Lincoln Electric COBRAMATIC IM597 User's Manual
Contents
1. Ate ECLT EUB N d S3HNJO3SNJMI 32018 30133130 IN3440J 3NIU 3 IE81 80 N d 271997 Ach 12L1 EM8 H S 13478 8541 ASSY 0lI23Ud EAA H S J 1X3 O4H0E NIHH K1587 1 Cobramatic Owner s Manual Page 29 MK WARRANTY REPAIR STATIONS ALABAMA AIRGAS MID SOUTH Birmingham AL 205 251 6835 WELDING ENGINEERING SUPPLY CO Prichard AL 334 457 8681 ARIZONA PRAXAIR Phoenix AZ 602 269 2151 ARKANSAS APPLIED SERVICES INC Benton AR 501 860 6464 RELIABLE WELDING REPAIR Greenwood AR 501 996 6688 CALIFORNIA ADVANCED WELDER REPAIR Commerce CA 323 263 7383 ARC PRODUCTS San Diego CA 619 628 1022 CAL WELD SUPPLY Fresno CA 209 445 0131 EMCO EAST Concord CA 94520 PRAXAIR DISTRIBUTION ARC RENT Long Beach CA 562 427 0099 R J KATES San Diego CA 619 565 6960 RED D ARC INC Carson CA SO CAL AIRGAS Gardena CA 310 523 9355 for MK Products COLORADO INDUSTRIAL GAS PROD amp SUPPLY 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 A 8 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 32808 407 290 9551 HOLO2. aT NAZ C HOLOWHOMOL YOLONHOYOL OERA 6PZYNZ ED Wee Old 00 oo ZY en dOHONOD 20 E00 SSvdA8 revo DAT V VSOd ld V oz SS9SNZ MEINES vu AOL OPZvNE M89 PO EH GSTIVLSNI LON SINJNOdWOOZS3HL x89 zu OLPRNZ ner 900 NI LELPNI l drAVi3H S 42018 TVNIWH31 ONISLONGOYd A JO IN3SNOO NALLIYM OO 3HLLNOHLM JSNLOVIANVA 01 SISVE V SY CASN YO LYW NINO ATIOHM S3HLIS ALVA GWUlHL Y OLO3SOTOSIQ YO O31 MER OK 38 LON AYN LI ONI SLOnGOtid HW JO ALH3IdOHd IHL SHLNIWNIOG SIHL K1587 1 Cobramatic Owner s Manual Page 27 u3292181 HIYOL 10d H BHOL Me Yi 1 N G37 BOLUDIGOGNI H G37 BOLUDIONI HOLIOW HOSOL a j amsuvuar aja H 2UAZ2C Wui 9181 HOSBHOIL Co H OGAZ 3399131 HIMOL MIO 10d H2HOL amp 3dIM 10d HIYOL MO 104 HIYOL 13W1S USOd A NM ja M 1381S ESOd N AAMT NDRDMSnNM EN ADOT Z 10dS MS EMS 33H10 7119 304 ee e 804 ne roi E SECO ClO 202 WHO GE 8 10dS MS EMS N SE O E uy lt z 2 z 9 95 0 O 309801 DAG DHAZET DBATLE K1587 1 Cobramatic Owner s Manual Page 28 COBRAMATIC
3. fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard tacing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 0 Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this 5 9 LINCOLN equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 SAFETY 8
4. LU K1587 1 Cobramatic Owner s Manual Page 22 Wire Harness for Input Power from Power Source Plug for Lincoln Wires terminated Power Source inside Cobramatic Cabinet 3 4 LE P N L10708 1 42VAC Interface Cable MK P N 843 0496 Control Cable Termination Chart Lincoln 14 Pin Cobramatic I FUREUR color Code Plug Receptacle Cabinet Terminal 42 VAC input White l J5 1 42 VAC input Black J5 2 Posa Start ref gnd Blue J6 2 Contactor Red J6 3 Contactor Orange J6 4 Ground Green Chassis K1587 1 Cobramatic Owner s Manual Page 23 182 0057 Ta d LE d a ca un COMPONENTS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY K1587 1 Cobramatic Owner s Manual Page 24 MK P N 003 1721 MAIN P C BOARD PARTS LIST COMPONENT MK P N DESCRIPTION RELAY 5V 500 Ohm 200MA RESISTOR carbon 25 watt 6 8K ohm RESISTOR carbon 50 watt 6 8K ohm RESISTOR carbon 25 watt 100 ohm RESISTOR carbon 25 watt 150 ohm RESISTOR carbon 25 watt 10K ohm RESISTOR carbon 25 watt 3 3K ohm RESISTOR carbon 25 watt 560 ohm RESISTOR carbon 25 watt 2 2K ohm RESISTOR carbon 25 watt 5 6K ohm DIODE 1 amp 800 volts IN4006 DIODE 2 5 amps 1KV HEP170 DIODE zener 1 watt 10 volts IN4740 DIODE zener 1 watt 6 8 volts IN4736 TRANSISTOR NPN 500MA 250 volts 2N5655 TRANSISTOR PNP 1 amp 50 volts 2N4249 TRANSISTOR unijunction 30 volts 2N2646 T
