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Cobramatic Manual

1. 11 4 H MOTOR P N 003 1630 S A 001 3091 42V S A 001 1906 115V AC ACK MOTOR RED MAIN BOARD 27V 27y RED HOT LJ S A 003 1721 42V com S A 003 1628 115V BLACK TRANSFORMER NER 1 P N 003 0773 115V P N 003 1723 42V As RELAY RELAY 157 0022 206 157 0023 5 6 5 LINE CORD 1 2 i SAFETY WIRE GREEN POSASTART CONNECTIONS WORK GROUND BLACK CLOSING _ T SEE NOTE 1 BLACK NEUTRAL WHITE AC LINE IN HOT BLACK CONTACTOR NEUTRAL WHITE AC VOLTAGE SEE NOTE 1 HOT BLACK AC H LAVE MOTOR EA NOTES 5 1 IF AN AC VOLTAGE CONTACTOR Renee SIGNAL IS REQUIRED MOVE THE BLACK WIRE FROM Jo 4 TO J5 4 AND THE WHITE WIRE FROM J6 3 TO 25 3 THE UNIT WILL NOW SUPPLY AC VOLTAGE ON THE BLACK HOT AND THE WHITE NEUTRAL WIRES BRAKE SOLENOID S A 003 2095 42V S A 003 2096 115V P N 003 1643 FRONT PANEL BOARD S A 003 2001 42V S A 003 2024 115V AMPHENOL AMPHENOL CONNECTOR CONNECTOR MS S MS W P N 003 1642 TORCH S CLOCK TORCH or MOTOR TORCH POT TORCH TRIGGER TORCH W C
2. PartNumber 436 0035 438 001 7 336 0038 301 0103 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 003 2014 003 0570 328 0112 003 0784 351 0758 327 0012 419 0080 003 2096 003 0773 336 0005 331 0002 345 0008 405 0724 003 1628 342 0410 336 0039 003 1673 351 0752 351 0744 351 0745 351 0082 411 0157 003 1698 415 0243 329 0219 331 0067 333 0007 341 0007 843 0064 003 0796 843 0327 351 0086 405 0757 351 0089 331 0049 411 0020 301 0087 Cobramatic Parts List P N 001 1132 Description SCREENED BASE CABINET COVER FRONT PCB 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 HEX 1 4 20 X 3 4 WASHER SHOULDER 0 265 ID INSULATOR POWER BLOCK POWER BLOCK ASSY INSULATOR SPOOL SCREW PH FIL TB 6 32 X 1 4 SCREW HEX 1 4 20 X 1 00 LG INSULATOR SLAVE MOTOR WASHER FLAT 1 4 WASHER SPRING LOCK 1 4 NUT HEX 1 4 20 SLAVE MOTOR 115V ASSY SPINDLE BRAKE ASSY SCREW SOCKET HD 3 8 16 X 1 00 LG PAWL RATCHET ASSY BUSHING SNAP 03 4 BLACK SCREW ST T F 6 32 X 1 4 LG SPRING EXTENSION BRAKE SOLENOID ASSY TRANSFORMER 115V ASSY SCREW PH FIL 6 32 X 3 8 LG WASHER FLAT 6 NUT SELF LOCKING 6 32 DECAL ELECTRONIC CONNECTION PCB MAIN 115V ASSY SPACER STACKING 6 32 X 0 534 LG SCREW PH FIL 10 32 X 3 8 LG FRONT PANEL ASSY BUSHING SN
3. onis pice Gur oH CRF apapakuq 10 Pre Setting Slave Motor Tension essen 11 WV GU rm mE 11 Operation soon GU EROR Vini nV CERE RR RR REOR GRE 12 En M 12 MEC 12 CV CC Start Operating Procedure 12 Maintenallce rd an On CE CR 14 TESTING Tn NEN T NE 14 Relay RZ suscipi magn t 14 the TT15 VAC CHCUUS De a t blo ss evant 15 Testing the Speed Control ai d 15 16 Cabinet and Torch HOOK UP 2 9999 2 17 18 Start and Contactor Connections eese 19 Drawno corr ET 20 Mam PG Connections esse AL ichs 25 Main PC Board Parts Placement 06 6 0 10000000 26 Mam PC Boara Palts vei m oem RF Hat aam og kapa a ER ADDS 27 FLORE Pane gus u ix u REA 28 Sep I 29 This page intentionally blank Cobramatic Owner s Manual P N 091 0246 7 INTRODUCTI ON Thank you for purchasing what we believe is the best built wire feeder on the market This manual details the installation of your Cobramatic Cabinet Properly installed adjusted and maintain
4. PRODUCTS Cobramatic Wire Feed Cabinet 16882 ARMSTRONG AVE I RVI NE CALI FORNI A92606 TEL 949 863 1234 FAX 949 474 1428 SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EQUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION OR MAINTENANCE OF THIS EQUIPMENT 1 1 INTRODUCTION This equipment is intended for ultimate application by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment Operation should not be undertaken without adequate training in the use of such equipment Training is available from many public and private schools or similar facilities Safe practices in the installation operation and maintenance of this equipment requires proper training in the art a careful study of the information provided with the equipment and the use of common sense Rules for safe use are generally provided by suppliers of welding power sources compressed gas suppliers and electrode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safety Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt obtain qualified help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPO
5. WHITE WIRE Position BLACK WIRE CLOSING CONTACTS CONTACTOR OUTPUT WHITE WIRE Cobramatic Owner s Manual P N 091 0246 19 9720 160 N d enuey S JeuMQ 5 02 FOR GROUND 2 FOR ITEM 26 6 FOR ITEM 2 8 FOR ITEM 41 3 FOR ITEM 14 FOR ITEM 27 3 FOR ITEM 2 6 FOR ITEM 33 gt gt eee gt gt ASSEMBLE ITEM 12 TO TO ITEM 32 J3 TO ITEM 32 J2 TO ITEM 32 J1 TO ITEM 32 J4 TO ITEM 32 J8 TEM 1 WITH 3M 90 HIGH STRENGTH ADHESIVE TEM 51 ITEM 54 AND ITEM 55 ARE NOT SHOWN FOR CLARITY TO ITEM 11 A TO ITEM 32 J7 TO ITEM 32 J6 2 WHITE TO BLACK TO GREEN TO WHITE TO BLACK TO UNLESS OTH TEM 32 5 1 ITEM 32 J5 2 CHASSIS B TEM 32 J6 3 ITEM 32 J6 4 ERWISE SPECIFIED SEE SHEET 1 DESCRIPTION 2 FOR ITEM 427 6 FOR ITEM 33 4 FOR ITEM 35 SEE PARTS LIST PARTS LIST M K PRODUCTS INC IRVINE CALIFORNIA APPROVED DATE C WESTLAKE 02 95 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES MM SURFACE ROUGHNESS NOT SCALE DRAWING SCALE COBRAMATIC ASSY 119 D 001 1132 L NONE SHEET 2 OF 2 VOLTS REV Qty 1 1
6. Broken electrical cable Relay K2 inoperative Loose J2 J3 P C board connector Soleniod defective Relay K2 inoperative Bad potentiometer Bad torch motor Broken electrical cable Bad speed control PCB Loose or no cable connections Relay K2 not sending contactor signal Contactor control cable loose or in wrong position Welding power source not working right Excessive spool drag pressure Dirty or worn conduit Incorrect pressure on drive rolls Idler roll stuck Wrong size contact tip Bad potentiometer Broken electrical cable in lead assy Bad speed control Idler roll upside down Rear wire guide missing Cobramatic Owner s Manual P N 091 0246 REMEDY Check AC circuit Replace fuse Check motor leads for shorts then replace fuse Replace switch Check switch for operation Check micro switch wires for continuity Check Replace relay K2 Check J2 J3 connectors Replace soleniod Check for 115VAC across J4 1 and J4 2 Check relay K2 for AC not present Check potentiometer with meter Check Replace motor Check motor and potentiometer wires for continuity Check Replace P C Board Check all power connections Check Replace relay K2 Check power supply owners manual for location and type of contactor signal required i e closing contacts or AC Check power supply for proper operation Decrease spool drag pressure inside hub Blow o
7. 122 0011 TRANSISTOR NPN 500MA 250 volts 2N5655 122 0004 TRANSISTOR PNP 1 amp 50 volts 2N4249 122 0013 TRANSISTOR unijunction 30 volts 2N2646 125 0028 THYRISTOR 8 amps 400 volts MCR21 98 6 101 0016 CAPACITOR ceramic 01uf 600VDC 101 0013 CAPACITOR Poly 047uf 200VDC 104 0060 CAPACITOR electrolytic 6 8uf 63 VDC 104 0002 CAPACITOR tantalum 10uf 20OVDC 101 0021 CAPACITOR ceramic 047uf 50VDC 124 0026 VARISTOR 130 volts 10 amps 124 0028 VARISTOR 56 volts 8 amps 1010116 cents CAPACITOR poly 3 3uf 250VAC 153 0866 CONNECTOR R A header 2 pin 153 0876 uuu ichs TERMINAL header 26 pin 153 0842 TERMINAL header 10 pin 153 0844 TERMINAL header 2 pin 186 0057 TERMINAL strip 4 pin 159 0850 CONNECTOR 6 pin 153 0867 CONNECTOR R A header 3 pin 152 0008 FUSE HOLDER PC mount 151 0001 FUSE AGC 2A 250V 151 0043 FUSE 3AG 4A 250V FAST ACT 151 0001 FUSE AGC 2A 250V 157 0022 usai ses RELAY 24VAC 4PDT 173 0026 SOCKET relay 15 pin 003 1307 JUMP
8. MAI N P C BOARD PARTS PLACEMENT Part Number 003 1628 Jumper iL i giui Qe REV SCRN BD NO 182 0057 a e c e p e REPLACED BY QUALIFIED SERMCE PERSONNEL ONLY Cobramatic Owner s Manual P N 091 0246 Page26 COMPONENT MAIN P C BOARD PARTS LIST Part Number 003 1628 P N DESCRIPTION 157 0144 toco tes RELAY 5V 500 Ohm 200MA 115 0154 RESISTOR carbon 25 watt 6 8K ohm 115 0042 RESISTOR carbon 50 watt 6 8K ohm 115 0120 RESISTOR carbon 25 watt 100 ohm 220277 RESISTOR carbon 25 watt 4 3K ohm 115 0122 RESISTOR carbon 25 watt 150 ohm 115 0144 uu uu u ana RESISTOR carbon 25 watt 10K ohm 115 0138 RESISTOR carbon 25 watt 3 3K ohm 115 0129 RESISTOR carbon 25 watt 560 ohm 115 0136 RESISTOR carbon 25 watt 2 2K ohm 143501471 RESISTOR carbon 25 watt 5 6K ohm 124 0002 DIODE 1 amp 800 volts IN4006 124 0003 DIODE 2 5 amps 1KV HEP170 124 0010 DIODE zener 1 watt 4 3 volts IN4731 124 0011 DIODE zener 1 watt 10 volts IN4740 124 0012 DIODE zener 1 watt 6 8 volts IN4736 122 0005 e ciue TRANSISTOR NPN 250MA 80 volts 2N4410
9. ZONE QTY i PART NO DESCRIPTION PARTS LIST MATERJAL pid T NGUYEN 05 90 as M K PRODUCTS ING SEE PARTS LIST ENGINEER DATE IRVINE CALIFORNIA FINISH CHECKED DATE Tee FRONT PANEL ASSY MR HEAT TREATMENT COBRAMATIC UNLESS OTHERWISE SPECIFIED N A DIMENSIONS ARE IN INCHES MM SIZE CAD FILE NO DWG NO REV TOLERANCES ARE SURFACE ROUGHNESS X ons pama 0 005 1 673 F 4 01 1 2 n MR 9720 160 N d enuey S JeuMQ 5 abed NO Description 1 003 0569 Bearing Assy 437 0645 Spindle Molded 1 723 0059 Disk Brake 431 1266 Back up Ring 3 419 0059 Compression Spring 2 3 4 5 3 331 0063 Washer Flat 7 3 330 3063 Shoulder Scr 1 4 x 5 8 Mod 437 0180 Washer Modified 419 0230 Compression Spring 431 0169 Spool Retainer 2 3 331 0200 Washer Flat 1 3 8x7 8x 1 32 TB 0570 tbl r LOCAN SP AGS PW DOCG ONSO Sr 1843 POETA APPR 45 SEL I ZO pANCOLND KU A AND GT JY BELL m P eae SEMA DO OTE AMOIL SALAD Lacu N A Bie Cea eee PHRASE BEAUX ar Gw 14 CER Spindle Brake Assy 003 0570F 9720 160 N d enuey 5 5 Assy Slave Motor 115V 3 4 1 ratio 003 2014A N N 23 24 25 6 27 LN NE EN _9_ 9 EN 5 EN ES EN 28 331 0044 003 2017 507 0128 4
