TRW Nelson Intra 2100 is a stud and pin welder working with a drawn arc. It takes studs up to 22 mm in diameter, you set the weld time from 0.01 to 1 s, and the supply is 3 x 400 V at a draw of 29 kVA. The machine weighs 248 kg and has a housing in class IP23.
What this machine is for
This is a machine for welding studs, threaded pins, sleeves and shear connectors to steel parts. The description points to heavy industry, machine building and automotive, steel structures, boiler houses and precast parts, and to series production and infrastructure repairs. A stud welder replaces drilling and tapping where hundreds of fixing points have to be set quickly.
The machine works with two methods. Drawn arc welding, with a ceramic ferrule or under gas shielding, gives a joint at larger diameters and handles S235, MP, KB, MR and S10 pins. Short cycle welding handles thin sheet from 0.6 mm, including galvanised pins on galvanised sheet, with a small heat affected zone.
The description gives the output in welds per minute: a KB 22 stud of 22.2 mm diameter is 3 welds, S 16 of 16.0 mm diameter is 6 welds, MP 16 of 14.6 mm diameter is 8 welds, and for S 10 of 10.0 mm diameter no limit is given. These numbers say how to plan the work cycle in series production.
Features and equipment
- Stepless adjustment of the welding current from 200 to 2100 A with a current reserve of 2350 A.
- Stepless adjustment of the weld time from 0.01 to 1.0 s, that is matching the energy to the pin diameter.
- Welding current stabilisation with automatic levelling of mains voltage swings.
- Self diagnostics of the system with signalling of overheating, a phase fault and a circuit failure.
- Work with a ceramic ferrule or under gas shielding, depending on the diameter and the demands on the weld.
- Input for an automatic stud feeder for series work.
- Works with NS 40 B, NS 40 SL and NS 20 BHD guns.
- Forced fan cooling and a working temperature from 0°C to 40°C.
The description also covers the TRW Nelson GD 25 gun for pins of large diameters. It takes pins from 3 to 25 mm in diameter and from 10 to 525 mm long, in steel and stainless steel, by the arc method with a ceramic ferrule or under gas shielding. It has lift adjustment from 0 to 6 mm in steps of 0.3 mm and a steplessly adjustable hydraulic damper, which controls the speed at which the pin plunges into the pool. An automatic length compensation system levels the differences that come from pin tolerances and the state of the surface. The welding cable is 2 m long with a section of 120 mm2, the control plug is 12 pin, the gun measures 68 x 180 x 295 mm, and the weight without the cable is 2.45 kg. A housing in impact resistant plastic insulates and takes site conditions. As an option you get a pin movement measuring system, which records the extension before welding and the course of the cycle, that is the plunge, the speed and the short circuit time. The gun carries the symbol S, that is approval for work in tight spaces with a raised risk of shock, protection against overload, a phase fault and a short circuit, and quality control of the welds is run to the EN ISO 14555 standard. The catalogue number of the gun is B 80 35 1255.
Technical data
| Brand | TRW Nelson |
|---|---|
| Type | stud welder, drawn arc and short cycle |
| Welding current | from 200 to 2100 A, stepless |
| Current reserve | 2350 A |
| Weld time | from 0.01 to 1.0 s |
| Stud diameter | up to 22 mm |
| Supply voltage | 3 x 400 V, 50/60 Hz |
| Power draw | 29 kVA |
| Mains fuse | 63 A CEE |
| Protection class | IP23 |
| Cooling | forced air, fan |
| Working temperature | from 0°C to 40°C |
| Weight | 248 kg |
| Dimensions (w x h x d) | 520 x 750 x 770 mm |
| GD 25 gun, pin diameter | from 3 to 25 mm |
| GD 25 gun, pin length | from 10 to 525 mm |
| GD 25 gun, lift | from 0 to 6 mm, steps of 0.3 mm |
| GD 25 gun, cable | 2 m, 120 mm2 |
| GD 25 gun, weight without cable | 2.45 kg |
What to watch out for
The product record gives a welding current up to 300 A, and the description of the welder a range from 200 to 2100 A with a reserve of 2350 A, so the value from the shop filter does not reflect the range of the machine. The supply is three phases 400 V at 50/60 Hz and a draw of 29 kVA, with a 63 A CEE fuse, that is a separate power circuit and a checked installation. The cooling is air, forced by a fan, the working temperature from 0°C to 40°C, the housing in class IP23.
A weight of 248 kg at dimensions of 520 x 750 x 770 mm means unloading with a forklift and a fixed station, not carrying by hand. You match the gun to the stud diameter: with large pins you need the model up to 25 mm, with smaller ones NS 40 B, NS 40 SL or NS 20 BHD are enough. You plan the ceramic ferrules or the shielding gas and the studs themselves separately, because they are consumables.
This unit is sold
This machine has already gone to a customer. Similar units are listed below, and if you want the same model, leave your contact details in the form and we will let you know when the next one arrives.