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Cebora KINGSTAR 400 TS - User Manual

Cebora KINGSTAR 400 TS
164 pages
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12/07/2021
3301065/A
IT MANUALE DI ISTRUZIONI PER PER SALDATRICI A FILO ...................PAG. 2
Istruzioni originali
Parti di ricambio e schemi elettrici / vedi Allegato
EN INSTRUCTION MANUAL FOR FOR WIRE WELDING MACHINE ............ PAGE 56
Translation of the original instructions
Spare parts and wiring diagrams / see Annex
ES MANUAL DE INSTRUCCIONES PARA SOLDADORA DE HILO ..............PAG. 110
Traducción de las instrucciones originales
Esquemas eléctricos & lista recambios / Ver Anexo
KINGSTAR 400 TS ART. 372.00 KINGSTAR 520 TS ART. 374.00
KINGSTAR 400 TS ROBOT ART. 372.80 KINGSTAR 520 TS ROBOT ART. 374.80

Table of Contents

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Summary

SYMBOLS

WARNINGS

2.1 Warning plate

Explains the symbols and warnings on the machine's identification plate.

GENERAL DESCRIPTION

3.1 Explanation of plate data

Details the meaning of various symbols and data on the machine's technical plate.

3.2 Installation

Provides instructions and warnings for safely installing the welding machine.

3.3 Mains connection

Describes how to properly connect the welding machine to the power supply.

3.4 Lifting and transport

Outlines safe procedures for lifting and transporting the welding equipment.

3.5 Installation and start up

Covers the initial setup and first-time operation of the welding machine.

3.5.1 Installing power source and wire feeder.

Details the physical assembly and connection of the power source and wire feeder.

3.6 Power source description

Identifies and describes the components and connectors on the power source.

3.7 Wire feeder description

Identifies and describes the components and connectors on the wire feeder.

3.7.1 Wire feeder panel description

Explains the controls and indicators on the wire feeder's front panel.

3.8.1 Power source rear panel connector description

Details the connectors located on the rear panel of the power source.

3.8.2 Cooling unit interface.

Describes the connection and function of the cooling unit interface.

3.9 Description of display

Explains the touchscreen display and its primary functions.

3.9.1 Navigation within a general screen

Guides the user on how to navigate through the display menus and options.

MIG WELDING

4.1 Power source-wire feeder connection

Instructions for connecting the power source to the wire feeder.

4.2 Selecting the synergistic curve:

How to choose appropriate welding parameters based on material and wire.

4.2.1 Description of the welding process

Explains different MIG welding processes like Pulse, Short, Root, SRS, 3D Pulse, Manual.

4.3 Start mode

Describes different methods for starting the welding arc (2T, 4T, 3 Level, HSA, CRA, SPOT).

4.3.1 SPOT mode

Details the settings for spot welding, including spot and pause times.

4.3.2 DOUBLE LEVEL mode

Explains the double level mode for adjusting wire speed and current.

4.3.3 Setting welding parameters

Describes how to adjust key welding parameters like inductance and arc length.

TIG DC WELDING.

5.1 Select welding process:

Guides on selecting TIG DC welding processes (APC Lift, APC, XP).

5.2 Start mode

Explains TIG start modes (2 stroke, 4 stroke, 3 level, 4 level).

5.3 Arc striking modes.

Details arc striking methods, specifically Lift contact ignition.

5.3.1 Lift contact ignition.

Step-by-step guide for initiating the arc using the lift contact method.

5.4 TIG parameter settings table.

Provides a table of adjustable parameters for TIG welding.

5.5 Pulse Menu

Explains the TIG Pulse function for thin sheets and parameter settings.

5.6 TIG DC APC

Describes the TIG DC APC process for maintaining constant heat input.

5.7 TIG DC XP

Details the TIG DC XP process with high-frequency pulses for better performance.

MMA WELDING

6.1 MMA DC Process

Explains the MMA DC welding process and initial setup.

6.2 MMA process parameters

Details adjustable parameters for MMA welding like Hot Start and Arc Force.

OTHER PANEL FUNCTIONS

7.1 JOB management

Covers saving, retrieving, and managing welding programs (JOBS).

