Nelson N1500i, Operation And Service Manual

Page 1: ...unit N1500i As of Aug 12 2021 Manual part number BE 1221 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany Stud welding unit N1500i For Control Board Software 1 06 and higher Operation and Se...

Page 2: ...liability 25 2 5 Use of original NELSON spare parts 26 2 6 Copyright 26 3 Delivery and Transport 28 3 1 Extent of delivery 28 3 2 Packing and dispatch 28 3 3 Inspection of incoming materials 28 3 4 In...

Page 3: ...be Cleaned 83 6 19 F Code F62 Gun as Remote 83 6 20 Code F63 Pecker Mode 83 6 21 F Code F64 Fieldbus Selection 83 6 22 F Code F65 Weld Complete 24V Signal 83 7 Function Codes 84 7 1 Error Codes 96 7...

Page 4: ...eration of the Nelweld N1500i welding unit can only be guaranteed with knowledge of the contents of these operating and service instructions In case of difficulty or ambiguity please contact the custo...

Page 5: ...trast to welding units with a thyristor control of the same capacity it was possible to considerably reduce the dimensions and the weight of the Nelweld N1500i The weld currents and weld times require...

Page 6: ...the arc the foreparts of the studs to be welded mostly have an ignition peak of aluminum It is preferable to use ceramic ferrules to protect the weld pool against atmospheric oxidization and contain t...

Page 7: ...distance between the stud and the workpiece The gun coil lifts the stud from the workpiece against the force of the compressed spring When the welding stud is lifted from the workpiece an pilot arc is...

Page 8: ...ons must be observed The weld gun has been set to the studs to be welded in the fac tory The stud type is noted on the type plate of the gun The studs to be welded are specified in chapter 6 3 7 1 6 C...

Page 9: ...on b Restrictions for power transmission c Only for momentary drawn arc procedure d Restrictions for the heat transfer e Up to 10 mm diameter and inert gas Bolt material Basic material ISO TR 15608 Gr...

Page 10: ...nically rolled fine grain structural steel and steel casting of a specified minimum yielding point of 360 N mm ReH 460 N mm Group 2 2 Thermo mechanically rolled fine grain structural steel and steel c...

Page 11: ...ion 400V CE Welding method Drawn arc short cycle and gas arc Input voltage 3 400VAC 10 System frequency 50 60Hz System fusing 63A per phase Output 57kVA No load voltage 75V ON period 6 Weld sequences...

Page 12: ...echnik GmbH Co KG Flurstra e 7 19 58285 Gevelsberg Type of cooling Fan AF Relative air humidity 0 to 50 at 40 Degrees C 0 to 90 at 20 Degrees C Dimensions B x H x T 280mm x 460mm x 780mm Weight 34Kg 4...

Page 13: ...wei Technik GmbH Co KG Flurstra e 7 19 58285 Gevelsberg 1 8 1 Dimensions 82 9 543 780 Front Side Rear Top Stud welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 177 77 280 279 5 38 418...

Page 14: ...der no 67 03 04 Weld guns for automatic supply Weld gun Type PFL 901 complete with accessories see PFL 901 operating instructions Shielding gas device on request Feeder for automatic stud supply speci...

Page 15: ...Stud Welding 1 512 387 006a Mobility Kit Automotive 1 512 387 041 Automatic Stud Feeder Interface Kit 1 512 387 052 NELWARE Software Package 1 512 387 053 Hardware and Fastener Kit 1 512 387 016 Prot...

Page 16: ...70 7 5 67 01 16 50 67 02 08 70 10 67 03 29 50 67 03 30 70 12 5 67 03 41 50 15 67 03 38 50 67 02 58 70 20 67 01 51 50 67 03 32 70 25 67 03 37 50 67 04 62 70 30 67 01 71 50 Composite Cable inclusive con...

