MK Products Cobramatic II User Manual

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Cobramatic® II

Wire Feed Cabinet

Owner’s Manual

Product: Cobramatic II

Cabinet Manual: 091-0392 Serial: 03040001 Voltage Rating: 42 VAC

100 VAC Revision: April 2003 Rev D Model Number: 150-004

150-204

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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 qualiﬁ ed 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 ﬁ lter lenses or plates (pro- tected by clear cover glass). This is a must for welding or cutting (and chipping) to protect the eyes from radiant energy and ﬂ ying metal. Replace cover glass when broken, pitted, or spattered.

Medical ﬁ rst aid and eye treatment. First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of ﬂ 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 ﬂ aps, and wear cufﬂ ess 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 conﬁ ned 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 conﬁ ned space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator.

Gas leaks in a conﬁ ned space should be avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders into a conﬁ ned space.

Leaving confined 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 ﬂ 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 ﬁ re and explosion are: com-

bustibles reached by the arc, flame, ﬂ ying sparks, hot slag, or heated material, misuse of compressed gases and cylinders, and short circuits.

BE AWARE THA T ﬂ ying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or ﬂ oor openings, out of sight of the goggled operator. Sparks can ﬂ y many feet.

To prevent ﬁ 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-ﬁ tting, ﬁ re-resistant covers or shields.

Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.

Fire watcher must be standing by with suitable fire 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 ﬂ 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 ﬂ ames.

An empty container that held combustibles, or that can produce ﬂ ammable or toxic vapors when heated, must never be welded on or cut, unless container has ﬁ rst been cleaned in accordance with industry standards.

This includes: a thorough steam or caustic cleaning (or a solvent of water

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washing, depending on the combustible’s solubility), followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment.

Water-ﬁ 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 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 ﬂ 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 (ﬁ 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 ﬂ 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 reﬁ ll any cylinder. Cylinder ﬁ ttings should never be modiﬁ ed

or exchanged.

3. Hose Prohibited use. Never use hose other than that designed for the speciﬁ ed gas. A general hose identiﬁ cation 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 ﬁ ttings.

No copper tubing splices. Use only standard brass ﬁ 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 ﬂ 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 oriﬁ ces 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 fitting 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 identiﬁ ed 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 efficient recommended pressure settings on regulators.

Check for leaks on ﬁ 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,

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is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks ﬂ 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, reflect 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. 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, ﬂ ameproof apron, and ﬁ 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 ﬁ lter plate shade no. 12 or denser must be used when welding. Place over face before striking arc.

Protect filter 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 ﬁ 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 ﬁ 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-reﬂ ective, noncom- bustible screens or panels. Allow for free air circulation, particularly at ﬂ 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 ﬂ ash goggles.

Before starting to weld, make sure that screen ﬂ 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 ﬁ re.

Loose cable connections may overheat or ﬂ ash and cause aﬁ re.

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 flow 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 ﬂ ammable liquid such as oil or fuel.

Three-phase connection. Check phase requirement of equipment before installing. If only three-phase 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 ﬂ 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® II Owner's Manual

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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® II Owner's Manual

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Table of Contents

Safety Guidlines....................................................... i-iv

Installation...................................................... Section A

Technical Speciﬁ cations........................................................ 1

Machine Grounding ............................................................. 1

Machine Location ............................................................... 1

Contactor Selection............................................................. 1

Input Power Connections ...................................................... 2

Wire Threading Procedure..................................................... 2

Torch Drive Roll Adjustment................................................... 4

Operation ....................................................... Section B

General Description ............................................................ 4

Controls and Settings........................................................... 4

Controls for Optional Timer Kit............................................... 5

Controls for Optional Meter Kit............................................... 6

Posa Start Operating Procedure .............................................. 6

Remote/Automatic Operation ................................................ 8

Performance and Fault Isolation Indicators................................. 8

Wire Feed Calibration Procedure............................................. 8

Accessories......................................................Section C

Optional Kits..................................................................... 9

Maintenance....................................................Section D

Routine Maintenance..........................................................10

Recommended Spare Parts ...................................................10

Testing the Torch...............................................................10

Testing the 115VAC Circuits ..................................................10

Troubleshooting................................................ Section E

Slave Motor Tension Test......................................................11

Troubleshooting Main Board..................................................12

Troubleshooting Guide ........................................................13

Appendices...................................................... Section F

Figures...........................................................................16

Exploded Parts View ...........................................................21

Electrical Schematics..........................................................27

Warranty Repair Stations Safety Warnings Warranty

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SECTION A INSTALLATION

TECHNICAL SPECIFICATIONS

Wire Diameter Capacity .030 - 1/16" ALL Types Wire Capacity 12" Standard (Insulated or Non-Insulated) Power Input 42 VAC 50/60 Hz 110 VAC 50/60 Hz 150 Watts Peak Wire Feed Rate (Depending on Torch used) 10--1000 ipm Weight 31 pounds Shipping Weight 37 pounds Compatible Torches All MK 7pin Amphenol Plug Mig Torches MK RoboKing Automated Torch

SUPPORT EQUIPMENT REQUIRED

MK 2000A Power Supply or any C. V. or C.C. power source of sufﬁ cient 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.

COOLANT RECOMMENDATIONS

Use a name-brand additive which does not contain reactive sulphur or chlorine and does not react with copper, brass, or aluminum. Here's also mixture that works well :

Use 3 Gallons (11.4 Liters) deionized water. (NOT DISTILLED) Use 1 Gallon (3.8 Liters) ethleyne glycol. Use 1 tsp (5 ml) liquid glycerin per gallon (3.8 Liters) of

mixture

Check coolant periodically to remain within limits of the following: Coolant Flow rate - 1 quart/minute at 45 p.s.i. Resistivity - 10K ohms/centimeter Ph Range - 5.5-8.5

Particle Size - .005"

MACHINE GROUNDING

The Cobramatic®II 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.

MACHINE LOCATION

The cabinet should be placed in a location where it can be protected from damage. Lead lengths and accessibility to input power(42/110VAC 50/60 Hz) must also be considered when installing the cabinet.

CONTACTOR SELECTION - (FIG. 1)

The Cobramatic® II is shipped from the factory in the closing contacts position. A six foot (6') contactor cable is supplied with the unit to which the black and white wires supply the contactor signal.

