Owner`s Manual DiamondBack™ Orbital Weldhead
Contents
1. Effective August 1 2008 This warranty supersedes all previous MK Products warranties and is exclusive with no other guarantees or warranties expressed or implied LI MI TED WARRANTY MK Products Inc Irvine California warrants that all new and unused equipment furnished by MK Products is free from defects in workmanship and material as of the time and place of delivery by MK Products No warranty is made by MK Products with respect to trade accessories or other items manufactured by others Such trade accessories and other items are sold subject to the warran ties of their respective manufacturers if any MK Products warranty does not apply to components having normal useful life of less than one 1 year such as relay points wire conduit tungsten and welding gun parts that come in contact with the welding wire including gas cups gas cup insulators and contact tips where failure does not result from defect in workmanship or material MK Products shall exclusively remedy the limited warranty or any duties with respect to the quality of goods based upon the following options 1 repair 2 replacement 3 where authorized in writing by MK Products the reasonable cost of repair or replacement at our Irvine California plant As a matter of general policy only MK Products may honor an original user s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods fr2. 114 PRODUCTS DiamondBack Orbital Weldhead Owner s Manual Product Manual Serial Voltage Rating Revision Model Number DiamondBack 091 0511 02100001 N A June 2009 Rev C 5006 E Table of Contents Safety Guidelines Installation Technical Specifications Electrical Mechanical Weldhead Connections Collet Selection amp Adjustment Tungsten Electrode Properties Gas Flow Rates Operations Weldhead Calibration Accessories Benchmount Extension Cable Collets Maintenance Preventative Maintenance Rotor Accuracy Cable Assembly Troubleshooting Arc Start Troubleshooting Operational Troubleshooting Appendices Diagram Parts List Appendix A Collets Appendix B Pre Ground Tungsten Electrodes Appendix C Overall Dimenisonal Drawings Warranty Declaration of Conformity for European Community CE Products Note gt This information is provided for units with CE certification see rating label on unit Manufacturer s Name M K P rod u cts y nc 16882 Armstrong Ave Irvine CA 92606 Declares that the product D lamon d B ac k conforms to the following Directives and Standards Directives Low Voltage Directive 73 23 EEC Electromagnetic Compatibility EMC Directive 89 336 EEC Standards Arc Welding Equipment Part I Welding Power Sources IEC 60974 1 September 1998 Second Edition Arc Welding Equipment Wirefeed Systems IEC 974 5 September 1997 Draft Rev
3. pointing outlet away from people and DiamondBack Owner s Manual Page ii 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 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
4. B Pre Ground Tungsten Electrodes Appendix C Overall Dimensional Drawings DiamondBack Owner s Manual Page 9 THIS PAGE INTENTIONALLY BLANK H TM DiamondBack Weldhead Exploded View ee No Qty Part No Description d APPLY MED STR THREAD LOCKING COMPOUND TO O D NOT FLANGE REMOVE ANY EXCESS APPLY RETAINING HIGH TEMP COMPOUND THREADS REMOVE ANY EXCESS 2 PI d APPLY COMPOUND JOINT NOALOX TO SCREWED CONTACT SURFACES TESO 6 1 1003 2165 Assy Motor Mount 17 1 003 2166 Assy GearSpurBeve 8 1003 2167 Assy Reed Swx 9 1003 2169 Assy Lead DiamondBack 118 6 338 0020 Scr SHC 6 32x 1 4 SST 6 328 0043 Scr SHC 10 24x 13 4 30 9 419 0063 SPG Comp 1 8 OD x 17 64 LG SST FOR ITEM 44 26 REF G gt ZA i P E ue y INSTALL HEAT SHRINK TUBING 3 0 INCH LONG 0 5 INCH FROM HOLE END OF ITEM 1 AS SHOWN SC Y 2 Lge AY OA FJ a eae i A Be PEF wee b ZI TC i 2 PL a i 3 b ASS ND 1 FOR ei dl E 3 1 FOR ITEM 1 P 4 Aach DS gt R EACH GPL gt gt ds EE 4 0 y Pd 8 435 1201 Shim 1 25 OD x 0 391 IDx 0 01 P PL a DN ls 2 FOR ITEM 44 SG 4 PL 2 FOR TEM 39 FOR TEM 40 Pi n DiamondBack Owner s Manual Page 11 THIS PAGE INTENTIONALLY BLANK DiamondBack Owner s Manual Page 12 DiamondBack Assembly Motor Mount P N 003 2165 WI
5. and other HOT parts 6 Safety Devices Safety devices such as interlocks and circuit breakers should not be disconnected or shunted out Before installation inspection or service of equipment shut OFF all power and remove line fuses or lock or red tag switches to prevent accidental turning ON of power Disconnect all cables from welding power source and pull all 115 volts line cord plugs Do not open power circuit or change polarity whilewelding If inanemergency 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 For selecting a quality product We want you to take Ott pride in operating this product as much pride as we have in bringing the product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your 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
