MK 227/228 CobraMAX Gun ACWC Owner Manual

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MK 227/228 CobraMAX Gun ACWC Owner Manual | Manualzz

Owner’s Manual

Product:

Manual:

Serial:

CobraMAX

091-0514

06100001

Voltage Rating: 24 VDC

Revision: Oct 2006 Rev D

Gun models: 227-xxx

228-xxx

200 Ampere Air Cooled

250 Ampere Liquid Cooled

Push-Pull Welding Guns

Table of Contents

Safety Considerations

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

Technical Specifications .....................................................................................1

Support Equipment Required .............................................................................1

Coolant Recommendations ................................................................................1

Gun Lead Connections ......................................................................................1

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

General ..............................................................................................................2

Controls and Settings .........................................................................................2

Drive Roll and Idler Rolls....................................................................................2

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

Optional Kits .......................................................................................................3

Conduits .............................................................................................................4

Snake Skins .......................................................................................................4

Contact Tips .......................................................................................................5

Gas Cups ...........................................................................................................5

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

Periodic Maintenance.........................................................................................6

Maintenance Tools .............................................................................................6

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...........................................................................................................15

Safety Warnings

Warranty

CobraMAX™ Owner's Manual

Declaration of Conformity for

European Community (CE) Products

Note

This information is provided for units with CE certification (see rating label on unit).

Manufacturer’s Name:

MK Products, Inc.

16882 Armstrong Ave.

Irvine, CA 92606

Declares that the product:

CobraMAX

conforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic Compatibility (EMC) Directive: 89/336/EEC

Standards

Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1

(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

CobraMAX™ Owner's Manual

SAFETy ConSIDErATIonS

ELECTRIC ARC WELDING EQUIPMENT

CAUTIon : rEAD BEForE ATTEMPTInG InSTALLATIon, oPErATIon or MAInTEnAnCE oF THIS EQUIPMEnT

short circuits.

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 qualified help before proceeding.

to the State of California to cause cancer and birth defects or other reproductive harm.

Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation. NEVER ventilate with oxygen.

Lead-, cadmium-, zinc-, mercury-, beryllium-bearing and similar materials, when welded or cut, may produce harmful concentrations of toxic fumes.

Adequate local exhaust ventilation must be used, or each person in the area, as well as the operator, must wear an air-supplied respirator. For beryllium, both must be used.

Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed form the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.

Work in a confined space only while it is being ventilated and, if necessary, while wearing an air-supplied respirator.

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-fitting, fire-resistant covers or shields.

Walls touching combustibles on opposite sides should not be welded on (or cut).

Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.

Fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:

1. Appreciable combustibles (including building construction) are within 35 feet.

2. Appreciable combustibles are further than 35 feet, but can be ignited by sparks.

3. Openings (concealed or visible) in floors or walls within 35 feet may expose combustibles to sparks.

1-2 GENERAL PRECAUTIONS

A. Burn Prevention

ELECTRIC ARC WELDING PRODUCES

H I G H I N T E N S I T Y H E AT A N D

ULTRAVIOLET RADIANT ENERGY

WHICH MAY CAUSE SERIOUS AND

PERMANENT EYE DAMAGE AND

WHICH MAY DAMAGE ANY EXPOSED

SKIN AREAS.

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

Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if downstream valves have been accidentally opened or left open. Check to be sure that the space is safe before reentering it.

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 flames.

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 flying metal. Replace cover glass when broken, pitted, or spattered.

Medical first aid and eye treatment. First aid facilities and a qualified first aid person should be available for each shift unless medical facilities are close by for immediate treatment of flash 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 flaps, and wear cuffless 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 confined 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

Vapors from chlorinated solvents can be decomposed by the heat of the arc

(or flame) 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, flame, flying sparks, hot slag, or heated material, misuse of compressed gases and cylinders, and short circuits.

BE AWARE THAT flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the goggled operator. Sparks can fly many feet.

To prevent fires and explosion:

Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause

A n e m p t y c o n t a i n e r t h a t h e l d combustibles, or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first 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-filling 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 flammable 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

CobraMAX™ Owner's Manual - Page i

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 (first 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 f a u l t y r e g u l a t o r s f o r r e p a i r t o 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 flame, 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 refill any cylinder.

