Stud welding unit N1500iVersion 1.31 7.June.2013Manual part number: 729-110-027Stud welding unit N1500iTMFast Start ManualFor Control Board Firmware Version 1.06 & Higher(See Nelson representative for full manual)Copyright 2013 Nelson Stud Welding, Inc. All rights reserved.Nelson Stud Welding, Inc. 7900 West Ridge Road Elyria, Ohio 44035 USA
INVERTER LIMITED WARRANTYNelson’s only warranty is that goods being sold will be free from defects inworkmanship and material. This warranty is expressly in lieu of other warranties,expressed or implied and whether statutory or otherwise, including any impliedwarranty of merchantability or fitness for a particular purpose.Nelson’s liability for breach of warranty shall arise only upon return of thedefective 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 suchdefects or, at Nelson’s option, to refunding the purchase price (less reasonabledepreciation based on actual use); provided, however, that Nelson will not acceptreceipt of equipment returned unless buyer has previously afforded Nelson’spersonnel a reasonable opportunity to inspect and repair said equipment atbuyer’s facility or such other location as is mutually agreeable. Notice to Nelsonmust be given within 30 days of such defect or failure and within two years or onemillion welds from the date the equipment was delivered, whichever comes first.No compensation or reimbursement for transportation costs of any kind will beallowed.Please note that this warranty does not extend beyond the original registeredpurchaser, and does not warrant equipment that has been modified by any partyother than Nelson, or equipment that has been improperly installed, improperlyoperated, or misused based upon industry standards, or equipment which has nothad reasonable and necessary maintenance, or equipment which has been usedfor operation outside of specifications for the equipment. Nelson shall never beliable for consequential damages.Nelson reserves the right to make engineering and/or part changes, at any timewithout notice, as a result of our commitment to continuous improvement. 2013 Nelson Stud Welding, Inc. All Rights Reserved.
WARNINGThe following Safety section is for n from the references listed in theAdditional Safety Information section. es, be sure to read and follow thesafety precautions listed below as well as all 1.other manuals, material safety data sheets,labels, etc. Failure to observe these precautions 2.3.can result in injury or death.PROTECT YOURSELF AND OTHERSSome welding, cutting, and gouging processesare noisy and require ear protection. The arc,like the sun, emits ultraviolet (UV) rays andother radiation which can harm the skin andeyes. Hot metal can cause burns. Training inthe proper use of the processes andequipment is essential to prevent accidents.Therefore:22.214.171.124.5.6.Always wear safety glasses with side shields in any workarea, even if welding helmets, face shields and gogglesare also required.Use a face shield fitted with filter shade #3 per ANSIZ87.1. Cover sparks and rays of the arc when operatingor observing operations. Warn bystanders not to watchthe arc and not to expose themselves to the rays of theelectric-arc or hot metal.Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high topped shoes, and a weldinghelmet or cap for hair protection, to protect against arcrays and hot sparks or hot metal. A flameproof apron mayalso be desirable as protection against radiated heat andsparks.Hot sparks or metal can lodge in rolled up sleeves,trousers cuffs or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing.Protect other personnel from arc rays and hot sparks withsuitable nonflammable partitions or curtains.Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.126.96.36.199.188.8.131.52.184.108.40.206.Remove all combustible materials well away from the workarea or cover the materials with a protectivenonflammable covering. Combustible materials includewood, cloth, sawdust, liquid and gas fuels, solvents, paintsand coatings, paper, etc.Hot sparks or hot metal can fall through cracks or crevicesin floors or wall openings and cause a hidden smolderingfire or fires on the floor below. Make certain that suchopenings are protected from hot sparks and metal.Do not weld, cut, or perform other hot work until the workpiece has been completely cleaned so that there are nosubstances on the work piece which might produceflammable or toxic vapors. Do not do hot work on closedcontainers. They may explode.Have appropriate fire extinguishing equipment handy forinstant use, such as a garden hose, water pail, sandbucket or portable fire extinguisher. Be sure you aretrained for proper use.Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when necessary.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 02269Be sure the power source frame (chassis) is connectedto the ground system of the input power.Connect the work piece to a good electrical ground.Connect the work cable to the work piece. A poor ormissing connection can expose you or others to a fatalshock.Use well-maintained equipment. Replace worn ordamaged cables.Keep everything dry, including clothing, work area,cables, torch/electrode holder and power source.Make sure that all parts of your body are insulated fromwork and from the ground.Do not stand directly on metal or the earth whileworking in tight quarters or a damp area; stand on dryboards or an insulating platform and wear rubbersoledshoes.Put on dry, hole-free gloves before turning on thepower.Refer to ANSI/ASC Standard Z49.1 for specificgrounding recommendations. Do not mistake the worklead for a ground cable.ELECTRICAL AND MAGNETIC FIELDSElectric and magnetic fields may bedangerous. Electric current flowing throughany conductor causes localized Electric andMagnetic Fields (EMF). Welding and cuttingcurrent creates EMF around welding cablesand welding machines. Therefore:1.2.3.FIRES AND EXPLOSIONSHeat from flames and arcs can start fires. Hotslag or sparks can also cause fires andexplosions. Therefore:1.ELECTRICAL SHOCKContact with live electrical parts and groundcan cause severe injury or death. DO NOT usewelding current in damp areas, if movementis confined, or if there is danger of falling.Therefore:Operators having pacemakers should consult theirphysician before welding. EMF may interfere with somepacemakers.Exposure to EMF may have other health effects whichare unknown.Operators should use the following procedures tominimize exposure to EMF:a. Route the electrode and work cables together. Securethem 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 workcables. Route cables on the same side of your body.d. Connect the work cable to the work piece as close aspossible to the area being welded.e. Keep welding power source and cables as far awayfrom your body as possible.FUMES AND GASESFumes and gases can cause discomfort orharm, particularly in confined spaces. Donot breathe fumes and gases. Shieldinggases can cause asphyxiation. Therefore:220.127.116.11.Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, orgouge on materials such as galvanized steel, stainlesssteel, copper, zinc, lead, beryllium, or cadmium unlesspositive mechanical ventilation is provided. Do notbreathe fumes from these materials.Do not operate near degreasing and sprayingoperations. The heat or arc rays can react withchlorinated hydrocarbon vapors to form phosgene, ahighly toxic gas, and other irritant gasses.If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation isnot adequate. Stop work and take necessary steps toimprove ventilation in the work areas. Do not continueto operate if physical discomfort persists.Refer to ANSI/ASC Standard Z49.1 (see listing on nextpage) for specific ventilation recommendations. 2013 Nelson Stud Welding, Inc. All Rights Reserved.
