Owner`s Manual
Contents
1. opere com as tampas removidas Desligue a corrente antes de fazer servi o e toque as partes el tricas nuas gt gt PEM 78821 FE 280 HAMAL ui e Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgehause oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e HAS t RU U EE 00066007 ORNKTMRAARS AGRA E Hao gel ABE culi gl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese J LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR ERREKO D NET EEE MA TFU EN E E BE CER BLUR R ER BL CHRP 9 Amo SSE AAAS HA 8 ETSI 25 gl aly al 4 giall lated CobraCooler Owner s2. Owner s Manual p 900 1ve 2 96 S 1W N eld 6 000 198 155 AN0 X SEn 1016 eseeuo 5 9000 622 v ve qeO Jewog Assy 9990 278 8 155 WO X S EN 1016 s uS 000 686 v 66 8 LSS 26 6 IIHd YOR 9105 0810 986 6 ees eee NIv L LSS 26 8 YOR 96 8210 966 81 12 YIL X 8 6 eonpeu 11 6610 66 97 ISS 91 8 0 Hd 26 6010 966 v 02 jaued qeg 1 Sq 2610 66 2 155 t L 4907 2920 222 v 1 qeg t l 2100 299 155 8 4907 Buuds 9096 960 686 z 81 anid 1091 6 X 18 6 esoH 1970 1890 621 27 ISS 8 1815 JeuseM 2600 1 6 1 anid loq 08 2 x dIv LesoH 00 0 166 us 1 ISS 076 1 06 106 6 0 626 91 0 sseooy 6800 85 000 2 Or LSS z x 26 8 09008 Hd Wld 126 6820 616 91 J9 OODEIGOD 19409 jured 2800 827 66 vid 529 urens 9690 S16 vi 19100081900 MODUM vvci SEv 2 9000 1921 22 21 19100021005 tvzL Stv 2 96 2010 10 s ir Duppoisisseuo Duuds 2200 SIP v 86 8200 102 0 6 600 106 4 96 2 620 1 8 6 UOIAN PIG 8 6 8 1 195 690 1220 0
3. and weather Replace caps securely when moving inders Stuck valve Do NOT use a hammer or wrench to open a cylinder valve that cannot be opened by hand Notify your supplier Mixing gases NEVER try to mix any gases in a cylinder NEVER refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps designed for the hose not ordinary wire or other substitute as a binding to connect hoses to fittings No copper tubing splices Use only stan dard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Suspend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly for leaks wear and loose connections Immerse pressured hose in water bubbles indicate leaks Repair leaky or worn hose by cutting area out and splicing Do NOT use tape 4 Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator Except for hydrogen crack valve momentarily pointing outlet CobraCooler Safety Page ii away from people and source
4. valves or safety devices Avoid electrical circuit contact with cylin ders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a seri ous accident See 1 3C ICC or DOT marking must be on each inder It is an assurance of safety when the cylinder is properly handled Identifying gas content Use only cylin ders with name of gas marked on them do not rely on color to identify gas con tent Notify supplier if unmarked NEVER DEFACE or alter name number or other markings on a cylinder It is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them separate from FULLS and return promptly Prohibited use Never use a cylinder or its contents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cylin ders clear of areas where they may be stuck Transporting cylinders With a crane use a secure support such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do not allow contents to exceed 55 degrees C 130 degrees F Cool with water spray where such exposure exists Protect cylinders particularly valves from bumps falls falling objects
5. and inert gases open fully to seal stem against possible leak for fuel gas open to less than one turn to permit quick emergency shut off Use pressure charts available from your supplier for safe and efficient recommended pressure settings on regulators Check for leaks on first pressurization and regularly thereafter Brush with soap solution Bubbles indicate leaks Clean off soapy water after test dried soap is combustible E User Responsibilities Follow all Safety Rules Remove leaky or defective equipment from service immediately for repair Read and follow user manual instructions F Leaving Equipment Unat tended Close gas supply at source and drain gas G Rope Staging Support Rope staging support should not be used for welding or cutting operation rope may burn 1 3 ARC WELDING Comply with precautions in 1 1 1 2 and this section Arc Welding properly done is a safe process but a careless operator invites trouble The equipment carries high currents at significant volt ages The arc is very bright and hot Sparks fly fumes rise ultraviolet and infrared energy radiates weldments are hot and compressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents A Burn Protection Comply with precautions in 1 2 The welding arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from l
6. 7 vr ee 100161 8 0 2500 26 9801 5074 18095 Po 880 50 1 11 FAOSZ VOI 1540 non pued 10 65 1 9 univ 26 8 5 980 678 2 06 7962 5001 9 2 1 X 0 15 6Zv0 eve 2 66 2922 200 91 6 1991 qOz L 90edS 1110 26 z 8 ssv e9ez eo0 6 LSS 0Z t L 9 00 1 6 8 72 6962500 z 155 26 8 X HNN 6900 176 2 92 8962 5001 NO ON 19100321409 CobraCooler Owner s Manual 7 Keep flammable materials away warning Do not touch electrically live parts or electrode with skin or wet clothing warning Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja P R ECAU ON e Mn del trabajo y de la tierra French ATTENTION German WARNUNG Portuguese Korean Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de fa terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da
