Lincoln Electric IM597 User Manual

WIRE FEEDER

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OPERATOR'S MANUAL

IM597

MK 091-0414

November 1999

Rev i

For use with Push-Pull Torches Model K1589, K1590, K1591, K1592

Safety Depends on You

Lincoln arc welding equipment is
designed and built with safety in
mind. However, your overall safety
can be increased by proper
installation...and thoughful operation
on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READING
THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most

importantly, think before you act
and be careful.

Cobramatic

®

World's Leader in Welding and Cutting Products

OPERATOR'S MANUAL

Premier Manufacturer of Industrial Motors

Sales and Service through Subsidiaries and Distibutors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

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K1587-1 Cobramatic® Owner's Manual -

Page 7

Table of Contents

Section 1 SPECIFICATIONS ........................................................... 10

Section 2 SUPPORT EQUIPMENT REQUIRED ................................ 10

Section 3 COOLANT RECOMMENDATIONS .................................... 10

Section 4 OPTIONAL ACCESSORIES .............................................. 10

Section 5 INSTALLATION .............................................................. 10

5.1 Location ................................................................................................. 10

5.2 42 VAC Input Power Connections ............................................................. 11

5.3 Posa Start Connection .............................................................................11

Section 6 WIRE THREADING PROCEDURE .................................... 11

6.1 Wire Spool Installation ............................................................................ 11

6.2 Threading Procedure ............................................................................... 11

6.3 Pre-Setting Slave Motor Tension ............................................................... 12

Section 7 OPERATION ................................................................... 12

7.1 General .................................................................................................. 12

7.2 Feeder Controls ...................................................................................... 12

7.3 CV/CC Posa Start Operating Procedure .................................................... 13

Section 8 MAINTENANCE............................................................... 14

8.1 Testing the Torch .................................................................................... 14

8.2 Relay K2 Operation .................................................................................15

8.3 Testing the Input Power Circuits ............................................................... 15

8.4 Testing the Speed Control ........................................................................ 15

MAIN PC BOARD CONNECTIONS ................................... 16

TROUBLE SHOOTING ..................................................... 17

DRAWINGS .................................................................... 18

K1587-1 Wire Feed Cabinet - Exploded View .............................................18

003-2016 Front Panel - Exploded View......................................................20

003-0570 Spindle Brake Assembly - Exploded View .................................... 21

003-1232 Slave Motor Assembly - Exploded View ...................................... 22

Wire Harness for Input Power from Power Source ...................................... 23

Main PC Board Parts Placement................................................................ 24

Front Panel Circuit Board ......................................................................... 26

SCHEMATICS.................................................................. 27

Wiring Schematic .................................................................................... 27

Torch Connections .................................................................................. 28

Block Diagram ........................................................................................ 29

WARRANTY REPAIR STATIONS ..................................... 30

K1587-1 Cobramatic® Owner's Manual -

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K1587-1 Cobramatic® Owner's Manual -

Page 9

Section 1 SPECIFICATIONS

Wire Diameter Capacity .................................... .030 - 1/16" ALL Types

Wire Capacity .................................................... 12" Standard

(Insulated or Non-Insulated)

Power Input ....................................................... 42 VAC 50/60 Hz,

............................................................................ 150 Watts Peak (3 amps)

Weight ................................................................ 31 pounds

Shipping Weight ............................................... 36 pounds

For Use with these Lincoln Torches ............... K1589,K1590,K1591,K1592

Section 2 SUPPORT EQUIPMENT REQUIRED

C.V. or C.C. Power Source of Sufficient Capacity for Your Needs.

Regulated Gas Supply and Hoses.

Properly Sized Power Leads from Power Source to Wire Feeder and Ground.

Water Source and Hose Capable of Providing a Minimum of 1 qt/min. at 45
p.s.i. when using water cooled torches.

Section 3 COOLANT RECOMMENDATIONS

1. Use a name-brand additive which does not contain reactive sulphur or
chlorine and does not react with copper, brass, or aluminum.

2. Check coolant periodically to remain within limits of the following:

A. Coolant Flow rate - 1 quart/minute at 45 p.s.i.
B. Resistivity - 10K ohms/centimeter
C. Ph Range - 5.5-8.5
D. Particle Size - .005"

Section 4 OPTIONAL ACCESSORIES

Replacement Plastic Guides for Slave Motor

Lincoln MK Products

Inlet Guide S23980-1 753-0062
Outlet Guide with Knob S23980-2 003-0428

Section 5 INSTALLATION

5.1 LOCATION

The cabinet should be placed in a location where it can be protected from
damage. Lead lengths and accessibility must also be considered when
installing the cabinet.

K1587-1 Cobramatic® Owner's Manual -

Page 10

5.2 42 VAC INPUT POWER CONNECTIONS

Your Wire Feeder comes factory ready with a harness to plug directly into all 14 pin

Lincoln Power Sources equipped with 42 VAC auxiliary.

