding workpiece may or may not be connected to earth ground This will vary with the...

Page 17: ...ect strive for precise centering of the stud and chuck Several remedial measures are available to reduce the magnetic blowing effect some of which are indicated below The polarity in the illustration...

Page 20: ...lter the unit from rain and snow Do not place on wet ground or in puddles STACKING N1500i cannot be stacked TILTING Place the machine directly on a secure level surface or on a recommended undercarria...

Page 21: ...60 30 94 75 30 7 5 575 25 75 75 24 7 5 Output on 3 phase input Duty 6 9 12 100 Amps 150 0 1200 1000 120 Volts 38 38 38 38 Input Volts Slow Blow Fuse lph Max kVA max lph eff kVA eff 1 Phase 50 60Hz Ele...

Page 22: ...Economy 1500A For 1500A weld current using less than 25ft 4 0 weld cable Use a bare minimum 68kW 85kVA generator with at least 1 5 regulation from no load to full load and less than 5 THD waveform di...

Page 24: ...panel settings See F19 in Section 4 1 6 Preset Values Factory presets or storage of custom values 7 On Off Power Switch The main switch controls the input power to the ma chine 8 Weld Time Stud Expert...

Page 25: ...hould be stationary and free of vibration particularly important in case of large and thin walledworkpieces 6 Chlorous solvents must be removed from the welding zone They may not be exposed to the arc...

Page 26: ...n buttons 8 to adjust time and current discretely 4 Push Stud Expert TM Mode button 9 in the Front Panel section and up down buttons 8 to adjust stud diameter and weld position or another process cond...

Page 27: ...mended to perform a gun calibration to set the F31 value and check the physical condition of the gun for any possible cause which could have prevented a normal drop If the actual weld time is much les...

Page 28: ...plunge distance parameters These mechanical parameters must be set on the connected NS40 or Light Duty drawn arc gun See the operating instructions of the corresponding weld gun for the settings See...

Page 29: ...ing before a weld tM in F32 tD in F32 After calibration tM in F32 should be fairly close to front panel time within a few milliseconds If not then something in your gun fastener or elsewhere in the pr...

Page 30: ...weld parameters will be determined with proper attention to factors such as the material and surface quality of the workpiece plate thickness welding position stud type stud dimensions etc in trial we...

Page 31: ...Type Stud Diameter mm Current Amps Time ms IS Studs 3 200 150 IS Studs 4 280 200 IS Studs 5 350 230 SD6 MR M8 S6 6 410 250 MP F M8 7 470 300 MR M10 S8 8 550 300 MP F M10 9 650 300 SD10 MR M12 S10 10 7...

Page 32: ...3 16 5mm 300 15 062 125 1 4 6mm 400 17 062 125 5 16 8mm 450 25 062 125 3 8 10mm 500 33 062 125 7 16 11mm 625 42 062 125 1 2 13mm 750 55 062 125 5 8 16mm 1100 67 093 187 3 4 19mm 1400 84 093 187 3 4 19...

Page 33: ...ble is programmed into the welder control system It provides automatic weld settings based on stud type and diameter Thereareconditionsthatwillfilterthetableforselection orrevealonlya subset ofthetabl...

Page 34: ...Base 390 200 210 340 Drawn Arc 7mm Full Base 430 230 230 390 Drawn Arc 7mm MP F M8 470 300 470 300 Drawn Arc 5 16 Pitch Base 440 230 240 390 Drawn Arc 5 16 Full Base 490 260 270 450 Drawn Arc 5 16 Pu...

Page 35: ...0 770 Drawn Arc 13mm Full Base 860 500 460 920 Drawn Arc If the vertical position is selected selection of some studs will provide a 10 increase in current and 15 reduction of weld time from the value...

Page 36: ...ACS Manual 29 Part No 729 110 053 V 1 03 2018 Nelson Stud Welding Inc All rights reserved 3 4 Rating Charts 3 4 1 Maximum Weld Cable Length Check with Nelson representative for a weld cable length cal...

Page 37: ...rated output at 200 400 VAC input higher 3 4 3 Energy Consumption Inverters can realize significant electricity saving over its life time Use the following online calculator to compute the savings ht...

Page 38: ...57 912 6 13 3 300 91 44 4 21 2 480 146 304 2 33 6 Based on 3 drop and max 7 below nominal at input power connection during weld The same guideline applies to power drops from the input power high cur...

Page 39: ...d The gun will lift and drop but no weld current will pass The gun s drop time ismeasured stored displayed and used in weld timing as will be described later in this document F2 Plunge short circuit o...

Page 40: ...his time measurement is reported after the weld is complete For example Front Panel Time 50ms Drop Time F31 20ms Plunge short circuit on time F2 50ms The weld profile would look like this The resultin...

Page 41: ...Time to be the same as the Front Panel Time This is done by releasing the gun coil during the pilot arc stage For example Front Panel Time 20ms Drop Time F31 30ms Plunge short circuit on time F2 50ms...

Page 42: ...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 Molten Stud Shape As the stud melts during the weld it has the potential to chang...

