Nelson N800iTM Operation manual

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of: 24.08.2021
Manual part number: BE 1227
Stud welding unit N800iTM
For Control Board Software 1.06 and higher
Operation and Service Manual

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of: 24.08.2021
Manual part number: BE 1227
TABLE OF CONTENTS
Stud welding unit N800iTM .................................................................... 1
Operation and Service Manual .......................................................... 1
1. Introduction ................................................................................................ 1
1.1 General ........................................................................................................1
1.2 Unit Description.........................................................................................2
1.3 Welding Method........................................................................................ 3
1.4 Operational Sequence ...............................................................................4
1.5 Welding Elements......................................................................................5
1.6 Ceramic Ferrules........................................................................................ 5
1.7 Material Combinations .............................................................................6
1.8 Technical Data............................................................................................8
1.9 Declaration of Conformity......................................................................14
2. Safety at work........................................................................................... 15
2.1 Safety Symbols .........................................................................................15
2.2 Safety notices............................................................................................ 16
2.3 Intended use ............................................................................................. 22
2.4 Guarantee and liability ...........................................................................23
2.5 Use of original NELSON spare parts.................................................... 24
2.6 Copyright..................................................................................................24
3. Delivery and Transport .......................................................................... 25
3.1 Extent of delivery.....................................................................................25
3.2 Packing and dispatch ..............................................................................25
3.3 Inspection of incoming materials .......................................................... 25
3.4 Intermediate range ..................................................................................25
3.5 Storage.......................................................................................................25
3.6 Transport...................................................................................................25
3.7 Operating Location..................................................................................26
4. Connection and Installation .................................................................. 28
4.1 Installation Precautions ..........................................................................28
4.2 Connection................................................................................................28
4.3 Arc Blowing Effect...................................................................................34
4.4 Connection Diagram Short‐Cycle and Drawn Arc Welding............. 36
4.5 Connection Diagram Shielding Gas......................................................37
4.6 Additional Cautions................................................................................38

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of: 24.08.2021
Manual part number: BE 1227
5. Control and Display Elements..............................................................40
5.1 Front Panel Controls and Displays ....................................................... 40
6. Operation .................................................................................................. 43
6.1 Advice on Stud Welding.........................................................................43
6.2 Basic Procedure........................................................................................44
6.3 Weld Parameters......................................................................................44
6.4 Rating Charts............................................................................................57
6.5 N800i Weld Cycle Timing ......................................................................58
6.6 Drop Time Variables ...............................................................................61
6.7 Inspection and testing of the weld ........................................................62
6.8 Weld process monitor ............................................................................. 66
6.9 Plunge Current.........................................................................................69
6.10 Pulse Welding (in main current).....................................................70
6.11 Pulse Cleaning (during the beginning of main arc stage) ...........71
6.12 Password Reset..................................................................................72
6.13 Demo Mode........................................................................................72
6.14 Cable Resistance Monitor.................................................................72
6.15 Constant Energy*...............................................................................73
6.16 Chuck Change Indicator...................................................................74
6.17 Configuring the stud feed interface to act as a ‘Weld Complete’
signal..........................................................................................................74
6.18 F Code F61 ‐ Pulse Cleaning Contaminant to be Cleaned...........75
6.19 F Code F62 ‐ Gun as Remote............................................................75
6.20 Code F63 ‐ Pecker Mode...................................................................75
6.21 F Code F64 ‐ Fieldbus Selection.......................................................75
6.22 F Code F65 ‐ Weld Complete 24V Signal ....................................... 75
7. Function Codes......................................................................................... 76
7.1 Error Codes...............................................................................................88
7.2 Weld Quality Problems...........................................................................94
8. Maintenance ............................................................................................. 98
8.1 Care and cleaning ....................................................................................98
8.2 Routine Maintenance ..............................................................................99
9. Drawings and parts lists....................................................................... 100
9.1 Explosion drawing Final Assembly N800i .........................................100
9.2 Cover Assembly......................................................................................103
9.3 Chassis Sub ASM ....................................................................................104
9.4 Front panel assembly ..............................................................................106
9.5 Vertical panel assembly ..........................................................................108
10.Troubleshooting .................................................................................... 106
10.1 How to use Troubleshooting guide...............................................106

