Nelson NCD+ Instruction & Maintenance Manual Download Page 1

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January 2016

Part No. 729-110-043 Rev. 1.02

Operating the
NCD+Contact Gun

Instruction & Maintenance Manual

These instructions are for experience operators.

If you are not fully familiar with the principles of operation and 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 equipment. Do not

attempt to install or operate the equipment until you have read and fully understand these
instructions.

If you do not fully understand these instructions, contact your supplier for further information. Be sure

to read the Safety section before utilizing this equipment.

Summary of Contents for NCD+

Page 1: ...afe 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 equipme...

Page 2: ...ess 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...

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: ...ended 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 adaptor...

Page 5: ...12 4 2 Setting Up Foot and Leg Assembly 12 4 3 Setting Spring Pressure 13 5 Weld Setup 14 6 Maintenance of Stud Welding System 15 6 1 Stud Welding Gun 15 6 2 Welding Cable Control Cable 15 6 3 Power C...

Page 6: ...1 Dismantling Reassembling Welding Guns 25 9 Schematics 26 9 1 NCD CTRL to GUN 7 PIN Contact 26 9 2 NCD CTRL TO GUN 12 PIN W LED Contact 28 10 Technical Specifications 29 10 1 Specifications 29 10 1 1...

Page 7: ...thin and or coated parts opposite the weld side Contact welding is generally used with carbon steel and stainless steel especially when weld appearance is not a prime consideration The contact weldin...

Page 8: ...entified so you can easily determine which gun you have 1 2 1 Operation of the Contact Gun The NCD Contact Gun is a capacitor discharge contact gun Since there is no coil there is only one wire that g...

Page 10: ...ry 2016 Part No 729 110 043 Rev 1 02 3 Features Figure 3 1 Contact Gun Refer to Setting Up Foot and Leg Assembly 1 CHUCK NUT 6 LEG SCREWS 2 TRIGGER 7 SPRING PRESSURE GAUGE 3 CONTROL CABLE 8 SPRING PRE...

Page 11: ...he proper stud length 4 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 4 1 Chuck and Stop Assem...

Page 12: ...d into the chuck adaptor The chuck must be in firm contact with the stud stop while tightening the chuck nut 4 2 Setting Up Foot and Leg Assembly The NCD guns come supplied with a foot and spark shiel...

Page 13: ...ith a flat bladed screwdriver or NCD Set Up Tool turn adjustment screw on the back of the weld gun to the recommended spring pressure 3 Adjust stud stick out 4 Loosen leg screws 5 Insert stud in chuck...

Page 14: ...ameters 4 Adjust voltage 5 Install chuck and stud stop 6 Adjust gun spring pressure 7 Adjust plunge Plunge is the distance the stud extends beyond the stand off posts or spark shield Loosen the leg lo...

Page 15: ...ate 6 2 Welding 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...

Page 16: ...ase metal should be torn out 2 Torque Test Stud shall be torqued until a pre specified loading is attained or until the stud fails or on thin plate a plug of the base material should tear out Physical...

Page 17: ...nto the molten pool faster Decreasing voltage Reducing the voltage reduces overall energy into the weld Make certain that combo cable is installed contact mode only Otherwise if gap mode remove combo...

Page 18: ...ible Solutions Molten metal runs away from the ground Incomplete or insufficient grounding can cause this problem Double Ground The addition of another ground on opposite sides of the weld area will r...

Page 19: ...CHUCK 9 A751 650 012 3 PIN LOCATING 10 A751 650 101 1 ROD ASM LIFTING 11 A751 650 104 1 BEARING RETAINER 12 A751 650 019 1 SPRING RETAINER 13 A751 650 020 1 NUT ADJUSTING SPRING 14 A751 650 021 1 SCRE...

Page 20: ...CAL MS 31 A726 013 002 1 COLLET 32 526 001 231 1 SPRING MAIN 33 A502 001 261 1 FOOT 34 A504 001 056 2 LEG 35 527 003 094 1 BEARING 36 524 005 103 2 SCREW LHC M3 X 5MM LG 37 729 023 025 1 PIN GROOVED 3...

Page 22: ...751 585 021 1 E RING 12 751 650 027 1 TRIGGER BUTTON 13 87 05 22 1 TRIGGER SPRING 14 751 650 022 1 M4 BRASS WASHER 15 751 650 211 1 TRIGGER ASM SWITCH 16 524 005 105 1 SCREW M5X10 SHC DIN91 17 751 650...

Page 23: ...EAD FORM 39 526 001 232 1 SPRING GROUND SENSE WIRE X 40 713 032 000 3 WIRE SPLICE 41 751 585 004 1 CABLE GROMMET 42 721 268 012 1 CONTROL CABLE ASSEMBLY X 43 720 519 080 1 WELD CABLE ASSEMBLY X 44 524...

Page 25: ...n halves together 4 Separate and remove the left gun body such that the internal components remain in the right half 5 Inspect parts for damage or excessive wear and replace if necessary 6 Reassemble...

Page 29: ...able Tripod Spark Shield Max Stud Length Depends on Accessories Dimensions without Cable 6 5 8 x 1 1 2 x 5 1 2 169 mm x 38 mm x 140 mm Weight without Cable 2 2 lb 1 kg Max Cable Length 19 ft 5 8 m Con...

Page 30: ...5 mm 500 001 355 0 112 0 118 4 Thd 3 mm 500 001 362 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 15...

Page 31: ...l 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 Europe Nelson Germany Postfach 40 20 58272 Gevelsberg German...

Page 32: ...0 90K Stainless Steel 3 160 75 90K 3 8 Carbon Steel 3 180 50 144K Weld parameters above were established as optimum for conditions in our lab Heavy base plate material was used for physical testing pu...

Page 33: ...ace quality welding position stud type stud dimensions etc SPRING PRESSURE CHART MATERIAL COMBINATION STUD MATERIAL Low Carbon Steel Stainless Steel Brass Aluminum 1100 Aluminum 5356 SPRING PRESSURE W...

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