6. available Appendix B Pre Ground Tungsten Electrodes Ld 18 Deg i Palin Tungsten set screw 321 1264 Diameter Tube OD__ Description Pap Number o ea TuNG3825006600 63509331332 Diameter NPS Description PartNumber e TUNG3 8250066NP 685 0987000 Diameter Metric Tibe Descripion Pap Number 60 0 TUNG3 32500660 0 MMOD 6850938147 DiamondBack Owner s Manual Page 15 Appendix C Overall Dimensional Drawings Side View Open SI Side View 90 Tilted DiamondBack Owner s Manual Page 16 Appendix C Overall Dimensional Drawings OR pri 0 91 W O COLLETS TO TUNGSTEN CENTER 4 KA ne 0 91 W COLLETS TO TUNGSTEN CENTER 9 75 2 75 Profile without Collets Profile with Collets Specifications subject to change without notice Dimensions provided are for reference only DiamondBack Owner s Manual Page 17 Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja PRECAUCION e HR del trabajo y de la tierra French ATTENTION German WARNUNG Portuguese ATENC O Korsan O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Is
7. heat of the arc or flame to form PHOSGENE a highly toxic gas and other lung and eye irritating products The ultraviolet radiant energy of the arc can also decompose trichloroethylene and perchloroethylene vapors to form 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 DiamondBack Owner s Manual Page i 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 Sparks sight of the goggled operator 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 anarea 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 cov
8. 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 Section A Installation Technical Specifications The DiamondBack weldhead was designed for process piping and manufacturing work cell applications The DiamondBack weldhead is capable of welding 2 Tube OD to 6 Nominal Pipe and associated fittings Electrical The DiamondBack uses a 24VDC motor with TACH feedback It is controlled by an orbital power supply motor control circuit to turn the rotor at the precise speed to create a near perfect weld Mechanical Power Cable Size 6 75A 600V Twist lock cable end connectors Gas Water Hose Size Nylon Tube 14 OD x 0 17 ID Double end shut off coupler Control Cable Specification 20AWG 12 conductor Weldhead Connections The DiamondBack comes equipped with an integrated 25 foot cable which connects to the CobraTig 150 orbital power supply The cable assembly provides a path for weld power operator control and motor signals and inert gas flow see Figure 1 Figure 1 Connecting to the CobraTig 150 The DiamondBack connects directly to the CobraTig 150 orbital power supply Welding Leads The two we
9. possibly fatally Before welding check ground for continuity Be sure conductors are touching bare metal of equipment frames DiamondBack Owner s Manual Page iii at connections Ifaline cord with a ground leadis provided with the equipment for connection to a switch box connect the ground lead to the grounded switch box If a three prong plug is added for connection to a grounded mating receptacle the ground lead must be connected to the ground prong only If the line cord comes with a three prong plug connect to a grounded mating receptacle Never remove the ground prong from a plug or use a plug with a broken ground prong 2 Connectors Fully insulated lock type connectors should be used to join welding cable lengths 3 Cables Frequently inspect cables for wear cracks and damage IMMEDIATELY REPLACE those with excessively worn or damaged insulation to avoid possibly lethal shock from bared cable Cables with damaged areas may be taped to give resistance equivalent to original cable Keep cable dry free of oil and grease and protected from hot metal and sparks 4 Terminals and Other Exposed Parts Terminals and other exposed parts of electrical units should have insulating covers secured before operation 5 Electrode Wire Electrode 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
10. rotor will jam with the meshing gears inside the weldhead This will push the tungsten into the weld being made and inevitably cause either an ARC FAULT or MOTOR FAULT or worse If the weldhead becomes jammed a Motor Stall will result Usually some foreign matter or a piece of tungsten electrode has fallen within the gear mechanism of the weldhead hindering the rotation of the gears Clearing a Jammed Weldhead In order to clear the jam turn the weldhead upside down and vigorously shake the weldhead Another way to attempt removal of the foreign matter is to jog the rotor in the reverse direction This is accomplished by depressing the reverse direction button Locate the red button through the hole in the bottom of the handle This is a momentary reverse switch which means the rotor will reverse momentarily when the JOG button is pressed while holding the red button down Before turning the weldhead right side up attempt to locate the foreign object If the jam cannot be cleared in this manner the weldhead must be returned to MK for disassembly to have the objects removed Gas Flow Rates Recommended arc gas flow rate is 35 CFH at 50 PSI using the CobraTig 150 Flow rates higher than 35 CFH can create turbulence within the weldhead chamber and blow the arc about If more gas coverage is required increase the pre purge time on the 00 Back up gas flow rates are typically between 5 and 20 CFH depending on internal volume a
