MK Products Cobra SX User Manual

Page 1
Fronius Compatible
Owner’s Manual
Product: Cobra® SX
Fronius Manual: 091-0646 Serial: 10090001 Voltage Rating: 24 VDC
Revision: Sept 2010 Gun models: 328-8xx
175 Ampere Push-Pull Welding Gun
Page 2
Page 3
Safety Considerations
Table of Contents
Installation
Technical Specications .........................................................................................1
Support Equipment Required .................................................................................1
Gun Lead Connections ..........................................................................................1
..................................................................................Section A
Operation ....................................................................................Section B
General ..................................................................................................................2
Controls and Settings .............................................................................................2
Drive Roll and Idler Rolls........................................................................................2
Accessories ................................................................................Section C
Optional Kits ...........................................................................................................3
Snake Skins ...........................................................................................................3
Contact Tips ...........................................................................................................4
Gas Cups ...............................................................................................................4
Maintenance ...............................................................................Section D
Periodic Maintenance.............................................................................................5
Maintenance Tools .................................................................................................5
Recommended Spare Parts List ............................................................................5
Troubleshooting ..........................................................................Section E
Troubleshooting Guide ...........................................................................................7
Testing The Gun .....................................................................................................7
Appendices .................................................................................Section F
Diagrams / Parts List ..............................................................................................9
Mechanical ...........................................................................................................10
Electrical...............................................................................................................17
Safety Warnings Warranty
Cobra® SX Fronius Compatible Owner's Manual
Page 4
Declaration of Conformity for
European Community (CE) Products
Note This information is provided for units with CE certication (see rating label on unit).
Manufacturer’s Name:
16882 Armstrong Ave. Irvine, CA 92606
Declares that the product: Cobra
conforms to the following Directives and Standards:
MK Products, Inc.
®
SX Fronius Compatible
Directives
Low Voltage Directive: 2006/95/EC
Electromagnetic Compatibility (EMC) Directive: 2004/108/EC
Standards
Electromagnetic Compatibility, (EMC): EN 60974-10: 2007
Torches And Guns For Arc Welding, EN 60974-7: 2005
Cobra® SX Fronius Compatible Owner's Manual
Page 5
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 qualied help before
proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING PRODUCES HIGH INTENSI TY 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 filter 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 first aid and eye treatment.
First aid facilities and a qualied 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 cuf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 con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 air­supplied respirator.
Work in a conned space only while it is
being ventilated and, if necessary, while wearing an air-supplied respirator.
Gas leaks in a conned space should be
avoided. Leaked gas in large quantities can change oxygen concentration dangerously. Do not bring gas cylinders
into a conned space.
Leaving conned 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 fire 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 floor 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 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.
Cobra® SX Fronius Compatible™ Owner's Manual - Page i
Page 6
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 rell any cylinder.
Cylinder ttings should never be modied
or exchanged.
3. Hose
Prohibited use. Never use hose other
than that designed for the specied gas. A general hose identi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 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 ori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 identi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 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 signicant 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, reect
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.
Cobra® SX Fronius Compatible™ Owner's Manual - Page ii
Page 7
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-reflective, 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 a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 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 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 three­prong 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. Ter minals an d Ot her Exp osed
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.
Cobra® SX Fronius Compatible™ Owner's Manual - Page iii
Page 8
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.
Cobra® SX Fronius Compatible Owner's Manual
Page 9
Section A Installation
Technical Specications
Wire Capacity
.030” - .035” (0.6mm - 0.9mm) Solid and hard wires .030” - 3/64” (0.8mm - 1.6mm) Aluminum .023" (0.6mm) capability using Optional Idler Roll, P/N 511-0113
Wire Speed
800 IPM (20.3 mpm) Max. at rated feeder Input Voltage (120VAC / 42VAC)
Duty Cycle
All ratings are using Argon Gas
175 Amps/25 Volts 60%
Support Equipment Required
• C.V. or C.C. Power Source of sufcient capacity for your needs.
