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2. YOSNISL 4061 00 318 2 u3dwnr THA HOD OVALE 96 02 600 GION31OS 3 88 82 02 500 YOLOW 3 15 HAST EL CobraMig 260 Owner s Manual Page 48 68 0 140 SNIMIAM TVEHSAINXI 092113 bl 456 BAYO N3NIAJI UY 28891 8 238083 YSMOd 6 8 2 9 2VAO8r 09v UWJX 21501 ee i DVADET YW4X T30VNCL 130VAC H d 08v 09v A 9 5 Mug TOWASE H 1120 L zS 235V 08V 0 X A BLK 13 130 dWV1 9 HOWABE Tis oce Co 9C YAMOd JN AOvC TA 19 tIW4X uU3MOd HJY 2VAS0C 21907 4 15 CobraMig 260 Owner s Manual Page 49 06 0 140 2 SNOILdO 104 1 583 092 WD 5100 98 1 N d SOL 1400 981 N d Nu5 D wo
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6. Lads MS T ZMS OSO L OVASTT WASITI JVAGIT OVASTT CobraMig 260 Owner s Manual Page 51 vLLO LZ0 JequinN jueuin2oQ NU Uasi SEIN Od 08 SdL 8059 ral CERICHI 02 AMS IVWuSHL sop fal UU UZ YS YS K gly HO L2VALNOO ia gt HOL3SLNOS L D 900 A N Al1HW4525V LAAN 224 8 a HSdWOP FLOWAY WwudW P TANYA 3DWILTIOA qs 48 MUAZ ga ran A 9 dnocz 13 LAINI OVALZ 900 1 MNIS IWH SI 7701 OTI OS LV SI 2701 OT ZH 09 LV HONS 2 LAS OL TOuINOD SOVLIOA 120 14 05 WSMOd 04 OL IOWLNOO HOWL IOA THNVd A Idd s 3 CobraMig 260 Owner s Manual Page 52 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese me BIA Donottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos
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8. 13 J1 02 RS 040504 8 ran pee 1 501 wm on 21 R13 IK EU TO COBRA FRONT PANEL SCRN BD NO 182 0057 ribbon cable es N ASSY NO 003 1628 TO COBRA FRONT PANEL 157 0022 24VAC 4PDT RELAY SOLENOID MOTOR TO TRANFORMER RELAY red wire 115 INPUT FROM INPUT TRANSFORMER red wire WHITE WIRE TO PSCP CLOSING CONTACTS CONTACTOR OUTPUT YELLOW WIRE ORANGE WIRE WORK GROUND black CobraMig 260 Owner s Manual Page 32 092 120 1402 19 4 szso ers er ONNEL 2 1 8 092 2 4000 55 7700 98 2 2 09Z A9 eld leues 2090 14860 609 1 9 049611 880507 1 9 097 40 ue ogz0 G0v vi 61 2 18 xHinN 8 00 156 amp IH 15 8 X 28 9 205 8810 922 2 Z 15 8 2 01 105 6200 922 v _8 9 4 05 000 2 0 pH IH erooese z 6 5 205 suozee 86 8 092 2 uondo w wesbeiq 06 0 1 0 2 097 49 6801 0 9 092 AO leu 1891 1710 160 23H 9 092 lddnS jewog Assy 12 600 v 092 16 2 600 1 092 0 1 2 001 Assy 981 800 1 2 092 0 seo Assy 1 600
9. 0 Lit 5 ueq maos 9220 5526 8 v 1001 OL 3207 500 666 8 6 00006 18000 v z snuiw 19xoeig 2901 uonduos q AiO ON Qr rZL 00 Ajquiassy yueg deg W030 BALIN 931312395 3S5 433H10 2 NMOHS Sv vif PAJ 30 S90 57 581 NI Sr OL VION NOUYIN3IMO Slay uf 51108 S77 ZOURCSH ONE 261 OL 59148 Wil anouon X7 MOLT 0581 M 0708 OF 750188 7018 Wan 51108 Ny BOVE SE ONE OL 52342 94 riu 557 7030 JAWSOd AddY CobraMig 260 Owner s Manual Page 42 eueidoew 16 4 4800 166 e qeo LLEL 00 Bt 002 9009 820010 ASSY ONUOD 1721 200 Pet 1 6200406 2 6 00969 uondusseq N d 2021 200 K quiessy jeueg zu 1 8 08 WALI OL NOLLOCBLLENI TVOINVHOSN X201 OL W HSYA HYlE N 301001 5810 CobraMig 260 Owner s Manual Page 43 8 6 4007 Buuds 1100 foz juejees peo edid 00 628 u v 6 punodwog 228 8 punoduio uorsouo2 nuv 6200 628 w v 21 UT 81 8 5 OW LdNv L ndv szvo esz 6
10. 20 190 023 705 6 031 Short 060 270 023 705 6 031 Short 036 Short 036 Short 040 Short 040 Short 040 Short 036 Short 035 308151 040 Short 6 TriMix 040 Short 040 Short TriMis S056He 7 125550 2 1 25 CobraMig 260 Owner s Manual Page 9 Sample Setup Aluminum The procedure described below is designed to help you familiarize yourself with this equipment and also provide you with a known procedure so that you may perform a successful weld Although these conditions may not be the exact ones needed for your specific application it will provide an example of the proper use and operation of this equipment MATERIALS NEEDED 1 CobraMig 260 system with torch of your choice 1lea 6 Gas Cup 3 8 10ea Contact Tips 044 621 0001 spray arc 1 Spool of clean 035 4043 Wire 1ea Oylinder of Argon gas w Regulator Flowmeter and Hose lea Stainless Steel Wire Brush 20 Weld coupons 2 X 6 X 1 8 6061T 6 Aluminum PROCEDURE Machine Set up Hook up the CobraMig 260 according to installation instructions in owners manual Install wire onto spindle and thread wire through torch according to wire threading procedure Make sure Wire Type switch is in the 030 035 ALUM position Press gun trigger and set gas flow to 25cfh Set the VOLTAGE control on front panel to 8 4 and the RANGE switch to Lo Turn the START to the off position Place the
11. POLARITY JUMPER in the positive connector and the ground clamp in the negative connector Press the gun trigger for six 6 seconds Adjust the wire feed speed until 32 inches of wire is measured in 6 seconds this equals 320 ipm Using the S S brush brush two weld coupons until the oxide is removed Position Material and Tack Weld Position the coupons on the work table to form a T fillet Place the gas cup near the work piece and tack weld one end Remember to provide pre purge before each weld by cracking the torch trigger and holding it for a few seconds before fully pressing the trigger This will reduce built up pressure and aid in arc starting Tack weld the other end Deposit Weld Securely clamp the workpiece to the table so that you have a clear view of the arc weld puddle and unwelded portion of the joint at all times Welding is done from right to left for a right handed operator and from left to right for a left handed operator known as Push or Forehand The torch CobraMig 260 Owner s Manual Page 10 should bisect the 90 degree angle made by the joint and a push angle of from 10 to 15 degrees in the direction of travel is used Strike an arc and move the torch progressively along the joint at a smooth steady rate Most operators unfamiliar with aluminum tend to move too slow and consequently overheat the plate A travel rate of 25 to 35 ipm should be used The arc should sound smooth and the weld
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15. 45 N 3 Strike an arc and move the torch progressively along the joint at a smooth steady rate A travel rate of 25 to 35 ipm should be used 4 The arc should sound smooth and steady If spatter occurs and the arc pops reduce the wire feed speed until the arc smooths out gU gt n u u L If u m L W z a3a3a amp 50 100 150 200 250 300 350 350 400 WELDING CURRENT AMPS DCRP Source Mg Fandacak Lirde Burnoff Characteristics Mild Steel Wire The above condition provides 16 5 volts and 89 amps If exact volts and amps are required purchase meter kit P N 005 0585 CobraMig 260 Owner s Manual Page 15 Section C Section D Accessories Optional Kits Remote Voltage Kit 005 0584 Enables the power supply to be controlled from 25 pendant LCD Meter Kit 005 0354 Digital Volt and AMp meters with memory feature to hold and alternately display volts and amps for 1 minute after welding Timer Kit 005 0586 Add on panel includes spot timer and stitch weld option Torch Hanger Kit 005 0169 Allows you to hang torch on side of power supply Easilly hooks on and off Gas Control Trigger Latch Kit 005 0674 Adds Pre Post Purge and Trigger function options Water Flow Kit 005 0253 Monitors water pressure in torch No water no arc Maintenance Routine Maintenance Maintenance of the torch will normally consist of a gene
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17. 91 81 8 01 oe LdNv L ndv oovo esz 91 14 8 ere LdNv L 9 10 68 fri 198 1 ndy 110 68 et SIN 81 8 8 01 ere 1dNv L 014 12110 684 zt Josues uano 8606 869 LE Wego 2191 169 or __________ 950 9900196 6 660 226 8 15 GLE 06 9 Ud Ud jos sooo 9ce 2 15 9 4 1611448 2920 666 0094870 x 011670 11 Jousem 1220 1661 8 us 9 181 12000 168 _ 8 6 91 8 6 105 9400 6868 1 6 uo usng pus 11200 616 z ueig esog 1084 6 Assy 2 200 1 uoljdiiosaq 40 ON 2902 200 Ajquiessy 083143412345 ASIMYFHLO 5537 5310 SQv3uH1 31vN OL 61 W31l 3AIS3HOV 0 15001 043 NV SQv3MHL OL 771 WALI ONDOdAOO 3AISOMMOO IINY V SQv3MHi OL 81f WILI 3AIS3HOY SNI901 QV3MHl 50 11114 333H1 3 1 40 HOV3 404 34n03204d 1 3448 SQNOO3S SI 15 S NVHL 3HOM dOSQ LON LISAN NOIIO3NNOO JHL 758 11114 131100 3 1 01 MIV 30 154 09 AT131VAIXONddV AlddV 7 9 2 11114 LIINI 1 ONId v 62 CobraMig 260 Owner s Manual 44 xig 2 10 deus 5680 1566 1 01 GO M 92 000 Assy 2991 00 6 14 55 710 987 8 __ zooor 1 Oy xoo1xeH N
