Nelson N1500i Operation manual

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N1500i
For Control Board Software 1.06 and higher
Operation and Service Manual

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Table of contents
1. Introduction ................................................................................................. 4
1.1 General .............................................................................................................. 4
1.2 Unit Description ............................................................................................... 5
1.3 Welding Method .............................................................................................. 6
1.4 Operational Sequence ...................................................................................... 7
1.5 Welding Elements ............................................................................................ 8
1.6 Ceramic Ferrules .............................................................................................. 8
1.7 Material Combinations.................................................................................... 9
1.8 Technical Data ................................................................................................ 11
1.9 Declaration of Conformity............................................................................. 17
2. Safety at work............................................................................................ 18
2.1 Safety Symbols................................................................................................ 18
2.2 Safety notices .................................................................................................. 19
2.3 Intended use ................................................................................................... 24
2.4 Guarantee and 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 Intermediate range ........................................................................................ 28
3.5 Storage............................................................................................................. 28
3.6 Transport......................................................................................................... 28
3.7 Operating Location........................................................................................ 29
4Connection and Installation.................................................................... 31
4.1 Installation Precautions ................................................................................. 31
4.2 Connection...................................................................................................... 31
4.3 Arc Blowing Effect ......................................................................................... 37
4.4 Connection Diagram Short-Cycle and Drawn Arc Welding..................... 40
4.5 Connection Diagram Shielding Gas ............................................................. 41
4.6 AdditionalCautions....................................................................................... 42
5. Control and Display Elements .................................................................. 44
5.1 Front Panel Controls and Displays ............................................................. 44
6. Operation.................................................................................................... 47
6.1 Advice on Stud Welding ............................................................................... 47
6.2 Basic Procedure............................................................................................... 48
6.3 Weld Parameters............................................................................................ 48

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
6.4 Rating Charts.................................................................................................. 62
6.5 N1500i Weld Cycle Timing ........................................................................... 65
6.6 Drop Time Variables...................................................................................... 69
6.7 Inspection and testing of the weld ............................................................... 70
6.8 Weld process monitor .................................................................................... 74
6.9 Plunge Current............................................................................................... 77
6.10 Pulse Welding (in main current) .................................................................. 79
6.11 Pulse Cleaning (during the beginning of main arc stage)......................... 80
6.12 Password Reset............................................................................................... 81
6.13 Demo Mode .................................................................................................... 81
6.14 Cable Resistance Monitor.............................................................................. 81
6.15 Constant Energy* ........................................................................................... 81
6.16 Chuck Change Indicator ............................................................................... 82
6.17 Configuring the stud feed interface to act as a ‘Weld Complete’ signal . 82
6.18 F Code F61 - Pulse Cleaning Contaminant to 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
7.2 Weld Process Problems................................................................................ 102
8. Maintenance ............................................................................................ 102
8.1 Care and cleaning ........................................................................................ 102
8.2 Routine Maintenance ................................................................................... 103
9. Drawings and parts lists......................................................................... 105
9.1 Explosion drawing Final Assembly N1500i.............................................. 105
9.2 Cover Assembly............................................................................................ 108
9.3 Chassis Sub ASM ......................................................................................... 109
9.4 Front panel assembly...................................................................................... 111
9.5 Horizontal panel assembly............................................................................. 113
9.6 Vertical panel sub assembly........................................................................... 115
10.Troubleshooting ..................................................................................... 117
10.1 How to use Troubleshooting guide ........................................................... 117
10.2 Problems / Possible Cause / Solution ............................................................ 119
10.3 Welding Problems ......................................................................................... 120
10.4 Wiring Diagram Nelweld N1500i ................................................................. 142
11.Annex ........................................................................................................ 143
11.1 Disposal of the Nelweld N1500i ................................................................. 143
11.2 Disposal in accordance with the European directive ............................. 144
11.3 Abbreviations............................................................................................... 146
11.4 Literature ...................................................................................................... 147

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
4
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
1. Introduction
1.1 General
The operating and service instructions to hand refer to the Nelweld N1500i welding
unit. They are intended for operating and service personnel.
Trouble-free operation 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 customer service of Nelson,
which will be very glad to help you.
The illustrations, specifications and technical data in these operating and service
instructions are in accordance with the status of As of June 06.2012.
Nelson reserves the right to make any technical modifications, which contribute to
an improvement in the Nelweld N1500i.