• Regulated gas supply and hoses.
Properly sized power leads from power source to wire feeder and
ground.
Gun Lead Connections
Power Cable
A #2 power cable is used on the Cobra® SX Fronius Compatible™ gun. The gun and Power Pin ends of the cable are stripped to the copper strands and wrapped with a copper strip. A setscrew holds the cable securely in the gun
body and in the Power Manifold with torque requirements of 55-60 in-lb.
Conduit
The Cobra® SX Fronius Compatible™ comes standard with a poly-lined
conduit, for feeding aluminum wire. The longer tting with a shallow groove
is used on the gun end. A set screw located on top of the gun handle secures the conduit in place. The cabinet end of the conduit is secured into the Power Pin connector with a set screw.
Gas Hose
The gas hose is pushed over a barbed tting on the end of the gun body and
secured by twisting the hose retainer to the end of the hose (shown below). The hose retainer is re-usable and can be removed and re-installed as needed.
Control Cable
A multi-conductor control cable is used on the Cobra Compatible™ gun. The gun end of the cable is secured with a cable clamp and the wires are connected to the potentiometer, the micro switch, the motor and the gun body mechanically. Slack is left in the electric cable as it exits the back of the gun to prevent cable and/or wire breakage. The cabinet end of the control cable uses a 9-Pin, rectangular connector.
Cobra® SX Fronius Compatible™ Owner's Manual - Page 1
®
SX Fronius
Page 10
Section B Operation
General
The Cobra® SX Fronius Compatible™ gun maintains a constant, steady, uniform wire feed speed, regardless of curved or looped wire conduit. The constant push exerted by the slave motor in the cabinet, combined with the
pull of the gun motor, causes the wire to literally oat friction-free through
the wire conduit. The 24VDC gun motor is controlled by a three and three­quarter (3 3/4) turn potentiometer in the gun handle.
Controls and Settings
Potentiometer
The laterally-positioned potentiometer is located in the lower end of the handle, providing up to 800 ipm with 3 3/4 turns.
Micro Switch
The micro switch assembly consists of the micro switch and leads.
Trigger Sensitivity
The amount of trigger lever travel can be shortened for a “quicker” or “more responsive” action.
A more sensitive trigger lever is produced by reducing the gap between the trigger lever and the micro-switch lever. By turning-in the Trigger Sensivity Adjustment Screw (Figure 1), it closes the gap between the trigger lever and the micro­switch lever. This will enable the operator to increase the sensivity of the trigger lever.
Sensitivity Adjustment
With the wire feeder turned on (with or without welding wire loaded), turn the screw in until the micro-switch is activated (Figure 2). Once activated, the gun and wire feeder motors will begin feeding wire. Retract the screw accordingly until the system is deactivated and adjusted to the operators’ liking.
Figure 1
Figure 2
Drive Roll and Idler Rolls
General
The Cobra® SX Fronius Compatible™ gun comes standard with a knurled drive roll and a grooved idler roll, ready for welding aluminum wire diameters from .030” up to 3/64”. An optional grooved idler roll, for wire diameter .023” is available as P/N 511-0113. Insulated V-Groove drive roll kits are also available for aluminum wire, (see Optional Kits).
Drive roll tension is accomplished with a unique spring-loaded pressure screw. The Cobra® SX Fronius Compatible™ comes from the factory with the pressure adjustment screw preset.
NO ADJUSTMENT is required for all sizes and types of wires.
Drive Roll Installation/Removal
Note:
Neither of the handles needs to be removed to access the Drive or Idler Rolls
1. Push the idler lever, this will relieve the pressure against the drive roll (as shown in Figure 3).
2. Align the Drive Roll Removal Tool (P/N 931-0100) over the ats of the
drive roll (as shown in Figure 4). Hold the gun with one hand or on a table top, with the other hand give the Removal Tool a quick snap-turn in the CLOCKWISE DIRECTION.