18. BOARD IS MOTOR LEADS ARE SHORTED DEFECTIVE OR MOTOR IS DEFECTIVE NOTE MOTOR CHECK a Remove the amphenol connector from the cabinet b Using an OHM meter check the resistance across pins A and B motor leads on torch amphenol The resistance across the motor should be between 5 and 10 ohms c open circuit or short circuit condition exists check the motor leads and motor independently CobraMig 260 Owner s Manual Page 22 EB FLOW CHART EB SYMPTOM COBRA MAIN BOARD F1 AND F3 FUSES ARE OK BUT NO WIRE FEED AT TORCH AND FEEDER NOT OPERATING PROBLEM AREA K2 RELAY ON COBRA MAIN BOARD TRANSFORMER RELAY OR TORCH MOUNTED MICRO SWITCH IS COBRA MAIN BOARD F1 FUSE OK GO TO FLOW CHART 3 IS THE COBRA FRONT COBRA MAIN BOARD L E D POWER LIGHT ON F1 FUSE IS BLOWN UNPLUG TORCH AMPHENOL FROM COBRA FRONT PANEL TRANSFORMER RELAY IS DEFECTIVE OR CABLE ASSEMBLY MISWIRED SEE NOTE JUMPER E AND F ON EITHER OF THE COBRA FRONT PANEL AMPHENOL CONNECTORS IS WIRE FEEDING OK YES COBRA I MAIN P C BOARD K2 RELAY MICRO SWITCH IS DEFECTIVE IS INOPERATIVE OR LOOSE J2 J3 CONNECTORS ON MAIN BOARD NOTE When the Cobra front panel power switch is on 115VAC is sent to the coil of Transformer Relay and 27 is sent to Cobra main board When the torch is triggered then K2 on Cobra main board is energized This action transfer 115 VAC to the slave motor brake solenoid and controlled volt
19. Lower the wire retainer bar onto the spool Threading Procedure Place wire size selector switch on front panel to the correct position for the wire being used Loosen end of wire from spool and cut off any kinked or bent portions Unreel and straighten out first 6 to 8 of wire Raise wire type lever to center position Route wire into inlet guide along drive roll groove and into wire conduit Flip wire type lever to show type of wire being used ALUM or STEEL Tighten the torch pressure adjusting knob so the wire will be picked up and fed through the contact tip Proper tension is achieved when wire does not slip if a small amount of pressure is added to the wire as it exits the tip Wire Retainer Bar The design of the patented Cobramatic Wire Retainer Bar performs two very important and very basic functions of the wire feeder a spool drag tension and b wire maintenance on the spool The spool drag tension is set by lowering the wire retainer bar onto the wire inside of the spool The spring tension of the wire retainer bar applies enough pressure on the spool so that when the torch trigger is released engaging the brake pall the spool does not overrun kicking wire off the spool Wire maintenance on the spool is performed by the applied pressure of the wire retainer bar spread across the coiled wire on the spool The replaceable pad P N 437 0255 of the wire retainer bar is designed to hold the wire on the spool maintainin
20. 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 Table of Contents Saftey Guidelines Installation Technical Specifications Machine Location Input Power Connections Machine Grounding Welding Torch Connections Shielding Gas Connections Coolant Connection Wire Threading Procedure Operation General Description Controls and Settings Posa Start Operating Procedure Process Settings Sample Setup Aluminium Sample Setup Stainless Sample Setup Steel Accessories Optional Kits Maintenance Routine Maintenance Power Supply Testing the Feeder Testing the Torch Testing the Speed Control Troubleshooting Warning Troubleshooting Guide Troubleshooting Flow Charts Diagrams Parts List Table of Contents Main PC Board Mechanical Electrical Warranty Repair Stations Safety Warnings Warranty Section Installation Technical Specifications Wire Diameter Capacity 030 1 16 ALL Types 023 hard wires Wire Capacity 12 Standard Insulated or Non Insulated Power Input user selectable by jumpers 208 VAC 60 Hz 50 amperes single phase 230 VAC 6
21. bajo carga con la piel a ropa moja da Aislese del trabajo y de la tierra Ne laissez nila peau ni des v te ments mouill s entrer en contact avec des pieces sous tension lsclez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e electro dos com a pele ou roupa molhada sale se da e terra e Hr ESRB Ie nit RR AR CE X HA HAR e cA Oz Nas olg Gal sl uie Yje Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout materiel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos A e EiS e254 Hc ola ALIAM a gll eda Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prol amp gez vos yeux vos oreilles et volre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vis
22. bead should be bright and shiny If spatter occurs and the arc sounds like a short arc condition decrease the wire feed speed or if the weld looks cold increase the voltage until a smooth spray transfer is achieved 5 a gt m m m n U m n m n U u z u 5 0 50 100 150 200 250 300 350 350 400 WELDING GURRENT AMPS DGRP Source Mig Welding Handbook Burnoff Characteristics 4043 wire Linde The above condition provides 20 volts and 112 amps If exact volts and amps are required purchase meter kit P N 005 0585 CobraMig 260 Owner s Manual Page 11 Sample Setup Stainless The procedure described below is designed to help you familiarize yourself with this equipment and also provide you with a known procedure so that you may perform a successful weld Although these conditions may not be the exact ones needed for your specific application it will provide an example of the proper use and operation of this equipment MATERIALS NEEDED lea CobraMig 260 system with torch of your choice 1lea 6 Gas Cup 3 8 10ea Contact Tips 040 621 0077 short arc 1ea of clean 035 stainless wire E308L SI lea Cylinder of 90HE 7 5AR 2 5CO2 gas w Regulator Flowmeter and Hose 20 Weld coupons 2 X 6 X 16 gauge stainless steel PROCEDURE Machine Set up Hook up the CobraMig 260 according to installation instructions in owners manual Install w
23. feeder not operating i e no slave motor or brake solenoid CobraMig 260 Troubleshooting Guide CAUSE Cobra I Main board fuse blown REMEDY Check 115 VAC circuit replace fuse Micro switch defective not being activated Replace switch Check switch for operation Relay K2 on Cobra I Main Board is inoperative Check Replace K2 relay Loose J2 J3 P C Board connectors on Cobra Board Check J2 J3 connection Broken electrical cable Check for continuity replace cable if needed Brake solenoid Slave motor inoperative Solenoid Slave motor defective Check for open circuit Relay K2 inoperative Check for 115 VAC across J4 1 2 Check relay K2 if 115 VAC not present No wire feed at torch feeder operating properly Bad torch Potentiometer Check potentiometer with meter Bad torch motor Check Replace motor Broken Electrical Cable Check motor and potentiometer wires for continuity Bad Speed control PCB Check Replace P C Board Wire feeds at one speed only Torch pot is defective or torch cable is shorted Check Replace torch pot Cobra main board is defective Check Replace Cobra Main P C Board No weld output wire feeds ok Loose or No cable connections Check all power connections Power Supply control board is defective Check Replace Power Supply control board Loose con
