Owner`s Manual
Contents
1. 03 laid JS sl gly alat sig GU Sall van pis LA CobraMAX Owner s Manual Page 17 LIMITED WARRANTY Effective October 1 2006 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 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 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 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 o2. Leads shown for reference only 227 Series Ultra Flex Cable Assemblies 15 4 5m 615 0601 15 001 2527 005 0690 001 0537 931 0110 25 7 6m 615 0601 25 001 2528 005 0691 001 0538 931 0122 35 10 71 615 0601 35 001 3812 005 0740 552 0181 931 0132 50 15 2m 615 0601 50 001 1042 005 0692 001 0665 931 0123 CobraMAX Owner s Manual Page 13 Liquid Cooled Lead Assembly This power cable has a boot that is common to many assemblies but must be removed from this end when used on the CobraMAXTM Leads shown for reference only 228 Series Liquid Cooled Cable Assemblies Length Conduit 4Liquid Power Control Gas Hose Liquid Hose Snake Cable Cable Skin 1574 5 001 0529 001 0530 552 0182 005 0692 001 0667 CobraMAX Owner s Manual Page 14 CobraMAX Electrical Torch Functions Ki o A x O El HF W 01909 Amphenol Connector Vievved from front of connector beecese st D OO O LU LL Cabinet End Amphenol Connector CobraMAX Owner s Manual Page 15 Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja P R ECAU C 1 O N e del trabajo y de la tierra French Ne laissez ni la peau ni des v te ments mouill s entrer en contact Keep flammable materiais away Mantenga el material combustible fuera del re
3. WK PRODUCTS Cobra Owner s Manual Product Manual Serial Voltage Rating Revision Gun models CobraMAX 091 0514 06100001 24 VDC Oct 2006 Rev D 227 XXX 228 XXX A 200 Ampere Air Cooled 250 Ampere Liquid Cooled Push Pull Welding Guns Table of Contents Safety Considerations Installation Technical Specifications Support Equipment Required Coolant Recommendations Gun Lead Connections Operation General Controls and Settings Drive Roll and Idler Rolls Accessories Optional Kits Conduits Snake Skins Contact Tips Gas Cups Maintenance Periodic Maintenance Maintenance Tools Recommended Spare Parts List Troubleshooting Troubleshooting Guide Testing The Gun Appendices Diagrams Parts List Mechanical Electrical Safety Warnings Warranty CobraMAX Owner s Manual Declaration of Conformity for European Community CE Products Note This information is provided for units vvith CE certification see rating label on unit Manufacturer s Name M R P rod u cts 5 nc 16882 Armstrong Ave Irvine CA 92606 Declares that the product 0 b ra M AX 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 I Welding Power Sources IEC 60974 1 September 1998 Second Edition Arc Welding Equipment Wirefeed Systems
4. 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 manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection CobraMAX Owner s Manual Section A CE Installation Technical Specifications Wire Capacity 030 045 0 6mm 1 2mm solid and hard wire 030 1 16 0 8mm 1 6mm aluminum and cored wire Wire Speed 800 IPM 20 3 mpm max at rated feeder input voltage 120VAC 42VAC Duty Cycle All ratings are using Argon gas 200 Amps 25 Volts Air cooled 60 250 Amps 25 Volts Liquid cooled 60 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 Liquid source and hose capable of providing a minimum of 1 quart 95 liter min at 45 p s i when using liquid cooled guns Coolant Recommendations 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 The coolant flow rate should be a minimum of 15 GPH 1 qt min between 35 and 45psi Contact the re circulat
5. 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 With 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 CobraMAX Owner s Manual SAFETY CONSIDERATIONS ELECTRIC ARC VVELDING 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 vvelding 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 s
6. speed control operation Idler roll upside down Place groove in idler roll toward top Rear wire guide missing Replace wire guide Wire walks out of drive rolls Broken electrical cable Check potentiometer wires for Wire feeds one speed only continuity or short CobraMAX Owner s Manual Page 7 Troubleshooting Guide Regardless of which gun or feeder used all MK Products push pull guns operate on the same principle The 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 gun 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 drag adjustment in the feeder is used simply to keep the wire slightly taut so it will not pull off the spool while feeding wire The high torque 24VDC gun motor is controlled by a solid state speed control located in the feeder and a pot located in the gun The gun motor potentiometer and micro switch are connected to the cabinet control box via a control cable and Amphenol connector If this cable becomes damaged a variety of symptoms can occur depending on which wire s break To test check each wire for continuity and shorts Remember the micro switch in the gun activates both the slave motor and gun motor circuits in the cabinet Ther
