MK Products Cobramatic 42VAC User Manual
Cobramatic® (42 Volt)
Wire Feed Cabinet
Owner’s Manual
Product: Cobramatic
Manual: 091-0498
Serial: 01010001
Voltage Rating: 42 VAC
Revision: Dec. 2001 A
Model Number: 150-205
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. Training is available
from many public and private schools or similar
facilities.
Safe practices in the installation, operation
and maintenance of this equipment requires
proper training in the art, a careful study of the
information provided with the equipment, and
the use of common sense. Rules for safe use
are generally provided by suppliers of welding
power sources, compressed gas suppliers,
and electrode suppliers. Careful compliance
with these rules will promote safe use of this
equipment.
The following Safety Rules cover some of the
more generally found situations. READ THEM
CAREFULLY. In case of any doubt, obtain
qualied help before proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING PRODUCES
HIGH INTENSITY HEAT AND ULTRAVIOLET
RADIANT ENERGY WHICH MAY CAUSE
SERIOUS AND PERMANENT EYE DAMAGE
AND WHICH MAY DAMAGE ANY EXPOSED
SKIN AREAS.
Wear helmet with safety goggles or glasses
with side shields underneath, appropriate lter
lenses or plates (protected by clear cover
glass). This is a must for welding or cutting
(and chipping) to protect the eyes from radiant
energy and ying metal. Replace cover glass
when broken, pitted, or spattered.
Medical rst aid and eye treatment. First aid
facilities and a qualied rst aid person should
be available for each shift unless medical
facilities are close by for immediate treatment
of ash burns of the eyes and skin burns.
Wear protective clothing - leather (or asbestos)
gauntlet gloves, hat, and high safety-toe shoes.
Button shirt collar and pocket aps, and wear
cufess trousers to avoid entry of sparks and
slag.
Avoid oily or greasy clothing. A spark may
ignite them.
Flammable hair preparations should not be
used by persons intending to weld or cut.
Hot metal such as electrode stubs and work
pieces should never be handled without gloves.
Ear plugs should be worn when working on
overhead or in a conned space. A hard hat should
be worn when others work overhead.
B. toxic Fume Prevention
WARNING: The use of this product may result
in exposure to chemicals known to the State of
California to cause cancer and birth defects or
other reproductive harm.
Adequate ventilation. Severe discomfort, illness
or death can result from fumes, vapors, heat, or
oxygen enrichment or depletion that welding (or
cutting) may produce. Prevent them with adequate
ventilation. NEVER ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-, beryllium-bearing
and similar materials, when welded or cut, may
produce harmful concentrations of toxic fumes.
Adequate local exhaust ventilation must be used,
or each person in the area, as well as the operator,
must wear an air-supplied respirator. For beryllium,
both must be used.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating
is removed form the work surface, the area is well
ventilated, or the operator wears an air-supplied
respirator.
Work in a conned space only while it is being
ventilated and, if necessary, while wearing an airsupplied respirator.
Gas leaks in a conned space should be avoided.
Leaked gas in large quantities can change oxygen
concentration dangerously. Do not bring gas
cylinders into a conned space.
Leaving conned space, shut OFF gas supply at
source to prevent possible accumulation of gases
in the space if downstream valves have been
accidentally opened or left open. Check to be sure
that the space is safe before reentering it.
Vapors from chlorinated solvents can be
decomposed by the heat of the arc (or ame) to
form PHOSGENE, a highly toxic gas, and other
lung and eye irritating products. The ultraviolet
(radiant) energy of the arc can also decompose
trichloroethylene and perchloroethylene vapors
to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or
cutting atmosphere or where the radiant energy can
penetrate to atmospheres containing even minute
amounts of trichloroethylene or perchloroethylene.
c. Fire And exPlosion Prevention
Causes of re and explosion are: combustibles
reached by the arc, ame, ying sparks, hot slag,
or heated material, misuse of compressed gases
and cylinders, and short circuits.
BE AWARE THAT ying sparks or falling slag can
pass through cracks, along pipes, through windows
or doors, and through wall or oor openings,
out of sight of the goggled operator. Sparks
can y many feet.