Cobra® SX Fronius Compatible™ Owner's Manual - Page 2
Page 11
Figure 3
3. Once the drive roll is loose, continue to spin drive roll in the clockwise direction to remove the drive roll from the gun.
4. Install a new drive roll on the left-hand threaded shaft. The drive roll will self-tighten when it is feeding wire.
Idler Roll Installation and Removal
(Reference Figure 5)
1. Using a slot type screwdriver, loosen idler screw.
2. Insert new idler roll onto screw, insuring that idler groove is toward top.
3. Tighten.
Section C Accessories
Optional Kits
The arcing of the wire at the knurled drive roll is typical of a contact tip which is too large for the wire or if the aluminum wire has excessive oxidation, reducing the contact between the wire and contact tip. Insulated Drive Roll Kits are used when the teeth on the knurled drive roll, arc to and soften the wire as it enters the barrel liner. The softened wire has a greater potential of being shaved and/or clogging in the barrel liner.
Insulated Groove Drive Roll Kit ......................................................005-0640
For .030" (0.8mm) dia. aluminum wire. Includes insulated drive roll and idler roll assy.
Insulated Groove Drive Roll Kit ......................................................005-0716
For .035" (0.9mm) dia. aluminum wire. Includes insulated drive roll and idler roll assy.
Insulated Groove Drive Roll Kit
For .040" (1.0mm) dia. aluminum wire. Includes insulated drive roll and idler roll assy.
Insulated Groove Drive Roll Kit ......................................................005-0718
For 3/64" (1.2mm) dia. aluminum wire. Includes insulated drive roll and idler roll assy.
Figure 4
Figure 5
......................................................005-0717
Snake Skins
Snake Skin protective covers are standard on the Cobra® SX Fronius Compatible by means of hook and loop - also known as Velcro®.
Snake Skin Cover 15ft leads .......................................................931-0110
Snake Skin Cover 25ft leads ...................................................... 931-0122
Snake Skin Cover 35ft leads ...................................................... 931-0132
Snake Skin Cover 50ft leads ...................................................... 931-0123
Cobra® SX Fronius Compatible™ Owner's Manual - Page 3
. Replacement covers may be ordered and replaced in the eld
Page 12
Conduits
at spiral steel conduit for steel & cored wire
615-0621-15 ....................................................................................15 ft./4.5m
615-0621-25 ....................................................................................25 ft./7.6m
615-0621-35 ..................................................................................35 ft./10.7m
615-0621-50 ..................................................................................50 ft./15.2m
Contact Tips
1/4" Diameter Contact Tip*
Wire Size Tip ID Arc Tip Length Part No.
.023” (0.6 mm) .031” (0.8 mm) Spray 1.50” (38.1 mm) 621-0057-25 .023” (0.6 mm) .031” (0.8 mm) Short 1.75” (44.5 mm) 621-0328-25 .030” (0.8 mm) .037” (0.9 mm) Spray 1.50” (38.1 mm) 621-0325-25 .030” (0.8 mm) .037” (0.9 mm) Short 1.75” (44.5 mm) 621-0326-25 .030” (0.8 mm) .040” (1.0 mm) Spray 1.50” (38.1 mm) 621-0076-25 .035” (0.9 mm) .045” (1.1 mm) Spray 1.50” (38.1 mm) 621-0001-25
621-0001-250
621-0001-500 .035” (0.9 mm) .040” (1.0 mm) Short 1.75” (44.5 mm) 621-0077-25 .035” (0.9 mm) .045” (1.1 mm) Short 1.75” (44.5 mm) 621-0002-25 3/64” (1.2 mm) .054” (1.37 mm) Spray 1.50” (38.1 mm) 621-0327-25 3/64” (1.2 mm) .060” (1.5 mm) Spray 1.50” (38.1 mm) 621-0003-25
621-0003-250
621-0003-500
**This size tip furnished with gun * All tips sold in quantities of 25
Also sold in quantities of 250
Gas Cups
Gas Cups
Cup Size Cup I.D. Part No.
