Owner`s Manual Liquid Cooled Fronius with Euro
Contents
1. 111 1 621 0065 Cup 10 Assy 621 0393 Tip HD Spray 060 Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 14 CUP INSULATOR AND O RING MAINTENANCE CAUTION Power off the coolant pump before disassembling liquid cooled barrels Unscrew Retaining Nut and slide back on barrel Using a firm pull and twist action the Liquid Cooled Gas Cup can be removed from the Cup Insulator Inspect the Cup Insulator and o rings included with Insulator for wear and proper lubrication It is considered good practice to replace all o rings at the same time To remove the Cup Insulator it must be UNSCREWED and pulled from the barrel Use a rag or towel due to o ring lubrication and wrap it around the Cup Insulator UNSCREW and pull when completly unthreaded from barrel Be sure the Insulator is fully unscrewed from the threads Pulling the Insulator over barrel threads will damage the threads on the Insulator Inspect o rings on barrel for wear and lubrication It is considered good practice to replace all o rings at the same time To install the Cup Insulator it must be pushed all the way onto the barrel then screwed onto the threads If necessary place small amount of o ring lubricant on the inside diameter of the Cup Insulator this will help it slide onto the barrel Push the Insulator onto the barrel until it bottoms out screw onto barrel threads The Insulator MUST be all the way onto the barrel to assur2. qq I PYTHON Liquid Cooled Fronius with Euro Connector PRODU CTS Owner s Manual Product Python Manual 091 0586 Serial 09020001 Voltage Rating 24 VDC Revision Feb 2009 Rev B Gun Models 233 8xx With Quick Connect Coolant Hose Fittings ff d EN if D p S 4 Z q N ff A E 400 Ampere Push Pull Welding Gun Table of Contents Safety Considerations Installation Technical Specifications Support Equipment Required Gun Lead Connections Coolant Recommendations Operation General Controls and Settings Trigger Adjustment Drive Roll and Idler Rolls Accessories Insulated Drive Roll Kits Replacement Kits Snake Skins Contact Tips Barrels Maintenance Periodic Maintenance Recommended Spare Parts List Troubleshooting Troubleshooting Guide Testing The Gun Appendices Diagrams Parts List Mechanical Electrical Warranty Declaration of Conformity for European Community CE Products Note gt This information is provided for units with CE certification see rating label on unit Manufacturer s Name M K P rod u cts J n C Manufacturer s Address 16882 Armstrong Ave Irvine CA 92606 Declares that the product Pyt h O n conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Standards Arc Welding Equipment Part I Welding Power Sources IEC 60974 1
3. September 1998 Second Edition Arc Welding Equipment Wirefeed Systems IEC 974 5 September 1997 Draft Revision Degrees of Protection Provided By Enclosures IP Code IEC 529 1989 November 1989 First Edition Insulation Coordination For Equipment With Low Voltage Systems Part I Principles Requirements and Tests IEC 664 1 1992 October 1992 First Edition Electromagnetic Compatibility EMC EN 50199 August 1995 Torches And Guns For Arc Welding EN 50078 SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EQUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION OR MAINTENANCE OF THIS EQUIPMENT 1 1 INTRODUCTION This equipment is intended for ultimate application by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment Operation should not be undertaken without adequate training in the use of such equipment Training is available from many public and private schools or similar facilities Safe practices in the installation 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
4. 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 clothing dry Never work in damp area without adequate insulation against electrical shock Stay on a dry duckboard or rubber mat when dampness or sweat cannot be avoided Sweat sea water or moisture between body and an electrically HOT part or grounded metal reduces the body surface electrical resistance enabling dangerous and possibly lethal currents to flow through the body 1 Grounding the Equipment When installing connect the frames of each unit such as welding power source control work table and water circulator to the building ground Conductors must be adequate to carry ground currents safely Equipment made electrically HOT by stray currents may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel Three phase connection Check phase requirement of equipment before installing If only three phase power is available connect single pha
