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Appendix

Page 62

Stud welding unit

operating manual

Date:

July 2021

INTRA 2100/1400

07.2021 / EN

Rev.:

9.3 Bibliography

The bibliographic sources used in this documentation in alphanumeric order,
indicating the title and time of publication:

DGUV infor-
mation 209-010:

“Arc welding”

DGUV reg. 3:

Accident prevention regulation “Electrical systems and work
equipment”

DGUV-R 100-500: Chapter 2.26 “Welding, cutting and related processes”

DIN 1910-100:

“Welding and related processes - Terminology” - Part 100: Metal
welding processes with additions to DIN EN 14610

DVS 0902:

“Arc stud welding with drawn arc” (information sheet)

EN 169:

Personal eye protection – Personal eye protection - Filters for
welding and related techniques - Transmittance requirements
and recommended use

EN 55011:

Industrial, scientific and medical equipment –

(VDE 0875-11)

Radio-frequency disturbance characteristics. Limits and methods
of measurement

EN 60529:

Degrees of protection provided by enclosures (IP code)

EN IEC 60974-1: Arc welding equipment

Part 1 - Welding power sources

EN 60974-4:

Arc welding equipment

(VDE 0544-4)

Part 4 – Recurring inspections and tests

EN IEC 60974-9: Arc welding equipment

Part 9 – Installation and use

EN IEC 60974-10: Arc welding equipment

Part 10 – Electromagnetic compatibility (EMC) requirements

EN IEC 60974-12: Arc welding equipment

Part 12 – Coupling devices for welding cables

EN ISO 13918:

Welding – studs and ceramic rings for arc stud welding

EN ISO 14555:

Welding – Arc stud welding of metallic materials

Содержание INTRA 2100

Страница 1: ...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...

Страница 2: ...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 oth...

Страница 3: ...l 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 dat...

Страница 4: ...ents 30 5 1 Operating elements 30 5 2 Display elements 32 6 Start 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 pr...

Страница 5: ...8 Repairs 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 s...

Страница 6: ...t 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 th...

Страница 7: ...ding 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 u...

Страница 8: ...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 gu...

Страница 9: ...le 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...

Страница 10: ...resses 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 secon...

Страница 11: ...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...

Страница 12: ...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...

Страница 13: ...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...

Страница 14: ...nium 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...

Страница 15: ...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...

Страница 16: ...quence 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 Dep...

Страница 17: ...erating manual NS 40 B Stud types and dimensions SC stud for short cycle drawn arc process SC stud type Shaft weld Threaded stud SC B M3 M8 4 mm 9 mm Stud bolt SC S 3 mm 9 mm Internally threaded socke...

Страница 18: ...4 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...

Страница 19: ...evere 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 preca...

Страница 20: ...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 s...

Страница 21: ...Depending on the process stud welding can produce strong electromagnetic fields These can be life threatening for people with heart pacemakers disturb or damage electrical or electronic devices irrec...

Страница 22: ...at devices in limit class A can cause radio interference in residential and business areas Safety measures during normal operation Use welding systems only in technically perfect condition Any unsafe...

Страница 23: ...d such that conductive parts moist walls and moist floors cannot be touched If it is not possible to use insulating materials due to additional hazards falling hazard special spacial conditions etc wo...

Страница 24: ...for use in residential and business areas because depending on the process there may be electromagnetic disturbances to external electrical and electronic devices The INTRA 2100 1400 is to be configu...

Страница 25: ...roperly attached safety equipment Start up after improperly done repairs Start up after repair done by unqualified personnel Independent design changes to the system Failure to adhere to the specified...

Страница 26: ...ng inspection The welding device has been carefully inspected at the factory before delivery However slight damage during transport is not always avoidable We therefore ask that upon delivery the weld...

Страница 27: ...snow etc welding outdoors or in unprotected rooms is prohibited In residential and business areas welding can cause radio interference This radio interference can be life threatening for people with...

Страница 28: ...d capacity must be at least double the weight of the welding device The INTRA 2100 1400 must be protected from high humidity and entry of fluids It must not be set up on fluid carrying lines To ensure...

Страница 29: ...0 welding device The power switch 1 must be in the O position 1 Power switch 2 NETWORK control lamp 3 START control lamp 4 COIL control lamp 5 Connector socket for earth cable X21 6 Connector socket f...

