Owner`s Manual
Contents
1. 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 Anemptycontainerthatheld combustibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depending on the combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective equipment Water filling just below working level may substitute for inerting A container with unknown contents should be cleaned see paragraph above Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut Hollow castings or containers must be vented2. MIL Cobra Fronius Compatible FAE Owner s Manual Product Cobra SX Fronius Manual 091 0646 Serial 10090001 Voltage Rating 24 VDC Revision Sept 2010 Gun models 328 8xx 175 Ampere Push Pull Welding Gun Table of Contents Safety Considerations Installation EEE Section Technical Specifications EE 1 Support Equipment FE ee 1 MEET Eee 1 PENN Section B EEE EEE EN 2 SNE 2 Drive Roll and Idler mio EE 2 ee o EEN Section C Optional re 3 Snake SKINS rarrernnreranreranrrnunernnnernnrennnrrnanernanennunennusennusennesnnunennunennunennusennusennnsnnnnene 3 TN 4 GAS CUPS EEE 4 Maintenance EE EE Section D Periodic Mamtenance 5 Maintenance Tools rrranenannnnrnanenannnarnanenanenasnnnenanenasennennennunenuennernnnenunnneennnenasnnesnnee D Recommended Spare Parts Uer 5 Troubleshooting EE section E Troubleshooung REI e EEE 7 TE NE Nr 7 12 Ve 611 go e Section F DANS PIGS E EE 9 Me 10 EICC 1 62 EE 17 Safety Warnings Warranty Cobra SX Fronius Compatible Owner s Manual Declaration of Conformity for European Community CE Products Note 3 This information is provided for units with CE certification see rating label on unit Manufacturer s Name M K P rod u cts y nc 16882 Armstrong Ave Irvine CA 92606 Declares that the product Co b ra SX F ron us Co m pati b e conforms to the following Directives and Standards Directives Low Voltage Directive 2006 95 EC Electro
3. AROUND ITEM 414 APPLY QUICK DRYING HOSE LUBRICANT NEAR END OF ITEM 13 FOR INSTALLATION OF ITEM 8 ITEM NOT SHOWN FOR CLARITY D gt ES Lead Assembly Air Cooled No Qty Description 15 Part No 25 Part No 35 Part No 50 Part No 6 54 TeWwap 41100 8 2 HoseRetainer 5 16 481188 9 1 Nut Handle Adapter 487028 S Hose Retainer is re usable and can be removed and re installed as needed Cobra SX Fronius Compatible Owner s Manual Page 15 Cobra SX Fronius Compatible Power Manifold Assembly Air Cooled P N 003 2373 e 2 TIGHTEN WITH 65 5 IN LBS TORQUE APPLY HIGH STRENGTH THREAD SEALANT TO THREADS APPLY SILICONE LUBRICANT FOR INSTALLATION Og APPLY LOW STRENGTH THREAD LOCKING TO EXTERNAL THREADS BEFORE INSTALLATION TIGHTEN WITH 30 IN LBS OF TORQUE Power Manifold Assembly Qty Part No Description 303 0097 O Ring Buna N 101 ID x 07W 321 1082 Set Screw Flat 1 4 20 x 3 8 SST 431 1905 Fitting 1 8 ID x 1 16 27 NPT 431 1948 Connector Thread FE Ne Not available separately 5 Cobra SX Fronius Compatible Owner s Manual Page 16 Cobra SX Fronius Compatible Electrical NNS YOLON NIE SU0I D3UUO unc abuelo UMOIG anig uaa SHUM yeg pay O O D Oo DN Gi sf Hi 9 Pin Rectangular Front View J0J98UUO Je nbuejooy Cobra SX Fronius Compatible Owner s Manual Page 17 AVISO DE PRECAUC
4. 8mm 1 1mm Tip Extender Classic Cup 1 4 Tip Stackable 615 0255 621 0017 615 0256 Spiral liner for tip extender Cobra SX Fronius Compatible Owner s Manual Page 4 Section D Maintenance Periodic Maintenance Your Cobramatic System 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 barrel drive rolls and conduit at regular intervals Remove spatter build up from inside of nozzles with a hardwood stick It is recommended that the conduit be blown out every time you add a new spool of wire The only parts on the Cobramatic system that are subject to normal wear are the conduit contact tips gas cups front body liners wire guides drive and idler rolls A supply of these parts should be maintained on hand The number of units in operation and the importance of minimal 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 If repairs do become necessary qualified shop maintenance personnel can easily replace any part Maintenance Tools Drive Roll Removal Tool 931 0100 Recommended Spare Parts List MENS NEN 615 0620 15 Conduit 15 ft EE EE 615 0620 25 Conduit 25 ft sesch 1 61502035 Condut35ft S 1 615062050 Conduit50ft 1 005 0604 TriggerAssykt 1 003 2190 PotentiometerAs