Page 17: ...2004 108 EEC The following harmonized European standards have been applied EN 60974 1 Arc welding equipment Part 1 Welding power sources 2005 EN 60974 12 Arc welding equipment Part 12 Coupling devices...

Page 18: ...afety at work and accident prevention regulations and have a training authorizing them to perform stud welding All persons who work with the unit are obliged to read and observe all the operating and...

Page 19: ...ations have to be observed Operating instructions must be kept where the Nelweld unit is used The ability to quickly consult the manual is highly recommended to all Nelweld users Safety signs stickers...

Page 20: ...as per DIN 4841 Part 4 Helmet as per EN 397 in case of overhead welding Ear protection plugs muffs as per DIN EN 352 is recommended In order to prevent back injury do not attempt to lift the Nelweld u...

Page 21: ...ic data carriers memories Magnetize and damage watches Potentially fatal for people with cardiac pacemakers Attention must be paid to the fact that the welding and earth cable are laid as close togeth...

Page 22: ...quired to reduce emitted interference for a secure fit of the supply tube system on the screwed in connection Warning During welding certain exposed parts of the weld gun such as the stud and the chuc...

Page 23: ...cal danger Increased electrical danger is to hand particularly when working In confined spaces with electrically conductive walls In wet damp extremely dry and hot rooms with restricted freedom of mov...

Page 24: ...eather e g rain with the N1500i should not be welded outdoors Wet equipment must dry out before use Operators must always use dry insulation between themselves and the welding equipment 2 3 Intended u...

Page 25: ...ther manufacturers Furthermore the observance of the general and particular safety advice in these operating and service instructions as well as relevant accident prevention regulations BGV D11 BGR 50...

Page 26: ...ulated maintenance intervals The Nelwled N1500i welding unit is only designed for the range of applications which is specified in on Intended use Note Before the Nelwled N1500i welding unit is used ou...

Page 27: ...entation are protected by copyright They contain texts and technical drawings that may neither be completely nor partly reproduced or used for competitive purposes or made accessible to third parties...

Page 28: ...val the welding unit has to be checked for damage as well as for the completeness of the parts within the extent of delivery Any possible transport damage and or missing parts have to be immediately m...

Page 29: ...influence upon the welding result To protect people not involved the operating location must be amply cordoned off and clearly marked with warning and informatory signs Inflammable and explosive mater...

Page 30: ...of Aug 12 2021 Manual part number BE 1221 Warning In keeping with standard EN 60974 10 the welding unit N1500i is sui ted for use in an industrial environment limit class A We expressely point out tha...

Page 31: ...n lines should be installed as far as possible without loops The Nelweld N1500i must be adequately protected against the intrusion of liquids It may not be installed on liquid bearing pipelines In ord...

Page 32: ...ignation Description 1 X1 Control cable connection 2 X2 Welding cable connection 3 X3 Welding cable connection 4 Gun Gas connection output 5 Bottle Gas connection input 6 Mains cable connection Warnin...

Page 33: ...n may be used In order to electrically protect the welding system against short circuits a 63A time delay slow blow fuse is required per phase Once these criteria have been met the switched off weldin...

Page 34: ...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 welding cable plug Warning The welding cable connection cannot be locked Ti...

Page 35: ...n The welding current return takes place via the earth ground cable which must be connected as follows to the earth ground cable socket of the Nelweld N1500i Earth Ground Cable Connection X3 Connect t...

Page 36: ...e optional When a gun with manual stud loading is connected the tubes from the gas source and the gun must be directly connected to the Nelweld 1500i Connection of the shielding gas source Symbol Conn...

Page 37: ...d as current conductors unless they are themselves the workpiece to be welded The welding current circuit may not be earth grounded Exception The workpiece itself or the workpiece fixture are earth gr...

Page 38: ...to reduce the consequences of the magnetic blowing effect some of which are indicated below Picture Remedial Measures In order to favorably influence the arc the earth terminals must be placed as symm...