11. the Collets The tolerance of the outside diameter of tubes and pipes vary so these variations are handled through the use of brass tipped setscrews referred to as plungers in the top Collet halves These plungers not only make up the diameter difference between the Collet and the part to be welded but they also act as an aid in the grounding path between the weldhead and the tube or pipe to be welded The tube or pipe is forced down into the bottom third of the collets which are screwed to a line bored concentric face in the weldhead side plates The plungers are adjusted as follows 1 Back the plungers out until the brass tip is flush or below the surface of the bored Collet surface 2 Place the parts to be welded into the Collets and clamp down the latches Adjust the latching mechanism of the weldhead to ensure a tight but not overly tight clamping of the Side Plate Jaws Alternately adjust the plungers on one side of the weldhead until contact is made and then add about 1 4 turn more At this point the tube should be firmly held in place The tube should not turn if attempting to rotate it by hand Repeat the process for the opposite side of the weldhead Once completed check the alignment of the parts A misalignment may be corrected by moving the left or right plunger in or out by a fraction of a turn and then repeating the opposite action to the opposing plunger on the same Collet Tungsten Electrode Properties The
12. to the State of California to cause cancer and birth defects or other reproductive harm Adequate ventilation Severe discomfort illness or death can result from fumes vapors heat or oxygen enrichment or depletion that welding or cutting may produce Prevent them with adequate ventilation NEVER ventilate with oxygen Lead cadmium zinc mercury beryllium bearing and similar materials when welded or cut may produce harmful concentrations of toxic fumes Adequate local exhaust ventilation must be used or each person in the area as well as the operator must wear an air supplied respirator For beryllium both must be used Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface the area is well ventilated or the operator wears an air supplied respirator Work in a confined space only while it is being ventilated and if necessary while wearing an air supplied respirator Gas leaks in a confined space should be avoided Leaked gas in large quantities can change oxygen concentration dangerously Do not bring gas cylinders into a confined Space Leaving confined space shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open Check to be sure that the space is safe before reentering it Vapors from chlorinated solvents can be decomposed by the
13. RCIAL 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 16882 Armstrong Ave Irvine CA 92606 Tel 949 863 1234 Fax 949 474 1428 PRODUCTS www mkproducts com August 1 2008 Rev A THIS PAGE INTENTIONALLY BLANK MIL PRODUCTS www mkproducts com 16882 Armstrong Ave Irvine California 92606 TEL 949 863 1234 FAX 949 474 1428
14. RE DIAGRAM 2 211 0079 I PIN TOR A E 74 5 AFTER SCREW INSTALLATION BACK F LL SCREW HOLES WITH ITEM 1 A T TEST INSTALLED ITEM 8 FO MUST E WITHIN 0 0 ERMINALS WITH HOT MELT GLUE AFTER ION A CUT MOTOR TERMINAL EXCESS DO NOT CUT WIRE LEADS A N PRIOR TO ASSEMBL EST MO T 250 mc 24v FOR SMOOTH OPERATION UNIT MAY REQUIRE MINOR PERCOSI ADJUSTMENT Assembly Motor Mount Qty PartNo Description SC NUIT OK z 1 15909 Conn Singe Rowa e 2 4210926 PiDowev4x7IBSST e 1 45102 Coupler Motor Gear Ls 1 49 708 Mod Gear Pinion 30T DiamondBack Owner s Manual Page 13 DiamondBack Assembly Lead P N 003 2169 A After installing leads secure snakeskin cover with tie wraps Assembly Lead TN Description ae mo frewa DiamondBack Owner s Manual Page 14 Appendix A Collets Diameter TubeOD___ Descripion PartNumber_ e COLB8000FLS6INOD 623 5006600 Diameter NPS_ Description PartNumber_ gt COL8000FLS6INNP 623 50066NP___ Diameter Metric Tube Descripion PartNumber__ 6 COL5008FLS60 00MMOD 623 5006 600MM Collets screws reference 18 in previous drawing 338 0020 Collets requiring sizes other then those listed above are considered Custom Collets Please consult factory for part number and pricing of Custom Collets Blank collets for the 5006 DiamondBack weldhead are not