Страница 30: ...electro technical personnel are to open the welding device or work within its housing The power supply values are marked on the INTRA 2100 1400 type plate following Pos No see illustration on page 24...

Страница 31: ...nce the welding cable should be kept as short as possible and free of loops following Pos No see illustration on page 24 The welding cable of the welding gun 10 is connected to the connector socket X2...

Страница 32: ...ective If the START control lamp 3 does not light up when the welding gun is activated the trigger current circuit is defective see Chapter 8 2 Troubleshooting 4 3 Earth cable connection The weld curr...

Страница 33: ...circuit is not to be earthed except if the workpiece or workpiece mount are mandatorily earthed pipes ship construction etc 4 Before connecting the earth clamps the following instructions for prevent...

Страница 34: ...arc by the welding cable can largely be prevented by turning the welding gun 90 With a one sided earth clamp the arc blows away from the clamp This situation can be eliminated with additional metal pl...

Страница 35: ...r switch 6 LED for gun coil circuit 2 Weld current potentiometer 7 Malfunction LED 3 Weld time potentiometer 8 Contact LED 4 System voltage LED 9 Operating mode selector switch 5 Start weld cycle LED...

Страница 36: ...switch on time is set from the potentiometer Function Selection of weld time Setting range 0 1 s 1 0 s 10 ms 100 ms The setting is done according to the weld process BH 10 or BH 100 The appropriate s...

Страница 37: ...lour change red Fault overheat LED green Contact Pos 8 LED lights up when the stud contacts the workpiece The external welding circuit is closed LED goes out when the stud is lifted from the workpiece...

Страница 38: ...than 80 m in the welding zone should not be exceeded 5 Contaminations of the welding zone such as rust scale zinc paint moisture greases and oils must be removed immediately before welding In most ca...

Страница 39: ...e removed from the welding zone They are not to be exposed to arc radiation 13 Check the setting values required for your welding task on the INTRA 2100 1400 welding device and on the connected gun 14...

Страница 40: ...operating manual or the following graphic Guidelines for weld parameters The settings values indicated in the following tables or graphics should be considered only as guidelines to be achieved under...

Страница 41: ...3 3 200 150 IS 4 4 280 200 IS 5 5 350 230 KB6 MR M8 S6 6 400 250 MP F M8 7 450 300 MR M10 S8 8 550 300 MP F M10 9 700 350 KB10 MR M12 S10 10 750 400 MM12 S12 12 950 500 MR M 16 13 1150 500 MP M 16 MI...

Страница 42: ...5 1 5 MP F M8 7 2 0 1 0 2 5 1 5 MR M10 S8 8 2 0 1 0 2 5 1 5 MP F M10 9 2 5 1 0 3 0 2 0 KB10 MR M12 S10 10 2 5 1 5 3 0 2 0 MM12 S12 12 2 5 1 5 3 0 2 0 MR M 16 13 3 0 1 5 3 0 2 0 MP M 16 MI M 10 15 3 0...

Страница 43: ...For stud types not listed the settings data must be selected according to the weld diameters listed in the tables or graphics above Please note that generally the stud s nominal diameter e g MR M 8 8...

Страница 44: ...Welding time t ms SC stud 3 0 M3 4 400 15 SC stud 4 0 M4 5 650 15 SC stud 5 0 M5 6 850 20 SC stud 6 0 M6 7 1000 20 SC stud 8 0 M8 9 1000 35 Rule of thumb for short cycle drawn arc process Weld current...

Страница 45: ...ameters listed in the table above Please note that generally the stud s nominal diameter e g SC B M 8 8 mm do NOT correspond to the diameter to be welded weld diameter Generally the weld diameter of t...

Страница 46: ...Page 41 Stud welding units Operating manual Date July 2021 INTRA 2100 1400 07 2021 EN Rev A ESF Weld stud with even front surface 0 0 0 5 1 0 1 5 2 0 2 5 3 0 4 5 6 7 8 9 LIFT STUD STICK OUT MM WELD DI...

Страница 47: ...by are adequately protected against blinding and electromagnetic fields Chapter 2 3 Check the configured device components for correct connection When connecting a gun with manual stud loading the ins...