If a 115 VAC contactor out signal is required, remove the screws from the left

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side of the cabinet and open door. Locate the black and white wire on #2 and #3 of terminal strip J16. Move black wire to #4 and white wire to #3 of terminal strip J15. The unit will now supply 115 VAC on the black (hot) and white (neutral) wires.

NOTE:

Refer to the power supply owner’s manual for location and type of contactor signal

required.

WARNING:

Disconnect the Cobramatic® Cabinet from all power sources

before changing contactor.

INPUT CONNECTIONS

POWER CONNECTIONS - (FIG. 2)

Connect the supplied 6' three (3) prong plug to a 115 VAC 50/60 Hz outlet. (For 42VAC export cabinets, no input power cord is provided.)

The input power cord is connected to the PC Board on terminal strip J15 #1 (neutral) and #2 (hot) and Ground to the cabinet chassis

POSA START CONNECTIONS - (FIG. 2)

When using a Constant Voltage (CV) Power source such as the MK2000A, the Posa Start lead need not be connected and switch 3 should be placed in the "INT" position. The Posa Start lead is internally connected to the P.C. board on terminal strip J16 terminal #1.

When using a Constant Current (CC) Power Source, attach the No. 14 single black lead which extends from the back of the Cobramatic® II to the negative terminal of the welding power source or work ground. Switch 3 must also be in the “EXT” position.

CABLE CONNECTIONS - (FIG. 3)

Connect the positive power cable (DCEP) from the power supply to the bottom hole on the power block and secure with bolt.

GAS HOSE - (FIG. 3)

Connect hose from regulator/ﬂ owmeter to the ﬁ tting on the power block using a 5/8"-18 IAA R.H. Gas ﬁ tting.

WATER CONNECTIONS - (FIG. 3)

When using a water cooled torch, connect the 5/8"-18 L.H. male ﬁ tting extending from the torch lead assemblies to your water supply line. The water return also uses a 5/8"-18 L.H. male ﬁ tting and connects to the lefthand ﬁ tting on the power block.

WIRE THREADING PROCEDURE

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.

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THREADING PROCEDURE

Place wire size selector switch on front panel to the correct position for the wire being used.

NOTE:

For 3/64" and 1/16" aluminum wire use the "ALL OTHER WIRES" position.

Loosen end of wire from spool and cut off any kinked or bent portions. Unreel and straighten out ﬁ rst 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; then add an additional 1/4 turn more.

CAUTION:

EXCESSIVE DRIVE ROLL TENSION WILL REDUCE RATHER THAN

IMPROVE WIRE FEED PERFORMANCE.

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.

SPINDLE DRAG ADJUSTMENT

Loosen nut inside spindle until spring is not compressed. When in the ".030-.035 Aluminum Only" position, tighten nut until you feel

spring start to compress then add 1 turn. Press the trigger and make sure the wire comes level off of the spool. If you

can see the wire cast when feeding, add a little more drag. (1/4 turn) When in the "All Other Wires" position, start with 3 turns of drag and adjust.

PRE-SETTING SLAVE MOTOR TENSION

All Cobramatic®s 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, then add an additional 1/4 turn.

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

WIRE GUARD

The Cobramatic® Wire Guard (P/N 005-0618) 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

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wear and will not contaminate the surface of the wire

TORCH DRIVE ROLL ADJUSTMENT

NOTE: Over-tightening of the drive rolls will cause excessive knurling and/or

deformation of the wire. When the complete system is set-up properly, feeding wire

out of the end of the torch and letting fall on the ground should

form a large uniform circle. If it forms a spiral or spring then

there is too much tension in the system, please refer to the Cabinet

Owners Manual for adjustment to the tension setting detailed there.

THIS IS THE NUMBER ONE CAUSE OF POOR WIRE FEED PERFORMANCE

SECTION B OPERATION

GENERAL DESCRIPTION

The Cobramatic® II is an analog input version of the popular Cobramatic® I Cabinet and operates on the same basic principles. 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 high torque 24 VDC torch pull motor is controlled by a solid state speed control and a potentiometer located in the torch, feeder or remotely.

The solid state control circuit provides a wide range of operating conditions and includes performance and fault isolation L.E.D. indicators. The wire feed speed command can be derived from the cabinet, torch, or from a 0-10 volt analog external signal. A variety of input/output signals make it highly suitable for automatic applications.

----------- IMPORTANT -----------

---------------------------------------------

CONTROLS AND SETTINGS (SEE FIG. 4)

ON/OFF SWITCH

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

WIRE SIZE SELECTOR SWITCH

The wire size selector switch changes the torque of the slave motor for the wire you are using. When in the ".030-.035 Aluminum Only Position", the slave motor produces approximately 1 1/2 lbs. 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 difﬁ culties.

POSA START CONTROL

When in the "ON" position, the wire feed command is derived from the Posa Start potentiometer. After arc initiation, the wire feed speed is controlled by the selected wire feed source, i.e., torch, cabinet, or remotely.

WIRE INCH

The Wire Inch button causes wire feed at the weld feed rate from the selected source, independent of Posa Start and may be used to observe or time

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the weld wire feed rate without turning Posa Start off. The contactor is not activated during "Wire Inch".

(NOTE: If the wire feed speed is set to accept a remote source, and no input

command voltage is present, no wire feed will occur).

TORCH ELECTRICAL RECEPTACLE

The Cobramatic® II has a 7 pin “W” clocked Amphenol connector to provide an electrical connecting point to the torch. See speciﬁ cations for more information.

CABINET WIRE FEED SPEED POTENTIOMETER (OPTIONAL - P/N 005-0166)

By selecting the cabinet potentiometer, the wire feed speed may be adjusted from the cabinet. See wire speed source, section 9.4. The counter dial directly reads in inches per minute (0 to 1000 IPM).

POWER CABLE INLET

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

CONDUIT INLET

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

SHIELDING GAS INLET

Provides access to the gas ﬁ tting inside the cabinet.

CONTROLS FOR OPTIONAL TIMER KIT (P/N 005-0196)

WATER INLET

Provides access to make the gun water connection to recirculator hose.

GAS PURGE

The Gas Purge button operates the gas solenoid in the cabinet. When the solenoid in the cabinet is used, a modiﬁ ed gas valve, P/N 431-1080, must be installed in the torch.