Page 43: ...umentation Simplified work testing In order to check the setting and functionality of the unit three studs must be welded prior to beginning the shift and the following tests are to be carried out on...

Page 44: ...ld Even weld flash ring no perceptible errors Corrective measures Not necessary No alteration to the electrical and mechanical parameters 2 Faulty weld Cross section not fully welded Corrective measur...

Page 45: ...rical and mechanical parameters 2 Faulty weld Constriction of the weld stud too long Corrective measures Increase plunge distance check lift check centering of the ceramic ferrule Decrease weld curren...

Page 46: ...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 mus...

Page 47: ...on the display To disable the welder upon a bad weld enable F33 The welder will flash weld error after seeing a NIO weld and no more welding can be performed thereafter until the user enters a passwor...

Page 48: ...out of tolerance the unit will flash the red triangle icon and display WELD ERROR ENTER PASSWORD Enter the password to resume welding Once the password is entered the triangle will still be flashing...

Page 49: ...Do not change F8 Chuck Saver OFF ON ON x F9 Gas Enable OFF ON OFF x F10 Gas Pre flowTime 10 to 2000 500 ms F11 Gas Post flow Time 10 to 2000 500 ms F12 Stud Feed Enable OFF ON OFF x This automatically...

Page 50: ...to 4 3G 0 Welds While in this F code press and hold the time down button to reset the counter F22 Total Counter 0 to 4 3G 0 Welds Non resettable F24 Stud Expert Mode Unit Selection English metric or b...

Page 51: ...eld is out of specified weld energy drop time range Flashes WELD ERROR and requires a password to continue Password is 123456 by default but can be changed to any number up to 9 digits Use lock mode 2...

Page 52: ...0 to MAX_CURRENT 800 Amps This is the current used for as the lower of the two currents during the weld The front panel current setting will be the high current MAX_CURRENT is that maximum current the...

Page 53: ...The difference between the caps is greater than 10 usually around 30V Remove the upgrade to v1 02 software See troubleshooting E004 REGULATION ERROR ARC WENT OUT The control sensed that the current w...

Page 54: ...ar when the sensor resets Thermal sensor on output PCB heatsink has been activated Wait for it to cool down See troubleshooting E012 SHORT CIRCUIT CHECK GUN LIFT SETTING If a short circuit was detecte...

Page 55: ...SHORT CYC LE The configurations of the drop time F31 and the front panel time make it such that the pilot arc supply must be on for more than 40ms The maximum time the pilot arc will stay on is 40ms s...

Page 56: ...the clear plastic plunge dampener housing to decrease the free travel Weld appears cold Time setting or current set ting is too low Check the stud burn off If the burn off is much less than what is ty...

Page 57: ...using to increase the 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...

Page 58: ...be wiped down with a dry cloth Rating plate and safety warnings must be very legible The front plate of the Nelweld N1500i should be cleaned with a mild oil dissolving cleansing agent The LED display...

Page 59: ...re that high voltage parts are protected and correct spacing is maintained All external sheet metal screws must be in place to assure case strength and electrical ground continuity 5 Replace machine c...

Page 61: ...1 100 1 CHASSIS SUB ASSEMBLY 6 724 485 010 2 LABEL ELECTRICAL GROUND ROHS 7 524 005 344 20 SCREW M4 X 8 PHMS BLACK SS 8 524 002 619 20 WASHER 8 LOCK BLACK SS 9 750 651 102 1 VERTICAL MAIN PANEL 1500i...

Page 62: ...Wear part Ssp Stud specific part Item QTY Part Number Comment Description 1 2 729 114 103 Stp HANDLE ASSEMBLY 2 1 750 615 201 Stp COVER 3 1 87 09 35 Stp LABEL CARDIAC PACEMAKER 4 1 724 485 012 Stp LAB...

Page 63: ...part Item QTY Part Number Comment Description 1 1 750 651 110 CHASSIS N1500i FACS 2 1 750 615 206 W Sp FOOT CHASSIS 3 16 524 002 620 SCREW 8 32 X 3 8 THREADFORM 4 1 717 999 013 FAN COOLING 5 4 524 005...

Page 64: ...4 577 014 DECAL DOT MATRIX DISPLAY N1500i FACS 3 1 709 256 015 SWITCH POWER ROTARY 63A N1500i 4 1 724 572 013 LABEL MANUEL WARNING ISO 5 1 750 651 104 FRONT CONNECTOR PANEL DINSE HUBBELL 6 2 714 166 0...

Page 65: ...1500i FACS 2 1 750 615 095 MOUNT PCB FACS 3 6 708 152 000 CARD GUIDE VERTICAL 4 1 750 649 040 PCB FACS GUN LIFT 5 1 750 649 045 PCB FACS INPUT 6 1 750 649 035 PCB FACS WELD OUTPUT A 7 1 750 610 062 PC...

Page 66: ...n 1 1 750 610 054 PCB SWITCHING ASM N1500i ROHS 2 1 750 610 408 MAIN TRANSFORMER SUB ASM 3 1 750 610 034 Sp OUTPUT RECTIFIER PCB ASM POHS 4 1 724 572 015 LABEL RE CONNECT INST N1500i FACS 5 1 750 651...

