Cobramatic® Wire Feed Cabinet Owner’s Manual Product: Cobramatic® Manual: 091-0539 Serial: 06110001 Voltage Rating: 115 VAC Revision: January 2010 Rev E Model Number: 150-006
Table of Contents Safety Guidelines Installation................................................................................. Section A Technical Specifications......................................................................................... 1 Machine Grounding............................................................................................... 1 Machine Location................................................................................................... 1.
Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). MK Products, Inc. Manufacturer’s Name: 16882 Armstrong 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.
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.
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.
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 Wire Diameter Capacity . ..................................... .030 - 1/16” Wire Spool Capacity ............................................ 12” Standard (Insulated or Non-Insulated) Power Input .......................................................... 115 VAC 50/60 Hz, . ............................................................................ 150 Watts Peak (1.3 amps) Weight . .................................................................
Coolant Supply and Return for Liquid Cooled Guns Using a recirculator with properly mixed coolant, as previously described, connect the coolant RETURN hose to the left middle fitting on the power block. Connect the coolant SUPPLY hose to the left top-most fitting on the power block (See Cabinet and Gun Connections page 16). The coolant hoses must have a male 5/8-18 left-hand thread to connect to the power block fittings. Use an 11/16” wrench to tighten.
IN - All other wires Figure 1 OUT - .030/.035 Aluminum ONLY Figure 2 Wire Spool Retainer In "Tool Mode"; used to change spindle drag. Figure 3 Wire Threading Procedure Place wire size selector switch on front panel to the correct position for the wire being used. Loosen end of wire from spool and cut off any kinked or bent portions. Unreel and straighten out first 6” to 8” of wire. Raise wire type lever on the slave motor assembly of feeder to center position.
Coolant Inlet (For Liquid Cooled Guns) Front panel access to connect the coolant hose to the middle fitting on the power block. Work Cable (Ground) Connect a work lead of sufficient size and length between the proper output stud on the power source and the work. Be sure the connection to the work ground makes tight metal to metal electrical contact. Improper work lead connections can result in poor arc initiation, and unsatisfactory weld results.
Controls and Settings On/Off Switch Placing the switch in the “ON” position energizes the feeder circuitry and the power indicator light. Wire Size Selector Switch The wire size selector switch changes the torque of the slave motor for the wire you are using. When in the .030-.035 aluminum only position, the slave motor produces approximately 1 1/2 lbs./inch of torque and approximately 4 1/2 lbs./inch when in the all other wires position.
across rows 3 & 5. For the 0-5 second range, move the jumpers across rows 5 & 7 (Figure 6a). Timing adjustment for the variable settings are as follows: Move the jumpers to either variable setting location. Turn potentiometer screw (Small flat or cross-head) half way. Pull gun trigger and count time between red contactor wire feed LED (L2) and yellow Gas Solenoid LED (L1). Adjust pot screw as necessary. Rows 1 & 3: 0.25 sec. fixed Rows 3 & 5: 0-1 sec. Rows 5 & 7: 0-5 sec.
The Posa Start feature allows the Cobramatic® feeder and gun to be used in conjunction with constant current DC welding power sources of open circuit voltage in excess of 55 volts - also, any constant voltage welding power source capable of a minimum of 50 amps. Once the PosaStart circuit has transferred from slow run-in to weld speed, the blue LED (L4) illuminates (Figure 7). Blue LED when PosaStart engages.
Section C Optional Kits The following is a list of Optional Power Supply Interface Cable Kits available for the Cobramatic® Wire Feeder. 8ft Interface Cable for Miller 14-Pin, 115VAC.................................005-0316 25ft Interface Cable for Miller 14-Pin, 115VAC...............................005-0658 When properly connected, these interface cables will supply all the necessary signals and power needed, from most Miller welding power supplies: a Closing Contact signal and 115VAC input power.
To test the motor voltage circuit and measure how much voltage is being delivered to the gun motor, place a voltmeter across diode test points TP1 & TP2 and depress gun trigger. A reading between 0 - 30 VDC should be observed, as the gun potentiometer is varied. Motor Voltage Test Point TP1 Motor Voltage Test Point TP2 Figure 9 For reference, see Main P.C. Board Connections picture in Section F Testing the Gun Motor Check Remove the amphenol connector from the cabinet.
Section E Troubleshooting Symptom No wire feed at gun, feeder not operating, i.e., no slave motor or brake solenoid. Brake solenoid inoperative. No wire feed at gun, feeder operating properly. Wire feeds, but welding wire is not energized. Wire feeds erratically. Wire feeds one speed only. Troubleshooting Cause Remedy F1 & F2 fuse(s) in feeder failed. Check AC circuit. Replace fuse(s). F3 (4 amp) fuse in feeder failed. Check motor leads for shorts then replace fuse.
Section F Appendices Diagrams/Parts List Main P.C. Board Connections.................................................... 13 Cabinet and Gun Connections.................................................. 14 001-4021 Cobramatic® Assembly.............................................. 15 003-2235 Cobramatic® Front Panel Assembly.......................... 17 003-2078 Cobramatic® Slave Motor Assembly.......................... 18 003-2063 Cobramatic® Power Block Assembly.........................