Cylinder fittings should never be modified or exchanged.

3. Hose

Prohibited use. Never use hose other than that designed for the specified gas.

A general hose identification 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 fittings.

No copper tubing splices. Use only standard brass fittings 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 flame.

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 orifices 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 identified 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 first 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 fly, fumes rise, ultraviolet and infrared energy radiates, weldments are hot, and compressed gases may be used.

The wise operator avoids unnecessary risks and protects himself and others from accidents.

A. Burn Protection

Comply with precautions in 1-2.

The welding arc is intense and visibly bright. Its radiation can damage eyes, penetrate lightweight clothing, reflect from light-colored surfaces, and burn the skin and eyes. Skin burns resemble

CobraMAX™ Owner's Manual - Page ii

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, flameproof apron, and fire-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 filter plate shade no. 12 or denser must be used when welding. Place over face before striking arc.

Protect filter plate with a clear cover plate.

Cracked or broken helmet or shield should NOT be worn; radiation can be passed through to cause burns.

Cracked, broken, or loose filter 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 field 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 floor 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 flash goggles.

Before starting to weld, make sure that screen flaps 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 fire.

Loose cable connections may overheat or flash and cause afire.

Never strike an arc on a cylinder or other pressure vessel. It creates a brittle area that can cause a violent rupture or lead to such a rupture later under rough handling.

D. Compressed Gas Equipment

Comply with precautions in 1-2D.

E. Shock Prevention

Exposed electrically hot conductors or other bare metal in the welding circuit, or in ungrounded, electrically-HOT equipment can fatally shock a person whose body becomes a conductor. DO

NOT STAND, SIT, LIE, LEAN ON, OR

TOUCH a wet surface when welding without suitable protection.

To protect against shock:

Keep body and clothing dry. Never work in damp area without adequate insulation against electrical shock. Stay on a dry duckboard, or rubber mat when dampness or sweat cannot be avoided.

Sweat, sea water, or moisture between body and an electrically HOT part - or grounded metal - reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body.

1. Grounding the Equipment

When installing, connect the frames of each unit such as welding power source, control, work table, and water circulator to the building ground. Conductors must be adequate to carry ground currents safely. Equipment made electrically HOT by stray currents may shock, possibly fatally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or a flammable 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. 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 flash 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.

CobraMAX™ Owner's Manual - Page iii

Thank You

For selecting a quality product. We want you to take 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.

CobraMAX™ Owner's Manual

Section A Installation

Technical Specifications

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

All ratings are using Argon gas

200 Amps/25 Volts

250 Amps/25 Volts

Air cooled - 60%

Liquid cooled - 60%

Support Equipment Required

• C.V. or C.C. power source of sufficient capacity for your needs.

• Regulated gas supply and hoses.

• Properly sized power leads from power source to wire feeder and ground.

• Liquid source and hose capable of providing a minimum of 1 quart

(.95 liter) / min. at 45 p.s.i. when using liquid cooled guns.

Coolant Recommendations

Use Cobra Coolant (Aluminum Protection), P/N 931-0060. Cobra Coolant does not contain reactive sulphur or chlorine and does not react with copper, brass or aluminum.

The coolant flow rate should be a minimum of 15 GPH (1 qt/min) between

35 and 45psi. Contact the re-circulator manufacturer for specifications on pressure.

Gun Lead Connections

Power Cable - Air Cooled

A #2 AWG power cable is used on the CobraMAX™ air cooled gun. The gun end is threaded into the gun body. The power cable fitting connects to the power block in the Cobramatic

®

wire feed cabinet.

Power Cable - Liquid Cooled

CobraMAX ™ liquid cooled gun utilizes a power/liquid cable with a #4 AWG cable inside a 5/8” (16MM) diameter hose.

IMPORTANT

Liquid cooled guns MUST be Liquid cooled.

Conduit

The CobraMAX

gun comes standard with a poly-lined conduit, for feeding aluminum wire. The longer fitting 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.

Gas Hose

The gas hose is secured over the barbed gas fitting with a tie wrap. The cabinet end of the gas hose uses our standard gas fitting (1/8” - 27 nps).

