CopperHead® Orbital Weldhead Owner’s Manual Product: Weldhead Manual: 091-0448 Serial: 01120001 Voltage Rating: N/A Revision: Feb 2009 Rev D Model Number: 5001 5002 5003
Table of Contents Safety Guidelines................................................................................................i - iii Installation...................................................................................................Section A Technical Specifications...................................................................................................................1 Electrical.....................................................................................................
Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). MK MillerProducts, Electric Mfg.Inc. Co. Manufacturer’s Name: 1635 W.Armstrong Spencer Street 16882 Ave.
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.
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.
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.
Thank You For selecting a quality product. We want you to take 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.
Section A Installation Technical Specifications Electrical The CopperHead® 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, ¼” OD x 0.
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. Operator Controls The operator controls are on the weldhead handle. The controls include the following: START/STOP The [START/STOP] button first starts the program. If pressed a second time, it will stop the program.
Collet Selection Figure 2 The Collets mount to the side-plates of the weldhead and maintain 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 two Collet halves; top and bottom. Two sets of Collets are needed to weld two tubes together. The Collet halves are identified “TOP” and “BOT”. The top Collet-half is distinguished by adjustable brass-tipped plungers.
5. Repeat the process for the opposite side of the weldhead. 6. 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 The recommended tungsten type to be used in the CopperHead® and the MK orbital welding system is 2% Ceriated, 1/16” diameter and .040” diameter.
3/32” hole is used for tungsten tooling (holders and extenders) however, a tungsten electrode can also be used. 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.
Be sure that the tungsten does not extend into the rotor teeth and that both setscrews are flush with the rotors surface (see Figure 5). Any length of tungsten that is protruding out the back of the rotor will jam with the meshing gears inside the weldhead. This will push the tungsten into the weld being made and inevitably cause an ARC FAULT. If the weldhead becomes jammed, a “Motor Stall” will result.
Weldhead Coolant Use Cobra Coolant (Aluminum Protection), P/N 931-0060. Cobra Coolant does not contain reactive sulphur or chlorine and does not react with copper, brass or aluminum. DO NOT USE AUTOMOTIVE ANTI-FREEZE This may contain additives that are not compatible with this equipment and will void the warranty. Section B Operations Weldhead Calibration The software program in the orbital welding power-supply provides for weldhead rotor speed and motor controller calibration.
two different speeds to get two times at high speed and two times at low speed. This raw data is displayed under the column “Measured”. The two readings per speed are averaged together to produce an average time. This is displayed under the column “Actual”. The expected values are under the column “Cal”. The corresponding speeds derived by the above‑mentioned method are displayed under the column “Actual” for the test results and under the column “Cal” for the expected results. column “Measured”.
What does all this mean to the operator? It means that the ACL® will calibrate the weldhead to its own motor voltage output and compensate for calculated errors derived during the Motor Calibration Sequence. The Motor Gain Error percentage is exactly how much the ACL® will compensate for with a particular weldhead connected. When a new or repaired weldhead is received, a calibration should be run to “benchmark” its performance.
The CobraTig® uses the home switch closure as an absolute indicator of rotor position and times the duration between switch closures as one complete revolution. Dividing this time into 60 seconds gives the rotor speed in rpm. Using this information the CobraTig® calculates the two sets of error parameters: Gain and Zero Offset for both Motor and Tach. For the Motor parameters, the Gain is a measure of the multiplying factor error on the speed.
hands to manipulate parts within the weldhead, which requires the use of a Benchmount. This Benchmount (P/N 005-0634) can be affixed to any table or counter edge and can hold any 5001, 5002, or 5003 CopperHead® as well as the 4000 MiniMicro and 5000 Mr. Micro™ orbital weldhead. Extension Cable When longer weldhead cables are needed, a weldhead extension cable is also available in a 25’ length.
Potentiometer The handle contains a trim potentiometer that is located on the Printed Circuit Board. This pot affects the tachometer calibration of the unit and only should be adjusted in the event of a major component change (such as the motor, PCB, etc.) To adjust the pot: 1. Remove the right cover of the Cable Assembly with Handles. 2. Using the Amphenol Connector, connect the Weldhead to either a CobraTig® 150 or an ACL®. 3. CobraTig® 150: 3.
3. Remove the two screws from the water-return/grounding bar and remove the bar. Some coolant fluid that is in this bar and the side-plate may leak out. 4. Remove the Side Plate Assembly by taking out the six mounting screws. 5. Remove the six screws from the Cover Assembly, lift the cover off and lay it on the bench. Once the cover is off, this will expose the brush plate, reed switch, and gear mechanism of the weldhead. 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. Proper arc gap is an important part of the proper use of your MK Orbital equipment. An improper arc gap can cause errant arc strikes to occur to other places within the weldhead. 2. Be sure that the tungsten is ground properly, (18° included angle and a .015” - .017” flat at the end of the tip).
Section F Drawings Head Assembly..........................................................................16 Side Plate Assembly..................................................................18 Standard Motor Assembly..........................................................19 Cable Assembly with Handles....................................................20 24 Pin Standard Cable Sub Assembly.......................................21 Extension Cable Assembly................................................
D I S C L A I M E R Individual components shown in the exploded parts drawing may not necessarily appear like the true components used. This drawing is for reference only.