7. DIANT ENERGY WHICH MAY CAUSE SERIOUS AND PER MANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates pro tected by clear cover glass This is must for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns Wear protective clothing leather or asbestos gauntlet gloves hat and high safety toe shoes Button shirt collar and pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Avoid oily or greasy clothing A spark may ignite them Flammable hair preparations should not be used by persons intending to weld or cut Hot metal such as electrode stubs and work pieces should never be handled without gloves Ear plugs should be worn when working on overhead or in a confined space A hard hat should be worn when others work overhead B Toxic Fume Prevention WARNING The use of this product may result in exposure to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Adequate ventilation Severe discomfort ill
8. Isole se da e terra REBHKE 795 08 5 0 81 807 2 555 4183 e sms 2458 BH FE mie OA MHA ou Ye SH slay sp il ol Oa pal al Qi dog Ye eie Mantenga el material combustible fuera del drea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos 8 REHELTREY ELA 9i 93nta s NTIENS esy xag ug AUDI gl Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o a vista ouvido corpo B ERU SITECREASUCE 8 323890548 50 HEAL 483 ie ule eae ang READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ET
9. LUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COM MERCIAL INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO RE SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER USE OF OTHER THAN GENUINE MK PRODUCTS CONSUMABLES PARTS AND ACCESSORIES MAY INVALIDATE YOUR PRODUCT WARRANTY August 1 2008 Rev A THIS PAGE INTENTIONALLY BLANK MIL PRODUCTS 16882 ARMSTRONG AVE IRVINE CALIFORNIA 92606 949 863 1234 FAX 949 474 1428 www mkproducts com
10. MIEL PRODUCTS x gt gt gt gt gt gt gt gt gt 00 Owner s Manual Product Manual Serial Voltage Rating Revision Model Number CobraCooler 091 0609 09100001 100 120 208 240VAC Sept 2009 Rev A 250 153 Table of Contents Safety Guidelines Technical Information Electrical Information Mechanical Information Connections Weldhead CobraTig 150 Latches Operation Coolant Accessories Weldhead Extension Cable Troubleshooting Troubleshooting Guide Appendix Diagrams Parts List Safety Warnings Warranty Section 1 Section 2 Section 3 Declaration of Conformity for European Community CE Products Note This information is provided for units with CE certification see rating label on unit Manufacturer s Name M K P rod u cts y nc 16882 Armstrong Ave Irvine CA 92606 Declares that the product C O b ra C O O re conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Standards Arc Welding Equipment Part Welding Power Sources IEC 60974 1 September 1998 Second Edition Arc Welding Equipment Wirefeed Systems IEC 974 5 September 1997 Draft Revision Degrees of Protection Provided by Enclosures IP Code IEC 529 1989 November 1989 First Edition Insulation Coordination For Equipment Wi
11. Manual Page 9 LIMITED WARRANTY Effective August 1 2008 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LI MI TED WARRANTY MK Products Inc Irvine California warrants that all new and unused equipment furnished by MK Products is free from defects in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warran ties of their respective manufacturers if any MK Products warranty does not apply to components having normal useful life of less than one 1 year such as relay points wire conduit tungsten and welding gun parts that come in contact with the welding wire including gas cups gas cup insulators and contact tips where failure does not result from defect in workmanship or material MK Products shall exclusively remedy the limited warranty or any duties with respect to the quality of goods based upon the following options 1 repair 2 replacement 3 where authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a de
12. RE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN CobraCooler Owner s Manual Page 8 Keep your head cut of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de 5 piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria eta Ab5omtNMT45ctuc Feet CF a uv emm edaeT REHAB Wels e Eyez 297 48 AAS AA FARAH faya al jan e jaa 9 00 e oux 21 0 call Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten
13. braCooler Safety Page iii ity Be sure conductors are touching bare metal of equipment frames at con nections If a line cord with a ground lead is provided with the equipment for connec tion to a switch box connect the ground lead to the grounded switch box If a three prong plug is added for connection to a grounded mating receptacle the ground lead must be connected to the ground prong only If the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken ground prong 2 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 3 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal arc welding equipment is ON and welding gun trigger is pressed Keep hands and body clear of wire and other HOT parts 6 Safety Devices Safety devices such as inte