PRE-PURGE

The smaller knob on the pre/post purge control may be turned clockwise to increase the pre-purge interval. The control cannot be turned off and provide a range of approximately .07 to 3.4 seconds. When the trigger is depressed, the gas solenoid will open, and all other functions will be inhibited until the end of the pre-purge interval, when normal welding will start. If the trigger is released during pre-purge, no weld will be initiated.

POST-PURGE

The larger knob on the pre/post purge control may be turned clockwise to increase the post-purge interval. This control cannot be turned off and provides approximately .07 to 4.5 seconds of post ﬂ ow. The post-purge will not activate unless an arc has been established.

BURN BACK

The larger knob on the spot time/Burn-back control may be turned clockwise to increase the burn-back interval. During this interval, all functions except wire feed are maintained and, thus, the arc burns the wire back towards the tip. Excessive burn-back may result in damage to the contact tip. The burnback control must be clicked on and is adjustable from .015 to .085 seconds. The burn-back control is not activated until an arc has been established.

SPOT TIME

The spot timer has the capability to time and terminate a weld cycle following a trigger ON command. The spot time function is initiated once the arc is

Cobramatic® II Owner's Manual - Page 5

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established, and, even if the trigger is held ON or released, the cycle will end at the spot timer time out. To initiate a new cycle, the trigger must be turned OFF (released) and re-triggered. The spot time knob must be clicked ON and the duration may be set from .07 to 3 seconds. The spot time may be used with all other functions; pre-purge, burn-back, post-purge.

NOTE: Even with the spot timer turned "ON", the wire will not time out

until you strike an arc. This provides very accurate, repetitive timing.

CONTROLS FOR OPTIONAL METER KIT (P/N 005-0190)

The LED meter provides a continuous reading of wire feed speed in inches per minute. When the trigger is energized, the meter will display weld voltage.

POSA START OPERATING PROCEDURE

GENERAL DESCRIPTION

The Posa Start feature allows the Cobramatic® II 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.

The Posa Start MUST be used with a Constant Current power source to provide arc initiation and may be used with a Constant Voltage power supply to help eliminate burn-backs at arc start.

CAUTION:

DO NOT OPERATE A Cobramatic

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. The Posa Start does not control the wire speed while welding.

II ON A POWER SOURCE HAVING A HIGH-

CV POSA START OPERATION

Attach Cobramatic® II to CV power source according to the installation instructions.

Turn the Cobramatic position.

Adjust power source to desired voltage for your weld condition. Depress gun trigger and adjust wire feed speed 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 the welding wire speed.

Strike an arc, and adjust wire feed rate at gun until correct condition is achieved.

II to the “ON” position and the Posa Start to the “OFF”

CC POSA START OPERATION

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

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Page 14

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

II 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 the welding wire speed.

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.

WIRE SPEED SOURCE (S1) (FIGURE 5)

The wire feed command may be obtained from the torch, cabinet, or from a 0-10VDC analog signal by simply changing switch 1 (S1) settings.

S1, a four-position dip switch, is located in the upper left hand corner of the Main PC Board and set as follows:

NOTE :

Only one switch may be "ON" at a time.

SWITCH 1 SETTINGS (S1) (FIGURE 5)

Position #1 No connection (NC) #2 Selects cabinet potentiometer. (opt) #3 Selects torch potentiometer. #4 Selects a remote 0-10VDC analog signal command through a 5K ohm potentiometer:

J22-1 Ground J22-3 Wiper TP5 10VDC or external source

TORCH COMPENSATING NETWORK (S2)

The Cobramatic® II circuit provides for linear control of the wire feed from less than one volt to ten volts. The torch compensating network is provided to match the torch motor gearbox ratio to the 0-10VDC linear control. Therefore, regardless of which type of torch is used, one volt will equal 100 ipm, two volts equals 200 ipm, etc.

To set up the network for the torch you are using, locate dip switch 2 (S2) in the upper left corner of the Main PC Board, and set as follows:

NOTE:

Only one switch may be "ON" at a time.

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Page 15

SWITCH 2 SETTINGS (S2)

Position #1 Cobra System III Torches (800ipm) Cobra Gold Torches RoboKing Torches Python CobraMax #2 Prince (750ipm) #3 King Cobra (700ipm) #4 Prince XL #5 not used (future)

During Posa Start Run-In Interval, the network is bypassed to permit very smooth, slow run-in to be achieved.

See wire feed calibration section for torch calibration procedure.

REMOTE/AUTOMATIC OPERATION (FIG. 5)

The Cobramatic® II cabinet may be set up to operate in a wide variety of automatic and semi-automatic applications. The remote input/output connector (J22) provides the electrical interface to your equipment. When the Cobramatic® is used in this capacity, timer kit, P/N 005-0196, should be installed to provide control of the gas, as well as spot time and burn-back functions, see optional kits.

PERFORMANCE & FAULT ISOLATION INDICATORS

GENERAL

The Cobramatic® II is equipped with LED indicators to aid in operation and trouble- shooting. The indicators check out individual circuits, respond to signals, and indicate overload conditions.

DETAILED OPERATION

When the cabinet is turned “ON”, D6 and D10, both green LED’s, will light. D6 indicates that 27V AC is being supplied to the board, and D10 indicates the presence of the 10VDC. When the trigger signal is supplied, either from the torch or remotely, D21 (trigger), a yellow LED, will light. After the pre-purge times out, D19 (wire forward), D34 (torch motor voltage) and D31 (Slave motor voltage), all yellow LED’s will light, and the welding wire will begin to feed. (Note: If the timer kit, P/N 005-0196, is not installed, D19 (wire forward), D34 (torch motor voltage), and D31 (115vac) indicators will light with the trigger signal. D34 indicates the presence of the torch motor voltage, whereas D31 indicates the presence of AC voltage for the brake solenoid and slave motor. When the arc is initiated, D17 (arc establish), a yellow LED, will light and remain on until the arc is extinguished.

D39, a red LED when lit, indicates a torch overload condition has occurred. Turn main power switch “OFF”, then back “ON” to reset. See trouble-shooting section, for more information.