5. cylinders Stuck valve Do NOT use a hammer or wrench to open a cylinder valve that cannot be opened by hand Notify your supplier Mixing gases NEVER try to mix any gases in a cylinder NEVER refill any cylinder Cylinder fittings should never be modified or exchanged 3 Hose Prohibited use Never use hose other than that designed for the specified gas A general hose identification rule is red for fuel gas green for oxygen and black for inert gases Use ferrules or clamps designed for the hose not ordinary wire or other substitute as a binding to connect hoses to fittings No copper tubing splices Use only standard brass fittings to splice hose Avoid long runs to prevent kinks and abuse Suspend hose off ground to keep it from being run over stepped on or otherwise damaged Coil excess hose to prevent kinks and tangles Protect hose from damage by sharp edges and by sparks slag and open flame Examine hose regularly for leaks wear and loose connections Immerse pressured hose in water bubbles indicate leaks Repair leaky or worn hose by cutting area out and splicing Do NOT use tape 4 Proper Connections Clean cylinder valve outlet of impurities that may clog 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 Bef
6. 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 Cobra SX Fronius Compatible Owner s Manual Page iii For selecting a quality product We want you to take UN pride in operating this product as much pride as we have in bringing the product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number 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 Manua
7. the micro switch and leads Trigger Sensitivity The amount of trigger lever travel can be 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 Sensivity Adjustment Screw Figure 1 it closes the gap between the trigger lever and the micro switch lever This will enable the operator to increase the sensivity of the trigger lever Sensitivity Adjustment With the wire feeder turned on with or without welding wire loaded turn the screw in until the micro switch is activated Figure 2 Once Figure 2 activated the gun and wire feeder motors will begin feeding wire Retract the screw accordingly until the system is deactivated and adjusted to the operators liking Drive Roll and Idler Rolls General The Cobra SX Fronius Compatible gun comes standard with a knurled drive roll and a grooved idler roll ready for welding aluminum wire diameters from 030 up to 3 64 An optional grooved idler roll for wire diameter 023 is available as P N 511 0113 Insulated V Groove drive roll kits are also available for aluminum wire see Optional Kits Figure 1 Drive roll tension is accomplished with a unique spring loaded pressure screw The Cobra SX Fronius Compatible comes from the factory with the pressure adjustment screw preset NO ADJUSTMENT is required for all sizes an
8. 5 210 Olt 3 O 8 4 0 O19 5 0 9 Pin Rectangular Front Vlew Cobra SX Fronius Compatible Owner s Manual Page 7 THIS PAGE INTENTIONALLY BLANK Cobra SX Fronius Compatible Owner s Manual Page 8 Section F Appendices And Diagrams Parts List Exploded VIEW PE ee at 10 Front Body Assembly 00 000 cc cee eee 12 Rear Body Assembly 13 Classic Cup Assembly 0 0 0 0 cece ee eee 14 Lead Assembly ccc ee eee ees 15 Power Manifold Assembly 16 Wiring Diagram 1 0 eee 17 Cobra SX Fronius Compatible Owner s Manual Page 9 A APPLY LOW STRENGTH THREAD LOCKING TO CONTACT SURACE 4 APPLY COMPOUND NAOLOX TO EXTERNAL THREAD Cobra SX Fronius Compatible Exploded View st Ne 7 EEK 4 e Call b e Ce Pir 1 PL 7 FOR HANDLE 10 gt O o a a X Lu a ec e lu Ka Cobra SX Fronius Compatible Owner s Manual Page 10 EN e d PL pepio 1000 2620 v EXE NE s 414idssusm 9006 r 6 et pue L p dE JUSM _ 000 Eee 0120 800 GI O Suel au sepniou UN ejpueH 9 Apog eeu ssv vrzz 00 Ovvx amp iepmousuoS oer 1 ole 4 EES ISS v eXze egiewodud cii LI vt uowws ssv Z6LZ 00 ISS9XEWOHS HOS enges v Joo SSv c6lc 00 acxzrionsuos some z a Soa sv seo 1 e ISSznxzesousuos voe v n EECHER 1 issanxorvonsaos vioosee u o essu e
