Nelson N1500i, N800i Fast Start Manual

Download

Page 1

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

Page 2

INVERTER 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.

Nelson’s liability for breach of warranty shall arise only upon return of the defective goods at Buyer’s expense after notice to Nelson of the claimed breach,

and shall be limited to furnishing a like quantity of such goods free from such defects or, at Nelson’s option, to refunding the purchase price (less reasonable depreciation based on actual use); provided, however, that Nelson will not accept

receipt of equipment returned unless buyer has previously afforded 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 such defect or failure and within two years or one million welds from the date the equipment was delivered, whichever comes first. No compensation or reimbursement for transportation costs of any kind will be allowed.

Please note that this warranty does not extend beyond the original registered purchaser, and does not warrant equipment that has been modified by any party other than Nelson, or equipment that has been improperly installed, improperly operated, or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of specifications for the equipment. Nelson shall never be liable for consequential damages.

Nelson reserves the right to make engineering and/or part changes, at any time without notice, as a result of our commitment to continuous improvement.

Page 3

WARNING

The following Safety section is for your protection. It summarizes precautionary information from the references listed in the Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe these precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS Some welding, cutting, and gouging processes

are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) rays and other radiation which can harm the skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields and goggles are also required.

2. Use a face shield fitted with filter shade #3 per ANSI Z87.1. Cover sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trousers cuffs or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with suitable nonflammable partitions or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS Heat from flames and arcs can start fires. Hot

slag or sparks can also cause fires and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.

3. Do not weld, cut, or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have appropriate fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket or portable fire extinguisher. Be sure you are trained for proper use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.

6. After completing operations, inspect the work 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 Use of Cutting and Welding Processes,”

available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

ELECTRICAL SHOCK Contact with live electrical parts and ground

can cause severe injury or death. DO NOT use welding current in damp areas, if movement is confined, or if there is danger of falling. Therefore:

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables..

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder and power source.

6. Make sure that all parts of your body are insulated from work and from the ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubbersoled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Refer to ANSI/ASC Standard Z49.1 for specific grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRICAL AND MAGNETIC FIELDS Electric and magnetic fields may be

dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Operators having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Operators should use the following procedures to minimize exposure to EMF: a. Route the electrode and work cables together. Secure

them with tape when possible.

b. Never coil the torch or work cable around your body. c. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

d. Connect the work cable to the work piece as close as

possible to the area being welded.

e. Keep welding power source and cables as far away

from your body as possible.

FUMES AND GASES Fumes and gases can cause discomfort or

harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. Therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gasses.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work areas. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing on next page) for specific ventilation recommendations.

Page 4

ELECTRICALLY POWERED EQUIPMENT Faulty or improperly electrified equipment

can cause injury or death. Therefore:

1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.

2. Before performing any work inside a power source, disconnect the power source from the incoming electrical power using the disconnect switch at the fuse box before working on the equipment.

3. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacture’s

recommendations.

4. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

CYLINDER HANDLING Cylinders, if mishandled, can rupture and

violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

“Precautions for Safe Handling of Compressed Gases in Cylinders”, which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington, VA 22202

HEARING PROTECTION Prolonged Noise from Capacitor Discharge

welding applications can damage hearing if levels exceed limits specified by OSHA. Therefore:

1. Use Approved ear plugs or ear muffs if noise level 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

1. Always disconnect electrical power prior to service to

prevent the fan from starting unexpectedly.

2. Keep all doors, panels, covers, and guards closed and

securely in place.

3. Have only qualified people remove guards or covers for

maintenance and troubleshooting as necessary.

4. Keep hands, hair, loose clothing, and tools away from

moving parts.

5. Reinstall panels or guards and close doors when

servicing is finished and before reenergizing welder.

warning and cause severe injury, therefore:

EYE PROTECTION Flying metal can injure eyes. Welding,

chipping, wire brushing and grinding can cause sparks and flying metal. As welds cool, they can throw off slag. Therefore:

1. Wear approved safety glasses with side shields even under your welding helmet.

2. Warn others nearby about flying metal hazard.

EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment

1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from:

• heat sources such as furnaces

• wet conditions such as water puddles and inclement

weather

• oil or grease

• corrosive atmospheres

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not

1. ANSI/ASC Z49.1 Safety in Welding and Cutting

2. AWS C5.1 Recommended Practices for Plasma Arc Welding

3. AWS C5.6 Recommended Practices for Gas Metal Arc Welding

4. AWS SP Safe Practices (Reprint) Welding Handbook

5. ANSI/AWS F4.1 Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances

can cause injury or death. Therefore:

ADDITIONAL SAFETY INFORMATION For more information on safe practices for

electric arc welding, refer to the following publications.

