Owner`s Manual Cobramatic® (42 Volt) Wire Feed
Contents
1. o o cN 99 19 0 9018 Josuag 8606 57 ale 81 8 9 ol aje jdup L 614 CLLO ESGZ sdug x du8 dy vLLO EGZ 148 ol aje lduy usng GLLO ESGZ 8 8 6 ol aje jdup H1 81 8 S 0 N 1dug 99 0 6 SLv0 S2 juejeeg edid 6200 8 zyz 9120 6700 28 lueleaS edid 1007 7700 5028 f Cobramatic Owner s Manual page 19 gt a E uv uv lt V 5 a 003 2146 ISI Sueg uonduos q ON Buueeg Assy 681 600 7 01 9 X SC PON 19145 195 5908 0868 GOS X 998 14 AUSM 85900 188 LSS VIE X 33 JUSM 9600 1868 MUL SCL X gi SZ 1941991 5 8150 1586 15 8 9 6 3901 INN 800576 950 X Lev 897 dwog 605 6500 61 GL 69 x 98 duoo 645 9600 61 Bury aleld 992 cO cN alpuldS 219 JaldepV QCLE LEV ejpuids joods Jeuleley 8600 57 pulds uolsuel qouy 6920 227 puids JeoedS 9790 2987 alpuldS 9790 16 exelg 1944 SIG 6500 62 91 S x G deg 8 002. Q G 9 gt G 2 12 18025 051 THOA 913M sT 130 l 1 AOL 5 dO Ms 10 1 00 SSvdAg om N69 318v2 YSod sa ra S19n008d XN tdf 30 1N3SNOO 1 100H1IM JYNLIVANNYN 303 1599 V 03S0 YO LYYd NI YO ATIOHM 57 Y 01 03501250 NO 031NIHd3N 031802 38 LON AVN 11 0270 ON SLONGOUd NW 30 ALYJJOYd 3H1 51 1 542006 SIH1 071 Cobramatic Owner s Manual page 22 C 4 Q i iz a 9 071 0367 HNN HNN HV 15 0 TW 220 0 050 0 403 f Cobramatic Owner s Manual 23 MK Warranty Repair Stations ALABAMA AIRGAS SOUTH INC Birmingham AL 205 251 6835 INDUSTRIAL WELDING SERVICES Quinton AL 205 674 3258 WELDING ENGINEERING SUPPLY CO Prichard AL 334 457 8681 WELDING MACHINE HOSPITAL Montgomery AL 334 832 9353 ARIZONA ALLSTATE ELECTRIC MOTOR CO Phoenix AZ 602 233 0500 PRAXAIR DISTRIBUTION INC Phoenix AZ 602 269 2151 ARKANSAS APPLIED SERVICES INC Benton AR 501 860 6464 ARKANSAS WELDING
3. Cobramatic 42 Volt Ir Wire Feed Cabinet Owners Manual PRODUCTS Product Cobramatic Manual 091 0498 Serial 01010001 Voltage Rating 42 VAC Revision Dec 2001 Model Number 150 205 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 operation 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 ULTRAVIOLET RADIANT ENERGY
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5. s Manual page 13 Cabinet and Torch Hook up Input Connections Coolant Supply Coolant Return Shielding Gas Welding Power Cobramatic Owner s Manual page 14 Torch Connections Power Water In Water Return 2808 jonuny SAUMO 26 9 XeH YN 16 Zi X 26 8 Id Ved 195 Zit x 26 9 Id Wed 19g 1S 0 Teidg eniseupy JS paw Buo WEIS 2504 21929 18 102800 2 89 dol wed Jaurensey ped 82 1euiensey PION ume 80 PION all Jeutensey 82 191 SS 8 80 145 1009 55 89 Md wq SS 39 de 80 Jaulensay Jaipuey 89 Buuds 01510 80 Buuds 00612 1 9 8 95 yoelg apis uae 80 Jay 15 40 ali Act Qi JaqunN IEuaS J000 2290 10005 1000 suononssul 82901 961911 2290 2990 162611 2930 uuo 313933 2294 ME deus 01916 deus ysng 09 aod r 313 zu TEOL pasu 16 0Z p i 3201 15 26 81207 NN 269 4201 INN 80 x ZE 9 ues 192845 MIG 1 2 1 X c 01 195 005 x 00596
6. HOx 5 0 8mTE E EC MH ETEMUTT U EL TMHORSRECED TE St py CIO 7 TAA HAA SA spect palai bagai Qi at Y pial Cobramatic Owners Manual page 30 LIMITED WARRANTY Effective March 1 2001 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY MK Products Inc Irvine California warrants that all new and unused equipment furnished by MK Products is free from defect 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 warranties 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 torch 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 Inthe case of MK Products breach of warranty or any other duty with respect to the quality of any
7. IND L SUPPLY Hot Springs AR 501 321 9922 CALIFORNIA ADVANCED WELDER REPAIR Commerce CA 323 263 7383 AIRGAS WEST INC Gardena CA 310 523 9355 ALL PHASE WELDER REPAIR amp CONSULTING Sacramento CA 916 331 0595 ARC PRODUCTS San Diego CA 619 628 1022 CAL WELD SUPPLY Fresno CA 209 445 0131 EMCO EAST Concord CA 925 798 4411 FRESNO OXYGEN Fresno CA 559 233 6684 INDUSTRIAL WELDER REPAIR LaPuente CA 626 961 7643 PRAXAIR DISTRIBUTION ArcRent Div Long Beach CA 562 427 0099 PRAXAIR DISTRIBUTION INC Bakersfield CA 661 327 5336 R J KATES San Diego CA 619 565 6960 RED D ARC INC Carson CA 310 233 3327 SOUTHWEST WELDER REPAIR Fontana CA 909 357 1661 SWEINHART ELECTRIC CO INC Long Beach CA 714 521 9100 COLORADO AIRGAS INTERMOUNTAIN INC Colorado Springs CO 719 473 1947 WELDERS amp EQUIP SVC amp TESTING Littleton CO 303 932 8755 WESTERN SLOPE WELDER REPAIR Grand Junction CO 970 243 9616 FLORIDA amp SPECIALTIES Lehigh Acres FL 941 368 7435 ACTION WELDING SUPPLY Jacksonville FL 904 786 2254 AMVEL CORPORATION Miami FL 305 592 5678 ELECTRICAL WELDERS SERVICE Orlando FL 407 999 5214 HAUN SYSTEMS REPAIR INC Orlando FL 407 681 6064 Cobramatic Owner s Manual page 24 J K CIRCUIT TECHNOLOGY Boynton Beach FL 561 733 7859 ROPER ELECTRIC MOTOR SERVICE Panama City FL 32405 850 769 6643 SMITTY S WELDER SERV
8. goods the exclusive remedies therefore shall be at MK Products option 1 repair 2 replacement 3 where authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Upon receipt of notice of apparent defect or failure MK Products shall instruct the claimant on the warranty claim procedures to be followed 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 defect within the following periods from the date of delivery of equipment to the original user 1 Torches Weldheads and Water Recirculators 2 All Other Equipment 3 Repairs 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 www mkproducts com PRODUCTS 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 Acopy 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 r