The 42 VAC is connected to the PC Board on terminal strip J5 #1 (neutral) and #2

(hot) and Ground to the Cabinet chassis.

5.3 POSA START CONNECTIONS

Posa Start circuitry aids welding starts by sensing arc establish signals. A
weld ground signal is required for this to circuit to work, which is provided
through the Power Harness to the Power Source and is internally connected
to the P.C. board on terminal strip J6 terminal 2.

Note: Place polarity switch to DCEP. Refer to scetion 7.3 for

power supply settings to insure proper Posa Start operation.

WARNING: TURN THE INPUT POWER TO THE POWER SOURCE OFF
AT THE DISCONNECT SWITCH BEFORE PERFORMING ANY WORK.

Section 6 WIRE THREADING PROCEDURE

6.1 WIRE SPOOL INSTALLATION

Release latches, and open right side door of cabinet.

Remove spool retainer from spindle hub.

Install wire spool onto spindle hub so that wire feeds from bottom of spool
towards slave motor. Make sure that the hole in the spool aligns with pin on
spindle hub. The white dot on the end of the spindle hub will aid in this
alignment.

Replace the spool retainer.

6.2 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.

Release tension from slave motor drive rolls.

Route wire into inlet guide, along drive roll groove, and into wire conduit.

Prevent the wire spool from turning with the palm of the right hand, and at the
same time grasp the slave motor pressure adjusting knob.

Pull the torch trigger and slowly tighten the slave motor pressure adjusting
knob until the slave motor stalls.

CAUTION:

EXCESSIVE DRIVE ROLL TENSION WILL

THAN IMPROVE WIRE FEED PERFORMANCE.

K1587-1 Cobramatic® Owner's Manual -

Page 11

REDUCE RATHER

Tighten the torch pressure adjusting knob so the wire will be picked up and
fed through the contact tip. Proper tension is achieved when wire does not
slip if a small amount of pressure is added to the wire as it exits the tip.

6.3 PRE-SETTING SLAVE MOTOR TENSION

All Cobramatics have preset adjusting nuts which enables spools of the same
wire diameter and type to be changed without further pressure adjustment
after initial set-up.

To preset the slave motor tension bottom out the pressure adjusting knob by
turning it completely clockwise.

Prevent the wire spool from turning and using a 9/16" wrench adjust the
preset nut until the slave motor stalls.

Correct pressure will now be achieved by simply bottoming out the pressure
adjusting knob.

6.4 WIRE GUARD

The Cobramatic® Wire Guard is designed to keep the welding wire from
jumping off the spool inside the wire feed cabinet. When the trigger is
released and the brake engages, especially when using a new spool that is
heavier towards the outside, the spool will tend to rotate more against the
spindle drag adjustment.

However since the wire is held by the slave motor it will not move and could
subsequently jump off the back of the spool and become lodged in the brake
mechanism, or jump off the front of the spool and electrically short-out to the
cabinet chassis. The wire guard will keep the wire from doing either.

The wire guard is designed to run inside the spool on top of the wire, and
when the brake is engaged the wire guard will hold the wire onto the spool.
The wire guard is made of a heavy woven nylon material that is resistant to
wear and will not contaminate the surface of the wire.

Section 7 OPERATION

7.1 GENERAL

The AC slave motor in the feeder runs at a fast, constant speed, but has very
low torque. It is always trying to feed more wire than the torch motor wants,
and when the motor gets all it wants, it slows the slave motor preventing a
bird’s nest. Because of the low torque produced by the slave motor, a brake
system is used to prevent wire overrun rather than tension. The drag
adjustment in the spindle is used to keep the wire slightly taut, so it will not
unspool while feeding wire. The 24 VDC torch pull motor is controlled by a
solid state speed control and a potentiometer located in the torch.

7.2 FEEDER CONTROLS

7.2.1 ON/OFF SWITCH

Placing the switch in the “ON” position energizes the feeder circuitry and the
power indicator light.

7.2.2 WIRE SIZE SELECTOR SWITCH

The wire size selector switch changes the torque of the slave motor for the

K1587-1 Cobramatic® Owner's Manual -

Page 12

wire you are using. When in the .030-.035 aluminum only position, the slave
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.)

7.2.3 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.

7.2.4 TORCH AMPHENOL CONNECTORS
The Cobramatic® contains a 7 pin “W” clocked amphenol.

7.2.5 CONDUIT INLET

The Conduit Inlet provides access to the slave motor outlet guide.

7.2.6 GAS INLET

Provides access to the gas fitting inside the cabinet.

7.2.7 POWER INLET

The Power Inlet provides access to the power block inside the cabinet.

7.3 CV/CC POSA START OPERATING PROCEDURE

7.3.1 GENERAL

The Posa Start feature allows the Cobramatic® to be used in combination
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.

(NOTE: Reverse polarity MUST be used.)

CAUTION:

DO NOT OPERATE A COBRAMATIC® ON A POWER SOURCE HAVING A

HIGH-FREQUENCY STARTING CIRCUIT BEFORE MAKING SURE THAT THE

HIGH-FREQUENCY PORTION OF THE POWER SOURCE IS TURNED OFF.

