Lincoln Electric IM597 User Manual

WIRE FEEDER

RETURN TO MAIN MENU

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

THIS PAGE INTENTIONALLY BLANK

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 -

Page 8

THIS PAGE INTENTIONALLY BLANK

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