Python 232-835 User Manual
Lincoln Compatible™
Owner’s Manual
Product: Python
Manual: 091-0618
Serial: 09020001
Voltage Rating: 24 VDC
Revision: Feb 2009
Gun models: 232-835
225 Ampere Air Cooled
Push-Pull Welding Gun
Table of Contents
Safety Considerations ........................................................................i-iii
Installation ............................................................................... Section A
Technical Specications .....................................................................................1
Support Equipment Required .............................................................................1
Gun Lead Connections ......................................................................................1
Operation .................................................................................Section B
General ..............................................................................................................1
Controls and Settings .........................................................................................2
Trigger Adjustment .............................................................................................2
Drive Roll and Idler Rolls....................................................................................2
Accessories .............................................................................Section C
Optional Kits .......................................................................................................3
Snake Skins ....................................................................................................... 4
Contact Tips .......................................................................................................4
Gas Cups ........................................................................................................... 4
Barrels ................................................................................................................5
Maintenance ............................................................................Section D
Periodic Maintenance.........................................................................................5
Recommended Spare Parts List ........................................................................ 6
Troubleshooting .......................................................................Section E
Troubleshooting Guide .......................................................................................8
Testing The Gun .................................................................................................8
Appendices ..............................................................................Section F
Diagrams / Parts List ..........................................................................................9
Mechanical .......................................................................................................10
Electrical...........................................................................................................16
Safety Warnings
Warranty
European Community (CE) Products
Note
Declaration of Conformity for
This information is provided for units with CE certication (see rating label on unit).
Manufacturer’s Name:
16882 Armstrong Ave.
Irvine, CA 92606
Declares that the product: Python
conforms to the following Directives and Standards:
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1
MK Products, Inc.
®
Lincoln Compatible
Directives
Low Voltage Directive: 73/23/EEC
Standards
(September 1998 - Second Edition)
Arc Welding Equipment: Wirefeed Systems: IEC 974-5
(September 1997 - Draft Revision)
Degrees of Protection Provided by Enclosures (IP Code): IEC 529:1989
(November 1989 - First Edition)
Insulation Coordination For Equipment With Low-Voltage Systems:
Part I: Principles, Requirements and Tests: IEC 664-1: 1992
(October 1992 - First Edition)
Electromagnetic Compatibility, (EMC): EN 50199
(August 1995)
Torches And Guns For Arc Welding, EN 50078
SAFETY CONSIDERATIONS
ELECTRIC ARC WELDING EQUIPMENT
CAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION
OR MAINTENANCE OF THIS EQUIPMENT
1-1 INTRODUCTION
This equipment is intended for ultimate
application by commercial/industrial users
and for operation by persons trained and
experienced in the use and maintenance
of welding equipment. Operation should
not be undertaken without adequate training in the use of such equipment. Training
is available from many public and private
schools or similar facilities.
Safe practices in the installation, operation and maintenance of this equipment
requires proper training in the art, a careful study of the information provided with
the equipment, and the use of common
sense. Rules for safe use are generally
provided by suppliers of welding power
sources, compressed gas suppliers, and
electrode suppliers. Careful compliance
with these rules will promote safe use of
this equipment.
The following Safety Rules cover some
of the more generally found situations.
READ THEM CAREFULLY. In case of
any doubt, obtain qualied help before
proceeding.
1-2 GENERAL PRECAUTIONS
A. Burn Prevention
ELECTRIC ARC WELDING PRODUCES
HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH
MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY
DAMAGE ANY EXPOSED SKIN AREAS.
Wear helme t with sa fet y goggles or
glasses with side shields underneath,
appropriate lter lenses or plates (protected by clear cover glass). This is a
must for welding or cutting (and chipping)
to protect the eyes from radiant energy
and ying metal. Replace cover glass
when broken, pitted, or spattered.
Medical first aid and eye treatment.
First aid facilities and a qualied rst aid
person should be available for each shift
unless medical facilities are close by for
immediate treatment of ash burns of the
eyes and skin burns.
Wear protective clothing - leather (or
asbestos) gauntlet gloves, hat, and high
safety-toe shoes. Button shirt collar and
pocket aps, and wear cufess trousers
to avoid entry of sparks and slag.
Avoid oily or greasy clothing. A spark
may ignite them.
Flammable hair preparations should not
be used by persons intending to weld
or cut.
Hot metal such as electrode stubs and work
pieces should never be handled without
gloves.
Ear plugs should be worn when working on
overhead or in a conned space. A hard hat
should be worn when others work overhead.