5. CEE KAY SUPPLY INC St Louis MO 324 644 3500 P G WALKER Springfield MO 417 862 1745 NORTH CAROLINA INDUSTRIAL MAINTENANCE OVERFLOW Fletcher NC 704 684 2000 M amp L WELDER REPAIR Asheville NC 828 250 9353 MACHINE amp WELDING SUPPLY CO Dunn NC 910 892 4016 NATIONAL WELDERS High Point NC 910 882 1110 K1587 1 Cobramatic Owner s Manual Page 31 MK WARRANTY REPAIR STATIONS NORTH CAROLINA contd NATIONAL WELDERS SUPPLY CO Charlotte NC 704 392 7317 OHIO ALBRIGHT WELDING SUPPLY Wooster OH 330 264 2021 ARC EQUIPMENT COMPANY Struthers OH 44471 333 750 9353 CnD MACHINE INC Canton OH 44706 330 478 8811 VALLEY NATIONAL GASES Lima OH 419 228 1008 RICK S WELDER REPAIR SERVICE Eastlake OH 440 269 1204 VALLEY NATIONAL GASES Toledo OH 419 241 9114 WELDINGHOUSE INC Cleveland OH 216 524 1955 OKLAHOMA BILL S WELDER REPAIR Oklahoma City OK 405 232 4799 AIRGAS MID SOUTH Tulsa OK 918 582 0885 RITE WELD SUPPLY INC dba OKLAHOMA WELDERS SUPPLY Madill OK 580 795 5561 PENNSYLVANIA GEOVIC WELDING SUPPLY Milton PA 717 742 9377 for MK Products J A CUNNINGHAM EQUIPMENT INC Philadelphia PA 215 426 6650 VALLEY NATIONAL GASES Pittsburgh PA 412 281 1835 SOUTH CAROLINA IND L ELECTRIC REWINDING CO OF SUMTER Sumter SC 803 773 9366 TENNESSEE NEXAIR Memphis TN 901 523 6821 TEXAS AIRGAS HOUSTON Houston TX 713 462 8027 DEN
6. WELDING SPARKS can M cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous Situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protec
7. Z4 MI dla 9 K1587 1 Cobramatic Owner s Manual Page 18 PARTS LIST K1587 1 Wire Feed Cabinet Qty Part Number 1 436 0122 1 438 0019 14 336 0038 4 301 0103 16 333 0043 336 0006 341 0005 329 0003 332 0009 261 0105 003 1674 261 0104 336 0037 329 0005 261 0372 331 0005 333 0009 341 0010 001 1232 003 0570 328 0112 003 0784 405 0886 327 0012 419 0080 003 2095 003 1723 336 0005 331 0002 345 0008 405 0909 003 1721 342 0410 336 0039 003 2016 351 0752 351 0744 351 0745 351 0082 411 0157 003 2015 415 0243 329 0219 331 0067 333 0007 341 0007 L10708 1 435 3121 261 0446 351 0086 405 0894 351 0089 331 0049 411 0020 003 1798 351 0758 301 0087 I O Ob OO N 7 A GA N Ns OR N NN N N N N 223232332 N O O1 Q N O oO O O1 N O o Om Om o O1 OQ Q SS SS P ROC WWW W C O Q P N O oO Oo JO OQ P N d O Q FW AN F OH LR P A PE PE O EF Qn AN N N N NN N N O N O1 gt al SQ Description Base Cabinet Screened Lincoln Cover Front PCB Lincoln Screw PH Fil T B 6 32 x 3 8 Rubber Feet Washer Int Star 6 Screw PH Fil 6 32 x 1 2 Nut Hex 6 32 Screw Hex1 4 20 x 3 4 Washer Shoulder 0 265 ID Insulator Power Block Power Block Assy Insulator Spool Screw PH Fil T B 6 32 x 1 4 Screw Hex 1 4 20 x 1 00 LG Insulator
8. late Sid era GS HN Ae wkl GU gl colas ilg Waat A al gg chant d i S ll piali dei edil Geh LU THIS PAGE INTENTIONALLY BLANK K1587 1 Cobramatic Owner s Manual Page 36 LIMITED WARRANTY Effective April 1 1998 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY MK Products lnc lrvine 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 subjectto the warranties oftheir 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 nozzles nozzle insulators and contact tips where failure does not result from defect in workmanship or material In the case of MK Products breach of warranty or any other duty with respect to the quality of any 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 Ir
9. lt x O lt a lt O O a 4399181 HIYOL 104 323013 A KIHOL 43399131 HJ4OL 19d HJ301 YOLOH HJ3D1 32013 S CT8l1 EUM N d EFST EBB N d Nu SW Su SH H01233NN02 30133NNGO TONJHJHE DK d E EFSS8 LS rS9Y928 or er lagz cE2a0 B S quvoa I3NVd LNO3J Acy IUT Egg 47 5 010N3185 save j Saute t3UHID3N 311H 3HL ONG 10H 32818 FHL NO 39U11 0 2H Alddf lS MON TIIA LIN 3H1 es Gr Ol Es 9f WOY3 ZIM SL1HM 3Hi ONE be Sf OL vs OF WONd ANIA 32H18 JHL 3 0H 03910038 S TIBNDIS BOLIUHINOJ 3981704 2U NU il II 936r8 Er8 U S 3199 89 0 1Z0 ONJ 3308 LIBLNOT IN 50 J 1281N0J SNISD J ER ONS 413166 TOA 1038 SLIOA OTIA N010N JUACF YOLUN YO OH TECT TATAR B S E31 88 N d 90 04 QS H A 3 H un AL H IH ST H LD N iA IN I H ein intel lesen 41511911915 1 les 3933005 CEES ad EEN Aj ERD CHI ALE Nunidu IH ALC lle em A nes es ex Indes kk rcl 99 N d
10. prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other Oy moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rode while the engine is running To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Sa