9. minimum of 1 quart per minute at 45 p s i when using water cooled torches Use a name brand additive which does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum Check coolant periodically to remain within limits of the following A Coolant Flow rate 1 quart per minute at 45 p s i B Resistivity 10K ohms centimeter C Ph Range 5 5 8 5 D Particle Size 005 inch MK Recommended Coolant Solution 1 part ethylene glycol 3 parts distilled water 1 teaspoon liquid glycerin Machine Grounding The Cobramatic and GMAW wire feeders are ground to the power source through the input cable The power source grounding terminal must be properly connected to electrical ground per the power source operating manual Mounting Location The cabinet should be placed in a location where it can be protected from damage Lead lengths and accessibility must also be considered when installing the cabinet Input Connections See Cabinet and Torch Hook Up in the Appendix 42 VAC Your Wire Feeder comes factory ready to connect into any standard 42VAC power supply The 42VAC is connected to the PC Board on terminal strip J5 1 neutral and 2 hot and Ground to the Cabinet chassis See diagram in the appendix Cobramatic Owner s Manual page 3 Section Continued Shielding Gas In accordance with the required support equipment the customer must provide a cylinder of shiel
10. 07 INN 8100 5676 dwog 6uuds 9800 6 94 1 X 8 9 GO duoo 6uuds LLCO 6LV 00 0 N pow Bums yog 9491 17 918207 891 98 PION 9 e S BuisnoH JOJO 5 PION 0 c0 v 20 767 JOJO 5 PION 49 p cEcO LEV Buue g deg SvcO v 5 vScO v LE X 0g x 9211 Duueeg 80 104 80 x x 9 8 9S10 L0S Jelpl 060 1098 1999 yeus 0810 209 los 9020 1169 UOIAN M aping 900 6 lt 944907 5700 8568 ZxnllqoN 958915 L000 SE8 9014 159 600 628 2910 1890 Cobramatic Owners Manual page 18 uv lt Q ea 3 Q 5 003 2063 sued uonduoseq ON 504 Josuas Assy vcl 00 uo usnd JeNeosey PNIS 00 56 8 8 X 9 8 105 7500 606 HS 9 18 JeuseM C000 188 00928 0 X 166702814 Jeusew 1110 1 S 9 UES AUSM 0400 56 HS GLE X 68 9 Ud 95 9000 988 Josuas uang JeoedS 5660 0276 9 90 aloH 6nld 9900 198
11. 5 jueuuueg 201 6700 68 Cobramatic Owner s Manual 20 ALI NS YOLIV INOI W ILM MANN NI NNO N 3LHA WANN S OLE 9 WOds dM Dw18 t lt O1t9 WOd43HWA SON SN 15072 CEYINOF SI IVNO ISHOIOVINOO 3DVLTOA OV NV HI 1L HA SNO LD3NNDD GNNOY een JHVLS VSOd WOD OV ejeje XOVE LOH IV 9 0 TL0 HOS sb ASTT 0 0 0 HDS s LOH OZ OLZO TZ0 HDS iB Em CH1THOLNOIONIYEMOd Hanssen Azt EZLT 00 H YOLOW E200 SL NA ASTT LLO 00 N d NIH AZZ f STNG JaNdoJSNVHL DI AV EN e LHi NOVz EDunos JHvVlsvsod Hovtvf lt 602 00 N d Ac TOOZ E00 N d 00 TZZT 00 N d 9602 00 d ASTI 7202 00 N d 8Z9T 00 4 GONADS Divia T3NVd NOUS ayvog N I 3 LINAVHSOO I 2 5 HOLMS NOYAL NYD Nur HOLMS NOYAL
12. 6 6650 POWER SOURCE REPAIR CO INC Collingdale PA 610 532 6460 VALLEY NATIONAL GASES Pittsburgh PA 412 281 1835 TENNESSEE NEXAIR Memphis TN 901 523 6821 TRAMCO Bristol TN 423 968 4499 NATIONAL RENTRAL amp REPAIR Knoxville TN 423 584 6390 TEXAS AIRGAS SOUTHWEST Houston TX 713 462 8027 ARC CONTROL Houston TX 713 941 4701 DENISON OXYGEN Denison TX 903 465 3369 FT WORTH WELDERS SUPPLY INC Ft Worth TX 817 332 8696 RITE WELD SUPPLY INC Fort Worth TX 817 626 8237 UTAH C W SILVER INDUSTRIAL SERVICE Salt Lake City UT 801 531 8888 VIRGINIA AIR PRODUCTS amp CHEMICALS Bristol VA 540 669 3161 Cobramatic Owner s Manual page 27 ARC WELDERS INC Ashland VA 804 798 1818 NORFOLK WELDERS SUPPLY Norfolk 804 622 6571 WASHINGTON AIRGAS NORPAC INC Tacoma WA 253 473 2282 A L WELDING PRODUCTS Tukwila WA 425 228 2218 AMERICAN EQUIPMENT SERVICES Kent WA 253 395 9947 HARRIS ELECTRIC INC Seattle WA 206 782 6668 OXARC INC Spokane WA 509 535 7794 PACIFIC WELDING SUPPLIES Tacoma WA 253 572 5302 PRECISION WELDER AND ENGINE REPAIR Seattle WA 206 382 6227 WEST VIRGINIA CARDINAL SALES amp SERVICE INC Clarksburg WV 304 622 7590 WISCONSIN INTERSTATE WELDING SALES CORP Appleton WI 920 734 7173 PRAXAIR DISTRIBUTION INC Brookfield WI 414 938 6365 CANADA A amp A WELDER SERVICES LTD Saskatoon Saskatchewa
13. AN ANN ARBOR WELDING SUPPLY CO Ypsilanti 734 572 0444 APEX WELDING GASES amp SUPPLY Muskegon Heights MI 616 722 3185 Cobramatic Owner s Manual page 25 AUTOMATIC WELD Midland 517 496 9245 GREAT LAKES EQUIPMENT 517 386 4630 HAMILTON ELECTRIC CO Saginaw 517 799 6291 SAGINAW WELDING SUPPLY CO FLINT WELDING SUPPLY Co Saginaw MI 517 793 9696 SOUTH PARK WELDING Marysville 810 364 6521 WELDING METALS INC Madison Heights MI 248 585 0480 WESAR COMPANY Three Rivers MI 616 483 9125 MINNESOTA MINNEAPOLIS OXYGEN CO Minneapolis MN 612 588 8855 OXYGEN SERVICE CO St Paul MN 612 644 7273 MISSOURI CEE KAY SUPPLY INC St Louis MO 324 644 3500 P G WALKER Springfield MO 417 862 1745 MISSISSIPPI NORDAN SMITH WELDING SUPPLY Hattiesburg MS 601 545 1800 3D SUPPLIES INC Jackson MS 601 353 3330 NEVADA SIERRA WELDING SUPPLY CO Sparks NV 775 359 0542 NEW JERSEY INDUSTRIAL ELECTRIC SERVICE CO Hawthorne NJ 973 423 1212 NEW YORK HAUN WELDING SUPPLY Syracuse NY 315 463 5241 NORTH CAROLINA HOLOX Colfax NC 336 996 1974 8 LWELDER REPAIR Asheville NC 828 250 9353 MACHINE AND WELDING SUPPLY CO Dunn NC 910 892 4016 MACHINE AND WELDING SUPPLY Greenville NC 252 752 3089 MACHINE AND WELDING SUPPLY CO Raleigh NC 919 772 9500 MACHINE AND WELDING SUPPLY CO