To prevent res and explosion:
Keep equipment clean and operable, free of
oil, grease, and (in electrical parts) of metallic
particles that can cause short circuits.
If combustibles are in area, do NOT weld or
cut. Move the work if practicable, to an area
free of combustibles. Avoid paint spray rooms,
dip tanks, storage areas, ventilators. If the
work cannot be moved, move combustibles at
least 35 feet away, out of reach of sparks and
heat; or protect against ignition with suitable
and snug-tting, re-resistant covers or shields.
Walls touching combustibles on opposite
sides should not be welded on (or cut).
Walls, ceilings, and oor near work should be
protected by heat-resistant covers or shields.
Fire watcher must be standing by with suitable
re extinguishing equipment during and for
some time after welding or cutting if:
1. Appreciable combustibles (including building
construction) are within 35 feet.
2. Appreciable combustibles are further than
35 feet, but can be ignited by sparks.
3. Openings (concealed or visible) in oors or
walls within 35 feet may expose combustibles
to sparks.
4. Combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
radiant or conducted heat.
Hot work permit should be obtained before
operation to ensure supervisor’s approval that
adequate precautions have been taken.
After work is done, check that area is free of
sparks, glowing embers, and ames.
An empty container that held combustibles,
or that can produce ammable or toxic vapors
when heated, must never be welded on or
cut, unless container has rst been cleaned in
accordance with industry standards.
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-lling 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
Cobramatic® Safety - page i
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 ammable 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. Pressure Regulators
Regulator relief valve is designed to protect
only the regulator from overpressure; it is
not intended to protect any downstream
equipment. Provide such protection with one
or more relief devices.
Never connect a regulator to a cylinder
containing gas other than that for which the
regulator was designed.
Remove faulty regulator from service
immediately for repair (rst close cylinder
valve). The following symptoms indicate a
faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Faulty Gauge - if gauge pointer does not move
off stop pin when pressurized, nor returns to
stop pin after pressure release.
Repair. Do NOT attempt repair. Send faulty
regulators for repair to manufacturer’s
designated repair center, where special
techniques and tools are used by trained
personnel.
2. Cylinders
Cylinders must be handled carefully to prevent
leaks and damage to their walls, valves, or
safety devices:
Avoid electrical circuit contact with cylinders
including third rails, electrical wires, or welding
circuits. They can produced short circuit arcs
that may lead to a serious accident. (See 1-3C)
ICC or DOT marking must be on each cylinder.
It is an assurance of safety when the cylinder is
properly handled.
Identifying gas content. Use only cylinders with
name of gas marked on them; do not rely on
color to identify gas content. Notify supplier if
unmarked. NEVER DEFACE or alter name,
number, or other markings on a cylinder. It is
illegal and hazardous.
Empties: Keep valves closed, replace caps
securely; mark MT; keep them separate from
FULLS, and return promptly.
Prohibited use. Never use a cylinder or its
contents for other than its intended use,
NEVER as a support or roller.
Locate or secure cylinders so they cannot be
knocked over.
Passageways and work areas. Keep cylinders clear
of areas where they may be stuck.
Transporting cylinders. With a crane, use a secure
support such as a platform or cradle. Do NOT lift
cylinders off the ground by their valves or caps, or
by chains, slings, or magnets.
Do NOT expose cylinders to excessive heat,
sparks, slag, and ame, etc. that may cause
rupture. Do not allow contents to exceed 55
degrees C (130 degrees F.) Cool with water spray
where such exposure exists.
Protect cylinders, particularly valves from bumps,
falls, falling objects, and weather. Replace caps
securely when moving cylinders.
Stuck valve. Do NOT use a hammer or wrench to
open a cylinder valve that cannot be opened by
hand. Notify your supplier.
Mixing gases. NEVER try to mix any gases in a
cylinder.
NEVER rell any cylinder.
Cylinder ttings should never be modied or
exchanged.
3. Hose
Prohibited use. Never use hose other than that
designed for the specied gas. A general hose
identication rule is: red for fuel gas, green for
oxygen, and black for inert gases.