5. 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 during and for some time after welding or cutting if 1 Appreciable combustibles including building construction are within 35 feet 2 Appreciable combustibles are further than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors or walls within 35 feet may expose combustibles to sparks 4 Combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radiant or conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precautions have been taken After work is done check that area is free of sparks glowing embers and flames An empty container that held combustibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depending onthe combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide Python Liquid Cooled Fron
6. 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 NEVER Connect a regulator designed for a particular gas or gases to acylinder containing any other gas Tighten connections When assembling threadedconnections cleanandsmooth seats where necessary Tighten If connection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGAadapter 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 open
7. Effective August 1 2008 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY MK Products Inc Irvine California warrants that all new and unused equipment furnished by MK Products is free from defects in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warran ties of their respective manufacturers if any MK Products warranty does not apply to components having normal useful life of less than one 1 year such as relay points wire conduit tungsten and welding gun parts that come in contact with the welding wire including gas cups gas cup insulators and contact tips where failure does not result from defect in workmanship or material MK Products shall exclusively remedy the limited warranty or any duties with respect to the quality of goods based upon the following options 1 repair 2 replacement 3 where authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the
8. 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 ELECTRICARCWELDINGPRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates protected by clear cover glass This isa mustfor 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
9. equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacements parts for or information on this equipment always supply the information you have recorded above Read this Owner s Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page iv Section A Installation C C Technical Specifications Wire Capacity Aluminum Cored see 030 1 16 0 8 mm 1 6 mm Solid and Hard Wire 030 045 0 8 mm 1 2 mm Wire Speed At rated feeder input voltage 800 ipm 20 3 mpm Duty Cycle 60 All ratings are using Argon gas 400 Amps Support Equipment Required e C V or C C power source of sufficient capacity for your needs e Regulated gas supply and hoses e Properly sized power leads from power source to wire feeder and ground Gun Lead Connections Power Cable Python liquid cooled guns utilize a specially designed cable with a 6 AWG cable inside a 5 16 13 mm diameter hose Liquid coolant is used with this cable and the 10 liquid cooled gas cup the system is rated at 400 amps 60 duty cy
10. look more toward the gun motor s 24VDC circuits speed control control cable or the gun motor If nothing operates look more toward the slave motor s input micro switch leads or micro switch Testing The Gun Reference the 9 pin rectangular diagram on the Python electrical diagram for information about pin outs and locations Motor Check Remove the connector from the cabinet Using the 9 pin connector check the resistance across pins 1 and 6 motor leads The resistance across the motor should be between 5 10 ohms as the potentiometer is turned If an open circuit or short exist check the motor leads and motor independently Testing the Gun Potentiometer Using the 9 pin connector check the resistance across pin 3 wiper and pin 2 The resistance should vary from 0 5K ohms as the potentiometer is turned Check the resistance across pin 3 wiper and pin 7 The resistance should vary from 5K 0 ohms as the potentiometer is turned Testing the Micro Switch Using the 9 pin connector check for continuity across pins 9 and 5 when the trigger is pressed 9 Pin Rectangular Front View Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 7 Troubleshooting Table No wire feed at gun feeder not operating i e no slave motor or brake solenoid Circuit breaker in feeder control box open Reset Micro switch defective not being activat