B. Toxic Fume Prevention
WARNING: The use of this product may
result in exposure to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.
Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors,
heat, or oxygen enrichment or depletion that
welding (or cutting) may produce. Prevent
them with adequate ventilation. NEVER
ventilate with oxygen.
Lead-, cadmium-, zinc-, mercury-, berylliumbearing and similar materials, when welded
or cut, may produce harmful concentrations
of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the
area, as well as the operator, must wear an
air-supplied respirator. For beryllium, both
must be used.
Metals coated with or containing materials
that emit toxic fumes should not be heated
unless coating is removed form the work
surface, the area is well ventilated, or the
operator wears an air-supplied respirator.
Work in a conned space only while it is
being ventilated and, if necessary, while
wearing an air-supplied respirator.
Gas leaks in a conned space should be
avoided. Leaked gas in large quantities
can change oxygen concentration dangerously. Do not bring gas cylinders into a
conned space.
Leaving confined space, shut OFF gas
supply at source to prevent possible accumulation of gases in the space if downstream valves ha ve be en ac cidental ly
opened or left open. Check to be sure that
the space is safe before reentering it.
Vapors from chlorinated solvents can be
decomposed by the heat of the arc (or
ame) to form PHOSGENE, a highly toxic
gas, and other lung and eye irritating products. The ultraviolet (radiant) energy of the
arc can also decompose trichloroethylene
and perchloroethylene vapors to form phosgene. DO NOT WELD or cut where solvent
vapors can be drawn into the welding or cutting atmosphere or where the radiant energy
can penetrate to atmospheres containing
even minute amounts of trichloroethylene
or perchloroethylene.
C. Fire and Explosion Prevention
Causes of re and explosion are: combustibles reached by the arc, ame, ying sparks,
hot slag, or heated material, misuse of
compressed gases and cylinders, and
short circuits.
BE AWARE THAT ying sparks or falling slag can pass through cracks, along
pipes, through windows or doors, and
through wall or oor openings, out of
sight of the goggled operator. Sparks
can y many feet.
To prevent res and explosion:
Keep equipment clean and operable, free
of oil, grease, and (in electrical parts) of
metallic particles that can cause short
circuits.
If combustibles are in area, do NOT weld
or cut. Move the work if practicable, to
an area free of combustibles. Avoid paint
spray rooms, dip tanks, storage areas,
ventilators. If the work cannot be moved,
move combustibles at least 35 feet away,
out of reach of sparks and heat; or protect
against ignition with suitable and snug-
tting, re-resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on (or
cut). Walls, ceilings, and oor near work
should be protected by heat-resistant
covers or shields.
Fire watcher must be standing by with
suitable 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
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 combus-
tibles, 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 inc ludes : 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
Python® Lincoln Compatible™ Owner's Manual - Page i
using protective equipment.
Water-lling just below working level may
substitute for inerting.
A c ontaine r wit h unk nown cont ents
sh ou ld be cleaned (se e 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.
1. Pressure Regulators
Regulator relief valve is designed to
protect only the regulator from overpressure; it is not intended to protect any
downstream equipment. Provide such
protection with one or more relief devices.
Never connect a regulator to a cylinder
containing gas other than that for which
the regulator was designed.
Remove faulty regulator from service
immediately for repair (rst close cylinder
valve). The following symptoms indicate
a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues to rise with downstream valve
closed.
Faulty Gauge - if gauge pointer does not
move off stop pin when pressurized, nor
returns to stop pin after pressure release.
Repair. Do NOT attempt repair. Send
faulty regulators for repair to manufacturer’s designated repair center, where
special techniques and tools are used
by trained personnel.
2. Cylinders
Cylinders must be handled carefully to
prevent leaks and damage to their walls,
valves, or safety devices:
Avoid electrical circuit contact with cylinders including third rails, electrical wires,
or welding circuits. They can produced
short circuit arcs that may lead to a serious accident. (See 1-3C)
ICC or DOT marking must be on each
cylinder. It is an assurance of safety
when the cylinder is properly handled.
Identifying gas content. Use only cylinders with name of gas marked on them;
do not rely on color to identify gas content. Notify supplier if unmarked. NEVER
DEFACE or alter name, number, or other
markings on a cylinder. It is illegal and
hazardous.
Empties: Keep valves closed, replace
caps securely; mark MT; keep them separate from FULLS, and return promptly.
Prohibited use. Never use a cylinder or its
contents for other than its intended use,
NEVER as a support or roller.