7. DER 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 QU REGARDE CET EQUIPMENT ET LES PRODUITS A 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 STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN CobraMAX Owner s Manual Page 16 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res 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 Entliiftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventila o 6 exhaust o para remover fumo da zona respirat ria EI APSMEMTFLSELT F i ORAL TD TP vo oRB ARES OE RR EGHAM MERE Ss SH7IAE 51595 Sana MASH aa TIAA SSH Asaaz 0 Ge dul TAL gaal bia jea A Aal Jaial Ad OAT liti ge gaat ag i Turn power off before servicing Desconectar el cable de ali ment
8. L TOOL derrer dl 931 0100 8020086 511 0101 CobraMAX Owner s Manual Page 6 Section E Troubleshooting Trouble Cause Remedy 115VAC Control fuse in feeder Replace fuse Control box blown NO wire ped at gun feeder Micro switch defective not Replace switch Check switch for not operting l e no slave 8 being activated operation motor or brake solenoid Broken electrical cable Check micro switch wires for continuity 24 VAC Control fuse in feeder Check motor leads for shorts then Control box blown replace fuse No wire feed at gun feeder a Broken electrical cable Check motor and potentiometer operting properly wires for continuity Bad speed control PCB Bad potentiometer Check potentiometer with meter See specific cabinet control box owners for speed control operation Loose or no cable connections Check all power connections Contactor control cable loose or Check power supply owners Wire feeds but welding wire in wrong position manual for location and type of is not engergized contactor signal required i e closing or 115VAC Welding power source Check power source Dirty or worn conduit Blow out or replace conduit Wire feeds erratically Wrong size contact tip See contact tip table Idler roll stuck Check for lock washer under idler roll or replace if damaged Bad potentiometer Check with meter Bad speed control See specific cabinet control box owners for
9. RNING 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 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 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 befor
10. TNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FUR NISHED BY MK PRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRIT ING MR s PRODUCTS ARE INTENDED FOR ULTI MATE PURCHASE BY COMMERCIAL I NDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAIN TENANCE 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 October 1 2006 THIS PAGE INTENTIONALLY BLANK CobraMAX Owner s Manual Page 19 BAK PRODUCTS 16882 Armstrong Ave Irvine California 92606 TEL 949 863 1234 FAX 949 474 1428 www mkproducts com
11. a de trabajo Gardez l cart da tout mat riel inflammable 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 ATTENTION German VVARNUNG Portuguese avec des pi ces sous tension lsolez vous du travail et de fa terre Ber hren Sie keine stromfiihrenden Entfernen Sie brennbarres Material Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e isolieren Sie sich von den Elektroden und dem Erdboden N n toque partes el tricas e elec ATE N O woos com a pele ou roupa malha Isole se da pe a e terra e Tragen Sie Augen Ohren und K r perschutz Mantenha inflam veis bem guarda Use prote o para a vista ouvido e dos s RAPTUBODMTORET IR 3885003894 KE GE CA THE TTC 127688 IT k VEITH NTVSMELTFSU R FRUSHCRMAELTE Su EE E EE 10 E ECKE Sat MM OREM 959 Sg WIEL ke 2 8 eis S28 Sc A77 aas ex AY So PSs seus e dra Xe dd Fe yya qi S Ae 24 HAE dar THAR Let 4815 ay 05 JA 290 Aal gue 499 dis de Ay 4 Ci pi Haars j aal Di Qi desp i 0 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 ENTEN
12. aci n de poder de la maquina antes de iniciar cualquier servicio D branchez ie courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig off nen Maschine anhalten Nao opere com as tampas removidas Desligue a corrente antes de fazer servigo N o toque as partes el tricas nuas AVFFYA F EAZCRUHY PSM SETURL FE BF MOTEL OR Sais Rita Ah ft Jal A Do not operate with panel open or guards off No operar con panel abierto o 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 Nao opere com os paineis abertos ou guardas removidas KANMPAN ERUHLALEE THUR EL GT RE 82122 2 2 ABTA D e Hido gg Aas Ss HAR Huby ails 09 juya ia Jadi Y e Ae Vol Als dual AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN O 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 5 87 H N EREEE MA 0 TL TRHORSMEC HD TPS HAMMAN EE RS E BE 58 7 RI SES SC KEE 01 gau SS AAAS SISAR HAY Seid EFSA 899 ari palal Ad d
13. ces 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 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 CobraMAX Owner s Manual Page ii 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 cy