WIRE FEED CALIBRATION PROCEDURE

CALIBRATION INSTRUCTIONS

The Cobramatic® II comes from the factory already calibrated for the torches indicated on the torch selector switch (S2), but further ﬁ ne-tuning can be done to the motor drive circuit by using trim pots R54 and R69. This adjustment may be necessary due to variations in different torch motor gearboxes, type of drive rolls used, age of torch and many other contributing factors. Each time you use a different torch on the cabinet you may want to re-check this calibration. While this adjustment is not critical for most

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applications, it is important when using a meter kit on the Cobramatic® II cabinet to make sure the demand and actual wire speeds are the same. It is equally important to maintain proper calibration when using a remote (0-10VDC) input to control wire speed, as this will expect certain results for each demand of input voltage.

The goal of this calibration procedure is to have 1 volt of input to equal 100 ipm at the torch, 2 volts equals 200 ipm, etc.

1. Insure that switch 2 (S2) is in the correct position for the torch you are using.

2. Insure that switch 1 (S1) is in the correct position for your control requirements (torch pot, cabinet pot or remote).

3. Set the pre-purge control to off, if so equipped. Turn Posa Start off.

4. Adjust the command voltage (TP11) to 2.00 VDC using the torch pot, cabinet pot or remote command depending on the position of (S1). Use J22-1 for ground reference.

5. Feed out wire for exactly six (6) seconds and measure. You should have 20 inches of wire for a 2 volt command. Repeat and compare the two segments of wire for an average length.

6. If wire length is less than 20 inches (200 IPM), increase (clock wise) R54 and repeat step 5. If wire length is is greater than 20 inches (200 IPM), decrease (counter-clock wise) R54 and repeat step 5. R54 adjustment is approximately 0.5 inches/turn (5 IPM/turn).

7. Adjust the command voltage (TP11) to 6.00 VDC using the torch pot, cabinet pot or remote command depending on the position of (S1),

8. Feed out wire exactly exactly six (6) seconds and measure. You should have 60 inches of wire for a 6 volt command. Repeat and compare the two segments of wire for an average length.

9. If wire length is less than 60 inches (600 IPM), increase (clockwise) R69 and repeat step 5. If wire length is greater than 60 inches (600 IPM), decrease (counter-clockwise) R69 and repeat step 8. R69 adjustment is approximately 1.0 inch/turn (10 IPM/turn).

10. Repeat steps 4 through 9 until the wire speed (IPM) matches the demand voltage (VDC).

SECTION C ACCESSORIES

Plastic Guides for Slave Motor

Inlet Guide . . . . . . . . . . . . . . . . . . . . 753-0062

Outlet Guide with Knob . . . . . . . . . . 003-0428

OPTIONAL KITS

Cabinet Potentiometer Kit . . . . . . . . 005-0166

Removes wire feed speed control from the torch to the cabinet and provides a 10-turn

counter dial.

Timer Kit . . . . . . . . . . . . . . . . . . . . . . 005-0196

Provides pre-purge, post-purge, Burn-back and spot-time

Meter Kit . . . . . . . . . . . . . . . . . . . . . . 005-0190

Displays both wire feed speed and weld voltage

Preset Adjusting Screw Kit . . . . . . . . 005-0125*

Water Flow Kit . . . . . . . . . . . . . . . . . 005-0253

Wire Guard Kit . . . . . . . . . . . . . . . . . 005-0618*

*standard on all wire feeders

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SECTION D MAINTENANCE

ROUTINE 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

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 qualiﬁ ed shop maintenance personnel.

Your Cobramatic® II 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. The following list comprises the most commonly replaced parts.

RECOMMENDED SPARE PARTS

QTY DESCRIPTION P/N 1 Brake Solenoid w/leads 003-2096

1 Main P.C. Board 003-1977 or 1 Main P.C. Board (exchange) 006-1977 1 Front Panel P.C. Board 003-1688 or 1 Front Panel P.C. Board (exchange) 006-1688 1 Slave Motor Drive Roll 511-0206 1 Slave Motor Idler Roll 501-0207 2+ Fuse AGC 2A 250V 151-0001

system that are subject to normal wear

TESTING THE T ORCH

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.

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

TESTING THE MICRO SWITCH

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

TESTING THE 115 VAC CIRCUITS

The 115 VAC circuit is protected by fuse F3. If F3 continually blows, remove J10 (Brake Solenoid), J12 (slave motor) and J15-3,4 (115 VAC Contactor) from the P.C. Board. Replace fuse, and retrigger system. If fuse does not blow; isolate the problem by plugging in J10, J12, and J15-3,4 one at a time until the fuse blows.

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SECTION E TROUBLESHOOTING

Regardless of which torch or feeder used, all MK Products push-pull guns operate on the same principle. The 115VAC 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 simply to keep the wire slightly taut, so it will not pull off the spool while feeding wire.

The 24VDC torch motor is controlled by a solid state speed control and a pot located in the torch, cabinet or remotely. The torch motor, potentiometer, and micro switch are connected to the cabinet via a control cable and amphenol. If this cable becomes damaged, a variety of symptoms can occur, depending on which wire(s) break. To test, check each wire for continuity and shorts.

Remember the micro switch in the torch activates both the 115VAC and 24V circuits in the cabinet. Therefore, if the slave motor and brake solenoid operate, but the torch does not, look more toward the 24V circuits, speed control, control cable, or the torch motor. If nothing operates, look more toward the 115VAC input, micro switch leads, or micro switch.

The objective of this trouble-shooting section is to identify and replace faulty assemblies, not individual component repairs.

SLAVE MOTOR TENSION TEST

To check for proper operation of the slave motor, the following test may be performed:

Disconnect welding power from Cobramatic® II cabinet. Plug Cabinet into 115VAC power outlet (different for export) and turn cabinet

"ON" Remove torch wire conduit from the outlet guide on the slave motor assembly . Cut a piece of .045" hard wire 10" long and make a small loop on one end

to attach the spring scale. Place the wire size selector switch on the front panel in the .030 & .035

ALUMINUM ONLY position. Insert the .045" hard wire into slave motor assembly, press trigger, and

tighten slave motor drive roll pressure adjusting nut until the drive roll stalls. The spring scale should read about 1 1/2 lbs of pull when the slave motor stalls.

Now repeat the test with the wire selector switch set to the "ALL OTHER WIRES" position.

Depress the torch trigger and readjust the drive roll pressure adjusting nut until the drive stalls once again. This time the spring scale should read approximately 4 1/2 lbs.