9. CH MAY CAUSE SEHIOUS 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 Thisisa must for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered Medical first aid and eye treatment First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash burns of the eyes and skin burns Wear protective clothing leather or asbestos gauntlet gloves hat and high safety toe shoes Button shirt collar and pocket flaps and wear cuffless trousers to avoid entry of sparks and slag Avoid oily or greasy clothing A spark may ignite them Flammable hair preparations should not be used by persons intending to weld or cut Hot metal such as electrode stubs and work pieces should never be handled without gloves Ear plugs should be worn when working on overhead or in a confined space A hard hat should be worn when others work overhead B Toxic Fume Prevention WARNING The use of this product may result in exposure to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Adequate ventilation Severe discomfort illness or death can re
10. ION French ATTENTION Portuguese ATEN O e Do not touch electrically live parts or electrode with skin or wet clothing insulate yourself tram work and ground No toque las partes o fos electrodos bajo carga con la piel o ropa moja da Alslese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mauill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et da la terre Bar hran Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung isolieren Sie sich von den Elektroden und dem Erdbodent 9 Nao toque partes el tricas e elec trodes corn a pele ou roupa molha da Isvie se da pega a terra e AXWooNTERS REMAKE 7PRNKKTMNGVIE Oo MINPP Z0 6 MENES HTVSMELT Fats e TRARY DEMMET GA 9 ff B oO RORERI SES eru SUSE Ss Sd ET yya YO San np e 24 HE S DAA Ach b d gn GN RE oen VO d real slp SANT A cl i ball Al caia H Asch P deg ve VG pa e Keep flammable materials away Mantenga a material combustible fuera del rea de trabajo e Gardaz l cart de tout mat riel intlammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos eMivQiuoveooMcostsiES BBA LTRZUEGA e BGEA S LE evt Fag Sc AX olg Ad fa Jail SN l gti ca e Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos
11. 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 date of delivery of equipment to the original user 1 Power Supplies and Wire Feed Cabinets 3 years 2 Weldheads Coolers Positioners and Push Pull Guns 1 year 3 Spool Guns and Spool Gun Modules enis LBO days 4 Repairs Exchanges Parts 90 days 16882 Armstrong Ave Irvine CA 92606 MIL PRODUCTS www mkproducts com Classification of any item into the foregoing categories shall be at the sole discretion of MK Products Notification of any failure must be made in writing within 30 days of such failure A copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal surface transportation charges one way for products ret
12. 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 Cobra SX Fronius Compatible Owner s Manual Page i 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair first close cylinder valve The following symptoms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pressure release Repair Do NOT attempt repair Send faulty regulators for repair to manufacturer s designated repair center where special techniques and tools are used by trained personnel 2 Cylinders Cylinders must be handled carefully to prevent leaks and damage to their walls valves or safety devices Avo
13. d into the Power Pin connector with a set screw Gas Hose The gas hose is pushed over a barbed fitting on the end of the gun body and secured by twisting the hose retainer to the end of the hose shown below The hose retainer is re usable and can be removed and re installed as needed Control Cable A multi conductor control cable is used on the Cobra SX Fronius Compatible gun The gun end of the cable is secured with a cable clamp and the wires are connected to the potentiometer the micro switch the motor and 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 Cobra SX Fronius Compatible Owner s Manual Page 1 Section B Operation General The Cobra SX Fronius Compatible gun maintains a constant steady uniform wire feed speed regardless of curved or looped wire conduit The constant push exerted by the slave motor in the cabinet combined with the pull of the gun motor causes the wire to literally float friction free through the wire conduit The 24VDC gun motor is controlled by a three and three quarter 3 3 4 turn potentiometer in the gun handle Controls and Settings Potentiometer The laterally positioned potentiometer is located in the lower end of the handle providing up to 800 ipm with 3 3 4 turns Micro Switch The micro switch assembly consists of
