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

1 Introduction Page 6
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
Drawn arc process with shielding gas
(BH 100 SG per DVS 0902)
For special cases, the INTRA 2100/1400 welding device can be retrofitted with a
gas module for stud welding under shielding gas. Here changes to the performance
data and parameter inputs must be taken into account.
Ceramic ring not required.
The weld studs for this weld process contain no aluminium preparation.
Only diameters up to 10 mm can be welded under shielding gas. The weld must be
in tub position, because otherwise the fluid weld metal will flow out of the welding
location. A fillet-shaped weld bead always forms, no dimensionally accurate
reproducible bead, as when welding with a ceramic ring.
For this, follow the applicable special regulations for welding under shielding gas (e.g.
DGUV-R 100-500, Chapter 2.26: “Welding, cutting and related processes”). Your
Tucker technical consultant will be happy to give you more information.
1.3.2 Short cycle weld process
(BH 10 per DVS 0902)
Due to its easy, flexible use, the short cycle weld process is one of the safest, most
versatile processes in sheet metal working.
In this process, generally studs up to 8 mm in diameter without a ceramic ring are
welded. Due to the short weld times of no more than 0.1 second, the melt zone is
narrow and the heat input is low, so that welding can easily be done on sheet metal
as thin as 0.6 mm. The short weld time also allows welding of some materials of
different kinds (e.g. brass studs on sheet steel), welding of galvanized studs on
galvanized sheet metal, and welding on easily contaminated surfaces.
Tucker SC weld studs have a special conical welding tip adapted to this process.
The enlarged flange diameter increases the mechanical resilience of short cycle
welding.
Stud with
welding flange

1 Introduction Page 7
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
Process
1. Placing the stud
The stud is slid into the stud holder with its tip
placed on the workpiece and welding gun pressed
down against the workpiece to the mount of the
support tube.
2. Lift
When the release button is pressed on the welding
gun, the stud lifts and an auxiliary arc is created.
3. Igniting the arc
Then the main arc is ignited, and the stud front
surface and base material are fused.
4. Welded stud
After the weld time is over, spring pressure
presses the stud into the liquid weld pool. A few
hundredths of a second after the release button is
pressed, the joint is created.
In comparison to the drawn arc process, the same weld diameters are welded weld
time decreased by a factor of 10, but considerably increased current. Therefore, no
additives to deoxidize the weld point are needed.
Lift

1 Introduction Page 8
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1.4 Material combinations
The material combinations listed in the table below have already been tested. The
weld angle for the material combinations is defined as follows:
a = suitable for any application, such as force transfer,
b = suitable with limitations for force transfer,
c = suitable with limitations only for heat transfer,
– = cannot be welded.
Explanation of superscript numbers:
1) Up to 10 mm diameter and shielding gas in tub position (PA),
2) Only during short cycle stud welding with drawn arc,
3) Maximum yield strength ReH ≤ 460 N/mm2.
Material
combination
Base material
EN ISO 15614-1
*)
Groups 1 and 2 3) EN ISO 15614-1
*)
Groups 3 and 4 EN ISO 15614-1
*)
Group 9 EN ISO 15614-2
*)
Groups 21 and 22.1
Stud
S 235
4.8 (weld suitable)
16 Mo 3 a b b 2) –
X 10 CrAl 18
X 10 CrAl 24
X 10 CrNiSi 25-4 c c c –
1.4301, 1.4303
1.4401, 1.4451
1.4571 b (a) 1) b a –
EN AW-AlMg 3
EN AW AlMg 5 – – – b
Group 1: Steels with minimum yield stress of ReH ≤ 360 N/mm2
Group 2: Standardized or thermodynamically treated fine-grain structural
steels with a minimum yield stress of Re> 500 N/mm2
Group 3: Annealed fine-grain structural steels with a minimum yield stress of
Re> 500 N/mm2
Group 4: Steels with Cr max. 0.75%, Mo max. 0.6%, V max. 0.3%
Group 9: Austenitic stainless steels
Group 21: Pure aluminium with max. 1.5% impurities
Group 22.1: Non-curable AlMg alloys with ≤3.5% Mg content
Material combinations that are not listed in the table can be tested in the welding
laboratory. Contact your Tucker GmbH technical consultant.
*) EN ISO 15614-1, 2: Specification and qualification of welding procedures for metallic materials – Welding
procedure test