11. AA BEE ARHAR e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas e Desligus a corrente antes de fazer servi o N o toque as partes el tricas nuas OXITFIAR H EIKRUR PERK ETRAZ Ft PYTUSCFtiv eso HE dats 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 Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N n opere com os paineis abertos ou guardas removidas OKRRMPDN ERVALALEE CREME L TUTE e Eet ECKE MSTA Ro e Bol dal Yee 21321 ORAR AVISO DE PRECAUCION ATTENTION WARNUNG Portuguese ATENC O ga ge Jan ed od e EAN ARA hia Ja Ad Aal decide Ad yA uu Aal Ge GAN Ja ust Axa Aj AUD Qd Act all e Tey cals 13 alil Jn ye de cual FIRE FR LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR WEIRHERRUNA H OETEERCHA ETEMUCTFSUD TLTRHORSRELEITTEN GEET ET ER DL B AE ECKE CET EE o A Eo SEN AAAS Gel
12. HEMATICS Wiring Schematic Torch Connections Block Diagram WARRANTY REPAIR STATIONS K1587 1 Cobramatic Owner s Manual Page 8 THIS PAGE INTENTIONALLY BLANK K1587 1 Cobramatic Owner s Manual Page 9 Section 1 Section 2 Section 3 Section 4 Section 5 SPECIFICATIONS Wire Diameter Capacity 030 1 16 ALL Types Wire Capacity 12 Standard Insulated or Non Insulated 42 VAC 50 60 Hz 150 Watts Peak 3 amps 31 pounds 36 pounds K1589 K1590 K1591 K1592 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 Water Source and Hose Capable of Providing a Minimum of 1 qt min at 45 p s i when using water cooled torches COOLANT RECOMMENDATIONS 1 Use a name brand additive which does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum 2 Check coolant periodically to remain within limits of the following A Coolant Flow rate 1 quart minute at 45 p s i B Resistivity 10K ohms centimeter C Ph Range 5 5 8 5 D Particle Size 005 OPTIONAL ACCESSORIES Replacement Plastic Guides for Slave Motor Lincoln MK Products Inlet Guide S23980 1 753 0062 Outlet Guide with Knob S23980 2 003 0428 INSTALLATION The cabinet should be placed in a location where it can be protec
13. HYRISTOR 8 amps 400 volts MCR218 6 CAPACITOR ceramic 01uf 600VDC CAPACITOR Poly 047uf 200VDC CAPACITOR electrolytic 6 8uf 63 VDC CAPACITOR tantalum 10uf 20VDC CAPACITOR ceramic 047uf 50VDC VARISTOR 130 volts 10 amps VARISTOR 56 volts 8 amps CONNECTOR R A header 2 pin TERMINAL header 26 pin TERMINAL header 10 pin TERMINAL header 2 pin TERMINAL strip 4 pin CONNECTOR 6 pin CONNECTOR R A header 3 pin FUSE HOLDER PC mount FUSE 3AG 4A 250V FUSE MDA7 7A Slow Blow RELAY 24VAC 4PDT SOCKET relay 15 pin JUMPER CABLE Relay Clip K1587 1 Cobramatic Owner s Manual Page 25 MK P N 003 2001 FRONT PANEL CIRCUIT BOARD COMPONENT MK P N DESCRIPTION RESISTOR wire wound 30 ohm 8 watt POTENTIOMETER 100K ohm RESISTOR carbon 2 7K ohm 1 2 watt LED green SWITCH DPDT p c mount SWITCH SPDT p c mount SWITCH SPDT p c mount HEADER 10pin 90 degree HEADER 26pin 90 degree HEADER 8pin 90 degree HEADER 8pin 90 degree a e la E e COMPONETS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY K1587 1 Cobramatic Owner s Manual Page 26 s lt m O O 7 89d NIVW VH8OD ONI SLONGOUd WW QION3310S 2uvug 86 zL Zrett NOG OLLLLNOO Py HOY YOLON dvo 1x3 OYOLOW HOWOL WIRING SCHEMATIC ANVd LNOYS HOLOWHOYOL 1V4809 OL
14. ISON OXYGEN Denison TX 903 465 3369 RITE WELD SUPPLY INC Fort Worth TX 817 626 8237 VIRGINIA NORFOLK WELDERS SUPPLY Norfolk VA 804 622 6571 WASHINGTON A L WELDING PRODUCTS Tukwila WA 425 228 2218 CASCADE AIRGAS WELDER S SUPPLY Seattle WA 206 224 0433 OXARC INC Spokane WA 509 535 7794 OXYGEN SALES amp SERVICE INC Tacoma WA 253 473 2282 K1587 1 Cobramatic Owner s Manual Page 32 MK WARRANTY REPAIR STATIONS for MK Products PACIFIC WELDING SUPPLIES Tacoma WA 253 572 5302 PRAXAIR Seattle WA 206 624 7033 AMERICAN EQUIPMENT SERVICES Kent WA 253 395 9947 WISCONSIN BENTLEY WELDING SUPPLY Brookfield WI 414 938 6365 CANADA ARC amp GENERATOR REPAIR Garson Ontario 705 525 2141 INDUSTRIAL ELECTRONIC SERVICES Calgary Alberta 403 279 3432 M R T REPAIR CENTER INC Montreal Qu bec 514 648 0800 OZARK ELECTRICAL MARINE LTD St John s Newfoundland 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 K1587 1 Cobramatic Owner s Manual Page 33 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground e No toq