No. 5 1/4" (6.4mm) 621-0079 No. 6 3/8” (9.5mm) 001-0137 No. 8 1/2” (12.7mm) 001-0138*
No. 10 5/8” (15.8mm) 001-0139
*standard - furnished with gun
sold in packs of 4 each
Gun Barrel Liners
Part Number Description
931-0137 Teon liner package, 5 pieces 615-0255 Spiral steel, .030 - .045” (0.8mm - 1.1mm) 621-0017 Tip Extender, Classic Cup, 1/4" Tip (Stackable) 615-0256 Spiral liner for tip extender
Cobra® SX Fronius Compatible™ Owner's Manual - Page 4
Page 13
Section D Maintenance
Periodic Maintenance
Your Cobramatic System is designed to provide years of reliable service. Maintenance of the gun will normally consist of a general cleaning of the wire
guide system, including barrel, drive rolls, and conduit at regular intervals. Remove spatter build-up from inside of nozzles with a hardwood stick. It is
recommended that the conduit be blown out every time you add a new spool of wire.
The only parts on the Cobramatic system that are subject to normal wear are the conduit, contact tips, gas cups, front body liners, wire guides, drive and idler rolls. A supply of these parts should be maintained on hand.
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. See the “Recommended spare parts list” for the most commonly replaced parts.
If repairs do become necessary, qualied shop maintenance personnel can
easily replace any part.
Tool Part Number
Drive Roll Removal Tool 931-0100
Recommended Spare Parts List
Qty. P/N Description
1 615-0620-15 Conduit 15 ft 1 615-0620-25 Conduit 25 ft 1 615-0620-35 Conduit 35 ft 1 615-0620-50 Conduit 50 ft 1 005-0694 Trigger Assy Kit 1 003-2190 Potentiometer Assembly 1 005-0710 Handle Kit 1 003-2197 Micro Switch Assembly 2 511-0101 Drive Roll 2 511-0001 Idler Roll
Maintenance Tools
DRIVE ROLL REMOVAL TOOL
Cobra® SX Fronius Compatible™ Owner's Manual - Page 5
931-0100
KNURLED DRIVE ROLL
511-0101
IDLER ROLL
511-0001
(.030" - 3/64")
IDLER ROLL
511-0113
(.023")
MICRO SWITCH ASSY
003-2197
Page 14
Section E Troubleshooting
Trouble Cause Remedy
Input power fuse in feeder/
No wire feed at gun, feeder not operating, I.e. no slave motor or brake solenoid.
No wire feed at gun, feeder operating properly
Wire feeds, but welding wire is not engergized.
Wire feeds erratically.
Wire feeds one speed only.
Wire walks out of drive rolls.
Control box blown. Micro-switch defective/not
being activated. Broken electrical cable. Check micro-switch wires for
Motor Control fuse in feeder/ Control box blown.
Bad potentiometer. Check potentiometer with meter. Broken electrical cable. Check motor and potentiometer
Bad speed control/PCB. See specic cabinet/control box
Loose or no cable connections. Check all power connections. Contactor control cable loose or
in wrong position.
Welding power source. Check power source. Dirty or worn conduit. Blow out or replace conduit. Wrong size contact tip. See contact tip table. Idler roll stuck. Check for lock washer under idler
Bad potentiometer. Check with meter. Broken electrical cable. Check potentiometer wires for
Bad speed control. See specic cabinet/control box
Idler roll upside-down. Place groove in idler roll toward
Rear wire guide missing. Replace wire guide.
Replace fuse.
Replace switch. Check switch for operation.
continuity Check motor leads for shorts; then
replace fuse.
wires for continuity.
owners for speed control operation.
Check power supply owners manual for location and type of contactor signal required, i.e., closing or 115VAC.
roll, or replace if damaged.
continuity or short.
owners for speed control operation.
top.