FAILURE TO TAKE THIS PRECAUTION WILL CAUSE PERMANENT DAMAGE

TO THE POSA START CIRCUITRY.

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.

7.3.2 CV POSA START OPERATION

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.
Adjust power source to desired voltage for your weld condition.

Depress gun trigger and adjust wire feed speed at gun to match voltage
setting. If approximate wire feed is not known, it is better to start with excess
wire feed rather than too little, in order to prevent a “burn-back”.

Turn the Posa Start switch to the “ON” position. Press torch trigger and,
using Run-in Speed Control, adjust wire feed rate to approximately 10% of
welding wire speed set at torch.
Strike an arc, and adjust wire feed rate at gun until correct condition is
achieved.

K1587-1 Cobramatic® Owner's Manual -

Page 13

7.3.3 CC POSA START OPERATION

Attach the Cobramatic® to a CC power source according to the installation
instructions.

Insure power supply high frequency switch is in the “OFF” position, and
power supply is set to DC reverse polarity.

The power supply contactor should be set to “Remote” or “Tig” and the
amperage control set to “Panel” or “Standard” depending on power supply.
Turn the Cobramatic® power switch to the “ON” position and the Posa Start
switch to the “OFF” position.

Adjust power source to desired amperage for your weld condition.

Press gun trigger and adjust wire feed speed at gun to match current setting.
If approximate wire feed speed is not known, it is better to start with excess
wire feed rather than too little, in order to prevent possible damage to the
contact tip.

Turn Posa Start switch to the “ON” position. Press torch trigger and, using
Run-in Speed Control, adjust wire feed speed to approximately 10% of
welding wire speed set at torch.

Strike an arc; if the wire stubs out, reduce wire feed rate at gun, or increase
amperage setting on power source.

NOTE: Because the Posa Start Run-in Speed always remains a percentage of the

actual welding wire feed rate, the Posa Start run-in speed will always slow down or

speed up proportional to any adjustment you now make at the gun. Therefore, if you

slow down the welding wire feed speed, you will have to increase the Run-in Speed

setting.

Section 8 MAINTENANCE

Maintenance of the torch will normally consist of a general cleaning of the
wire guide system, including tubes, drive rolls, and conduits at regular
intervals.

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 a qualified
shop maintenance man.

Your Cobramatic® is designed to provide years of reliable service. Normal
wear and component failure may require occasional service.

The number of units in operation and the importance of minimal "down time"
will determine to what extent spare parts should be stocked on hand.

8.1 TESTING THE TORCH

8.1.1 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.

K1587-1 Cobramatic® Owner's Manual -

Page 14

8.1.2 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.
Check the resistance across pin “D” (wiper) and pin “G”. The resistance
should vary from 5K - 0 ohms.

8.1.3 TESTING THE MICRO SWITCH

Using the torch amphenol, check for continuity across pins “E” and “F” when
the trigger is pressed.

8.2 RELAY K2 OPERATION

When the torch trigger is pressed, 24VAC is sent to the coil of relay K2.
When K2 is energized, AC is sent to the slave motor, spool brake, and the AC
contactor. Relay K2 is also responsible for sending 24VAC to the speed
control circuit and shorting the torch motor leads together when the trigger is
released for the dynamic braking system. K2 also provides the closing
contactor signal.

8.3 TESTING THE INPUT POWER CIRCUITS

The AC circuits are protected by fuses F2 and F3. If F2 and F3 continually
blow, remove J4 (Brake Solenoid), J7 (slave motor) and J5-3,4 (AC
Contactor) from the P.C. Board. Replace fuse, and retrigger system. If fuse
does not blow; isolate the problem by plugging in J4, J7, and J5-3,4 one at a
time until the fuse blows.

8.4 TESTING THE SPEED CONTROL

NOTE: The torch should be tested first and the amphenol must be connected to the

Cobramatic® to perform this test.

Place a voltmeter across diode D10 and press torch trigger. A reading of 0 ­24VDC should be observed, as the torch potentiometer varied.

24.024.0

24.0

24.024.0

D10

VDC

+

_

K1587-1 Cobramatic® Owner's Manual -

Page 15

MAIN P.C. BOARD CONNECTIONS

Note: For Cabinet ­Remote Pot Kit, Remove
Jumper from J13-J14. Plug
Remote Pot Kit into J14.

J14

J13

J1

CURRENT SENSOR
(Posa Start)

J2

FRONT PANEL

1 12 2 33 4 4

Control

Cable
LE P/N L10708-1
MK P/N 843-0496

J3

FRONT PANEL

J4

BRAKE SOLENOID

J7

SLAVE MOTOR

J8

J5J6

TRANSFORMER

Input Power - 42VAC

Input Power - 42VAC

Chasis Ground

Closing Contacts Out

Closing Contacts Out

Weld Connection Ref (-)

Not Used

K1587-1 Cobramatic® Owner's Manual -

Page 16

TROUBLESHOOTING

TROUBLE CAUSE REMEDY

No wire feed at torch, feeder
not operating, i.e., no slave
motor or brake soleniod.