Use ferrules or clamps designed for the hose (not
ordinary wire or other substitute) as a binding to
connect hoses to ttings.
No copper tubing splices. Use only standard brass
ttings to splice hose.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to keep it from being run
over, stepped on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open ame.
Examine hose regularly for leaks, wear, and loose
connections. Immerse pressured hose in water;
bubbles indicate leaks
Repair leaky or worn hose by cutting area out and
splicing. Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may
clog orices and damage seats before connecting
regulator. Except for hydrogen, crack valve
momentarily, pointing outlet away from people and
sources of ignition. Wipe with a clean, lintless
cloth.
Match regulator to cylinder. Before connecting,
check that the regulator label and cylinder marking
agree, and that the regulator inlet and cylinder
outlet match. NEVER Connect a regulator
designed for a particular gas or gases to a cylinder
containing any other gas.
Tighten connections. When assembling
threaded connections, clean and smooth seats
where necessary. Tighten. If connection leaks,
disassemble, clean, and retighten, using properly
tting wrench.
Adapters. Use a CGA adapter (available from
your supplier) between cylinder and regulator,
if one is required. Use two wrenches to tighten
adapter marked RIGHT and LEFT HAND
threads.
Regulator outlet (or hose) connections may be
identied by right hand threads for oxygen and
left hand threads (with grooved hex on nut or
shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through suitable
vent before opening cylinder (or manifold
valve) by turning adjusting screw in (clockwise).
Draining prevents excessive compression
heat at high pressure seat by allowing seat to
open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Stand to side of regulator while opening
cylinder valve.
Open cylinder valve slowly so that regulator
pressure increases slowly. When gauge
is pressurized (gauge reaches regulator
maximum) leave cylinder valve in following
position: for oxygen and inert gases, open
fully to seal stem against possible leak; for fuel
gas, open to less than one turn to permit quick
emergency shut-off.
Use pressure charts (available from your
supplier) for safe and efcient recommended
pressure settings on regulators.
Check for leaks on rst pressurization and
regularly thereafter. Brush with soap solution.
Bubbles indicate leaks. Clean off soapy water
after test; dried soap is combustible.
e. user resPonsiBilities
Follow all Safety Rules.
Remove leaky or defective equipment from
service immediately for repair. Read and follow
user manual instructions.
F. leAvinG equiPment unAttended
Close gas supply at source and drain gas.
G. roPe stAGinG-suPPort
Rope staging-support should not be used for
welding or cutting operation; rope may burn.
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 signicant voltages. The arc is very bright
and hot. Sparks y, 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.
The welding arc is intense and visibly bright.
Its radiation can damage eyes, penetrate
lightweight clothing, reect from light-colored
surfaces, and burn the skin and eyes. Skin
burns resemble acute sunburn; those from
gas-shielded arcs are more severe and painful.
Cobramatic® Safety - page ii
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, ameproof apron, and re-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. Eyes may
be damaged by radiant energy when exposed
to the electric arc, even when not looking in the
direction of the arc. Never look at an electric
arc without protection.
Welding helmet or shield containing a lter
plate shade no. 12 or denser must be used
when welding. Place over face before striking
arc.
Protect lter plate with a clear cover plate.
Cracked or broken helmet or shield should
NOT be worn; radiation can be passed through
to cause burns.
Cracked, broken, or loose lter plates must be
replaced IMMEDIATELY. Replace clear cover
plate when broken, pitted, or spattered.
Flash goggles with side shields MUST be worn
under the helmet to give some protection to the
eyes should the helmet not be lowered over the
face before an arc is struck. Looking at an arc
momentarily with unprotected eyes (particularly
a high intensity gas-shielded arc) can cause a
retinal burn that may leave a permanent dark
area in the eld of vision.
3. Protection of Nearby Personnel
Enclose the welding area. For production
welding, a separate room or enclosed bay is
best. In open areas, surround the operation
with low-reective, noncombustible screens
or panels. Allow for free air circulation,
particularly at oor level.