14. d types of wires Drive Roll Installation Removal Note Neither of the handles needs to be removed to access the Drive or Idler Rolls 1 Push the idler lever this will relieve the pressure against the drive roll as shown in Figure 3 2 Align the Drive Roll Removal Tool P N 931 0100 over the flats of the drive roll as shown in Figure 4 Hold the gun with one hand or on a table top with the other hand give the Removal Tool a quick snap turn in the CLOCKWISE DIRECTION Cobra SX Fronius Compatible Owner s Manual Page 2 Section C Figure 3 Figure 4 3 Once the drive roll is loose continue to spin drive roll in the clockwise direction to remove the drive roll from the gun 4 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 Reference Figure 5 1 Using a slot type screwdriver loosen idler screw 2 Insert new idler roll onto screw insuring that idler groove is toward top 3 Tighten X Groove Towards i NS Top of Idler Roll SS Screw FA Idler Arm MM spring Figure 5 Accessories Optional Kits The arcing of the wire at the knurled drive roll is typical of a contact tip which is too large for the wire or if the aluminum wire has excessive oxidation reducing the contact between the wire and contact tip Insulated Drive Roll Kits are used when the teeth on the knurled drive roll arc to and soften the
15. en 0 uonduoseg ous EE oun mm om ISI SHEd ET Ia sniuU0Cl4 XS 921900 Cobra SX Fronius Compatible Owner s Manual Page 11 TM Cobra SX Fronius Compatible Front Body Assembly 003 2191 Front Body Assembly ENE EEE rain ny Idler Roll 023 e Cobra SX Fronius Compatible Owner s Manual Page 12 Cobra SX Fronius Compatible Rear Body Assembly 003 2244 Rear Body Assembly ENDE Not Available Separately 303 0097 0 Ring 2 005 321 0518 SCR 1 4 20x3 8 321 1104 Conduit SCR Cobra SX Fronius Compatible Owner s Manual Page 13 Cobra SX Fronius Compatible Classic Cup Barrel Assembly 003 2340 N INSTALL ITEM 6 TO ITEM 2 THEN INSTALL ITEM 5 TRIM OFF LINER FROM NICK L TUBE TO 0 06 INCH N APPLY SILICONE LUBRICANT TO O RINGS BEFORE INSTALL ING Classic Cup Barrel Assembly 001 0138 8 Assy Gas Cup MEN Not available separately 301 0101 Barrel Insulator Qty 1 oor MEE 3 30 pkg 981 1 1 1 pkg 931 0137 Barrel Liner PK 5 pcs 621 0001 Tip 045 x 25 OD Cobra SX Fronius Compatible Owner s Manual Page 14 Cobra SX Fronius Compatible Lead Assembly TIGHTEN TORQUE 10025 N LDS A zi TIGHTEN TORQUE 7 180 10 IN LBS TRIM TEFLON LINER AFTER ASSEMBLY TEFLON LINER TO PROTRUDE 4 44 INCHES BEYOND ITEM 7 PLACE ITEM 3 APPROXIMATELY 3 FT FROM THE END OF THE HEAD ASSEMBLY AND 3 INCHES INSIDE THE END OF ITEM 12 ON THE LEAD END DO NOT WRAP
16. erman WARNUNG Portuguese ATENCAO LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANGA DO EMPREGADOR ES MRP AD DIEFEET EIER EFRBMLTF AW CL TRHOREAREK GEIT FE BRAMMER GR EA OSE ERR Do REEL AE FR AE GN REDIERE ECKE 0 also em OASE SISATE FAR HAA TAG PSM HEN Aan ve AU gll bandet aud y ljdlandet Qui al eli la s i SU Aal isch ag lg can L Cobra SX Fronius Compatible Owner s Manual LIMITED WARRANTY Effective August 1 2010 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 t es 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
17. id electrical circuit contact with cylinders including third rails electrical wires or welding circuits They can produced short circuit arcs that may lead to a serious accident See 1 3C ICC or DOT marking must be on each cylinder It is an assurance of safety when the cylinder is properly handled Identifying gas content Use only cylinders with name of gas marked on them do not rely on color to identify gas content Notify supplier if unmarked NEVER DEFACE or alter name number or other markings on a cylinder It is illegal and hazardous Empties Keep valves closed replace caps securely mark MT keep them separate from FULLS and return promptly Prohibited use Never use a cylinder or its contents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cylinders clear of areas where they may be stuck Transporting cylinders With a crane use a secure support such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do notallow 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
