Product Description Cobramatic® MK Manual Part Number 091-0495 MK Form Number CB/OM-5 NWSA Form Number 550 Effective with Serial Number 12001 Voltage Rating Printing/Rev. Date This manual applies to the following model numbers 115 VAC August 2002 D 150-005 Cobramatic® Wire Feed Cabinet 16882 Armstrong Ave., Irvine, CA 92606 Tel 949/863-1234 Fax 949/474-1428 www.mkproducts.
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.
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.
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.
Table of Contents Saftey Guidelines Installation .........................................................................Section A Technical Specifications .......................................................................1 Machine Grounding .............................................................................1 Machine Location ................................................................................1 Input Power Connections ..............................................................
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Section A Installation Technical Specifications Wire Diameter Capacity ...................................... .030 - 1/16” ALL Types Wire Spool Capacity ........................................... 12” Standard (Insulated or Non-Insulated) Power Input ......................................................... 115 VAC 50/60 Hz, ............................................................................... 150 Watts Peak (1.3 amps) Weight ..................................................................
Shielding Gas In accordance with the required support equipment, the customer must provide a cylinder of shielding gas, a pressure regulator, a flow control valve, and a hose from the flow control valve to the left bottom-most fitting on the power block. The end of the hose must have a male connector to fit the female 5/8-18 brass fitting. Use a 11/16” wrench to tighten.
To change this setting, it is easier done without the spool of wire on the spindle. Remove the wire spool retainer and re-install it reversed back onto the Spindle Tension Knob (Fig. 3). In the “Tool Mode”, the square shaped end of the retainer fits onto the Knob. Grab the retainer and turn in the COUNTERCLOCKWISE direction until it stops. The Knob is now set to the OUT position (.030/.035 AL Only). Wire Spool Retainer In "Tool Mode"; used to change spindle drag.
Welding Torch Connections Work Cable Connect a work lead of sufficient size and length (see table below) between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal to metal electrical contact. Poor work lead connections can result in poor arc initiation, poor weld results and activation of the ground lead protector. Current 60% Duty Cycle 300A 400A 500A 600A Work Lead Lengths Up to 50ft. (15.2m) 0 (53mm) 00 (67mm) 00 (67mm) 000 (85mm) 10-100ft.
motor produces approximately 1 1/2 lbs. inches and approximately 4 1/2 lbs. inches when in the all other wires position. NOTE: Operating the cabinet with the switch in the wrong position will cause wire feed difficulties. Posa Start Controls The Posa Start Run-in Speed Control, located on the front panel, provides adjustment for slow wire run-in. Once the arc has been established, the wire feed speed is automatically changed from the slow run-in speed to the welding speed set on the torch potentiometer.
Note: Reverse polarity MUST be used. Posa Start Connections Attach the #14 single black lead which extends from the back of the cabinet to the negative terminal of the power supply or work ground. The Posa Start lead is internally connected to the P.C. board on terminal strip J6, terminal 2. CV Posa Start Operations Attach Cobramatic® to CV power source according to the installation instructions. Turn the Cobramatic® to the “ON” position and the Posa Start to the “OFF” position.
Section C OPTIONAL KITS The following is a list of Optional Kits available for the Cobramatic® Wire Feeder. A detailed description of each kit is given later in this section.
Remove spatter build-up from inside of nozzles with a hardwood stick. The only parts on the Cobramatic® system that are subject to normal wear are the conduit, contact tips, gas cups, front body liners, wire guides, drive and idler rolls. A supply of these parts should be maintained on hand. If repairs do become necessary, any part can easily be replaced by qualified maintenance personnel. Your Cobramatic® is designed to provide years of reliable service.
Testing the Torch Motor Check Remove the amphenol connector from the cabinet. Using the torch amphenol, check the resistance across pins “A” and “B” (motor leads). The resistance across the motor should be between 5-10 ohms. If an open circuit or short exist, check the motor leads and motor independently. Testing the Potentiometer - “W” Clocked Using the torch amphenol, check the resistance across pin “D” (wiper) and pin “C”. The resistance should vary from 0 - 5K ohms.