24. in workmanship or material In the case of MK Products breach of warranty or any other duty with respect to the quality of any goods the exclusive remedies therefore shall be at MK Products option 1 repair 2 replacement 3 where authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Upon receipt of notice of apparent defect or failure MK Products shall instruct the claimant on the warranty claim procedures to be followed As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user 1 Torches Weldheads amp Water Recirculators 2 All Other Equipment 3 Repairs MK Products Inc 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Notification of any failure must be made in writing within 30 days of such failure Acopy ofthe invoice showing the date of sale must accompany products returned for warranty repair or replacement equipment returned to MK Products for service must be pr
25. input cable connects this contact to the frame of the welder This ensures proper grounding of the welder frame when the welder plug is inserted into the receptacle LINE 2 one Chassis Ground Welding Torch Connections Work Cable Connect a work lead of sufficient size and length see table below between the proper output stud on the power source and the work Be sure the connection to the work makes tight metal to metal electrical contact Poor work lead connections can result in poor arc initiation poor weld results and activation of the ground lead protector Work Lead Lengths Current 60 Up to 50ft 10 1 00ft Duty Cycle 15 2m 15 2 30 4m 300A 0 53mm 0 67mm 400A 00 67mm 00 85mm 500A 00 67mm 00 85mm 600A 000 85mm 000 107mm Control Cable The 7 Pin W Clocked connector screws onto the mating receptacle on the front panel of the wire feeder This provides all electrical signals motor voltage potentiometer control amp trigger to and from the feeder to the torch CobraMig 260 Owner s Manual Page 3 Wire Conduit I nlet Front panel access to attach conduit to front of slave motor assembly Power Cable I nlet Front panel access to attach power cable air or water to top of power block Gas Inlet Front panel access to attach gas hose to bottom fitting of power block Water Inlet For Water Cooled Torches Front panel access to connect the water hose to the
26. only it does not represent actual inches per minute but a percentage of the speed dialed by the torch potentiometer REMOTE VOLTAGE See Optional Kits This option enables the weld voltage control to be adjusted from a remote hand pendant TI MER KI T See Optional Kits This option provides Spot Welding or Stitch Welding operation from the Cobramig 260 In the Spot Mode timing can be adjusted for a welding time of 5 to 4 seconds and a Burnback time of 0 to 25 seconds In the Stitch Mode the unit can be commanded to Turn On from 5 to 4 seconds and Turn Off from 25 to 1 second DI GI TAL VOLT AMP METER See Optional Kits The LCD meter provides an alternating display of Volts and Amps during and after welding for up to 1 minute using a built in memory GAS CONTROL TRI GGER LATCH See Optional Kits The Gas Purge Trigger Latch Kit is a dual function kit The kit includes an easy to install interface control PC board a 24VAC solenoid for pre and post purge control a modified valve stem for the welding torch and a front panel Switch for activating the Trigger Latch mechanism The gas control times have been preset to 0 5 seconds pre purge and 1 0 seconds post purge This offers an optimum amount of inert gas shielding prior to striking the arc and after the arc has been extinguished CobraMig 260 Owner s Manual Page 7 The Trigger Latch mechanism gives the operator the flexibility of normal trigger operation pull
27. output voltage It is infinitely variable between the ranges The scale surrounding the WELD voltage control is a relative scale only it does not represent actual voltage RANGE SWITCH The LO range provides from 12 to 22 volts and the HI range provides from 22 to 32 volts POLARITY J UMPER The polarity jumper allows for easy reversal of the electrode polarity For Reverse polarity DCRP plug jumper into the plus connector below jumper plug For Straight polarity DCSP plug jumper into minus connector below jumper plug The work cable plugs into whichever connector is not used for the polarity jumper COBRAMATI C CONTROLS ON OFF SWITCH Placing the switch in the ON position energizes the feeder circuitry and the power indicator light WIRE SIZE SELECTOR SWITCH The wire size selector switch changes the torque of the slave motor for the wire you are using When in the 030 035 aluminum only position the slave motor produces approximately 2 Ibs inches and approximately 3 Ibs inches when in the all other wires position NOTE Operating the cabinet with the switch in the wrong position will cause wire feed difficulties POSA START CONTROLS The Start Control selects a Run in Speed which is slower than the actual welding speed After arc initiation the wire feed speed control is transfered to the potentiometer in the torch handle The scale surrounding the Run in Speed Control is a relative scale
28. 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 equip ment 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 pro tected 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 pres
29. 0 Hz 45 amperes single phase 416 VAC 60 Hz 26 amperes single phase 480 VAC 60 Hz 24 amperes single phase Rated Output 60 duty cycle 260 amperes 26 8 7KW 2 ranges 12 22V 22 32V 40 Vdc max OCV 230 Ibs dry 260 Ibs shipping 15 w x 32 h x 34 d For Use with Torch Prefix Numbers 210 211 212 213 225 226 SUPPORT EQUI PMENT REQUI RED Regulated Gas Supply and 6 Gas Hose Water Source and Hose Capable of Providing a Minimum of 1 qt min at 45 p s i when using water cooled torches Machine Location The unit should be placed in a location where it can be protected from damage For the longest unit life and best efficiency avoid locations exposed to dust corrosive fumes high ambient temperatures or high humidity Moisture and dirt on components can cause corrosion and or shorting of circuits Adequate air circulation is needed at all times in order to prevent overheating and possible damage to internal parts Maintain at least 12 inches of free air space on all sides of unit An eye bolt and mounting hole is provided for lifting unpacking purposes Do not have the gas cylinder or any other equipment mounted to this unit when using the lifting eye bolt Do not suspend this unit overhead Input Power Connections This welding power supply is designed to be operated from single phase 208 230 416 or 480 VAC 60 Hz input power and is provided with Voltage Links for converting power requirements in the f
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31. 2907 Asse ejpuids 91 1961 190 9219 1908119 95 19043 2 2 ILI HO P 22 S WALIMOSS gt PH INGLIHOS Z QE INS LI HOA F WALI HOH 9 OC 8303 N31I 8047 CobraMig 260 Owner s Manual Page 40 pesn jou 82 9 v 6 9 SWA ________ 69018669 PIE LXZE B 14 Ud 06 1600 96 ec ennosioid 6060 192 091 ze v 4007 6000 666 v Le 8 Heis x 200 666 9 OE 2 1 X 22 8 14 Ud MODS ocoo oee z 62 9160 1982 014 1015 5200 6626 oeu 2900 9898 2200 228 uv ve 81 91 s nN 2100 196 z Ez 91 9 l4 6600 166 z zz 91 9 4007 Buds 0100 666 z 12 X 81 91 6 195 6200 626 z oz ssej e1qi4 5 2010 192 uv 6 VOO noop epora 8800 92 Xs 8 2721 200 1 8 6 X 0 14 Ud 0100 966 z 9 piel X 1200 66 2 St osen eooo fer Assy 1900 98 1 21 2 1 91 8 6 2500 622 8 6 4901 Buds 1100 66 OL 2 1 X 26 98 I d ud maos 9000 66 z 8 1 15 6200 666 v