Viewing the weld. Provide face shields for all
persons who will be looking directly at the weld.
Others working in area. See that all persons
are wearing ash goggles.
Before starting to weld, make sure that screen
aps or bay doors are closed.
B. toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to
the outside air. Carbon monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment’s rated capacity. Do not overload
arc welding equipment. It may overheat cables
and cause a re.
Loose cable connections may overheat or ash
and cause are.
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a
violent rupture or lead to such a rupture later under
rough handling.
d. comPressed GAs equiPment
Comply with precautions in 1-2D.
e. shock Prevention
Exposed electrically hot conductors or other bare
metal in the welding circuit, or in ungrounded,
electrically-HOT
equipment can fatally shock a person whose body
becomes a conductor. DO NOT STAND, SIT, LIE,
LEAN ON, OR TOUCH a wet surface when welding
without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work in damp
area without adequate insulation against electrical
shock. Stay on a dry duckboard, or rubber mat
when dampness or sweat cannot be avoided.
Sweat, sea water, or moisture between body and
an electrically HOT part - or grounded metal reduces the body surface electrical resistance,
enabling dangerous and possibly lethal currents to
ow through the body.
1. Grounding the Equipment
When installing, connect the frames of each unit
such as welding power source, control, work
table, and water circulator to the building ground.
Conductors must be adequate to carry ground
currents safely. Equipment made electrically HOT
by stray currents may shock, possibly fatally. Do
NOT GROUND to electrical conduit, or to a pipe
carrying ANY gas or a ammable liquid such as oil
or fuel.
Three-phase connection. Check phase requirement
of equipment before installing. If only threephase power is available, connect single-phase
equipment to only two wires of the three-phase
line. Do NOT connect the equipment ground lead
to the third (live) wire, or the equipment will become
electrically HOT - a dangerous condition that can
shock, possibly fatally.
Before welding, check ground for continuity. Be
sure conductors are touching bare metal of
equipment frames at connections.
If a line cord with a ground lead is provided with
the equipment for connection to a switch box,
connect the ground lead to the grounded switch
box. If a three-prong plug is added for connection
to a grounded mating receptacle, the ground lead
must be connected to the ground prong only. If the
line cord comes with a three-prong plug, connect
to a grounded mating receptacle. Never remove
the ground prong from a plug, or use a plug with a
broken ground prong.
2. Connectors
Fully insulated lock-type connectors should be
used to join welding cable lengths.
3. Cables
Frequently inspect cables for wear, cracks, and
damage. IMMEDIATELY REPLACE those with
excessively worn or damaged insulation to avoid
possibly lethal shock from bared cable. Cables
with damaged areas may be taped to give
resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and
protected from hot metal and sparks.
4. Terminals and Other Exposed Parts
Terminals and other exposed parts of electrical
units should have insulating covers secured
before operation.
5. Electrode Wire
Electrode wire becomes electrically HOT when
the power switch of gas metal-arc welding
equipment is ON and welding gun trigger is
pressed. Keep hands and body clear of wire
and other HOT parts.
6. Safety Devices
Safety devices such as interlocks and circuit
breakers should not be disconnected or
shunted out.
Before installation, inspection, or service of
equipment, shut OFF all power, and remove
line fuses (or lock or red-tag switches) to
prevent accidental turning ON of power.
Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity
while welding. If, in an emergency, it must be
disconnected, guard against shock burns or
ash from switch arcing.
Leaving equipment unattended. Always shut
OFF, and disconnect all power to equipment.
Power disconnect switch must be available
near the welding power source.
Cobramatic® Safety - page iii
For selecting a quality product. We want you to take
Thank You
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.
Please record your equipment identification information below for future reference. This
information can be found on your machine nameplate.
Model Name & Number _____________________
Code & Serial Number _____________________
Date of Purchase _____________________
Whenever you request replacements parts for, or information on this equipment always
supply the information you have recorded above.
Read this Owner’s Manual completely before attempting to use this equipment. Save this manual
and keep it handy for quick reference. Pay particular attention to the safety instructions we
have provided for your protection.