11. to access the drive or idler rolls 1 Pull the cam lever away from the idler roll This will relieve the pressure against the drive roll as shown in Figure 1 Align the drive roll removal tool over the flats of the drive roll as shown in Figure 2 Hold the gun with one hand or on a table top with the other hand give the removal tool a quick snap turn in the Figure 1 CLOCKWISE DIRECTION Once the drive roll is loose continue to spin drive roll in the clockwise direction to remove the drive roll from the gun Install a new drive roll on the left hand threaded shaft The drive roll will self tighten when it is feeding wire Idler Roll Installation and Removal Fi 2 Reference Figure 3 gare 1 Using a slot type screwdriver loosen idler screw taking care not to lose lock washer under idler roll Insert new idler roll and lock washer onto screw insuring that idler groove is toward top and lock washer is beneath Tighten screw until tight NOTE Lock washer must be under idler roll or it will not turn freely Idler Roll t JIK croove Towards Top Lock Washer Idler Arm Screw Spring Figure 3 Section C Options and Accessories Insulated Drive Roll Kits Used to prevent preheating of the wire which may soften it and clog the liner This picking up of current at the drive rolls rather than at the contact tip is usually not a problem unless using too large of a contact tip or exce
12. MK s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COM MERCIAL INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO RE SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER USE OF OTHER THAN GENUINE MK PRODUCTS CONSUMABLES PARTS AND ACCESSORIES MAY INVALIDATE YOUR PRODUCT WARRANTY Warranty on the Python Welding Gun is recognized and administered by the original equipment manufacturer known as MK Products Inc 16882 Armstrong Ave Irvine CA 92606 MEE PRODUCTS www mkproducts com Tel 949 863 1234 Fax 949 474 1428 This page intentionally blank MIL PRODUCTS 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 www mkproducts com
13. 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 preventleaks and damage to their walls valves or safety devices Avoid electrical circuit contact with cylinders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a serious accident See 1 3C ICC or DOT marking must be on each cylinder It is an assurance of safety when the cylinder is properly handled Identifying gas content Use only cylinders with name of gas marked on them do not rely on color to identify gas content Notify supplier if unmarked NEVER DEFACE or alter name number or other markings on a cylinder It is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them separate from FULLS and return promptly Prohibited use Never use a cylinder or its contents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cylinders clear of areas where they may be stuck Transporting cylinders With a crane use a secure support such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to ex
14. Section D Maintenance Periodic Maintenance Your Python is designed to provide years of reliable service Maintenance of the gun will normally consist of a general cleaning of the wire guide system including barrels drive rolls and conduits at regular intervals Remove spatter build up from inside of nozzles with a hardwood stick The only parts that are subject to normal wear are the conduit contact tips nozzles barrel liners wire guides drive and idler rolls A supply of these parts should be maintained on hand The number of units in operation and the importance of minimal down time will determine to what extent spare parts should be stocked on hand See the recommended spare parts list for the most commonly replaced parts It is recommended that you blow out your conduit each time you install a new spool of wire If repairs do become necessary qualified shop maintenance personnel can easily replace any part Reference the table below for suggested Maintenance Tools used with the Python welding gun Maintenance Tools Drive Roll Removal Tool 931 0100 Tip Removal Tool 931 0002 Recommended Spare Parts Listed in the table below is the factory recommendation of the necessary spare parts which should be kept on hand for maintaining proper operation of the Python welding gun This list in no way indicates that these parts are more likely to fail or cause equipment damage This is not an indication of premature fail
15. cessive 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 supplier Mixing gases NEVER try to mix any gases in a cylinder NEVER refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps designed for the hose not ordinary wire or other substitute as a binding to connect hoses to fittings No copper tubing splices Use only standard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Suspend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly forleaks 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