10. both ways for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TOPERFORMANCE 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 OROF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TOANY ANDALL EQUIPMENT FURNISHED BY MK PRODUCTS ISEXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK PRODUCTS ARE INTENDED FORULTIMATE PURCHASE BY COMMERCIAL INDUSTRIAL USERS AND FOR OPERATIONBY PERSONS TRAINEDAND 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 PRODUCTS MK PRODUCTS INC 16882 ARMSTRONG AVE IRVINE CALIFORNIA 92606 949 863 1234 FAX 949 474 1428
11. only it does not represent actual inches per minute 7 2 4 TORCH AMPHENOL CONNECTORS The Cobramatic contains a 7 pin W clocked amphenol For S clocked torches order kit p n 005 3563 See specifications for torch compatibility 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 CV CC POSA START OPERATING PROCEDURE 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 ofa minimum of 50 amps Cobramatic Owner s Manual P N 091 0246 12 NOTE Reverse polarity MUST be used CAUTION DO 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 OPERA
12. 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 a safe process but a careless operator invites trouble The equipment carries high currents at significant voltages The arc is very bright and hot Sparks fly fumes rise ultraviolet and infrared energy radiates weldments are hot and compressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents A Burn Protection Comply with precautions in 1 2 The welding arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from light colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those from gas shielded arcs are more severe and painful DON T GET BURNED COMPLY WITH PRECAUTIONS 1 Protective Clothing Wear long sl
13. weld or cut where the air may contain flammable dust gas or liquid vapors such as gasoline D Compressed Gas Equipment The safe handling of compressed gas equipment is detailed in numerous industry publications The following general rules cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair first close cylinder valve The following symptoms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pressure release Repair Do NOT attempt repair Send faulty regulators for repair to manufacturer s designated repair center where special techniques and tools are used by trained personnel 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls valves or safety devices Avoid electrical circuit contact with cylinders including third rails electrical wires or welding circuits They can produced short c
14. 21 0128 001 3092 261 0213 431 0347 501 0118 507 0130 501 0156 431 0334 342 0063 333 0006 328 0026 328 0029 511 0206 321 0060 753 0265 753 0210 328 0024 431 1082 413 0209 331 0050 419 0211 345 0047 003 0273 Description Assy torque motor 115V Hel gear 10T Pin Spring 1 16 x 3 8 LG AsSy gear box slave motor Insulator gear box Casting gear reduction Shaft bearing reduction Shaft gear Bearing cap Cap Spacer 1 4 x 0 171 ID Washer lock spring 8 Screw socket hd 48 32 x 5 8 Screw socket hd 48 32 x 1 00 Drive roll slave motor Screw set 10 24 Guide outlet Guide wire 21 2 Screw socket hd 48 32 x 3 8 Nut stop shaft Arm idler roll Washer 01 4 Spring comp 0 62 OD x 0 062 Nut adjust Knob pressure shaft Washer flat 10 MAI N P C BOARD CONNECTI ONS Note For Cabinet Remote Pot Kit Remove Jumper from J13 J14 Plug Remote Pot Kit into J14 Co ee CURRENTSENSOR pp 5 Rt Posa Start 1 gt 4517 03 R3 05 R6 C2 a amen FRONT PANEL WT za R10 e xx S gt 2 R9 e R12 R13 1 2 l NW 7 i gt FRONT PANEL F2 Wie Lm BRAKE SOLENOID TT 46 45 SLAVE MOTOR TRANSFORMER 115VAC CONTACTOR OUT 115VAC CONTACTOR OUT INPUTCONNECTIONS INPUTCONNECTIONS GROUND CLOSING CONTACTS OUT CLOSING CONTACTS OUT WELD CONNECTION NOCONNECTION Cobramatic Owner s Manual P N 091 0246 Page25