Cobra® SX Fronius Compatible™ Owner's Manual - Page 6
Page 15
Troubleshooting Guide
Regardless of which gun or feeder used, all MK Products’ push-pull guns operate on the same principle. The slave motor in the feeder runs at a fast, constant torque, but has very low torque. It is always trying to feed more wire than the gun 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 feeder is used simply to keep the wire slightly taut, so it will not pull off the spool while feeding wire.
The high torque 24VDC gun motor is controlled by a solid state speed control located in the feeder, and a pot located in the gun. The gun motor, potentiometer, and micro switch are connected to the cabinet/control box via a control cable and Amphenol connector. 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 gun activates both the slave motor and gun motor circuits in the cabinet. Therefore, if the slave motor and brake solenoid operate, but the gun does not, look more toward the gun motor’s 24 V circuits, speed control, control cable, or the gun motor. If nothing operates, look more toward the slave motor’s input, micro switch leads, or micro switch.
Testing The Gun
Reference the 9-pin rectangular diagram
on the Cobra® SX Fronius Compatible electrical diagram
for information about pin-outs and locations.
Motor Check
Remove the connector from the cabinet. Using the 9-pin connector, check the resistance across pins “1” and “6”
(motor leads). If an open circuit (more than K ohms) or short (less than 2 ohms) exists, check
the motor leads and motor independently.
Testing the Gun Potentiometer
Using the 9-pin connector, check the resistance across pin “3” (wiper) and pin “2”. The resistance should vary from 0 - 5K ohms as the potentiometer is turned.
Check the resistance across pin “3” (wiper) and pin “7”. The resistance should vary from 5K - 0 ohms as the potentiometer is turned.
Testing the Micro Switch
Using the 9-pin connector, check for continuity across pins “9” and “5” when the trigger is pressed.
Cobra® SX Fronius Compatible™ Owner's Manual - Page 7
Page 16
THIS PAGE INTENTIONALLY BLANK
Cobra® SX Fronius Compatible™ Owner's Manual - Page 8
Page 17
Section F Appendices And Diagrams / Parts List
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Body Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Classic Cup Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lead Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cobra® SX Fronius Compatible™ Owner's Manual - Page 9
Page 18
Cobra® SX Fronius Compatible
Exploded View
APPLY LOW STRENGTH THREAD LOCKING TO CONTACT SURACE
APPLY COMPOUND NAOLOX TO EXTERNAL THREAD
Cobra® SX Fronius Compatible™ Owner's Manual - Page 10
Page 19
Parts List
SX Fronius Compatible
®
Cobra
Handle Kit: Includes line items 10, 15,
and 18
1 005-0710
9 4 333-0006 Wshr Spr Lk #8 18 1 437-0292 Door Molded
8 4 333-0003 Wshr Spr Lk #4 17
6 - - - 15 1 431-1760 SCR Shoulder 1/8 x 4-40
7 1 003-2244 Assy Rear Body 16
5 1 003-2197 Assy Switch 14 1 421-0713 Pin Dowel 3/32 x 3/4 SST
4 1 003-2192 Assy Motor 13 4 338-0159 SCR SHC M3 x 6 SST
3 1 003-2191 Assy Body 12 2 338-0153 SCR SHC 1-72 x 3/8
2 1 003-2190 Assy Potentiometer 11 4 338-0034 SCR SHC 8-32 x 1/2 SST