15. JL ay Ae de y es ll aa e Harp s READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A 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 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 e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria ta APSOBWENMTY XK 5CUC FEU 9 amp 3U0HUBICEONIKUCT EU oS ass KE h AAA e das TE BALE Wasa e SAXIAORYE SUR saatz AA A
16. L0 Lzp 338 1 Joyow o e s sse xoq 1899 LEZL 100 L Joyejnsul xoq 1889 ELZO L9Z 339 1 Bugseo uogonpel 1889 pe0 Lep 339 1 yeusuogonperBuueeg 8LLO LOS 339 1 yeys 1809 0ELO 209 339 1 Buueeq del 96L0 LOS 339 1 deg peeo Lep 339 1 PILZLOXp L se0eds 900 2v Jas 8 Buuds 00 Jeysem 9000 tt Jas 8 9 X ZE BH pujexoos mars 9200 826 PENTZ 00 X ZE 8 PU Jey oos mens 6200 8ZE BEI Jo OW aAe s jo1 eA 90Z0 LLS 339 1 VIL X PT OLH MAIS jas 0900 LzE 3389 77 EIP 8 G Jenno ai PPNO Z 086EZS 3439 11 elp 8 G Jenno eum aping Z900 ESZ PEN sse qns qouy 9 L0 E00 338 1 ep Z L am epin9 1 086 25 PEN ep Z L a aping 900 892 438 4 8 X ZE 8 PU jexoos wem YZ00 8ZE BC yeys dos nn Z80L Leb 43 wae joa ien 60Z0 ELt 43 PI y eysem OGOO LEE 339 11 290 0 x po z9 0 duioo Buds LLZO 6Lp 3391 ysnipe MN 2v00 Sbe 339 1 qouy yeys a1nsseid Z0 00 339 1 OL ey Jeep pb00 Lee Jut 1 1 Buuds 0 jeuseM 6000 43 Joo eAe s joije p 2020 105 339 1 8 X v LJepinous majos LOOO DEE 339 1 VIE X y 19plnous mess y000 0 43 HL JS JU JUIS Jeysem v900 t6 PET VIE X 0Z b 1 PU eY mans 9BZO DZE sae gt 0 0 lt m 5 gt Bs o N e N I e e Z D x I z 2 gt po Q Lo 2 Q x
17. NOT OPERATE A COBRAMATIC 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 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 7 3 2 CV POSA START OPERATION Attach Cobramatic to CV power source according to the installation instructions Turn the Cobramatic to the ON position and the Posa Start to 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 Posa Start switch to the ON 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 K1587 1 Cobramatic Owner s Manual Page 13 Section 8 7 3 3 CC POSA START OPERATION Attach the Cobramatic to a CC power source according to the installati
18. Power 42VAC wEB Input Power 42VAC Control E Chasis Ground Cable LE P N L10708 1 MK P N 843 0496 Closing Contacts Out UII Weld Connection Ref W Not Used Closing Contacts Out K1587 1 Cobramatic Owner s Manual Page 16 TROUBLE No wire feed at torch feeder not operating i e no slave motor or brake soleniod Brake soleniod inoperative No wire feed at torch feeder operating properly Wire feeds but welding wire is not energized Wire feeds erratically Wire feeds one speed only Wire walks out of drive rolls TROUBLESHOOTING CAUSE REMEDY F2 amp F3 MDA7 7A Slow Blow Check AC circuit Replace fuse fuse in feeder blown F1 4 amp fuse in feeder blown Check motor leads for shorts then replace fuse Micro switch defective not being Replace switch Check switch for activated Broken electrical cable operation Check micro switch wires for continuity Relay K2 inoperative Check Replace relay K2 Loose J2 J3 P C board Check J2 J3 connectors connector Soleniod defective Replace soleniod Relay K2 inoperative Check for 42VAC across J4 1 and J4 2 Check relay K2 for AC not present 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 Loose or no cable connections Check all power connections Relay K2 not s
19. RONT PANEL LINCOLN 351 0748 SNAP PLUG 91 12 MK P N NOCUIT ey DD Z JLA NO P ZONE K1587 1 Cobramatic Owner s Manual Page 20 gt 0 o lt o x Wi i m T Q o e N LO Q e e e Z D x 1 gt 2 gt T o T x ul L Sid i 860 160 ant iex NOUu23HI0 SIHI TINA F PARF Men NOUVI07 S87 1 YIONN Iv SILVIOY IVHI STIONIIS AINO 123638 SON FIONIdS N3HM ONITVGH 3TV2S IHI ZION 31V108 OL SINVIS FIONIGS Til t Hd NI NMOHS 319NY JHI 1V TINA ONY Nid 9NINIVI3H FHL OL OHVANVT H2VLIV Z 1 OU Sv XONddY NOUISOd S860 1S0 3NniXi4 OL O S0 00 N d ASSY 310NIdS 31201 I 4S31 Tis Iqrozso ar TE L X8 X8 1814 1SUSEM 00c0 1 Jeuiejes Joods 69L0 LEy Duo ies NN 8100 Sve 91 S eld Jaysem OOLO LEE Buuds uorsseiduoT 0 c0 6Lv pay pow Yeysem 08L0 2Er POW 8 9 X L 19S Jepinous EI0E 0EE EU ISUSEJA E900 LEE Duude uolsseidwo5 6900 61 y Bury dn yoeg 9921 Ler eig ASIA 6G00 ECZ peplon elpuids Sv90 V Nm stil CO P ol on Assy Buueeg 69S0 00 uonduoseg ON Hed K1587 1 Cobramatic Owner s Manual Page 21 JOQUINN Ped PAF uloour It Sued uondwsog voan o on e s 1ojoui enblo1 0Z L 00 L 038 dyz 1806 eH gZL0O OS 338 1 61 7 1 x 91 1 uid Duude 8z