TROUBLESHOOTING MAIN BOARD

MAIN BOARD - Test Points High - 9 to 10 volts

Low - 1 volt or less A voltmeter is required for the following test. TP3 is ground. Turn the unit “OFF” and unplug the J9 connector going to the timer board, if

so equipped, from the main board. Turn unit “ON” and set meter to DC.

Cobramatic® II Owner's Manual - Page 11

Page 19

27VAC INPUT

Set voltmeter to AC. Place negative on TP1 and positive on TP4; should have 27 to 30VAC at all times.

10V SUPPLY

Place negative lead on TP3 and positive on TP5. Should have 10VDC with trigger “ON” or “OFF”.

15V SUPPLY

Place negative on TP3 and positive on TP2; should have 14.3 to 15.7VDC at all times.

TRIGGER SIGNAL

Place negative lead on TP3 and positive on TP8, should be high; press trigger--should go low.

WIRE FORWARD SIGNAL

Place negative on TP3 and positive on TP9, should be high; press trigger-should go low.

TORCH MOTOR VOLTAGE

Place negative on TP3 and positive on TP10. Press torch trigger and change wire feed speed potentiometer--should vary from 0-27VDC.

INHIBIT CIRCUIT

Place negative on TP3 and positive on TP7, should be high; press trigger-should go low.

Units with Timer Kit Installed (J9)

Follow above steps, except note the following changes: Turn unit “OFF” and plug in the J9 connector. Trigger signal high may only be 7VDC. Inhibit circuit should be low at all times

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Page 20

TROUBLESHOOTING GUIDE

Trouble Cause Remedy

F3 (2 amp) fuse in feeder blown. Check 115 VAC circuit. Replace fuse.

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.

Wire feeds, but welding wire is not energized.

Wire feeds erratically.

Wire feeds one speed only.

Wire walks out of drive rolls.

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

Loose J13, PC board connector Check J13 connector. Solenoid defective Replace Main PC board defective Switch 1 on Main PC board in wrong

position. Bad Speed control/PCB Check/replace Main PC board

Broken electrical cable Bad torch motor (D39 LED “ON”) Check/replace motor.

Bad Potentiometer Check potentiometer with ohm meter. Loose or no cable connections Check all power connections Relay K1 not sending contactor signal. Check/replace relay K1.

Contactor control cable loose or in wrong position.

Welding power source Check power source for operation. Excessive spool drag pressure Dirty or worn conduit. Blow out or replace conduit Incorrect pressure on drive rolls.

Idler roll stuck Wrong size contact tip See contact tip table in torch manual.

Bad potentiometer. Check with meter. Broken electrical cable. Bad speed control. Check/replace Main PC board.

Idler roll upside-down. Place groove in idler roll toward top. Rear wire guide missing. Replace wire guide.

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

Check for D31 LED operation/replace board.

Select cabinet, torch or remote position.

Check motor and potentiometer wires for continuity.

Check power supply owners manual for location and type of contactor signal required, I.e.; closing or 115VAC.

Decrease spool drag pressure inside hub.

Adjust pressure at both feeder and torch.

Check for lock washer under idler roll, or replace if damaged.

Check potentiometer wires for continuity or short.

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SECTION F APPENDICES DIAGRAMS AND PARTS LISTS

Figure 1, Contactor Hook-up Selection................................. 16

Figure 2, Input Power and Posa Start Connections ................... 17

Figure 3, Cabinet and Torch Hook-Up Diagram........................ 18

Figure 4, Front Panel - Controls Layout................................ 19

Figure 5, Main Board Switch Settings and Remote Connections.... 20

001-3070 Cobramatic® II Assembly ...................................... 21

003-1701 Front Panel Assembly.......................................... 23

003-1674 Power Block Assembly ......................................... 24

003-2078 Slave Motor Assembly.......................................... 25

003-0570 Spindle Brake Assembly....................................... 26

071-0252 Multi Function Timer Board................................... 28

071-0296 Front Panel...................................................... 29

071-0330 Meter............................................................. 30

071-0365 Main Board ...................................................... 31

071-0366 Wiring Diagram ................................................. 34

Cobramatic® II Owner's Manual - Page 15

Page 23

CLOSING CONTACTOR WIRE POSITION

(As Shipped From Factory)

WHITE WIRE

BLACK WIRE

CONTACTOR HOOK-UP SELECTION

FIGURE 1

J16

J15

120VAC CONTACTOR WIRE POSITION

WHITE WIRE

BLACK WIRE

NOTE :

BOTH TYPES OF CONTACTOR OUTPUTS ARE AVAILABLE SIMULTANEOUSLY, THERE IS NO SWITCH TO SELECT BETWEEN THE DIFFERENT TYPES, YOU MUST MOVE THE CONTACTOR LEADS BETWEEN TERMINAL STRIPS (J15) AND (J16)

Cobramatic® II Owner's Manual - Page 16

Page 24

INPUT POWER AND POSA START CONNECTIONS

FIGURE 2

POSA START VOLT SENSE

(S3 - see text for correct position)

POSA START WORK GROUND CONNECTION

BLACK WIRE

J22

INT EXT

INPUT POWER WIRE POSITION

J16

J15

GROUND

TERMINAL

WHITE WIRE BLACK WIRE

GREEN WIRE

Cobramatic® II Owner's Manual - Page 17

Page 25

CABINET AND TORCH HOOK-UP DIAGRAM

FIGURE 3

115VAC

Supply

Cable

Water In

Input Power Cable must be connected to bottom hole or Posa-Start will not operate properly!

Upper hole is to be used only when connecting to the Prince spoolgun to the cabinet as a push-pull system.

