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© 2016 Nelson Stud Welding, Inc.  

Page 4 

All Rights Reserved. 

January 2016 

Part No. 729-110-043 Rev. 1.02 

 

 

 

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+

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 9: ...2016 Nelson Stud Welding Inc Page 9 All Rights Reserved January 2016 Part No 729 110 043 Rev 1 02 2 LED Option...

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 21: ...2016 Nelson Stud Welding Inc Page 21 All Rights Reserved January 2016 Part No 729 110 043 Rev 1 02 8 1 2 Exploded Drawing...

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 24: ...2016 Nelson Stud Welding Inc Page 24 All Rights Reserved January 2016 Part No 729 110 043 Rev 1 02 8 2 2 Exploded Drawing...

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 26: ...2016 Nelson Stud Welding Inc Page 26 All Rights Reserved January 2016 Part No 729 110 043 Rev 1 02 9 Schematics 9 1 NCD CTRL to GUN 7 PIN Contact...

Page 27: ...2016 Nelson Stud Welding Inc Page 27 All Rights Reserved January 2016 Part No 729 110 043 Rev 1 02 NCD CTRL TO GUN 12 PIN Contact...

Page 28: ...2016 Nelson Stud Welding Inc Page 28 All Rights Reserved January 2016 Part No 729 110 043 Rev 1 02 9 2 NCD CTRL TO GUN 12 PIN W LED Contact...

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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