14. e if it is safe to weld or cut Hollow castings or containers must be vented before welding or cutting They can explode Explosive atmospheres NEVER weld or cut where the air may contain flam mable dust gas or liquid vapors such as gasoline D Compressed Gas Equipment The safe handling of compressed gas equipment is detailed in numerous indus try publications The following general rules cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from over pressure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair first close cylinder valve The following symptoms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pressure release Repair Do NOT attempt repair Send faulty regulators for repair to manufac turer s designated repair center where special techniques and tools are used by trained personnel 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls
15. electrically HOT equipment can fatally shock a person whose body becomes aconductor DONOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection To protect against shock Keep body and clothing dry Never work in damp area without adequate insulation against electrical shock Stay on a dry duckboard or rubber mat when dampness or sweat cannot be avoided Sweat sea water or moisture between body and an electrically HOT part or grounded metal reduces the body surface electrical resis tance enabling dangerous and possibly lethal currents to flow through the body 1 Grounding the Equipment When installing connect the frames of each unit such as welding power source control work table and water circulator to the building ground Conductors must be adequate to carry ground currents safely Equipment made electrically HOT by stray currents may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel Three phase connection Check phase requirement of equipment before install ing If only three phase power is available connect single phase equipment to only two wires of the three phase line Do NOT con nect the equipment ground lead to the third live wire or the equipment will become electrically HOT a dangerous condition that can shock possibly fatally Before welding check ground for continu Co
16. fect within the following periods from the date of delivery of equipment to the original user 1 Power Supplies and Wire Feed Cabinets 2 Weldheads CobraCooler Positioners Prince XL and Prince XL Spool Guns Python CobraMAX Cobra SX 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 114 PRODUCTS www mkproducts com Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Notification of any failure must be made in writing within 30 days of such failure A copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal surface transportation charges one way for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDI NG ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS IS EXC
17. icated return the CobraCooler to horizontal Let the CobraCooler run for a few minutes to expel any air pockets that may still be present in the system The weldhead is above the CobraCooler beyond the workable range as illustrated in Section 8 Reduce the vertical distance of the weldhead and the CobraCooler to a workable range The weldhead and or extensions has not been used previously used and the weldhead was elevated 15 ft above the CobraCooler before the lines were filled with coolant Lower the weldhead to the level of the CobraCooler Let the CobraCooler run for a few minutes with the weldhead at this level to expel any air pockets that may still be present in the system CobraCooler Owner s Manual Page 4 Section 10 Appendices Diagrams Parts List CobraCooler Assy Bill of Material CobraCooler Owner s Manual 5 WALI 91 WALI 803 Z nal 304 z vf WEL 220 D Ow a E 9 0 0 lt e o 5 O 200 9990 8 I 4 20 21 ecd WAL 803 01 Z 2 NILI 802 p 4 5 2 2 k 2 3573 318VO 20 TNO HOLIMS Adana QUAE 2610 6651 ESCH g WALI 403 r Page 6 CobraCooler
18. ight colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those from gas shielded arcs are more severe and painful DON T GET BURNED COMPLY WITH PRE CAUTIONS 1 Protective Clothing Wear long sleeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark sub stantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place over face before striking arc Protect filter plate with a clear cover plate Cracked or broken helmet or shield should NOT be worn radiation can be passed through to cause burns Cracked broken or loose filter plates must be replaced IMMEDIATELY Replace clear cover plate when broken pitted or spattered Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck Looking at an arc m
19. mation you have recorded above Read this Owner s Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection Section 1 Section 2 Section 3 Section 4 Technical Information Line Power 120 230 50 60 HZ Single Phase ONLY Reservoir Capacity Approximately 1 gal 3 78 On level surface fill per requirements indicated on the site gauge on front of the CobraCooler Coolant Type Use Cobra Coolant Aluminum Protection P N 931 0060 Cobra Coolant does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum System Pressure Maximum system pressure is 21 75 PSI as specified by the pump manufacturer Electrical Information Pump 12 Volt DC 2 amps AC Power for Cooling Unit Panel switchable rear panel fuse holder Front Panel Indicators Spinning Flow Indicator Mechanical Information Dry Weight 13 9 Ibs 6 30 kg Height 5 5 in 14 0 cm Width 8 5 in 21 6 cm Depth 19 in 48 3 Connections 4 1 Weldhead The CobraCooler is designed to be used with CopperHead model orbital weldheads The connectors on the rear panel of the CobraCooler include the coolant IN OUT bottom top female quick disconnect connectors The male connectors from a water cooled orbital weldhead can be attached to this unit in any config
