MK Products Cobra SX User Manual

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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

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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

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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 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

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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

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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

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