Cobramatic® Owner’s Manual - page iv
Table of Contents
Saftey Guidelines..............................................................................i
Installation .........................................................................Section A
Technical Specications .......................................................................3
Machine Grounding .............................................................................3
Machine Location ................................................................................3
Input Power Connections .....................................................................3
Wire Threading Procedure ...................................................................4
Welding Torch Connections ..................................................................5
Operation............................................................................Section B
General Description .............................................................................5
Recommended Processes and Equiment ...............................................5
Controls and Settings ..........................................................................6
POSA Start Operating Procedure...........................................................6
Accessories .........................................................................Section C
Optional Kits .......................................................................................7
Maintenance .......................................................................Section D
Routine Maintenance ...........................................................................8
Testing the Feeder...............................................................................8
Testing the Torch ................................................................................9
Troubleshooting ................................................................. Section E
Troubleshooting Guide .......................................................................10
Diagrams/Parts List ..........................................................Section F
Main PC Boards .................................................................................12
Mechanical .......................................................................................13
Electrical ...........................................................................................21
Warranty Repair Stations
Safety Warnings
Warranty
Cobramatic® Owner’s Manual - page 1
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Cobramatic® Owner’s Manual - page 2
Section A Installation
Technical Specications
Wire Diameter Capacity ............................... .030 inch - 1/16 inch ALL Types
Wire Spool Capacity ...................................12 inch Standard
.......................................................................(Insulated or Non-Insulated)
Power Input ................................................. 42 VAC 50/60 Hz,
.......................................................................150 Watts Peak (3 amps)
Weight ..........................................................41 pounds
Shipping Weight .........................................46 pounds
For Use with torch prex number ............. 14X, 16X, and 21X
Support Equipment Required
C.V. or C.C. power source of sufcient capacity for your needs.
Regulated gas supply and hoses.
Properly sized power leads from power source to wire feeder and ground.
Coolant Recommendations
Coolant recirculator and hose capable of providing a minimum of 1 quart per
minute at 45 p.s.i. when using water cooled torches.
Use a name-brand additive which does not contain reactive sulphur or
chlorine and does not react with copper, brass, or aluminum.
Check coolant periodically to remain within limits of the following:
A. Coolant Flow rate - 1 quart per minute at 45 p.s.i.
B. Resistivity - 10K ohms/centimeter
C. Ph Range - 5.5-8.5
D. Particle Size - .005 inch
MK Recommended Coolant Solution:
1 part ethylene glycol
3 parts distilled water
1 teaspoon liquid glycerin
Machine Grounding
The Cobramatic® and GMAW wire feeders are ground to the power source
through the input cable. The power source grounding terminal must be
properly connected to electrical ground per the power source operating
manual.
Mounting 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.
Input Connections
(See Cabinet and Torch Hook-Up in the Appendix)
42 VAC
Your Wire Feeder comes factory ready to connect into any standard 42VAC
power supply.
The 42VAC is connected to the PC Board on terminal strip J5 #1 (neutral)
and #2 (hot) and Ground to the Cabinet chassis. See diagram in the
appendix.
Cobramatic® Owner’s Manual - page 3
Section A
(Continued)
Shielding Gas
In accordance with the required support equipment, the customer must
provide a cylinder of shielding gas, a pressure regulator, a ow control valve,
and a hose from the ow control valve to the left bottom-most tting on the
power block.
The end of the hose must have a male connector to t the female 5/8-18
brass tting. Use a 11/16” wrench to tighten.
Coolant Supply and Return (if used)
Using a recirculator with properly mixed coolant, as previously described,
connect the coolant RETURN hose to the left middle tting on the power
block. Connect the coolant SUPPLY hose to the left top-most tting on the
power block.
The coolant hoses must have a male 5/8-18 left-hand thread to connect to the
power block ttings. Use an 11/16” wrench to tighten.
Welding Power
The electrode cable coming from the welding power supply should be afxed
with a 1/2” copper ring lug. Using a 9/16” wrench, remove the 3/8” bolt and
washer from the bottom of the power block. Use a 9/16” wrench to tighten.