16. cle The welding power connection is incorporated through the central body connector The power cable ends are threaded fittings which screw into the gun body and the central body connector These connections utilize a conductive sealant and are tightened to a specific torque setting reference lead assembly drawing in the Appendix for details Conduit The Python comes standard with a poly lined conduit for feeding aluminum wire The longer fitting with a shallow groove is used on the gun end A set Screw located on top of the gun handle secures the conduit in place The cabinet end of the conduit is incorporated into the central body connector The conduit liner extends from the central body adapter fitting and is designed to slide into the TPS 2700 wire drive up to the trailing drive rolls Gas Hose The gas hose is pushed over a barbed fitting on the gun body and secured with a plastic tie wrap The cabinet end of the gas hose is incorporated into the central body connector Coolant Connections The blue coolant supply hose is pushed over a barbed fitting on the gun body and secured with a plastic tie wrap The red coolant return hose connects through the central body connector Both hose fittings are male quick connect fittings Control Cable A multi conductor control cable is used on the Python The gun end of the cable is secured with a cable clamp and the wires are connected to the potentiometer micro switch motor and
17. d Cooled 6 Straight 6 Curved 45 12 Straight 12 Curved 45 18 Straight 18 Curved 45 Optional 300 Amp Water Cooled Barrel Assemblies Straight Water Cooled Barrel Assembly 300 Amps Curved 45 Water Cooled Barrel Assembly 300 Amps Curved 60 Water cooled Barrel Assembly 300 Amps Barrel Removal and Installation CAUTION Power off the coolant pump before removing or loosening liquid cooled cups and barrels To remove the barrel assembly loosen the patented EZ Lock taper lock nut until it is clear of the threads Pull barrel out of the gun body To replace a barrel assembly push the barrel assembly into the gun body until it clicks to a stop To assure proper seating of the barrel open the drive idler roll door in the top of the handle The rear face of the barrel should now be flush with the gun body Take care not to damage the o rings when inserting into the body Tighten taper lock nut assembly firmly so that barrel cannot rotate while welding Barrel Rotation To rotate a barrel assembly loosen the patented EZ Lock taper lock nut assembly no more than 1 turn Rotate barrel to the position of your choice and re tighten taper lock nut assembly firmly so that the barrel cannot rotate CAUTION Do not attempt to weld without the barrel being tightly secured in the gun body or damage to the barrel or body may result Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 5
18. date of delivery of equipment to the original user 1 Power Supplies and Wire Feed Cabinets 2 Weldheads CobraCooler Positioners Prince XL and Prince XL Spool Guns Python CobraMAX Cobra SX 3 Sidewinder Spool Gun Prince SG Spool Guns Modules 180 days 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 ofthe invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal surface transportation charges one way for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING 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
19. e proper coolant passage and from blocking the gas outlet orifices Push Liquid Cooled Gas Cup onto Cup Insulator Slide Retaining Nut forward and tighten Insulator Barrel Gas Outlet Orifices Correct Installation Incorrect Installation Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 15 Python Lead Assembly P N 003 2310 Series APPLY HOSE LUBRICATION INSIDE HOSE s EFORE INSTALLATION C SECURE HOSE WITH TIE WRAP APPLY HOSE LUBRICATION INSIDE HOSE BEFORE INSTALLATION gt SECURE HOSE WITH TIE WRAP APPLY COMPOUND NOALOX TO THREAD FOR INSTALLATION Python Lead Assembly No Qty Description 003 2285 003 2288 261 0094 321 0071 411 0045 e t CowuttmerF ing 491 1788 437 0265 8 1 Assy Hose Liquid Red Quick Conn 552 0211 9 1 Assy Hose Liquid Blue Quick Conn 552 0238 15 552 0238 25 552 0238 3 52 0241 3 15 0620 35 615 0620 50 43 0680 35 843 0680 50 3 843 0656 843 0658 843 0657 931 0110 931 0122 931 0132 931 0123 Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 16 552 0238 50 552 0241 50 O O o Q O e aya Python Electrical Schematic Connector Pinout GUN TRIGGER Gun Connections EN Sis 9 Pin Rectangular Front Vlew 0000000 TF OnNOMAW O Rectangular Connector Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 17 LIMITED WARRANTY
