Stud welding unit N1500i
Version 1.31 7.June.2013
Manual part number: 729-110-027
32
Nelson Stud Welding, Inc. • 7900 West Ridge Road • Elyria, Ohio 44035 • USA
Problem
Possible Cause
Solution
Stud „hangs-up“ during the
weld
Plunge dampening is too
little.
If the gun is a Heavy Duty gun, it is equipped with Tranquil Arc
®
. Screw in the clear plastic plunge dampener
housing to decrease the free travel.
Plunge is too short.
Plunge is measured by the amount of stud protruding beyond the bottom edge of the ferrule. Ensure proper
plunge settings are being used, and correct, if necessary.
Mechanical bind in accesso-
ries or ferrule.
Position the foot or ferrule grip of the gun so that the stud is centered in the ferrule opening. If the stud is off-
center, it can restrict the plunging motion of the stud during welding.
Time setting or current set-
ting is too high.
Check the stud burn-off. If the burn-off is much greater than what is typical for that diameter stud, the time and
current settings may not be correct. Ensure proper current and time settings are being used. Correct the settings
and perform weld inspections.
Plunge dampening is too
great.
If the gun is a Heavy Duty gun, it is equipped with Tranquil Arc
®
. Back out the clear plastic plunge dampener
housing 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 and clean the gun.
On Heavy Duty guns, ensure that the weld cable is centered between the legs and does not rub on them.
Base material contaminati-
on.
Contamination of the base plate or stud may cause the arc to become erratic. Ensure that there is no rust, scale,
oil, water, residue, paint, galvanization, etc. present between the stud and the work piece. Welding to a clean
plate can help diagnose if there is any foreign substance on the base material or studs.
Incorrect ferrule.
Ensure that the ferrule being used is the proper ferrule for the stud size and application.
Actual main arc time is dif-
ferent than the programmed
weld time set-point. No er-
ror is displayed.
F31 gun drop time is not ca-
librated against the gun in
use. Go to F31 and perform
calibration. If the welder is
expected to be used for both
short cycle and drawn arc in
production; or be used toge-
ther with guns with and
without plunger dampener,
it is recommened to set F48
to “auto” or “average” to
match the welder and gun
seamlessly.
Short circuit in the middle of a weld, due to low lift height, out of position welding, or welding into angle iron.
Short longer than 100ms will generate E012 error code. If the problem occurs only with long weld cables and/or
small diameter weld cables, upgrade firmware to V1.06 or higher.