Brake soleniod inoperative.

No wire feed at torch, feeder
operating properly.

F2 & F3 (MDA7 7A Slow Blow)
fuse in feeder blown.

F1 (4 amp) fuse in feeder blown. Check motor leads for shorts, then

Micro-switch defective/not being
activated. Broken electrical cable.

Relay K2 inoperative. Check/Replace relay K2.

Loose J2, J3, P.C. board
connector

Soleniod defective. Replace soleniod.

Relay K2 inoperative. Check for 42VAC across J4-1 and J4-2

Bad potentiometer. Check potentiometer with meter.

Bad torch motor. Check/Replace motor.

Broken electrical cable. Check motor and potentiometer wires

Bad speed control/PCB. Check/Replace P.C. Board.

Loose or no cable connections. Check all power connections.

Check AC circuit. Replace fuse

replace fuse

Replace switch. Check switch for
operation. Check micro switch wires for
continuity.

Check J2, J3 connectors.

Check relay K2 for AC not present.

for continuity.

Wire feeds, but welding wire
is not energized.

Wire feeds erratically.

Wire feeds one speed only

Wire walks out of drive rolls

Relay K2 not sending contactor
signal.

Contactor control cable loose or in
wrong position.

Welding power source not working
right.

Excessive spool drag pressure. Decrease spool drag pressure inside

Dirty or worn conduit. Blow out or replace conduit.

Incorrect pressure on drive rolls. Adjust pressure at both feeder and

Idler roll stuck. Check for lock washer under idler roll, or

Wrong size contact tip. See contact tip table.

Bad potentiometer. Check with meter.

Broken electrical cable in lead
assy.

Bad speed control. Check/Replace P.C. Board.

Idler roll upside-down. Place groove in idler roll towards top.

Rear wire guide missing. Replace wire guide.

Check/Replace relay K2.

Check power supply owners manual for
location and type of contactor signal
required, i.e. closing contacts or AC.

Check power supply for proper
operation.

hub.

torch.

replace if damaged or worn.

Check potentiometer wires for continuity
or shorts.

K1587-1 Cobramatic® Owner's Manual -

Page 17

Exploded View - K1587-1 Wire Feed Cabinet

K1587-1 Cobramatic® Owner's Manual -

Page 18

PARTS LIST - K1587-1 Wire Feed Cabinet

No. Qty. Part Number Description
1 1 436-0122 Base, Cabinet, Screened, Lincoln
2 1 438-0019 Cover, Front, PCB, Lincoln
3 14 336-0038 Screw, PH Fil T/B #6-32 x 3/8
4 4 301-0103 Rubber Feet
5 16 333-0043 Washer, Int-Star #6
6 4 336-0006 Screw, PH Fil #6-32 x 1/2
7 6 341-0005 Nut, Hex #6-32
8 2 329-0003 Screw, Hex1/4-20 x 3/4
9 2 332-0009 Washer, Shoulder 0.265 ID
10 1 261-0105 Insulator Power Block
11 1 003-1674 Power Block Assy.
12 1 261-0104 Insulator, Spool
13 2 336-0037 Screw, PH Fil T/B #6-32 x 1/4
14 2 329-0005 Screw, Hex 1/4-20 x 1.00 LG
15 1 261-0372 Insulator, Slave Motor
16 2 331-0005 Washer, Flat 1/4
17 2 333-0009 Washer, Spring Lock 1/4
18 2 341-0010 Nut, Hex 1/4-20
19 1 001-1232 Slave Mtor 42V Assy.
20 1 003-0570 Spindle Brake Assy.
21 1 328-0112 Screw, Socket HD 3/8-16 x 1.00 LG
22 1 003-0784 Pawl Ratchet Assy.
23 1 405-0886 Decal, Warning (T13297)
24 2 327-0012 Screw, ST T/F #6-32 x 1/4 LG
25 1 419-0080 Spring Extension
26 1 003-2095 Brake Solenoid, 42V Assy.
27 1 003-1723 Transformer, 42V Assy.
28 16 336-0005 Screw, PH, Fil, #6-32 x 3/8 LG
29 5 331-0002 Washer, Flat #6
30 4 345-0008 Nut, Self-Locking #6-32
31 1 405-0909 Decal, Electronic Connection
32 1 003-1721 PCB, Main Assy.
33 6 342-0410 Apcer, Stacking #6-32 x 0.534 LG
34 4 336-0039 Screw, PH. Fil. #10-32 x 3/8 LG
35 1 003-2016 Assy, Panel, Front, Lincoln
36 1 351-0752 Bushing Snap 1.12ID, 1.50 Dia Mtg. Hole
37 1 351-0744 Bushing Snap 1.00ID, 1.375 Dia Mtg. Hole
38 4 351-0745 Bushing Snap 15/16ID, 1.125 Dia Mtg. Hole
39 1 351-0082 Cap Plug 7/8 Dia Mtg. Hole
40 1 411-0157 Clamp Cable Strain Rel.
41 1 003-2015 Assy, Doors, Lincoln
42 1 415-0243 Handle Carry
43 4 329-0219 Screw, Hex #10-24 x 1/2 LG
44 4 331-0067 Washer, Flat #10
45 4 333-0007 Washer, Spring Lock #10
46 4 341-0007 Nut, Hex #10-24
47 1 L10708-1 Control Cable, Lincoln 42V
48 1 435-3121 Holder Capacitor
49 0.25ft 261-0446 Mylar Tape
50 4 351-0086 Thread Insert #6-32
51 1 405-0894 Serial Number ID Plate, Lincoln
52 4 351-0089 Thread Insert #10-32
53 2 331-0049 Washer, Flat 1/4
54 4 411-0020 Tie Wrap
55 1 003-1798 External Cap Assy
56 1 351-0758 Bushing, Snap. dia3/4, Black
57 1 301-0087 Wire Guard