Locate or secure cylinders so they cannot
be knocked over.
Passageways and work areas. Keep cylinders clear of areas where they may be
stuck.
Transporting cylinders. With a crane, use
a secure support such as a platform or
cradle. Do NOT lift cylinders off the ground
by their valves or caps, or by chains, slings,
or magnets.
Do NOT expose cylinders to excessive heat,
sparks, slag, and ame, etc. that may cause
rupture. Do not allow contents to exceed
55 degrees C (130 degrees F.) Cool with
water spray where such exposure exists.
Protect cylinders, particularly valves from
bumps, falls, falling objects, and weather.
Replace caps securely when moving cylinders.
Stuck valve. Do NOT use a hammer or
wrench to open a cylinder valve that cannot
be opened by hand. Notify your supplier.
Mixing gases. NEVER try to mix any gases
in a cylinder.
NEVER rell any cylinder.
Cylinder ttings should never be modied
or exchanged.
3. Hose
Prohibited use. Never use hose other
than that designed for the specied gas. A
general hose identication rule is: red for
fuel gas, green for oxygen, and black for
inert gases.
Use ferrules or clamps designed for the
hose (not ordinary wire or other substitute)
as a binding to connect hoses to ttings.
No copper tubing splices. Use only stan-
dard brass ttings to splice hose.
Avoid long runs to prevent kinks and abuse.
Suspend hose off ground to keep it from
being run over, stepped on, or otherwise
damaged.
Coil excess hose to prevent kinks and
tangles.
Protect hose from damage by sharp edges,
and by sparks, slag, and open ame.
Examine hose regularly for leaks, wear, and
loose connections. Immerse pressured
hose in water; bubbles indicate leaks
Repair leaky or worn hose by cutting area
out and splicing. Do NOT use tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that
may clog orices and damage seats before
connecting regulator. Except for hydrogen,
crack valve momentarily, pointing outlet
away from people and sources of ignition.
Wipe with a clean, lintless cloth.
Match regulator to cylinder. Before connecting, check that the regulator label
and cylinder marking agree, and that the
regulator inlet and cylinder outlet match.
NEVER Connect a regulator designed for a
particular gas or gases to a cylinder contain-
ing any other gas.
Tighten connections. When assembling
threaded connections, clean and smooth
seats where necessary. Tighten. If connection leaks, disassemble, clean, and
retighten, using properly tting wrench.
Adapters. Use a CGA adapter (available
from your supplier) between cylinder
and regulator, if one is required. Use
two wrenches to tighten adapter marked
RIGHT and LEFT HAND threads.
Regulator outlet (or hose) connections
may be identied by right hand threads
for oxygen and left hand threads (with
grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain regulator of residual gas through
suitable vent before opening cylinder
(or manifold valve) by turning adjusting
screw in (clockwise). Draining prevents
excessive compression heat at high
pressure seat by allowing seat to open
on pressurization. Leave a djust ing
screw engaged slightly on single-stage
regulators.
Stand to side of regulator while opening
cylinder valve.
Open cylinder valve slowly so that regulator pressure increases slowly. When
gauge is pressurized (gauge reaches
regulator maximum) leave cylinder valve
in following position: for oxygen and inert
gases, open fully to seal stem against
possible leak; for fuel gas, open to less
than one turn to permit quick emergency
shut-off.
Use pressure charts (available from your
supplier) for safe and efcient recommended pressure settings on regulators.
Check for leaks on rst pressurization
and regularly thereafter. Brush with soap
solution. Bubbles indicate leaks. Clean
off soapy water after test; dried soap is
combustible.
E. User Responsibilities
Follow all Safety Rules.
Remove leaky or defective equipment
from service immediately for repair. Read
and follow user manual instructions.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be
used for welding or cutting operation;
rope may burn.
1-3 ARC WELDING
Comply with precautions in 1-1, 1-2, and
this section. Arc Welding, properly done,
is a safe process, but a careless operator
invites trouble. The equipment carries
high currents at significant 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.
Python® Lincoln Compatible™ Owner's Manual - Page ii
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, 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.
Cra cked or broken helmet or shield
should NOT be worn; radiation can be
passed through to cause burns.
Cracked, broken, or loose lter plates
mus t be re p lac ed I MME DIAT E LY.
Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST be
worn under the helmet to give some protection to the eyes should the helmet not
be lowered over the face before an arc
is struck. Looking at an arc momentarily
with unprotected eyes (particularly a high
intensity gas-shielded arc) can cause a
retinal burn that may leave a permanent
dark area in the eld of vision.