Page 5

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg Germany

CONTENTS

Connection and Installation. ........................................................... 1

1.1 Installation Precautions ............................................................................ 1

1.2 Connection ................................................................................................. 1

1.2.1 Input Connection ............................................................................... 3

1.2.2 Single Phase Connections ................................................................. 3

1.2.3 Change Input Voltage (Reconnect) ................................................. 4

1.2.4 Connection of the Welding Cable ................................................... 6

1.2.5 Connection of the Control Cable ..................................................... 6

1.2.6 Connection of the Ground Cable ..................................................... 7

1.2.7 Connection of the workpiece ........................................................... 7

1.3 Specifications ............................................................................................. 8

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 Reading the Time Display ................................. 12

2.2.3 Lift distance and plunge distance parameters: .................................... 13

2.2.4 Calibrate the gun drop time F31 ............................................................ 13

2.2.5 Weld Parameter Presets .......................................................................... 14

2.2.6 Recommended Weld Parameters ........................................................... 15

2.2.7 Weld Parameters and Settings ............................................................... 16

2.2.8 Parameters for short - cycle procedure ................................................. 18

2.2.9 Parameter for drawn - arc procedure .................................................... 18

Operational Function Codes & Error Code ................................ 19

3.1 How to Access Full List ............................................................................ 19

3.2 Diagnostic Error Codes ............................................................................ 27

3.2.1 Notes on which F codes change automatically .................................... 30

3.3 Weld Process Problems ............................................................................ 31

Page 6

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

1 Connection and Installation

1.1 Installation Precautions

Attention must be paid to the fact that the welding unit is installed on horizontal, vibration-free and non-slip floor space The load-carrying capacity of the floor space should be at least double the weight of the welding unit.

When working in high-lying locations, such as bridges, ladders or platforms the N1500i must be secured against the risk of falling.

The Nelweld N1500i must be adequately protected against the intrusion of liquids. It may not be installed on liquid-bearing pipelines.

In order to guarantee unimpeded temperature exchange with the environment, a minimum clearance of 1 m (39.4 inch) 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.

1.2 Connection

With the exception of the input power cable all the connecting elements are arranged in a functional manner on the front plate of the N1500i.

Page 7

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

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

Warning!

Prior to any connection work the Nelweld N1500i welding unit must be switched off. The input power switch of the unit must be in the >>0<< position!

Page 8

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Warning!

1.2.1

Input Connection

The Nelweld N1500i may be operated with an input power voltage of 200-230VAC/50/60Hz or 400-460VAC/50/60Hz as configured by the reconnect 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 and L3 of the input line switch (black and white wires

of the factory - installed input cord if equipped).

•

Reconnect instructions for selecting the input voltage still applies

whether using 1 phase or 3 phase operation.

•

Isolate and securely tape L2 (red wire).

Page 9

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Warning!

1.2.3

Change Input Voltage (Reconnect)

This 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 disconnected from main power.

Move lead #200 at small aux. block per graphic for desired voltage.

Move jumper and lead # 14 on large terminal block per graphic for desired voltage. (See photo next page.)

Page 10

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Voltage Connect Section

*575V Not Shown

Page 11

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

1.2.4

Connection of the Welding Cable

Connection of the welding cable of the gun is effected by means of the welding cable socket of the N1500i which is marked with the gun symbol.

It must be noted that procedurally safe operation of the system can only be guaranteed when NS40 and Light Duty guns are connected.

Welding Cable Connection (X2)

Connect the welding cable 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 cable socket serves to take the control cable plug of the gun. The signals to control the gun are transmitted via the control cable.

In keeping with the weld gun to be connected , the control cable socket of the welding unit is 4-pole in design, some may be 2-pole.

Control Cable Connection (X1)

Pin 1: Gun coil (-)

Pin 2: Gun coil (+) Pin 3: Start button of the gun (+)

Pin 4: Start button of the gun (-)

The connection must be secured by “screwing on” the control cable

plug!

Control Cable Connection (X1)

Silver Pin: White Wire

Brass Pin: Black Wire

Page 12

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Warning!

Connect the earth ground cable plug into the proper socket of the

Note!

1.2.6

Connection of the Ground Cable

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)

Nelweld N1500i.

The connection must be secured by a full “turn to the right” of

the earth ground cable plug!

Use cable resistance monitor (see section 3.15) to continuously monitor loose

1.2.7

connector fault condition in production.

Connection of the workpiece

When connecting the earth ground terminals attention must be paid to the following:

The earth ground terminals must be connected directly to the workpiece or to the workpiece fixture (welding bench, welding grid).

Steel constructions, tracks, pipelines, etc. may not be used 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 grounded compulsorily (pipelines, shipbuilding, etc.).

Place the earth ground terminals if possible at the same distance from the point of welding when two ground clamps are used.

Page 13

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Input Volts

Slow-

Blow Fuse

lph. Max

kVA max.

lph. eff.

kVA eff.

Phase

50/60Hz

Electrical

Specifications

200-300

183

7.3

400-460

7.5

575

7.5

Output on 3 phase input

Duty

12%

100%

Amps

1500

1200

1000

120 Volts

Input Volts

Slow-

Blow Fuse

lph. Max

kVA max.

lph. eff.

kVA eff.