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
5
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
1.2 Unit Description
The Nelweld N1500i is a mobile welding unit, which in connection with a manual-
loading gun serves to weld metallic studs onto workpiece surfaces that are suited for
welding.
Commercially available studs can be welded both according to the drawn-arc
and the short-cycle welding method with the Nelweld N1500i. The variation in
method must be selected with the function code.
The Nelweld N1500i works on the basis of a compact inverter power source and
with extremely short weld times supplies constant weld currents up to 1500A.
In this connection,the rectified mains voltage is transformed into high frequency
voltage by means of an inverter. The inverted voltage is transmitted by a high-
frequency transformer and rectified on the out- put side.
As a consequence of the high control rate of the Nelweld N1500i the reproducibility of
the welds is increased, and the quality of the welds clearly improved.
In contrast 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 required for stud welding can be set stepless on the
appropriately display function keys.
The entire weld cycle is coordinated by the control unit of the Nelweld N1500i and
can be visually traced by means of the LED display elements. Fault messages are
issued, and numerically coded, on the error display.
In order to keep the temperature level of the Nelweld N1500i as low as possible the
N1500i has two thermostats to monitor internal temperature level. One thermostat
is used to turn on the fan automatically when the internal temperature reaches a
level. Another thermostat checks if ahigherunsafelevelis reachedandstopsthe
inverterand dis- plays an error message.
Ifthe temperatureis exceeded, the weldingunit preventswelding temporarily. Thermal
overloadis indicated by meansofa flashingwarning triangle and E011 displayed if
function key pressed.
In the Europeversionthe Nelweld N1500ihasa 4-polecontrolcablesocket to transmit
the controls signals to the configured weld gun.
The gun configuration always follows from the variation in method used. Thus, the

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
6
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
drawn-arc method requires the connection of a gun of type NS 40-B. Short-cycle
welding must be performed with an NS 40 SL or PFL 901 gun.
See the pertinent gun operating instructions for knowledge on hand- ling weld guns
in a professional and safe manner.
The bright dot matrix display shows the function codes in plain text and can
typically even be read in sunlight.
1.3 Welding Method
Commercially available studs with a diameter of up to 16mm can be welded with
the Nelweld N1500i.
•with the drawn-arc method (16mm)
•with the short-cycle method (12mm)
The drawn-arc method serves to full-surface weld studs of specific geometric
dimensions to metallic workpieces, which should have a wall thickness of at least ¼
of the stud diameter.
In order to guarantee deoxidization of the weld pool and to better ignite 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 the molten liquid metal in order to centerthearc. In addition
to this, the moltenmetal is prevented from cooling too quickly.
When welding overhead or in a horizontal position the ceramic ferrule ensures that
the weld bead always has a constant shape and provides the user with protection
against spatter.
The short-cycle method is a variation of the drawn-arc method, which in extremely
short weld times makes no special demands of the type of stud tip.
With the exception of the shorter weld times, the operational sequence is identical
with that of normal arc welding.
In keeping with the short-cycle method welding studs can also be weldedon
coatedwith oil contaminationworkpiecesurfaces, themini- mum plate thickness of
which should not exceed 0.6mm.
On account of the extremely short weld times the studs can also be welded
without ceramic ferrule. To protect the weld pool, particularly with aluminum welds, it
is advisable to use inert gas.

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
7
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
The introduced inert gas displaces the air from the welding zone. If welds are to
be carried out under inert gas, it is preferable to use studs with a tapered welding tip.
1.4 Operational Sequence
When welding in keeping with the drawn-arc method the gun must be loaded with a
stud and a ceramic ferrule. When welding in keeping with the short-cycle method
the ceramic ferrule is usually not used.
The loaded gun is pressed onto the workpiece at a right angle until the supporting
tube touches the workpiece. The stud projecting from the supportingtube is pushed
backat the same time compressingthe pressure spring of the gun.
When the weld command is given, a pilot arc flows along the short circuit 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 drawn to begin
with and then the main arc is ignited.
During the travel motion the arc melts the end of the stud and an ap- proximately
equallysized area onthe workpieceso thatapoolof liquid metal is formed under the
arc and the stud.
As soon as the gun coil is switched off-circuit the stud accelerates back onto the
workpiece as a result of the force of the pressure spring.
Once the stud plunges into the weld pool, the main arc extinguishes, and the weld
current is switched off. The stud is pressed into the still liquid molten mass before
the weld pool solidifies.
The gun is removed from the stud. When welding with ceramic fer- rules the latter
must be knocked off the cooled stud.
1.4.1 Welding sequence diagram:
1.Placing
the
welding
stud
2.Drawing
the
auxiliary
arc
3.Ignitingthe
main arc
4.Immersing
the welding
stud
5.Endof welding