15. 36 pounds For Use with Torch Prefix Numbers 145 146 147 148 149 162 163 210 211 212 213 216 and 109 156 118 133 160 161 when kit p n 005 3563 is installed SUPPORT EQUI PMENT REQUI RED 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 RECOMMENDATI ONS 1 Useaname 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 OPTI ONAL ACCESSORI ES Plastic Guides for Slave Motor Inlet Guide 753 0062 Outlet Guide with Knob 003 0428 Optional Kits Cabinet Pot Kit 005 0615 S Clocked Sup Kit 005 3563 Pre set Adj Screw 005 0125 Water Flow Kit 005 0253 Wire Guard Kit 005 0618 Standard on all Wire Feeders Cobramatic Owner s Manual P N 091 0246 Page9 Section 5 Section 6 INSTALLATI ON 5 1 LOCATION The cabinet should be placed in a location where it can be protected from damage Lead lengths and accessibility to a 115 VAC 50 60 Hz outlet must also be considered when installing t
16. 3V 1N4006 N TERMINAL BLOCK 6 R4 6 8K 1 2W 2N5655 RELAY4PDT 27 o r3 XFMR AC OUT H D 5V COIL D oo c N 2 TRANSFORMER SW AC L IN SW AC L OUT SW AC H OUT SW AC H IN SW TORQUE IN SW TORQUE OUT wh MAIN SW JP3 Q3 2N4249 9720 160 N d enuey S JeuMQ 2 4402 AC IN L AC IN H CONTACT AC CONTACT AC AWN GU TERMINAL BLOCK 5 6c eDeg LU Jl x NOTINSTALLED REVISIONS REV P ZONE DATE APPR DCN 10249 10 95 a ETS DCN 11110 DCN 11547 ias JP1 POSA JUMPER CABLE 20 BYPASS 003 1307 Q POSA START IN POTCW TORCHPOT WPPER TORCHPOTCON TRIGGER 27VH IN IRIGGERZ VH N O A TORCHMOTOR TORCH MOTOR i 27VAC LED TO COBRA FRONT PANEL TORCH MOTOR TORCH MOTOR 2 LED 1 Q 2 EXT CAP MOTOR AC H d CAP AC d MOTOR AC da Tm MOTOR AC L d SLAVE MOTOR 4 SOLAC zm Q2 BRAKE SOLENOID M K PRODUCTS INC COBRA 1 MAIN PCB 071 0270 9720 160 N d enuey S JeuMQ 2 1490 02 EXT CAPACITOR ASSY S A 003 1798 42V ONLY i WELDING CURRENT DETECTOR CABLE P N 003 1631 P N J3 003 1243
17. AP 1 12 ID 1 50 DIA MTG HOLE BUSHING SNAP 1 00 ID 1 375 DIA MTG HOLE BUSHING SNAP 15 16 ID 1 125 DIA MTG HOLE CAP PLUG 7 8 DIA MTG HOLE CLAMP CABLE STRAIN REL DOORS ASSY HANDLE CARRY SCREW HEX 10 24 X 1 2 LG WASHER FLAT 10 WASHER SPRING LOCK 10 NUT HEX 10 24 CABLE CONTACTORSFT POWER CABLE ASSY POSASTART CABLE THREAD INSERT 6 32 SERIAL NUMBER I D PLATE THREAD INSERT 10 32 WASHER FLAT 1 4 TIE WRAP WIRE GUARD Cobramatic Owner s Manual P N 091 0246 Page 21 9720 160 N d enuey S JeuMQ 5 cc obed STAR WASHER MECHANICAL INSTRUCTION FRONT PANEL NUT ON OFF SWITCH WIRE TYPE SWITCH POSASTART ON OFF SWITCH Numour S CONNECTOR COVER BLANK HOLE WITH SNAP PLUG P N 351 0748 NOTES UNLESS OTHERWISE SPECIFIED OPTIONAL CEMA 1 AM 41 M RU NS ff 7 Z A 351 0748 SNAP PLUG 91 12 003 1631 CABLE POWER ASSY 003 1332 401 0012 CABLE RIBBON ASSY KNOB 1 00 301 0023 GROMMET PNL MTG LED REF NUT HEX 15 32 5 003 2024 PCBA FRONT PANEL 110V 4 2 327 0110 SCREW PH FIL ST 6 32 3 REF 1 003 1643 S CONNECTOR OPTIONAL 2 1 003 1642 W CONNECTOR ASSY 1 1 436 0021 FRONT PANEL P
18. ER CABLE Cobramatic Owner s Manual P N 091 0246 Page27 FRONT PANEL CIRCUIT BOARD Part Number 003 2024 COMPONENT P N DESCRIPTION sip 113 0599 lt uuu u u RESISTOR wire wound 400 ohm 5 watt FO ete een ee EE 119 0020 orte ano POTENTIOMETER 100Kohm acm 1415 00 7 RESISTOR carbon 2 7K ohm 1 2 watt ere 124 0045 LED green OV Ih sicat amete bons 1159 9567 20 cones SWITCH DPDT p c mount AL UE 15953586 uuu SWITCH SPDT p c mount el AT ERR ERE 159 3586 cut SWITCH SPDT p c mount discas en yum da 1598 0842 oiov HEADER 10pin 90 degree To 153 0876 HEADER 26pin 90 degree 15320660 HEADER 8 90 degree 153 0860 HEADER 8 90 degree REV MEM SCRN BD NO 182 0058 c CN c gt COMPONETS TO BEREPLACED BY QUALIFIED SERVICE PERSONNEL ONLY Cobramatic Owner s Manual P N 091 0246 Page 28 THIS DOCUMENT iS THE PROPERTY OF MK PRODUCTS INC IT MAY NOT BE COPIED REPRINTED OR DISCLOSED TO A THIRD PARTY EITHER WHOLLY OR IN PART OR USED AS A BASIS FOR MANUFACTURE WITHOUT THE PRIOR WRITTEN CONSENT OF MK PRODUCTS INC R3 D4 68K D5 1N4733 5 1v 1N4740 10V WELD VOLT R6 150 D WELDVOLTC x Qr 184731 4
19. EVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded connections clean and smooth seats where necessary Tighten If connection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGA adapter available from your supplier between cylinder and regulator if one is required Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads Regulator outlet or hose connections may be identified by right hand threads for oxygen and left hand threads with grooved hex on nut or shank for fuel gas 5 Pressurizing Steps Drain regulator of residual gas through suitable vent before opening cylinder or manifold valve by turning adjusting screw in clockwise Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization Leave adjusting screw engaged slightly on single stage regulators Stand to side of regulator while opening cylinder valve Open cylinder valve slowly so that regulator pressure increases slowly When gauge is pressurized gauge reaches regulator maximum leave cylinder valve in following position for oxygen and inert gases open fully to seal stem against possible leak for fuel gas open to less than one turn to permit quick emergency shut off Use pressure charts available from your supplier for safe and efficient