15. 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 UNFALLVERH TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN DiamondBack Owner s Manual Page 18 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de fos humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaga Use ventilac o e exhaust o para remover fumo da zona respirat ria 8 2950 84 57 Fa ORAPHELTISERLTTAUN ORD CEFR EA RRR e 427 EE usse 5245 48 MAS AS Fer ESE Aas A ye Lg daly del e AA gial bia ja gl Jaial 6 Je den uin ill ge il ng ud Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier ser
16. and Tungsten Preparation sections Put the tungsten electrode through the appropriate hole on the top of the rotor Place the appropriate thickness gauge between the tungsten electrode and the part to be welded so that the tungsten electrode is at the correct gap Be certain the thickness gauge is perpendicular to the tungsten electrode Tighten the setscrew to secure the tungsten electrode in the rotor DiamondBack Owner s Manual Page 3 Recommended Arc Gap The proper arc gap is an important part of the proper use of your orbital welding equipment Improper arc gap can cause arc strikes to occur to your Collets Be sure the arc gap is as short as possible consistent with the process and weld current level but not so short as to crash or touch the weld being made If no arc gap is known when designing a weld procedure a good rule of thumb is as follows Work Cell Apps Wall Thickness x 0 5 0 010 Field Apps Match Arc Gap to Wall Thickness up to max gap of 070 Some applications may require variance on this dimension depending on pipe concentricity and ovality CAUTION Do not over tighten the tungsten set screw Over tightening the setscrew can crack and splinter the tungsten causing errant starts and arc wander Be sure that the tungsten does not extend into the rotor teeth and that both setscrews are flush with the rotors surface Any length of tungsten that is protruding out the back of the
17. ductors or other bare metal in the welding circuit or in ungrounded electrically HOT equipment can fatally shock a person whose body becomes a conductor DO NOT STAND SIT LIE LEAN ON OR TOUCH a wet surface when welding without suitable protection To protect against shock Keep body and clothing dry Never work in damp area without adequate insulation against electrical shock Stay on a dry duckboard or rubber mat when dampness or sweat cannot be avoided Sweat sea water or moisture between body and an electrically HOT part or grounded metal reduces the body surface electrical resistance enabling dangerous and possibly lethal currents to flow through the body 1 Grounding the Equipment When installing connect the frames of each unit such as welding power source control work table and water circulator to the building ground Conductors must be adequate to carry ground currents safely Equipment made electrically HOT by stray currents may shock possibly fatally Do NOT GROUND to electrical conduit or to a pipe carrying ANY gas or a flammable liquid such as oil or fuel Three phase connection Check phase requirement of equipment before installing If only three phase power is available connect single 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
18. ers or shields Walls touching combustibles on opposite sides should not be welded on or cut Walls ceilings and floor near work should be protected by heat resistant covers or shields Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if 1 Appreciable combustibles including building construction are within 35 feet 2 Appreciable combustibles are further than 35 feet but can be ignited by sparks 3 Openings concealed or visible in floors or walls within 35 feet may expose combustibles to sparks 4 Combustibles adjacent to walls ceilings roofs or metal partitions can be ignited by radiant or conducted heat Hot work permit should be obtained before operation to ensure supervisor s approval that adequate precautions have been taken After work is done check that area is free of sparks glowing embers and flames An empty container that held combustibles or that can produce flammable or toxic vapors when heated must never be welded on or cut unless container has first been cleaned in accordance with industry standards This includes a thorough steam or caustic cleaning or a solvent of water washing depending onthe combustible s solubility followed by purging and inerting with nitrogen or carbon dioxide and using protective equipment Water filling just below working level may substitute for inerting A contai
19. 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 clog orifices and damage seats before connecting regulator Except for hydrogen crack valve momentarily