Section E Troubleshooting Troubleshooting Symptom No wire feed at torch, feeder not operating, i.e., no slave motor or brake solenoid. Brake solenoid inoperative. No wire feed at torch, feeder operating properly. Cause Remedy F3 (2amp) fuse in feeder blown. Check AC circuit. Replace fuse. F1 (4amp) fuse in feeder. Check motor leads for shorts, then replace fuse. Micro-switch defective/not being activated. Broken electrical cable. Replace switch. Check switch for operation.
Section F Appendices Diagrams/Parts List Main P.C. Board Connections .............................................. 13 Cabinet and Torch Hook-Up................................................ 14 001-4011 Cobramatic Assembly.......................................... 15 003-2110 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.
Cabinet and Torch Hook-up Input Connections Torch Connections Coolant Supply Power/ Water In Coolant Return Shielding Gas Welding Power Cobramatic® Owner’s Manual - page 14 Gas Water Return
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1 1 1 1 1 2 1 1 1 1 1 2 3 4 5 6 7 8 9 10 351-0835 003-1642 436-0144 401-0012 345-0004 341-0050 301-0023 003-2024 003-1631 003-1332 No. Qty. Part No. Snap btn Ø1/2 hold blk Assy con 7p “w” cb SS pnl fr Cobramatic Knob Ø1.0 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 Front Panel Assy.
1 1 1 1 1 1 1 1 1 A/P A/P A/P Ref 1 13 14 15 16 17 18 19 20 21 22 23 24 25 26 437-0230 1 1 11 431-1576 435-01582 1 1 9 10 12 419-0211 Cobramatic® Owner’s Manual - page 18 751-0018 031-0167 823-0051 835-0001 823-0043 753-0210 511-0206 507-0130 501-0207 501-0156 501-0118 437-0254 437-0245 437-0232 437-0231 419-0085 1 345-0018 330-0258 328-0259 8 1 5 1 4 4 328-0024 003-2069 1 2 3 7 1 2 003-0176 6 1 1 No. Qty. Part No. Cap .5 X .
Cobramatic® Owner’s Manual - page 19 1 1 1 3 A/R A/R A/R 15 16 17 18 19 1 1 9 10 14 1 8 13 435-3038 2 7 1 1 6 1 1 5 11 351-0066 431-1612 1 4 12 342-0395 1 3 823-0044 823-0043 823-0029 753-0475 753-0466 753-0115 753-0114 753-0112 336-0005 333-0252 331-0777 331-0002 329-0054 313-0021 1 2 003-1243 1 1 No. Qty. Part No.
1 3 3 1 1 1 3 1 1 1 1 1 1 1 1 1 A/R 1 2 3 4 5 6 7 8 Cobramatic® Owner’s Manual - page 20 9 10 11 12 13 14 15 16 17 823-0049 751-0018 723-0059 437-0645 437-0645 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. Thread locking permanent Cap .5 X .5 lg vinyl black Disk ratchet brake Spindle Spacer spindle Knob tension spindle Retainer spool spindle Adapter spiral spindle Plate back-up ring Spg comp .85 X .
Cobramatic® Owner’s Manual - page 21 Wire Color Blue Red Orange White Black Green Pin H C D J A B Chassis J5-2 J5-1 J6-4 J6-3 J6-2 Terminal Wire List Ground 115V Hot 115V Neutral Closing Contact Closing Contact PosaStart Function 005-0608 005-0659 8ft., 115 VAC Lincoln Interface Control Cable 25ft.
Cobramatic® Owner’s Manual - page 22 Red Orange White Black Green A B G I K Chassis J5-2 J5-1 J6-4 J6-3 Terminal Function Ground 115V Hot 115V Neutral Closing Contact Closing Contact NOTE: Posa Start lead from Cobramatic® must be attached to working (welding) ground. Wire Color Pin Wire List 005-0316 005-0658 8ft., 115 VAC Miller Interface Control Cable 25ft.