1 Introduction Page 9
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
Therefore, all weldable materials can be processed with the stud welding process.
The standards and regulations that apply to construction technology, boiler,
machine, reactor and shipbuilding in regard to mechanical properties, chemical
composition and suitability of the materials for welding must be observed.
1.4.1 Combinations for the drawn arc process
Generally, for the drawn arc process, combinations of like materials are to be
preferred (see the table on the previous page).
This means that steel-steel and aluminium-aluminium joints can be created.
So-called “black-white joints” (e.g. S235 with 1.4301) lead to a hard martenistic,
brittle weld metal in the welding zone. This welding is not suitable for high-strength
joints. For such applications, we recommend using Tucker DUO studs that always
have the same kind of material in the welding zone. Please ask your Tucker
technical advisor.
During execution of aluminium welds, you should also get in touch with your
Tucker technical consultant.
1.4.2 Combinations for the short cycle process
To a limited extent, the short cycle process also allows some combinations of
unlike materials (see the table on the previous page).
The special advantage here is the option to weld galvanized studs with galvanized
sheet metal. Generally, however, cold-rolled sheet metals and profiles should be
favoured.

1 Introduction Page 10
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1.5 Technical data
1.5.1 INTRA 2100 technical data
Max. weld diameter - Drawn arc
- Short cycle 22mm 9mm
Weld current, continuously adjustable
Current reserve for weld Ø
(measured with standard equipment on a stable network) 200 – 2100 A
Welding output in continuous operation
(drawn arc, with standard equipment) Stud Weld Ø
Welding
sequence
KB 7/8” 22.2mm 3 units/min
S 16 16.0mm 6 units/min
MP 16 14.6mm 8 units/min
S 10 8.0mm
∞
Weld time, continuously adjustable - Drawn arc
- Short cycle 0.1 s – 1 s 0.01 s – 0.1 s
Dimensions width
Height
Depth
Weight
520mm
750mm
770mm
248 kg
Connection voltage 50/60 Hz – Standard
(options upon request)
Nominal power
Network protection per phase (at 400 V)
Connected load
Protection type
CEE power plug (at 400 V)
3 ~ 400 V
29 kVA
63 A
168 kVA
IP 23
63 A (3L+PE)
Cooling type
External cooling (fan installed)
Operating temperature
0°C to +40°C
Storage temperature
-25°C to +55°C
Relative humidity
0% to 50% at 40°C
0% to 90% at 20°C

1 Introduction Page 11
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1.5.2 INTRA 1400 technical data
Max. weld diameter - Drawn arc
- Short cycle 16mm 9mm
Weld current, continuously adjustable
Current reserve for weld Ø
(measured with standard equipment on a stable network) 200 – 1400 A
Welding output in continuous operation
(drawn arc, with standard equipment) Stud Weld Ø
Welding
sequence
S 16 16.0mm 6 units/min
MP 16 14.6mm 8 units/min
MR 16 13.2mm 10 units/min
S 10 10.0mm
∞
Weld time, continuously adjustable - Drawn arc
- Short cycle 0.1 s – 1 s 0.01 s – 0.1 s
Dimensions width
Height
Depth
Weight
520mm
750mm
770mm
190 kg
Connection voltage 50/60 Hz – Standard
(options upon request)
Nominal power
Network protection per phase (at 400 V)
Connected load
Protection type
CEE power plug (at 400 V)
3 ~ 400 V
25 kVA
63 A
51.8 kVA
IP 23
63 A (3L+PE)
Cooling type External cooling (fan installed)
Operating temperature 0°C to +40°C
Storage temperature -25°C to +55°C
Relative humidity
0% to 50% at 40°C
0% to 90% at 20°C

1 Introduction Page 12
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1.6 Accessories (optional):
•Weld guns for manual stud loading:
1 Welding gun: Type NS 40 SL
complete with accessories: see operating manual NS 40 SL
1 Welding gun: Type NS 40 (B-1, B-2, B-3, B-4)
complete with accessories: see operating manual NS 40 B
•Stud (types and dimensions):
SC stud for short cycle drawn arc process:
SC stud (type)
Shaft Ø / weld Ø
Threaded stud (SC - B) M3 - M8 / 4 mm - 9 mm
Stud bolt (SC - S) 3 mm - 9 mm
Internally threaded socket (SC
- I)
M3 - M5 / 7 mm - 9 mm
Sawtooth stud (SC - Z) M 3 -M8 / 4 mm - 9 mm
DA stud for drawn arc process:
DA stud (type)
Shaft Ø / weld Ø
Threaded stud (MP, MPF) M6 - M12 / 5.3 mm - 10.8 mm
Threaded stud (M, MD) M8 – M12 / 6 mm - 12 mm
Threaded stud (MR) M6 – M12 / 4.7 mm – 9.5 mm
Stud bolt (SC - S) 3 mm - 12 mm
Internally threaded socket (MI) M4 – M8 / 10 mm - 12 mm
Head bolt (KB) ≤ 10 mm