18. l 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 Cobra SX Fronius Compatible Owner s Manual Section A CC Installation Technical Specifications Wire Capacity 030 035 0 6mm 0 9mm Solid and hard wires 030 3 64 0 8mm 1 6mm Aluminum 023 0 6mm capability using Optional Idler Roll P N 511 0113 Wire Speed 800 IPM 20 3 mpm Max at rated feeder Input Voltage 120VAC 42VAC Duty Cycle All ratings are using Argon Gas 175 Amps 25 Volts 6096 Support Equipment Required 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 A 2 power cable is used on the Cobra SX Fronius Compatible gun The gun and Power Pin ends of the cable are stripped to the copper strands and wrapped with a copper strip setscrew holds the cable securely in the gun body and in the Power Manifold with torque requirements of 55 60 in lb Conduit The Cobra SX Fronius Compatible 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 secure
19. low out or replace conduit Wire feeds erratically Wrong size contact tip See contact tip table Idler roll stuck Check for lock washer under idler roll or replace if damaged Bad potentiometer Check with meter Broken electrical cable Check potentiometer wires for Wire feeds one speed only continuity or short Bad speed control See specific cabinet control box owners for speed control operation Idler roll upside down Place groove in idler roll toward Wire walks out of drive rolls top Rear wire guide missing Replace wire guide Cobra SX Fronius Compatible Owner s Manual Page 6 Troubleshooting Guide Regardless of which gun or feeder used all MK Products push pull guns operate on the same principle The slave motor in the feeder runs at a fast constant torque but has very low torque It is always trying to feed more wire than the gun motor wants and when the motor gets all it wants it slows the slave motor preventing a bird s nest Because of the low torque produced by the slave motor a brake system is used to prevent wire overrun rather than tension The drag adjustment in the feeder is used simply to keep the wire slightly taut so it will not pull off the spool while feeding wire The high torque 24VDC gun motor is controlled by a solid state speed control located in the feeder and a pot located in the gun The gun motor potentiometer and micro switch are connected to the cabinet control box via a contr
20. m gas shielded arcs are more severe and painful Cobra SX Fronius Compatible Owner s Manual Page ii DON T GET BURNED COMPLY WITH PRECAUTIONS 1 Protective Clothing Wear long sleeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark substantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look at an electric arc without protection Welding helmet or shield containing a filter plate shade no 12 or denser must be used when welding Place over face before striking arc Protect filter plate with a clear cover plate Cracked or broken helmet or shield should NOT be worn radiation can be passed through to cause burns Cracked broken or loose filter plates must be replaced IMMEDIATELY Replace clear cover plate when broken pitted or spattered Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet notbe lowered overthe face before an arc is struck Looking at an arc momentarily with unprotected eyes particularl
21. magnetic Compatibility EMC Directive 2004 108 EC Standards Electromagnetic Compatibility EMC EN 60974 10 2007 Torches And Guns For Arc Welding EN 60974 7 2005 Cobra SX Fronius Compatible Owner s Manual SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EQUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION OR MAINTENANCE OF THIS EQUIPMENT 1 1 INTRODUCTION This equipment is intended for ultimate application by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment Operation should not be undertaken without adequate training in the use of such equipment Training is available from many public and private schools or similar facilities Safe practices in the installation operation and maintenance of this equipment requires proper training in the art a careful study of the information provided with the equipment and the use of common sense Rules for safe use are generally provided by suppliers of welding power sources compressed gas suppliers and electrode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safety Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt obtain qualified help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRICARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHI
22. o 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 The equipment carries high currents at significant voltages The arc is very bright and hot Sparks fly fumes rise ultraviolet and infrared energy radiates weldments are hot and compressed gases may be used The wise operator avoids unnecessary risks and protects himself and others from accidents A Burn Protection Comply with precautions in 1 2 The welding arc is intense and visibly bright Its radiation can damage eyes penetrate lightweight clothing reflect from light colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those fro
23. ol 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 Hemember 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 look more toward the gun motor s 24 V circuits speed control control cable or the gun motor If nothing operates look more toward the slave motor s input micro switch leads or micro switch Testing The Gun Reference the 9 pin rectangular diagram on the Cobra SX Fronius Compatible electrical diagram for information about pin outs and locations Motor Check Hemove the connector from the cabinet Using the 9 pin connector check the resistance across pins 1 and 6 motor leads If an open circuit more than K ohms or short less than 2 ohms exists 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 110 01
24. onduits flat spiral steel conduit for steel amp cored wire SE EE ere 15 ft 4 5m 515 052 EE EE EN ERT 25 ft 7 6m SELLE M 35 ft 10 7m SUO 50 ft 15 2m Contact Tips 1 4 Diameter Contact Tip Wire Size Tip ID Arc Tip Length Part No 023 0 6 mm 031 0 8 mm Spray 1 50 38 1 mm 621 0057 25 023 0 6 mm 031 0 8 mm Short 1 75 44 5 mm 621 0328 25 030 0 8 mm 037 0 9 mm Spray 1 50 38 1 mm 621 0325 25 030 0 8 mm 037 0 9 mm Short 1 75 44 5 mm 621 0326 25 030 0 8 mm 040 1 0 mm Spray 1 50 38 1 mm 621 0076 25 035 0 9 mm 045 1 1 mm Spray 1 50 38 1 mm 621 0001 25 621 0001 250 621 0001 500 035 0 9 mm 040 1 0 mm Short 1 75 44 5 mm 621 0077 25 035 0 9 mm 045 1 1 mm Short 1 75 44 5 mm 621 0002 25 3 64 1 2 mm 054 1 37 mm Spray 1 50 38 1 mm 621 0327 25 3 64 1 2 mm 060 1 5 mm Spray 1 50 38 1 mm 621 0003 25 621 0003 250 621 0003 500 t Also sold in quantities of 250 This size tip furnished with gun All tips sold in quantities of 25 Gas Cups Gas Cups CupSize CuplD PartNo standard furnished with gun tsold in packs of 4 each 5 8 15 8mm Gun Barrel Liners 931 0137 Teflon liner package 5 pieces Spiral steel 030 045 0
25. ore connecting check that the regulator label and cylinder marking agree and that the regulator inlet and cylinder outlet match NEVER Connect a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded connections clean and smooth seats where necessary Tighten If connection leaks disassemble clean and retighten using properly fitting wrench Adapters Use a CGA adapter available from your supplier between cylinder and regulator if one is required Use two wrenches to tighten adapter marked RIGHT and LEFT HAND threads Regulator outlet or hose connections may be identified by right hand threads for oxygen and left hand threads with grooved hex on nut or shank for fuel gas 5 Pressurizing Steps Drain regulator of residual gas through suitable vent before opening cylinder or manifold valve by turning adjusting screw in clockwise Draining prevents excessive compression heat at high pressure seat by allowing seat to open on pressurization Leave adjusting screw engaged slightly on single stage regulators Stand to side of regulator while opening cylinder valve Open cylinder valve slowly so that regulator pressure increases slowly When gauge is pressurized gauge reaches regulator maximum leave cylinder valve in following position for oxygen and inert gases open fully to seal stem against possible leak for fuel gas open t
