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© 2016 Nelson Stud Welding, Inc.  

 Page 4 

All Rights Reserved. 

February 2016 

Part No. 729-110-042 v1.03

 

 

ELECTRICALLY POWERED EQUIPMENT 

Faulty or improperly electrified equipment can cause 
injury or death. 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. 

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. 

 

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 can cause 
injury or death. Therefore:

 

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.

 

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  modify  it  in  any 
manner.

 

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. 

 

ADDITIONAL SAFETY INFORMATION 

For more information on safe practices for electric arc 
welding, refer to the following publications. 

HEARING PROTECTION 

Prolonged Noise from Capacitor Discharge welding 
applications can damage hearing if levels exceed limits 
specified by OSHA. Therefore: 

 

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.

 

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 warning and 
cause severe injury, therefore: 

   

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.

 

   

 

   

Summary of Contents for NCD+ Auto-Gap Gun

Page 1: ...d safe practices for arc welding equipment we urge you to read AWS SP Safe Practices available from the American Welding Society Do not permit untrained persons to install operate or maintain the equi...

Page 2: ...s 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 give...

Page 3: ...y 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...

Page 4: ...nded purpose Do not modify it in any manner 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...

Page 5: ...tting Up Foot and Leg Assembly 12 3 3 Setting Spring Pressure Auto Gap Mode 13 3 3 1 Setting Travel Lift and Spring Pressure in Gap Mode 13 3 3 2 Setting Spring Pressure in Contact Mode 14 3 3 3 Chang...

Page 6: ...o 729 110 042 v1 03 7 3 2 Triggering Contact 24 7 4 Gun Coding 24 7 4 1 Dismantling Reassembling Gap Contact Welding Guns 24 8 Schematics 25 8 1 NCD CTRL TO GUN 12 PIN Auto Gap 25 8 2 Specifications 2...

Page 7: ...vides superior weld reliability with aluminum and other non ferrous metals Contact welding is generally used with carbon steel and stainless steel especially when weld appearance is not a prime consid...

Page 8: ...ion tip is flashed off leaving an arc space 3 The remaining stored energy is discharged across the arc space Stud and base material are heated 4 The spring pressure plunges the stud into the work piec...

Page 9: ...and two wires that go to the trigger When the trigger is pulled the stud rises off the workpiece The gun de energizes and the main spring then pushes the stud back towards the workpiece The arc begin...

Page 10: ...l Rights Reserved February 2016 Part No 729 110 042 v1 03 2 Features 1 CHUCK NUT 2 TRIGGER 3 CONTROL CABLE 4 WELD CABLE 5 GUN BODY 2 HALVES 6 FOOT ASSEMBLY 7 BELLOWS 8 SPRING ADJUSTMENT COLLAR 9 MAIN...

Page 11: ...pin assembly for the proper stud length 3 1 2 Adjusting Chuck and Stop Assembly The unit should be switched off before inserting or changing a chuck To adjust the Chuck and Stop Assembly Figure 3 1 Ch...

Page 12: ...located in the center of the spark shield To install the foot unscrew the leg screws and place them through the holes in the foot Reattach the leg screws to the legs Maintain concentricity between th...

Page 13: ...ded screwdriver or NCD Set Up Tool 525 001 200 turn the travel adjustment screw on the back of the weld gun counter clockwise until it stops 4 Loosen leg screws 5 Insert stud in chuck 6 Adjust foot so...

Page 14: ...Set Up Tool 525 001 200 turn travel adjustment screw on the back of the weld gun counter clockwise until it stops 4 Loosen leg screws 5 Insert stud in chuck 6 Adjust foot so that the stud stick out ma...

Page 15: ...o weld in contact mode In order to make this change follow these steps 1 Loosen set screws 5 2 places 2 Remove the foot and leg assembly and bellows 3 Remove the chuck nut and chuck 4 Unscrew part 41...

Page 16: ...ng pressure and gap lift using a stud per section 3 3 1 4 Adjust voltage 5 Replace the set up stud with a new one 6 Begin production welding after sample welds have been validated for strength and app...

Page 17: ...ding Cable Control Cable When checking cables for continuity it is important to slightly pull on all the connectors so that if there is a break the wires will be pulled apart The continuity check can...

Page 18: ...Torque Test Stud shall be torqued until a pre specified loading is attained or until the stud fails On thin plate a plug of the base material should tear out Physical test procedures for inspecting m...

Page 19: ...e faster drop time and the faster drop time extinguishes the arc sooner Increasing spring pressure Speeding up the weld time and extinguishes the arc sooner Decreasing voltage Reducing the voltage red...

Page 20: ...plunge Refer to Sections 3 3 and 8 4 Varying gauges of sheet metal Changes in sheet metal can usually be compensated for by changing the settings on the power supply Springs inside weld tool have fat...

Page 21: ...ZINC 8 524 005 101 2 SCREW M5X16 FHSC ZINC 9 524 005 103 1 SCREW M3X5 LHS DIN7984 10 524 005 104 1 NUT M5 THICK 11 524 005 105 1 SCREW M5X10 SHC DIN912 12 526 001 233 1 SPRING COMPRESSION 13 526 001 2...

Page 22: ...4 751 650 204 1 COIL HOLDER 35 751 650 209 1 WASHER RESIDUAL 36 751 650 210 1 WASHER SPRING 37 751 650 211 1 SWITCH TRIGGER ASM 38 751 650 216 1 COIL ASM 39 751 650 241 1 SCREW CD FL SPRING ADJUSTING...

Page 23: ...2016 Nelson Stud Welding Inc Page 23 All Rights Reserved February 2016 Part No 729 110 042 v1 03 7 2 Exploded Drawing...

Page 24: ...he front cap 2 and rear cap 1 2 Remove the caps and lay the gun on its right side 3 Remove 3 screws that hold the gun halves together 4 Separate and remove the left gun body such that the internal com...

Page 25: ...2016 Nelson Stud Welding Inc Page 25 All Rights Reserved February 2016 Part No 729 110 042 v1 03 8 Schematics 8 1 NCD CTRL TO GUN 12 PIN Auto Gap...

Page 26: ...pless Screw Adjustment Front Ends Adjustable Tripod Spark Shield Max Stud Length Depends on Accessories Dimensions without Cable 7 1 4 x 1 1 2 x 5 1 2 184 mm x 38 mm x 140 mm Weight without Cable 2 2...

Page 27: ...2 0 236 6 mm 500 001 390 0 125 5 Thd 1 8 500 001 359 0 250 1 4 500 001 356 0 134 0 138 10 Ga 6 Thd 500 001 360 0 312 0 315 5 16 8 mm 500 001 361 0 157 4 mm 500 001 369 0 375 3 8 500 001 357 0 164 8 Th...

Page 28: ...Spring Pressure Capacitance M3 6 Carbon Steel 12 3 120 15lbs 54K Stainless Steel 12 3 100 15lbs 54K M4 8 Carbon Steel 12 3 120 7lbs 54K Stainless Steel 12 3 120 15lbs 54K M5 10 Carbon Steel 12 3 130 1...

Page 29: ...635 9353 Fax 909 468 2112 Subsidiaries International England Nelson U K Ltd 47 49 Edison Rd Rabans Lane Ind l Estate Aylesbury HP19 8TE UK Phone 44 1296 433500 Fax 44 1296 487930 Middle East Asia Paci...

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