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Related Manuals for Cebora SHIPYARD
Summary of Contents for Cebora SHIPYARD
- Page 1 INSTRUCTION MANUAL - Translation of the original intructions SHIPYARD Item no 1665 To be matched only with items 382 and 383 SYNSTAR SYNSTAR SYNSTAR 400 TS Item no 382 SYNSTAR 500 TS Item no 383 SYNSTAR 350 TS Item no 379...
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Page 2: Table Of Contents
TABLE OF CONTENT SYMBOLS ����������������������������������������������������������������������������������������������������������������������������������������������������������� 39 WARNINGS ��������������������������������������������������������������������������������������������������������������������������������������������������������� 39 LIFTING AND TRANSPORT ..............................39 INSTALLATION ��������������������������������������������������������������������������������������������������������������������������������������������������� 39 MAINS CONNECTION ................................39 ENVIRONMENTAL AND STORAGE CONDITIONS ......................... 40 3.3 GAS CYLINDERS ..................................40 GENERAL INFORMATION ............................... 40 WARNING PLATE ..................................41 GENERAL DESCRIPTIONS ������������������������������������������������������������������������������������������������������������������������������� 42 EXPLANATION OF TECHNICAL SPECIFICATIONS ........................ - Page 3 © CEBORA S.p.A. The copyright of these operating instructions is owned by the manufacturer. The contents of this document may be subject to change.
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Page 4: Symbols
SYMBOLS The colour of the box indicates the category into which the operation falls: DANGER, WARNING, CAUTION, NOTICE or INSTRUCTION. DANGER Indicates a situation of imminent danger that could cause severe injury to people. WARNING Indicates a situation of potential danger that could cause severe injury to people. Indicates a situation of potential danger that could cause slight injury to people and CAUTION material damage to equipment if not respected. Provides important information to the user that could lead to damage to equipment if WARNING not observed. INSTRUCTION Procedure to be followed to achieve optimal use of the equipment. WARNINGS DANGER Before handling, unpacking, installing and using the welding power source, it is obligatory to read the General warnings manual code 3301151�... -
Page 5: Environmental And Storage Conditions
DANGER ♦ Make sure that the mains voltage matches the voltage indicated on the specifications plate of the welding machine. Connect a plug of adequate capacity for the current consumption I1 indicated on the data plate. Make sure that the yellow/green conductor of the power cable is connected to the plug’s earth contact. ♦ If mains power extensions are used, the cable supply cross-section must be appropriately sized. Do not use extensions longer than 30 m. ♦ It is essential to use the device only if connected to a power supply with an earth conductor. ♦ Using the device connected to the mains without an earth conductor or to a socket without a contact for this conductor constitutes very serious negligence. The manufacturer declines all responsibility for damage to people or property that may occur. ♦ The user is bound to have the efficiency of the earth conductor of the system and the device in use periodically checked by a qualified electrician. 3�2 Environmental and storage conditions The device must be installed and operated only on an appropriate, stable, flat surface and not in the open air. The user must ensure that the ground is flat and not slippery and that the workplace is properly lit. Safe use of the device must be ensured at all times. The device can be damaged by particularly high quantities of dust, acids, gases or corrosive substances. Prevent the device from coming into contact with high quantities of smoke, steam, oil mist or grinding powders! Poor ventilation will result in reduced performance and damage to the device: ♦ Observe the recommended environmental conditions. ♦ Leave cooling air inlets and outlets unobstructed. ♦ Leave a minimum distance of 0.5 m from any obstructions. Ambient temperature range under working conditions from -10 °C to +40 °C, under transportation and storage conditions from -20 °C to +55 °C. Air relative humidity: up to 50% at 40 °C, up to 90% at 20 °C. -
Page 6: Warning Plate