Cobramatic® II Owner's Manual - Page 18

Page 26

FRONT PANEL - CONTROLS LAYOUT

FIGURE 4

Cobramatic® II Owner's Manual - Page 19

Page 27

MAIN BOARD SWITCH SETTINGS AND REMOTE CONNECTIONS

J22 Analog Signal Connector Pin-Outs

Circuit ground J22-1

Trigger

(cycle start) Contact Closure ref. to J22-1 J22-2

FIGURE 5

INT EXT

POSA START

VOLT SENSE

TORCH

SELECTIONS

WIRE SPEED

SELECTIONS

Wire speed command input (+)1V = 100 ipm J22-3

0-10VDC @ 50ma to ref to J22-1 (-)

Arc established output (+) 10VDC with ref. to J22-4

J22-1 during arc. 10K ohm source impedance

Torch

potentiometer ref. voltage (+) J22-5

1V = 100 ipm 0-10VDC output ref to J22-1 (-)

Gas purge Input Contact closure to J22-1 J22-6

Wire forward Input Contact closure to J22-1 J22-7

J16 Signal Connector Pin-Outs

Weld ground Input J16-1

Closing Contactor Output - trigger J16-2

Closing Contactor Output - trigger J16-3

Closing Contact Output - Arc Est. J16-4

Closing Conatct Output - Arc Est. J16-5

Cobramatic® II Owner's Manual - Page 20

Page 28

Cobramatic® II Owner's Manual - Page 21

Page 29

Cobramatic® II Owner's Manual - Page 22

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Cobramatic® II Owner's Manual - Page 24

Page 32

003-2078a

Slave Motor Assembly, 115V

1 1 003-0178 Assy Knob Conduit

2 1 003-2069 Assy Torque Motor 115 V

No. Qty. Part No. Description

3 1 328-0024 Scr Shc 8-32 x /8 Stl

4 1 328-0259 Scr Shc 8-32 x 1-1/8 Stl

5 1 330-0258 Scr Shldr 1/4 x 1/4 x 10-24

6 1 345-0018 Nut Lock 5-16-18

7 1 419-0085 Spring Comp 1/32 x OD .40

8 1 419-0211 Spring Comp OD 5/8 x 1/16

9 1 431-1576 Bolt Swing Mod

10 1 435-1582 Plate Locate Slave Motor

11 1 437-0230 Housing Slave Motor Mold

12 1 437-0231 Handle Mold Slave Motor

13 1 437-0232 Arm Idler Mold Slave Motor

14 1 437-0245 Cap Bearing Mold

15 1 437-0254 Sleeve Spring

16 1 501-0118 Bearing 1.125 x .50 x .31

17 1 501-0156 Bearing .875 x .38 x .28

18 1 501-0207 bearing Idler Roll

19 1 507-0130 Shaft Gear

20 1 511-0206 Drive Roll

21 1 753-0210 Guide Wire Inlet

22 A/R 823-0043 Loctite Threadlocking

23 A/R 835-0001 Grease Mobliux 2

24 A/R 823-0051 Loctite Retaining Compound

25 REF 031-0167 Test Procedure

26 1 751-0018 Cap .5 x .5 Lg Vinyl Black

Cobramatic® II Owner's Manual - Page 25

Page 33

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Cobramatic® II Owner's Manual - Page 26

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Spindle Brake Assy.