14. CI al hk iade dirs Miti ge cal axi ud Turn power off belore servicing Besconactar al cable de at mentacl n de poder de la m quina antes de iniciar cualquier servicio D branchez le courani avant l enire Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff Maschine anhalten Nao opere as tampas removidas Desligue correnta antes de fazar servi o N toque as partas nuas e aF Y PERCI E STMT eth HOES e xcu AMS Sh lee e Do nol operate with panal open guards off operar con pana ablerte guardas quitadas N op rez pas aver les panneaux ouverts pu aves les dispositifs de protection enlev s Anlage nie ohne Schirzgeh usag oder Innenschutzverkleidung in Betrieb setzen afastado das partes moventas N o opere com os paineis abertos guardas removidas Z LEUT ESL GTA MARRS BST BE E WE debe Apa cuu ii Sigel A Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO AS PARTES DE USC E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR fosse
15. CONSUMABLES 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 ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STEELERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Cobramatic Owner s Manual page 29 your hear nut of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de zona de res piracidn Mantenga la cabeza fuera de los humos Utilica ventilaci n o aspiraci n para gases Gardez la tile 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 und Entliftung des Arbeltsplatzes Mantenha sau rosta da fumaga Use ventila o e exhausto para remover fume da zona respirat ria Es APEMEBTESIELT Feu 2 g75 Y22456 MAS 2123821214 SER ge lae daly
16. Cobramatic Owner s Manual page 9 Testing the Speed Control NOTE The torch should be tested first and the amphenol must be connected to the Cobramatic to perform this test Place a voltmeter across diode D10 and press torch trigger A reading of 0 24VDC should be observed as the torch potentiometer varied Le m T T y Q Testing the Torch Motor Check Remove the amphenol connector from the cabinet Using the torch amphenol check the resistance across pins motor leads The resistance across the motor should be between 5 10 ohms If an open circuit or short exist check the motor leads and motor indepen dently Testing the Potentiometer W Clocked Using the torch amphenol check the resistance across pin D wiper and The resistance should vary from 0 5K ohms Check the resistance across pin D wiper and pin G The resistance should vary from 5K 0 ohms Testing the Micro Switch Using the torch amphenol check for continuity across pins E and F when the trigger is pressed Cobramatic Owners Manual page 10 Section E Troubleshooting TROUBLESHOOTING SYMPTOM CAUSE REMEDY No wire feed at torch feeder not operating i e no slave motor or brake solenoid F2 amp F3 MDA7 7A Slow Blow fuse in feeder blown Chec
17. ICE West Palm Beach FL 561 845 1224 TRI GAS Miami FL 305 592 3180 TRI STATE SALES amp LEASING Lake City FL 904 397 3340 GEORGIA B amp W INDUSTRIAL SERVICES Augusta GA 706 738 8722 MC CULLOUGH ELEC MOTOR SVC Atlanta GA 404 688 5251 HAWAII DC ELECTRIC INC Aiea 808 483 8900 IDAHO NORCO Boise ID 208 336 1643 ILLINOIS INDUSTRIAL WELDER REBUILDERS Alsip IL 708 371 5688 RELIABLE EQUIPMENT REPAIR Hamel IL 618 633 5000 SCHERER INDUSTRIAL GROUP INC Galesburg IL 309 342 4125 or 888 964 3526 INDIANA AGA GAS INC Hammond IN 219 989 9030 AIRGAS MID AMERICA INC Evansville IN 800 371 5688 COX EQUIPMENT CO Indianapolis IN 317 241 8881 EVANSVILLE ARMATURE INC Evansville IN 812 428 9034 MODERN SUPPLY CO INC Evansville IN 812 425 9353 PRAXAIR DISTRIBUTION INC Speedway IN 317 481 4550 SUTTON GARTEN COMPANY Indianapolis IN 317 264 3236 IOWA AIRGAS NORTH CENTRAL Des Moines IA 515 266 1111 CEDAR RAPIDS WELDING SUPPLY Cedar Rapids IA 319 365 1466 ELECTRICAL ENGINEERING amp EQUIPMENT Des Moines IA 515 266 8890 WRIGHT WELDING SUPPLY Ft Dodge IA 515 576 0640 KANSAS KANOX Hutchinson KS 316 665 5551 KENTUCKY GENERAL WELDING PRODUCTS Louisville KY 502 635 5218 RED D ARC Lexington KY 800 245 3660 WELDING EQUIPMENT Louisville KY 502 636 0545 LOUISIANA RED BALL OXYGEN Shreveport LA 318 425 3211 MICHIG
18. IT 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 resistance 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 installing If only three phase power is available connect single phase equipment to only two wires of the three phase line Do NOT connect 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 continuity Be sure conductors are touching bare metal of equipment frames at connections If a line cord with a grou
19. 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 standard 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 away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before connecting check that the regula
20. WHICH MAY CAUSE SERIOUS AND PERMANENT 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 protected by clear cover glass This is a 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 Aspark 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 illness or death can r