1 1 005-0694 Trigger Kit 10 11 338-0014 SCR SHC 4-40 x 1/2 SST
No. Qty. Part No. Description No. Qty. Part No. Description
Cobra® SX Fronius Compatible™ Owner's Manual - Page 11
Page 20
Cobra® SX Fronius Compatible
Front Body Assembly
003-2191
Front Body Assembly
No. Qty. Part Number Description
1 1 325-0206 SCR Pan 10-24x.34 2 1 419-0120 Comp Spring 3 1 431-1728 SCR SH.093x4-40 4 - - Not Available Separately 5 1 431-1731 Idler Arm/Lever 6 1 511-0101 Drive Roll 7 1 511-0001 Idler Roll (.030" - 3/64") 7 opt 511-0113 Idler Roll (.023" - .035")
Cobra® SX Fronius Compatible™ Owner's Manual - Page 12
Page 21
Cobra® SX Fronius Compatible
Rear Body Assembly
003-2244
Rear Body Assembly
No. Qty. Part Number Description
1 - - Not Available Separately 2 2 303-0097 0-Ring 2-005 3 1 321-0518 SCR 1/4-20x3/8 4 1 321-1104 Conduit SCR
Cobra® SX Fronius Compatible™ Owner's Manual - Page 13
Page 22
Cobra® SX Fronius Compatible
Classic Cup Barrel Assembly
003-2340
Classic Cup Barrel Assembly
No. Qty. Part No. Description
1 1 001-0138 #8 Assy Gas Cup 2 - - Not available separately 3 1 301-0101 Barrel Insulator 4 2 303-0097 O-Ring 2-005 5 1 pkg. 931-0137 Barrel Liner PK, 5 pcs 6 1 621-0001 Tip, .045 x .25 OD
Cobra® SX Fronius Compatible™ Owner's Manual - Page 14
Page 23
Cobra® SX Fronius Compatible™ Lead Assembly
Lead Assembly - Air Cooled
No. Qty. Description 15' Part No. 25' Part No. 35' Part No. 50' Part No.
1 1 Assy Boot Torch 003-2153 2 1 Assy Power Manifold, A/C 003-2373 3 2 Wrap Spiral Cord 261-0094 4 1 Retainer Ring 313-0140-1.062 5 4 Screw SHC 4-40 x 1/2 SST 338-0014 6 4 Tie Wrap 411-0045 7 1 Conduit Liner Fitting 431-1788 8 2 Hose Retainer, 5/16 431-1898
9 1 Nut Handle Adapter 437-0265 10 1 Handle RH Lead Universal 437-0315-BLACK 11 1 Handle LH Lead Universal 437-0316-BLACK 12 1 Snake Skin 931-0110 931-0122 931-0132 931-0123 13 1 Assy Gas Hose 552-0241-15 552-0241-25 552-0241-35 552-0241-50 14 1 Conduit Tef Tube 615-0620-15 615-0620-25 615-0620-35 615-0620-50 15 1 Assy Controller Cable 005-0381-15 005-0381-25 005-0381-35 005-0381-50 16 1 Assy Power Cable Global 843-0640-15 843-0640-25 843-0640-35 843-0640-50
* Hose Retainer is re-usable and can be removed and re-installed as needed
Cobra® SX Fronius Compatible™ Owner's Manual - Page 15
Page 24
Cobra® SX Fronius Compatible
Power Manifold Assembly, Air Cooled
P/N 003-2373
APPLY HIGH STRENGTH THREAD SEALANT TO THREADS
Power Manifold Assembly
No. Qty. Part No. Description
1 3 303-0097 O-Ring Buna-N .101 ID x .07W 2 1 321-1082 Set Screw Flat 1/4 - 20 x 3/8 SST 3 1 321-1104 Set Screw Conduit 4 1 431-1905 Fitting 1/8 ID x 1/16 - 27 NPT 5 1 431-1948 Connector Thread 6 - - Not available separately
Cobra® SX Fronius Compatible™ Owner's Manual - Page 16
Page 25
Cobra® SX Fronius Compatible™ Electrical
Cobra® SX Fronius Compatible™ Owner's Manual - Page 17
Page 26
Cobra® SX Fronius Compatible Owner's Manual
Page 27
Cobra® SX Fronius Compatible Owner's Manual
Page 28
16882 Armstrong Ave. Irvine, CA 92606 Tel (949)863-1234 Fax (949)474-1428 www.mkproducts.com
Cobra® SX Fronius Compatible Owner's Manual
August 1, 2010
Page 29
THIS PAGE INTENTIONALLY BLANK
Page 30
16882 Armstrong Ave.
Irvine, California 92606
TEL (949) 863-1234 FAX (949) 474-1428
www.mkproducts.com
Loading...