It is recommended to make this connection last, after connecting the gas and
coolant hoses. Reference Input Connections gure in the Appendix.
Wire Threading Procedure
Wire Spool Installation
Release latches, and open right side door of cabinet.
Remove spool retainer from spindle hub.
Raise wire retainer bar to latched position.
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 nut.
Lower the wire retainer bar onto the spool.
Wire Spool Drag Setting
NOTE:
Standard factory setting of the Spindle Tension Knob is set for All Other Wires.
There are two visible position settings for this Knob, IN - All Other Wires
(Fig. 1) and, OUT - .030/.035 Al Only (Fig. 2). The Spindle Tension Knob
must be set to match the Wire Size Selector Switch on the Cobramatic®
front panel.
IN - All other wires
Figure 1
Cobramatic® Owner’s Manual - page 4
OUT - .030/.035 Aluminum ONLY
Figure 2
Section A
(Continued)
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 ts onto the Knob. Grab the retainer and turn in the
COUNTER-CLOCKWISE 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.
Figure 3
To reset the Knob back to the factory setting of All Other Wires, use the
retainer as described above, and turn in the CLOCKWISE direction until it
stops. The Knob is now set to the IN position. Turning the retainer and
Knob in this direction may require more effort, since turning CLOCKWISE is
working against a spring.
Load wire spool onto spindle according to the previous instructions.
Replace the spool retainer nut.
Lower the wire retainer bar onto the spool.
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 rst 6” to 8” of wire.
Raise wire type lever to center position.
Route wire into inlet guide, along drive roll groove, and into wire conduit.
Flip wire type lever to show type of wire being used.
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.
Wire Retainer Bar
The design of the patented Cobramatic® Wire Retainer Bar performs two
very important and very basic functions of the wire feeder: a) spool drag
tension, and b) wire maintenance on the spool.
The spool drag tension is set by lowering the wire retainer bar onto the wire
inside of the spool. The spring tension of the wire retainer bar applies enough
pressure on the spool so that when the torch trigger is released, engaging the
brake pall, the spool does not overrun kicking wire off the spool.
Wire maintenance on the spool is performed by the applied pressure of the
wire retainer bar spread across the coiled wire on the spool. The replaceable
pad (P/N 437-0255) of the wire retainer bar is designed to hold the wire on
the spool, maintaining the smooth layering of the wire and keeping it from
jumping off, and possibly, electrically shorting to the cabinet chassis.
Cobramatic® Owner’s Manual - page 5
Section B
(Continued)
Welding Torch Connections
Work Cable
Connect a work lead of sufcient 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.
Work Lead Lengths
Current 60% Up to 50ft. 10-100ft.
Duty Cycle (15.2m) (15.2-30.4m)
300A 0 (53mm) 0 (67mm)
400A 00 (67mm) 00 (85mm)
500A 00 (67mm) 00 (85mm)
600A 000 (85mm) 000 (107mm)
Control Cable
The 7-Pin “W” Clocked connector screws onto the mating receptacle on the
front panel of the wire feeder. This provides all electrical signals (motor
voltage, potentiometer control & trigger) to and from the feeder to the torch.
Wire Conduit Inlet
Front panel access to attach conduit to front of slave motor assembly.
Power Cable Inlet
Front panel access to attach power cable (air or water) to top of power block.
Gas Inlet
Front panel access to attach gas hose to bottom tting of power block.
Water Inlet (For Water Cooled Torches)
Front panel access to connect the water hose to the middle tting on the
power block.
Section B Operation
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 spool drag
tension is produced by the patented Wire Retainer Bar mechanism to keep
the wire slightly taut. The 24 VDC torch pull motor is controlled by a solid
state speed control and a potentiometer located in the torch.
Recommended Processes and Equipment
The Cobramatic® is recommended for use in the GMAW and FCAW welding
applications. It is recommended for use with constant voltage power sources.
The Cobramatic® is capable of feeding wires (diameter capacity) ranging
from .023” through .045” solid/cored and .030” through 1/16” aluminum.
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
Cobramatic® Owner’s Manual - page 6
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