Pro Spot NP-3 User manual

Instruction Manual
MNL-NP-3-1.4
NP-3
Nitrogen
plastic welder

5932 Sea Otter Place
Pro Spot International, Inc.
Carlsbad, CA 92010
Toll Free: (877) PRO SPOT
Phone: [phone]
Fax: [phone]
E-mail: [email protected]om
Web: www.prospot.com
Pro Spot Training and Services
About Pro Spot
Pro Spot International specializes in quality welding and repair products for the collision repair industry. Pro
Spot owns three patents for special welding equipment and applications, and works with the largest auto
manufacturers in the world. Pro Spot is a proud 'MADE IN THE USA' manufacturer in Carlsbad, CA. The turnkey
facility includes Design, Engineering, Machine and Sheet Metal Shops, Powder Coating, Assembly, Training and
Customer Support. The Pro Spot equipment line includes resistance spot welders, aluminum & steel dent
repair systems, pulse MIG welders, rivet guns and tools, dust-free sanding systems, fume extraction and more.
Pro Spot provides on-going training to all of our distributors and their
technicians, therefore, all owners of Pro Spot products receive complete
training rst hand. Pro Spot has two ASE certied training programs that
are I-CAR alliance approved. Pro Spot has a fully equipped training
facility at their Headquarters in Carlsbad, CA for groups to come in and
train on all products. To stay up-to-date, Pro Spot oers their unique
My.prospot.com which includes interactive training courses for shops
and technicians to access online.
Pro Spot is constantly striving to improve. Whether that means design-
ing innovative equipment, implementing cutting edge technical
support or further improving their already extensive training programs,
Pro Spot is always looking for ways to better our customer's experiences.

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Table of Contents
1. Cart Assembly Instructions ..................................................................................................
2. Safety .............................................................................................................................................
3. System Setup ...........................................................................................................................
4. User Interface Setup .............................................................................................................
5. Basic Welding Instructions
Identifying The Material .................................................................................................
Preparing The Surface .....................................................................................................
Aligning The Damage .....................................................................................................
Nitrogen Plastic Welding ...............................................................................................
6. Advanced Gun Settings .......................................................................................................
7. Smoothing Iron Setup ..........................................................................................................
8. Appendix ...................................................................................................................................
9. Notes ............................................................................................................................................
5
9
10
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11
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12
13
13
14
15

21
14
13
12
11
23
32
28
14
29
14
8
13
27
16
22
21
19
4
3
13
11
1
18
17
20
15
25
29
2
12 10
13
3031 33
13
35
19 90-0530 : HANDLE BRACKET 2
20
N-33 : M4 HEX NUT 4
21
S-266 : 1/4-20 X 3/4 PHMS 2
22 90-0243 : CABLE HOOK 1
23
90-0199 : GUN HOOK 1
24
M-88 : TANK CHAIN, 27.5” (NOT SHOWN) 1
25
90-0551 : UPPER SHELF 1
26
90-0571 : UNIVERSAL CART AXLE 1
27
90-0513 : BOTTOM TRAY, SHORT 1
28
90-0517 : BOTTLE BRACKET 1
29
90-0572 : 4 X 10 TOOL BOARD 2
30
52-3211 : LICENSE PLATE NUT 4
31
S-1212 : #12 X 1/2 PHSMS 4
32
90-0611 : BACK SIDE, NON-COMBI 1
33
90-0557 : BOTTLE BRACE 1 1
34
90-0558 : BOTTLE BRACE 2 1
35
90-0605 : TANK TROLLEY 1
ITEM NO. DESCRIPTION QTY.
1 90-0508 : TOP SHELF 1
2
90-0509 : CART SIDE 1 1
3
51-0008 : SLIDE RAIL (SET) 2
4
90-0511 : DRAWER 1
5
61-0003 : 6” SOLID WHEEL 2
6
W-82 : 1/2” FLAT WASHER 4
7
SR-07 : 1/2” EXTERNAL SNAP RING 2
8
P2-09 : 2” SWIVEL CASTER 2
9
P-05 : 1/4-20 U-BOLT 2
10
W-20 : 1/4” LOCK WASHER 4
11
90-0515 : 1 DRAWER BRACKET 2
12
N-06 : 1/4-20 HEX NUT 4
13
S-209 : M5 X 10 PHMS 43
14
S-43 : M6 X 10 PHMS 16
15
S-97 : M1 X 8 PHMS 8
16
90-0516CARTSIDE 2 1
17
90-0516 : SHELF 1
18
90-0528 : FRONT HANDLE 1
NP-3 CART ASSEMBLY INSTRUCTIONS