Page 39: ...welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 Note The polarity in the illustration refers to ferromagnetic materials When welding aluminum attention must be paid to reverse polarit...

Page 40: ...5394 Gie en Germany 4 4 Connection Diagram Short Cycle and Drawn Arc Welding Note This is a general connection diagram and is to be used along with previous connection instructions as connector lo cat...

Page 41: ...en Germany 4 5 Connection Diagram Shielding Gas shielding gas gun or feeder Note This is a general connection diagram and is to be used along with previous connection instruc tions as connector locati...

Page 42: ...sance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles Caution DO NOT MOUNT OVER COMBUSTUBLE SURFACES Where there is a combustible surface directly under s...

Page 43: ...y connected for 575V from the factory Open the access panel on the rear of the machine POWER CORD CONNECTION A power cord is provided and wired into the machine Follow the power cord connection instru...

Page 44: ...Stud welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 44 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany 5 Control and Display Elements 5 1 Front Panel Controls and Displays...

Page 45: ...the machine I ON 0 OFF Upon powering up the internal control software per forms a series of diagnostic tests to ensure correct connection and operation of the power source 8 Weld Time Stud Ex pert Dis...

Page 46: ...nual part number BE 1221 46 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany Weld Tool Icon Gun Coil Green Energized Red Flashing Undetected glows green when button is pressed Trigger Detect...

Page 47: ...stainless wire brush or scraper 5 Take care that the workpiece is stored free from vibrations particularly important in case of large and thinwalled workpieces 6 Chlorous solvents must by all means be...

Page 48: ...tion and up down buttons 4 to adjust time and current discretely 2 Push Stud Expert TM Mode button 2 in the Front Panel section and up down buttons 4 to adjust stud diameter and weld position or anoth...

Page 49: ...it means the rated duty cycle is exceeded during operation It is advised to check the value of F2 and possibly reduce the value of F2 to reduce the on time and increase the studs per minute without c...

Page 50: ...2 The plunge also needs to be appropiately set 3 When the E009 error appears the lift and plunge should be reviewed 4 If the error is E004 or E007 it generally means no pilot arc 5 Check input voltage...

Page 51: ...ing pressed turns ON the selected preset has been successfully programmed Note The weld parameter presets depends on to choosen weld method short cycle drawn arc 6 3 6 Recommended Weld Parameters The...

Page 52: ...s without warranty of any kind either expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular application Performance suitability for a...

Page 53: ...ize Current Amps Time ms Preset Bank 2 1 SC Studs 3 0 M3 4 mm 400 15 2 SC Studs 4 0 M4 5 mm 500 15 3 SC Studs 5 0 M5 6 mm 600 20 4 SC Studs 6 0 M6 7 mm 700 25 5 SC Studs 6 0 M6 7 mm 700 25 6 SC Studs...

Page 54: ...5 mm 350 230 4 SD6 MR M8 S6 6 mm 410 250 5 MP F M8 7 mm 470 300 6 MR M10 S8 8 mm 550 300 7 MP F M10 9 mm 650 300 8 SD10 MR M12 S10 10 mm 750 350 9 M12 S12 12mm 950 450 0 S16 SD16 16mm 1400 550 Preset...

Page 55: ...4 1500 840 Preset bank 2 is loaded such that presets 0 9 are as described above when in short cycle mode Preset bank 0 or 1 are loaded such that presets 0 9 are as described above when in drawn arc m...

Page 56: ...ing etc It is recommended to perform weld robustness test current time tolerance graph using the values below as center points to determine optimum welding parameters for the application Preset Stud S...

Page 57: ...8 SR 6 400 250 1 0 1 5 2 0 2 5 36 MP F M10 S8 7 450 300 1 0 1 5 2 0 2 5 32 MR M10 S8 8 550 300 1 0 1 5 2 0 2 5 32 MP F M10 9 700 350 1 0 2 0 2 5 3 0 28 SD10 MR M12 S10 10 750 400 1 5 2 0 2 5 3 0 25 Ru...