14. d Cooled Lead Assembly Wiring Diagram CobraMAX Owner s Manual Page 9 o gt CO ke o Q Gei LLI gt lt lt D Hm Q O O SQVAYHL OL Zp WALI AlddY VY SQVAYHL OL 97 WALI AlddV Y SQV3UH L OL Gp WALI AlddY W SAOVAYNS LOVLNOO OL SP WALI AlddV VW ONITIVLSNI 38093338187 WALI AlddV Ki SAOVAYNS LOVLNOO 046 WALI AlddV Mi ALIHV19 HO4 NMOHS LON tr ANY SZ SWALI WV CobraMAX Owner s Manual Page 10 10910849995 pue GZ OZ ZL SW Y Su sepnjour oa el y i sexem osos soe e sdy w seen ewwer aooo 17 77 suse aoee Del e xvneiaoo sf ano seo sv eres TT SST 0 nore wwe if o on E EE veers Te pE LE 81 sue eu 59211001 1 9194511 SE Duuoi maen i z 7 71717 78705445557 x mee fa EIER EE San ISI SHEd 0110911540 CobraMAX Owner s Manual Page 11 CobraMAX Front Body Assembly 003 2141 Front Body Assembly PartNo Description Separately Not Available Separately La Dr 309 0082 washer Lock o Ds Li 419 0092 spring Comp 0 91 0D x0 201D Le Li 424 0525 Pin Dowel 18x 785s 431 1598 Arm Idler Python 511 0001 Assy Idler Wire Feed 511 0101 Drive Roll Gold CobraMAX Owner s Manual Page 12 Ultra Flex Air Cooled Lead Assembly This power cable has a boot that is common to many assemblies but must be removed from this end when used on the CobraMAXTM Fower Cable ctrical Cable
15. de 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 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 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 E
16. 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 contact 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 ICC or DOT marking must be on each cylinder It is 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 co
17. e 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 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 atmospheres containing even minute amounts of trichloroethylene or perchloroethylene C 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 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 CobraMAX Owner s Manual Page i short circuits 1 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 pro
18. e Drive Roll Kit For 040 1 0mm dia aluminum wire and insulated idler roll assy Insulated Groove Drive Roll Kit For 045 1 2mm dia aluminum wire and insulated idler roll assy Insulated Groove Drive Roll Kit For 062 1 6mm dia aluminum wire and insulated idler roll assy Gas Purge Trigger Latch Kit 005 0641 Includes insulated groove drive roll 005 0642 Includes insulated groove drive roll 005 0643 Includes insulated groove drive roll 005 0644 Includes insulated groove drive roll 005 0674 This kit is required when using the CobraMAX on Cobramatic models 150 003 amp 150 005 and the CobraMig 260 model 186 002 Pre Post BurnBack Spot Timer kit 005 0196 This kit is required when using the CobraMAX on Cobramatic II model 150 004 Handle Kit Includes left and right handles screws and drive roll door Trigger Kit 005 0694 Trigger adjustment kit includes a spring and sensitivity adjustment screw replacement for all Python CobraMAX guns Micro Switch Kit 005 0701 Replacement micro switch assembly for all Python CobraMAX guns Potentiometer Kit 005 0695 Replacement potentiometer assembly for all Python CobraMAX guns 005 0700 Conduits flat spiral steel conduit for steel amp cored wire standard conduit with additional protective cover 001 0774 15 ft 4 5m 25 ft 7 6m 50 ft 15 2m 615 0208 615 0216 615 0218 Snake Skins Snake Skin protective covers are no
19. efore if the slave motor and brake solenoid operate but the gun does not look more toward the gun motor s 24 V circuits speed control control cable or the gun motor If nothing operates look more toward the slave motor s input micro switch leads or micro switch Testing The Gun Reference the W clocked gun wiring diagram on the CobraMAX electrical diagram in appendix for information about pin outs and locations Motor Check Remove the gun connector from the cabinet Using the gun amphenol connector check the resistance across pins A and B motor leads The resistance across the motor should be between 5 10 ohms as the potentiometer is turned If an open circuit or short exist check the motor leads and motor independently Testing the Potentiometer W Clocked Using the gun Amphenol connector check the resistance across pin D wiper and pin C The resistance should vary from 0 5K ohms as the potentiometer is turned Check the resistance across pin D wiper and pin G The resistance should vary from 5K 0 ohms as the potentiometer is turned Testing the Micro Switch Using the gun Amphenol connector check for continuity across pins E and F when the trigger is pressed CobraMAX Owner s Manual Page 8 Section F Appendices Diagrams Parts List CobraMAX Exploded View 003 2141 Front Body Assembly Ultra Flex Air Cooled Lead Assembly Liqui
20. er 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 castings 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 10165 cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure itis 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