Phase

50/60Hz

Electrical

Specifications

200-300

200

3.5

400-460

112

3.5

Output on single phase input

Duty

Amps

800

Volts

Idle watts: 100W or less, fan off

Height: 16.7 (42cm)

Unit Weight: 75lbs (34Kg) (w/cord)

Operating Temperature: -20 to +40 Degrees C

Unit Length: 28in (71cm)

Storage Temperature: -40 to +60 Degrees c

Width: 10.7in (27cm)

Efficiency at rated output

: 88%

Open - Circuit Voltage: 75V

Note!

Prior to connecting the earth ground terminals the following advice on avoiding any arc blowing must be observed!

1.3 Specifications

Page 14

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

2 Control and Display Ele-

ments

Page 15

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

1 Time/Current Mode

Enables Time/Current weld parameter selection

2 Stud Expert Mode

Setup selection by stud diameter and other process parameter such as weld position

3 Function Mode

Configuration Change or Troubleshooting

4 Up/Down Arrow Keys

Add or subtract numeric values in time or current function

5 Lock/Unlock Keys

The unit has a lockout feature that prevents any changes from being made to the front panel settings. See F19 in section 3

6 Preset Values

Factory presets or storage of custom values

7 On/Off Power Switch

The main switch controls the input power to the machine. Upon powering up, the internal control software performs a series of diagnostic tests to ensure correct connection and operation of the power source.

Weld Time/Stud Expert Display/Material Display

The TIME setting is displayed on the front panel LOWER display. It can be changed using the Up/ Down arrow keys to the right of the time display in one 1ms increments.

9 Warning alert

This indicator turns ON when a fault condition occurs. Please refer to F1 in the troubleshooting section of this guide for fault condition descriptions and resolution.

Weld Tool Icon

Graphical representation of gun operation and welding process. (see below for more inforamation)

Weld Current/Stud Diameter Display

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.

2.1 Front Panel Controls and Displays

1. Explanations see next page

Page 16

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

Nelson Stud Welding, 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 actual weld time for animation)

Trigger Indicator

Contact Detect (Green)

Good/Bad Weld Indicator (Green/Red)

Page 17

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

2.2 Weld Parameters

You can program this unit in 2 ways: directly setting the current and time values; or use the Stud Expert (tm) mode based on stud diameter.

2.2.1

Setting Current and Reading the Current Display

The current setting is the current setting during a weld, and can be viewed in the front panel’s upper display. It can be changed using Up/ Down arrow keys to the right of the current display in one (1) amp increments. As each of these keys are pressed, the current setting will increase or decrease at a faster rate.

After each weld, actual current and time will be displayed briefly before the set values are displayed again.

If the display shows an actual weld time is much longer than programmed, e.g., the sum of the front panel time and F2 (short circuit on-time), a cold plunge may have occured that can result in a bad weld. If this condition persists, it is recommended to do a gun calibration to set the F31 value, and check the physical condition of the gun for any causes of preventing a normal drop. If the actual weld time is less than the front panel time, it 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 fault condition, see section 7.3.19). 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 cold plunge.

In normal operating modes, the desired setting and the actual current will be the same. In this situation the display does not change during or after a weld. However, in conditions where it is not possible for the power source to deliver the desired current, a warning light will light on the front panel display. This typically occurs when using high currents with small or excessively long weld cables.

2.2.2

Setting the Time and Reading the Time Display

The time setting is displayed on the front panel lower display. It can be changed using Up/Down arrow keys to the right of the time display in one (1) millisecond (0.001 second) increments. As each of these keys reinput power pressed, the time setting will increase or decrease at a faster rate. The time display is used to display both the desired time setting and the actual weld time.

In normal operating modes, the desired setting and the actual weld time will be the same. When this is the case, the display does not change during or after a weld. However, if an error condition occurs, the

Page 18

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Note!

proper error code will be displayed on the front panel display. This will typically happen if a weld is aborted early.

2.2.3

Lift distance and plunge distance parameters:

•

The mechanical parameters must be set on the respectively connected weld gun NS40 and Light Duty drawn arc gun.

•

See the operating instructions of the corresponding weld gun for the settings.

•

See the gun operating instructions and diagrams below respectively for the guide values for the welding method.

Lift Settings

Maximum lift height (at +/-10% of rated input voltage, NS40 and NS20HD): 2.5mm (0.1”).

Proper gun lift settings are as follows:

All studs within the weld range are listed at 2mm lift and below.

The plunge also needs to be appropiately set.

When the E009 error appears the lift and plunge should be reviewed.

If the error is E004 or E007 it generally means no pilot arc.

Check input voltage from unit control panel using F18 and read capacitor voltage.

If the lift capability is marginal, i.e. it lifts a low lift height, but fails to lift at slightly higher lift height, consult your Nelson Rep.