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
8
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
The weld time asper drawn-arc methodis approx. 100ms-1000ms.
For the short-cycle method the weld time is approx. 10ms - 100ms.
1.5 Welding Elements
According to the short-cycle method threaded studs (SC-B; SC-Z), in- ternal inserts
(SC-1) and pin studs (SC-S) of various dimensions and materials can be welded.
In keeping with the drawn-arc method threaded studs, head studs and cylinder pins
and other welding elements (according to EN ISO 13918) can be welded.
The following conditions 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 Ceramic Ferrules
Ceramic ferrules (according to EN ISO 13918) are used when welding in keeping
with thedrawn-arc method.Theyform a combustion chamber around the weld,
which centers the arc and protects the user against welding spatter.
In addition to this, the cooling down rate of the weld is reduced and an even shape of
the bead is achieved.
The following conditions have to be observed:
•An appropriate ceramic ferrule is required for every stud diameter
•For differing ceramic ferrules corresponding ceramic ferrule holders are needed
The LFH 000 catalogue offers an overview of the Nelson ceramic ferrule product

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
9
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
range.
1.7 Material Combinations
The welding suitability of the different metals and the combinations of bolt material
and base material depend on the welding process.
The material combinations listed in the following table have been tried and tested and
comply with ISO/TR 156081.
Explanation of the superscript letters:
a) For example for power transmission
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
Group
s 1
and
ISO/TR
15608
Group
s 2.2,
3 ... 6
ISO/TR 15608
Group
s 8
and
10
ISO/TR 15608
Group
s 21
and
22
S23
5
4.6
16 Mo3
Well suitable
for any
application a
Suitable with
restrictions bSuitable with restrictions b c
Not
suitable for
welding
1.4742 Suitable with
restrictions bSuitable with restrictions bSuitable with restrictions bSuitable with restrictions b
1.4762
1.4828 Suitable with
restrictions bSuitable with restrictions bSuitable with restrictions b
Not suitable
for
welding
1.4841

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
10
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
1.4301
1.4303
1.4401
1.4529
1.4541
1.4571
Suitable with
restrictionb Well
suitable for any
application a e
Suitable with
restrictionsb
Well
suitable for
any
applicationa
Not suitable
for welding
EN AW-AIMg3
EN AW-AIMg5 Not suitable
for welding Not suitable for welding
Not
suitable
for
welding
Suitable
with
restrictionsb
Group 1:
Steel with a specified minimum yielding point ReH
≤460 N/ mm²
Group 2.1
Thermo-mechanically rolled fine-grain structural
steel and steel casting of a specified minimum
yielding point of 360 N/ mm² < ReH
≤
460 N/mm²
Group 2.2:
Thermo-mechanically rolled fine-grain structural steel
and steel casting of a specified minimum yielding
point ReH > 460 N/mm²
Group 3:
Hardened and tempered and precipitation-hardened
steel,but no rustproof steel, of a specified minimum
yielding point ReH > 360 N/mm²
1.
ISO/TR 15608: Welding Guidance on Grouping Metallic Materials
(2000 06)
Group 4:
Low vanadium-alloyed Cr-Mo-(Ni) steel with Mo ≤
0.7% and V ≤ 0,1%
Group 5:
Vanadium-free Cr-Mo steel with C ≤ 0,35%)
Group 6:
Highly vanadium-alloyed Cr-Mo-(Ni) steel
Group 8:
Austenitic steel
Group 10:
Austenitic ferritic rustproof steel (duplex)
Group 21:
Pure aluminum ≤ 1% impurities or alloy contents