20. e 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 For production welding a separate room or enclosed bay is best In open areas surround the operation with low reflective noncombustible screens or panels Allow for free air circulation particularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See thatall persons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic Fume Prevention Comply with precautions in 1 2B Generator engine exhaust must be vented to the outside air Carbon monoxide can kill C Fire and Explosion Prevention Comply with precautions in 1 2C Equipment s rated capacity overload arc welding equipment overheat cables and cause a fire Do not It may 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
21. ed Replace switch Check switch for operation Broken electrical cable Check micro switch wires for continuity No wire feed at gun feeder operating properly Circuit breaker in feeder control box open Check motor leads for short Reset Bad potentiometer Check potentiometer with meter Broken electrical cable Check motor and potentiometer wires for continuity Wire feeds but welding wire is not energized Loose or no cable connections Check all power connections Welding power source Check power source Wire feeds erratically Dirty or worn conduit Blow out or replace conduit Wrong size contact tip See contact tip table Idler roll stuck Check for lock washer under idler roll or replace if damaged Wire feeds one speed only Bad potentiometer Check with meter Broken electrical cable Check potentiometer wires for continuity or short Bad speed control See specific feeder control owner s manual for speed control operation Wire walks out of drive rolls Idler roll upside down Rear wire guide missing Place groove in idler roll toward top Replace wire guide Consult wire feeder and welding power supply owners manuals for further problem solving solutions Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 8 Section F Appendices Python Diagra
22. en Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decomposed by the heat ofthe 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 vaporstoform phosgene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene C Fire and Explosion Prevention Causes of fire and explosion are combustibles reached by the arc flame flying sparks hot slag or heated material misuse of compressed gases and cylinders and short circuits BE AWARE THAT flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the goggled operator Sparks can fly many feet To prevent fires and explosion Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause 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
23. er is standard on the Python See below for replacement part numbers 615 0621 15 615 0621 25 615 0621 35 615 0621 50 Contact Tips Heavy Duty Contact Tip 3 8 Diameter 030 0 8mm 035 0 9mm 040 1 0mm 045 1 1mm Spray Short Spray Short 1 57 39 9mm 1 82 46 2mm 1 57 39 9mm 1 82 46 2mm 621 0390 25 621 0396 25 621 0391 25 621 0391 250 621 0391 500 621 0397 25 047 1 2mm 054 1 37mm Spray Short 1 57 39 9mm 1 82 46 2mm 621 0392 25 621 0392 250 621 0392 500 621 0398 25 060 1 5mm Spray 1 57 39 9mm 621 0393 25 621 0393 250 621 0393 500 1 16 1 6mm 074 1 9mm 085 2 16mm Spray Spray 1 57 39 9mm 621 0394 25 621 0395 25 Use of tip removal tool is recommended standard furnished with gun tsold in a quantity of 250 tt sold in a quantity of 500 Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 4 Gun Barrel Liners 931 0137 Teflon liner package 5 pieces 615 0338 Steel wire only 030 1 16 0 8 0 9mm Barrel Assemblies mau 450 Amps Water Cooled 300 Amps Water Cooled P N 003 2317 P N 003 2380 Standard on WC Optional on WC The Python comes standard with a 60 curved barrel The barrel assembly locks to the Python body using the patented EZ Lock system Optional Barrels Liqui
24. ing 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 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 Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page ii 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
25. ire 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 welding power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity while welding If in an emergency it must be disconnected guard against shock burns or flash from Switch arcing Leaving equipment unattended Always shut OFF and disconnect all power to equipment Power disconnect switch must be available near the welding power Source Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page iii For selecting a quality product We want you to take Ott pride in operating this product as much pride as we have in bringing the product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your
