Nelson INTRA 2100 User manual

Operating manual
Stud welding unit
INTRA 2100/1400
for
drawn arc and short-term drawn arc processes
Edition:
2021-07
Revision:
Rev. A / 07.2021 / EN
EN
Document number

INTRA 2100/1400
Operating
manual
Model / Device:
Stud welding unit
Original-
Manufacturer
TUCKER GmbH
A Division of STANLEY Engineered Fastening
Max-Eyth-Straße 1
D-35394 Gießen, Germany
Tel.: [phone]
Fax: [phone]
E-mail: [e-mail]
Internet:
www.tucker.eu
www.stanleyengineeredfastening.com/brands/tucker
Imprint
Responsible for the content from STANLEY Engineered Fastening in
this medium according to Section 5 of the German
Teleservices Act:
is the manufacturer Tucker GmbH
Stanley, Tucker and other logos are registered trademarks belonging
to Stanley Black & Decker, Inc.
Restricted confidentiality
No part of this manual may be
transmitted, reproduced and/or copied
by any electronic or mechanical means without obtaining prior written
permission from Tucker GmbH!
© Copyright Tucker GmbH 2021. All rights reserved!

Table of Contents
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
TABLE OF CONTENTS
Chapter
Page
1Introduction.............................................................................................1
1.1 General remarks............................................................................1
1.2 Device description ........................................................................2
1.3 Description of stud welding process..........................................4
1.3.1 Drawn arc process.......................................................................................4
1.3.2 Short cycle weld process.............................................................................6
1.4 Material combinations..................................................................8
1.4.1 Combinations for the drawn arc process......................................................9
1.4.2 Combinations for the short cycle process....................................................9
1.5 Technical data .............................................................................10
1.5.1 INTRA 2100 technical data........................................................................10
1.5.2 INTRA 1400 technical data........................................................................11
1.6 Accessories (optional): ..............................................................12
1.7 Declaration of Conformity..........................................................13
2Work safety ...........................................................................................14
2.1 Safety symbols............................................................................14
2.2 Safety instructions......................................................................15
2.3 Intended use ................................................................................19
2.4 Warranty and liability..................................................................20
2.5 Copyright......................................................................................20
3Delivery and transport .........................................................................21
3.1 Scope of delivery ........................................................................21
3.2 Packaging and dispatch.............................................................21
3.3 Incoming inspection...................................................................21

Table of Contents
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
3.4 Interim storage ............................................................................21
3.5 Transport......................................................................................22
3.6 Location of use............................................................................22
3.7 Device set-up...............................................................................23
4Connection tasks..................................................................................24
4.1 Power cable connection.............................................................25
4.2 Welding gun connection............................................................26
4.3 Earth cable connection ..............................................................27
4.4 Workpiece connection................................................................28
5Control and display elements.............................................................30
5.1 Operating elements.....................................................................30
5.2 Display elements.........................................................................32
6Start-up and weld quality check.........................................................33
6.1 Notes about stud welding..........................................................33
6.2 Adjusting the weld parameters .................................................35
6.2.1 Settings data for drawn arc process ..........................................................36
6.2.2 Settings data for short cycle process.........................................................39
6.3 Commissioning conditions........................................................42
6.4 Functional test.............................................................................43
6.5 Checking weld quality ................................................................45
6.5.1 Visual inspection “drawn arc process” .......................................................46
6.5.2 Visual inspection “short cycle drawn arc process” .....................................47
6.5.3 Mechanical inspection (general)................................................................48
7Maintenance..........................................................................................49
7.1 Care and cleaning .......................................................................49
7.2 Maintenance intervals.................................................................50

Table of Contents
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
8Repairs...................................................................................................51
8.1 Notes on repair............................................................................51
8.2 Troubleshooting..........................................................................52
8.2.1 Fault: Power supply...................................................................................53
8.2.2 Fault: Overload/phase error......................................................................54
8.2.3 Fault: Gun function...................................................................................55
8.2.4 Fault: Welding ..........................................................................................56
8.2.5 Electronics error search.............................................................................57
9Appendix................................................................................................59
9.1 Disposal of the welding device .................................................59
9.2 Abbreviations ..............................................................................61
9.3 Bibliography ................................................................................62

1 Introduction Page 1
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1 Introduction
1.1 General remarks
This operating manual is about the INTRA 2100/1400 welding device and is intended
for operating and service personnel.
The INTRA 2100/1400 welding device can only be operated safely and reliably with
knowledge of the contents of this operating manual. Before starting up your device,
we ask that you thoroughly read this operating manual.
If anything is difficult or unclear, please contact Tucker customer service, who will be
glad to help you.
The illustrations, information and data in this operating manual were valid as of July
2021.
Tucker reserves the right to make technical changes that contribute to improvement
of the INTRA 2100/1400 welding device.
Also follow our instructions for safely operating the system in chapter 8.2
“Troubleshooting” of this operating manual. This will greatly ease independent
solution of problems.
In addition, we recommend looking through DVS leaflet 0902 “Arc stud welding with
drawn arc” and DGUV information 209-010 “Arc welding”, as well as standards EN
ISO 14555 “Welding - Arc stud welding of metallic materials” and EN ISO 13918
“Welding - Studs and ceramic ferrules for arc stud welding”.