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Main P.C. Board Connections JP1 Adj. Gas Purge Jumper P2 Post-Purge Trim Pot P1 Pre-Purge Trim Pot JP2 Adj.
Cabinet and Gun Connections Input Gun Water Cooled Coolant Return Power Cable Coolant Supply Shielding Gas Welding Power Power Cable Welding Power Cobramatic® Owner’s Manual - page 14 Coolant Hose Gun Air Cooled Input Shielding Gas Gas Hose Gas
Cobramatic® Owner’s Manual - page 15
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436-0144 003-1642 1 1 1 2 1 1 1 1 3 4 5 6 7 8 9 10 Cobramatic® Owner’s Manual - page 17 Assy swx gas/trigger Assy con 7p “w” cb SS pnl fr Cobramatic Knob 1.0 blk Nut hex lock 4-40 Nut 3/8 - 32 st Grommet panel mount Assy pcb fr pnl cb 1 110V Cable power assy Assy cbl rbn 26c Description DISCLAIMER Individual components shown in the exploded parts drawing may not necessarily appear like the true components used. This drawing is for reference only.
No. Qty. 1 1 2 1 3 1 4 4 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 Description Assy knob conduit Assy torque motor 115V Scr shc 8-32 X 3/8 stl Scr shc 8-32 X 1-1/8 stl Scr Shldr 1/4 X 1/4 X 10-24 Nut Lock 5/16-18 Spring comp Spring comp Bolt swing mod Plate locate slave motor Housing slave motor mold Handle mold slave motor Arm idler mold slave motor Cap bearing mold Sleeve spring Bearing 1.125 X .50 X .31 Bearing, .875 X .38 X .
A A A A B A A Torque: 92 in-lb to 108 in-lb B 1 1 1 1 1 1 3 2 11 12 13 14 15 16 17 18 19 20 2 7 10 1 6 - 2 5 9 1 4 1 2 3 8 1 1 2 1 Cobramatic® Owner’s Manual - page 19 333-0011 - - - 753-0475 753-0466 753-0115 753-0114 753-0112 435-3038 431-1612 - 342-0395 336-0005 333-0252 331-0777 331-0002 329-0054 313-0021 003-1243 No. Qty. Part No.
1 3 3 1 1 1 3 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 Cobramatic® Owner’s Manual - page 20 8 9 10 11 12 13 14 15 16 751-0018 723-0059 437-0645 437-0260 437-0259 437-0258 431-3726 431-1266 419-0095 419-0059 345-0018 331-0313 331-0095 331-0063 330-3063 003-2139 No. Qty. Part No. Cap .5 X .5 lg vinyl black Disk ratchet brake Spindle Spacer spindle Knob tension spindle Spool Retainer Nut Adapter spiral spindle Plate back-up ring Spg comp .85 X .69 X .75 spg comp .468 X .437 X .
Cobramatic® Owner’s Manual - page 21 Qty. 2 1 2 1 1 1 1 2.50 FT No. 1 2 3 4 5 6 7 8 844-0089 753-3285 561-0017 552-0205 405-0762 185-0476 153-0868 153-0853 Part No. Cable 22GA/2CNDT flex Adptr FE 5/8-18 to M 1/8 NPT Gas solenoid 24V Assy gas connector Label self-lam .8 x 1.
071-0401 Cobramatic® Block Diagram Cobramatic® Owner’s Manual - page 22
071-0400 Cobramatic® Main PC Board Cobramatic® Owner’s Manual - page 23
071-0400 Cobramatic® Main PC Board Cobramatic® Owner’s Manual - page 24
071-0370 Cobramatic® Gun and Front Panel Connections Cobramatic® Owner’s Manual - page 25
INPUT / OUTPUT CONFIGURATION FOR TB1 Monitor Wire Feed Speed Use digital volt meter between: TB1 – 1(GND) and TB1 – 2(MSPD). Measured value defined as: Reading x 100 = Wire Feed Speed. Example: 3.54 VDC is equivalent to 354 IPM MSPD VOLT METER 8 7 6 5 4 3 2 1 GND TB1 Remote/External Trigger Install jumper between: TB1 – 1(GND) and TB1 – 3(TRIG) to trigger system.
Torch Pot Output Some power supplies can utilize a variable DC voltage signal from the gun potentiometer adjustment as their external voltage control. Adjusting the potentiometer at the gun will give 0 to 10VDC output between TB1 – 1 (GND) and TB1 – 6 (POT). POT 8 7 6 5 4 3 2 1 GND TB1 A common “synergic” type of setup is to have the gun potentiometer signal control the welding voltage of the welding power supply.
Manual Gas Purge Jumper from TB1-7 to TB1-1 to externally operate the gas solenoid in the cabinet.
Cobramatic® Owner’s Manual
Cobramatic® Owner’s Manual
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.
16882 Armstrong Ave. Irvine, California 92606 Tel 949.863.1234 Fax 949.474.1428 www.mkproducts.