Liquid Hose

If so equipped; one end of the liquid hose is secured over the barbed liquid fitting with a tie wrap and the other end is connected to the center fitting on the power block.

Electric Cable

CobraMAX™ Owner's Manual - Page 1

A seven conductor control cable is used on the CobraMAX

gun. The gun end of the control cable is secured to the gun with a boot clamp and soldered to the pot assembly, tirgger and liquid leads. Slack is left in the electric cable as it exits the back of the gun to prevent cable breakage. The cabinet end has a seven pin “W” clocked amphenol connector.

Section B operation

General

The CobraMAX

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 float 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.

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, it closes the gap between the trigger lever and the micro-switch 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. 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.

Drive Roll and Idler Rolls

General

The CobraMAX

gun comes standard with a knurled drive roll and a grooved idler roll, which will handle both steel and aluminum wire with diameters from

.030-1/16 inch. Optional insulated V-groove drive rolls are also available for aluminum wire if desired (see optional kits).

Drive roll tension is accomplished with a unique spring-loaded pressure screw. The CobraMAX ™ 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. Pull the cam lever away from the idler roll. This will relieve the pressure

CobraMAX™ Owner's Manual - Page 2

against the drive roll (as shown in Figure 1).

2. Align the drive roll removal tool (P/N 931-0100) over the flats of the drive roll (as shown in Figure 2). 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.

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.

Cam Lever

Figure 1

Figure 2

Idler Roll Installation and Removal

(Reference Figure 3)

1. Using a slot type screwdriver, loosen idler screw, taking care not to lose lock washer under idler roll.

2. Insert new idler roll and lock washer onto screw, insuring that idler groove is toward top and lock washer is beneath.

Figure 3

3. Tighten.

NOTE: Lock washer must be under idler roll or it will not turn freely.

Section C

Accessories

A gas flow control mechanism (i.e. solenoid or valve) is required so the

CobraMAX

can be used on Cobra

®

wire feeders. The following kits are available depending on the wire feeder used. The factory set times (in seconds) for normal and latched trigger functions is 0.25 pre-purge and 1.0 post-purge.

Optional Kits

Insulated Drive Roll Kits are used to prevent preheating of the wire which may soften it and clog the liner. This picking up of current at the drive rolls rather than at the contact tip is usually not a problem unless using too large of a contact tip or excessively oxidized aluminum wire.

Insulated Groove Drive Roll Kit

......................................................005-0640

For

.030" (0.8mm) dia. aluminum wire. Includes insulated groove drive roll

CobraMAX™ Owner's Manual - Page 3

and insulated idler roll assy.

Insulated Groove Drive Roll Kit

......................................................005-0641

For

.035" (0.9mm) dia. aluminum wire. Includes insulated groove drive roll and insulated idler roll assy.

Insulated Groove Drive Roll Kit

......................................................005-0642

For

.040" (1.0mm) dia. aluminum wire. Includes insulated groove drive roll and insulated idler roll assy.

Insulated Groove Drive Roll Kit

......................................................005-0643

For

.045" (1.2mm) dia. aluminum wire. Includes insulated groove drive roll and insulated idler roll assy.

Insulated Groove Drive Roll Kit

......................................................005-0644

For

.062" (1.6mm) dia. aluminum wire. Includes insulated groove drive roll and insulated idler roll assy.

Gas Purge/Trigger Latch Kit

...........................................................005-0674

This kit is required when using the CobraMAX

on Cobramatic

®

, models 150-

003 & 150-005 and the CobraMig

®

260, model 186-002.

Pre/Post/BurnBack/Spot Timer kit ................................................ 005-0196

This kit is required when using the CobraMAX ™ on Cobramatic ® II, model

150-004.

Handle Kit.........................................................................................005-0700

Includes left and right handles, screws and drive roll door.

Trigger Kit.........................................................................................005-0694

Trigger adjustment kit includes a spring and sensitivity adjustment screw replacement for all Python ® /CobraMAX™ guns.

Micro Switch Kit...............................................................................005-0701

Replacement micro switch assembly for all Python

®

/CobraMAX™ guns.