3�5 Warning plate The following numbered text reflects the numbered boxes on the plate. B. Wire feed rollers can injure the hands. C. The welding wire and wire feeder unit are live during welding. Keep hands and metal objects well away. Electric shocks caused by the welding electrode or cable can be fatal. Protect yourself properly against the danger of electric shocks. 1.1 Wear insulated gloves. Never touch the electrode with bare hands. Never wear damp or damaged gloves. 1.2 Insulate yourself from the workpiece and the ground. 1.3 Disconnect the supply cable plug before working on the machine. Inhaling fumes produced by welding can be harmful to the health. 2.1 Keep your head away from the fumes. 2.2 Use a forced ventilation system or local exhaust to remove fumes. Use a suction fan to remove fumes. Sparks generated by welding can cause explosions or fires. 3.1 Keep flammable materials well away from the welding area. 3.2 Sparks caused by welding can cause fires. Keep an extinguisher nearby and ensure that someone is ready to use it. 3.3 Never weld with closed containers. Arc rays may injure the eyes and burn the skin. 4.1 Wear a safety helmet and goggles. Use appropriate ear protectors and overalls with the collar buttoned up. Use helmet masks with filters of the correct grade. Wear a full-body protection. Read the instructions before using the machine or carrying out any operation on it. Do not remove or cover warning labels. -
Page 7: General Descriptions
GENERAL DESCRIPTIONS The device is a multi-process system suitable for MIG/MAG welding and MMA welding (with the exception of cellulosic welding), developed with inverter technology. The device may be used only for the purposes described in this manual. The device must not be used to defrost pipes. 4�1 Explanation of technical specifications This device is manufactured according to the following standards: IEC 60974-1 / IEC 60974-2/ IEC 60974-5/ IEC 60974-10 (CL. A) / IEC 61000-3-11 / IEC 61000-3-12 (see note 2). Serial number, to be indicated on any request regarding the welding machine. Three-phase static frequency converter transformer-rectifier Suitable for MIG-MAG welding Suitable for MMA welding Secondary open-circuit voltage Duty cycle percentage. The duty cycle expresses the percentage of 10 minutes during which the welding machine can run at a given current without overheating Welding current Secondary voltage with I2 current Rated supply voltage 3~ 50/60Hz 50 or 60-Hz three-phase power supply... -
Page 8: Protections
During transport of the device, ensure that applicable national and regional accident prevention guidelines and regulations are observed. This applies in particular to guidelines concerning transport and shipping risks. Carefully read the “Lifting and transporting” section in General Warnings code 3301151 DANGER Tipping a device over may endanger life! Position the device stably on a solid, flat base. A maximum angle of inclination of 10° is allowed. Do not lift or transport live devices. The machine should not be positioned on sloping planes, to prevent tilting or any uncontrolled movement. WARNING To move the power source, fit the missing rear wheels and adhere scrupulously to the following instructions. Disconnect the device from the power supply before moving it. During transport of the device, ensure that all applicable local accident prevention guidelines and regulations are observed. CAUTION After transport or relocation and before operating, a visual inspection must be performed on the device to check for any damage. Ensure any damage is repaired by qualified CEBORA authorised technical assistance staff before operating the device. The capacity of the lifting device must be at least 20% greater than that of the load to be lifted. When lifting the power source and the wire feeder, use only the eyebolts located on the top of the power source and on the wire feeder spool support. All harnessing devices (straps, buckles, chains, etc.) that are used together with the device or its components must be checked at regular intervals (e.g. for mechanical damage, corrosion or alterations caused by environmental factors). Check intervals and scope must at least comply with national standards and directives in force from time to time. 3301291 3301291-EN... - Page 9 WARNING Position the welding machine so as to allow the free circulation of air inside and, as much as possible, prevent metal or other dusts from entering. The machine must be installed by professional personnel. All connections must be carried out according to current regulations, and in full compliance with safety laws in the country where the device is used. Carefully read the “Mains connection” section in General Warnings code 3301151. WARNING The installation and management of this system must comply with the CEI EN 60974-9 standard. Make sure that the mains voltage matches the voltage indicated on the specifications plate of the power source� Connect a plug of adequate capacity for the current consumption I1 indicated on the data plate. Make sure that the yellow/green conductor of the power cable is connected to the plug’s earth contact. The capacity of the overload cut-out switch or fuses, positioned between the power supply network and the power source, must be adequate for current I1 consumed by the power source. DANGER It is essential to use the device only if connected to a power supply with an earth conductor. Using the device connected to the mains without an earth conductor or to a socket without a contact for this conductor constitutes very serious negligence.