20. LOCK fg TORCH MOTOR TORCH POT TORCH TRIGGER MK Products Irvine Calif Block Diagram Cobramatic 115V 42V E Document Number Rev iJ 071 0282 THI SPAGEI NTENTI ONALLY BLANK Cobramatic Owner s Manual P N 091 0246 Page 31 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 Inc Irvine California warrants that all new and unused equipment furnished by MK Products is free from defect in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warranties of their respective manufacturers if any MK Products warranty does not apply to components having normal useful life of less than one 1 year such as relay points wire conduit tungsten and welding torch parts that come in contact with the welding wire including 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 w
21. SED 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 WARNING The use of this product may result in exposure to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Adequate ventilation Severe discomfort illness or death can result from fumes vapors heat or oxygen enrichment or depletion that weldin
22. TION 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 the welding wire speed Strike an arc and adjust wire feed rate at gun until correct condition is achieved 7 3 3 CC POSA START OPERATION Attach the Cobramatic to a CC power source according to the installation instructions Insure power supply high frequency switch is in the OFF position and power supply is set to DC reverse polarity The power supply contactor should be set to Remote or Tig and the 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
23. djustment after initial set up To preset 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 6 4 WIRE GUARD The Cobramatic Wire Guard is designed to keep the welding wire from jumping off the spool inside the wire feed cabinet 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 Cobramatic Owner s Manual P N 091 0246 11 Section 7 OPERATI ON 7 1 GENERAL The Cobramatic is an up dated version of the popular Cobramatic Cabinet and operates on the same ba
24. ed for your welding conditions it will prove to be areliable welding system producing consistently uniform welds The Cobramatic can be used with any Constant Voltage CV or Constant Current CC type power source CV CC Posa Start Run in Speed is included as a standard feature The Cobramatic has a 7 pin W clocked amphenol torch connector for easy hook up to the complete line of MK Products 7 pin W clocked amphenol torches The 7 pin S torches may also be connected by using an S clocked amphenol adaptor kit P N 005 3563 In order to assure optimum performance of your Cobramatic equipment familiarize yourself with the contents of this manual and carefully follow all instructions This manual will not only guide you in installing your Cobramatic equipment but will also be a handy reference for optional items replacement parts and consumables Cobramatic Owner s Manual P N 091 0246 8 Section 1 Section 2 Section 3 Section 4 SPECI FI CATI ONS Wire Diameter Capacity 030 1 16 ALL Types Wire Capacity 12 Standard Insulated or us Non Insulated Power 1 115 VAC 50 60 Hz 150 Watts Peak 1 3 amps 2 e 31 pounds Shipping Weight
25. eeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark substantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place over face before striking arc Protect filter plate with a clear cover plate Cracked or broken helmet or shield should NOT be worn radiation can be passed through to cause burns Cracked broken or loose filter plates must be replaced IMMEDIATELY Replace clear cover plate when broken pitted or spattered Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck Looking at an arc momentarily with unprotected eyes particularly a high intensity gas shielded arc can cause a retinal burn that may leave a permanent dark area in the field of vision 3 Protection of Nearby Personnel Enclose the welding area Fo
26. g or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryllium bearing and similar materials when welded or cut may produce harmful concentrations of toxic fumes Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration dangerously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decomposed by the heat of the arc or flame to form PHOSGENE a highly toxic gas and other lung and eye irritating products The ultraviolet radiant energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form phos