K1587-1 Cobramatic® Owner's Manual -

Page 19

Exploded View - MK P/N 003-2016 Front Panel

K1587-1 Cobramatic® Owner's Manual -

Page 20

Exploded View - MK P/N 003-0570 Spindle Brake Assy.

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K1587-1 Cobramatic® Owner's Manual -

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Page 21

Exploded View - MK P/N 001-1232 Slave Motor Assy.

34 3/REF 324-0286 Screw, flat hd 1/4-20 x 3/4

33 3/REF 333-0064 Washer c'sink int star 1/4

32 1/REF 330-0004 Screw, shoulder 1/4 x 3/4

31 1/REF 330-0001 Screw, shoulder 1/4 x 3/8

30 1/REF 501-0207 Idler roll-slave motor

29 1/REF 333-0009 Washer, lock spring 1/4

28 3/REF 331-0044 Washer flat #10

27 1/REF 003-0273 Pressure shaft, knob

26 1/REF 345-0047 Nut, adjust

25 1/REF 419-0211 Spring, comp. 0.62 od x 0.062

24 1/REF 331-0050 Washer, 1/4 id

23 1/REF 413-0209 Idler roll arm

22 1/REF 431-1082 Nut, stop shaft

K1587-1 Cobramatic® Owner's Manual -

21 3/REF 328-0024 Screw, socket hd #8-32 x 3/8

20 1/REF 753-0062 Guide, wire 1/2 dia.

20 1/REF S23980-1* Guide, wire 1/2 dia.

19 1/REF 003-0176 Knob, sub-assy.

18 1/REF 753-0062 Guide, wire outlet 5/8 dia.

18 1/REF S23980-2* Guide, wire outlet 5/8 dia.

17 2/REF 321-0060 Set screw #10-24 x 1/4

16 1/REF 511-0206 Drive roll-slave motor

Page 22

9 1/REF 507-0130 Gear Shaft

15 2/REF 328-0029 Screw, socket hd #8-32 x 1.00

14 2/REF 328-0026 Screw, socket hd #8-32 x 5/8

13 4/REF 333-0006 Washer, lock spring #8

8 1/REF 501-0118 Bearing reduction shaft

12 4/REF 342-0063 Spacer, 1/4 x 0.171 id

11 1/REF 431-0334 Cap

10 1/REF 501-0156 Cap bearing

7 1/REF 431-0347 Gear reduction casting

6 1/REF 261-0213 Gear box insulator

5 1 001-1231 Gear box assy-slave motor

3 1/REF 421-0128 Spring pin 1/16 x 1/4 lg

2 1/REF 507-0128 Hel gear 24p-8t-0.33

1 1 003-1720 Torque motor s/a

Parts List

No. Qty. MK P/N Description

* Lincoln Electric Part Number

Wire Harness for Input Power from Power Source

Plug for Lincoln
Power Source

Wires terminated
inside Cobramatic
Cabinet

LE P/N L10708-1 42VAC Interface Cable
(MK P/N 843-0496)

Control Cable Termination Chart

Function Color Code

42 VAC input White I J5-1

42 VAC input Black K J5-2

Posa Start ref. gnd Blue H J6-2

Contactor Red C J6-3

Contactor Orange D J6-4

Ground Green B Chassis

K1587-1 Cobramatic® Owner's Manual -

Lincoln 14 Pin

Plug Receptacle

Page 23

Cobramatic I

Cabinet Terminal

MAIN P.C. BOARD

PARTS PLACEMENT

COMPONENTS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY.