Page 67: ...Nelson Stud Welding Inc All rights reserved 7 FACS Board Set 7 1 Dot Matrix User Interface Dot Matrix Connections J31 CAN Bus 24V supply J32 CAN Bus 24V supply J33 Address jumper J34 Product variant J...

Page 68: ...ific drivers that interface with power components such as the 1 SCR 3 IGBTs Pilot arc control Charge Discharge 750 649 035 SMPS Output Connections J1 CAN Bus 24V supply J2 CAN Bus 24V supply J3 Addres...

Page 69: ...ights reserved 7 3 Gun Interface Handles trigger and coil 2 4 wire systems 750 649 040 Gun Interface Connections J11 CAN Bus 24V supply J12 CAN Bus 24V supply J13 Address jumper J14 Product Type J15 P...

Page 70: ...utdown mechanism redundant voltage on terminal sensor phase detection capacitor voltage V F slope compensation 750 649 045 Input Sensing Connections J21 CAN Bus 24V supply J22 CAN Bus 24V supply J23 A...

Page 71: ...describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting If the problem is accompanied by a flashing warning symbol see...

Page 72: ...the manual for recommended fuse and breaker size l Welding procedure is drawing too much output cur rent or duty cycle is too high Reduce output current duty cycle or both l There is internal damage t...

Page 73: ...l Are input cables correct size See table 4 3 4 adjustments have been checked and the problem persists contact your local Nelson Authorized The thermal light and fan keep turning on and off l Check t...

Page 74: ...least likely 1 A cable short in the combo cable external to the unit 2 A wiring or switch short in the gun 3 Internal wiring from the gun driver board to the weld output board weldoutput board to the...

Page 75: ...ntrol board with a meter then trace it back through the system components per below Likely items to check in order from most likely to least FACS Input board Switch board s Wiring to the FACS Input bo...

Page 76: ...wer up downarrows to check left and right voltages Likely problems or items to check in order from most likely to least likely Try reducing F2 which gives the most opportunity for delivering current t...

Page 77: ...t up process When the main relay is closed there should be 0V between the two power terminals of the power input relay board If the voltage is higher the input board main relay is not energized Replac...

Page 78: ...goes through a series of relay closures 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 N1500...

Page 79: ...FACS Input board to the switch board in V F circuit Check 750 649 045 FACS Input board J24 pins 14 2 for one pair pins 15 3 for the other 4 If the input voltage measures to be correct and the switch b...

Page 80: ...the normal range for this adjustment to be made As you turn the potentiometer on the switch board to adjust the V F measurement observe F18 on the user interface on both left and right sides to tune...

Page 81: ...Replace the switch boards both 3 Replace the FACS output SMPS boards 8 3 9 E009 Could Not Establish Pilot Arc Fatal meaning you have to power down to continue welding No Acknowledge meaning the error...

Page 82: ...exists No Description The voltage to frequency signals as provided by the switch boards to the FACS input board are not within a window defined by the control board indicating that they are invalid o...

Page 83: ...22VDC while open near 0VDC while closed 3 Scroll on user interface using time up down arrows for other errors that may indicate another problem Measure 20VDC supply on weld output terminals with conn...

Page 84: ...puts Make sure the control can sense the voltage appropriately 4 Replace control board 8 3 12 E013 Weld Failed Out of Tolerance Fatal meaning you have to power down to continue welding No Acknowledge...

Page 85: ...iewing F31 The unit will measure the new drop time and use it in weld timing Increase the short circuit on time F2 This is extra assurance that even with varying gun drop times the current will stay o...

Page 86: ...xist as long as the unit is powered on Note welding can continue while the error exists No Description The Configuration of the drop time F31 and the front panel time make it such that the pilot arc s...

Page 87: ...eded 7 Switch board is out of calibration 8 Switch board malfunctioned If lower display reads CYCLE Check Duty Cycle of the power unit If lower display reads CAP Step 1 Check Switch Board Calibration...

Page 88: ...Manual 83 Part No 729 110 053 V 1 03 2018 Nelson Stud Welding Inc All rights reserved 9 Wiring Diagram Nelweld N1500i For 575 units move the 200 wire add the 203 wire and change the rating plate to PN...

Page 89: ...N1500i FACS Manual 84 Part No 729 110 053 V 1 03 2018 Nelson Stud Welding Inc All rights reserved For 575 units move the 200 wire add the 203 wire and change the rating plate to PN 724 574 000...

Page 90: ...ription 750 610 054 Switchboard A 750 610 055 Switchboard B 709 256 015 Main Power Switch 750 510 022 Input Board 750 610 062 Pilot Arc Board 750 649 065 Dot Matrix User Interface 750 649 035 SMPS Out...

Page 91: ...2731 Phone 909 468 2105 800 635 9353 Fax 909 468 2112 Subsidiaries International England Nelson U K Ltd 47 49 Edison Rd Rabans Lane Industrial Estate Aylesbury HP19 8TE UK Phone 44 1296 433500 Fax 44...

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