20. gauge reaches regulator maximum leave cylinder valve in following position for oxygen and inert gases open fully to seal stem against possible leak for fuel gas open to less than one turn to permit quick emergency shut off Use pressure charts available from your supplier for safe and efficient recommended pressure settings on regulators Check for leaks on first pressurization and regularly thereafter Brush with soap solution Bubbles indicate leaks Clean off soapy water after test dried soap is combustible E User Responsibilities Follow all Safety Rules Remove leaky or defective equipment from service immediately for repair Read and follow user manual instructions F Leaving Equipment Unattended Close gas supply at source and drain gas G Rope Staging Support Rope staging support should not be used for welding or cutting operation rope may burn 1 3 ARC WELDING Comply with precautions in 1 1 1 2 and this section Arc Welding properly done is a safe process but a careless operator invites trouble 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 brig
21. he tungsten electrode or poor arc starts arc wander and inclusions may occur See Figure 4 No other parts should be ground with these wheels since contamination of the electrode could result and create problems with arc initiation arc wander during the weld and tungsten inclusions in the weld bead All tungsten supplied by MK Products Inc is prepared using the latest manufacturing techniques in order to meet the geometry specifications as described above Correct Lengthwise grind marks don t restrict current Diamond ground mirror finish is best Incorrect Crosswise grind marks restrict welding current cause arc wander risk inclusions Figure 4 Installing the Tungsten Electrode The electrode is mounted in the rotor and held in place with a setscrew To insert the electrode jog the rotor around until the setscrew is exposed approximately at the twelve o clock position and loosen the setscrew Insert a properly prepared electrode from the top of the rotor and tighten the setscrew Be sure to set the appropriate arc gap prior to welding Setting the Arc Gap 1 Place the part to be welded on the lower Collets with the clamps in the upright open position Jog the rotor until the tungsten hole in the rotor is sitting directly over the part with access to the tungsten set screw approximately at twelve o clock Prepare the tungsten electrode with the right length and shape as explained in the Tungsten Geometry
22. ht Its radiation can damage eyes penetrate lightweight clothing reflect from light colored surfaces and burn the skin and eyes Skin burns resemble acute sunburn those from gas shielded arcs are more severe and painful DON T GET BURNED COMPLY WITH PRECAUTIONS 1 Protective Clothing Wear long sleeve clothing in addition to gloves hat and shoes As necessary use additional protective clothing such as leather jacket or sleeves flameproof apron and fire resistant leggings Avoid outer garments of untreated cotton Bare skin protection Wear dark substantial clothing Button collar to protect chest and neck and button pockets to prevent entry of sparks 2 Eye and Head Protection Protect eyes from exposure to arc Eyes may be damaged by radiant energy when exposed to the electric arc even when not looking in the direction of the arc Never look 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 Protectfilter 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
23. ied help before proceeding 1 2 GENERAL PRECAUTIONS A Burn Prevention ELECTRICARC 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 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
24. ision Degrees of Protection Provided by Enclosures IP Code IEC 529 1989 November 1989 First Edition Insulation Coordination For Equipment With Low Voltage Systems Part I Principles Requirements and Tests IEC 664 1 1992 October 1992 First Edition Electromagnetic Compatibility EMC EN 50199 August 1995 Torches And Guns For Arc Welding EN 50078 SAFETY CONSIDERATIONS ELECTRIC ARC WELDING EQUIPMENT CAUTION READ BEFORE ATTEMPTING INSTALLATION OPERATION OR MAINTENANCE OF THIS EQUIPMENT 1 1 INTRODUCTION This equipment is intended for ultimate application by commercial industrial users and for operation by persons trained and experienced in the use and maintenance of welding equipment Operation should not be undertaken without adequate training in the use of such equipment Training is available from many public and private schools or similar facilities Safe practices in the installation operation and maintenance of this equipment requires proper training in the art a careful study of the information provided with the equipment and the use of common sense Rules for safe use are generally provided by suppliers of welding power sources compressed gas suppliers and electrode suppliers Careful compliance with these rules will promote safe use of this equipment The following Safety Rules cover some of the more generally found situations READ THEM CAREFULLY In case of any doubt obtain qualif