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
11
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 7-19, 58285 Gevelsberg
Group 22:
Not heatproof alloysNote!
Note!
Please consult a Nelson expert for material combinations that are not
listed in the table and applications where aluminum studs should be
welded.
1.8 Technical Data
Unitdesignation/Type: Stud welding unit / N1500i Version:
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-loadvoltage: 75V
ON period: 6%
Weld sequences for at biggest diameter
• Drawn-arc method: max. 7 weld/min
• Short-cyclemethod: max. 30 weld/min
Weld current range: 50-1500A
Weld time range for
• Drawn-arc method: 100ms-1000ms
• Short-cyclemethod: 5ms-100ms
Unit fuses F1, F2: 1A, 600V, fusing slow response
characteristics
Protection type due to casing: IP23 S
Protectionclass: 1 (one)
OperatingTemperature: -0 to +40 Degrees C
StorageTemperature: -25 to +55 Degrees C

Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
12
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 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/43Kg w/ mains cable
Mains plug: CEE (5 pole); 63A at 400V
Mains cable: H07RN-F 4G16 (4x16mm2)
Length: 4m

11
Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstraße 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
418,77
460
428,27
9,50

14
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
1.8.2 Accessories (optional)
Weld guns for manual stud loading:
Weld gun: Type NS 40 SL
complete with accessories: see NS 40 SL operating
instructions Shielding gas device: order no. 67-03-04
Weld gun: Type NS 40 (B-1, B-2, B-3, B-4)
complete with accessories: see NS 40 B operating
instructions Shielding gas device: order 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:
(specific to the studs): Type FFL 100, hand operated“
complete with accessories: see FFL 100 operating
instructions Mains cable for the feeder: on request (220V)
Gas hose pipe:
10 m shielding gas hose pipe system (Nelweld N1500i-gun): order no. 67-07-50
Connecting cable (standard):
Nelweld N1500i - Workpiece:
Earth cable H01N2-D (with 2 earth holders):
Cable cross-section: 2 x 35 mm2
Minimum bending radius: 130 mm
Length 5.0m: order no. 68-01-92 (others on request)

15
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
Nelweld N1500i - Feeder:
Welding cable:
Cable cross-section: 50mm2
Length 5.0m: order no. 68-03-63 (others on request)
Control cable, 7-pole:
Cable cross-section: 8 x 0.5mm2
Length 5.0m: order no. 68-04-82 (others on request)
1.8.3 Option Kits / Accessories
Quantity
Part Number
Description
1
512-387-005
a
Mobility Kit (General Stud Welding)
1
512-387-006
a
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
Protective Gas Kit
1
751-692-050
NS40N W/ Plunge Dampener, 2wire
1
751-585-200
NS40N W. Short Cycle Core, 2wire
1
751-585-700
NS40, FL, MD, W/ Composite Cable
1
722-000-150
2/0 Combination Cable-HD Gun 50Ft.
1
722-000-154
2/0 Combination Cable-SD Gun 50Ft.
1
722-000-155
2/0 Combination Cable-SD Gun 25Ft.
1
722-000-156
4/0 Combination Cable-SD Gun 25Ft.
1
512-387-055
Ethernet patch cable
CONTACT NELSON STUD WELDING SALES REPRESENTATIVE FOR AVAILABILITY

16
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
1.8.4 Guns cable extension incl. control cable
Length (m)
Cross section (mm
2
)
Part Number / Socket inclusive control cable with BIN 4
50
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 control cable with BIN 4
67
107
7,5
722-000-165
a
722-000-167
a
15
722-000-164
a
722-000-166
a
1.8.5 Mass cable extension
Length (m) Cross section (mm2)
Part Number / Socket
50
70
5 68-03-61 / 50 BKa
68-03-63 / 50 BK/SK
b
68-04-39 / 70
10 652-23-41 / 50 67-02-09 / 70/95
15
67-03-78 / 50
-