Страница 48: ...ector switch setting determines the weld time range Short cycle process 10 ms 100 ms Drawn arc process 0 1 s 1 0 s 4 Load a stud into the gun s stud holder For welding with ceramic rings the ceramic r...

Страница 49: ...the weld time ends the solenoid actuator is depowered 11 The stud dips into the melt bath the arc goes out and the weld current is switched off 12 Pull the welding gun as straight as possible off the...

Страница 50: ...documentation Simplified work inspection To check the device settings and functionality before start of shift three studs must be welded on which the following tests must be made 1 Visual inspection...

Страница 51: ...e electrical and mechanical parameters 2 Defective weld Constriction on the weld stud too long Corrective action Enlarge stud stick out check lift check centring of the ceramic ring Decrease welding c...

Страница 52: ...sible flaws Corrective action Not necessary No change to the electrical and mechanical parameters 2 Defective weld Diameter not fully welded Corrective action Increase welding current and or welding t...

Страница 53: ...lity test also see EN ISO 15614 1 2 include Tube bending test Impact bending test Tensile test Folding test Impact bending test Notch bending test Macrosection Hardness test The most commonly used tes...

Страница 54: ...be wiped with dry cloths The type plate and safety instructions must be easily readable The INTRA 2100 1400 s front plate must be cleaned with a grease cutting cleaning agent The LED display elements...

Страница 55: ...y Visual inspection outside the device housing welding cable control cables and hoses Power plug and power cable Display and control elements Connector sockets and connection plugs Components assembli...

Страница 56: ...cal repair preferably familiar with welding cutting and related processes see EN 60974 4 Repairs to the INTRA 2100 1400 welding device are to be done only as part of maintenance The INTRA 2100 1400 ca...

Страница 57: ...on diagram in Chapter 4 see illustration on page 24 Warning If there is a system malfunction the welding device must be switched off unplugged and secured against restart After the problem has been re...

Страница 58: ...s No 3 No 3 3 Power supply defective or loose contact Check network protection Check power supply OK No 4 Replace fuse 4 Cable break Measure through the cable OK No 5 Replace the cable 5 Power switch...

Страница 59: ...ite LED ready No 7 3 Device overloaded inadequate cooling Check fan Fan runs No 5 No 4 4 Phase error L1 Fuse F41 defective Blower connection fan Check power supply fuse plug cable Check the fuse 315 m...

Страница 60: ...No 6 5 Control line defective Replace the control cable Replace gun OK ready No 12 6 Coil defective Replace the coil Replace gun OK ready No 12 7 PCB connection defective Check the connection plug fo...

Страница 61: ...5 Contact detection defective Check the PCB plug X41 OK No 7 No 6 6 Connection X41 open Make the connection OK ready No 7 7 PCB defective Replace the PCB OK ready No 14 8 Pilot current fault Does the...

Страница 62: ...connections Diagnostic LEDs H3 H4 H7 H9 H141 briefly go on when the release button on the welding gun is pressed Place the welding gun on the workpiece Contact LED Pos 8 goes on If no display Connect...

Страница 63: ...ing manual Date July 2021 INTRA 2100 1400 07 2021 EN Rev A F1 F3 Fuse elements X1 X4 Plug connection H2 H18 Diagnostic LEDs Internal control card example illustration for the INTRA 2100 device F1 X4 X...

Страница 64: ...one Plastic container VER SA Components containing mercury Undamaged Closed plastic container Hg absorber VER of mercury LCDs Undamaged Dense container HM VER Cables wires None No requirements VER Com...

Страница 65: ...B2B devices1 and therefore intended only for commercial use Tucker stud welding units and system components must never be disposed of with household waste or at municipal collection points According...

Страница 66: ...opean standard ESF Weld stud with even front surface HPE Bundesverband Holzpackmittel Paletten Exportverpackung e V I A amperage in amperes IEC International Electro technical Commission IEC Norm Inte...

Страница 67: ...ersonal eye protection Filters for welding and related techniques Transmittance requirements and recommended use EN 55011 Industrial scientific and medical equipment VDE 0875 11 Radio frequency distur...

Страница 68: ...ation of welding procedures for metallic materials Welding procedure test Part 1 Arc and gas welding of steels and arc welding of nickel and nickel alloys EN ISO 15614 2 Specification and qualificatio...

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