25. it should be replaced Dirty tungsten can cause poor arc starts and tungsten inclusions Make sure that the part to be welded is tight in the Collets or a loose ground will result If the part to be welded can be turned in a latched Collet tighten the Collet plungers Avoid any tooling that might have sharp edges or points or this will cause an arc strike to the Collets or the Side Plate Clamp To insure reliable arc starting and extended tungsten life the pre purge settings should be determined by the size of the tube and weldhead size the smaller the tube in a given size weldhead the longer the pre purge time If an arc strike occurs to the Collet or Side Plate Clamp the resulting arc spot may induce future arc strikes Be sure to smooth out any arc spots with a fine abrasive pad or cover it with appropriate insulating tape 9 Be sure that there is a tube in the weldhead before trying to make a weld Operational Troubleshooting If the weldhead does not return to the Home position but continues to rotate when the Home switch is pressed the Reed Switch is most likely defective The DiamondBack weldhead must be returned to the factory for any and all repairs NOTE Disassembly of weldhead will void the warranty DiamondBack Owner s Manual Page 7 THIS PAGE INTENTIONALLY BLANK Section F Appendices Exploded View Bill of Material Assembly Motor Mount Assembly Leads Appendix A Collets Appendix
26. lding Power Leads use a twist lock type of power connector These are designed to attach directly to the rear panel of the CobraTig 150 The male connector connects to the receptacle labeled FLECTRODE The female connector connects to the receptacle labeled GROUND Control Cable The 24 MS type pin connector attaches to the mating receptacle on the rear panel of the orbital welding power supply All of the Control Feedback and Welding functions of the weldhead transfer through this connector The operator controls are on the weldhead handle They include JOG GAS NEXT LEVEL FINAL SLOPE and START STOP Figure 2 Gas Hose Figure 2 The gas connector is a double end shut off type valve that prevents flow or leakage out of either the unit or the gas hose if the connection is broken The gas hose connector from the weldhead plugs into the GAS OUT receptacle DiamondBack Owner s Manual Page 1 Collet Selection The three piece collet assembly mounts to both the jaws and the bottom face plate of the weldhead and maintains the weld joint alignment of the parts to be welded The collets are manufactured to correspond with the outside diameter of the material to be welded Each set of collets has three pieces two sides and one bottom Two sets of collets are needed to weld two tubes together Appendix A lists collet part numbers for tube and pipe Collet Adjustment The parts to be welded are held in place by
27. nd component configuration Typically when welding components with relatively large internal volumes a separate source for backup purge gas is recommended NOTE Disassembly of weldhead will void the warranty DiamondBack Owner s Manual Page 4 Section B Section C Operation Weldhead Calibration The software program in the orbital welding power supply provides for weldhead rotor speed and motor controller calibration This calibration program consists of driving the rotor at two predetermined speeds 1 0 and 0 5 RPM The start and end of each rotation are detected by the passage of the reed switch or nome sensor in the weldhead The rotation is clocked by the computer and by process of adjusting and recalculating provides very accurate and consistent speeds NOTE IT IS MANDATORY THAT THE WELDHEAD BE CALIBRATED EACH TIME THE SYSTEM IS TURNED ON FAILURE TO CALIBRATE THE WELDHEAD MAY RESULT IN THE WELDHEAD OPERATING AT A ROUGH ADJUSTMENT THAT MAY NOT PROVIDE CORRECT ROTOR SPEED AGAINST THE CONTROLLERS DEMAND SPEED CobraTig 150 The report generated by this unit is not as elaborate as the report from the ACL however it does show some very important information It shows both the MOTOR and TACH gain values The calibration and adjustment is still the same The Zero Offset for both the MOTOR and TACH is also shown MOTOR Calibration report MOTOR gain 4 6 Zero offset 0 30 RPM TACH gain 1 9 Ze
28. ned 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 contents for other than its intended use NEVER as a support or roller Locate or secure cylinders so they cannot be knocked over Passageways and work areas Keep cylinders clear of areas where they may be stuck Transporting cylinders With a crane use a secure support such as a platform or cradle Do NOT lift cylinders off the ground by their valves or caps or by chains slings or magnets Do NOT expose cylinders to excessive heat sparks slag and flame etc that may cause rupture Do not allow contents to exceed 55 C 130 F Cool with water spray where such exposure