7.1.1 Saving a welding JOB

Step-by-step guide to saving a welding JOB to memory.

7.1.2 Modifying a JOB

Instructions on how to edit existing welding JOBs.

7.1.3 Deleting a JOB

How to remove unwanted welding JOBs from memory.

7.1.4 Copying a JOB

Procedure for duplicating existing welding JOBs.

7.1.5 Welding with a JOB

How to select and activate a saved JOB for welding.

7.1.6 JOB Details

Viewing detailed information about a saved JOB.

7.1.7 Allow adjustment of a JOB

Enabling adjustments to parameters within a saved JOB.

7.1.8 Saving and loading an individual JOB from a USB drive

Managing JOBs by backing them up to or loading them from a USB drive.

7.2 Power source status menu

Accessing information on welding time, output, temperatures, and wire feed.

7.3 Accessories menu

Accessing and managing various connected accessories for the power source.

7.3.1 Cooling unit

Details on operating and managing the cooling unit.

7.3.2 Welding mask

Explains the setup and function of the welding mask T-LINK system.

7.3.3 Push-Pull Torch

Information on activating and using the Push-Pull Torch system.

7.3.3.1 Push-Pull Torch Custom

Customizing the Push-Pull Torch operation.

7.3.3.2 Push-Pull Calibration

Procedure for calibrating the Push-Pull Torch for optimal performance.

7.3.3.3 Push-Pull Force

Adjusting the torque for the Push-Pull motor to ensure linear wire feed.

7.3.4 Torch Calibration

Calibrating the welding torch, likely for specific kits like SRS.

7.3.5 Max Inching

Setting a limit for wire emergence to prevent issues during startup.

7.3.6 Quality Control

Refers to a separate manual for Quality Control features.

7.3.7 Gas regulation Kit

Information on the gas regulation kit for MIG processes.

7.3.8 Input potentiometer

Explains the function of the input potentiometer for remote control.

7.4 Settings menu

Access point for configuring various machine settings.

7.4.1 Production Mode

Details a software option for production mode.

7.4.2 Setting the clock, language

How to set the system clock and select the user interface language.

7.4.3 User management

Manages user profiles (Normal, Expert, Administrator) and their permissions.

7.4.4 USB management

Operations for managing USB drives, including firmware updates and backups.

7.4.5 LAN setup

Configuring network settings for connecting the machine to a LAN.

7.4.6 Advanced functionalities

Information on API REST interface for Industry 4.0 integration.

7.4.7 Restore factory setup

Procedures for resetting the machine to its original factory settings.

7.4.8 Name of power source and system

Setting a custom name for the power source and system.

7.5 Status bar

Explains the icons and indicators shown on the main menu status bar.

7.6 Info Menu

Accessing information about the machine, distributor, and installing options.

WEBAPP

ROBOT CONFIGURATION

9.1 Description of the system

Overview of the CEBORA KINGSTAR Welding System for automated welding.

9.2 Connection procedure

Steps for configuring CANopen and enabling the robot interface.

9.3 DIP switch and terminal settings

Details DIP switch and terminal configurations for different interfaces.

9.4 Rear connectors for robot interface and accessories

Diagrams and identification of connectors on the rear panel.

9.4.1 Connector CN1 - 10 pin female

Pinout and description for the CN1 connector.

9.4.2 Connector CN2 - 7 pin female

Pinout and description for the CN2 connector, used for robot control.

9.4.3 Connector CN3 - 7 pin female

Pinout and description for the CN3 connector, for optional control panels.

9.4.4 Connector CN4 - 10 pin female

Pinout and description for the CN4 connector, for emergency signals.

9.4.5 CN6- SRS Control connector

Identifies the connection for the SRS Control accessory.

9.4.6 CN7- SRS Control connector

Identifies the connection from the power source-wire feeder.

9.5 Robot interface configuration parameters

Setting communication parameters for the robot interface.

QUALITY CONTROL

TECHNICAL SPECIFICATIONS

ERROR CODES

Cebora KINGSTAR 400 TS Specifications

General IconGeneral
Input Voltage400V
Power SupplyThree-phase
Protection ClassIP23
Welding ProcessMMA, TIG
Welding Current Range400 A
Duty Cycle400A at 60%

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