Potentiometer Kit.............................................................................005-0695

Replacement potentiometer assembly for all Python ® /CobraMAX™ guns.

Conduits

flat spiral steel conduit for steel & cored wire

615-0208 ................15 ft./4.5m

615-0216 ................25 ft./7.6m

615-0218 ................50 ft./15.2m standard conduit

with additional protective cover

001-0774 ................ 15 ft./4.5m

001-0775 ................ 25 ft./7.6m

001-0777 ................ 50 ft./15.2m

Snake Skins

Snake Skin protective covers are now standard on all guns. You may order spare replacement covers to protect the lead assy of the gun when the factory one becomes damaged or worn. It can easily be replaced in the field by means of Velcro © .

Snake skin cover 13ft (for 15ft leads) ..........................................931-0110

Snake skin cover 23ft (for 25ft leads) ......................................... 931-0122

Snake skin cover 33ft (for 35ft leads) ......................................... 931-0132

Snake skin cover 48ft (for 50ft leads) ......................................... 931-0123

CobraMAX™ Owner's Manual - Page 4

Contact Tips

To remove contact tip when using full liquid cooled gas cup (P/N 621-0065), contact tip removal tool (P/N 931-0002) must be used.

Wire Size

Heavy Duty Contact Tip - 3/8" Diameter*

Tip ID Arc Tip Length

Part no.

.030” (0.8mm) .040” (1.0mm) Spray 1.57” (39.9mm) 621-0390-25

.035” (0.9mm) .045” (1.1mm)

.047” (1.2mm) .054” (1.37mm)

Short

Spray

Short

Spray

1.82” (46.2mm) 621-0396-25

1.57” (39.9mm) 621-0391-25

621-0391-250 †

621-0391-500 ††

1.82” (46.2mm) 621-0397-25

1.57” (39.9mm)

621-0392-25

.060” (1.5mm)

Short

Spray

1/16” (1.6mm) .074” (1.9mm)

.085” (2.16mm)

*

Use of tip removal tool is recommended

**This size tip furnished with gun

† Also sold in quantities of 250

††

Also sold in quantities of 500

Spray

Spray

621-0392-250

621-0392-500

††

1.82” (46.2mm) 621-0398-25

1.57” (39.9mm) 621-0393-25**

621-0393-250 †

621-0393-500 ††

1.57” (39.9mm) 621-0394-25

621-0395-25

Gas Cups

Cup Size

No. 6

No. 8*

No. 10

*standard - furnished with gun

Gas Cups

Cup I.D.

3/8” (9.5mm)

1/2” (12.7mm)

5/8” (15.8mm)

Part Number

931-0137

615-0341

621-0423

615-0248

Part no.

621-0420

621-0421

621-0422

Gun Barrel Liners

Description

Teflon liner package, 5 pieces

Spiral steel, .030 - .045” (0.8mm - 1.1mm)

CobraMAX tip extender

Spiral steel liner for tip extender

CobraMAX™ Owner's Manual - Page 5

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.

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 downtime 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, qualified shop maintenance personnel can easily replace any part.

Maintenance Tools

Tool

Contact tip removal tool

Drive roll removal tool

Gas valve removal tool

Part Number

931-0002

931-0100

931-0584

2

2

1

1

Qty.

1

1

1

1

2

10

5

Recommended Spare Parts List

Part no.

Description

615-0601-35 Conduit - 15 ft

615-0601-35

615-0601-35

615-0601-35

437-0253

005-0694

005-0695

005-0700

005-0701

511-0101

005-0686

Conduit - 25 ft

Conduit - 35 ft

Conduit - 50 ft

Drive roll door

Trigger assy kit

Potentiometer assy kit

Handle kit

Micro switch assy kit

Drive roll

Idler roll kit

DRIVE ROLL

REMOVAL TOOL

931-0100

IDLER ROLL KIT

005-0686

KNURLED DRIVE ROLL

511-0101

MICRO SWITCH ASSY

005-0701

CobraMAX™ Owner's Manual - Page 6

Section E Troubleshooting

Trouble

No wire feed at gun, feeder not operting, I.e. no slave motor or brake solenoid.

No wire feed at gun, feeder operting properly

Wire walks out of drive rolls.