K1587-1 Cobramatic® Owner's Manual -

Page 24

MK P/N 003-1721

MAIN P.C. BOARD

PARTS LIST

COMPONENT # MK P/N DESCRIPTION

K1 ................................. 157-0144...................... RELAY, 5V 500 Ohm 200MA

R3 ................................. 115-0154...................... RESISTOR, carbon .25 watt 6.8K ohm

R4, R5 .......................... 115-0042 ...................... RESISTOR, carbon .50 watt 6.8K ohm

R12, R13 ...................... 115-0120 ...................... RESISTOR, carbon .25 watt 100 ohm

R6 ................................. 115-0122...................... RESISTOR, carbon .25 watt 150 ohm

R7 ................................. 115-0144...................... RESISTOR, carbon .25 watt 10K ohm

R8 ................................. 115-0138...................... RESISTOR, carbon .25 watt 3.3K ohm

R9 ................................. 115-0129...................... RESISTOR, carbon .25 watt 560 ohm

R10 ............................... 115-0136...................... RESISTOR, carbon .25 watt 2.2K ohm

R11 ............................... 115-0141...................... RESISTOR, carbon .25 watt 5.6K ohm

D1 ................................. 124-0002...................... DIODE, 1 amp 800 volts (IN4006)

D6-D10 ......................... 124-0003...................... DIODE, 2.5 amps 1KV (HEP170)

D4 ................................. 124-0011...................... DIODE, zener 1 watt 10 volts (IN4740)

D5 ................................. 124-0012...................... DIODE, zener 1 watt 6.8 volts (IN4736)

Q2 ................................ 122-0011 ...................... TRANSISTOR, NPN 500MA 250 volts (2N5655)

Q3 ................................ 122-0004 ...................... TRANSISTOR, PNP 1 amp 50 volts (2N4249)

Q4 ................................ 122-0013 ...................... TRANSISTOR, unijunction 30 volts (2N2646)

Q5 ................................ 125-0028 ...................... THYRISTOR, 8 amps 400 volts (MCR218-6)

C1, C5, C8, C9 ............. 101-0016 ...................... CAPACITOR, ceramic .01uf 600VDC

C2 ................................. 101-0013...................... CAPACITOR, Poly .047uf 200VDC

C3 ................................. 104-0060...................... CAPACITOR, electrolytic 6.8uf 63 VDC

C4, C6 .......................... 104-0002 ...................... CAPACITOR, tantalum 10uf 20VDC

C7 ................................. 101-0021...................... CAPACITOR, ceramic .047uf 50VDC

RV1, RV5, RV6, RV7 .... 124-0026...................... VARISTOR, 130 volts 10 amps

RV2, RV3, RV4............. 124-0028 ...................... VARISTOR, 56 volts 8 amps

J1 ................................. 153-0866 ...................... CONNECTOR, R/A header 2 pin

J2 ................................. 153-0923 ...................... TERMINAL, header 26 pin

J3 ................................. 153-0842 ...................... TERMINAL, header 10 pin

J4 ................................. 153-0844 ...................... TERMINAL, header 2 pin

J5, J6 ............................ 186-0057...................... TERMINAL, strip 4 pin

J7, J8 ............................ 153-0850...................... CONNECTOR, 6 pin

J13, J14 ........................ 153-0867 ...................... CONNECTOR, R/A header 3 pin

Fuse Holder .................. 152-0008...................... FUSE HOLDER, PC mount

F1 ................................. 151-0043 ...................... FUSE, 3AG 4A 250V

F2, F3 ........................... 151-0021 ...................... FUSE, MDA7 7A Slow Blow

K2 ................................. 157-0022...................... RELAY, 24VAC 4PDT

K2 Socket ..................... 173-0026 ...................... SOCKET, relay 15 pin

Jumper ......................... 003-1307...................... JUMPER CABLE

Clip ............................... 157-0023 ...................... Relay Clip

K1587-1 Cobramatic® Owner's Manual -

Page 25

MK P/N 003-2001

FRONT PANEL CIRCUIT BOARD

COMPONENT # MK P/N DESCRIPTION

R1 ................................. 113-0062...................... RESISTOR, wire wound 30 ohm, 8 watt

R2 ................................. 119-0020...................... POTENTIOMETER, 100K ohm

R3 ................................. 115-0037...................... RESISTOR, carbon 2.7K ohm, 1/2 watt

D1 ................................. 124-0045 ...................... LED, green

SW1 ............................. 159-3587...................... SWITCH, DPDT, p.c. mount

SW2 ............................. 159-3586...................... SWITCH, SPDT, p.c. mount

SW3 ............................. 159-3586...................... SWITCH, SPDT p.c. mount

J1 ................................. 153-0842 ...................... HEADER, 10pin, 90 degree

J2 ................................. 153-0924 ...................... HEADER, 26pin, 90 degree

J3 ................................. 153-0860 ...................... HEADER, 8pin, 90 degree

J4 ................................. 153-0860 ...................... HEADER, 8pin, 90 degree

COMPONETS TO BE REPLACED BY QUALIFIED SERVICE PERSONNEL ONLY.