21. Winston Salem NC 336 723 9651 NATIONAL WELDERS SUPPLY CO High Point NC 910 882 1110 NATIONAL WELDERS SUPPLY CO Charlotte NC 704 392 7317 OHIO AGA GASSES INC Lima OH 419 228 2828 ALBRIGHT WELDING SUPPLY Wooster OH 330 264 2021 ARC EQUIPMENT COMPANY Struthers OH 333 750 9353 ARC SERVICES INC Toledo OH 419 478 6204 BELAIR PRODUCTS INC Akron OH 330 253 3116 BIG RIVER ELECTRIC Gallipolis OH 740 446 4360 Cobramatic Owners Manual page 26 CnD MACHINE INC Canton OH 44706 330 478 8811 RICK S WELDER REPAIR SERVICE Eastlake OH 440 269 1204 VALLEY NATIONAL GASES Hilliard OH 614 771 1311 VALLEY NATIONAL GASES Lima OH 419 228 1008 VALLEY NATIONAL GASES Toledo OH 419 241 9114 WEILER WELDING INC Dayton OH 937 222 8312 WELDINGHOUSE INC Cleveland OH 216 524 1955 VOLLMER ELECTRIC CO Columbus OH 614 476 8800 WEILER WELDING CO INC Dayton OH 937 222 8312 WELDINGHOUSE INC Cleveland OH 216 524 1955 OKLAHOMA AIRGAS MID SOUTH Tulsa OK 918 582 0885 BILL S WELDER REPAIR Oklahoma City OK 405 232 4799 MUNN SUPPLY Enid OK 580 234 4120 OKLAHOMA WELDERS SUPPLY Madill OK 580 795 5561 OREGON Industrial Source Inc Eugene OR 541 344 1438 PENNSYLVANIA ALLWELD EQUIPMENT REPAIR Pittsburgh PA 412 821 8460 GEOVIC WELDING SUPPLY Milton PA 717 742 9377 CONNINGHAM EQUIPMENT INC Philadelphia PA 215 42
22. X 1592 PIUS 14SM 15 00529 X 0192 42 HSM 1586 X ZEB 1S 125 ME X 02 425 195 2 JG v X 22 8 ud Ued 95 Dac 184 SAVA 2991003 N 10046 OPinSUI 3490019 Jesu At 80 13 lud Assy dol 8 105 Assy olg JeWOd Assy 80 Assy Ach oom e e s Assy Aap X3 deo Assy Att Assy ute god Assy 82 Wed Assy Aiquiossy 00 00 x 5 c 2 E Cobramatic Owners Manual page 16 1811 sued uonduoseq ER 199 OL 189 ASSY EHE 199 INd ASSY 82d 1002500 1 X18 91 WOHO XH LAN L 310114 903 eae 82 NOO ASSY E E X18 TAN Ql 2 1 dVNS seso 1se 1 V lt O c G J D G 5 003 2109 Cobramatic Owners Manual 17 uv lt L aad gt 45 gt 5 003 2060 uonduoseq qouy Assy 9210 8600 Jojo Assy 11 600 BS 22 8 945 195 200 826 BS 9 1 26 8 945 105 690 868 VC OLX X D L 4pluS 195 98Sc0 0 94 4907 Buuds 9000 81 91 64 49
23. a oder Elektroden mit Ihram K rper odar feuchter Kleidung solieren Sie sich von dan Elektroden und dem Erdboden toque partes alec trodos a pele ou roupa molha Portuguese 15016 56 da pe a e terra SORRPONTER 2 048 2 F uv e 17 14 75 78 35 pu wan Ni T FERE 2338 32 EH fr AME Wl ue pl 3491 a Gaal dag Jj Mantanga al material combustible fuera del drea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sle brennbartes Material Mantenha inflam veis bem guarda CHE EU H5 7 596 18 6 da FE aa cls AM ai gl Wear eye ear and body protection Prot jase los ojos log aides y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec n para vista ouvido corpo ERUSTELSER amp LTT wu ez HETH dpi y die READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE
24. an 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 atmospheres containing even minute amounts of trichloroethylene or perchloroethylene FiRE AND ExPLOSION PREVENTION Causes of fire and explosion are combustibles reached by the arc flame flying sparks hot slag or heated material 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 Cobramatic Safety page i or doors and through wall or floor openings out of sight of the goggled operator Sparks 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 snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat res
25. ding gas a pressure regulator a flow control valve and a hose from the flow control valve to the left bottom most fitting on the power block The end of the hose must have a male connector to fit the female 5 8 18 brass fitting Use a 11 16 wrench to tighten Coolant Supply and Return if used Using a recirculator with properly mixed coolant as previously described connect the coolant RETURN hose to the left middle fitting on the power block Connect the coolant SUPPLY hose to the left top most fitting on the power block The coolant hoses must have a male 5 8 18 left hand thread to connect to the power block fittings Use an 11 16 wrench to tighten Welding Power The electrode cable coming from the welding power supply should be affixed with a 1 2 copper ring lug Using a 9 16 wrench remove the 3 8 bolt and washer from the bottom of the power block Use a 9 16 wrench to tighten It is recommended to make this connection last after connecting the gas and coolant hoses Reference Input Connections figure in the Appendix Wire Threading Procedure Wire Spool Installation Release latches and open right side door of cabinet Remove spool retainer from spindle hub Raise wire retainer bar to latched position Install wire spool onto spindle hub so that wire feeds from bottom of spool towards slave motor Make sure that the hole in the spool aligns with pin on spindle hub The white dot on the end of the spindle h
26. dle fitting on the power block Operation General The AC slave motor in the feeder runs at a fast constant speed but has very low torque It is always trying to feed more wire than the torch motor wants and when the motor gets all it wants it slows the slave motor preventing a bird s nest Because of the low torque produced by the slave motor a brake system is used to prevent wire overrun rather than tension The spool drag tension is produced by the patented Wire Retainer Bar mechanism to keep the wire slightly taut The 24 VDC torch pull motor is controlled by a solid state speed control and a potentiometer located in the torch Recommended Processes and Equipment The Cobramatic is recommended for use in the GMAW and FCAW welding applications It is recommended for use with constant voltage power sources The Cobramatic is capable of feeding wires diameter capacity ranging from 023 through 045 solid cored and 030 through 1 16 aluminum Controls and Settings On Off Switch Placing the switch in the ON position energizes the feeder circuitry and the power indicator light Wire Size Selector Switch The wire size selector switch changes the torque of the slave motor for the wire you are using When in the 030 035 aluminum only position the slave Cobramatic Owner s Manual page 6 Section Continued motor produces approximately 1 1 2 Ibs inches and approximately 4 1 2 Ibs inches w