Cobramatic® Owner’s Manual - page 23 Red Orange Green Black White A B G E F Wire Color Pin J5-1 J5-2 Chassis J6-4 J6-3 Terminal Wire List 115V Neutral 115V Hot Ground Closing Contact Closing Contact Function 005-0614 8ft Interface Cable for Thermal Arc 19-Pin, 115VAC
Cobramatic® Owner’s Manual - page 24 J5-1 Chassis J6-4 J6-3 White Green Blue Orange White w/ Black or Red B D M U V J6-2 J5-2 Black A Terminal Wire Color Pin Wire List Closing Contact Closing Contact PosaStart Ground 115V Neutral 115V Hot Function 005-0614 8ft Interface Cable for ESAB 19-Pin, 115VAC
Cobramatic® Owner’s Manual - page 25 SAFETY WIRE AC VOLTAGE CONTACTOR AC LINE IN CLOSING CONTACTOR POSA START CONNECTIONS 1 1 J8 1 2 3 4 5 6 J4 1 2 1 J12 1 2 1 J7 1 2 3 4 5 6 J14 1 J1 1 J3 4A J5 1 2 3 4 1 J2 SCH 071-0270 AC IN AC IN 27VAC J6 F3 F2 F1 1 2 3 4 RELAY CLIP P/N 157-0023 RELAY K2 P/N 157-0022 NEUTRAL - WHITE HOT - BLACK GREEN 5K SCH 071-0370 (115V) SCH 071-0367 (42V) J2 J4 J3 THIS DOCUMENT IS THE PROPERTY OF MK PRODUCTS INC. MK PRODUCTS INC.
WELD VOLT (+) WELD VOLT (-) C.CONTACT C.CONTACT SW. SW. SW. SW. SW. SW. Cobramatic® Owner’s Manual - page 26 AC IN (L) AC IN (H) CONTACT AC (L) CONTACT AC (H) 1 JP3 AC (L) AC (L) AC (H) AC (H) TORQUE TORQUE 1 130V RV6 TERMINAL BLOCK 5 1 2 3 4 J5 MAIN SW. 1 2 3 4 5 6 7 8 9 10 J3 IN OUT OUT IN IN OUT XFMR AC (L) 27V (L) XFMR AC IN (H) 27V (H) XFMR AC OUT (H) TRANSFORMER 1 2 3 4 5 6 J8 TERMINAL BLOCK 6 1 2 3 4 J6 1 F2 F3 1 JP2 130V RV5 K2A 5 1 .
Cobramatic® Owner’s Manual - page 27 P26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 J2 P10 1 2 3 4 5 6 7 8 9 10 J1 (N) (N) (H) (H) POWER INDICATOR LED (H) POWER INDICATOR LED (N) TORCH MOTOR (-) TORCH MOTOR (+) TORCH TRIGGER 27VAC (H) TORCH TRIGGER 27VAC (H) TORCH POT CCW TORCH POT WIPER TORCH POT CW POSA START POSA START 115VAC 115VAC 115VAC 115VAC TORQUE TORQUE 2.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com ALABAMA AIRGAS - SOUTH, INC. Birmingham, AL 205/251-6835 DIXIE WELDING SUPPLY Attalla, AL 256/538-6157 KIBRO, INC. Theodore, AL 251/653-4672 WELDING ENGINEERING SUPPLY CO. Prichard, AL 334/457-8681 INDUSTRIAL WELDING SERVICES Quinton, AL 205/674-3258 WELDING MACHINE HOSPITAL Montgomery, AL 334/832-9353 ALASKA RNR, INC.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com COLORADO AIRGAS - INTERMOUNTAIN, INC. Colorado Springs, CO 719/473-1947 WELDERS & EQUIP. SVC. & TESTING Littleton, CO 303/932-8755 WESTERN SLOPE WELDER REPAIR Grand Junction, CO 970/243-9616 CONNECTICUT ABCO WELDING & INDUSTRIAL SUPPLY CO.