27. g dry Never work in damp area without adequate insulation against electrical shock Stay on a dry duckboard or rubber mat when dampness or sweat cannot be avoided Sweat sea water or moisture between body and an electrically HOT part or grounded metal reduces the body surface electrical resistance enabling dangerous and possibly lethal currents to flow through the body 1 Grounding the Equipment When installing connect the frames of each unit such as welding power source control work table and water circulator to the building ground Conductors must be adequate to carry ground currents safely Equipment made electrically HOT by stray currents may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel Three phase connection Check phase requirement of equipment before installing If only three phase power is available connect single phase equipment to only two wires of the three phase line Do NOT connect the equipment ground lead to the third live wire or the equipment will become electrically HOT a dangerous condition that can shock possibly fatally Before welding check ground for continuity Be sure conductors are touching bare metal of equipment frames at connections If a line cord with a ground lead is provided with the equipment for connection to a switch box connect the ground lead to the grounded switch box If a th
28. gene 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 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 short circuits If combustibles are in area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work cannot be moved move combustibles at least 35 feet away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields Fire watcher must be standing by with suitable fire extinguishing equipment d
29. he cabinet 5 2 CONTACTOR SELECTION The Cobramatic is shipped from the factory in the closing contacts position A eight foot 8 contactor cable is supplied with the unit to which the black and white wires supply the contactor signal NOTE THEPOWER SUPPLY OWNER S MANUAL FOR LOCATION AND TYPE OF CONTACTOR SIGNAL REQUIRED WARNING Disconnect the Cobramatic Cabinet from all power sources before changing contactor If a 115 VAC signal is required remove the screws from the left side of the cabinet and lift up the cover door Locate the white and black wire on J6 3 and J6 4 Move the black wire from J6 4 to J5 4 and white wire from J6 3 to J5 3 Theunit will now supply 115 VAC on the black hot and white neutral wires 5 3 115 VAC CONNECTI ONS Connect the supplied 8 three 3 prong plug to a 115 VAC 50 60 Hz outlet The 115 VAC cord is connected to the PC Board on terminal strip J5 1 neutral and 2 hot and Ground to the Cabinet chassis 5 4 POSA START CONNECTI ONS Attach the No 14 single black lead which extends from the back of the Cobramatic to the negative terminal of the welding power source or work ground The Posa Start lead is internally connected to the P C board on terminal strip J6 terminal 2 WIRE THREADI NG PROCEDURE 6 1 WIRE SPOOL I NSTALLATI ON Release latches and open right side door of cabinet Remove spool retainer from spindle hub Install wire spool onto spindle hub so that w
30. here authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Upon receipt of notice of apparent defect or failure MK Products shall instruct the claimant on the warranty claim procedures to be followed As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user 1 Torches and Weldheads 1 year 2 All Other Equipment 3years BI mmc 90 days MK PRODUCTS INC 16882 ARMSTRONG AVENUE IRVINE CA 92606 TEL 949 863 1234 FAX 949 474 1428 MI Classification of any item into the foregoing categories shall be atthe 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
31. ier Mixing gases NEVER try to mix any gases in a cylinder NEVER refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps designed for the hose not ordinary wire or other substitute as a binding to connect hoses to fittings No copper tubing splices Use only standard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Suspend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly for leaks wear and loose connections Immerse pressured hose in water bubbles indicate leaks Repair leaky or worn hose by cutting area out and splicing Do NOT use tape 4 Proper Connections Clean cylinder valve outlet of impurities that may clog orifices and damage seats before connecting regulator Except for hydrogen crack valve momentarily pointing outlet away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match N