1 Introduction Page 13
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
1.7 Declaration of Conformity
EU Declaration of Conformity in accordance with Machinery Directive
2006/42/EU Appendix II 1A
Document name:
Intra 1400_00_EN
Manufacturer:
Authorized to compile technical
documentation:
STANLEY Engineered Fastening
Matthias Appel
TUCKER GmbH
TUCKER GmbH
Max-Eyth-Strasse 1
Max-Eyth-Strasse 1
35394 Giessen
35394 Gießen
Germany
Germany
Product name:
Control and power unit for stud arc welding
Models:
Intra 1400, Intra 2100
Serial Number:
Year of construction:
The manufacturer hereby declares that the products stipulated above comply with all
relevant provisions and requirements of the following applicable directives:
2006/42/EU – Machine directive
2014/30/EU ‒ EMC Directive
The conformity assessment was conducted for machines not subject to Appendix IV with
internal production controls for manufacturing machines according to Appendix VIII.
References of the directives as published in the Official Journal of the European Union.
The following harmonized standards were used:
DIN EN IEC 60974-1:2018-12
Arc welding equipment - Part 1: Welding power sources
DIN EN IEC 60974-12:2012-03
Arc welding equipment - Part 12: Coupling devices for
welding cables
DIN EN 60204-1:2019-06
Safety of machinery - Electrical equipment of machines
- Part 1: General requirements
DIN EN 60529:2014-09
Degrees of protection provided by enclosures
Notified body:
EMC Test NRW GmbH
Emil-Figge-Straße 76, 44227 Dortmund
EU ID number:
1946
EU type examination certificate:
010/21-d
Represented by the chief executive officer:
Thomas Ehrhardt
Location, date:
Giessen, 2021-08-25
Legally binding signature:
This declaration certifies conformity with the above-mentioned guidelines

2 Work safety Page 14
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
2 Work safety
2.1 Safety symbols
Safety instructions and warnings are for your personal safety and for product safety.
In this operating manual, they are highlighted by the following safety symbols.
The safety symbol used has the following meaning:
The caution sign calls attention to potentially hazardous situations. It
is always used in connection with one of the additional terms defined
below.
The additional terms have the following meaning:
Danger: This means that death, severe bodily injury or severe property
damage will occur if the appropriate precautionary measures are not
taken.
Warning: This means that death, severe bodily injury or severe property
damage may occur if the appropriate precautionary measures are not
taken.
Caution: This means that minor bodily injury or property damage may occur if
the appropriate precautionary measures are not taken.
This sign indicates important information about proper handling of the
product or special instructions that should receive special attention.
Warning:
•Everyone who works on the INTRA 2100/1400 is obligated, before
starting work, to read and follow the safety instructions in this
operating manual!
•The system owner is obligated to allow only people familiar with the
work safety and accident prevention regulations to work on the INTRA
2100/1400.

2 Work safety Page 15
Stud welding units Operating manual Date: July 2021
INTRA 2100/1400 07.2021 / EN Rev.: A
2.2 Safety instructions
A prerequisite for safe handling and trouble-free operation of the INTRA 2100/1400
welding device is knowledge of the following safety instructions.
Informal safety instructions:
•The operating manual must always be stored at the place where the INTRA
2100/1400 is used.
•The safety symbols and type plate must be kept legible.
Training of personnel:
•The stud welding system’s operating personnel must:
- be trained in handling welding technology equipment,
- have had stud welding qualification training,
- know the content of this operating manual.
•Set-up and electrical personnel must:
- have had training enabling them to make repairs,
- have authorization to start up electrical circuits and devices according to the
safety standards.
•Personnel in training are allowed to:
- work on the welding system only under the supervision of experienced technical
personnel.
Personal safety equipment:
•It is mandatory to wear the following safety equipment:
flame-resistant safety clothing covering the entire body,
welder’s goggles with protection filter (per EN 169),
Safety gloves,
safety helmet (for overhead welding),
Ear protection (plugs, headset) is recommended.
•During welding, touchable parts of the welding gun, such as studs, stud holder and
all electrically connected parts carry current.
Therefore, do not wear any electrically conductive jewellery (ring, watch or chain)!