ELECTRICALLY POWERED EQUIPMENTFaulty or improperly electrified equipmentcan cause injury or death. Therefore:18.104.22.168.Always have qualified personnel perform the installation,troubleshooting, and maintenance work. Do not performany electrical work unless you are qualified to performsuch work.Before performing any work inside a power source,disconnect the power source from the incoming electricalpower using the disconnect switch at the fuse box beforeworking on the equipment.Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacture’srecommendations.Ground the equipment in accordance with the U.S.National Electrical Code and the manufacturer’srecommendations.CYLINDER HANDLINGCylinders, if mishandled, can rupture andviolently release gas. Sudden rupture ofcylinder, valve, or relief device can injure orkill. Therefore:22.214.171.124.5.Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition.Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages,benches, walls, post, or racks. Never secure cylinders towork tables or fixtures where they may become part ofan electrical circuit.When not in use, keep cylinder valves closed. Have valveprotection cap in place if regulator is not connected.Secure and move cylinders by using suitable handtrucks. Avoid rough handling of cylinders.Locate cylinders away from heat, sparks, and flames.Never strike an arc on a cylinder.For additional information, refer to CGA Standard P-1,“Precautions for Safe Handling of Compressed Gases inCylinders”, which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington, VA22202HEARING PROTECTIONProlonged Noise from Capacitor Dischargewelding applications can damage hearing iflevels exceed limits specified by OSHA.Therefore:1.2.3.EYE PROTECTIONFlying metal can injure eyes. Welding,chipping, wire brushing and grinding cancause sparks and flying metal. As welds cool,they can throw off slag. Therefore:1.2.Wear approved safety glasses with side shields evenunder your welding helmet.Warn others nearby about flying metal hazard.EQUIPMENT MAINTENANCEFaulty or improperly maintained equipmentcan cause injury or death. Therefore:126.96.36.199.5.6.Always have qualified personnel perform the installation,troubleshooting, and maintenance work. Do not performany electrical work unless you are qualified to performsuch work.Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.Do not abuse any equipment or accessories. Keepequipment away from: heat sources such as furnaces wet conditions such as water puddles and inclementweather oil or grease corrosive atmospheresKeep all safety devices and cabinet covers in positionand in good repair.Use equipment only for its intended purpose. Do notADDITIONAL SAFETY INFORMATIONFor more information on safe practices forelectric arc welding, refer to the followingpublications.188.8.131.52.5.ANSI/ASC Z49.1 Safety in Welding and CuttingAWS C5.1 Recommended Practices for Plasma ArcWeldingAWS C5.6 Recommended Practices for Gas Metal ArcWeldingAWS SP Safe Practices (Reprint) Welding HandbookANSI/AWS F4.1 Recommended Safe Practices forWelding and Cutting of Containers That Have HeldHazardous SubstancesUse Approved ear plugs or ear muffs if noise level ishigh.Warn others nearby about noise hazard.For additional information, refer to OSHA SafetyStandards 3074.MOVING PARTS CAN CAUSE INJURYElectric fan can start at any time withoutwarning and cause severe injury, therefore:184.108.40.206.5.Always disconnect electrical power prior to service toprevent the fan from starting unexpectedly.Keep all doors, panels, covers, and guards closed andsecurely in place.Have only qualified people remove guards or covers formaintenance and troubleshooting as necessary.Keep hands, hair, loose clothing, and tools away frommoving parts.Reinstall panels or guards and close doors whenservicing is finished and before reenergizing welder. 2013 Nelson Stud Welding, Inc. All Rights Reserved.
Stud welding unit N1500iVersion 1.31 7.June.2013Manual part number: 729-110-027CONTENTS1 Connection and Installation. . 11.1 Installation Precautions . 11.2 Connection . 11.2.1 Input Connection . 31.2.2 Single Phase Connections . 31.2.3 Change Input Voltage (Reconnect) . 41.2.4 Connection of the Welding Cable . 61.2.5 Connection of the Control Cable . 61.2.6 Connection of the Ground Cable.