27. e according to the previous instructions Replace the spool retainer nut Lower the wire retainer bar onto the spool Threading Procedure Place wire size selector switch on front panel to the correct position for the wire being used Loosen end of wire from spool and cut off any kinked or bent portions Unreel and straighten out first 6 to 8 of wire Raise wire type lever to center position Route wire into inlet guide along drive roll groove and into wire conduit Flip wire type lever to show type of wire being used Tighten the torch pressure adjusting knob so the wire will be picked up and fed through the contact tip Proper tension is achieved when wire does not slip if a small amount of pressure is added to the wire as it exits the tip Wire Retainer Bar The design of the patented Cobramatic Wire Retainer Bar performs two very important and very basic functions of the wire feeder a spool drag tension and b wire maintenance on the spool The spool drag tension is set by lowering the wire retainer bar onto the wire inside of the spool The spring tension of the wire retainer bar applies enough pressure on the spool so that when the torch trigger is released engaging the brake pall the spool does not overrun kicking wire off the spool Wire maintenance on the spool is performed by the applied pressure of the wire retainer bar spread across the coiled wire on the spool The replaceable pad P N 437 0255 of the wire reta
28. esult 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 beryllium bearing and similar materials when welded or cut may produce harmful concentrations 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 accumulation of gases in the space if downstream 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 products The ultraviolet radiant energy of the arc c
29. esulting from shipping Normal surface transportation charges both ways 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 REPRESENTA TION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVI SION MIGHTARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUD ING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERI ENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENTAND 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 DATE March 1 2001 Cobramatic Owner s Manual page 31 MEE PRODUCTS 16882 Armstrong Ave Irvine California 92606 Tel 949 863 1234 Fax 949 474 1428 sales mkprod com
30. etinal 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 noncombustible 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 overload arc welding equipment It may overheat 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 such a 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 electrically HOT equipment can fatally shock a person whose body becomes a conductor DO NOT STAND S
31. from gas shielded arcs are more severe and painful DON T GET BURNED COMPLY WITH PRECAUTIONS 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 substantial 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 momentarily with unprotected eyes particularly a high intensity gas shielded arc can cause a r
32. han 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 UNATTENDED Close gas supply at source and drain gas G STAGING SUPPORT staging support should not be used for welding or cutting operation 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 voltages 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 light colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those
33. hen in the all other wires position NOTE Operating the cabinet with the switch in the wrong position will cause wire feed difficulties Posa Start Controls The Posa Start Run in Speed Control located on the front panel provides adjustment for slow wire run in Once the arc has been established the wire feed speed is automatically changed from the slow run in speed to the welding speed set on the torch potentiometer Posa Start Operating Procedure General The Posa Start Run in Speed Control located on the front panel provides adjustment for slow wire run in Once the arc has been established the wire feed speed is automatically changed from the slow run in speed to the welding speed set on the torch potentiometer The Posa Start feature allows the Cobramatic to be used in combination with constant current DC welding power sources of open circuit voltage in excess of 55 volts also any constant voltage welding power source capable of a minimum of 50 amps Note Reverse polarity MUST be used Posa Start Connections Attach the 14 single black lead which extends from the back of the cabinet to the negative terminal of the power supply or work ground The Posa Start lead is internally connected to the P C board on terminal strip J6 terminal 2 CV Posa Start Operations Attach Cobramatic to CV power source according to the installation instruc tions Turn the Cobramatic to the ON position and the Posa Start t