26. ius with Euro Connector Owner s Manual Page i 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 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
27. 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 sleeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark substantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look atan 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 b
28. ms Parts List Head Assembly Exploded Parts View Head Assembly Parts List Front Body Assembly Parts View Rear Body Assembly Parts View Barrel Assembly Parts View Cup Insulator and O Ring Maintenance Lead Assembly Parts View Electrical Connector Pinout Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 9 Python Head Assembly P N 003 2286 u z 4 a ui lt A Apply compound Noalox to contact surfaces for installation Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 10 129 0 9AW 6 uonejnsu eqni 9 00 yoso uoyyAd qouM 19100 9920 uoy d p ploWiooq S20 7 VC PU 5690 900 6 p Sway eui s pnioul 3 lpueH uoul d Jojo dens G8SL Ser ra Fa ca E31 E EA Or P X 8 4 Jepinoys og zz9i iev 8 2 X Zee I MOQ Uld 9100 1ZP 8 CXZ L OHS 9S gsio 9 OL aE ent ec ON Heal REGO Een Ajquassy peo rat E NOM Ex ET 8e x oz ee xeH mesos Levey oz CM EUR Lm EN t L L L L L L L L L v LS OL E X Oy y uong JOS LSS 8 S Ot Z8 Illud HA 49S LSS 8 X Ot v C8 Illud H4 49S OGAPZ JO OW uoul d 9 M Apog seey Assy YY 10d 0J3u0 p ds Assy Assy M epinc U9J0 100g ssy V XMS OJIN FN Jod qouy Assy uoul d O M pog 1u0J4 Assy Wy 1366111 wuy Je p weg Assy niuo44 uou d mar Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 11 Pyth
29. on Front Body Assembly P N 003 2108 Items 3 4 amp 9 available as package kit P N 005 0686 Python Front Body Assembly No 2 Description EE E Ea Not available separately Qty BENI a 325 0206 5 1 4190092 0 29x 0 047 x 0 32 Comp Spring E Ea E 511 0104 Items 3 4 amp 9 available as package kit Part number 005 0686 Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 12 Python Rear Body Assembly P N 003 2287 2 APPLY SILICONE LUBRICANT FOR INSTALLATION Python Rear Body Assembly fa Not available separately 2 6 303 006 O Ring 145 ID x 07 W 321 1104 Set Screw Mod Conduit 336 0020 Scr PH Phil 4 40 x 5 16 SST 411 0243 Tie Wrap SCR 4 Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 13 Python Barrel Assembly P N 003 2317 Apply silicone lubricant to items 5 and 6 before installing Python Liquid Cooled 60 Barrel Assembly No Qty PartNo Description I _ Notavailable separately 2 1 00322 Assy Taper Lock Bare Fs t zeron msusterBare La t 25 0361 insulator Cup with fve O Rings S s 2030010 O Ring 4891Dx 07W Pe 2 2030094 O Ring 301 IDx 07W Lr t 3130091 Retaining Ring 0 625 Shat 1 43r097 Retaining Nut AES 9 431 1774 Cup Insulator Barrel 1 1 1 1 0 70ft 615 0178 Liner Tef 0 084 ID x 0 174 OD
30. on shortened for a quicker or more responsive action A more sensitive trigger lever is produced by reducing the gap between the trigger lever and the micro switch lever By turning in the trigger sensitivity adjustment screw it closed the gap between the trigger lever and the micro switch ms lever iet This will enable the operator to increase the sensitivity of the trigger lever Sensitivity Adjustment With the wire feeder turned on with or without welding wire loaded turn the screw in until the micro switch is activated Once activated the supa NUNT PES gun and wire feeder motors will begin feeding pre setting the micro switch wire Retract the screw accordingly until the aban Ve MOVON system is deactivated and adjusted to the operators satisfaction Drive Roll and Idler Rolls The Python comes standard with a knurled drive roll and a grooved idler roll which will handle both steel and aluminum wire with diameters from 030 1 16 inch Optional insulated V groove drive rolls are also available for aluminum wire if desired see optional kits Drive roll tension is accomplished with a unique spring loaded pressure screw The Python comes from the factory with the pressure adjustment Screw preset NO ADJUSTMENT REQUIRED FOR ANY WIRE SIZE OR ALLOY Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 2 Drive Roll Installation Removal Note Neither of the handles needs to be removed
31. 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 welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryllium bearing and similar materials when welded or cut may produce harmful concentrations of toxic fumes Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration dangerously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left op