32. ircuit arcs that may lead to a serious accident See 1 3C ICC or DOT marking must be on each cylinder lt 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 contents to exceed 55 degrees C 130 degrees F Cool with water spray where such exposure exists Protect cylinders particularly valves from bumps falls falling objects and weather Replace caps securely when moving cylinders Stuck valve Do NOT use a hammer or wrench to open a cylinder valve that cannot be opened by hand Notify your suppl
33. ire 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 6 2 THREADING PROCEDURE Cobramatic Owner s Manual P N 091 0246 10 Place wire size selector switch on front panel to the correct position for the wire being used Loosen end of wire from spool and cut off any kinked or bent portions Unreel and straighten out first 6 to 8 of wire 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 ROLLTENSION WILL REDUCE RATHER THAN IMPROVE WIRE FEED PERFORMANCE 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 6 3 PRE SETTI NG SLAVE MOTOR TENSI ON Read Sections 6 1 amp 6 2 before performing this operation All Cobramatics have preset adjusting nuts which enables spools of the same wire diameter and type to be changed without further pressure a
34. ng power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity while welding lf 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 This page intentionally blank Cobramatic Owner s Manual P N 091 0246 5 Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 5 1 5 2 5 3 5 4 6 1 6 2 6 3 6 4 7 1 7 2 7 3 8 1 8 2 8 3 8 4 Table Of Contents e iato t a E quy Gu 8 ssa inicio wi wa Dr 9 Support Equipment Required 9 Coolant 9 Optional Accessories 9 iussus xs ceci vedo ER ER u or GR RD ER D RD E s 10 10 CONCACEOF SElCCUON saz Sica usa 10 115 VAC CODDOCHOFS 10 Posa Start CODTIecHO dtes vacio ou Suwa a edt O 10 Wire Threading Procedure 10 Wire DOO SEAN QUON ss 10 Tnreaqing PFOEBQUEFO
35. 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 TESTING THE TORCH 8 1 1 MOTOR CHECK a Remove the amphenol connector from the cabinet b 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 c If an open circuit or short exist check the motor leads and motor independently 8 1 2 TESTING THE POTENTIOMETER W CLOCKED a Using the torch amphenol check the resistance across pin D wiper and pin C The resistance should vary from 0 5K ohms b Check the resistance across pin D wiper and pin G The resistance should vary from 5K 0 ohms 8 1 3 TESTING THE POTENTIOMETER 5 CLOCKED a Using the torch amphenol check the resistance across pin D wiper and pin C The resistance should vary from 0 5K ohms b Check the resistance across pin D wiper and pin A The resistance should vary from 5K 0 ohms 8 1 4 TESTING THE MICRO SWITCH a Using the torch amphenol check for continuity across pins E and F when the trigger is pressed 8 2 RELAY K2 OPERATI ON When the torch trigger is pressed 24VAC is sent to the coil of relay K2 When K2 is energized 115VAC is sent to the slave motor spool brake and the 115VAC contactor Relay K2 is also responsible for sending 24VAC to the speed control ci
36. r 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 Equipments rated capacity Do not overload arc welding equipment It may overheat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pressure vessel It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling D Compressed Gas Equipment Comply with precautions in 1 2D E Shock Prevention Exposed electrically hot conductors or other bare metal in the welding circuit or in ungrounded electrically HOT equipment can fatally shock a person whose body becomes a conductor DO NOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection To protect against shock Keep body and clothin
37. rcuit and shorting the torch motor leads together when the Cobramatic Owner s Manual P N 091 0246 Page 14 trigger is released for the dynamic braking system K2 also provides the closing contactor signal 8 3 TESTING THE 115 VAC CIRCUITS The 115 VAC circuit is protected by fuse F3 If F3 continually blows remove J4 Brake Solenoid J7 slave motor and J5 3 4 115 VAC 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 8 4 TESTING THE SPEED CONTROL NOTE The torch should be tested first and the amphenol must be connected to the Cobramatic to perform this test Place a voltmeter across diode D10 and press torch trigger A reading of 0 24VDC should be observed as the torch potentiometer varies JPI Q2 153 02 03 R3 05 R6 4 nol R9 Cobramatic Owner s Manual P N 091 0246 15 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 F3 2 amp fuse in feeder blown F1 4 amp fuse in feeder blown Micro switch defective not being activated