29. ner with unknown contents should be cleaned see paragraph above Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut Hollow castings or containers must be vented before welding or cutting They can explode Explosive atmospheres NEVER weld or cut where the air may contain flammable dust gas or liquid vapors such as gasoline D Compressed Gas Equipment The safe handling of compressed gas equipment is detailed in numerous industry publications The following general rules cover many of the most common situations 1 Pressure Regulators Regulator relief valve is designed to protect only the regulator from overpressure it is not intended to protect any downstream equipment Provide such protection with one or more relief devices Never connect a regulator to a cylinder containing gas other than that for which the regulator was designed Remove faulty regulator from service immediately for repair first close cylinder valve The following symptoms indicate a faulty regulator Leaks if gas leaks externally Excessive Creep if delivery pressure continues to rise with downstream valve closed Faulty Gauge if gauge pointer does not move off stop pin when pressurized nor returns to stop pin after pressure release Repair Do NOT attempt repair Send faulty regulators for repair to manufacturer s designated repair center where special techniques and tools are used by trai
30. not be lowered over the face before an arc is struck Looking at an arc momentarily with unprotected eyes particularly a high intensity gas shielded arc can cause a retinal burn that may leave a permanent dark area in the field of vision 3 Protection of Nearby Personnel Enclose the welding area For production welding a separate room or enclosed bay is best In open areas surround the operation with low reflective noncombustible screens or panels Allow for free air circulation particularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See 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 con
31. olez 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 N o toque partes el tricas e elec trodes com a pele ou roupa molha da Isole se da pega e terra OFRON 25 2 23 5 5 760 5 O 6 778 150 FE CM 998 0 SUSE 35 Yu FE HSS YO Saz ng 2744 HZ HAX DEALS All W EN oat ye dem aan Bt qr s Malt DD dich 7 Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos 98940 600808 46 op 99904 mia So AJA DIA Ant G A AM al gl ea e Keep flammable materials away Wear eye ear and body protection e eii los ojos los o dos y el cuerp Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschuiz Use proteg o para a vista ouvido e B FRUSHERBRELTE AM CARR 589008 ex WY zo A ESHIAIS daly dye de Ally gadag ci sd acre ap y 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
32. om the date of delivery of equipment to the original user 1 Power Supplies and Wire Feed Cabinets 2 Weldheads CobraCooler Positioners Prince XL and Prince XL Spool Guns Python CobraMAX Cobra SX 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 Acopyofthe invoice showing the date of sale must accompany products returned for warranty repair or replacement All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping MK Products will not be responsible for any damages resulting from shipping Normal surface transportation charges one way for products returned for warranty repair or replacement will be borne by MK Products except for products sold to foreign markets ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDI NG ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING MK s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COM ME
33. pically 2 sets are required per each weldhead See Appendix A for Part Numbers Maintenance Due to the complexity of the DiamondBack there is no maintenance permitted for the DiamondBack with the exception of preventive maintenance adjustments and replacement of consumables NOTE Disassembly of weldhead will void the warranty Preventative Maintenance Prior to performing any maintenance the weldhead should be tested to benchmark its performance A normal calibration should be run and the required correction noted If the weldhead is running slowly or sluggishly this usually indicates that there is an excessive load on the drive motor and that maintenance is required Rotor Accuracy Weld uniformity depends on the accuracy of the position of the rotor during welding Rotor rotation should be circular in motion in a plane at right angles to the tube and concentric with the center of the tube to be welded Any deviation from the proper tracking or discontinuity in the rotor will appear in the weld Problems in the plane of rotation are usually associated with Collets and can be corrected by Collet modification Discontinuities with rotor motion are more serious and may require replacement of the rotor the race or both Proper replacement requires factory tooling and is not a field repair Cable Assembly An electrical measurement should be made to determine continuity from the positive cable connector to the rotor and f