1 Introduction Page 2
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1.2 Device description
The INTRA 2100/1400 is a robust, high-performance welding control device and
together with the NS 40 B or NS 40 SL welding gun forms a reliable stud welding
system.
When properly used, this device will always provide good, reliable work results.
Welding Process
–Drawn arc process
- Short cycle weld process
High weld performance
INTRA 2100: 2100 A, up to 22 mm weld diameter
INTRA 1400: 1400 A, up to 16 mm weld diameter
High weld safety
This device’s premium characteristics ensure consistently reliable operation and
outstanding work results.
Welding is automatically prevented if there is overheating, a phase failure or an
electrical fault in the welding gun current circuit.
The 35% power reserve ensures automatically ensures safe welding even under
maximum loads and in continuous operation.
High-quality weld results are even achieved with very long connections and under
unfavourable conditions.
Weld current and weld time settings
Continuous adjustment of these two important weld parameters is crucial to
safe, reproducible welding.
Constant current automation
The built-in constant current automation reliably evens out primary system voltage
fluctuations (max. ± 10%) within wide limits up to maximum weld current. Modern
micro-electronics ensure consistent quality of your work results.
Re-release lock
The re-release lock prevents unintentional double welding if the welded stud is still
in the placed welding gun.

1 Introduction Page 3
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
S symbol
The INTRA 2100/1400 devices bear the “S” symbol and are
approved for “welding in tight spaces and under elevated electrical
hazards” (see DGUV Information 209-010).
Standard equipment
•1 INTRA 2100/1400 control device with crane lugs and fixed casters (casters
with parking brakes).
•1 NS 40 B or NS 40 SL welding gun with 5 m or 3 m connecting cable, with
customer’s choice of stud holder (NS 40 B welding gun complete with foot plate
and ceramic ring holder).
•2 earth cable, 5 m long, with clamp
Special equipment
•Weld gun extension cable
•Earth cable extension
•Table device for stationary use of welding gun for recurring tasks
Options
•Shielding gas module for drawn arc welding without ceramic ring
•Automatic stud feeder

1 Introduction Page 4
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1.3 Description of stud welding process
According to DIN 1910-100, the stud welding processes are to be assigned to arc
pressure welding. This weld process generally welds peg-shaped connection
elements full surface to the workpiece.
The INTRA 2100/1400 welding device can be used to weld ordinary commercial
studs both in the drawn arc process (abbreviated BH 100 according to DVS 0902)
and the short cycle drawn arc process (abbreviated BH 10 according to DVS 0902):
1. Drawn arc process
(red NS 40 B welding gun)
Welding with ceramic ring
2. Short cycle weld process
(dark grey NS 40 SL welding gun)
Welding without a ceramic ring, especially on thin (and galvanized) sheet metal
The desired process is selected by moving the selector switch (see Chapter 5.1
“Operating elements”) and connecting the matching welding gun (see Chapter
4.2 “Welding gun connection”).
1.3.1 Drawn arc process
Usually, this process is called the “normal” stud welding process. It is generally
used in a diameter range from 3 mm to 25 mm with weld times up to 1 second.
The INTRA 2100/1400 compact devices allow welding of maximum diameters of
16 mm to 22 mm.
The Tucker weld studs have a specially shaped tip (see the following illustrations)
with a special aluminium preparation adapted to the stud diameter. The aluminium
serves as an ignition aid and reliably deoxidizes the melt.
Stud with even front surface Stud with conical front surface

1 Introduction Page 5
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
Process
1. Placing the stud
The stud is inserted into the stud holder and
ceramic ring in the welding gun’s ceramic ring
holder. The tip of the stud rests on the base
material and the welding gun is pressed against
the workpiece until the ceramic ring’s entire
surface lies on the workpiece.
2. Lifting and igniting the arc
When the release button is pressed on the welding
gun, the stud lifts and an auxiliary arc is created.
Then the main arc is ignited; the stud and the base
material fuse.
3. Immersion
After the weld time is over, spring pressure presses
the stud into the liquid weld pool.
4. Welded stud
The bond is created a few tenths of a second after
the release button is pressed. The welding gun is
not pulled from the stud until about 1 second of
dwell time. The melted material is then hardened.
Then the ceramic ring is removed.
Drawn arc process with ceramic ring
(BH 100 KR per DVS 0902)
For this standard process, for every weld, a ceramic ring adapted to the weld stud is
necessary. The ceramic ring concentrates the arc on the weld point and shields the
melt from the ambient air, preventing harmful oxidation of the melt. It holds the melt
together and forms a defined, reproducible weld bead. The ceramic ring also
decreases the cooling speed of the weld point, preventing undesirable hardening of
the base material. Moreover, it protects the welder from the arc and hot weld
splatter.
Ceramic ring