38. ree prong plug is added for connection to a grounded mating receptacle the ground lead must be connected to the ground prong only the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken ground prong 2 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 3 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY HEPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal arc welding equipment is ON and welding gun trigger is pressed Keep hands and body clear of wire and other HOT parts 6 Safety Devices Safety devices such as 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 weldi
39. sic principles The 115 VAC 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 FEEDER CONTROLS 7 2 1 ON OFF SWITCH Placing the switch in the ON position energizes the feeder 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 wire you are using When in the 030 035 Aluminum Only position the slave motor produces approximately 1 1 2 lb inches of torque and approximately 4 1 2 lb inches of torque 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 Control selects a Run in Speed which is slower than the welding speed After arc initiation the wire feed speed is controlled by the potentiometer in the gun The scale surrounding the Run in Speed Control is a relative scale
40. 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 1096 of the welding wire speed otrike an arc if the wire stubs out reduce wire feed rate at gun or increase amperage setting on power source Cobramatic Owner s Manual P N 091 0246 Page 13 Section 8 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 MAI NTENANCE Maintenance of the torch will normally consist of a general cleaning of the wire guide system including tubes drive rolls and conduits at regular intervals Remove spatter 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 person Your Cobramatic is designed to provide years of reliable service Normal wear and component failure may require occasional service The
41. uring and for some time after welding or cutting if 1 Appreciable combustibles including building construction are within 35 feet 2 Appreciable combustibles are further than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors or walls within 35 feet may expose combustibles to sparks 4 Combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radiant or conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precautions have been taken After work is done check that area is free of sparks glowing embers and flames An empty container that held combustibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depending on the combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective equipment Water filling just below working level may substitute for inerting A container with unknown contents should be cleaned see paragraph above Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut Hollow castings or containers must be vented before welding or cutting They can explode Explosive atmospheres NEVER
42. ut or replace conduit Adjust pressure at both feeder and torch Check for lock washer under idler roll or replace if damaged or worn See contact tip table Check with meter Check potentiometer wires for continuity or shorts Check Replace P C Board Place groove in idler roll towards top Replace wire guide Page 16 CABINET AND TORCH HOOKUP DIAGRAM Work Ground Cable Power Cable x Start Ground Cable Contactor W Cable To water return To gas supply mI Welding Torch Input Power Cable must be connected to bottom hole or Posa Start will not operate properly Upper hole is to be used only when connecting the Prince spoolgun to the cabinet as a push pull system Cobramatic Owner s Manual P N 091 0246 17 INPUT POWER CONNECTIONS only apply rated voltage for cabinet d TTC REV MEM lt SCRN BD NO 182 0057 S N s ASSY NO 003 1628 Do not put input power here INPUT POWER CONNECTIONS GREENWIRE WHITE WIRE BLACK WIRE O REV MEME 182 0057 SCRN BD NO ASSY NO 003 1628 PD RYS POSA START WORK GROUND CONNECTION POSA START amp CONTACTOR CONNECTIONS R5 R4 b E MN i 9 R12 R13 Le RV4 Choose BLACK WIRE 4 RV6 115VAC CONTACTOR OUTPUT

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