2.2.4

Calibrate the gun drop time F31

It is recommended to calibrate the gun so that the welder understands the gun drop time and delivers the precise main arc time programmed. The calibration is a good practice when you exchange the gun, especially when you change process between short cycle mode (maximum main arc time is 100 ms) and drawn arc (mininum main arc time is 100 ms), or change gun type or plunge dampener (shock absorber). Simply go to F31, and shoot a stud. The actual gun speed is measured and the actual drop time is saved in F31.

Page 19

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Note!

When you display F31 on the front panel and make a weld, F31 should automatically update with actual drop time from the new weld. The newly updated F31 value should match with tD in F32. Another way is simply read tD in F32 from previous weld and adjust F31 to match it. Generally speaking, this equation should hold within a few milliseconds: Front Panel Time - F31 setting 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 else in process is not exactly repeatable.

Special cases:

If the stud shorts before the gun coil is de-energized, or, if the stud shorts after the weld current is shut off, the drop time (tD) can't be measured.

2.2.5

In each case, F31 does not update. F32 (tD) shows each of these cases 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 off, increase F2 to give the machine a chance to measure drop time (tD).

Exit the F31 screen for production welding. Otherwise, F31 may be continuously changing after each weld resulting in inconsistent settings in production.

If you accidentally recall a preset, F31 value can be changed to the value associated with the preset. Check F31.

Weld Parameter Presets

The power source has ten available preset configurations. Each of these is assigned a time and current setting for commonly welded stud sizes. To select a preset, simply press key 1, 2, 3, 4, 5, 6, 7, 8, 9, 0. When a preset is selected, the time and current are displayed on the front panel, and the LED on the selected preset key lights.

Nelweld users are not restricted to pre-programmed presets, but may save more usable weld settings. To do so, first select the desired time and current settings using the corresponding Up/Down arrow. Then press and hold the desired preset key for 4 seconds. The preset values

Page 20

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Note!

will be replaced by the desired custom values. When the orange LED of the preset button being pressed turns ON, the selected preset has been successfully programmed.

The weld parameter presets depends on to chosen weld method (short cycle, drawn arc).

2.2.6

Recommended Weld Parameters

The values specified in the tables and diagrams respectively must be seen merely as guide values, which were achieved under optimized welding conditions.

The best possible weld parameters must always 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 welds.

Attention must be paid to the fact that the trial welds are for the most part equivalent to the real conditions in the current production process.

In obtaining the best welding result, the electrical and mechanical weld parameters must be preceisely adjusted to the respective welding task.

Upon suspicion of faulty welds the settings on the welding unit and the weld gun must be optimized.

The weld parameters in the tables and in Stud Expert are provided as is, 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 any specific application should be determined by the user. The user assumes all liability of the use or the results of the use of the recommended weld parameters.

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 21

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Preset

Nelson Stud Type

Stud Size 

Current (Amps)

Time (ms)

Preset

Bank

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 [6.0 M6]

7 mm

700

25 7

SC-Studs [6.0 M6]

7 mm

700

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

Preset

Nelson Stud Type

Stud Size 

Current (Amps)

Time (ms)

Preset

Bank

1**

1 IS-Studs

3 mm

200

150

2 IS-Studs

4 mm

280

200

3 IS-Studs

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

Note!

2.2.7

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 (Short Cycle)

The duty cycle limits for the Nelweld N1500i can be seen in the Stud Weld Rate table below. If the duty cycle is exceeded, and a weld is attempted, a “Wait” prompt will be displayed. “Wait” will disappear when the unit is ready for another weld. If the unit reaches an abnormally high temperature, a failsafe thermal sensor will protect the unit and display E011. The unit will resume operation once the temperature has returned to safe operating range.

Factory Preset Weld Settings (Drawn Arc)

Page 22

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Preset

Nelson Stud Type

Stud Size 

Current (Amps)

Time (ms)

Preset

Bank

0**

1 Drawn arc stud

3/16”

300

150

2 Drawn arc stud

1/4”

450

170

3 Drawn arc stud

5/16”

500

250

4 Drawn arc stud

3/8”

550

330

5 Drawn arc stud

7/16”

675

420

6 Drawn arc stud

1/2”

800

550

Drawn arc stud

5/8”

1200

670

Drawn arc stud

3/4”

1500

840

Drawn arc stud

3/4”

1500

840

Drawn arc stud

3/4”

1500

840

* Preset bank 2 is loaded (such that presets 0-9 are as described above) when in short cycle mode.

** Prest bank 0 or 1 are loaded (such that presets 0-9 are as described above) when in drawn arc mode.

Bank 0 is loaded when a 2 - wire gun interface is used.

Bank 1 is loaded when a 4 - wire gun interface is used.

Note: The preset bank may be selected manually using Function Code F44.

Page 23

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Preset

Stud

Size 

Current (Amps)

Time

(msec)

Lift

(in.)

Plunge

(in.)