K1587-1 Cobramatic® Owner's Manual -

Page 26

COBRAMATIC®

WIRING SCHEMATIC

K1587-1 Cobramatic® Owner's Manual -

Page 27

COBRAMATIC®

TORCH CONNECTIONS

K1587-1 Cobramatic® Owner's Manual -

Page 28

COBRAMATIC®

BLOCK DIAGRAM

K1587-1 Cobramatic® Owner's Manual -

071-0368

Page 29

MK WARRANTY REPAIR STATIONS

for MK Products

ALABAMA

AIRGAS MID-SOUTH
Birmingham, AL
205/251-6835

WELDING ENGINEERING SUPPLY CO.
Prichard, AL
334/457-8681

ARIZONA

PRAXAIR
Phoenix, AZ
602/269-2151

ARKANSAS

APPLIED SERVICES, INC.
Benton, AR
501/860-6464

RELIABLE WELDING REPAIR
Greenwood, AR
501/996-6688

CALIFORNIA

ADVANCED WELDER REPAIR
Commerce, CA
323/263-7383

ARC PRODUCTS
San Diego, CA
619/628-1022

CAL-WELD SUPPLY
Fresno, CA
209/445-0131

EMCO EAST
Concord, CA 94520

PRAXAIR DISTRIBUTION (ARC RENT)
Long Beach, CA
562/427-0099

R. J. KATES
San Diego, CA
619/565-6960

RED-D-ARC, INC.
Carson, CA

COLORADO

INDUSTRIAL GAS PROD. & SUPPLY
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

FLORIDA

A & I SPECIALTIES
Lehigh Acres, FL
941/368-7435

ACTION WELDING SUPPLY
Jacksonville, FL
904/786-2254

AMVEL CORPORATION
Miami, FL
305/592-5678

ELECTRICAL WELDERS SERVICE
Orlando, FL 32808

407/290-9551

HOLOX LTD.
Merrit Island, FL
407/454-4106

HAUN SYSTEMS REPAIR
Orlando, FL
407/872-0011

ROPER ELECTRIC MOTOR SERVICE
Panama City, FL 32405
850/769-6643

SMITTY’S WELDER SERVICE
West Palm Beach, FL
561/845-1224

TRI-GAS
Miami, FL
305/592-3180

SO-CAL AIRGAS
Gardena, CA
310/523-9355

K1587-1 Cobramatic® Owner's Manual -

GEORGIA

MC CULLOUGH ELEC. MOTOR SVC.
Atlanta, GA
404/688-5251

Page 30

MK WARRANTY REPAIR STATIONS

for MK Products

B&W INDUSTRIAL SERVICES
Augusta, GA
706/738-8722

IDAHO

NORCO
Boise, ID
208/336-1643

ILLINOIS

BODINE ELECTRIC OF DECATUR
Decatur, IL
217/423-2593

INDUSTRIAL WELDER REBUILDERS
Alsip, IL
708/371-5688

PCI ENERGY SERVICES
Lake Bluff, IL
847/680-8100

RELIABLE EQUIPMENT REPAIR
Hamel, IL
618/633-5000

INDIANA

APCO GAS TECH
Speedway, IN
317/481-4550

EVANSVILLE ARMATURE, INC.
Evansville, IN
812/428-9034

IOWA

CENTRAL STATES AIRGAS
Des Moines, IA
515/266-1111

CEDAR RAPIDS WELDING SUPPLY
Cedar Rapids, IA
319/365-1466

KANSAS

KANOX
Hutchinson, KS
316/665-5551

LOUISIANA

GREENE WELDING SUPPLY
West Monroe, LA
318/340-9206

RED BALL OXYGEN CO.
Shreveport, LA
318/425-3211

MICHIGAN

APEX WELDING GASES & SUPPLY
Muskegon Heights, MI
616/722-3185

WESAR COMPANY
Three Rivers, MI
616/483-9125

MINNESOTA

MINNEAPOLIS OXYGEN CO.
Minneapolis, MN

612/588-8855

OXYGEN SERVICE CO.
St. Paul, MN
612/644-7273

MISSOURI

CEE-KAY SUPPLY, INC.
St. Louis, MO
324/644-3500

P.G. WALKER
Springfield, MO
417/862-1745

NORTH CAROLINA

INDUSTRIAL MAINTENANCE OVERFLOW
Fletcher, NC

704/684-2000

M & L WELDER REPAIR
Asheville, NC
828/250-9353

MACHINE & WELDING SUPPLY CO.
Dunn, NC
910/892-4016

KENTUCKY

GENERAL WELDING PRODUCTS
Louisville, KY
502/635-5218

K1587-1 Cobramatic® Owner's Manual -

NATIONAL WELDERS
High Point, NC
910/882-1110

Page 31

MK WARRANTY REPAIR STATIONS

for MK Products

NORTH CAROLINA (contd.)