20. Slave Motor Washer Flat 1 4 Washer Spring Lock 1 4 Nut Hex 1 4 20 Slave Mtor 42V Assy Spindle Brake Assy Screw Socket HD 3 8 16 x 1 00 LG Pawl Ratchet Assy Decal Warning T13297 Screw ST T F 26 32 x 1 4 LG Spring Extension Brake Solenoid 42V Assy Transformer 42V Assy Screw PH Fil 46 32 x 3 8 LG Washer Flat 6 Nut Self Locking 6 32 Decal Electronic Connection PCB Main Assy Apcer Stacking 6 32 x 0 534 LG Screw PH Fil 2310 32 x 3 8 LG Assy Panel Front Lincoln Bushing Snap 1 121D 1 50 Dia Mtg Hole Bushing Snap 1 00ID 1 375 Dia Mtg Hole Bushing Snap 15 16ID 1 125 Dia Mtg Hole Cap Plug 7 8 Dia Mtg Hole Clamp Cable Strain Rel Assy Doors Lincoln Handle Carry Screw Hex 10 24 x 1 2 LG Washer Flat 10 Washer Spring Lock 10 Nut Hex 10 24 Control Cable Lincoln 42V Holder Capacitor Mylar Tape Thread Insert 6 32 Serial Number ID Plate Lincoln Thread Insert 10 32 Washer Flat 1 4 Tie Wrap External Cap Assy Bushing Snap dia3 4 Black Wire Guard K1587 1 Cobramatic Owner s Manual Page 19 Exploded View MK P N 003 2016 Front Panel NUT HEX 15 32 DESCRIPTION PARTS LIST 301 0023 GROMMET PNL MTG LED REF 003 2001 PCB 42VAC ASSY 003 1631 CABLE POWER ASSY 003 1332 CABLE RIBBON ASSY 401 0012 KNOB 61 00 327 0110 SCREW PH FIL ST 6 32 003 1643 S CONNECTOR OPTIONAL 003 1642 W CONNECTOR ASSY 436 0123 F
21. WIRE FEEDER IM597 EEN Revi OPERATOR S MANUAL Cobramatic For use with Push Pull Torches Model K1589 K1590 K1591 K1592 Safety Depends on You Lincoln arc welding equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL World s Leader in Welding and Cutting Products EL LECTRIC Sales and Service through Subsidiaries and Distibutors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Premier Manufacturer of Industrial Motors Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The Above For Diesel Engines PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to
22. When the trigger is released and the brake engages especially when using a new spool that is heavier towards the outside the spool will tend to rotate more against the spindle drag adjustment However since the wire is held by the slave motor it will not move and could subsequently jump off the back of the spool and become lodged in the brake mechanism or jump off the front of the spool and electrically short out to the cabinet chassis The wire guard will keep the wire from doing either The wire guard is designed to run inside the spool on top of the wire and when the brake is engaged the wire guard will hold the wire onto the spool The wire guard is made of a heavy woven nylon material that is resistant to wear and will not contaminate the surface of the wire OPERATION 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 drag adjustment in the spindle is used to keep the wire slightly taut so it will not unspool while feeding wire The 24 VDC torch pull motor is controlled by a solid state speed control and a potentiometer located in the torch 7 2 1 ON OFF SWITCH Placing the switch in the ON position energizes the feed
23. X LTD Merrit Island FL 407 454 4106 HAUN SYSTEMS REPAIR Orlando FL 407 872 0011 ROPER ELECTRIC MOTOR SERVICE Panama City FL 32405 850 769 6643 SMITTY S WELDER SERVICE West Palm Beach FL 561 845 1224 TRI GAS Miami FL 305 592 3180 GEORGIA MC CULLOUGH ELEC MOTOR SVC Atlanta GA 404 688 5251 K1587 1 Cobramatic Owner s Manual Page 30 MK WARRANTY REPAIR STATIONS B amp W INDUSTRIAL SERVICES Augusta GA 706 738 8722 IDAHO NORCO Boise ID 208 336 1643 ILLINOIS BODINE ELECTRIC OF DECATUR Decatur IL 217 423 2593 INDUSTRIAL WELDER REBUILDERS Alsip IL 708 371 5688 PCI ENERGY SERVICES Lake Bluff IL 847 680 8100 RELIABLE EQUIPMENT REPAIR Hamel IL 618 633 5000 INDIANA APCO GAS TECH Speedway IN 317 481 4550 EVANSVILLE ARMATURE INC Evansville IN 812 428 9034 IOWA CENTRAL STATES AIRGAS Des Moines IA 515 266 1111 CEDAR RAPIDS WELDING SUPPLY Cedar Rapids IA 319 365 1466 KANSAS KANOX Hutchinson KS 316 665 5551 KENTUCKY GENERAL WELDING PRODUCTS Louisville KY 502 635 5218 for MK Products LOUISIANA GREENE WELDING SUPPLY West Monroe LA 318 340 9206 RED BALL OXYGEN CO Shreveport LA 318 425 3211 MICHIGAN APEX WELDING GASES amp SUPPLY Muskegon Heights MI 616 722 3185 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