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com ILLINOIS CMS ELECTROMECHANICAL SERVICES, INC. Galesburg, IL 309/342-4125 – 888/9643526 FRED ARMS ELECTRIC MOTOR REPAIR Stone Park, IL 708/343-6262 RELIABLE EQUIPMENT REPAIR Hamel, IL 618/633-5000 ROCKFORD INDUSTRIAL WELDING SUPPLY Rockford, IL 815/226-1900 INDUSTRIAL WELDER REBUILDERS Alsip, IL 708/371-5688 INDIANA AGA GAS, INC. Hammond, IN 219/989-9030 AIRGAS - MID AMERICA, INC.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com MASSACHUSETTS NEW YORK DELO WELDING AIMTEK WELDING SUPPLY SUPPLY Auburn, MA Syracuse, NY 508/832-5035 315/478-2188 DYNAMIC WELD’G & REPAIR Bayshore, NY 631/643-1308 HAUN WELDING SUPPLY Syracuse, NY 315/463-5241 ANN ARBOR WLDG SUPPLY CO.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com JACKSON WELDING SUPPLY Rochester, NY 585/235-2920 NORTH CAROLINA ADAMS WELDER REPAIR & ELECTRICAL SERVICE, INC. Nashville, NC 252/459-1960 HOLOX LTD. Colfax, NC 336/996-1974 M & L WELDER REPAIR Asheville, NC 828/250-9353 MACHINE & WELDING SUPPLY CO. Dunn, NC 910/892-4016 MACHINE AND WELDING SUPPLY CO. Greenville, NC 252/752-3089 MACHINE AND WELDING SUPPLY CO.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com ARC SYSTEMS SERVICES Central Point, OR 541/665-2676 E C COMPANY dba ELECTRICAL CONSTRUCTION COMPANY Portland, OR 800/452-1511 INDUSTRIAL SOURCE Eugene, OR 541/344-1438 ALLWELD EQUIPMENT REPAIR Pittsburgh, PA 412/821-8460 BY DESIGN Columbia, PA 717/681-9494 GEOVIC WELDING SUPPLY Milton, PA 717/742-9377 J.A. CUNNINGHAM EQUIPMENT, INC. Philadelphia, PA 215/426-6650 JOSEPH PINTO, JR.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com VERMONT W.J. WELDING EQUIPMENT REPAIR, INC. N. Clarendon, VT 802/775-7422 VIRGINIA AIR PRODUCTS & CHEMICALS, INC. Bristol, VA 540/669-3161 ARC WELDERS, INC. Ashland, VA 804/798-1818 N.W. MARTIN CO. Springfield, VA 703/644-0120 NORFOLK WELDERS SUPPLY Norfolk, VA 804/622-6571 ARCET EQUIPMENT CO. Hampton, VA 757/728-9353 WASHINGTON AIRGAS - NORPAC, INC.
MK WARRANTY REPAIR STATIONS for MK Products as of 8/29/02 for most up-to-date list, please visit www.mkproducts.com A&A WELDER SERVICES LTD. Saskatoon, Saskatchewan 306/934-1601 ARC & GENERATOR REPAIR Garson, Ontario 705/525-2141 B. HARRIS WELDING SVCS. Dartmouth, Nova Scotia 902/468-6255 BARRY HAMEL EQUIPMENT LTD. Coquitlam, B.C. 604/945-9313 D-TECH WELD SERVICES Regina, Saskatchewan 306/586-9353 ELECTRO-MÉCANIK, INC. Sainte-Foy, Quebec 418/683-1724 GPR INDUSTRIES 1994 LTD.
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Cobramatic® Owner’s Manual
Effective January 1, 2000 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 defect in workmanship and material as of the time and place of delivery by MK Products. No warranty is made by MK Products with respect to trade accessories or other items manufactured by others.
16882 Armstrong Ave. Irvine, California 92606 Tel 949.863.1234 Fax 949.474.1428 www.mkproducts.