- Page 10 Fig. 1 ♦ Fit the male support to the wire feeder and the female support to the power source (see fig. 2). The small wheels must be mounted on the wire feeder base, together with the torch support (see fig. 2). The assembled wire feeder must be positioned on the power source support. Fig. 2. ♦ Block one end of connection BA, by fixing the tab BB to the bottom of the machine (see fig. 3). 3301291 3301291-EN...
- Page 11 Fig. 3 ♦ Connect all wiring on the back of the power source (see fi g. 4). Fig. 4 ♦ Avoid coiling the connection to minimise inductive effects that could affect welding. Connect the other end of connection BA to the wire feeder (see fi g. 5). 3301291-EN 3301291...
- Page 12 Fig. 5 ♦ The coolant fluid hoses must be connected to the quick-fitting valves located below the base of the wire feeder (see fig. 6), by observing the colour coding on the trolley front side. Fig. 6 Note on gas connection Carefully read the sections “Explosions”, “Hazardous gases and vapours” and “Gas cylinders” in General Warnings code 3301151. 3301291 3301291-EN...
- Page 13 DANGER All cylinders and pressure regulators used in welding operations should be handled with care. If the gas cylinder is not connected, leave the valve protection in place. Always use gas cylinders suited to various types of application as well as appropriate accessories (pressure/flow regulators, pipes, fittings, etc.). Only use gas cylinders and accessories in good condition. If a gas cylinder valve is open, move your face away from the point where the gas emerges. When you have finished welding or cutting, close the valve of the gas cylinder used. Make sure no inert gas is leaking from the cylinders. Inert gas is colourless and odourless. An environment saturated with inert gas is devoid of oxygen, which causes asphyxiation of people in the environment. ♦ Position the cylinder on the support and fix it with the 2 straps; ensure that the straps are secured tightly to the cylinder to prevent dangerous tilting. ♦ Connect the gas hose to the outlet of the pressure regulator. ♦ Open the side door of the wire feeder. ♦ Connect the earth cable to socket 9 and through the terminal to the workpiece. ♦ Fit the wire coil on the support. The coil must be fitted so that the wire unwinds in an anticlockwise direction. ♦ Make sure the drive roller is correctly positioned according to the diameter and type of wire used. ♦ Cut the welding wire with a well-sharpened tool, keeping it between your fingers so that it cannot unwind, insert it inside the pipe exiting from the gear motor and, with the aid of a finger, insert it inside the steel tube until it emerges from the adapter. ♦ Fit the welding torch.