Page 58: ...00i studs requiring 800A will not appear in the list for selection Input Power If the maximum current on the N1500i is limited to 800A due to single phase input power studs requiring 800A will not dis...

Page 59: ...l Base 370 190 200 320 Drawn Arc 6mm SD6 MR M8 S6 410 250 410 250 Drawn Arc 6mm SC Bolzen M6 700 25 700 25 Short Cycle 6mm WTOP M6 1150 40 1150 40 Short Cycle 6mm ATC M6 730 30 730 30 Short Cycle 1 4...

Page 60: ...ull Base 560 310 300 540 Drawn Arc 9mm MP F M10 650 300 650 300 Drawn Arc 10mm Pitch Base 560 300 300 530 Drawn Arc 10mm Full Base 630 350 340 620 Drawn Arc 10mm SC Bolzen M10 1100 40 1100 40 Short Cy...

Page 61: ...660 590 1270 Drawn Arc 16mm Full Base 1120 670 600 1280 Drawn Arc 16mm S16 SD16 1400 550 1400 550 Drawn Arc 17mm Full Base 1220 730 650 1420 Drawn Arc 18mm Full Base 1310 790 700 1560 Drawn Arc 19mm F...

Page 62: ...igger The gun will lift and release for the programmed weld time Continue holding the trigger for 2 more seconds The gun will lift for 2 seconds then release During the 2 seconds a manual measurement...

Page 63: ...tor 6 4 2 Energy Consumption Inverters can realize significent electricity saving over its life time Use the following online calculator to compute the savings http www nelsonstud com calcutator energ...

Page 64: ...Cable mm2 70 21 34 10 6 115 35 05 8 10 220 67 06 6 13 3 340 103 63 4 21 2 550 167 64 2 33 6 Based on 3 drop and max 7 below nominal at input power connection during weld The same guideline applies to...

Page 65: ...pt a weld The gun will lift and drop but no weld current will pass The gun s drop time is measured stored displayed and used in weld timing as will be described later in this document F2 Plunge short...

Page 66: ...l Time Plunge short circuit on time F2 50ms 50ms 100ms but the arc would exist only during the Actual Weld Time or 50ms The important thing to note is that normally the stud begins to drop at Front Pa...

Page 67: ...68 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany Stud welding unit N1500i As of Aug 12 2021 Manual part number BE 1221...

Page 68: ...e Gun Control and Trigger Switch Circuit The rate in which the gun coil energy is removed plays a large part in how fast the stud will drop If the coil only has an anti parallel diode in either the gu...

Page 69: ...on 3 Inspect foot alignment Adjust if necessary A misaligned foot will almost guarantee stud hang up Make sure the stud is centered in the ferrule 4 Inspect chuck Replace if necessary Check for a good...

Page 70: ...tached to the quality docu mentation Continuous production monitoring In continuous production monitoring visual inspection of all welded studs is in general sufficient On suspicion of a faulty weld a...

Page 71: ...teration to the electrical and mechanical parameters 2 Faulty weld Cross section not fully welded Corrective measures Increase weld current and or weld time possibly change polarity 3 Faulty weld Larg...

Page 72: ...ive measures Not necessary No altera tion to the electrical and mechanical parameters 2 Faulty weld Constriction of the weld stud too long Corrective measures Increase plunge distance check lift check...

Page 73: ...as record keeping contact Nelson for Nelware PC software 6 8 2 Set up weld monitor tolerance Two tolerances must be configured F34 gun drop time tolerance and F35 weld energy tolerance F34 sets up a t...

Page 74: ...flash weld error after seeing a NIO weld and no more welding can be performed thereafter until the user enters a password The password is the same as in Lock mode 2 or 3 F19 and default password is 1...

Page 75: ...on F19 determines how the unit responds to the LOCK key when in the Time Current mode or Stud Expert mode It lets the user configure the level of security as required for the circumstances Lock Mode 1...