20. ness or death can result from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryl lium bearing and similar materials when welded or cut may produce harmful con centrations of toxic fumes Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration dangerously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accu mulation of gases in the space if down stream valves have been accidentally opened or left open Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decomposed by the heat of the arc or flame to form PHOSGENE a highly toxic gas and other lung and eye irritating prod ucts The ultraviolet
21. omentarily with unprotected eyes particularly a high intensity gas shielded arc can cause a retinal burn that may leave a permanent dark area in the field of vision 3 Protection of Nearby Personnel Enclose the welding area For production welding a separate room or enclosed bay is best In open areas surround the operation with low reflective noncombus tible screens or panels Allow for free air circulation particularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic Fume Prevention Comply with precautions in 1 2B Generator engine exhaust must be vented to the outside air Carbon monoxide can kill C Fire and Explosion Prevention Comply with precautions in 1 2C Equipment s rated capacity Do not over load arc welding equipment It may over heat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pressure vessel It creates a brittle area that can cause a violent rupture or lead to sucha rupture later under rough handling D Compressed Gas Equipment Comply with precautions in 1 2D E Shock Prevention Exposed electrically hot conductors or other bare metal in the welding circuit or in ungrounded
22. r 567 0012 CobraCooler Owner s Manual Page 2 Section 8 Flow Rate Flow Rate with MK Weldhead 25 FT Total Flow Rate in GPH 15 Height in FT Flow Rate with MK Weldhead and 25 FT Extension 50 FT Total 0 2 m z 2 7 5 7 6 5 6 5 5 5 4 5 4 3 5 3 2 5 2 1 5 1 0 5 0 0 10 15 20 25 30 35 40 45 50 55 Height in FT Flow Rate with MK Weldhead and 50 FT Extension 75 FT Total Flow Rate in GPH 7 5 7 6 5 6 5 5 5 4 5 4 3 5 3 2 5 2 1 5 1 0 5 0 0 25 30 35 40 45 50 55 60 65 70 75 80 Height in FT All testing done with MK Products CopperHead weldheads CobraCooler Owner s Manual 3 Section 9 Troubleshooting CobraCooler does not turn on Symptom Troubleshooting Cause CobraCooler is not plugged into an electrical outlet Remedy Plug the CobraCooler into an electrical outlet The external fuse failed Replace fuse The Flow Indicator is not rotating Indicating that the coolant is not flowing The male connectors from the water cooled orbital weldhead are not properly connected to the CobraCooler Connect both male connectors fully to the female quick disconnect connectors that are located on the back side of the CobraCooler The pump is not primed Elevate the front face of the CobraCooler to assist the flow of coolant into the pump After flow is ind
23. r work should be protected by heat resistant covers or shields Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if 1 Appreciable combustibles including building construction are within 35 feet 2 Appreciable combustibles are further than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors or walls within 35 feet may expose combustibles to sparks 4 Combustibles adjacent to walls ceil ings roofs or metal partitions can be ignited by radiant or conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precautions have been taken After work is done check that area is free of sparks glowing embers and flames An empty container that held combus tibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depending on the combustible s solubility followed by purging and inert ing with nitrogen or carbon dioxide and using protective equipment Water filling just below working level may substitute for inerting A container with unknown contents should be cleaned see paragraph above Do NOT depend on sense of smell or sight to determin
24. radiant energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmo spheres containing even minute amounts of trichloroethylene or perchloroethylene C Fire and Explosion Prevention CobraCooler Safety Page i Causes of fire and explosion are com bustibles reached by the arc flame flying sparks hot slag or heated mate rial misuse of compressed gases and cylinders and short circuits BE AWARE THAT flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of Sparks sight of the goggled operator can fly many feet To prevent fires and explosion Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are in area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work cannot be moved move combustibles at least 35 feet away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor nea
25. rlocks and circuit breakers should not be discon nected or shunted out Before installation inspection or service of equipment shut OFF all power and remove line fuses or lock or red tag Switches to prevent accidental turning ON of power Disconnect all cables from welding power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity while welding If in an emer gency it must be disconnected guard against shock burns or flash from switch arcing Leaving equipment unattended Always shut OFF and disconnect all power to equipment Power disconnect switch must be avail able near the welding power source For selecting a quality product We want you to take Ott pride in operating this product as much pride as we have in bringing the product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacements parts for or information on this equipment always supply the infor