34. iner bar is designed to hold the wire on the spool maintaining the smooth layering of the wire and keeping it from jumping off and possibly electrically shorting to the cabinet chassis Cobramatic Owner s Manual page 5 Section Continued Section B Welding Torch Connections Work Cable Connect a work lead of sufficient size and length see table below between the proper output stud on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact Poor work lead connections can result in poor arc initiation poor weld results and activation of the ground lead protector Work Lead Lengths Current 60 Up to 50ft 10 1008 Duty Cycle 15 2m 15 2 30 4m 300A 0 53mm 0 67mm 400A 00 67mm 00 85mm 500A 00 67mm 00 85mm 600A 000 85mm 000 107mm Control Cable 7 Pin Clocked connector screws onto the mating receptacle on the front panel of the wire feeder This provides all electrical signals motor voltage potentiometer control amp trigger to and from the feeder to the torch Wire Conduit Inlet Front panel access to attach conduit to front of slave motor assembly Power Cable Inlet Front panel access to attach power cable air or water to top of power block Gas Inlet Front panel access to attach gas hose to bottom fitting of power block Water Inlet For Water Cooled Torches Front panel access to connect the water hose to the mid
35. istant 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 ceilings 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 combustibles 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 inerting 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 determine if it is safe to weld or cut Hollow casting
36. k AC circuit Replace fuse F1 4 amp fuse in feeder blown Check motor leads for shorts then replace fuse Micro switch defective not being activated Broken electrical cable Replace switch Check switch for operation Check micro switch wires for continuity Relay K2 inoperative Check Replace relay K2 Loose J2 J3 P C board connector Check J2 J3 connectors Brake solenoid inoperative Solenoid defective Replace solenoid Relay K2 inoperative Check for 42VAC across J4 1 and J4 2 No wire feed at torch feeder operating properly Bad potentiometer Check potentiometer with meter Bad torch motor Check Replace motor Broken electrical cable Check motor and potentiometer wires for continuity Bad speed control PCB Check Replace P C Board Wire feeds but welding wire is not energized Loose or no cable connections Check all power connections Relay K2 not sending contactor signal Check Replace relay K2 Contactor control cable loose or in wrong position Check power supply owners manual for location and type of contactor signal required i e closing contacts or AC Welding power source not working right Check power supply for proper operation Wire feeds erratically Dirty or worn conduit Blow out or replace conduit Incorrect pressure on drive rolls Adjust pressure at torch Idler r
37. manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection Cobramatic Owners Manual page Table of Contents Saftey Guidelines Installation Technical Specifications Machine Grounding Machine Location Input Power Connections Wire Threading Procedure Welding Torch Connections Operation General Description Recommended Processes and Equiment Controls Settings POSA Start Operating Procedure Accessories Optional Kits Maintenance Routine Maintenance Testing the Feeder Testing the Torch Troubleshooting Troubleshooting Guide Diagrams Parts List Main PC Boards Mechanical Electrical Warranty Repair Stations Safety Warnings Warranty Cobramatic Owner s Manual page 1 This page intentionally blank Cobramatic Owner s Manual page 2 Section Installation Technical Specifications Wire Diameter Capacity 030 inch 1 16 inch ALL Types Wire Spool Capacity 12 inch Standard Insulated or Non Insulated 42 VAC 50 60 Hz 150 Watts Peak 3 amps 41 pounds 46 pounds 14X 16X and 21X Support Equipment Required C V or C C power source of sufficient capacity for your needs Regulated gas supply and hoses Properly sized power leads from power source to wire feeder and ground Coolant Recommendations Coolant recirculator and hose capable of providing a
38. n 306 934 1601 ARC amp GENERATOR REPAIR Garson Ontario 705 525 2141 BARRY HAMEL EQUIPMENT LTD Coquitlam B C 604 945 9313 ELECTRO MECANIK INC Sainte Foy Quebec 418 683 1724 GPR INDUSTRIES 1994 LTD Grande Prairie Alberta 780 532 5900 HYPERDYNAMICS TECHNOLOGIES LTD Pickering Ontario 905 683 9938 INDUSTRIAL ELECTRONIC SERVICES Calgary Alberta 403 279 3432 LADEL Ltd Quebec Canada 819 376 6577 M R T REPAIR CENTER INC Montreal Quebec 514 648 0800 OZARK ELECTRICAL MARINE LTD St John s Newfoundland 709 726 4554 PEEL ENGINES Mississauga Ontario 905 670 1535 PROMOTECH LECTRIQUE Inc Fleurimont Qu bec 819 822 2111 WELDERS SUPPLY Winnipeg Manitoba 204 772 9476 WELDING WIDE SERVICES INC Brampton Ontario 905 874 9992 WELDTEC B C Canada 604 545 3886 CHINA PHT GROUP COMPANY Beijing China Cobramatic Owner s Manual page 28 Do not touch electrically tive parts Keep flammable materials away electrode with skin or wet clothing Insulate yoursell from werk and ground No toque las partes p los electrodos bajo carga con ja piel R ECAU C O N dal trabajo y da la tierra French ATTENTION German WARNUNG laissez ni la pean des v te ments moull s entrer contact aver des pi ces sous tension Isolez vous du travall et de ta terre e Ber hren Sie keine stromfihrenden Tail