Page 76: ...it is desirable to set a cur rent level different than the main arc current during plunge For these applications enable F46 to use a different current level then set the plunge current level using F4...

Page 77: ...Stud welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 The same weld made with standard method plunge current is the same as the main arc current is shown below for comparison By defaul...

Page 78: ...to configure square wave pulse welding peak current peak time background current and background time Pulse welding is enabled by enabling F49 The background current level is set by the front panel cur...

Page 79: ...abled by enabling F37 For the peak pulse it attempts to go the maximum rated current for 4ms with a 10ms pause or low pilot current in between Due to the inductance of the weld circuit it is often bel...

Page 80: ...itor When enabled with F55 the cable resistance can be measured and compared after each weld When out of tolerance window defined by F56 and error E016 is generated to tell the user to check for loose...

Page 81: ...o act as a Weld Complete signal Use v1 06 firmware or later Make F12 ON Make F54 OFF One time only Before powering on unit press and hold the fol lowing buttons I t mode 1 5 and 0 through boot up If d...

Page 82: ...The default is set to 0 This function is used to increase the number of pecks to perform a series of lift plunge actions prior to the weld The inverter will attempt a weld as soon as it detects contac...

Page 83: ...in the table below The table below is for firmware version 1 05 only F code Description Possible Values Default Unit Notes F0 Language ENGLISH GERMAN ITALIAN SPANISH FRENCH ENGLISH x F1 Error Display...

Page 84: ...Stud Expert Mode process STUD WELD STUD WELD x F7 Calibration Values 700 to 850 750 Clock cycles Used by manufacturing Do not change F8 Chuck Saver OFF ON ON x F9 Gas Enable OFF ON OFF x F10 Gas pre...

Page 85: ...feed is enabled F15 Stud feed style AFTER CON TACT BREAK AFTER WELD AFTER CONTACT BREAK x When to get the signal This only applies when stud feed is enabled F16 Stud feed on air trigger OFF ON OFF x T...

Page 86: ...ck again It will prompt for the same password entered when originally locked Pass word can be up to 9 characters Mode 3 Same as mode 2 except user can tog gle between presets and cannot change the val...

Page 87: ...OWN BUT TON HOLD TIME x While in this F code press and hold the time down button to reset all F codes to default F27 Scroll Speed 100 to 500 150 ms Controls text scrolling speed F28 Pilot Arc Extensio...

Page 88: ...overridden by using the arrow keys This value changes to 7ms when short cycle mode is enabled 12ms when disabled This value changes automati cally depending on F30 short cycle mode and the gun interf...

Page 89: ...e tolerance allowed from target weld drop time for deter mining good bad weld F35 Weld Energy Tolerance 1 to 20 10 This defines the tolerance allowed from target weld drop time for deter mining good b...

Page 90: ...ed welds Hold the time down arrow to reset F43 Diagnostic Data Phases PWM AVG ABORT code Capacitor imbalance or Duty Cycle Phases X This gives extra diagnostic data after each weld If the power unit i...

Page 91: ...ime func tion is the only way to configure the drop time In Auto mode F31 automa tically gets a new value taken from the first weld done after power up and af ter the gun is unplugged In Average mode...

Page 92: ...0ms passes 20ms in short cycle mode F54 Near Maximum Output Warning OFF ON OFF X Enable this to throw an error code E015 when the unit is near the maximum output power capability 95 F55 Cable Connecto...

Page 93: ...to be cleaned Zinc or Galva nized to Primer Paint Oil or Oxide Primer Paint X Use this function to designate how the pulse cleaning function determines ab orts pulsing and begins the main arc Select...

Page 94: ...e ap propriate fieldbus selection to deter mine the IO map and sequence of signals For standard mode disable this F code F65 Weld Complete 24V Signal OFF ON OFF For automated systems this output signa...