003-0570F

Page 34

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

ALABAMA

AIRGAS - SOUTH, INC. Birmingham, AL 205/251-6835

DIXIE WELDING SUPPLY Attalla, AL 256/538-6157

INDUSTRIAL WELDING SERVICES Quinton, AL 205/674-3258

KIBRO, INC. Theodore, AL 251/653-4672

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

WELDING MACHINE HOSPITAL Montgomery, AL 334/832-9353

ALASKA

F AIRBANKS AERO SERVICES Fairbanks, AK 907/479-6666

RNR, INC. dba Rubey Engine & Electric Anchorage, AK 907/336-5152

ARIZONA

PRAXAIR DISTRIBUTION, INC. Phoenix, AZ 602/269-2151

ALLSTATE ELECTRIC MOTOR CO. Phoenix, AZ 602/233-0500

VERN LEWIS WLDG. SUPPLY Phoenix, AZ 602/252-0341

ARKANSAS

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

ARKANSAS WELDING IND’L SUPPLY Hot Springs, AR 501/321-9922

EL DORADO WELDING & IND’L SUPPLY El Dorado, AR 870/863-4088

CALIFORNIA

ADVANCED WELDER REPAIR Commerce, CA 323/263-7383

AIRGAS - WEST, INC. Gardena, CA 310/523-9355

ALL PHASE WELDER REPAIR & CONSULTING Sacramento, CA 916/331-0595

ARC PRODUCTS San Diego, CA 619/628-1022

ARCO WELDER REPAIR Santa Fe Springs, CA 562/921-5240

ARK WELDER REPAIR Fresno, CA 559/292-4714

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

DELTA-TECH Sun Valley, CA 818/767-4234

EMCO EAST WELD’R REPAIR Concord, CA 925/798-4411

FRESNO OXYGEN Fresno, CA 559/233-6684

INDUSTRIAL ELECTRICAL CO Modesto, CA 209/527-2800

INDUSTRIAL WELDER REPAIR LaPuente, CA 626/961-7643

NESCO WELDING SUPPLY Fontana, CA 909/427-9670

PRAXAIR DISTRIBUTION (ARC RENTS) Signal Hill, CA 562/989-3212

PRAXAIR DISTRIBUTION, INC. Bakersﬁ eld, CA 661/321-9922

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

Cobramatic® II Owner's Manual

Page 35

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

RED-D-ARC, INC. Carson, CA 310/233-3327

SIMS-ORANGE WELDING SUPPLY Santa Ana, CA 714/549-9393

SOUTHWEST WELDER REPAIR Fontana, CA 909/357-1661

SWEINHART ELECTRIC CO., INC. Long Beach, CA 714/521-9100

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

CONNETICUT

ABCO WELDING & INDUSTRIAL SUPPLY CO. Waterford, CT 800/962-0285

TECH AIR Milford, CT 203/783-1834

DELAWARE

KEEN COMPRESSED GAS New Castle, DE 302/594-4555

FLORIDA

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

AAA GENERATOR & PUMP Ft. Myers, FL 941/332-1136

ACTION WELDING SUPPLY Jacksonville, FL 904/786-2254

AMVEL CORPORATION Miami, FL 305/592-5678

ELECTRICAL WELDERS SERVICE Orlando, FL 407/999-5214

HAUN SYSTEMS REPAIR, INC. Orlando, FL 407/681-6064

HOLOX Ocala, FL 352/351-4417

J.K. CIRCUIT TECHNOLOGY Boynton Beach, FL 561/733-7859

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

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

TRI-GAS Miami, FL 305/592-3180

TRI-STATE SALES & LEASING Lake City, FL 904/397-3340

TRI-TECH Sarasota, FL 941/758-3825

V.A. ELECTRICAL MOTORS CENTER Hialeah, FL 305/825-3327

WELD DIRECT CORPORATION Jacksonville, FL 904/387-5664

GEORGIA

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

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

HAWAII

DC ELECTRIC, INC. Aiea, HI 808/483-8900

Cobramatic® II Owner's Manual

Page 36

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

IDAHO

NORCO Boise, ID 208/336-1643

ROSSITER ELECTRIC Idaho Falls, ID 208/529-3665

ILLINOIS

CMS ELECTROMECHANICAL SERVICES, INC. Galesburg, IL 309/342-4125 – 888/964-3526

FRED ARMS ELECTRIC MOTOR REPAIR Stone Park, IL 708/343-6262

INDUSTRIAL WELDER REBUILDERS Alsip, IL 708/371-5688

RELIABLE EQUIPMENT REPAIR Hamel, IL 618/633-5000

ROCKFORD INDUSTRIAL WELDING SUPPLY Rockford, IL 815/226-1900

INDIANA

AGA GAS, INC. Hammond, IN 219/989-9030

AIRGAS-MID AMERICA, INC. Evansville, IN 800/424-8905

B & H ELECTRIC Seymour, IN 812/522-5607

COX EQUIPMENT COMPANY Indianapolis, IN 317/241-8881

EV ANSVILLE ARMATURE, INC. Evansville, IN 812/428-9034

HARRISON ELECTRIC, INC. Michigan City, IN 219/879-0444

MODERN SUPPLY CO., INC. Evansville, IN 812/425-9353

PRAXAIR DISTRIBUTION, INC. Speedway, IN 317/481-4550

SUTTON-GARTEN COMPANY Indianapolis, IN 317/264-3236

IOWA

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

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

ELECTRICAL ENGRG. & EQUIPMENT Des Moines, IA 515/266-8890

SUPERIOR WELDING SUPPLY Waterloo, IA 319/236-9660

WRIGHT WELDING SUPPLY Ft. Dodge, IA 515/576-0640

KANSAS

AEROFORM CORPORATION Coffeyville, KS 620/251-1430

KANOX Hutchinson, KS 316/665-5551

KENTUCKY

GENERAL WELDING PRODUCTS Louisville, KY 502/635-5218

RED-D-ARC Lexington, KY 800/245-3660

WELDING EQUIPMENT Louisville, KY 502/636-0545

LOUISIANA

GT SVCS OF MORGAN CITY Morgan City, LA 985/385-4135

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

Cobramatic® II Owner's Manual

Page 37

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

WELDERS EQUIPMENT CO. Broussard, LA 337/837-5701

WELDERS SUPPLY & EQUIP. Port Allen, LA

225/346-4712

MARYLAND

CCM MECH/ELEC REPAIR SERVICE Owings, MD 301/855-7508

MASSACHUSETTS

AIMTEK WELDING SUPPLY Auburn, MA 508/832-5035

MICHIGAN

ANN ARBOR WELDING SUPPLY CO. Ypsilanti, MI 734/572-0444

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

AUTOMATIC WELD Midland, MI 517/496-9245

GREAT LAKES EQUIPMENT Clare, MI 517/386-4630

HAMILTON ELECTRIC CO. Saginaw, MI 517/799-6291

PLYMOUTH WAYNE, INC. Wixom, MI 248/735-7700

SAGINAW WELDING SUPPLY CO. Saginaw, MI 517/793-9696

SIMPKINS ELECTRICAL SVC. Michigan Center, MI 517/764-7766

SOUTHPARK WELDING Marysville, MI 810/364-6521

WELDING METALS, INC. Madison Heights, MI 248/585-0480

WESAR COMPANY Three Rivers, MI 616/483-9125

WILSON WELDING & MEDICAL GASES Warren, MI 586/751-7400

MINNESOTA

AIRGAS – NORTH CENTRAL Albert Lea, MN 507/373-2411

CAPITOL CITY WELDING SUPPLY St. Paul, MN 651/224-4843

CENTRAL McGOWAN St. Cloud, MN 320/252-5292

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 Springﬁ eld, MO 417/862-1745

ROD’S SERVICE, INC. St. Louis, MO 314/721-6000

MISSISSIPPI

NORDAN SMITH WELDING SUPPLY Hattiesburg, MS 601/545-1800

3D SUPPLIES, INC. Jackson, MS 601/353-3330

MONTANA

VALLEY WELDERS SUPPLY Billings, MT

406/256-3330

Cobramatic® II Owner's Manual

Page 38

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

NEVADA

SIERRA WELDING SUPPLY CO. Sparks, NV 775/359-0542

NEW JERSEY

INDUSTRIAL ELECTRIC SERVICE CO. Hawthorne, NJ 973/423-1212

NEW YORK

DELO WELDING SUPPLY Syracuse, NY 315/478-2188

DYNAMIC WELD’G & REPAIR Bayshore, NY 631/643-1308

HAUN WELDING SUPPLY Syracuse, NY 315/463-5241

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

MACHINE AND WELDING SUPPLY CO. Greenville, NC 252/752-3089

MACHINE AND WELDING SUPPLY CO. Raleigh, NC 919/772-9500

MACHINE AND WELDING SUPPLY CO. Winston-Salem, NC 336/723-9651

NATIONAL WELDERS SUPPLY CO. High Point, NC 910/882-1110

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

OHIO

AGA GASES, INC. Lima, OH 419/228-2828

ALBRIGHT WELDING SUPPLY Wooster, OH 330/264-2021

ALL ABOUT SERVICE Wickliffe, OH 440/516-0303

ARC EQUIPMENT COMPANY Struthers, OH 333/750-9353

ARC SERVICES, INC. Toledo, OH 419/478-6204

BELAIR PRODUCTS, INC. Akron, OH 330/253-3116

BIG RIVER ELECTRIC Gallipolis, OH 740/446-4360

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

ELECTRIC WELDER REPAIR Cuyahoga Heights, OH 216/271-5600

MAINTENANCE UNLTD. & TOOL REPAIR Cincinnati, OH 513/554-1313

O.E. MEYER CO. Sandusky, OH 419/621-4201

OHIO AIR PRODUCTS Canton, OH 330/821-2771

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

S.D. NOLD, INC. Lisbon, OH 330/424-3134

Cobramatic® II Owner's Manual

Page 39

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

VALLEY NATIONAL GASES Cincinnati, OH 513/241-5840

VALLEY NATIONAL GASES Hilliard, OH 614/771-1311

VALLEY NATIONAL GASES Lima, OH 419/228-1008

VALLEY NATIONAL GASES Toledo, OH 419/241-9114

VOLLMER ELECTRIC CO. Columbus, OH 614/476-8800

WEILER WELDING CO., INC. Dayton, OH 937/222-8312

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

OKLAHOMA

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

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

MUNN SUPPLY Enid, OK 580/234-4120

OKLAHOMA WELDERS SUPPLY Madill, OK 580/795-5561

OREGON

ARC SYSTEMS SERVICES Central Point, OR 541/665-2676

E C COMPANY dba ELECTRICAL CONSTRUCTION CO. Portland, OR 800/452-1511

INDUSTRIAL SOURCE Eugene, OR 541/344-1438

WELDER SERVICE & REPAIR Redmond, OR 541/548-8711

PENNSYLVANIA

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. EQUIPMENT CO. E. Lansdowne, PA 610/259-4100