21. has a seven pin VV clocked amphenol connector Operation General The CobraMAX gun maintains a constant steady uniform wire feed speed regardless of curved or looped wire conduit The constant push exerted by the slave motor in the cabinet combined with the pull of the gun motor causes the wire to literally float friction free through the wire conduit The 24VDC gun motor is controlled by a three and three quarter 3 3 4 turn potentiometer in the gun handle Controls and Settings Potentiometer The laterally positioned potentiometer is located in the lower end of the handle providing up to 800 ipm with 3 3 4 turns Micro Switch The micro switch assembly consists of the micro switch and leads Trigger Sensitivity The amount of trigger lever travel can be shortened Trigger Sensitivity for a quicker or more responsive action Adustmont Soen Location Amore sensitive trigger lever is produced by reducing the gap between the trigger lever and the micro switch lever By turning in the trigger sensivity adjustment screw it closes the gap between the trigger lever and the micro switch lever This will enable the operator to increase the sensivity of the trigger lever Sensitivity Adjustment With the wire feeder turned on with or without welding wire loaded turn the screw in until the micro switch is activated Once activated the gun and wire feeder motors will begin feeding wire Retract the screw accord
22. ingly until the system is deactivated and adjusted to the operators liking ey RN DOS Of ee pre seting De micro smtch lever for shorter trigger motion Drive Roll and Idler Rolls sensitivity General The CobraMAX gun comes standard with a knurled drive roll and a grooved idler roll which will handle both steel and aluminum wire with diameters from 030 1 16 inch Optional insulated V groove drive rolls are also available for aluminum wire if desired see optional kits Drive roll tension is accomplished with a unique spring loaded pressure screw The CobraMAX comes from the factory with the pressure adjustment screw preset NO ADJUSTMENT IS REQUIRED FOR ALL SIZES AND TYPES OF WIRES Drive Roll Installation Removal Note Neither of the handles needs to be removed to access the drive or idler rolls 1 Pull the cam lever away from the idler roll This will relieve the pressure CobraMAX Owner s Manual Page 2 against the drive roll as shown in Figure 1 Align the drive roll removal tool P N 931 0100 over the flats of the drive roll as shown in Figure 2 Hold the gun with one hand or on a table top with the other hand give the removal tool a quick snap turn in the CLOCKWISE DIRECTION Once the drive roll is loose continue to spin drive roll in the clockwise direction to remove the drive roll from the gun Install a new drive roll on the left hand threaded shaft The drive roll will self tighten whe
23. ituations READ THEM CAREFULLY In case of any doubt obtain qualified help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRICARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY 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 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 WA
24. lding 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 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 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 a quality product We want you to take OW 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
25. linder 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 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 Unattended 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 asafe 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 Pr
26. n it is feeding wire Figure 1 Figure 2 Idler Roll Installation and Removal Reference Figure 3 1 Using a slot type screwdriver loosen idler screw taking care not to lose lock washer under idler roll 2 Insert new idler roll and lock washer onto screw insuring that idler groove is toward top and lock washer is beneath idler Roll EE Towards Top Lock Washer Idler Arm S screw x Spring Figure 3 3 Tighten NOTE Lock washer must be under idler roll or it will not turn freely Accessories A gas flow control mechanism i e solenoid or valve is required so the CobraMAX can be used on Cobra wire feeders The following kits are available depending on the wire feeder used The factory set times in seconds for normal and latched trigger functions is 0 25 pre purge and 1 0 post purge Optional Kits Insulated Drive Roll Kits are used to prevent preheating of the wire which may soften it and clog the liner This picking up of current at the drive rolls rather than at the contact tip is usually not a problem unless using too large of a contact tip or excessively oxidized aluminum wire Insulated Groove Drive Roll Kit 005 0640 For 030 0 8mm dia aluminum wire Includes insulated groove drive roll CobraMAX Owner s Manual Page 3 and insulated idler roll assy Insulated Groove Drive Roll Kit For 035 0 9mm dia aluminum wire and insulated idler roll assy Insulated Groov
27. ntents 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 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 orifi