26. s of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded connections clean and smooth seats where necessary Tighten If connection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGA adapter available from your supplier between cylinder and regulator if one is required Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads Regulator outlet or hose connections may be identified by right hand threads for oxygen and left hand threads with grooved hex on nut or shank for fuel gas 5 Pressurizing Steps Drain regulator of residual gas through suitable vent before opening cylinder or manifold valve by turning adjusting screw in clockwise Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization Leave adjusting screw engaged slightly on single stage regulators Stand to side of regulator while opening cylinder valve Open oylinder valve slowly so that regula tor pressure increases slowly When gauge is pressurized gauge reaches regulator maximum leave cylinder valve in following position for oxygen
27. t DO NOT SPILL COOLANT INTO THE UNIT An electrical short may occur if coolant is spilled into the unit It is recommended that all coolant be removed from the CobraCooler prior to shipping After draining some coolant may still remain in the internal pump radiator filter and circulatory tubing Accessories Weldhead Extension Cable Weldhead extension cable P N 005 0635 It comes complete with all the necessary cabling to adapt the MK orbital weldheads control cable with 24 pin connector electrode and ground cables inert gas hose and water hose assembly with quick disconnect connectors This 25 ft extension cable is to mate any of the MK CopperHead series weldheads to the CobraCooler A 50 ft is also available under P N 005 0635 50 Spare Parts 7 1 Fuse WARNING DISCONNECT UNIT FROM ALL POWER SOURCES PRIOR TO CHANGING FUSE ELECTRIC SHOCK CAN KILL Located on the rear panel of the CobraCooler is a 0 50 amp BUSS fuse If the unit does not turn on with the power switch check the integrity of the fuse Turn the fuse cap on the front panel and remove fuse Check fuse using continuity meter Replace if necessary 7 2 Coolant Flow Filter WARNING DISCONNECT UNIT FROM ALL POWER SOURCES PRIOR TO CHANGING MESH FILTER ELECTRIC SHOCK CAN KILL Periodically the mesh screen filter may require cleaning and or replacement Replaceable Parts List Description Part Number 151 0043 Mesh Filte
28. th Low Voltage Systems Part Principles Requirements and Tests IEC 664 1 1992 October 1992 First Edition Electromagnetic Compatibility EMC EN 50199 August 1995 Torches And Guns For Arc Welding EN 50078 SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EQUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION OR MAINTENANCE OF THIS EQUIPMENT 1 1 INTRODUCTION This equipment is intended for ultimate application by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment Operation should not be undertaken without adequate training in the use of such equipment Training is available from many public and private schools or similar facilities Safe practices in the installation opera tion and maintenance of this equipment requires proper training in the art a careful study of the information provided with the equipment and the use of common sense Rules for safe use are generally provided by suppliers of welding power sources compressed gas suppliers and electrode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safety Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt obtain qualified help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRA VIOLET RA
29. uration These coolant connectors are a double end shut off valve type This means if the cooler is turned on and there is nothing plugged into these connectors no fluid will flow out of the connector Similarly the connectors on the end of the weldhead hose work in the same manner No fluid will flow from the end of the hose unless it is plugged into the cooler 4 2 CobraTig 150 Latches The CobraCooler easily attaches to the bottom of the CobraTig 150 using a four corner mounted spring locked latches These latches are already mounted to the four outside corners of the CobraCooler Place the CobraTig 150 on top of the CobraCooler so that all sides are even and flush Lift the finger handle of the latch and raise the spring up over the shoulder washer on the CobraTig 150 Press down on the finger handle until the locking spring engages Lift the finger handle to test the locking spring Repeat process on all four latches CAUTION DO NOT ATTEMPT TO LIFT THE UNIT UNTIL ALL FOUR LATCHES ARE LOCKED To disengage the CobraTig 150 press on the locking spring and lift the finger handle until the spring is released from the shoulder washer CobraCooler Owner s Manual 1 Section 5 Section 6 Section 7 Operation 5 1 Coolant CAUTION COOLANT MUST BE ADDED PRIOR TO OPERATING From the top of the CobraCooler open the access panel unscrew the fill plug and pour in the coolan
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