39. nd a front panel switch for activating the Trigger Latch mechanism The gas control times have been preset to 0 5 seconds pre purge and 1 0 seconds post purge This offers an optimum amount of inert gas shielding prior to striking the arc and after the arc has been extinguished The Trigger Latch mechanism gives the operator the flexibility of normal trigger operation pull trigger to weld release trigger to stop This also offers the comfort of latched trigger operation pull trigger once to latch and weld pull trigger again to unlatch and stop 005 0675 Water Pressure Kit By monitoring the pressure from the water recirculator the switch uses the pressure as the key safety element in protecting the torch from overheating Cobramatic Owner s Manual page 8 Section D Continued Section D while welding If there is a loss of water pressure the switch will keep the arc from igniting so no welding takes place without water cooling the torch The benefit of the water pressure switch far exceeds the minimal cost of its purchase and installation This kit when installed into the wire feeder is physically adaptable to all makes and models of water recirculators using standard fittings left hand threaded Maintenance Routine Maintenance Maintenance of the torch will normally consist of a general cleaning of the wire guide system including tubes drive rolls and conduits at regular intervals Remove spatter b
40. nd lead is provided with he equipment for connection to a switch box connect the ground lead to the grounded switch box If a three prong plug is added for connection 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 a grounded mating receptacle Never remove he 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 Cobramatic Safety page iii 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 interlocks and circuit breakers should not be disconnected or shunted out Before installation inspection or ser
41. ntact with cylinders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a serious accident See 1 3C CC or DOT marking must be on each cylinder tis an assurance of safety when the cylinder is properly handled identifying gas content Use only cylinders with name of gas marked on them do not rely on color to identify gas content 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 cylinders 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 and weather Replace caps securely when moving cylinders Stuck valve Do
42. o the OFF position Adjust power source to desired voltage for your weld condition Depress gun trigger and adjust wire feed speed at gun to match voltage setting If approximate wire feed is not known it is better to start with excess wire feed rather than too little in order to prevent a burn back Turn the Start switch to the position Press torch trigger and using Run in Speed Control adjust wire feed rate to approximately 10 of welding wire speed set at torch Strike an arc and adjust wire feed rate at gun until correct condition is achieved CC Posa Start Operation Attach the Cobramatic to a CC power source according to the installation instructions Insure power supply high frequency switch is in the OFF position and power supply is set to DC reverse polarity The power supply contactor should be set to Remote or Tig and the Cobramatic Owner s Manual page 7 Section C Continued Section C amperage control set to Panel or Standard depending on power supply Turn the Cobramatic power switch to the ON position and the Posa Start switch to the OFF position Adjust power source to desired amperage for your weld condition Press gun trigger and adjust wire feed speed at gun to match current setting If approximate wire feed speed is not known it is better to start with excess wire feed rather than too little in order to pre
43. oll stuck in torch Check for lock washer under idler roll or replace if damaged or worn Wrong size contact tip See contact tip table Wire feeds one speed only Bad potentiometer Check with meter Broken electrical cable in lead assy Check potentiometer wires for continuity or shorts Bad speed control Check Replace P C Board Wire walks out of drive rolls Idler roll upside down Place groove in idler roll towards top Rear wire guide missing Replace wire guide Cobramatic Owner s Manual page 11 Section F Appendices Diagrams Parts List Main Board Connections Cabinet and Torch Hook Up 001 4010 Cobramatic Assembly 003 2109 Cobramatic Front Panel Assembly 003 2060 Cobramatic Slave Motor Assembly 003 2063 Cobramatic Power Block Assembly 003 2146 Cobramatic Spindle Brake Assembly 071 0387 Cobramatic Block Diagram 071 0270 Cobramatic Main P C Board 071 0367 Cobramatic Torch Connections Cobramatic Owner s Manual page 12 Main P C Board Connections L FRONT PANEL d gt N gt Vn vw lt FRONT PANEL 24 SOLENOID J7 SLAVE MOTOR 15 28 TRANSFORMER 42 VAC Contactor Out 42 VAC Contactor Out Input Power 42 VAC Input Power 42 VAC Posa Start Welding Ground Closing Contacts Out Closing Contacts Out Chassis Ground Cobramatic Owner