1 3/16”

5mm 300

.062

.125 2 1/4”

6mm 400

.062

.125 3 5/16”

8mm 450

.062

.125 4 3/8”

10mm 500

.062

.125 5 7/16”

11mm 625

.062

.125 6 1/2”

13mm 750

.062

.125 7 5/8”

16mm 1100

.093

.187 8 3/4”

19mm 1400

.093

.187 9 3/4”

19mm 1400

.093

.187 0 3/4”

19mm 1400

.093

.187

Stud Weld Rate

Parameters listed ar those used testing, and should be used only when considering operating duty

cycle

Stud Size

Time

(sec)

Current

(A)

Weld Rate (Studs Per Minute)

(in)

Nelweld 1500i

3/16”

5mm

0.15

300

261

1/4”

6mm

0.17

400

171

5/16”

8mm

0.25

450

105

3/8”

10mm

0.33

500

7/16”

11mm

0.42

625

1/2”

13mm

0.55

750

5/8”

16mm

0.67

1100

3/4”

19mm

0.84

1400

Note!

2.2.8

Parameters for short - cycle procedure

The following parameters are only starting points (guide values) which must be adjusted to specific application conditions (base material, work piece surface condition, weld position, gun type, weld circuit inductance and grounding etc.). It is recommended to perform weld robustness test (currenttime tolerance graph) using the values below as center points to determine optimum welding parameters for the application.

2.2.9

Parameter for drawn - arc procedure

Drawn Arc Welding

*Assuming 3 Input Power and a short circuit on - time of 100ms

Page 24

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

3 Operational Function Codes & Error Code

3.1 How to Access Full List

The v1.06 inverter firmware ‘hides’ the full F code list, only revealing the most common used. The purpose of this section is to clarify how to acess this list.

By Default,

F0 - Language F1 - Error Display F2 - Plunge Short Circuit 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 List’. Release the key. Now, all F codes are accessible. To go back to the simple list, press and hold the F key again to read ‘Simple F List’ on the display. Release the key. This must be done in either

the I\t or Stud Expert modes (not while viewing an F code).

The inverter will remember the setting during power-down. Please see operators manual for the full F code list.

Note: Press and hold F key for at least 8 seconds to show whole F Code List.

Page 25

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Firmware version 1.06

F code

Description

Possible Values

Default

Unit

Notes

F0 Language

ENGLISH,GERMAN , ITALIAN, SPANISH, FRENCH,

ENGLISH

Error Display

E--- to E018

E---

Plunge Short Circuit

On-Time

0 to 150

When short cycle mode is enabled, this defaults to 20ms. When disabled, this defaults to 80ms for 2wire gun interface, 20ms for 4-wire gun interface.

Stud Expert Mode

Easy Access

POSTION, MATERIAL,

PROCESS

POSITION

x F4

Stud Expert Mode

Position

DOWNHAND, VERTICAL,

OVERHEAD

DOWN HAND

x F5

Stud Expert Mode

Material

MILD STEEL, STAINLESS

STEEL, ALUMINUM

MILD STEEL

x F6

Stud Expert Mode

Process

STUD WELD

Calibration Values

700 to 850

750

Clock cycles

Used by manufacturing. Do not change

Chuck Saver

OFF ON

Gas Enable

OFF ON

OFF

F10

Gas Preflow Time

10 to 2000

500

F11

Gas Postflow Time

10 to 2000

500

F12 Stud Feed Enable

OFF ON

OFF

This automatically turns on ‘short cycle mode’ when enabled. Disabling it does not disable ‘short cycle mode’.

F13

Stud Feed Time

10 to 2000

Pulse width of stud feed signal. This only applies when stud feed is enabled.

F14

Stud Feed Normal Level

NORMAL CLOSED,

NORMAL OPEN

This only applies when stud feed is enabled.

F15

Stud Feed Style

AFTER CONTACT BREAK,

AFTER WELD

AFTER CONTACT

BREAK

When to get the signal. This only applies when stud feed is enabled.

Page 26

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

F code

Description

Possible Values

Default

Unit

Notes

F16

Stud Feed on Air

Trigger

OFF ON

OFF

To feed a stud even when triggering the gun while not welding. This only applies when stud feed is enabled.

F17

Loadbank Enable

OFF

For manufacturing. This is a read-only function used for burn-in testing.

F18

Capacitor V-F Readings

0-65535

Time-up/down to see both sides

F19

Lock Mode

1 to 4

Mode 1: Use the lock key to toggle blocking on all keys - no password protection. Mode 2: Use the lock key to enter a password, lock key as 'enter'. From there, all keys are blocked until you press lock again. It will prompt for the same password entered when originally locked. Password can be up to 9 characters. 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.

F20

Debug

ENTER DEBUG MODE

ENTER DEBUG

MODE

Used by manufacturing and service.

F21

User Counter

0 to 4.3G

Welds

While in this F code, press and hold the time-down button to reset the counter

F22

Total Counter

0 to 4.3G

Welds

(Non-resettable)

F23

Chuck Stripper

OFF ON

OFF

F24

Stud Expert Mode Unit

Selection

English, metric, or both

English

Lets user select which units are displayed as stud sizes while in Stud Expert mode. This defaults to English with 2-wire gun interfaces and Metric with 4-wire gun interfaces.