NATIONAL WELDERS SUPPLY CO.
Charlotte, NC
704/392-7317

OHIO

ALBRIGHT WELDING SUPPLY
Wooster, OH
330/264-2021

ARC EQUIPMENT COMPANY
Struthers, OH 44471
333/750-9353

CnD MACHINE, INC.
Canton, OH 44706
330/478-8811

VALLEY NATIONAL GASES
Lima, OH
419/228-1008

RICK’S WELDER REPAIR SERVICE
Eastlake, OH
440/269-1204

VALLEY NATIONAL GASES
Toledo, OH
419/241-9114

WELDINGHOUSE, INC.
Cleveland, OH
216/524-1955

OKLAHOMA

BILL’S WELDER REPAIR
Oklahoma City, OK
405/232-4799

AIRGAS MID-SOUTH
Tulsa, OK
918/582-0885

J.A. CUNNINGHAM EQUIPMENT, INC.
Philadelphia, PA
215/426-6650

VALLEY NATIONAL GASES
Pittsburgh, PA
412/281-1835

SOUTH CAROLINA

IND’L ELECTRIC REWINDING CO. OF
SUMTER
Sumter, SC
803/773-9366

TENNESSEE

NEXAIR
Memphis, TN
901/523-6821

TEXAS

AIRGAS HOUSTON
Houston, TX
713/462-8027

DENISON OXYGEN
Denison, TX
903/465-3369

RITE-WELD SUPPLY, INC
Fort Worth, TX
817/626-8237

VIRGINIA

NORFOLK WELDERS SUPPLY
Norfolk, VA
804/622-6571

WASHINGTON

A-L WELDING PRODUCTS
Tukwila, WA

425/228-2218

RITE-WELD SUPPLY, INC
dba OKLAHOMA WELDERS SUPPLY
Madill, OK

580/795-5561

PENNSYLVANIA

GEOVIC WELDING SUPPLY
Milton, PA
717/742-9377

K1587-1 Cobramatic® Owner's Manual -

CASCADE AIRGAS/WELDER’S SUPPLY
Seattle, WA

206/224-0433

OXARC, INC
Spokane, WA
509/535-7794

OXYGEN SALES & SERVICE, INC
Tacoma, WA
253/473-2282

Page 32

MK WARRANTY REPAIR STATIONS

PACIFIC WELDING SUPPLIES
Tacoma, WA
253/572-5302

PRAXAIR
Seattle, WA
206/624-7033

AMERICAN EQUIPMENT SERVICES
Kent, WA

253/395-9947

WISCONSIN

BENTLEY WELDING SUPPLY
Brookfield, WI
414/938-6365

CANADA

ARC & GENERATOR REPAIR
Garson, Ontario
705/525-2141

for MK Products

INDUSTRIAL ELECTRONIC SERVICES
Calgary, Alberta
403/279-3432

M.R.T. REPAIR CENTER, INC.
Montreal, Québec
514/648-0800

OZARK ELECTRICAL MARINE LTD.
St. John’s Newfoundland

PEEL ENGINES
Mississauga, Ontario
905/670-1535

PROMOTECH électrique, Inc.
Fleurimont, Québec
819/822-2111

WELDERS SUPPLY
Winnipeg, Manitoba
204/772-9476

WELDING WIDE SERVICES, INC.
Brampton, Ontario
905/874-9992

K1587-1 Cobramatic® Owner's Manual -

Page 33

THIS PAGE INTENTIONALLY BLANK

K1587-1 Cobramatic® Owner's Manual -

Page 36

Effective April 1, 1998

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. Such trade accessories and other items
are sold subject to the warranties 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 torch parts that come in
contact with the welding wire, including nozzles, nozzle insulators,
and contact tips where failure does not result from defect in
workmanship or material.

In the case of MK Products’ breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be at MK Products’ option: (1) repair; (2) replacement;
(3) where authorized in writing by MK Products, the reasonable
cost of repair or replacement at our Irvine, California plant; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Upon receipt of notice of apparent
defect or failure, MK Products shall instruct the claimant on the
warranty claim procedures to be followed.

As a matter of general policy only, MK Products may honor an
original user’s warranty claims on warranted equipment in the
event of failure resulting from a defect within the following periods
from the date of delivery of equipment to the original user:

1. Torches and Weldheads ........................................ 1 year

2. All Other Equipment ............................................. 3 years

3. Repairs ................................................................... 90 days

Classification of any item into the foregoing categories shall be at
the sole discretion of MK Products. Notification of any failure must
be made in writing within 30 days of such failure.

A copy of the invoice showing the date of sale must accompany
products returned for warranty repair or replacement.

All equipment returned to MK Products for service must be
properly packaged to guard against damage from shipping. MK
Products will not be responsible for any damages resulting from
shipping.

Normal surface transportation charges (both ways) 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, INCLUDING 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 PRODUCTS ARE INTENDED FOR ULTIMATE
PURCHASE BY COMMERCIAL/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 RE­SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS’
WARRANTIES TO ANY CONSUMER.

MK Products, Inc.

16882 Armstrong Ave.
Irvine, CA 92606
Tel [phone]
Fax [phone]

World's Leader in Welding and Cutting Products

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

Premier Manufacturer of Industrial Motors

FORM : LW-8
DATE : April 1, 1998