34. recommended tungsten type to be used in the DiamondBack and the MK Orbital Welding System is 2 Ceriated 3 32 inch diameter 1 16 inch diameter tungsten is also available for the DiamondBack orbital weldhead Appendix B gives the MK part numbers for pre ground tungsten electrodes and an illustrated formula to determine the length of tungsten electrode required using a given weldhead size with a specified tube or pipe diameter These lengths of tungsten are long enough to allow the setscrew to securely hold the tungsten while maintaining a relatively close arc gap and keep the tungsten from sticking out the back of the rotor while using a large arc gap Tungsten Geometry The recommended grind angle and shape for tungsten is 18 included angle and a 015 inch flat Figure 3 Regardless of the electrode tip geometry selected it is important that consistent electrode geometry be used once a welding procedure is established Deg 18 Included gt wi 015 Flat Figure 3 DiamondBack Owner s Manual Page 2 Changes in electrode geometry can significantly influence the weld bead shape and size therefore electrode tip configuration is a welding variable that should be defined during procedure development Tungsten Preparation Tungsten electrodes should be properly ground for consistent results If the electrode is to be hand ground use a dedicated diamond wheel The grinding marks should be perpendicular to t
35. ro offset 0 02 RPM Should these MOTOR amp TACH gain values return with number of 0 00 and 0 00 RPM the calibration was invalid and should be re run Results containing all zeros are an indication that the weldhead is in need of service MOTOR Calibration report MOTOR gain 0 0 Zero offset 0 00 RPM TACH gain 0 0 Zero offset 0 00 RPM NOTE If all values for MOTOR or WELDER calibration are zeros it means that weldhead calibration did not complete successfully and is not valid A recalibration is highly reccomended at this time Accessories Table Edge Benchmount The DiamondBack M weldhead can be used while held in the operator s hand However due the weight and size of the weldhead at times it may be necessary for the operator to use both hands to manipulate parts within the weldhead and which requires the use of a Table Edge Weldhead Benchmount This Table Edge Benchmount P N 005 0680 can be affixed to any table or counter edge and can hold the DiamondBack Model 5006 orbital weldhead Extension Cable When longer weldhead cables are needed a weldhead extension cable is also available in a 25 length The extension cable P N 005 0635 has all the connections needed to connect the DiamondBack to the CobraTig 150 welding leads gas and control interface DiamondBack Owner s Manual Page 5 Section D Collets A set of Collets is defined as 3 each 120 segments for each side of the weldhead Ty
36. rom the negative cable connector to the jaws on the weldhead Resistance measurements should be less than 0 1 ohms A measurement should also be made to verify that no conductivity exists between the positive and negative power cables Any measurable conductivity through the weldhead will severely reduce arc start reliability The resistance measurement must be greater than 20 MQ when measured between the tungsten and the jaws A visual inspection should be made to determine the condition of the weldhead and the cable assembly If there are damaged or worn items the weldhead should be returned for factory service DiamondBack Owner s Manual Page 6 Section E Troubleshooting Arc Start Troubleshooting If you experience intermittent arc start problems or strikes to the Collet or Side Plate Clamp instead of the part to be welded check for the following 1 The proper arc gap is an important part of the proper use of your MK Orbital equipment Improper arc gap can cause arc strikes to occur to your Side Plate Clamp or Collets Be sure that the tungsten is ground properly 18 included angle and a 015 017 flat at the end of the tip Sharpening should be accomplished with the grind marks parallel to the longitudinal axis of the tungsten not around the tungsten reference Figure 3 Parts must be clean with no oxidation oils solvents or other insulating surface contaminant If the tungsten is contaminated at any time
37. vicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig opt nen Maschine anhaiten N o opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas e AFHIR nomi EUA Fe dock ELL GER e THA ANS AAA A n Ah i Qd ul I ell e Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas ONAMPAN ERNALLEE 988825 75 CRAKTARAARS ATRAE Ko e mdo del deg Ss OHA L t cals HI Ja Ha Xu ye de Geck S i d Aus AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 55 A 0118 2 gt MA ETBRLTFEN TL TMHORASREC HDT FSU Bi EE AR DD ER 3E TE E O A AAA ES EA o A IRE ol FIS SEE era SAGA HALO Seid 94 58 EPA deal cali Ali d Cha S i Mail di Aal lie vi SO gicali lates sl ai LA DiamondBack Owner s Manual Page 19 LIMITED WARRANTY
Download Pdf Manuals
Related Search