F25

Software Versions

A: DSP version B: Coldfire

version

A: DSP version

Time-up/down to see both versions

F26

Restore Factory Defaults

HOLD TIME DOWN

BUTTON

HOLD TIME

DOWN BUTTON

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

Controls text scrolling speed

Page 27

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

F code

Description

Possible Values

Default

Unit

Notes

F28

Pilot Arc Extension

0 to 10

This is the time the control will wait to start the main arc after establishing a stable pilot arc.

F29 Chuck Change Counter

OFF to 1000000

OFF

Welds

Increments by 1000; Press down key until value equals OFF to disable. This function counts down and turns the chuck change indicator ON when it reaches zero.

F30

Short Cycle Mode

OFF ON

OFF

Turn this on to limit weld time to 100ms. This is

automatically turned on when ‘stud feed’ is enabled,

but not automatically turned off. Changing this

mode affects other F codes. See section on ‘which F codes change automatically’.

F31

Drop Time

0 to 100

This is a drop time measurement function THAT DOES AN ACTUAL WELD. If F48 (Drop Time Configuration) is in either Manual or Auto mode, the measurement taken during the weld (while viewing this function) will be stored in this function and used in weld timing. The measured value may be overridden by using the arrow keys. This value changes automatically depending on F30 (short cycle mode) and the gun interface installed in the unit.

F32

Weld Results

I= Current (Amps) V= Voltage (Volts)

tM=Main current time (ms)

E= Energy (Joules)

tD=Drop Time (ms)

tP=Pilot Time (ms) Pass\Fail indicator

Cable Resistance (milliohms)

This F code gives information about the last weld. To save these weld results as the target (for weld

comparison), press and hold the ‘Lock’ key. To clear

targets, exit to time\current mode and click the 'Lock' key + the desired preset key at the same time. For the main preset (no preset), use the 'Lock' key + the time-down arrow key.

Page 28

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

F code

Description

Possible Values

Default

Unit

Notes

F33

Disable Welding on

Weld Error

OFF ON

OFF

Turn this on to disable welding when a weld error occurs or when a weld 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 or 3 to set the password.

F34

Drop Time Tolerance

0 to 1000

100

This defines the tolerance allowed from target weld drop time for determining good/bad weld.

F35

Weld Energy Tolerance

1 to 20

This defines the tolerance allowed from target weld energy for determining good/bad weld.

F36

Process Monitor Error

Code on Failed Weld

OFF ON

OFF

When enabled, an error code is given when the weld is out of tolerance.

F37

Pulse Cleaning Enable

OFF ON

OFF

When enabled, the weld current will pulse high current and low current before the weld.

F38

Pulse Cleaning

Threshold Voltage

0.00 to 50.00

30.00

Volts

Threshold voltage to stop pulsing and begin the main weld. When voltage is less than this value, it terminates pulsing and starts the weld.

F39

Pulse Cleaning

Maximum Pulses

1 to 36

Pulses

Maximum number of pulses before starting main weld.

F40

Pulse Cleaning Time to Subtract for Each Pulse

0 to 500

Time to remove from the main weld time per pulse done prior to the weld.

F41

Passing Weld Counter

0 to 4.3B

Welds

When process monitor is used, this holds a count of ‘passing’ welds. Hold the time down arrow to reset.

F42

Failed Weld Counter

0 to 4.3B

Welds

When process monitor is used, this holds a count of ‘failed’ welds. Hold the time down arrow to reset.

F43 Diagnostic Data

# Phases, PWM AVG,

ABORT code, Capacitor

imbalance, or Duty Cycle

# Phases

This gives extra diagnostic data after each weld. If the power unit is at the maximum output in voltage and current, PWM AVG will be 100%.

Page 29

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

F code

Description

Possible Values

Default

Unit

Notes

F44

Preset Bank

0 to 3

Bank

This determines which preset the 0-9 buttons are accessing. By selecting the preset bank, up to 40 presets can be accessed. For example, if the preset bank is set to 0, preset button 5 will access preset 5. If preset bbank is set to 1, preset button 5 will access preset 15. This F code changes automatically depending on short cycle mode and the gun interface installed in the power unit.

F45

Calibration Offset Value

0 to 250

Used by manufacturing. Do not change.

F46

Plunge Current

Enable

OFF ON

OFF

When enabled, the current will change to the selected value while the stud is plunging.

F47

Plunge Current

50 to MAX_CURRENT

200

Amps

When Plunge Current (F46) is enabled, this current will be used during the plunge 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

In Manual mode, F31 (Drop Time Function) is the only way to configure the drop time. In Auto mode, F31 automatically gets a new value taken from the first weld done after power-up and after the gun is reconnected. In Average mode, the average of the last 10 welds' drop times are used and displayed in F31.

F49 Pulse Weld Enable

OFF ON

OFF

Enable this to use pulse welding, where the main current pulses to a high and low current setting at variable time settings per F codes F50-F52.

