General Information; Introduction; General Service Policy; Safety Information - Cebora SYNSTAR 200 M Manual De Servicio

1

GENERAL INFORMATION.

1.1

Introduction.

The purpose of this manual is to train personnel assigned
to carry out maintenance on the power source art. 322 for
MIG/MAG welding systems.
1.2

General service policy.

It is the responsibility of the customer and/or operator
to use the equipment appropriately, in accordance with
the instructions in the Instructions Manual, as well as to
maintain the equipment and related accessories in good
working condition, in compliance with the instructions
provided in the Service Manual.
Any internal inspection or repairs must be carried out by
qualified personnel who are responsible for any interven-
tion on the equipment.
Any maintenance operation must be carried out in
compliance with standard CEI 26-29 (IEC 60974-4).
After making repairs, take care to organize the wiring so
that there is secure insulation between the primary and
secondary sides of the power source.
It is forbidden to attempt to repair damaged electronic
boards or modules; replace them with original Cebora
spare parts.
1.3

Safety information.

The safety notes provided in this manual are an integral
part of those given in the Instructions Manual.
Therefore, before working on the machine, please read the
paragraph on safety instructions in the aforementioned
manual.
Always disconnect the power cord from the mains, and
wait for the internal capacitors to discharge (1 minute) be-
fore accessing the interior of the equipment.
Some internal parts, such as terminals and dissipaters,
may be connected to mains or otherwise hazardous po-
tentials.
It is therefore forbidden to work with the safety guards
removed from the machine unless strictly necessary.
In this case, take special precautions such as wearing insu-
lating gloves and footwear and working in a perfectly dry
environment with dry clothing.
1.4

Electromagnetic compatibility.

Please read and observe the instructions provided in the
paragraph "Electromagnetic compatibility" of the Instruc-
tions Manual.
3302316/A
2

SYSTEM DESCRIPTION.

2.1 Introduction.
The Synstar 200 M is a system suitable for synergic MIG/
MAG and pulsed synergic MIG/MAG welding processes,
realized with inverter technology.
It is made up of the electronic power source (art. 322), with
integrated wire feeder unit and a series of accessories to
adapt to various types of use (see list in the Sales Cata-
logue).
The power source is controlled by microprocessor-based
circuits, which manage the operative functions of the
welding system and the operator interface.
The operator interface is developed via the Control Panel
built into the power source front panel.
The working programs respond to pre-programmed
synergic curves, that can be recalled from the control panel.
2.2

Technical specifications.

In order to verify the technical specifications, see the ma-
chine plate, Instructions Manual and Sales Catalogue.
2.3

Power source.

The art. 322 is a DC controlled-current power source com-
posed by a single-phase rectifier bridge, a DC/DC con-
verter (boost converter) a DC/AC converter (inverter) and
an ulterior rectifier bridge.
Referring to the electrical diagram in par. 5.1, drawing 4.1
and table 4.2, one may identify the main blocks that make
up the power source.
The main switch (40) powers the power board (45) which
contains all power elements of the power source.
More precisely in the power board (45) they can be iden-
tified (Fig. 2.3.1):
− the mains voltage filter for reduction of the conducted
interferences reflected in the mains;
− the input rectifier bridge that converts the mains voltage
in not stabilized DC voltage, for the boost converter
operation;
− the boost converter that transforms the not stabilized
DC voltage in 395 Vdc stabilized DC voltage, for
inverter operation;
− the DC-capacitors for the levelling of the DC voltage
generated by the boost converter;
− the igbt inverter, that generates the square wave
alternated voltage for the TF5 power transformer,
installed on the power board (45);
− the TA, TF4, for the relief of the TF5 power transformer
primary winding current;
− the rectifier bridge of the TF5 power transformer
secondary current.
EN
17