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Page 14: Description Of The Device
DESCRIPTION OF THE DEVICE 6�1 Front view DISPLAY Touch screen for displaying welding parameters KNOB For selecting and adjusting welding parameters CONNECTOR For connecting MIG torch controls CONNECTOR DB9 type (RS 232) connector to be used for updating the welding programs QUICK-FITTING VALVES Connect the red and blue hose of the welding torch (red with red, blue with blue) CENTRAL ADAPTER For connection to the MIG welding torch SOCKET Socket for connecting the electrode clamp in MMA welding CONNECTOR USB-type connector to be used for updating the welding programs EARTH CABLE OR SOCKET Socket (-) for connecting the earth cable connector TANK CAP SLOT Slot to inspect the coolant fluid level 3301291 3301291-EN... -
Page 15: Rear View
6�2 Rear view PLUG Plug for connecting the power cable floating connector of the power source-wire feeder extension PLUG Socket for connecting the services cable floating connector of the power source-wire feeder connection GAS FITTING SWITCH Starts and stops the machine MAINS CABLE SOCKET Socket (+) for connecting the power cable floating connector of the power source-wire feeder extension SOCKET Socket for connecting the services cable floating connector of the power source-wire feeder connection FUSE HOLDER QUICK-FITTING VALVES Connect the red and blue pipes of connection Item No 2069, which joins the power source to the wire feeder 3301291-EN 3301291... -
Page 16: Description Of Touch Screen Display Functions
DESCRIPTION OF TOUCH SCREEN DISPLAY FUNCTIONS When the machine is switched on, for a few moments the display screen shows: the machine item number, the serial number, the firmware version, the firmware development date and the release number of the synergic curve table and power source options. This information is also given in menu 7�1 MIG Process� Main screen Pushbutton A The screen displays the welding current in amps, welding voltage in volts, the suggested thickness in mm and the welding wire speed in m/min. During welding the display shows continuous current and voltage values and, once welding is completed, the last value in amps and volts is displayed together with... -
Page 17: Start Mode
7�1�2 Start mode To choose the start mode, select pushbutton C Start modes are the same for all MIG/MAG processes Set the desired start mode using the appropriate pushbuttons. When start mode has been selected, the associated section turns orange. START pushbutton pressed START pushbutton released The START command for manual applications is available in the wire feeder, either on the torch adapter - it can be activated using the corresponding pushbutton on the torch - or on the remote control connector. 2 stroke mode Mode appropriate for short welding bursts. Welding is started by pressing the START pushbutton and ends when the pushbutton is released. -
Page 18: Setting Welding Parameters
7�1�3 Setting welding parameters Adjusting inductance� This can be selected using pushbutton D. This function can be used to switch between a narrow, hard arc with deep penetration (negative values) and a broad, smooth arc (positive values). The adjustment can range between +/- 9.9, 0 is the factory setting� Adjusting arc length� This can be selected using key E. If necessary, arc length (welding voltage) can be corrected by +/- 9.9 V for the specific welding job, 0 is the factory setting. 7�2 Main menu This can be selected using pushbutton F Select to enter the Main Menu� 7�2�1 Selecting the welding process The PROCESS pushbutton can be used to select the MIG/MAG or MMA process. - Page 19 ■ Start mode This can be selected using pushbutton C The selection is between Mode 2T, Mode 4T and Mode 3L� Turn knob 2 to select the parameter and confirm the selection by pressing the knob. To select mode, turn knob 2. To confirm the selection, press knob 2 or key ■ SPOT mode The operator can choose between Spot time and pause time function.
- Page 20 ■ Double level mode Active in synergic MIG/MAG processes only. This mode involves changing wire speed (and consequently also current intensity) between two levels. Before setting double-level welding, weld a short bead to determine the wire speed and thus the current to obtain the optimum bead penetration and width for the type of weld required. In this way the wire feed speed is determined; the set SPEED DIFFERENCE parameter will be added to or subtracted from this value.