44. s or containers must be vented before welding or cutting They can explode Explosive atmospheres NEVER weld or cut where the air may contain flammable dust gas or liquid vapors such as gasoline D CompresseD Gas EQUIPMENT The safe handling of compressed gas equipment is detailed in numerous industry 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 overpressure 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 manufacturer 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 valves or safety devices Avoid electrical circuit co
45. tor 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 Cobramatic Safety page ii 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 cylinder valve slowly so that regulator pressure increases slowly When gauge is pressurized gauge reaches regulator maximum leave cylinder valve in following position for oxygen and inert gases open fully to seal stem against possible leak for fuel gas open to less t
46. ub will aid in this alignment Replace the spool retainer nut Lower the wire retainer bar onto the spool Wire Spool Drag Setting NOTE Standard factory setting of the Spindle Tension Knob is set for All Other Wires There are two visible position settings for this Knob IN All Other Wires Fig 1 and OUT 030 035 Al Only Fig 2 The Spindle Tension Knob must be set to match the Wire Size Selector Switch on the Cobramatic front panel Spindle Knob IN IN All other wires OUT 030 035 Aluminum ONLY Figure 1 Figure 2 Cobramatic Owner s Manual page 4 Section Continued To change this setting it is easier done without the spool of wire on the spindle Remove the wire spool retainer and re install it reversed back onto the Spindle Tension Knob Fig 3 In the Tool Mode the square shaped end of the retainer fits onto the Knob Grab the retainer and turn in the COUNTER CLOCKWISE direction until it stops The Knob is now set to the OUT position 030 035 AL Only Wire Spool Retainer In Tool Mode used to change spindle drag Figure 3 To reset the Knob back to the factory setting of All Other Wires use the retainer as described above and turn in the CLOCKWISE direction until it stops The Knob is now set to the IN position Turning the retainer and Knob in this direction may require more effort since turning CLOCKWISE is working against a spring Load wire spool onto spindl
47. uild up from inside of nozzles with a hardwood stick The only parts on the Cobramatic system that are subject to normal wear are the conduit contact tips gas cups front body liners wire guides drive and idler rolls A supply of these parts should be maintained on hand If repairs do become necessary any part can easily be replaced by qualified maintenance personnel Your Cobramatic is designed to provide years of reliable service Normal wear and component failure may require occasional service The number of units in operation and the importance of minimal down time will determine to what extent spare parts should be stocked on hand Testing the Feeder Relay K2 Operation When the torch trigger is pressed 24VAC is sent to the coil of relay K2 When K2 is energized AC is sent to the slave motor spool brake and the AC contactor Relay K2 is also responsible for sending 24VAC to the speed control circuit and shorting the torch motor leads together when the trigger is released for the dynamic braking system K2 also provides the closing contactor signal Testing the Input Power Circuits The AC circuits are protected by fuse F3 If F3 continually blows disconnect J4 Brake Solenoid J7 Slave Motor and J5 3 amp 4 if connected AC Contactor Out from the PC board Replace fuse and re trigger system If fuse does not blow isolate problem by reconnecting J4 J7 and J5 3 amp 4 one at a time until the fuse blows
48. vent possible damage to the contact tip Turn Posa Start switch to the ON position Press torch trigger and using Run in Speed Control adjust wire feed speed to approximately 10 of weld ing wire speed set at torch Strike an arc if the wire stubs out reduce wire feed rate at gun or increase amperage setting on power source CAUTION Do Not operate this wire feeder on a power source having a high frequency starting circuit before making sure that the high frequency portion of the power source is turned off Failure to take this precaution will cause permanent damage to the Posa Start circuitry NOTE Because the Posa Start Run in Speed always remains a percentage of the actual welding wire feed rate the Posa Start run in speed will always slow down or speed up proportional to any adjustment you now make at the gun Therefore if you slow down the welding wire feed speed you will have to increase the Run in Speed setting OPTIONAL KITS The following is a list of Optional Kits available for the Cobramatic Wire Feeder A detailed description of each kit is given later in this section P N Description 005 0674 Gas Purge Trigger Latch Kit 005 0675 Water Pressure Kit 005 0674 Gas Purge Trigger Latch Kit The Gas Purge Trigger Latch Kit is a dual function kit The kit includes an easy to install interface control PC board a 24VAC solenoid for pre and post purge control a modified valve stem for the welding torch a
49. vice 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 emergency 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 available near the welding power source For selecting quality product We want you to take QU 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 information you have recorded above Read this Owner s Manual completely before attempting to use this equipment Save this
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