32. 7 CobraMig 260 Prodcut Description MT PSAWE MK Manual Part Number 091 0506 MK Form Number CM260MT OM PRODUCTS EE _ Effective with serial number Voltage Ratings Printing Date October 2001 This manual applies to the following CobraMig 260 186 003 model numbers CobraMig 260 Power Suppl y Wire Feeder 208V 230V 416V 480V Multi Tap Voltage Version 16882 Armstrong Ave Irvine California 92606 TEL 949 863 1234 949 474 1428 www mkproducts com 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 appli cation by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equip ment Operation should not be undertaken with out adequate training in the use of such equip ment 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 informa tion provided with the equipment and the use of common sense Rules for safe use are gen erally provided by suppliers of welding power Sources compressed gas suppliers and elec trode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safet
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34. ER T1 DIODES CAPACITORS START TURN OFF ALL POWER AND DISCONNECTS USING AN OHM METER MEASURE THE RESISTANCE AT J6 1 WELD VOLTS AND J6 2 WORK GROUND ON COBRA I MAIN BOARD READING SHOULD BE APPROX 25 OHM DISCONNECT DIODES FROM POWER TRANSFORMER T1 POWER TRANSFORMER T1 ANODE D1 FROM T1 6 IS DEFECTIVE ANODE D2 FROM T1 5 IS READING AT J6 1 AND J6 2 APPROX 25 OHM NOW SET OHM METER ON DIODE CHECK MODE CAPACITORS SHORTED MEASURE DIODE RESISTANCE PLACE LEAD ON ANODE AND LEAD ON HEATSINK READING SHOULD BE APPROX 300 TO 800 OHMS PLACE LEAD ON ANODE AND LEAD ON HEATSINK READING SHOULD BE OPEN DIODE IS DEFECTIVE CobraMig 260 Owner s Manual Page 27 FLOW CHART SYMPTOM POSA START NO WORKING PROPERLY PROBLEM AREA CURRENT SENSOR COBRA I MAIN BOARD READ POSA START SECTION TO CHECK POSA START POT REMOVE J2 ON COBRA I MAIN BOARD TURN ON POSA START SWITCH USING OHM METER METER RESISTANCE AT J2 1 AND J2 2 RIBBON CABLE READING SHOULD VARY FROM 0 TO 100K OHM IS READING OK PLUG IN J2 sit DEFECTIVE REMOVE J1 ON COBRA I MAIN BOARD USING OHM METER MEASURE RESISTANCE OF CURRENT SENSOR THE READING SHOULD BE OPEN IS READING OK USING A VOLT METER MEASURE THE WELD VOLTAGE CURRENT SENSOR IS DEFECTIVE AT J6 2 AND J6 1 ON COBRA MAIN BOARD CLOSED ALL THE TIME SET POSA POT 1 4 TURN ON SET TORCH POT MAXIMUM CW TURN ON COBRAMIG 260 TRIGGER AND ADJUST WELD VO
35. LTS TO APPROX 15V JUMPER J1 1 AND J1 2 ON COBRA 1 MAIN BOARD DOES TORCH MOTOR SPEED INCREASE WHEN JUMPER IS ADDED COBRA I MAIN BOARD CURRENT SENSOR IS DEFECTIVE IS DEFECTIVE OPEN ALL THE TIME CobraMig 260 Owner s Manual Page 28 FLOW CHART ETN SYMPTOM NO WELD OUTPUT REMOTE VOLTAGE POT INSTALLED PROBLEM AREA JUMPER ON POWER SUPPLY CONTROL BOARD PSCB IN WRONG POSITION REMOTE PENDANT IS DEFECTIVE IS REMOTE VOLTAGE KIT 005 0584 INSTALLED GO TO FLOW CHART 7 DO YOU WANT TO USE PENDANT OR FRONT PANEL VOLTAGE CONTROL KNOB PENDANT SET JUMPER ON BACK OF WELD SET JUMPER ON BACK OF WELD VOLTAGE CONTROL PANEL TO THE VOLTAGE CONTROL PANEL TO THE PANEL POSITION REMOTE POSITION AND CHECK THAT THE PENDANT IS PLUGGED INTO THE FRONT PANEL CONNECTOR IS FRONT PANEL VOLTAGE IS REMOTE VOLTAGE KNOB WORKING NOW PENDANT WORKING NOW YES READY TO WELD GO TO FLOW CHART 7 READY TO WELD NOTE WHEN THE REMOTE VOLTAGE POT KIT IS INSTALLED AND THE JUMPER IS INTHE REMOTE POSITION YOU MAY ONLY USE THE REMOTE POT THE FRONT PANEL VOLTAGE POT IS DISABLED UNTIL YOU MOVE THE JUMPER BACK TO FRONT PANEL POSITION CobraMig 260 Owner s Manual Page 29 FLOW CHART SYMPTOM CONTACTOR CLOSED WIRE ALWAYS ENERGIZED PROBLEM AREA POWER SUPPLY CONTROL BOARD K2 RELAY MAIN BOARD TRIAC START YES IS PSCB LED D7 ON JUMP TP1 5 IS PSCB LED D12 ON IS PSCB FUSE F1 OK PSCB I
36. Meter to check resistance across pin D wiper and pin A of Torch plug Should vary from 0 to 5k ohm while turning pot CobraMig 260 Owner s Manual Page 25 FLOW CHART SYMPTOM NO WELD OUTPUT NO VOLTAGE CONTROL PROBLEM AREA POWER SUPPLY CONTROL PSCB THERMOSTAT TRIAC CONTACTOR SIGNAL PWR SWX BOARD START IS PSCB LED D7 ON 5 DOES IT HAVE 12 VOLTS JUMPER TP1 TO TP5 ON PSCB IS PSCB F1 FUSE OK NO YES NO IS PSCB LED D12 ON YES ESGB IS DEFECTIVE TRANSFORMER RELAY IS DEFECTIVE OR PSCB IS DEFECTIVE SM REPOSITION JUMPER DISCONNECT FUSE TO TP2 AND TP4 USING VOLTMETER MEASURE WELD VOLTAGE AT COBRA MAIN BOARD 6 1 AND J6 2 DOES OUTPUT VARY WHEN VOLTAGE KNOB IS TURNED APPROX LO 10 32VDC 29 40VDC REPOSITION JUMPER TO TP2 ADD SECOND JUMPER TO TP1 AND TP3 AND TP5 IS WELD OUTPUT AT MAXIMUM DOES OUTPUT VARY WHEN APPROX 35 40VDC VOLTAGE KNOB IS TURNED APPROX LO 10 32VDC 29 40VDC PSCB IS DEFECTIVE TRIAC IS DEFECTIVE K2 RELAY ON THERMOSTAT COBRA MAIN TERMINALS LOOSE OR BOARD DOES NOT THERMOSTAT IS SEND CLOSING DEFECTIVE CONTACT SIGNAL OPEN ALL THE TIME OR TORCH SWITCH IS DEFECTIVE TRIAC RESISTANCE CHECK Use meter in Diode mode Pin 3 to Pin 4 2 3 Pin 1 to Pin 2 open CobraMig 260 Owner s Manual Page 26 FLOW CHART SYMPTOM DISCONNECT FUSE BLOWS WHEN TORCH IS TRIGGERED PROBLEM AREA POWER TRANSFORM
37. RR PH EU BU TTE TERR SAILS Beale AA lay 44 al e Aul jja gl Jaai Ag as Al EAL glasi 0 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue corrente antes de fazer servi o toque as partes eletricas nuas EF ERAT v k T 9 C Tau e kg X MEER As aui 24 e Do not operate with panel or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschuteverkleidung in Betrieb setzen Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e MERITO fE eggo wel dem a jual da diy agni Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG EROR Chinese K
38. S DEFECTIVE REMOVE JUMPER PSCB IS DEFECTIVE TRANSFORMER FROM TP1 TP5 RELAY IS DISCONNECT J6 ON PSCB DEFECTIVE OR NO AC INPUT CHECK DISCONNECT FUSE CONTACTOR STILL CLOSED IS THE WELDING USING OHMMETER VOLTAGE CHECK FOR CONTROLLABLE CONTINUITY ACROSS J6 3 AND J6 4 ON MAIN PC BOARD PSCB IS DEFECTIVE DISCONNECT J5 ON THE PSCB NO CLOSED SIGNAL PSCB IS DEFECTIVE SF EO PEL REPLACE IF IS THE WELDING NECESSARY WIRE STILL YES ENERGIZED NO REPLACE TRIAC PSCB IS DEFECTIVE CobraMig 260 Owner s Manual Page 30 Section Appendices Diagrams Parts List Main P C Board Connections 001 3850 Top Level 003 2134 Power Supply Assembly 003 1586 Multi Tap Bracket Assembly 003 1584 Logic Transformer Assembly 003 2131 Wire Feeder Assembly 003 2135 Front Panel Assembly 003 2130 Back Panel Assembly 003 2132 Deck Assembly 003 1774 Heat Sink Assembly 003 1714 Cap Bank Assembly 003 1703 Control Panel Assembly 003 2063 Cobramatic Power Block Assembly 003 2109 42 VAC Front Panel Assembly 003 2061 Cobramatic Spindle Brake Assembly 003 2078 Slave Motor Assembly 071 0321 Universal Input 071 0390 Universal Input with Options 071 0370 Front Panel 071 0714 Power Supply Control Board CobraMig 260 Owner s Manual Page 31 STANDARD CONNECTI ONS MAI N BOARD REMOTE POT JUMPER For cabinet pot operat ion Remo jumper connect cabinet pot cable to TO CURRENT SENSOR c Start J14
39. SYMPTOM FUSE ON COBRA I IS BLOWN WHEN TORCH IS TRIGGERED PROBLEM AREA COBRA MAIN BOARD SLAVE MOTOR OR BRAKE SOLENOID NOTE The 115VAC on Cobra I Main P C Board is protected by Fuse If F3 continually blows unplug J4 Brake Solenoid J7 Slave Motor from the P C Board Replace the fuse and retrigger If fuse does not blow isolate the problem by plugging in J4 and J7 one at a time until the fuse blows START Resistance Check Slave Motor J7 6 to J7 1 2 150 ohm F3 FUSE BLOWN J7 4 to J7 2 150 ohm COBRA MAIN BOARD b Brake Solenoid J4 1 to J4 2 80 ohm UNPLUG CONNECTORS J4 BRAKE SOLENOID J7 SLAVE MOTOR RE TRIGGER TORCH IS COBRA MAIN BOARD F3 FUSE OK GO TO FLOW CHART 3 COBRA MAIN BOARD F1 FUSE IS BLOWN PLUG IN J4 RE TRIGGER TORCH IS COBRA MAIN BOARD YES F3 FUSE OK SLAVE MOTOR 15 SLAVE MOTOR IS PLUG IN J7 DEFECTIVE RE TRIGGER TORCH IS COBRA MAIN BOARD F3 FUSE OK BRAKE SOLENOID IS OK BRAKE SOLENOID IS DEFECTIVE CobraMig 260 Owner s Manual Page 21 FLOW CHART SYMPTOM COBRA MAIN BOARD F1 FUSE IS BLOWN PROBLEM AREA COBRA MAIN BOARD OR TORCH MOTOR IS COBRA MAIN BOARD F1 FUSE OK UNPLUG TORCH AMPHENOL FROM COBRA FRONT PANEL GO TO FLOW CHART 4 COBRA I MAIN BOARD F1 AND F3 ARE OK BUT WIRE FEED AND TORCH NOT OPERATIVE JUMPER E AND F ON EITHER OF THE COBRA FRONT PANEL AMPHENOL CONNECTORS IS COBRA MAIN BOARD F1 FUSE OK COBRA MAIN P C
