SALIENT CHARACTERISTICS.pdf

Salient Characteristics for a Battery Stud Welder Project #330-310

17 Jul 2025

1. A Battery Stud Welder (Nelson Stud Welding, N900b Welding System, Part #N900BMD1FACS or equal) shall be provided. Nelson Stud machine has been extensively tested and found acceptable by qualified personnel for use on board the tended units. Testing conducted included all aspects of the machine and gun functionality for acceptable shot stud welds in the horizontal, vertical and overhead positions. The tranquil arc option for this specific machine and gun set-up was a key point analyzed. The interest was due to the precise control of weld gun plunger speed during the stud shooting evolution. Testing concluded less to no under-cut of the top portion welded stud in the vertical position. This is important due to first-time (visually acceptable stud shot) quality needs when working on/to HY-80 base material. Stray current from gun to ground was also tested during the actual stud welding process and found acceptable. This is important due to the restrictive nature of welding in certain areas of the tented unit. Due to previous authorized purchases the weld shop now owns, operates and maintains this specific weld machine. Craftsman/Maintenance personnel have been trained / qualified to operate and maintain this equipment. TRF and PSNS weld shops have this specific stud welding machine in their inventory fit form and function apply for stud gun interchangeability and consumables. Nelson is the proprietary 0EM of Steel Tranquil–Arc R and the program allowing it to function Nelware TM. The Battery Stud Welder shall include the following minimal capabilities/features/items:

• Dependable, light-weight and compact unit (not to exceed 65lbs)

• Up to 920 amps for ½” full base diameter stud welding

• 10 preset buttons

• 7” LCD display

• Medium duty gun, NS-40N MD (or equal).

• Weld quality indicator

• Precision control at 60,000 Hz frequency

• Welder material construction includes steel, stainless steel, aluminum, heat resistant steel, advanced high strength steel

• Stud diameter: 12 gauge to ½”

• Weld process: Flexible Arc System-Drawn arc, Battery Powered.

• Weld time: 5-1000 ms

• Full charged battery in 2-3 hours from a standard 120V outlet.

• Full charge capacity weld rate: 1,500 ea - 3/16” studs, 1,100ea - ¼” studs, 300ea - 3/8” studs, 150ea - ½” studs.

• Welder insulation: IP23S

• Built-in arc energy watchdog to detect bad welds from actual process signals.

• Built-in gun watchdog to match gun speed and adaptively compensate for gun wear.

• Built-in cable and connector watchdog to detect cable wear and loose connector.

• Capability to choose setting from stud diameter and capability to be re-programmed by a user spreadsheet.

• Pulse waveform capability that reduces heat input, cuts surface contaminants and stiffens arc for out-of-position welds.

• Plunge current capability that saves electricity, reduces cable wear, and maintains arc energy despite gun wear.

• Cold plunge prevention capability that extends arc time when stud plunge is slowed down.

• Production weld quality record keeping capability and arc signals oscilloscope.

• Equipment must be a battery powered cold drawn arc, capable up-to ½ dia.

portable stud shooting machine.

• Equipment must be able to be maintained or repaired through US Navy Repair Code Personnel or able to be trained for maintenance or repair purposes on the equal type of equipment.

• Equipment must include: Welding Gun with MD Dinse/Hubble - 25’ and 2/0 Dinse connected Ground Cable - 15FT. This equipment should interchangeable with existing Nelson N1500i and N800i equipment.

• Equipment must include a battery charger 120V.

• Battery Powered Stud Machine must have approved NRTL or provide an approved vendor supplied QAI Laboratories Testing, Inspection and Certification (as outlined in paragraph #2)

• Dimensions should be 21.5"L x 11.25"W x 15.5"H @ 63lbs

2. Safety Requirement - The equipment and its component parts shall be in compliance with applicable Code of Federal Regulations (CFR) Title 29, Part 1910. By definition, any equipment will be deemed acceptable and approved by TRF, Bangor, if it meets specific Occupational Safety and Health Administration (OSHA) conditions outlined in CFR Title 29, Part 1910; Subparts "O" and "S". Specifically, equipment will be "Accepted" by TRF, Bangor, if it has been inspected and found by a Nationally Recognized Testing Laboratory (NRTL) to conform to specified plans or procedures of applicable codes. The equipment (as a whole system) shall be Nationally Recognized Testing Laboratory (NRTL) inspected and certified (by an OSHA authorized third party).

One (1) “hard” copy of the NRTL certification report shall be provided. If the equipment type/model has already been NRTL inspected and certified, a certification report (one (1) “hard” copy) or documentation mounted on the equipment, (which acknowledges it is NRTL certified), shall be provided.