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Page 21: Accessories Menu
7�3 Accessories menu Activate the various accessories available in the power source from the following menu. WARNING If accessories are present in the welding system, they must be connected to the power source before powering up. Connecting/disconnecting accessories while the power source is switched on leads to system malfunctions and under extreme circumstances could compromise the integrity of the welding system. CEBORA SpA does not provide warranty coverage for inappropriate use of the welding system. To access the Accessories menu, select Menu->Accessories 7�3�1 Cooling unit The cooling unit to be used with the SYNSTAR power sources is Item No. 1686 - GRV22. On power source Item No 379 it is optional, but standard on power sources Item No 382 and 383. The status bar always shows the cooling unit icon H and unit status is shown in the upper part of the icon: OFF, ON, AUTO Knob 2 is used to select/activate the operating mode: Cooling unit disabled Cooling unit always on AUTO Cooling unit operates in synchrony with the welding process For correct connection of the cooling unit Item No 1686 to the power source, consult instruction manual code 3301297. Coolant requirements The power source is supplied with a minimum quantity of coolant fluid: the customer is responsible for filling the tank before the system is used. Use only Cebora coolant (Item No 1514) and read the MSDS carefully to ensure its safe use and correct conservation. The 5 litre capacity tank inlet is located to the front of the power source. Fill up to max level and top up to make up the volume of fluid in the pipes after the first system start-up. NOTE: small fluid leaks will occur during use of the system and particularly when changing the torch or consumables. -
Page 22: Push-Pull Torch
7�3�2 Push-pull torch Use knob 2 to select Push-Pull mode: Binzel torch; for Item No 382 and 383: connect a Binzel torch with 42 VDC motor to the wire feeder; for Item No 379: connect a Binzel torch with a 24 VDC motor. The machine is ready to weld. Both wire feed motors, the main and the Push-Pull motor, are already synchronised. -
Page 23: Settings Menu
7�4 Settings menu This menu is used for the welding power source basic settings 7�4�1 Machine status Use knob 2 to select Machine status mode. The power source status menu displays information about power source output voltage and current, power source internal temperatures, motor voltage and current, battery voltage. 7�4�2 Date and Time Setting Use knob 2 to select Clock Setup mode. Adjust values by turning knob 2 and confirm by pressing. -
Page 24: Usb Port Management
Insert the pen drive into the power source USB port. Install Options Select this item to install the software options in the power source. The option release file loaded on the USB drive must have the extension .txt and is supplied by Cebora after purchasing the option. Insert the pen drive into the power source USB port. Installation can also be carried out using the keypad. Use the F key to enter the Main menu, press the key. -
Page 25: Calibration
7�4�9 Calibration Use knob 2 to select Calibration mode. The purpose of this function is to provide specialised personnel with guidance on how to calibrate Cebora power sources in compliance with IEC EN 60974 -14. The power source calibration must be carried out by qualified personnel. Cebora Technical For instructions, contact Assistance Service. -
Page 26: Copying A Welding Job
7�5�4 Copying a welding JOB Select the memory position of the JOB to be copied by turning knob 2 Press pushbutton and the JOB will be copied to the memory. Select a free memory position using 2 and press The JOB will be copied to the new position. 7�5�5 Welding with a JOB Select the memory position of the JOB to be used by turning knob 2. Press the Job Mode pushbutton to activate welding with the selected JOB Press the pushbutton The Job Mode operating mode is active with the selected JOB (2 in the example). -
Page 27: Mig Welding
MIG WELDING ♦ Connect the earth cable to the socket 9 (-). ♦ Connect the cable connector of the power source-wire feeder connection to the rear socket 17. ♦ Connect the service connector of the power source-wire feeder connection to the rear connector 18. ♦ Connect the cable connector of the power source-wire feeder connection to the rear plug of wire feeder 12. ♦ Connect the service connector of the power source-wire feeder connection to the rear connector of wire feeder 13. ♦ Connect the gas hose emerging from the power source-wire feeder connection to the rear fitting of wire feeder. 8�1 Description of the welding process In the Main Menu, after selecting process, choose welding type MIG: Mig Pulse, Mig PulseHD, Mig Short, Mig ShortHD or Mig Manual For all the processes indicated below (except for MIG Manual), the welding parameters are adjusted synergically using knob 2. Individual processes are available only for the individual synergic curves for which they have been developed or which are allowed by the process. -