17
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
A. BK: SOCKET CONTACT
B. BK/SK: PLUG CONTACT
1.9 Declaration of Conformity
Manufacturerand technical Nelson Stud Welding, Inc
documentationholder: 7900 West Ridge Road
Eyria, Ohio 44036-2019 USA
EuropeanRepresentative: Tucker GmbH,
Mail / Post: Max-Eyth-Str.1,
35394 Gießen, Germany
Hereby declare, that the welding unit of type Nelweld N1500i for the welding of studs
in keeping with the drawn-arc and short-cycle welding method was developed,
constructed and manufactured in accordance with the following EC guidelines:
Low voltage 2006/95/EEC
• EMC 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 for welding cables”
(2005)
EN 60529 “Degrees of protection provided by enclosures (IP- Code)” (2000)
EN 60974-10 “Arc welding equipment – Part 10: Electromagnetic compatibility (EMC)
requirements” (2003)
Thefollowingnationalstandardsandspecificationshavebeenapplied:
Accident prevention regulation BGV A3
“Electrical installations and operating materials“(1997)
Operating working material BGR 500 (2007) Technical documentation are on hand.
TheoperatingandserviceinstructionspertinenttotheNelweldN1500i are available,
•in the original version
•in the operator’s language
Manufacturer: EuropeanRepresentative:
Ken Caratelli DetlevVierschilling
ManagingDirector ManagingDirector

18
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
2. Safety at work
2.1 Safety Symbols
Safetynoticesand warningsare madeonthe onehandfor yourpersonal safety and
on the other hand for product safety. In these operating instructions they are made
to stand out by means of the following safety symbol.
The applied symbol has the following meaning:
The caution sign draws your attention to potentially dangerous
situations. It is always used in connection with one of the
supplementary terms which are defined as follows.
The used supplementary terms have the following meaning:
Warning!
The system operator is obliged only to allow persons to work with the
unit,
who are acquainted with the safety at work and accident prevention
regulations and have a trainingauthorizing them to performstud welding!
All persons who work with the unit are obliged to read and observe all t
he
operating and service instructions of the welding unit prior to
commencing work! In addition, the operating instructions of the weld gun
connected in each case must be read and observed!
Danger The addendum means that death, grievous bodily harm or
considerable damage to property will occur if the
corresponding preventive measures are not taken.
Warning
The addendum means that death, grievous bodily harm or
considerable damage to property can occur if the
corresponding preventive measures are not taken.
Caution The addendum means that slight bodily harm or damage to
property can occur if the corresponding preventive measures
t tk
This sign contains important information about the correct
method of handling the product or special advice, to which
particular reference is to be made.

19
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
2.2 Safety notices
Safety should be one of the utmost concerns for each user of a Nelweld unit.
Knowledge of and careful attention to all safety advice granted in this manual is
highly advised by Nelson Stud Welding, Inc.
Observing all safety warnings and advice is a prerequisite for safe and correct
handling and trouble-free operation of the Nelweld series of stud welding power
supplies.
Knowledge ofthe following safetynotices is a prerequisite for safe and correct
handling and trouble-free operation of the Nelweld N1500i.
In addition,the technicalregulationsfor safe and professional working as well as the
generally valid accident prevention regulations 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, etc. must remain attached to the Nelweld unit at all times.
They should remain free from dirt and be kept in legible condition
Personnel training
Warning!
Only a qualified electrician should perform any work inside the unit’s
casing. Any work done should be made in accordance with all local
and national electrical codes. Failure to do so may result in bodily
injury or death.
The operating personnel of the welding unit must:
•be instructed in handling welding appliances
•have had training, which permits stud welding
•know the contents of these operating and service instructions
The maintenance and the electrical specialists must:
•have had training, which qualifies to carry out repairs
•be entitled to operate electrical circuits and appliances in accordance with safety
engineering standards

20
Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany.
Stud welding unit N1500i
As of: Aug 12.2021
Manual part number: BE 1221
Apprentices or personnel receiving on the job training may:
•only work with the welding unit under supervision of an experienced person
Personal protection equipment (PSA):
Welding spatter, arcs and a noise level of 75dB. Consequently, the wearing of the
following personal protection equipment is a mandatory stipulation:
Symbol Beschreibung
Hardly inflammable protective clothing covering the whole body as per EN
470
Welder's protective filter with safety plates according to DIN EN 169
Protective gloves 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 notattemptto lift the Nelweld unit alone.
Seek the assistance of at least one other person when moving or lifting
the unit.
During welding, exposed parts of the welding head are current carrying. For this
reason wear no electrically conductive jewelry (wrist watch or chain).
Protective measures at the workplace:
The workplace must be such that people in the vicinity are adequately protected
against the harmful effects of optical radiation.
Spacelimiters and protectivescreensmust beplaced in such a way that the reflection
and permeability of any radiation are for the most part avoided.
Combustible and inflammable materials must be removed from the welding zone.