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of: 24.08.2021
Manual part number: BE 1227
10.2 Problems / Possible Cause / Solution............................................108
10.3 Welding Problems ...........................................................................109
10.4 Wiring Diagram Nelweld N800i....................................................131
11.Annex ....................................................................................................... 132
11.1 Disposal of the Nelweld N800i......................................................132
11.2 Disposal in accordance with the European directive.................133
11.3 Abbreviations...................................................................................134
11.4 Literature ..........................................................................................135

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of 24.08.2021
Manual part number: BE 1227
1
1. Introduction
1.1 General
The operating and service instructions to hand refer to the Nelweld N800i welding
unit. They are intended for operating and service personnel.
Trouble‐free operation of the Nelweld N800i welding unit can only beguaranteed with
knowledge of the contents of these operating and ser‐vice instructions.
In case of difficulty or ambiguity please contact the customer service ofNelson, 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 24.01.2012.
Nelson reserves the right to make any technical modifications, which contribute to
an improvement in the Nelweld N800i.

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of 24.08.2021
Manual part number: BE 1227
2
1.2 Unit Description
The Nelweld N800i 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 N800i. The variation in method must be
selected with the function code.
The Nelweld N800i works on the basis of a compact inverter power source and with
extremely short weld times supplies constant weld currents up to 800A.
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 N800i the re‐producibility 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 N800i.
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 N800i 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 N800i as low as possible the
N800i 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 a higher unsafe level is reached and stops the inverter and
displays an error message.
If the temperature is exceeded, the welding unit prevents welding temporarily. Thermal
overload is indicated by means of a flashing warning triangle and E011 displayed if
function key pressed.
In the Europe version the Nelweld N800i has a 4‐pole control cable socket to transmit
the controls signals to the configured weld gun.
The gun configuration always follows from the variation in method used. Thus, the
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 gun.

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
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Manual part number: BE 1227
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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 12mm can be welded with the
Nelweld N800i welding unit both in keeping with:
•the short‐cycle method (7mm)
•the drawn‐arc method (10mm).
The drawn‐arc method serves to full‐surface weld studs of specific geometric
dimensions to metallic workpieces, which should have a wallthickness 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 againstatmospheric
oxidization and contain the molten liquid metal in order to center the arc. In addition to
this, the molten metal is prevented fromcooling too quickly.
When welding overhead or in a horizontal position the ceramic ferruleensures 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, whichin extremely short
weld times makes no special demands of the type ofstud tip.
With the exception of the shorter weld times, the operational sequenceis identical with
that of normal arc welding.
In keeping with the short‐cycle method welding studs can also be welded on coated with
oil contamination workpiece surfaces, the mini‐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, particularlywith aluminum welds, it is advisable
to use inert gas.
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 studswith a tapered welding tip.

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of 24.08.2021
Manual part number: BE 1227
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1.4 Operational Sequence
When welding in keeping with the drawn‐arc method the gun must beloaded 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 thesupporting tube
touches the workpiece. The stud projecting from the supporting tube is pushed back at
the same time compressing the 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 thestud 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 equally
sized area on the workpiece so that a pool of liquid metal is formed under the arc and the
stud.
As soon as the gun coil is switched off‐circuit the stud accelerates backonto 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.
Welding sequence diagram:
1.Placing
the
welding
stud
2.Drawing
the
auxiliary
arc
3.Ignitingthe
main arc
4.Immersing
the welding
stud
5.Endofwelding
The weld time as per per drawn‐arc method is approx. 100ms ‐1000ms.

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of 24.08.2021
Manual part number: BE 1227
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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
1.6 Ceramic Ferrules
Ceramic ferrules (according to EN ISO 13918) are used when welding in keeping with
the drawn-arc method. They form 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 range.
.