26. rc can also decompose trichloroethylene and perchloroethylene vapors to form phosgene DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichloroethylene or perchloroethylene C Fire and Explosion Prevention Causes of fire and explosion are combustibles reached by the arc flame flying sparks hot slag or heated material misuse of compressed gases and cylinders and short circuits BE AWARE THAT flying sparks or falling slag can pass through cracks along pipes through windows or doors and through wall or floor openings out of sight of the goggled operator Sparks can fly many feet To prevent fires and explosion Keep equipment clean and operable free of oil grease and in electrical parts of metallic particles that can cause short circuits If combustibles are in area do NOT weld or cut Move the work if practicable to an area free of combustibles Avoid paint spray rooms dip tanks storage areas ventilators If the work cannot be moved move combustibles at least 35 feet away out of reach of sparks and heat or protect against ignition with suitable and snug fitting fire resistant covers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields
27. rson 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 oweat 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 f only three phase power is available connect single phase equipment to only two wires of the three phase line Do NOT connect the equipment ground lead to the third live wire or the equipment will become electrically HOT a dangerous condition that can shock possibly fatally Before welding check ground for continuity Be sure conductors are touching bare metal of equipmen
28. s Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover tumo da zona respirat ria Oba AHSMAMTESELT F v RATHER THREL TF Eu e HANNE ud MIE EG ESA e U37 8714F wee FeR SR MAS AA 7AA 7H ETIE HEHHE OE ge faa dul jte gal ida biia syn d aal eil Jgd pdin uu AU oe RA nyt ud Turn power off before servicing e Desconectar al cable de alt mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant Fentre tlen Strom var Wartungsarbeiten abschalten Netzstrom v llig ott nen Maschine anhalten e N n opere com as tampas removidas e Desligue a corrente antes de fazer servign N o toque as partes el tricas nuas e Avi YA Be ACRU A PSEC EF RMA v FE BE TFS Lt e RR TEEN e xTHO SHE Xem Axa Li i J th arm JAN die Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection eniev s e Anlage nle ohne Schutzgah usa oder Innenschutzverkleidung in Betrieh setzen e Mantenha se afastado das partes moventes e N o opere com os painais abertos Ou guardas removidas e NER ERUHL IE f CEWMIESLEVCF U o KST RUNE EAT AE ME ergo dz iude EX obel AS ibiyi dals 13 aal LA Ja VO Aale eui AK dl Aa AVISO DE PRECAUCION French ATTENTION G
29. semby 1 0050710 HandeKit 4 1 0032197 X MicoSwithAssemby 2 9851 000 JL Drive Rol S 2 510001 JlderRol 4 MIN sch sch DRIVE ROLL REMOVAL TOOL 931 0100 KNURLED DRIVE ROLL 511 0101 IDLER ROLL 511 0001 030 3 64 IDLER ROLL 511 0113 023 MCRO SWTCHASSY 003 2197 Cobra SX Fronius Compatible Owner s Manual Page 5 Section E Troubleshooting Trouble Cause Remedy Input power fuse in feeder Replace fuse TU Control box blown er aa Micro switch defective not Replace switch Check switch for not operating l e no slave being activated operation motor or brake solenoid Broken electrical cable Check micro switch wires for continuity Motor Control fuse in feeder Check motor leads for shorts then Control box blown replace fuse Bad potentiometer Check potentiometer with meter No wire feed at gun feeder Brok l operating properly roken electrical cable Check motor and potentiometer wires for continuity Bad speed control PCB See specific cabinet control box owners for speed control operation Loose or no cable connections Check all power connections Contactor control cable loose or Check power supply owners Wire feeds but welding wire in wrong position manual for location and type of is not engergized contactor signal required i e closing or 115VAC Welding power source Check power source Dirty or worn conduit B