Page 95: ...cuit Seetroubleshooting E002 BROWNOUT CONDI TION CHECK PRIMA RY VOLTAGE The input voltage dipped low enough to drop out auxiliary supplies Welding is stopped until power is restored so as to prevent i...

Page 96: ...if the voltage skyrockets after closing relays x Input voltage is too high Seetroubleshooting E007 INPUT VOLTAGE TO LOW FLIPSWITCHTO CORRECTVOLTAGE SETTING On boot up only after clo sing the charge re...

Page 97: ...short circuit was detected for at least 100ms the weld aborts to protect the power unit Check the gun lift setting Under normal welding conditions this should not hap pen Seetroubleshooting E013 WELD...

Page 98: ...ded to in form the user If the output voltage is at the maximum due to long or small cables high lift the actual current may start to drop below the desired current This war ning can be disabled using...

Page 99: ...optime F31 andthefront 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 so it is possible the arc will go out before...

Page 100: ...x weld time F30 Short Cycle Mode OFF 12ms 20ms 1 Drawn Arc Metric Values 1000ms 100ms Limits Stud Expert studs Limits presets to 100ms min weld time F12 Sud Feed Enable ON ON 2 Wire Gun Interfaces Act...

Page 101: ...proper current and time settings are being used Reduce the current setting and perform weld inspections as described in Sections 2 7 4 and 2 7 5 Plunge is too short Plunge is measured by the amount of...

Page 102: ...s is the proper ferrule for the stud size and application Inconsistent gun lift Perform a Lift Check as specified in Section 4 5 14 Consult Section 2 6 to ensure proper lift settings are being used Co...

Page 103: ...If the stud is off center it can restrict the plunging motion of the stud during welding Time setting or current setting is too high Check the stud burn off If the burn off is much greater than what...

Page 104: ...plate or stud may cause the arc to become erratic Ensure that the re is no rust scale oil water residue paint galvanization etc present between the stud and the work piece Welding to a clean plate can...

Page 105: ...ures at least once every six months It is good practice to keep a preventive maintenance record a record tag attached to the machine works best Neither aggressive or alcoholic agents nor combustible l...

Page 106: ...switched off disconnected from the mains and secured against restart Only a qualified electrician should perform any work inside the unit s casing Any work done should be made in accordance with all l...

Page 107: ...kage or oozing Replace boards if needed 1 Examine the sheet metal case for dents or breakage Repair the case as required Keep the case in good condition to ensure that high voltage parts are protected...

Page 108: ...cker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany 9 Drawings and parts lists 9 1 Explosion drawing Final Assembly N1500i 24 21 5 6 22 35 36 37 13 33 14 10 7 8 41 40 16 31 39 30 11 15 18 4 16 31...

Page 109: ...FLAT SS 15 2 524 005 278 Stp SCREW M4 X 25 SHCS 16 4 87 07 86 Sp LABEL HIGH VOLTAGE 17 6 524 001 308 Stp WASHER RETAINER 8 32 18 1 750 610 431 HORIZONTAL PANEL SUB ASM 19 8 524 005 276 Stp WASHER M6 F...

Page 110: ...FERRITE CLAMP ON 5MM NS 1 716 050 101 Sp FERRITE CLAMP ON 9MM NS 4 713 107 000 Stp WIRE FERRULE 4 AWG YELLOW NS 4 713 109 000 Stp WIRE FERRULE 6 AWG GREEN NS 1 723 242 001 Sp HARNESS PWR SUPPLY TO CO...

Page 111: ...ly TORQUE NUT TO 4 N M 35 40 IN Lbs 9 2 1 Parts list cover assembly Item QTY Part Number Comment Description 1 2 729 114 001 Sp HANDLE ASSEMBLY 2 1 750 610 245 Sp COVER CE 3 4 524 005 147 Stp WASHER M...

Page 112: ...N1500i As of Aug 12 2021 Manual part number BE 1221 109 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany 9 3 Chassis Sub ASM Note Rotate strain relief 30 degrees clockwise to have access to...