24. across pins E and F when the trigger is pressed 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 The AC circuits are protected by fuses F2 and F3 If F2 and F3 continually blow remove J4 Brake Solenoid J7 slave motor and J5 3 4 AC Contactor from the P C Board Replace fuse and retrigger system If fuse does not blow isolate the problem by plugging in J4 J7 and J5 3 4 one at a time until the fuse blows 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 iP Ji ww LE IECH 02 os RS 04 05 86 Ja me cn HAN D mi Om D I o avs K1587 1 Cobramatic Owner s Manual Page 15 Note For Cabinet Remote Pot Kit Remove Jumper from J13 J14 Plug Remote Pot Kit into J14 CURRENT SENSOR Posa Start FRONT PANEL Y vo ESCH EUM Ra LEE FRONT PANEL EN BRAKE SOLENOID apor am 4 ci J7 SLAVE MOTOR J8 TRANSFORMER mum input
25. and cut off any kinked or bent portions Unreel and straighten out first 6 to 8 of wire Release tension from slave motor drive rolls Route wire into inlet guide along drive roll groove and into wire conduit Prevent the wire spool from turning with the palm of the right hand and at the same time grasp the slave motor pressure adjusting knob Pull the torch trigger and slowly tighten the slave motor pressure adjusting knob until the slave motor stalls CAUTION EXCESSIVE DRIVE ROLL TENSION WILL REDUCE RATHER THAN IMPROVE WIRE FEED PERFORMANCE K1587 1 Cobramatic Owner s Manual Page 11 Section 7 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 All Cobramatics have preset adjusting nuts which enables spools of the same wire diameter and type to be changed without further pressure adjustment after initial set up To preset the slave motor tension bottom out the pressure adjusting knob by turning it completely clockwise Prevent the wire spool from turning and using a 9 16 wrench adjust the preset nut until the slave motor stalls Correct pressure will now be achieved by simply bottoming out the pressure adjusting knob The Cobramatic Wire Guard is designed to keep the welding wire from jumping off the spool inside the wire feed cabinet
26. cluding tubes drive rolls and conduits 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 If repairs do become necessary any part can easily be replaced by a qualified shop maintenance man 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 8 1 1 MOTOR CHECK Remove the amphenol connector from the cabinet Using the torch amphenol check the resistance across pins A and B 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 independently K1587 1 Cobramatic Owner s Manual Page 14 8 1 2 TESTING THE POTENTIOMETER W CLOCKED Using the torch amphenol check the resistance across pin D wiper and pin C 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 8 1 3 TESTING THE MICRO SWITCH Using the torch amphenol check for continuity
27. e must both be set up properly to achieve maximum benefit from the welding package The Wire Feeder Gun section of the welding package is fully warranted by MK Products and Lincoln Electric and can be serviced at the MK Products Service locations listed inside the back cover of this manual Spare parts may be purchased from either company if so indicated by a part number in the respective company part number column in the parts listings THIS PAGE INTENTIONALLY BLANK K1587 1 Cobramatic Owner s Manual Page 7 Table of Contents Section 1 SPECIFICATIONS Section 2 SUPPORT EQUIPMENT REQUIRED Section 3 COOLANT RECOMMENDATIONS Section 4 OPTIONAL ACCESSORIES Section 5 INSTALLATION 5 1 Location 5 2 42 VAC Input Power Connections 5 3 Posa Start Connection Section 6 WIRE THREADING PROCEDURE 6 1 Wire Spool Installation 6 2 