F50

Pulse Weld

High Current

50 to MAX_CURRENT

300

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 unit can deliver given the power conditions and model.

F51

Pulse Weld High Time

5 to 1000

1000

This is the time the weld will deliver the front panel current (F50 current).

F52

Pulse Weld Low Time

5 to 1000

1000

This is the time the weld will deliver the low current.

Page 30

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

F code

Description

Possible Values

Default

Unit

Notes

F53

Cold Plunge Prevention

Enable

OFF ON

OFF

Enable this to continue delivering weld current beyond the same time settings if the stud does not short circuit before the weld current is scheduled to shut off. It will extend until a short circuit is detected or until 100ms passess (20ms in short cycle mode).

F54

Near Maximum Output

Warning Enable

OFF ON

Enable this to throw an error code E015 when the unit is near the maximum output power capability (>=95%)

F55

Cable \ Connector

Monitor Enable

OFF ON

OFF

Enable this to compare each weld’s cable drop to a

target value. To save a target value, press the LOCK key while viewing this function. Do this after making a weld.

F56

Cable \ Connector Monitor Tolerance

1 to 100

Percentage cable resistance from the saved target value that is considered acceptable. If out of tolerance, an E016 error will be generated.

F57

Lock Mode 4

Adjustment Percentage

1 to 20

Percentage the user may adjust the front panel time and current from the preset parameters while locked in lock mode 4.

F58

Keep Gun Lift Enable

OFF ON

OFF

Keeps the lifted after the weld for 5 seconds for the purpose of troubleshooting applications.

F59

Delay: Pilot current start

to gun lift

0 to 10

Delay from the time the gun coil is energized to the time the pilot arc is turned on.

F60

Constant Energy Enable

OFF ON

OFF

Enable this to deliver constant energy to a weld referenced by a target weld (stored as a preset).

F61

Pulse Cleaning

Contaminant to Be

Cleaned

Zinc or Galvanized to Primer

Paint, Oil or Oxide

Primer Paint...

Use this function to designate how the pulse cleaning function determines aborts pulsing and begins the main arc. Select 'Zinc\Galvanized' to start the main arc when the sensed voltage is above the threshold set in F38.

F62 Gun as Remote

OFF ON

OFF

Enable this to make the gun select presets based on the gun trigger as an input. Press and hold the gun trigger 2 seconds beyond the lift check to increment presets within a preset bank.

Page 31

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

F code

Description

Possible Values

Default

Unit

Notes

F63

Pecker Mode

0 to 20

# of

Pecks

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 contact between the stud and work piece or after the number of pecks is performed. When zero, pecking is disabled.

F64 Fieldbus Selection

OFF, Van Rob, Ford, GM

OFF

For automated systems, select the appropriate fieldbus selection to determine 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 signal is given after each weld to indicate that the weld was successful. The signal is 24VDC (unregulated), active high, 500ms long.

F66

Diagnostic Mode

0 to 4

Factory use only.

Other features:

•

To enter/exit demo mode, press 1,2, and 3 simultaneously. This will disable welding and flash LEDs.

Page 32

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

3.2 Diagnostic Error Codes

Error

Number

Error Display

What this really means

Fatal – meaning you

have to power down to

reset. Otherwise, you

weld again to reset.

Likely problem

E - - -

E - - -: NO ERRORS

Really, no errors.

E001

SHORTED CONTROL CABLEFIX CONTROL CABLE AND/ OR GUN

The gun control cables were shorted or the gun coil resistance is too low.

Shorted cable-external wiring problem in the gun circuit

-See troubleshooting-

E002

BROWNOUT CONDITION CHECK PRIMARY VOLTAGE

The input voltage dipped low enough to drop out auxiliary supplies. Welding is stopped until power is restored so as to prevent internal damage.

Brown out on input power line E002(A) Brownout while idle E002(B) Brownout while welding

-See troubleshooting-

E003

CAPACITOR VOLTAGE IMBALANCE

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 troubleshooting-

E004

REGULATION ERROR-ARC WENT OUT

The control sensed that the current was more than 50% low and the control is applying the maximum allowable pulse width for 10ms.

Current sensor wiring or extremely high load

-See troubleshooting-

E005

REGULATION ERRORSHORT CIRCUIT-COULDN’T CONTROL CURRENT

The control sensed that the current was more than 50% high and the control is applying the minimum allowable pulse width for 10ms.

Current sensor wiring or dead short circuit

-See troubleshooting-

E006

INPUT VOLTAGE TOO HIGH

This happens if the capacitor voltage exceeds 470V during bootup process.

Input voltage is too high

-See troubleshooting-

E007 INPUT VOLTAGE TO LOW

On boot-up only, after closing the charge relay, the caps have 10 seconds to get the proper voltage.

Incorrect voltage setting or broken/bad V-F signal from one or more switch boards.

-See troubleshooting-

Page 33

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Error

Number

Error Display

What this really means

Fatal – meaning you

have to power down to

reset. Otherwise, you

weld again to reset.