Page 113: ...HASSIS 2 1 717 512 013 W Sp FAN 3 1 86 44 38 Sp STRAIN RELIEF 4 2 524 005 292 Stp SCREW M4 X 70 PHMS SS 5 4 729 022 008 W Sp LEVER PAD 6 2 524 005 284 Stp WASHER FENDER M4 SS 7 2 524 005 153 Sp NUT M4...

Page 114: ...Stud welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 111 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany 9 4 Front panel assembly 8 12 7 2 7 4 13 5 6 3 7 9 1 10 11...

Page 115: ...IGGER CONN 4 WIRE BINDER 5 1 714 232 003 COVER CONNECTOR BINDER NOT SHOWN 6 2 524 005 271 SCREW M3 X 12 PHCRMS SS 7 2 714 166 099 W Sp DINSE FEMALE 8 1 700 142 003 Sp CURRENTTRANSDUCER 9 2 520 001 320...

Page 116: ...welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 113 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany 9 5 Horizontal panel assembly 10 12 8 14 1 14 2 11 3 15 13 5 7 16 F2 F1 4...

Page 117: ...T BRIDGE 10 6 524 005 262 Stp SCREW M6 x17 x 12 PHCRMS 11 4 524 005 210 Stp NUT KEPS M4 x 7 x 375 12 2 524 005 197 Stp SCREW M6 x 1 x20 SHCS SS 13 4 524 005 155 Stp SCREW M4 x 7 x 12 PHCRMS 14 12 524...

Page 118: ...GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany 9 6 Vertical panel sub assembly 10 2 12 5 1 13 16 7 4 10 10 A 8 3 B 15 17 14 11 10 10 9 Stud welding unit N1500i As of June 06 2012 Manual part numb...

Page 119: ...RANSFORMER SUB ASM 7 1 723 245 007 Sp AUXILIARY TRANSFORMER SUB ASM 8 4 729 114 005 Sp SPACER 9 4 729 114 020 Sp STANDOFF HEX 10 20 524 005 210 Stp KEPS NUT M4 X 0 7 11 4 524 005 284 Stp WASHER M4 DIN...

Page 120: ...O NOT remove plexiglass when the power is on This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the procedure listed below LOCATE PROBLEM...

Page 121: ...ny Stud welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 Note If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Nelson Author...

Page 122: ...properly sized See rating section of the manual for recommended fuse and breaker size Welding procedure is drawing too much output current or duty cycle is too high Reduce output current duty cycle o...

Page 123: ...mended misadjustment havebeenchecked andtheproblem persists contact yourlocalNelson AuthorizedField ServiceFacility Poor welding performance Check for loose or faulty welding cables Make sure the mach...

Page 124: ...cknowledge meaning the error will exist as long as the unit is powered on Note welding can continue while the error exists Yes Description The gun drive circuit sensed a current spike of 10A or greate...

Page 125: ...played and if welding the weld will stop im mediately 15VDC is located at pins 1 and 11 of JP11 on the control board The error will be futher classified into E002 A or E002 B E002 A The browout occure...

Page 126: ...ck that 15VDC exists at the control board while unit is not welding idle If it does not exist at idle check primary power and replace power supply or aux transformer as necessary Using a scope determi...

Page 127: ...he high range 400 the primary capacitor bank has the potential to go out of balance such that they are not the same voltage When they are 20VDC out of balance for 10ms the weld will be aborted to prot...

Page 128: ...power supply etc This exists as a safety mechanism in case current sensing fails This is most likely caused by the arc actually popping out Likely problems or items to check in order from most likely...

Page 129: ...s that the current was 150 or higher of the setting while the control to the power system was at the minimum for 15ms it will abort the weld and display this error This will happen if the current sens...