40. Y 8900 981 10 01 2 01 DV 1nd oce 0600 60 40 Cj Nid OL C 2 lt OBST 651 4018 Nid OL d M 9 181 OL N3349 89 W3ll V3 P 8 aL 01 3380 2 W3u 803 v3 v 5 181 01 NMOMB 8 181 OL 39NvUO 1 181 OL MOTA 00 30 Zh OL YOLIBNNOD 291 00 30 1 67 01 8291 00 20 Z Sr 01 10 91 30 OL 6910 15 30 01 39NvuO S3HvVAQuVH TIVLSNI 180338 NE 7 5031 WOHs 381903 HSINEVA 440 3dVH28 vi Con Sz WAL 53903 123108d 2 Cm 62 00 53003 1031088 N17 Vv SNOILINYLSNI ATEWASSY CobraMig 260 Owner s Manual Page 35 qi 5 0 uoneinsu 2610 1902 1 921 z 94 4 970 192 uos 9 6 uuoo 606069 1 9 26g 1 600 wa 01 60 68 2 22 781 uod 1000 58 2 6 2081 22 105 88 Om 600088 8 2 21607 6800 2681 uondusseq 7891 200 K quiessy 1euuoJsueJ 21601 CobraMig 260 Owner s Manual Page 36 8820 269 9 peq 227 9 2920 2698 vi 092 jeued t 6091 1 zi o iejpuew 809 169 Buuds 0600 61
41. age to the torch motor TRANSFORMER RELAY VOLTAGES When torch trigger is depressed 115 COM White Pin A to 115 HOT Neu Pin B 115 27 COM Brown Pin 7 to 27 VAC HOT Orange Pin 9 27 VAC 27 COM Yellow Pin 4 to 27 VAC HOT Blue Pin 6 27 CobraMig 260 Owner s Manual Page 23 SYMPTOM FLOW CHART NO WIRE FEED AT TORCH FEEDER OPERATING PROPERLY PROBLEM AREA COBRA MAIN BOARD TORCH POT OR TORCH MOTOR GO TO FLOW CHART COBRA I MAIN BOARD F1 FUSE IS BLOWN SYSTEM OK CABLE IS BROKEN OR TORCH POT IS DEFECTIVE CABLE IS BROKEN OR TORCH MOTOR IS DEFECTIVE NOTES 1 Check TORCH POT at plug connector a Testing the poteniometer W Clocked Using Ohm Meter to check resistance across pin D wiper and pin C of Torch plug Should vary from 0 to 5k ohm while turning pot Using Ohm Meter to check resistance across pin D wiper and pin G of Torch plug Should vary from 0 to 5k ohm while turning pot IS COBRA MAIN BOARD F1 FUSE OK CHECK FOR LOOSE CABLES AT COBRA FRONT PANEL AND MAIN P C BOARD IS THE TORCH WORKING OK NOW WAS METER READING OK WAS METER READING OK b Testing the poteniometer S Clocked Using Ohm Meter to check resistance across pin D wiper and pin C of Torch plug Should vary from 0 to 5k ohm while turning pot Using Ohm Meter to check resistance across pin D wiper and pin A of Torch p
42. ated with welding and conditions can change from day to day due to any number of external influences MK Products Customer Service Department is ready to assist you should you need help setting up your equipment in the field Please be aware that we do not specialize in process parameter problems but are willing to share our resources if it might help you achieve better quality welds MK Products reserves the right to change any settings associated with this welding guide you may request the most up to date guide by calling our Customer Service department during normal working hours To use chart locate material thickness and wire diameter Then read across for values to use REF is the value dialed on the Weld Voltage knob on the front panel this is only a reference value CobraMig 260 Welding Guide Material IPM Dia Alloy Type Cup Gas Flow Range Xfer Ref 04 370 030 4043 40 Spray 6 20 Low Shot 32 930 4043 040 Spray 6 Ar Low Spray 035 4043 4 ay Low Short 030 4043 040 Spray 6 Ar 20 Low Shot 25 4 i 035 4043 044 Spray 6 20 Low Spray 720 4 L L Sr 62 035 5355 O44 Spray 8 Low Sra 035 5356 044 Spray 8 Ar 20 Low Spray 92 045 4043 60 Spray 8 Ar 25 Low Spray 76 250 370 045 4043 060 Spray 8 25 High Spray 22 475 080 Spray
43. autions in 1 2 The welding arc is intense and visibly bright Its radiation can damage eyes penetrate light weight clothing reflect from light colored sur faces 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 leg gings 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 unde
44. bers Link match numbers on Link SHOA 230 Volts with numbers on Terminal with numbers on Terminal Strip Always read Voltage Strip Always read Voltage right side up on Link right side up on Link IMPORTANT This unit has low and high power terminal blocks TB1 amp TB2 that must have the SAME jumper configuration Put BOTH Voltage Links to same terminal block screws SEE SAMPLE HOOK UP DIAGRAM BELOW FOR EXAMPLE OF VOLTAGE LINK PLACEMENT CobraMig 260 Owner s Manual Page 2 Route input cable through strain relief and connect to power block as shown in the diagram following Tighten strain relief and replace side panel with all hardware removed Machine Grounding Before starting the installation check with the local power company if there is any question about whether your power supply is adequate for the voltage amperes phase and frequency specified on the welder nameplate Also be sure the plannted installation will meet the U S National Electrical Code and local code requirements This welder may be operated from a single phase line or from one phase of a two or three phase line The CobraMig 260 is supplied connected for 480 Volt input If the welder is to be operated on another voltage it must be reconnected according to the instrucitons WARNING Make certain that the input power is electrically disconnected before removing the screw on the reconnect panel access cover A green wire in the
45. braMig 260 Owner s Manual Page 47 6850 140 QUVONVIS 109 TVSU3AINN 092072 S120003d OL WSL O OL 01147 wad Wr TOSLNOOAO ITOASLO WN XIddnS M Od NOS OL Ia wad Wm oaos SALON u3 10 X10 HOdO L ty 91600 SW YOLDINNOD 1ON3HdA V V 9 04 00 AlddfiS 5100 981 N d 0153135 LAANI 281 800 Z LN d U3WHOdSNVd L d3MOd Ns IVAH 8800 21 N d m 18 U3MOd munt 2 aay 1800 901 N d X 05 0000 T 752 00 98L N d ANNOYS 0656 6SLN d Go A 009 to 30010 9500 ELL N d MSS sz 1 1 n 00 621 N d 009 WSL YAMOd 10 ost LEM E f 42 1 600 37872 9 INOJ Z 9r 1 2 OL 923802 OL 00318 2 DAK 11 A 5 400 O ELN d 000 021 N d 5 6 U
46. d 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 ceil ings 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 radi ant or conducted heat Hot work permit should be obtained before oper ation to ensure supervisor s approval that ade quate 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 accor dance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depend ing on the combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective eq
47. e LH M D v800 L N d YW4X DNI 51020084 DW 537 MNS 1 0656 6651 N d caoz cova ddNSYIMOd ANNA YIMOd 92 QIOHRISSTHI SVS Ln O y WALC OL Law 30010 1800 401 N d v X 05 4N 00006 00 SZL N d A009 VS Z u3MOd tp LLL 00 N d 318V2 1N NHS p 412 HNSIVSH oT o YHL 2 3 T CaM IOHLNOD2S3SVIIOAXLO WAY MOdHOd n k 6900 981 N d 2018 993802 C9r1vu805 OL 4000 ELN 5000 0211 N d a asoquor MELO OL OLOA NVTVN 1 9 OL ET OL Wm Xlddns WA 2 L gt LONAN TWSUSA NO 092 WOSSS HOLOHISS LNAN T SALON 92902 1 9 1 900 OL 5 00 981 7851 00 N d 80123145 LNdNI YWAX 21901 cal 993802 1 91 8802 OL HAG O A OWAL 5850 500 N d LIA 85 1 00 2911 200 31872 v2El 00 N dpg 9 aav 8888 HOYOL of Lf T SLINN ZH OS
48. e an arc and move the torch progressively along the joint at a smooth steady rate A travel rate of 20 to 25 ipm should be used The arc should sound smooth and steady If spatter occurs and the arc pops reduce the wire feed speed until the arc smooths out 5 a gt m u m m n 0 1 mn m n U m W 13 m 0 50 100 150 200 250 300 350 350 400 8 Source WELDING CURRENT AMPS DGRP Mig Welding Handbook Linde Burnoff Characteristics 300 Series Stainless The above condition provides 20 volts and 40 amps If exact volts and amps are required purchase meter kit P N 005 0585 CobraMig 260 Owner s Manual Page 13 Sample Setup Steel The procedure described below is designed to help you familiarize yourself with this equipment and also provide you with a known procedure so that you may perform a successful weld Although these conditions may not be the exact ones needed for your specific application it will provide an example of the proper use and operation of this equipment MATERIALS NEEDED lea CobraMig 260 system with torch of your choice lea 6 Gas Cup 3 8 10ea Contact Tips 040 621 0077 short arc lea of clean 035 steel wire E70 S6 lea Cylinder of 75Argon 25CO2 gas w Regulator Flowmeter and Hose 20ea Weld coupons 2 X 6 X 16 gauge mild steel PROCEDURE Machine Set up Hook up the CobraMig 260 according to installation instructions in ow