32. se 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 groundfor continuity Besure 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 three prong plug is added for connection to a grounded mating receptacle the ground lead must be connected to the ground prong only If the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken ground prong 2 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 3 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode w
33. ssively oxidized aluminum wire Insulated Groove Drive Roll Kit 005 0640 For 030 0 8 mm dia aluminum wire Includes insulated drive roll and idler roll assy Insulated Groove Drive Roll Kit 005 0716 For 035 0 9 mm dia aluminum wire Includes insulated drive roll and idler roll assy Insulated Groove Drive Roll Kit 005 0642 For 040 1 0 mm dia aluminum wire Includes insulated drive roll and idler roll assy Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 3 Insulated Groove Drive Roll Kit 005 0718 For 3 64 1 2 mm dia aluminum wire Includes insulated drive roll and idler roll assy Insulated Groove Drive Roll Kit 005 0644 For 062 1 6 mm dia aluminum wire Includes insulated drive roll and idler roll assy Replacement Kits Handle Kit Gun 005 0699 Left and right handles screws and drive roll door as a replacement for all Python guns Trigger Kit 005 0694 Trigger adjustment kit includes a spring and sensitivity adjustment screw replacement for all Python guns Micro Switch Kit Replacement micro switch assembly for all Python guns 005 0701 Potentiometer Kit 005 0695 Replacement potentiometer assembly for all Python guns Barrel Insulator Kit 005 0696 Replacement barrel insulator and taper lock nut Conduits Flat spiral steel conduit for steel amp cored wire 15 ft 4 5m 25 ft 7 6m 35 ft 10 7m 50 ft 15 2m Snake Skins A Snake Skin protective cov
34. the gun body mechanically Slack is left in the electric cable as it exits the back of the gun to prevent cable and or wire breakage The cabinet end of the control cable uses a 9 Pin rectangular connector Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 1 Coolant Recommendations Use Cobra Coolant Aluminum Protection P N 931 0060 Cobra Coolant does not contain reactive sulphur or chlorine and does not react with copper brass or aluminum The coolant flow rate should be a minimum of 15 GPH 1 qt min between 35 and 45psi Contact the re circulator manufacturer for specifications on pressure Section B Operation General The Python maintains a constant steady uniform wire feed speed regardless of curved or looped wire conduit The constant push exerted by the slave motor in the cabinet combined with the pull of the gun motor causes the wire to literally float friction free through the wire conduit The 24VDC gun motor is controlled by a three and three quarter 3 3 4 turn potentiometer in the gun handle Controls and Settings Potentiometer The laterally positioned potentiometer is located in the lower end of the handle providing up to 800 ipm 20 3 mpm with 3 3 4 turns Micro Switch The micro switch assembly consists of a normally open micro switch and solder attached leads PW Trigger Sensitivity Trigger Sensitivity Adjustment Screw The amount of trigger lever travel can be Locati
35. ure or defect in manufacture of said parts Recommended Spare Parts List Qty Part Number Description Python Liquid Cooled Fronius with Euro Connector Owner s Manual Page 6 Section E Troubleshooting Guide To aid in troubleshooting problems with your welding equipment it is best to understand the basic theory of operation for this Push Pull System The slave motor in the feeder runs at a fast constant speed but has very low torque Itis always trying to feed more wire than the gun motor wants and when the motor gets all it wants it slows the slave motor preventing a bird s nest Because of the low torque produced by the slave motor a brake system is used to prevent wire overrun rather than tension The drag adjustment in the feeder is used simply to keep the wire slightly taut so it will not pull off the spool while feeding wire The high torque 24VDC gun motor is controlled by an electric speed control located in the feeder and a pot located in the gun The gun motor potentiometer and micro switch are connected to the cabinet control box via a control cable and Amphenol connector If this cable becomes damaged a variety of symptoms can occur depending on which wire s break To test check each wire for continuity and shorts Remember the micro switch in the gun activates both the slave motor and gun motor circuits in the cabinet Therefore if the slave motor and brake solenoid operate but the gun does not
Download Pdf Manuals
Related Search