Page 130: ...C and 470VDC 2 Improper adjustment of voltage to frequency circuit to switch board Each switch board 1 board in the case of the N800i has a pair of wires to provide an open collector signal to the con...

Page 131: ...some power down up cycles 3 Broken connection from control board to the switch board in V F circuit Check control board JP1 pins 1 9 for one pair 2 10 for the other 4 If the input voltage measures to...

Page 132: ...age setting on the back of the unit 2 Improper adjustment of voltage to frequency circuit to switch board Each switch board has a pair of wires to provide an open collector signal to the control board...

Page 133: ...ch will involve some power down up cycles 3 Broken connection from control board to the switch board in V F circuit Check control board JP1 pins 1 9 for one pair 2 10 for the other 4 If the input volt...

Page 134: ...ding can continue while the error exists No Description When a dangerous primary current is sensed by means of the Current transformer sensors in the back of the unit near the fan plenum the control w...

Page 135: ...If no stud voltage is sensed after 20ms it is assumed that the gun didn t lift and the control throws this error Note If the gun lifts and no arc exists it will try to turn the main current on and wil...

Page 136: ...Description The voltage to frequency signal as provided by the switch boards to the control board are not within a window defined by the control board indicating that they are invalid or caused by noi...

Page 137: ...or more welding The normally closed temperature sensor is located on the output board and connects to pins 1 and 6 of JP3 on the control board The sensor closes when it reaches 80 deg C Likely problem...

Page 138: ...nit aborts welds and displays this error if this condition occurs during the main arc time If this occurs during the plunge time the error is not displayed but the weld is aborted as this is expected...

Page 139: ...No Description If the unit is configured to compare each weld results Actual current voltage time etc to a given weld target it will display this error when the last weld is out of the configured tol...

Page 140: ...rror exists No Description The gun coil was de energized and the stud did not hit the molten pool before current was hut off This lends itself to cold welds Adjustments should be made to the unit sett...

Page 141: ...nt it will display this warning When this warning is being displayed there is a possibility that the weld current will start to sag As shown in the picture below if the demanded voltage for any given...

Page 142: ...ce target was saved using F55 and F56 upon each weld the unit will measure the weld cable resistance If for any weld the resistance is outside of the tolerance windo set by F56 this warning will be di...

Page 143: ...rc blew out For this condition check surface conditions and clean the work piece of any ferrule dust or debris 10 3 18 E018 Warning Drop Time is too long for Short Cycle Fatal meaning you have to powe...

Page 144: ...le is being exceeded 2 Switch board is out of calibration 3 Switch board malfunctioned If lower display reads CYCLE Check Duty Cycle The N1500I is reated at 9 If lower display reads CAP Step 1 Check S...

Page 145: ...Stud welding unit N1500i As of Aug 12 2021 Manual part number BE 1221 142 Tucker GmbH Mail Post Max Eyth Str 1 35394 Gie en Germany 10 4 Wiring Diagram Nelweld N1500i...

Page 146: ...requirements VER Circuit boards Free of GB No requirements VER Plastics pure grade Free of bromide compounds No requirements VER Plastics mixed None No requirements HM VER Mercury containing componen...

Page 147: ...ironmental regulations must be observed Proof of expert and competent disposal must be furnished in accordance with KrW AbfG Law Regarding Waste Recycling and Man agement 1994 11 2 Disposal in accorda...

Page 148: ...Germany In accordance with the European 2002 96 EC directive on waste electrical and electronic equipment and within the scope of this directive s translation into national law Nelson offers the colle...

Page 149: ...Community EMC Electromagnetic compatibility EN European standard ESF Welding stud with an even fore part I A Current in amps IEC International Electrotechnical Commission IEC Norm International Stand...

Page 150: ...es IP Code 2000 EN 60974 1 Arc welding equipment Part 1 Welding power sources 2005 EN 60974 12 Arc welding equipment Part 12 Coupling devices for welding cable 2005 EN ISO 13918 Welding Studs and cera...