Threading Procedure 6 3 Pre Setting Slave Motor Tension Section 7 OPERATION 7 1 General 7 2 Feeder Controls Z3 CV CC Posa Start Operating Procedure Section 8 MAINTENANCE 8 1 Testing the Torch 8 2 Relay K2 Operation 8 3 Testing the Input Power Circuits 8 4 Testing the Speed Control MAIN PC BOARD CONNECTIONS TROUBLE SHOOTING DRAWINGS K1587 1 Wire Feed Cabinet Exploded View 003 2016 Front Panel Exploded View 003 0570 Spindle Brake Assembly Exploded View 003 1232 Slave Motor Assembly Exploded View Wire Harness for Input Power from Power Source Main PC Board Parts Placement Front Panel Circuit Board SC
28. ending contactor Check Replace relay K2 signal Contactor control cable loose or in Check power supply owners manual for wrong position location and type of contactor signal required i e closing contacts or AC Welding power source not working Check power supply for proper right operation Excessive spool drag pressure Decrease spool drag pressure inside hub Dirty or worn conduit Blow out or replace conduit Incorrect pressure on drive rolls Adjust pressure at both feeder and torch Idler roll stuck Check for lock washer under idler roll or replace if damaged or worn Wrong size contact tip See contact tip table Bad potentiometer Check with meter Broken electrical cable in lead Check potentiometer wires for continuity assy or shorts Bad speed control Check Replace P C Board Idler roll upside down Place groove in idler roll towards top Rear wire guide missing Replace wire guide K1587 1 Cobramatic Owner s Manual Page 17 2 0 LIHS 3NOM wk 3 0982 100 ds E ON wa EN Zt 3z o i Y N NOON SS mine ze SIOA Zr ILYAVHEOD ASSY m AUT 73 Al TON Si12n O0xd am ISM Sayd NOS ON ge 3Mcf a ON L I33HS 335 i 4 E E FUME EEN SUON NSILDSNK OD A3no s13 o i Q O Lo o o LL o LI N co LO v x LI gt gt Lo o xe O o x LL cr FOI HO 8
29. er circuitry and the power indicator light 7 2 2 WIRE SIZE SELECTOR SWITCH The wire size selector switch changes the torque of the slave motor for the K1587 1 Cobramatic Owner s Manual Page 12 wire you are using When in the 030 035 aluminum only position the slave motor produces approximately 1 1 2 Ibs inches and approximately 4 1 2 Ibs inches when in the all other wires position NOTE Operating the cabinet with the switch in the wrong position will cause wire feed difficulties 7 2 3 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 7 2 4 TORCH AMPHENOL CONNECTORS The Cobramatic contains a 7 pin W clocked amphenol 7 2 5 CONDUIT INLET The Conduit Inlet provides access to the slave motor outlet guide 7 2 6 GAS INLET Provides access to the gas fitting inside the cabinet 7 2 7 POWER INLET The Power Inlet provides access to the power block inside the cabinet 7 3 1 GENERAL 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 CAUTION DO
30. fety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE CALIFORNIA PROPOSITION 65 WARNINGS The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm The Above For Gasoline Engines 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS y E may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around yo
31. ge 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 and Sales SpecNumber K xxx Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment There are some important topics covered in the manual about how this system works and how it is different than wire feeders you may be use to Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment The Wire Feeder Gun section of the welding package is a push pull system which means that there is a motor in the wire feeder as well as the welding gun Thes
32. he work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 x ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these
33. la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables E Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN Rer zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important po