Page 28: Mma Dc Welding
MMA DC WELDING SYNSTAR range power sources are able to manage the MMA process in DC mode. This welding machine is suitable for welding all types of electrodes, with the exception of cellulosic (AWS 6010). ♦ Make sure that the Power On switch is in position 0 (OFF), then connect the welding cables, respecting the polarity required by the manufacturer of the electrodes that you will be using and the terminal of the earth cable to the workpiece is at the closest point to the weld, ensuring that the electrical contact is good. ♦ Do not touch the torch or the electrode holder and the earth clamp simultaneously. ♦ Turn on the machine using the Power On switch. ♦ Select MMA process. ♦ Adjust the current based on the electrode diameter, welding position and type of weld to be made. After welding, always switch off the power source by removing the electrode from the electrode holder. WARNING Beware of electrical shocks. When the main switch is in ON position, the electrode and the non-insulated part of the electrode holder are live. Therefore, make sure that the electrode and the non-insulated part of the electrode holder do not come into contact with electrically conductive or earthed persons or components (e.g. outer casing, etc.). -
Page 29: Error Codes
ERROR CODES Error management is divided into two categories: Hardware errors [E]. These cannot be reset and require the power source to be restarted. They are displayed on the screen with a red background. Alarms [W] linked to an external condition that can be reset by the user and does not require the power source to be restarted. These are displayed on the screen with an amber background. Code Type Error Description Action EEPROM error detected by the power source Switch the power source off and on. If the internal board problem persists, contact technical assistance General fault error detected by the power Switch the power source off and on. If the [E] source internal slave board problem persists, contact technical assistance... - Page 30 Code Type Error Description Action Write error in the FLASH on the MASTER panel Switch the power source on and off. If the error board persists, contact technical assistance. Switch the power source on and off. If the error Output current sensor offset reading problem persists, contact technical assistance. Check there are no mechanical blockages in the wire feeder rollers. If the motor turns at an uncontrollable speed, check the wiring Motor speed out of control.
- Page 31 Code Type Error Description Action Check the coolant level. Check the centrifugal pump turns correctly. If it does not turn Coolant pressure too low. correctly, release using a release screw. If the problem persists, contact technical assistance. Check the pressure switch connection is intact. Cooling unit not connected If the problem persists, contact technical assistance. Check that the door of the wire feeder Wire feeder compartment door is properly closed. If the door open.
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Page 32: Technical Specifications
TECHNICAL SPECIFICATIONS Provided the impedance of the public low-voltage network at the point of common coupling (PCC) is lower than the Zmax value indicated in the tables below, this unit complies with IEC 61000 3-11 and IEC 61000 3-12 and can be connected to low-voltage networks. It is the responsibility of the installer or user of the unit to ensure, by contacting the distribution network provider if necessary, that the network impedance is in compliance with the impedance restrictions specified. The tables below show the technical data of the power sources for welding processes that can be used in manual mode (MIG/MAG and MMA) and in the field of automation (MIG/MAG only). SYNSTAR 350 TS Item No� 379 Mains voltage (U1) 3 x 230 V 3 x 400 V 3 x 230 V 3 x 400 V Mains voltage tolerance (U1) +15% / -20% Mains frequency 50/60 Hz Mains fuse (delayed action) 28 A 16 A 28 A 16 A 13.3 kVA 40%... - Page 33 SYNSTAR 400 TS Item No� 382 Mains voltage (U1) 3 x 400 V Mains voltage tolerance (U1) +15% / -20% Mains frequency 50/60 Hz Mains fuse (delayed action) 25 A Apparent power 17.5 kVA 100% Mains connection Zmax 26 mΩ Power factor (cosɸ) 0.99 Welding current range 10 ÷ 400 A 10 ÷ 380 A Welding current 10 min/40 °C (IEC 60974-1) 400 A 100% 380 A 100% Open-circuit voltage (U0) 57 V Usable electrodes Ø...
- Page 34 SYNSTAR 500 TS Item No� 383 Mains voltage (U1) 3 x 400 V Mains voltage tolerance (U1) +15% / -20% Mains frequency 50/60 Hz Mains fuse (delayed action) 25 A 25 kVA 40% 25 kVA 40% Apparent power 22 kVA 60% 22 kVA 60% 16.5 kVA 100% 16.5 kVA 100% Mains connection Zmax 30 mΩ Power factor (cosɸ) 0.99 Welding current range 10 ÷ 500 A 10 ÷ 500 A 500 A 40% 500 A 40% Welding current 10 min/40°C (IEC 60974-1)
- Page 35 SHIPYARD Item No 1665 3301291-EN 3301291...
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