Cause

115VAC Control fuse in feeder/

Control box blown.

Micro-switch defective/not being activated.

Broken electrical cable.

24 VAC Control fuse in feeder/

Control box blown.

Bad potentiometer.

Broken electrical cable.

Bad speed control/PCB.

Rear wire guide missing.

Replace fuse.

Remedy

Replace switch. Check switch for operation.

Check micro switch wires for continuity

Check motor leads for shorts; then replace fuse.

Check potentiometer with meter.

Check motor and potentiometer wires for continuity.

See specific cabinet/control box owners for speed control operation.

Wire feeds, but welding wire is not engergized.

Loose or no cable connections.

Check all power connections.

Contactor control cable loose or in wrong position.

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

Wire feeds erratically.

Welding power source.

Dirty or worn conduit.

Wrong size contact tip.

Idler roll stuck.

Bad potentiometer.

Broken electrical cable.

Check power source.

Blow out or replace conduit.

See contact tip table.

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

Check with meter.

Wire feeds one speed only.

Bad speed control.

Check potentiometer wires for continuity or short.

See specific cabinet/control box owners for speed control operation.

Idler roll upside-down.

Place groove in idler roll toward top.

Replace wire guide.

CobraMAX™ Owner's Manual - Page 7

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 speed, 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 "W" clocked gun wiring diagram on the CobraMAX™ electrical diagram (in appendix) for information about pin-outs and locations.

Motor Check

Remove the gun connector from the cabinet.

Using the gun amphenol connector, check the resistance across pins “A” and

“B” (motor leads). The resistance across the motor should be between

5 - 10 ohms as the potentiometer is turned.

If an open circuit or short exist, check the motor leads and motor independently.

Testing the Potentiometer - “W” Clocked

Using the gun Amphenol connector, check the resistance across pin “D”

(wiper) and pin “C”. The resistance should vary from 0 - 5K ohms as the potentiometer is turned.

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

Testing the Micro Switch

Using the gun Amphenol connector, check for continuity across pins “E” and

“F” when the trigger is pressed.

CobraMAX™ Owner's Manual - Page 8

Section F Appendices

Diagrams / Parts List

Cobra

MAX™ Exploded View . . . . . . . . . . . . . . . . . . . . . . . . .10

003-2141 Front Body Assembly . . . . . . . . . . . . . . . . . . . . . . .12

Ultra-Flex Air Cooled Lead Assembly

. . . . . . . . . . . . . . . . . . .13

Liquid Cooled Lead Assembly

. . . . . . . . . . . . . . . . . . . . . . . .14

Wiring Diagram

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

CobraMAX™ Owner's Manual - Page 9

CobraMAX™ Exploded View

CobraMAX™ Owner's Manual - Page 10

CobraMAX™ Owner's Manual - Page 11

CobraMAX™

Front Body Assembly

003-2141

Front Body Assembly

no.

Qty.

Part no.

Description

1 Not Available Separately

8

9

6

7

10

4

5

2

3

Not Available Separately

1 325-0206 Scr Ph 10-24-3/8

1 333-0082 Washer Lock 10

1 419-0092 Spring Comp 0.31 OD x 0.20 ID

1 421-0525 Pin Dowel 1/8 x 7/8 Sst

1 431-1663 Scr Adjust Idler

1 431-1598 Arm Idler Python

1 511-0001 Assy Idler Wire Feed

1 511-0101 Drive Roll Gold

CobraMAX™ Owner's Manual - Page 12

Ultra-Flex Air Cooled Lead Assembly*

This power cable has a boot that is common to many assemblies but must be removed from this end when used on the

CobraMAX™.

*Leads shown for reference only

Length Conduit

227 Series Ultra-Flex Cable Assemblies

Power Cable Control Cable

Gas Hose

15'/4.5m

615-0601-15 001-2527 005-0690 001-0537

25'/7.6m

615-0601-25

35'/10.7m

615-0601-35

50'/15.2m

615-0601-50

001-2528

001-3812

001-1042

005-0691

005-0740

005-0692

001-0538

552-0181

001-0665

CobraMAX™ Owner's Manual - Page 13

Snake Skin

931-0110

931-0122

931-0132

931-0123

Liquid Cooled Lead Assembly*

This power cable has a boot that is common to many assemblies but must be removed from this end when used on the

CobraMAX™.