28. or manufacturer for specifications on pressure Gun Lead Connections Power Cable Air Cooled A 2 AWG power cable is used on the CobraMAX air cooled gun The gun end is threaded into the gun body The power cable fitting connects to the power block in the Cobramatic wire feed cabinet Power Cable Liquid Cooled CobraMAX liquid cooled gun utilizes a power liquid cable with a 4 AWG cable inside a 5 8 16MM diameter hose IMPORTANT Liquid cooled guns MUST be Liquid cooled Conduit The CobraMAX gun comes standard with a poly lined conduit for feeding aluminum wire The longer fitting with a shallow groove is used on the gun end A set screw located on top of the gun handle secures the conduit in place Gas Hose The gas hose is secured over the barbed gas fitting with a tie wrap The cabinet end of the gas hose uses our standard gas fitting 1 8 27 nps Liquid Hose If so equipped one end of the liquid hose is secured over the barbed liquid fitting with a tie wrap and the other end is connected to the center fitting on the power block Electric Cable CobraMAX Owner s Manual Page 1 Section B A seven conductor control cable is used on the CobraMAX gun The gun end of the control cable is secured to the gun vvith a boot clamp and soldered to the pot assembly tirgger and liquid leads Slack is left in the electric cable as it exits the back of the gun to prevent cable breakage The cabinet end
29. otection 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 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 si
30. quipment 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 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 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 li
31. rd furnished with gun Gun Barrel Liners 931 0137 615 0341 621 0423 615 0248 3 8 9 5mm 1 2 12 7mm 5 8 15 8mm 621 0420 621 0421 621 0422 Teflon liner package 5 pieces Spiral steel 030 045 0 8mm 1 1mm CobraMAX tip extender Spiral steel liner for tip extender CobraMAX Owner s Manual Page 5 Section D Maintenance Periodic Maintenance Your Cobramatic system is designed to provide years of reliable service Maintenance of the gun vvill normally consist of a general cleaning of the vvire guide system including barrel drive rolls and conduit at regular intervals Remove spatter build 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 The number of units in operation and the importance of minimal downtime will determine to what extent spare parts should be stocked on hand See the recommended spare parts list for the most commonly replaced parts If repairs do become necessary qualified shop maintenance personnel can easily replace any part Maintenance Tools Contact tip removal tool 931 0002 Drive roll removal tool 931 0100 Gas valve removal tool 931 0584 Recommended Spare Parts List 006 0707 REMOVA
32. riginal 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 Power Supplies and Wire Feed Cabinets 3 years 2 Weldheads Positioners Prince XL and Prince XL Spool Guns Python CobraMAX Cobra SX Cobra MX 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 P RO D U CTS 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 CON TRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FI
33. tect 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 near 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 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 Wat
34. ve 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 aline cord with a ground lead is provided with the 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 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 CobraMAX Owner s Manual Page iii 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 we
35. w standard on all guns You may order spare replacement covers to protect the lead assy of the gun when the factory one becomes damaged or worn It can easily be replaced in the field 15 ft 4 5m 25 ft 7 6m 50 ft 15 2m by means of Velcro Snake skin cover 13ft Snake skin cover 23ft Snake skin cover 33ft Snake skin cover 48ft for 15ft leads for 25ft leads for 35ft leads for 50ft leads 931 0110 931 0122 931 0132 931 0123 CobraMAX Owner s Manual Page 4 To remove contact tip when using full liquid cooled gas cup P N 621 0065 contact tip removal tool P N 931 0002 must be used Heavy Duty Contact Tip 3 8 Diameter Contact Tips 030 0 8mm 040 1 0mm Spray Short 1 57 39 9mm 1 82 46 2mm 621 0390 25 621 0396 25 035 0 9mm 045 1 1mm Spray 1 57 39 9mm 1 82 46 2mm 621 0391 25 621 0391 250 621 0391 500 621 0397 25 047 1 2mm 054 1 37mm 1 57 39 9mm 1 82 46 2mm 621 0392 25 621 0392 250t 621 0392 500tt 621 0398 25 060 1 5mm 1 57 39 9mm 621 0393 25 621 0393 250t 621 0393 500 t 1 16 1 6mm 074 1 9mm 085 2 16mm 1 57 39 9mm 621 0394 25 621 0395 25 Use of tip removal tool is recommended This size tip furnished with gun t Also sold in quantities of 250 tt Also sold in quantities of 500 Gas Cups No 6 No 8 No 10 standa
Download Pdf Manuals
Related Search