49. en Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decom posed 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 trichloroeth ylene and perchloroethylene vapors to form phos gene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmo sphere 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 an
50. g the smooth layering of the wire and keeping it from jumping off and possibly electrically shorting to the cabinet chassis Operation General Description The CobraMig 260 is a constant voltage CV DC welding power supply with a built in Cobramatic wire feeder which operates on the same basic principles as all other Cobramatics The 115VAC slave motor in the feeder side 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 torch motor gets all it wants it slows the slave motor to the speed that the torch is running 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 high torque 24VDC torch pull motor is controlled by a solid state speed control located on the main board and the potentiometer located on the torch The lower portion of the unit houses the power supply components Power supply controls include a range switch and a variable voltage control Controls and Settings ON OFF SWITCH Placing the switch in the ON position energizes the power supply and places the unit in the ready to weld status The power indicator light should be on at this time CobraMig 260 Owner s Manual Page 6 WELD VOLTAGE The weld voltage knob adjusts the power supply
51. h 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 resis tance 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 electri cally 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 require ment 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
52. he Feeder Relay K2 Operation 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 circuit and shorting the torch motor leads together when the trigger is released for the dynamic braking system K2 also provides the closing contactor signal Testing the 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 Testing the Torch Motor Check Remove the amphenol connector from the cabinet Using the torch amphenol check the resistance across pins and leads The resistance across the motor should be between 5 10 ohms If an open circuit or short exist check the motor leads and motor independently Testing the Potentiometer W Clocked Using the torch amphenol check the resistance across pin D wiper and pin C The resistance should vary from 0 5K ohms Check the resistance across pin D wiper and The resistance should vary from 5K 0 ohms Testing the Micro Switch Using the torch amphenol check for continuity acro
53. ield Consult your local electrical utility if there are any questions about the type of electrical system at the installation site or how proper connections to the welding machine have to be made CobraMig 260 Owner s Manual Page 1 WARNING A fused line disconnect switch should be installed in the input circuit to the welding machine This would ensure a complete removal of all electrical power when performing service Conductor Fuse Guide Copper Copper Line Wire Grounding Amps Size Conductor Rating Min Size Free Air 2028 50 60AMP No8 8 230 45 60AMP 8 8 __416 26 40AMP Nog 8 480 24 40AMP No8 No8 Based 60 duty cycle Line Volts Before connecting input power cord verify input power requirements by checking data plate on rear of unit Do not connect if your input power voltage is different from the voltage indicated on the input specification panel Turn off all power at the disconnect Remove the right lower panel as viewed from front and locate power block at rear of unit Determine input Voltage and MOVE both Voltage Links to match INPUT VOLTAGE on BOTH Terminal blocks TB1 and TB2 these need to be set the same or damage WILL occur to the unit SICA 9LP 208 Volts Voltage Link 22858285288 EXAMPLE 230Volts EXAMPLE 208 Volts 2 230 Volte jumper position 208 Volts jumper position A match num
54. ire onto spindle and thread wire through torch according to wire threading procedure Make sure Wire Type switch is in the All Others position Press gun trigger and set gas flow to 25cfh Set the VOLTAGE control on front panel to 5 and the RANGE switch to Lo Turn the START to the off position Place the POLARITY JUMPER in the positive connector and the ground clamp in the negative connector Press the gun trigger for six 6 seconds Adjust the wire feed speed until 8 inches of wire is measured in 6 seconds this equals 80 ipm Position Material and Tack Weld Position the coupons on the work table to form a T fillet Place the gas cup near the work piece and tack weld one end Remember to provide pre purge before each weld by cracking the torch trigger and holding it for a few seconds before fully pressing the trigger This will reduce built up pressure and aid in arc starting Tack weld the other end Deposit Weld Securely clamp the workpiece to the table so that you have a clear view of the arc weld puddle and unwelded portion of the joint at all times Welding is done from left to right for a right handed operator and from right to left for a left handed operator known as Drag or The torch CobraMig 260 Owner s Manual Page 12 should bisect the 90 degree angle made by the joint and a drag angle of from 10 to 15 degrees is used N MN 45 NC Strik
55. log orifices and damage seats before con necting regulator Except for hydrogen crack valve momentarily pointing outlet away from people and sources of ignition Wipe with a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded connections clean and smooth seats where neces sary 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 turn ing adjusting screw in clockwise Draining pre vents 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 reg
56. lug Should vary from 0 to 5k ohm while turning pot CobraMig 260 Owner s Manual Page 24 CHECK TORCH POT SEE NOTE 1 BELOW CHECK TORCH MOTOR SEE NOTE 2 BELOW COBRA MAIN BOARD IS DEFECTIVE 2 Check TORCH MOTOR a Unplug the Torch from the front panel b Using the Ohm Meter Check the resistance across pin A and pin B motor leads of Torch plug The resis tance should be about 5 to 10 ohms C If open of short circuit exists then check motor leads and motor for additional prob lems FLOW CHART SYMPTOM WIRE FEEDS AT ONE SPEED ONLY NO CONTROL BY POT SETTING ON TORCH PROBLEM AREA TORCH MOTOR POTENIOMETER OR CABLE OR COBRA MAIN BOARD UNPLUG TORCH AMPHENOL FROM COBRA FRONT PANEL CHECK THE W CLOCKED S CLOCKED POTENIOMETER PER NOTE BELOW WAS METER READING OK TORCH POT IS DEFECTIVE COBRA MAIN P C BOARD OR IS DEFECTIVE TORCH CABLE IS DEFECTIVE NOTES 1 Check TORCH POT at plug connector a Testing the poteniometer W Clocked Using Ohm Meter to check resistance across pin D wiper and pin C of Torch plug Should vary from 0 to 5k ohm while turning pot Using Ohm Meter to check resistance across pin D wiper and pin G of Torch plug Should vary from 0 to 5k ohm while turning pot b Testing the poteniometer S Clocked Using Ohm Meter to check resistance across pin D wiper and pin C of Torch plug Should vary from 0 to 5k ohm while turning pot Using Ohm