*Leads shown for reference only

Length

228 Series Liquid Cooled Cable Assemblies

Conduit #4 Liquid/Power

Cable

Control

Cable

Gas Hose Liquid Hose Snake

Skin

15'/4.5m

615-0601-15 001-2521 005-0690 001-0537 001-0529 931-0110

25'/7.6m

615-0601-25 001-2524 005-0691 001-0538 001-0530 931-0122

35'/10.7m

615-0601-35

50'/15.2m

615-0601-50

843-0342

843-0338

005-0740 552-0181

005-0692 001-0665

552-0182

001-0667

931-0132

931-0123

CobraMAX™ Owner's Manual - Page 14

CobraMAX™ Electrical

E

D

F

G

C

A

B

"W" Clocked

Amphenol Connector

Viewed from front of connector

CobraMAX™ Owner's Manual - Page 15

CobraMAX™ Owner's Manual - Page 16

CobraMAX™ Owner's Manual - Page 17

LIMITED WARRANTY

Effective October 1, 2006

This warranty supersedes all previous MK Products warranties and is exclusive, with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY - MK Products Inc., Irvine, California warrants that all new and unused equipment furnished by MK

Products is free from defects in workmanship and material as of the time and place of delivery by MK Products. No warranty is made by MK Products with respect to trade accessories or other items manufactured by others. Such trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any.

Classification of any item into the foregoing categories shall be at the sole discretion of MK Products. Notification of any failure must be made in writing within 30 days of such failure.

A copy of the invoice showing the date of sale must accompany products returned for warranty repair or replacement.

All equipment returned to MK Products for service must be properly packaged to guard against damage from shipping.

MK Products will not be responsible for any damages resulting from shipping.

MK Products’ warranty does not apply to components having normal useful life of less than one (1) year, such as relay points, wire conduit, tungsten, and welding gun parts that come in contact with the welding wire, including gas cups, gas cup insulators, and contact tips where failure does not result from defect in workmanship or material.

Normal surface transportation charges (one way) for products returned for warranty repair or replacement will be borne by MK

Products, except for products sold to foreign markets.

MK Products shall, exclusively remedy the limited warranty or any duties with respect to the quality of goods, based upon the following options:

(1) repair

(2) replacement

(3) where authorized in writing by MK Products, the reasonable cost of repair or replacement at our Irvine, California plant.

As a matter of general policy only, MK Products may honor an original user’s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user:

1. Power Supplies and Wire Feed Cabinets ........3 years

2. Weldheads, Positioners, Prince XL and Prince XL

Spool Guns, Python, CobraMAX, Cobra SX, Cobra MX

..........................................................................1 year

3. Sidewinder

®

Spool Gun, Prince SG Spool Guns,

Modules ....................................................... 180 days

4. Repairs/Exchanges/Parts ............................. 90 days

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY

IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION AS

TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CON-

TRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY

IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE, OR

COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY

OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR

PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FUR-

NISHED BY MK PRODUCTS, IS EXCLUDED AND DISCLAIMED

BY MK PRODUCTS.

EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRIT-

ING, MK’s PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE

BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY

PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAIN-

TENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS

OR CONSUMER USE. MK PRODUCTS’ WARRANTIES DO NOT

EXTEND TO, AND NO RE-SELLER IS AUTHORIZED TO EXTEND

MK PRODUCTS’ WARRANTIES TO ANY CONSUMER.

USE OF OTHER THAN

YOUR PRODUCT WARRANTY.

GENUINE

MK PRODUCTS’

CONSUMABLES, PARTS, AND ACCESSORIES MAY INVALIDATE

16882 Armstrong Ave.

Irvine, CA 92606

Tel (949)863-1234

Fax (949)474-1428 www.mkproducts.com

October 1, 2006

THIS PAGE INTENTIONALLY BLANK

CobraMAX™ Owner's Manual - Page 19

16882 Armstrong Ave.

Irvine, California 92606

TEL (949) 863-1234 FAX (949) 474-1428 www.mkproducts.com

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