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of 24.08.2021
Manual part number: BE 1227
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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
2.1
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 b
Suitable with
restrictions b c
Not suitable
for welding
1.4742
Suitable with
restrictions b
Suitable with
restrictions b
Suitable with
restrictions b
Suitable with
restrictions b
1.4762
1.4828
Suitable with
restrictions b
Suitable with
restrictions b
Suitable with
restrictions b
Not suitable
for
welding
1.4841

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
As of 24.08.2021
Manual part number: BE 1227
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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

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
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Manual part number: BE 1227
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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
Unit designation/Type: Stud welding unit / N800i
Version: 400V CE
Welding method: Drawn‐arc, short‐cycle and gas‐arc
Input voltage: 3~400VAC (+/‐10%)
System frequency: 50/60Hz
System fusing: 32A (slow‐blow)
Output: 32kVA
No‐load voltage: 75V
ON period: 3%
Weld sequences for at biggest diameter
•Drawn‐arc method: max. 5 weld/min
•Short‐cycle method: max. 60 weld/min
Weld current range: 50‐800A
Weld time range for
•Drawn‐arc method: 100ms‐1000ms
•Short‐cycle method: 5ms‐100ms
Unit fuses F1, F2: 1,5A, 600V, Electronic fusing
Protection type due to casing: IP23S
Protection class: 1 (one)
Operating Temperature: ‐20 to +40 Degrees C
Storage Temperature: ‐40 to +60 Degrees C
Type of cooling: AF (thermostatically controlled)
Relative air humidity: 0% to 50% at 40 Degrees C
0% to 90% at 20 Degrees C
Dimensions: B x H x T
(250mm x 340mm x 535mm)
Weight: 21Kg
Mains plug: CEE (5 pole); 32A at 400V

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
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Manual part number: BE 1227
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Mains cable: H07RN‐F 4G 6 (4x6mm2)
Length: 3m

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Top
Stud welding unit N800i
As of 24.08.2021
Manual part number: BE 1227
1.8.1 Dimensions
Front Side Rear
10

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
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Manual part number: BE 1227
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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 instructionsShielding
gas device: order no. 67‐03‐04
Gas hose pipe:
10 m shielding gas hose pipe system
(Nelweld N800i‐gun): order no.67‐07‐50
Connecting cable (standard):
Nelweld N800i ‐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)

Tucker GmbH, Mail / Post: Max-Eyth-Str.1, 35394 Gießen, Germany
Stud welding unit N800i
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Manual part number: BE 1227
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1.8.3 Option Kits / Accessories
Quantity
Part Number
Description
1
512‐387‐005a
Mobility Kit (General Stud Welding)
1
512‐387‐006a
Mobility Kit Automotive
1
512‐387‐041
Automatic Stud Feeder Interface Kit
1
512‐387‐052
NELWARE Software Package
1
512‐387‐053
Hardware and Fastener Kit
1
751‐585‐703a
Composite Gun, NS 40, FL 67mm²
1
751‐585‐801a
Composite Gun, NS 20, FL 107mm²
1
512‐387‐056
Ethernet patch cable
a. Contact Nelson Stud Welding sales representative for availability
1.8.4 Guns cable extension incl. control cable
Length
(m)
Cross section (mm2)
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

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Stud welding unit N800i
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Manual part number: BE 1227
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7,5
722‐000‐165a
722‐000‐167a
15
722‐000‐164a
722‐000‐166a
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/SKb
68‐04‐39 / 70
10
652‐23‐41 / 50
67‐02‐09 / 70/95
15
67‐03‐78 / 50
‐
a. BK: Socket contact
b. BK/SK: Plug contact

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Stud welding unit N800i
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2. Safety at work
2.1 Safety Symbols
Safety notices and warnings are made onthe one handfor yourpersonal safety and
on the other hand for product safety. In these operating instructions they are made
to stand out bymeans 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
regulationsand have atraining authorizing them to perform stud welding!
All persons who work with the unit are obliged to read and observe all the
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
are not taken.
This sign contains important information about the correct
method of handling the product or special advice, to which
particular reference is to be made.

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Stud welding unit N800i
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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 of the following safety notices is a prerequisite for safe and correct
handling and trouble‐free operation of the Nelweld N800i.
In addition, the technical regulations for 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