34. on 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 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 prevent 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 welding 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 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 MAINTENANCE Maintenance of the torch will normally consist of a general cleaning of the wire guide system in
35. t sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger
36. ted from damage Lead lengths and accessibility must also be considered when installing the cabinet K1587 1 Cobramatic Owner s Manual Page 10 Section 6 Your Wire Feeder comes factory ready with a harness to plug directly into all 14 pin Lincoln Power Sources equipped with 42 VAC auxiliary The 42 VAC is connected to the PC Board on terminal strip JS 1 neutral and 2 hot and Ground to the Cabinet chassis Posa Start circuitry aids welding starts by sensing arc establish signals A weld ground signal is required for this to circuit to work which is provided through the Power Harness to the Power Source and is internally connected to the P C board on terminal strip J6 terminal 2 Note Place polarity switch to DCEP Refer to scetion 7 3 for power supply settings to insure proper Posa Start operation WARNING TURN THE INPUT POWER TO THE POWER SOURCE OFF AT THE DISCONNECT SWITCH BEFORE PERFORMING ANY WORK WIRE THREADING PROCEDURE Release latches and open right side door of cabinet Remove spool retainer from spindle hub 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 hub will aid in this alignment Replace the spool retainer Place wire size selector switch on front panel to the correct position for the wire being used Loosen end of wire from spool
37. the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 LINCOLN B w SAFETY w PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs e
38. tive garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode if damaged 3 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from
39. ue las partes p los electrodos bajo carga con la pie o ropa moja da O Aislese del trabajo y de la tierra e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sle keine stramf hrenden 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 trodos cam a pele ou roupa molha da Isole se da pega e terra VARFORAER YUMHCE FPRHKECMHHEUCIE UI ke K E EE CZ ZE RTUSRELTFEL ET X pu mit E Se VERACERMAMIARER o YTA SYSE VE SA EE qa Su m Ae end AXE Sax HAL JUD W 2222 uil gl oye pan lp APA stat Aal eau Al D dau ule VIe La e Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammabie e Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos KU TE AO Ke BENLLTRBREUERA of TDEABACRLIMM ess Sang ge AIX sig Ap AS A det XUI Al au Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo 0 B HAUNHEAMRELTF UV SREM H2RARHSEIGNIBA ex AY ZA 374 HESHA
40. ur body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded Do not work next to welding power source Mar 95 LINCOLN D ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure t
41. ur le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 Mie v for selecting a QUALITY product by MK Lincoln Electric We Than ES ou want you to take pride in operating this MK Products Inc Lincoln Electric Company product ses as much pride as we have in bring ing this product to you Please Examine Carton and Equipment For Dama
42. urned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING 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 EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO RE SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER FORM DATE LW 8 April 1 1998 Premier Manufacturer of Industrial Motors Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
43. vine 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 and Weldheads 1 year 2 All Other Equipment 3 years A 90 days MK Products Inc 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 guy World s Leader in Welding and Cutting 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 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 both ways for products ret
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