CopperHead® Owner’s Manual - Page 17 3 3 1 3 2 23 24 25 26 27 3 18 0.25 ft 20 17 22 1 16 - 4 15 21 2 14 * 2 13 1 1 12 19 1 11 20 1 10 1 7 1 1 6 1 1 5 8 1 4 9 1 1 2 1 1 3 Qty No. SHIM GEAR BRS SHIM GEAR SPR WAVE 3 WAVE SLEEVE MOTOR MOUNT WSHR FLAT 0.125 X 0.250 X 0.022 SST tubing ht shrk 3/8 blk --- SWITCH REED SPRING COMP 1/8 OD X 17/64LG SST SCR PN SLOT 4-40 X 3/4 SS SCR SHC 6-32 X 3/8 SS SCR SHC 4-40 X 1/4 SS O-RING 0.176 ID X 0.
CopperHead® Side Plate Cover Assembly D I S C L A I M E R Individual components shown in the exploded parts drawing may not necessarily appear like the true components used. This drawing is for reference only. Side Plate Cover Assembly No. Qty.
CopperHead® Standard Motor Assembly Standard Motor Assembly No. Qty. Description COPPERHEAD I COPPERHEAD II COPPERHEAD III 1 1 CON HSG RECPT 5POS 0.156CTRS 153-0008 2 4 TERM CRIMP FEMALE 18-24GA 153-0304 3 1 MOTOR MODIFIED WELDHEAD 211-0066 4 0.5 FT TAPE KAPTON 261-0518 5 1 SHAFT COUPLER 311-0002 311-0008 6 3 SCR SHC 4-40 X 1/4 SST 328-0237 7 1 PIN SPRING 0.063 X 0.375 421-0128 8 1 PIN SPRING 0.063 X 0.
CopperHead® Cable Assembly with Handles 003-2050 Cable Assembly with Handles No. Qty. Part No.
CopperHead® 24 Pin Standard Cable Sub Assembly 003-1396 No. 1 24 Pin Standard Cable Sub Assembly Qty. Part No. Description 1 153-0556 PLUG, 24P, SHELL 24 2 1 185-0384 WASHER, LOCK, TERMINAL #6 3 0.
CopperHead® Extension Cable Assembly 005-0635 (25 ft Extension) 005-0635-50 (50 ft Extension) The maximum length between the weldhead and the power suppply is 75 feet (two Extension Cables.
Section G Appendixes Appendix A Appendix B Appendix C Appendix D Appendix E CopperHead® Reference Dimensions.......................................24 Limitations on Allowable Extension Cord Length......................25 Collets.......................................................................................26 Locating Mandrels.....................................................................28 Pre-Ground Tungsten Electrodes.............................................
Appendix A CopperHead® Reference Dimensions Dimension Reference (in.) C D Model A B E F 5001 11.5 1.50 1.48 2.96 0.67 1.62 5002 13.20 2.20 2.05 4.10 0.67 1.62 5003 14.18 2.62 2.54 5.08 0.67 1.
Appendix B Limitations on Allowable Extension Cord Length Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft.
Appendix C Collets Part # Description Part # 5001 CopperHead® 328-0237...................................................... SCR SHC 4-40X1/4 SS 623-0151....................................................... COL 5001 FLS BLANK 623-0110-0.125........................................ COL 5001 FLS 1/8 623-0110-0.188...................................... COL 5001 FLS 3/16 623-0110-0.250........................................ COL 5001 FLS 1/4 623-0110-0.313......................................
Appendix C Collets Part # Description Part # 624-0210-0.625......................................... COL 5002 EXT 5/8IN 624-0210-0.750......................................... COL 5002 EXT 3/4IN 624-0210-0.875......................................... COL 5002 EXT 7/8IN 624-0210-1.000........................................... COL 5002 EXT 1 IN 624-0210-1.250..................................... COL 5002 EXT 1-1/4 IN 624-0210-1.500..................................... COL 5002 EXT 1-1/2 IN 624-0210-1.750.
Appendix C Collets Part # Description 624-0310-3/4NP........................................ COL 5003 EXT 3/4 624-0310-3/8NP........................................ COL 5003 EXT 3/8 624-0310-1/2NP........................................ COL 5003 EXT 1/2 624-0310-1/4NP........................................ COL 5003 EXT 1/4 624-0310-1-1/2NP.................................. COL 5003 EXT 1-1/2 624-0310-1-1/4NP.................................. COL 5003 EXT 1-1/4 624-0310-2-1/2NP............................
AppendixE CTungsten Collets Appendix Part # Diameter Description Description 14.33 MM 14.5 MM 15.0 MM 16.0 MM 16.5 MM 17.2 MM 18.0 MM 20.0 MM 21.2 MM 21.3 MM 21.4 MM 22.4 MM 23.0 MM 25.0 MM 26.0 MM 26.9 MM 28.0 MM 30.0 MM 32.0 MM 33.7 MM 35.0 MM 36.0 MM 36.5 MM 38.0 MM 40.0 MM 42.4 MM 43.0 MM 44.0 MM 44.5 MM 45.1 MM 48.
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LIMITED WARRANTY Effective August 1, 2008 This warranty supersedes all previous MK Products warranties and is exclusive, with no other guarantees or warranties expressed or implied. LIMITED WARRANTY - MK Products Inc., Irvine, California warrants that all new and unused equipment furnished by MK Products is free from defects in workmanship and material as of the time and place of delivery by MK Products.
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