POWER SOURCE REPAIR CO., INC. Collingdale, PA 610/532-6460

VALLEY NATIONAL GASES Pittsburgh, PA 412/281-1835

SOUTH CAROLINA

CAROLINA WELDER SERVICE Lake City, SC 843/687-0413

TENNESSEE

INDUSTRIAL MACHINE REPAIRS Rogersville, TN 423/272-8199

NATIONAL RENTAL & REPAIR Knoxville, TN 423/584-6390

NEXAIR Memphis, TN 901/523-6821

QUALITY WELD’G EQUIPMENT Nashville, TN 615/726-5282

TRAMCO Bristol, TN 423/968-4499

TEXAS

AIRGAS - SOUTHWEST, INC. Austin, TX 512/835-0202

Cobramatic® II Owner's Manual

Page 40

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

AIRGAS - SOUTHWEST, INC. Houston, TX 713/462-8027

DENISON OXYGEN Denison, TX 903/465-3369

FT. WORTH WELDERS SUPPLY, INC. Fort Worth, TX 817/332-8696

GPC SERVICES, INC. San Angelo, TX 915/655-4545

LEKTROTECH, INC. Greenville, TX 903/454-7146

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

TexAir WELDING SUPPLY Longview, TX 903/238-9353

WELDING MACHINE & TORCH REPAIR San Antonio, TX 210/680-8390

UTAH

ARC SERVICES, LLC West Valley City, UT 801/975-1121

C.W. SILVER INDUSTRIAL SERVICE Salt Lake City, UT 801/531-8888

W.J. WELDING EQUIPMENT REPAIR, INC. N. Clarendon, VT 802/775-7422

NORFOLK WELDERS SUPPLY Norfolk, VA 804/622-6571

WASHINGTON

AIRGAS - NORPAC, INC. Tacoma, WA 253/473-2282

AIRGAS – NORPAC, INC. Vancouver, WA 360/574-5311

A-L WELDING PRODUCTS Tukwila, WA 425/228-2218

AMERICAN EQUIPMENT SERVICES Kent, WA 253/395-9947

HARRIS ELECTRIC, INC. Seattle, WA 206/782-6668

OXARC, INC. Spokane, WA 509/535-7794

PACIFIC WELDING SUPPLIES Tacoma, WA 253/572-5302

PRECISION WELDER & ENGINE REPAIR Seattle, WA 206/382-6227

WEST VIRGINIA

CARDINAL SALES & SERVICE, INC. Clarksburg, WV 304/622-7590

WILLARD C. STARCHER Spencer, WV 304/927-2520

VIRGINIA

AIR PRODUCTS & CHEMICALS, INC. Bristol, VA 540/669-3161

ARC WELDERS, INC. Ashland, VA 804/798-1818

ARCET EQUIPMENT CO. Hampton, VA 757/728-9353

N.W. MARTIN CO. Springﬁ eld, VA 703/644-0120

WISCONSIN

INTERSTATE WELDING SALES CORP. Appleton, WI 920/734-7173

MOSINEE MACHINE & ELECTRIC Mosinee, WI 715/693-0858

PRAXAIR DISTRIBUTION, INC. Brookﬁ eld, WI 414/938-6365

VALLEY NATIONAL GASES Milwaukee, WI 414/281-9540

Cobramatic® II Owner's Manual

Page 41

MK Warranty Repair Stations

Please visit www.mkproducts.com for most up-to-date listings.

as of 04/17/03

WELDER REPAIR & SERVICE, INC. Fredonia, WI 262/692-3068

CANADA

A&A WELDER SERVICES LTD. Saskatoon, Saskatchewan 306/934-1601

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

B. HARRIS WELDING SVCS. LTD. 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. Grande Prairie, Alberta 780/532-5900

HYPERDYNAMICS TECHNOLOGIES L TD. Pickering, Ontario 905/683-9938

INDUSTRIAL ELECTRONIC SERVICES Calgary, Alberta 403/279-3432

LADEL LTD. Quebec 819/376-6577

LeBLANC ELECTRO-TECH, INC. Boucherville, Quebec 450/449-5244

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

OZARK ELECTRICAL MARINE LTD. St. Johns, Newfoundland 709/726-4554

PEEL ENGINES Mississauga, Ontario 905/670-1535

PROMOTECH ÉLECTRIQUE, INC. Fleurimont, Quebec 819/822-2111

WELDERS SUPPLY Winnipeg, Manitoba 204/772-9476

WELDERTECH Calgary, Alberta 403/279-3432

WELDTEC B.C. 604/545-3886

CHINA

PHT Group Company Beijing, China 86-10-6858 8395

Cobramatic® II Owner's Manual

Page 42

Cobramatic® II Owner's Manual

Page 43

Cobramatic® II Owner's Manual

Page 44

Effective March 1, 2001

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, Weldheads and Water Recirculators.......1 year

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

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

Classiﬁ cation of any item into the foregoing categories shall be at the sole discretion of MK Products. Notiﬁ cation 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 PAR TICULAR 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 RE-SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS’ WARRANTIES TO ANY CONSUMER.

MK Products, Inc. 16882 Armstrong Ave. Irvine, CA 92606 Tel (949)863-1234 Fax (949)474-1428

Cobramatic® II Owner's Manual

DATE : March 1, 2001

Page 45

MK Products, Inc.

16882 Armstrong Ave.

Irvine, California 92606

http://www.mkproducts.com

Tel (949) 863-1234

Fax (949) 474-1428