3. Protection of Nearby Personnel
Enclose the welding area. For production
welding, a separate room or enclosed
bay is best. In open areas, surround the
operation with low-reective, noncombustible screens or panels. Allow for free
air circulation, particularly at oor level.
Viewing the weld. Provide face shields
for all persons who will be looking directly
at the weld.
Others working in area. See that all per-
sons 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 engi ne exha us t mus t be
vented to the outside air. Carbon mon-
oxide 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 over-
heat cables and cause a re.
Loose cable connections may overheat or
ash and cause are.
Never strike an arc on a cylinder or other
pressure vessel. It creates a brittle area
that can cause a violent rupture or lead to
such a rupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed electrically hot conductors or
other bare metal in the welding circuit, or in
ungrounded, electrically - HOT equipment
can fatally shock a person whose body
becomes a conductor. DO NOT STAND, SIT,
LIE, LEAN ON, OR TOUCH a wet surface
when welding without suitable protection.
To protect against shock:
Keep body and clothing dry. Never work
in damp area without adequate insulation
against electrical shock. Stay on a dry
duckboard, or rubber mat when dampness
or sweat cannot be avoided. Sweat, sea
water, or moisture between body and an
electrically HOT part - or grounded metal
- reduces the body surface electrical resistance, enabling dangerous and possibly
lethal currents to ow through the body.
1. Grounding the Equipment
When installing, connect the frames of
each unit such as welding power source,
control, work table, and water circulator to
the building ground. Conductors must be
adequate to carry ground currents safely.
Equipment made electrically HOT by stray
currents may shock, possibly fatally. Do
NOT GROUND to electrical conduit, or to a
pipe carrying ANY gas or a ammable liquid
such as oil or fuel.
Three-phase connection. Check phase
requirement of equipment before installing. If only 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
Frequ ently inspect cables for wear,
cracks, and damage. IMMEDIATELY
REPLACE those with excessively worn
or damaged insulation to avoid possibly
lethal shock from bared cable. Cables
with damaged areas may be taped to give
resistance equivalent to original cable.
Keep cable dry, free of oil and grease,
and protected from hot metal and sparks.
4. Terminals and Other Exposed Parts
Terminals and other exposed parts of
electrical units should have insulating
covers secured before operation.
5. Electrode Wire
Electrode wire becomes electrically HOT
when the power switch of gas metal-arc
welding equipment is ON and welding
gun trigger is pressed. Keep hands and
body clear of wire and other HOT parts.
6. Safety Devices
Safety devices such as interlocks and
circuit breakers should not be disconnected or shunted out.
Before installation, inspection, or service
of equipment, shut OFF all power, and
remove line fuses (or lock or red-tag
switches) to prevent accidental turning
ON of power. Disconnect all cables from
welding power source, and pull all 115
volts line-cord plugs.
Do not open power circuit or change
polarity while welding. If, in an emergency, it must be disconnected, guard
against shock burns or ash from switch
arcing.
Leaving equipment unattended. Always
shut OFF, and disconnect all power to
equipment.
Power disconnect switch must be available near the welding power source.
Python® Lincoln Compatible™ Owner's Manual - Page iii
Section A Installation
Technical Specications
Wire Capacity
.030" - .045" (0.6mm - 1.2mm) solid and hard wire
.030" - 1/16" (0.8mm - 1.6mm) aluminum and cored wire
Wire Speed
800 IPM (20.3 mpm) Max. at rated feeder Input Voltage (120VAC / 42VAC)
Duty Cycle - 60% (All ratings are using Argon Gas)
225 Amps/25 Volts Air cooled standard
Support Equipment Required
• C.V. or C.C. Power Source of sufcient capacity for your needs.
• Regulated gas supply and hoses.
• Properly sized power leads from power source to wire feeder and
ground.
Gun Lead Connections
Power Cable
A #2 power cable is used on the Python® Lincoln 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 Python
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 gun body and secured
with the hose retainer. On the Power Manifold the hose has a crimped tting
screwed into the Power Manifold.
Electric Cable
A multi-conductor control cable is used on the Python® Lincoln Compatible™.
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 7-Pin, Amphenol connector.
®
Lincoln Compatible™ comes standard with a poly-lined conduit,
Section B Operation
General
The Python® Lincoln 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 three-quarter (3
3/4) turn potentiometer in the gun handle.
Python® Lincoln Compatible™ Owner's Manual - Page 1
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