Likely problem

E008

PRIMARY OVERCURRENT ERROR

A primary overcurrent occurred.

On-board control PCB failure

-See troubleshooting-

E009

NO GUN LIFT DURING PILOT ARC PERIOD

The gun did not lift within the pilot arc period

Shorted gun control cable, mechanical binding of the gun, pilot arc pcb failure, or excessive contaminants on work surface.

-See troubleshooting-

E010

CAPACITOR VOLTAGE COULD NOT BE READ

The sensed capacitor V-F signal is not within the acceptable bounds.

Check V-F signal from Switch Boards

-See troubleshooting-

E011

UNIT TOO HOT PLEASE WAIT

The thermal sensor was tripped. This error will disappear 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 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 happen.

-See troubleshooting-

E013

WELD FAILED –OUT OF TOLERANCE

The last weld was out of tolerance from the target weld by weld energy or drop time.

The error display will determine and display the offending parameter. Change the weld wetup accordingly.

-See troubleshooting-

E014 NO STUD HIT DETECTION

The stud is expected to hit the workpiece after the gun coil is de-energized, but before the main current is turned off. If it is not detected, this error will occur.

Incorrect weld parameter setup. Check drop time, weld time, and plunge time. Press LOCK button to clear error.

-See troubleshooting-

Page 34

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

Error

Number

Error Display

What this really means

Fatal – meaning you

have to power down to

reset. Otherwise, you

weld again to reset.

Likely problem

E015

WARNING - NEAR MAXIMUM WELDING OUTPUT CAPACITY

If the unit is delivering 95% of the maximum power capacity, it will display this warning. It will not damage the unit to operate at this level, but is intended to inform 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 warning can be disabled using F54

Small weld cable, long weld cable

-See troubleshooting-

E016

WARNING _ CHECK WELD CABLES AND CONNECTORS

- PRESS 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

PILOT ARC BLEW OUT DURING PILOT STAGE

Arc voltage was detected to have been higher than 60V after the gun lifted, which is too high to still have an arc.

Debris on the work moterial.

E018

WARNING - DROP TIME IS TOO LONG FOR SHORT CYCLE

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, so it is possible the arc will go out before the main arc starts. For consistent welds, reconfigure the drop time and\or front panel time to satisfy the equation

F code \ Front panel configuration ADDITIONAL WARNING WAIT ON UPPER DISPLAY AND CYCLE OR CAP ON LOWER DISPLAY

1. Weld duty cycle is exceeded

2. Switch board out of calibration

3. Switch board malfunction

1 of 3 reasons.

-See troubleshooting-

Page 35

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

3.2.1

Notes on which F codes change automatically

4-Wire Gun Interfaces

Action Result F31 - Drop TIme

F2 - Plunge

Short Circuit

F44 - Preset Bank

F30 - Short

weld weld

Other Notes

Enable = ON

For firmware version 1.06 and higher.

On-Time

Cycle Enable

max

min

F30

Short Cycle

7ms 20ms

2 (Short Cycle

Mode = ON Values)

100ms

5ms

Limits Stud Expert studs, 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 min weld time.

F12

Sud Feed

- - - ON

2-Wire Gun Interfaces

F2 - Plunge

Action Result F31 - Drop TIme Short Circuit F44 - Preset Bank

F30 - Short

weld

Other Notes

On-Time

Cycle Enable

max

min

F30

Short Cycle

35ms 20ms

2 (Short Cycle

Mode = ON Values)

100ms

5ms

Limits Stud Expert studs, Limits presets to 100ms max weld time.

F30

Short Cycle 0 (Drawn Arc

Mode = OFF

35ms 100ms

English Values)

1000ms

Limits Stud Expert studs, Limits

100ms presets to 100ms min weld time.

F12

Sud Feed

- - - ON

Page 36

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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

3.3 Weld Process Problems

Problem

Possible Cause

Solution

Weld appears “hot”

Time setting or current setting 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. Reduce the current setting and perform weld inspections.

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.

Incorrect ferrule.

Ensure that the ferrule being used in the welding process is the proper ferrule for the stud size and application.

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 decrease the free travel.

Weld appears “cold”

Time setting or current setting is too low.

Check the stud burn-off. If the burn-off is much less 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.

Incorrect ferrule.

Ensure that the ferrule being used in the welding process is the proper ferrule for the stud size and application.

Inconsistent gun lift.

Perform a Lift Check. Ensure proper lift settings are being used. Correct the lift to the proper setting if the lift is improperly set.

Perform weld inspections.

Inconsistent gun lift.

Perform a Lift Check, several times. Ensure proper lift settings are being used. If lift results are inconsistent, disassemble and clean the gun.

Too much plunge.

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.

Page 37

Stud welding unit N1500i Version 1.31 7.June.2013

Manual part number: 729-110-027

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 accessories 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 offcenter, it can restrict the plunging motion of the stud during welding.

Time setting or current setting is too high.

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 contamination.

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 different than the programmed weld time set-point. No error is displayed.

F31 gun drop time is not calibrated 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 together 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.