STEP 1: BASE ASSEMBLY
STEP 1 COMPLETE.
STEP 1A: ATTACH WHEELS TO AXLE WITH 1/2” FLAT
WASHERS AND 1/2” EXTERNAL SNAP RING.
STEP 1B: FASTEN AXLE TO TANK TROLLEY USING UBOLTS, PLATES,
1/4” LOCK WASHERS, AND 1/4-20 HEX NUTS. TIGHTEN
FIRMLY BUT DO NOT OVER TIGHTEN
STEP 1C: ATTACH SWIVEL CASTORS TO FRONT HALF OF BASE
WITH M6 X 10 PHMS.
STEP 1D: ATTACH TANK TROLLEY TO BASE WITH M5 X 10 PHMS.
STEP 2: CHASSIS ASSEMBLY
STEP 2A: ATTACH SIDE PANELS TO BOTTOM TRAY WITH
M5 X 10 PHMS.
STEP 2B: ATTACH BACK PANEL TO BOTTOM TRAY AND
SIDE PANELS WITH M5 X 10 PHMS.
STEP 2C: ATTACH SHELVES AND BOTTLE BRACES WITH
M5 X 10 PHMS.
STEP 2D: SNAP IN TOOL PANELS.
STEP 2E: SECURE HOOKS TO TOOL PANELS WITH
#12 X 1/2 PHSMS AND BLACK PLASTIC LICENSE
PLATE NUTS.

STEP 3: DRAWER ASSEMBLY
STEP 3A: ATTACH NP-3 MOUNT BRACKETS WITH M4 X 8 PHMS.
IF YOU DO NOT HAVE THE NP3 MOUNTING BRACKET TO ATTACH TO THE TOP SHELF.
SCREW ON YOUR NP3 THROUGH THE BOTTOM OF THE TOP SHELF WITH M6 X 30 PHMS.
STEP 3B: ATTACH OUTER SLIDE RAILS TO THE DRAWER BRACKETS WITH M4 HEX NUTS.
STEP 3C: ATTACH DRAWER BRACKETS TO THE TOP SHELF WITH M5 X 10 PHMS.
STEP 3D: ATTACH INNER SLIDE RAILS TO DRAWER WITH M4 X 8 PHMS.

STEP 4: FINAL ASSEMBLY
STEP 4A: ATTACH TOP SHELF AND HANDLE BRACKETS TO SIDE PANELS WITH M6 X 10 PHMS.
STEP 4B: ATTACH BOTTLE BRACKET TO BACK PANEL WITH M5 X 10 PHMS.
STEP 4C: MATE SLIDE RAILS TOGETHER AND SLIDE ALL THE WAY IN.
STEP 4D: SCREW FRONT HANDLE TO HANDLE BRACKETS WITH 1/4-20 X 3/4 PHMS.
CART COMPLETE

Safety
1. Refer to OSHA for recommended PPE.
2. If any melted plastic comes in contact with your skin, wash with borax soap and
water or alcohol.
3. Make sure you are working in a well ventilated area.
4. Keep chemicals such as gasoline, brake uids and other solvents out of the work area.
5. PVC plastics can produce poison gas when burned and should be kept away from
excess heat and ames.
6. Avoid any contact with your skin when using hot air welders and airless welders as
they can produce very high temperatures when in use.
7. Identify a re extinguisher close enough to use if necessary.
8. Always turn o all welding equipment when repair procedures are complete.

System Setup
1. Connect 120V power cable to the back of the unit.
2. Thread 1/4” male coupler plug to air inlet on the back of the unit.
3. Connect air to male coupler plug.
Warning: Incoming Air Pressure
must not exceed 130 psi.
4. Thread the Nitrogen regulator into the nitrogen tank.
5. Connect the gas hose from Nitrogen regulator to the barb tting on the back of the unit.
6. Open the Nitrogen tank valve and set the regulator output pressure to roughly
80 psi.
User Interface Setup
1. Switch on the power. You will be presented with a welcome screen and then the system home
screen.
Air Press - The compressed air pressure set by the Air Control dial. The air keeps the
heating element cool while the hot air gun is not in use.
Gas Press - The nitrogen gas pressure set by the Nitrogen Control dial. The hot air gun
trigger activates the nitrogen gas. You have to adjust the gas pressure while holding
the trigger.
Air Power - The power delivered to the hot air gun. This determines how hot the hot air
gun gets.
Iron Power - The power delivered to the soldering iron. This determines how hot the
soldering iron gets.
2. Use a phillips screwdriver to unlock the Air Control dial by turning counter-clockwise until dial is loose.
For machines with the push-pull type regulators, pull the Air Control dial to unlock it.
3. Turn the dial until Air Press reads 8 psi.
4. Use a phillips screwdriver to lock the Air Control dial by turning clockwise until dial is tight.
For machines with the push-pull type regulators, push the Air Control dial to lock it.
Welcome Screen: Home Screen:

5. Use a phillips screwdriver to unlock the Air Control dial by turning counter-clockwise until dial is loose.
For machines with the push-pull type regulators, pull the Nitrogen Control dial to unlock it.
6. Hold the trigger and turn the dial until Gas Press reads 2 psi then release the trigger.
7. Use a phillips screwdriver to lock the Air Control dial by turning clockwise until dial is tight.
For machines with the push-pull type regulators, push the Nitrogen Control dial to lock it.
8. Plug the soldering iron into the Iron outlet on the front of the machine.
Warning: Only plug the iron into this outlet. Any other devices may
be damaged.
9. Plug the hot air gun into the plastic welder section on the front of the machine.
Basic Welding Instructions
Identifying The Material
The rst step in plastic repair is identifying the base material of the repair piece. If you look
on the backside of 99.99% of all plastic found in cars, you will nd an ISO code. The ISO
code is an abbreviation for the type of plastic. For example, a common ISO code found on
bumper covers is TPO which is the abbreviation for thermoplastic olen. If this is the case,
retrieve a TPO rod from your accessory drawer. Refer to Appendix A for ISO Code reference.
Preparing The Surface
Surface preparation is very important to create a strong, lasting weld. Use the 80 grit.
sandpaper provided to prepare the backside of the repair area surface. Use a rotary tool
and conical bit to grind a narrow channel along the surface crack. Use any non-corrosive,
degreaser to clean the surface area of any particulate and oils.
Aligning The Damage
We recommend two alignment methods.
1. Hot Staples (preferred method) - Permanent alignment which provides a long-term
structural reinforcement. Plug the hot staple welder into the cigarette adaptor on
the front of the machine. Follow the illustrated instructions in the hot staple welder
kit to align the damage.
2. Aluminum Tape - Temporary alignment which provides no long-term structural
backing. Simply lay a strip of aluminum tape along the front side of the damaged
area to maintain alignment. Smooth the tape so that it has as much surface contact
as possible. This not only guarantees adhesion but it also prevents heat distortion in
the bumper.

Nitrogen Plastic Welding
1. Push and hold the Iron Control button.
The LED next to the knob turns
green and the soldering iron
begins to heat up.
2. Push and hold the Hot Air Control button.
The LED next to the knob turns green and hot air ows out of
the gun. If the LED ashes orange, there is not enough
compressed air or nitrogen owing through the gun.
3. Place the rod or ribbon perpendicular
to the bumper at the beginning of the
tear as shown.
4. Pull the trigger and angle the gun so the
hot nitrogen is directed at both the bumper
and the rod or ribbon.
5. Once the rod or ribbon begins to melt into the bumper, apply a very slight downward
pressure and begin to work at a backward angle of roughly 45 directing the hot nitrogen
towards where the rod or ribbon meets the bumper.
6. At the end of the tear, use the gun nozzle to melt and tear away the rod or ribbon.
7. Return the gun to its holster and take the soldering iron out.
8. Use the soldering iron to smooth the edges of the rod or ribbon into the bumper until
there is no visible seam between the two.
9. Allow several minutes for the bumper to cool down.
10. Repeat all steps above on the front side of the tear.
11. Use a 120 grit DA sander at low speed to sand the rod or ribbon so that it is ush with the
bumper. If the plastic browns, it means your sander speed is too fast and is burning the plastic.
Hot Air
Control
Iron
Control

Cycle through advanced hot air settings by pressing the hot air button
(as shown in the menu diagram above).
• Air Heater Power
- This setting adjusts the power delivered to the 550W heating element in the hot
air gun. The default is set at 300W.
• Min Heater Flow
- This setting adjusts the minimum air flow required to activate the heating ele-
ment in the hot air gun. If the Min Airflow is not met a “low flow” error message
will be displayed on the home screen and the heater will not turn on.
• Min Nitro Pressure
- This setting adjusts the minimum Nitrogen flow required to activate the heating ele-
ment in the hot air gun. If the Min Nitrogen-flow is not met a “low-flow” error message
will be displayed on the home screen and the heater will not turn on.
• Air Auto-Off
- This setting adjusts the not air gun auto shut down timer. This prevents stress on the
heating element which can result in a reduced lifespan.
1. Plug the iron into the outlet on the lower front panel of the NP-3.
2. To turn on the iron, press and hold the “Iron Control” button on the front panel. This can only be done
from the home/status screen.
3. adjust iron settings to your liking, the default power is set to 60W this controls the iron’s temperature.
Auto-off controls the automatic shut off timer.
Advanced Gun Settings:
Home Screen:
Hot Air
Control
Air Power: Low Air Flow Protection:
Air Auto-Off: Low Nitrogen Flow Protection:
Smoothing Iron Setup:
Home Screen:
Iron
Control Iron Power: Iron Auto-Off:

Name
Polypropylene (PP)
Acrylonitrile Butadiene Styrene (ABS)
Location
Bumper covers (usually bvlended with EPDM),
inner fenders, radiator shrouds, interior panels,
gas tanks
Instrument panels, grilles, trim moldings, consoles,
armrest supports
Thermoplastic Olen (TPO) Bumper covers, air dams, grills, interior parts,
instrument panels
Polyurethane (PUR) Flexible bumper covers, ller panels, rocker
panel covers
Polyamide (Nylon or PA) Radiator tanks, headlamp bezels, exterior trim
nish parts
Xenoy (Polycarbonate blend) Bumper covers
Polyethylene (PE) Overow tanks, inner fender panels, valences,
interior trim panels, gas tanks
Appendix A

NOTES

5932 Sea Otter Place
Pro Spot International, Inc.
Carlsbad, CA 92010
Toll Free: (877) PRO SPOT
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.prospot.com