57. middle fitting on the power block Shielding Gas Connection Remove the screws from the left hinged door as viewed from the front and open door Route the gas hose from the regulator flowmeter through the grommet on the back panel and into the 5 8 18 R H fitting on the power block DANGER Welding gases can cause serious injury or death Read manufacturer s instructions before installing using or servicing the regulator gas hose or gas cylinder Do not touch cylinder with electrode Keep cylinder away from all electrical circuits Keep gas cylinder secured so that it cannot move CobraMig 260 Owner s Manual Page 4 Coolant Connection Water Cooled Torches Only Connect the water return line from the recirculator through the grommet on the rear panel and into the 5 8 18 L H thread on the power block The water IN hose connects directly to the torch water IN fitting it does not pass through the power supply Wire Threading Procedue Wire Spool Installation Release latches and open right side door of cabinet Remove spool retainer nut from spindle hub Raise wire retainer bar to latched position Install wire spool onto spindle hub so that wire feeds from bottom of spool towards slave motor Make sure that the hole in the spool aligns with pin on spindle hub The white dot on the end of the spindle hub will aid in this alignment Replace the spool retainer nut Lower the wire retainer bar onto
58. nection at thermostat terminals Check connections to thermostat Thermostat is defective Relace thermostat K2 relay on Cobra main board is not sending closing contact signal Check Replace relay K2 Triac is defective Check Replace triac Remote panel voltage jumpers in wrong place Check position of Remote Panel Jumpers No weld output fan motor does not run either No primary power input Connect primary power Primary power connections are loose Check for secure connections on the primary power Primary disconnect switch off or fuses open Close switch or replace fuse CobraMig 260 main power switch defective Replace power switch Low weld voltage Low input voltage Check for proper input voltage 208 230 416 480 VAC Input Voltage jumper in wrong position Place jumper in position to match input voltage One of two diodes is defective or blown Check Replace power switch Wall disconnect fuse blows when torch trigger is depressed Recifiers Capacitors damaged or defective Check for short J6 1 2 on Cobra main boards hould read about 25 ohms Replace rectifiers capacitors if necessary Posa Start not operating Posa Start pot or Posa Start switch is defective Check Replace if necessary Current sensor is defective or Posa Start circuit on Cobra main board is defective Check Replace curren
59. ners manual Install wire onto spindle and thread wire through torch according to wire threading procedure Make sure Wire Type switch is in the All Others position Press gun trigger and set gas flow to 25cfh Set the VOLTAGE control on front panel to 5 8 and the RANGE switch to Lo Turn the START to the off position Place the POLARITY JUMPER in the positive connector and the ground clamp in the negative connector Press the gun trigger for six 6 seconds Adjust the wire feed speed until 13 inches of wire is measured in 6 seconds this equals 130 ipm Position Material and Tack Weld Position the coupons on the work table to form a T fillet Place the gas cup near the work piece and tack weld one end Remember to provide pre purge before each weld by cracking the torch trigger and holding it for a few seconds before fully pressing the trigger This will reduce built up pressure and aid in arc starting Tack weld the other end Deposit Weld Securely clamp the workpiece to the table so that you have a clear view of the arc weld puddle and unwelded portion of the joint at all times Welding is done from left to right for a right handed operator and from right to left for a left handed operator known as Drag or Backhand The torch CobraMig 260 Owner s Manual Page 14 should bisect the 90 degree angle made by the joint and a drag angle of from 10 to 15 degrees is used N ES
60. operly packaged to guard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal surface transportation charges both ways for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTA TION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVI SION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANT ABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TOANYANDALL EQUIPMENT FURNISHED BY MK PRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE MK PRODUCTS WARRANTIES DO NOT EXTEND TO AND NO RE SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS WARRANTIES TO ANY CONSUMER DATE March 1 2001 MK PRODUCTS INC 16882 ARMSTRONG AVE IRVINE CALIFORNIA 92606 949 863 1234 949 474 1428
61. orean JE LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR EL TRHORSMECH OTT vx EA P HE BB R Ba EE BB EL KE BJ SR PODER PRP RAN AAS PR lt m UB ol SAMS SISA aS s J ab gl gial ciel agil y gnat A LIMITED WARRANTY Effective March 1 2001 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY MK Products Inc lrvine California warrants that all new and unused equipment furnished by MK Products is free from defect in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold 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
62. r 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 high intensity gas shielded arc can cause 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 weld ing 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 Fire and Explosion Prevention Comply with precautions in 1 2C Equipment s rated capacity Do not overload arc welding equipment It may overheat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pres sure 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 wit
63. ral 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 Power Supply Periodically inspect all cables and hoses for damage or breaks in the insulation jacket particularly at the plugs or ends Repair or replace cables or hoses as necessary Remove grease and dirt from components and remove moisture from electrical parts and cables Be sure that all connections are clean and tight WARNING ELECTRIC SHOCK can kill Shut off disconnect and unplug unit before cleaning unit Every six months blow out or vacuum dust and dirt from the internal components of the power supply Remove the side panels and use a clean dry air stream or vacuum suction for the cleaning operation If repairs do become necessary any part can easily be replaced by a qualified shop maintenance man Your CobraMig 260 is designed to provide years of reliable service Normal wear and component failure may require occasional service The number of units in operation and the importance of minimal down time will determine to what extent spare parts should be stocked on hand CobraMig 260 Owner s Manual Page 16 Testing t
64. re 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 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 c
65. sed Keep hands and body clear of wire and other HOT parts 6 Safety Devices Safety devices such as interlocks and circuit break ers should not be disconnected or shunted out Before installation inspection or service of equip ment 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 emergency it must be discon nected 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 have in bringing the product to you For selecting a quality product We want you to take QA pride in operating this product as much pride as we Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase
66. ss pins E and F when the trigger is pressed Testing the Speed Control NOTE The torch should be tested first and the torch panel amphenol must be connected to the Cobramatic I to perform this test Place a voltmeter across diode D10 and press torch trigger A reading of 0 24VDC should be observed as the potentiometer varied 00820 88 e MNE nap m Cobramtatic Main Board CobraMig 260 Owner s Manual 17 Section E 4 TROUBLESHOOTI WARNING Turn off input power switch unplug primary power cord and wait 5 minutes before performing any service to this equipment This will ensure that all storage capacitors have discharged to a relatively safe level The following pages detail the trouble shooting section of this manual please read carefully and use caution when performing service on any electrical equipment All service is to be per formed by a qualified service technician Before calling for customer service please go over the trouble shooting page to help solve your equipment problem If the flow charts can not help you please have the following information on hand before calling our service personnel Company name Your name Your phone number Power supply Model No Primary power source Symptoms of failure Weld conditions CobraMig 260 Owner s Manual Page 18 TROUBLE No wire feed at torch
67. t sensor or Cobra main board Erratic weld output Ground clamp loose at work connection Check ground clamp for secure attachment Capacitors defective Replace capacitors if necessary Voltage and wire feed settings are not correct Readjust as necessary CobraMig 260 Owner s Manual Page 19 FLOW CHART SYMPTOM NO WIRE FEED AT TORCH FEEDER NOT OPERATING PROBLEM AREA COBRA MAIN BOARD K2 RELAY TORCH MOTOR CABLE MICRO SWITCH SLAVE MOTOR BRAKE SOLENOID IS COBRA MAIN BOARD FUSE OK IS COBRA 1 MAIN BRAKE SOLENOID OR BOARD F1 FUSE OK SLAVE MOTOR DEFECTIVE MICRO SWITCH TRANSFORMER MOTOR LEADS RELAY OR K2 RELAY ON COBRA SHORTED OR TORCH I MAIN BOARD IS DEFECTIVE OR MOTOR IS DEFECTIVE LOOSE J2 J3 ON COBRA PC BOARD GO TO FLOW CHART 4 GO TO FLOW CHART 3 GO TO FLOW CHART 2 COBRA MAIN BOARD F1 AND COBRA I MAIN BOARD F1 COBRA 1 MAIN BOARD F3 FUSES ARE OK BUT WIRE FUSE IS BLOWN FUSE IS BLOWN FEED AND TORCH NOT OPERATING TROUBLE No wire feed at torch feeder not operating ie No slave motor or brake solenoid action CAUSE 2 amp Fuse on Main board on wire feeder F1 4 Fuse on Main board on wire feeder Micro Switch defective Not being activated Broken electrical cable Transformer relay Relay K2 inoperative Loose J2 J3 Cobra Main P C board connections CobraMig 260 Owner s Manual Page 20 FLOW CHART
68. ta ouvido corpo eB FAURBCRMAREL HREMSBHRAAR HY sare did cl gal en READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your haad aut of fumes Use ventilation or exhaust to remove fumes from breathing zona Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera los humos Utilice ventilaci n 0 aspiraci n para gases Gardez t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour dter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fir gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaustao para remover fumo da zona respirat ria bf SBS T KC UT O
69. the spool Wire Spool Drag Setting NOTE Standard factory setting of the Spindle Tension Knob is set for All Other Wires There are two visible position settings for this Knob IN All Other Wires Fig 1 and OUT 030 035 Al Only Fig 2 The Spindle Tension Knob must be set to match the Wire Size Selector Switch on the Cobramatic front panel To change this setting it is easier done without the spool of wire on the spindle Remove the wire spool retainer and re install it reversed back onto the Spindle Tension Knob Fig 3 In the Tool Mode the square shaped end of the retainer fits onto the Knob Grab the retainer and turn in the COUNTER CLOCKWISE direction until it stops The Knob is now set to the OUT position 030 035 AL Only Spindle Knob IN Spindle Knob OUT gt Wr 7 f e 2 IN All other wires OUT 030 035 Aluminum ONLY Wire Spool Retainer In Tool Mode Figure 1 Figure 2 used to change spindle drag Figure 3 To reset the Knob back to the factory setting of All Other Wires use the retainer as described above and turn in the CLOCKWISE direction until it stops The Knob is now set to the IN position Turning the retainer and Knob in this direction may require more effort since turning CLOCKWISE is working against a spring Load wire spool onto spindle according to the previous instructions Replace the spool retainer nut CobraMig 260 Owner s Manual Page 5 Section
70. to manufacturer s desig nated repair center where special techniques and tools are used by trained personnel 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls valves or safety devices Avoid electrical circuit contact with cylinders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a serious accident See 1 3C ICC or DOT marking must be on each cylinder It is an assurance of safety when the cylinder is properly handled Identifying gas content Use only cylinders with name of gas marked on them do not rely on color to identify gas content Notify supplier if unmarked NEVER DEFACE or alter name number or other markings on a cylinder It is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them separate from FULLS and return promptly Prohibited use Never use a cylinder or its con tents 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 ruptu
71. trigger to weld release trigger to stop This also offers the comfort of latched trigger operation pull trigger once to latch and weld pull trigger again to unlatch and stop POSA START OPERATI NG PROCEDURE General The Posa Start Run in Speed Control located on the front panel provides adjustment for slow wire run in Once the arc has been established the wire feed speed is automatically changed from the slow run in speed to the welding speed set on the torch potentiometer This slow run in speed helps to reduce burn backs and push back during arc start Posa Start Operation Turn the Cobramatic to the position and the Posa Start to the 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 1096 of the welding wire speed Strike an arc and adjust wire feed rate at gun until correct condition is achieved CobraMig 260 Owner s Manual Page 8 PROCESS SETTINGS The following table is provided as a guide to assist you in setting up for standard welding processes Please be aware that there are many variables associ
72. uipment Water filling just below working level may substi tute 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 itis 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 equip ment is detailed in numerous industry publica tions 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 contain ing gas other than that for which the regulator was designed Remove faulty regulator from service immedi ately 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
73. ulator pres sure 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 set tings on regulators Check for leaks on first pressurization and reg ularly 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 ser vice 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 signifi cant voltages The arc is very bright and hot Sparks fly fumes rise ultraviolet and infrared energy radiates weldments are hot and com pressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents A Burn Protection Comply with prec
74. 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 bear ing 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 cylin ders 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 acciden tally opened or left op
75. y Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt obtain quali fied 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 EXPOSED SKIN AREAS Wear helmet with safety goggles or glasses with side shields underneath appropriate filter lenses or plates protected by clear cover glass This is a must for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facili ties 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

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