30. sult from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryllium bearing and similar materials when welded or cut may produce harmful concentrations of toxic fumes Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration dangerously Do not bring gas cylinders into a confined space Leaving confined space shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decomposed by the heat of the arc or flame to form PHOSGENE a highly toxic gas and other lung and eye irritating products The ultraviolet radiant energy of the a
31. t 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 HEPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode wire becomes electrically HOT when the power switch of gas metal arc welding equipment is ON and welding gun trigger is pressed Keep hands and body clear of wire and other HOT parts 6 Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out Before installation
32. urned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MKPRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING 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 Tel 949 863 1234 Fax 949 474 1428 August 1 2010 Cobra SX Fronius Compatible Owner s Manual THIS PAGE INTENTIONALLY BLANK 11 PRODUCTS 16882 Armstrong Ave Irvine California 92606 TEL 949 863 1234 FAX 949 474 1428 www mkproducts com
33. wire as it enters the barrel liner The softened wire has a greater potential of being shaved and or clogging in the barrel liner Insulated Groove Drive Roll Kit 005 0640 For 030 0 8mm dia aluminum wire Includes insulated drive roll and idler roll assy Insulated Groove Drive Roll Kit 005 0716 For 035 0 9mm dia aluminum wire Includes insulated drive roll and idler roll assy Insulated Groove Drive Roll Kit 005 0717 For 040 1 0mm dia aluminum wire Includes insulated drive roll and idler roll assy Insulated Groove Drive Roll Kit 005 0718 For 3 64 1 2mm dia aluminum wire Includes insulated drive roll and idler roll assy Snake Skins Snake Skin protective covers are standard on the Cobra SX Fronius Compatible Replacement covers may be ordered and replaced in the field by means of hook and loop also known as Velcro Snake Skin Cover 15ft leade ee eeceeeceeceeeeeeeeeceeeueeueeeeeneess 931 0110 Snake Skin Cover 25ft leads occ ceeceecceeceeceeceeeeeeceeneeneeeeens 931 0122 Snake Skin Cover 3bft leade cece ceecceeceeeeeceeeeeeceeceseaeeaeeeeeees 931 0132 Snake Skin Cover 50ft leads oo ceeeecceeceeceeceeeceeceeeneeneeeeeeees 931 0123 Cobra SX Fronius Compatible Owner s Manual Page 3 C
34. y a high intensity gas shielded arc can cause a retinal burn that may leave a permanent dark area in the field of vision 3 Protection of Nearby Personnel Enclose the welding area For production welding a separate room or enclosed bay is best In open areas surround the operation with low reflective noncombustible screens or panels Allow for free air circulation particularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic Fume Prevention Comply with precautions in 1 2B Generator engine exhaust must be vented to the outside air Carbon monoxide can kill C Fire and Explosion Prevention Comply with precautions in 1 2C Equipment s rated capacity Do not overload arc welding equipment It may overheat cables and cause a fire Loose cable connections may overheat or flash and cause afire Never strike an arc on a cylinder or other pressure vessel It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling D Compressed Gas 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 pe
35. yeux vos oreilles et volre corps e Tragen Ste Augen Ohren und K r perschutz Use prote o para a vista ouvida e como H ERU SC GBEREUTCF AM CARR 3258H9 ECGNSERA ex He Sai vS37 FEN Apis duo ele Al y gadag ci p k e eeh I READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Cobra SX Fronius Compatible Owner s Manual amp Keep your head out o fumes Use ventilation or exhaust to remove fumes from breathing zona Los humos fuera de l zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gasas e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter las fum es des zonas fe travail e Vermelden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung de
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