advertisement
▼
Scroll to page 2
of 62
CobraMig 260 Power Supply/Wire Feeder 208V 230V 416V 480V Multi-Tap Voltage Version 16882 Armstrong Ave., Irvine, California 92606 TEL(949)863-1234 FAX(949)474-1428 www.mkproducts.com 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 qualified help before proceeding. 1-2 GENERAL PRECAUTIONS A. Burn Prevention ELECTRIC ARC WELDING PRODUCES HIGH INTENSITY HEAT AND ULTRAVIOLET RADIANT ENERGY WHICH MAY CAUSE SERIOUS AND PERMANENT EYE DAMAGE AND WHICH MAY DAMAGE ANY EXPOSED SKIN AREAS. Wear helmet with safety goggles or glasses with side shields underneath, appropriate 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 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 airsupplied respirator. 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. 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 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 snugfitting, 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. 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. An empty container that held 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 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 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 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. 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. Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being run over, stepped on, or otherwise damaged. F. Leaving Equipment Unattended Coil excess hose to prevent kinks and tangles. Rope staging-support should not be used for welding or cutting operation; rope may burn. 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 singlestage 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. Close gas supply at source and drain gas. G. Rope Staging-Support 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 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 lowreflective, 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. phase equipment to only two wires of the threephase 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 Equipment’s rated capacity. Do not overload arc welding equipment. It may overheat cables and cause a fire. 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. Loose cable connections may overheat or flash and cause afire. Keep cable dry, free of oil and grease, and protected from hot metal and sparks. 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. 4. Terminals and Other Exposed Parts D. Compressed Gas Equipment 5. Electrode Wire Comply with precautions in 1-2D. 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. C. Fire and Explosion Prevention Comply with precautions in 1-2C. 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- Terminals and other exposed parts of electrical units should have insulating covers secured before operation. 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 linecord 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. Table of Contents Saftey Guidelines ...........................................................................i Installation ........................................................................ Section A Technical Specifications .................................................................................... 1 Machine Location ............................................................................................ 1 Input Power Connections ................................................................................... 1 Machine Grounding .......................................................................................... 3 Welding Torch Connections ................................................................................. 3 Shielding Gas Connections ................................................................................. 4 Coolant Connection ......................................................................................... 5 Wire Threading Procedure.................................................................................. 5 Operation ..........................................................................Section B General Description ......................................................................................... 6 Controls and Settings ....................................................................................... 7 Posa Start Operating Procedure ........................................................................... 8 Process Settings .............................................................................................. 9 Sample Setup - Aluminium ............................................................................... 10 Sample Setup - Stainless.................................................................................. 12 Sample Setup - Steel ...................................................................................... 14 Accessories ........................................................................Section C Optional Kits................................................................................................ 16 Maintenance ......................................................................Section D Routine Maintenance ...................................................................................... Power Supply ............................................................................................... Testing the Feeder......................................................................................... Testing the Torch .......................................................................................... Testing the Speed Control ................................................................................ 16 16 17 17 17 Troubleshooting ..................................................................Section E Warning ..................................................................................................... 18 Troubleshooting Guide .................................................................................... 19 Troubleshooting Flow Charts ............................................................................. 20 Diagrams/Parts List .............................................................Section F Table of Contents .......................................................................................... Main PC Board .............................................................................................. Mechanical .................................................................................................. Electrical .................................................................................................... Warranty Repair Stations Safety Warnings Warranty 31 32 33 48 Section A Installation Technical Specifications Wire Diameter Capacity ........... .030 - 1/16" ALL Types, .023 hard wires Wire Capacity ............................ 12" Standard (Insulated or Non-Insulated) Power Input, user selectable by jumpers ............. 208 VAC 60 Hz, 50 amperes, single phase .................................................... 230 VAC 60 Hz, 45 amperes, single phase .................................................... 416 VAC 60 Hz, 26 amperes, single phase .................................................... 480 VAC 60 Hz, 24 amperes, single phase Rated Output @ 60% duty cycle .................................. 260 amperes @ 26 Vdc - (8.7KW) .................................................... 2 ranges (12-22V) (22-32V) .................................................... 40 Vdc max OCV Weight ........................................ 230 lbs (dry), 260 lbs (shipping) Size ............................................ 15"w x 32"h x 34"d For Use with Torch Prefix Numbers ......................... 210, 211, 212, 213, 225, 226 SUPPORT EQUIPMENT REQUIRED Regulated Gas Supply and 6' Gas Hose. Water Source and Hose Capable of Providing a Minimum of 1 qt/min. at 45 p.s.i. when using water cooled torches. Machine Location The unit should be placed in a location where it can be protected from damage. For the longest unit life and best efficiency, avoid locations exposed to dust, corrosive fumes, high ambient temperatures or high humidity. Moisture and dirt on components can cause corrosion and/or shorting of circuits. Adequate air circulation is needed at all times in order to prevent overheating and possible damage to internal parts. Maintain at least 12 inches of free air space on all sides of unit. An eye bolt and mounting hole is provided for lifting/unpacking purposes. Do not have the gas cylinder or any other equipment mounted to this unit when using the lifting eye bolt. Do not suspend this unit overhead. Input Power Connections This welding power supply is designed to be operated from single-phase 208, 230, 416 or 480 VAC 60 Hz input power and is provided with Voltage Links for converting power requirements in the field.. Consult your local electrical utility if there are any questions about the type of electrical system at the installation site, or how proper connections to the welding machine have to be made. CobraMig 260 Owner's Manual - Page 1 WARNING A fused line disconnect switch should be installed in the input circuit to the welding machine. This would ensure a complete removal of all electrical power when performing service. Before connecting input power cord verify input power requirements by checking data plate on rear of unit. Do not connect if your input power voltage is different from the voltage indicated on the input specification panel. Turn off all power at the disconnect. Remove the right lower panel, as viewed from front, and locate power block at rear of unit. Determine input Voltage and MOVE both Voltage Links to match INPUT VOLTAGE on BOTH Terminal blocks "TB1" and "TB2", these need to be set the same or damage WILL occur to the unit. Voltage Link - - - IMPORTANT - - This unit has low and high power terminal blocks (TB1 & TB2) that must have the SAME jumper configuration. Put BOTH Voltage Links to same terminal block screws. SEE SAMPLE HOOK UP DIAGRAM BELOW FOR EXAMPLE OF VOLTAGE LINK PLACEMENT. CobraMig 260 Owner's Manual - Page 2 Route input cable through strain relief and connect to power block as shown in the diagram following. Tighten strain relief and replace side panel with all hardware removed. Machine Grounding Before starting the installation, check with the local power company if there is any question about whether your power supply is adequate for the voltage, amperes, phase, and frequency specified on the welder nameplate. Also, be sure the plannted installation will meet the U.S. National Electrical Code and local code requirements. This welder may be operated from a single phase line or from one phase of a two or three phase line. The CobraMig 260 is supplied connected for 480 Volt input. If the welder is to be operated on another voltage, it must be reconnected according to the instrucitons. WARNING: Make certain that the input power is electrically disconnected before removing the screw on the reconnect panel access cover. A green wire in the input cable connects this contact to the frame of the welder. This ensures proper grounding of the welder frame when the welder plug is inserted into the receptacle. Welding Torch Connections Work Cable Connect a work lead of sufficient size and length (see table below) between the proper output stud on the power source and the work. Be sure the connection to the work makes tight metal to metal electrical contact. Poor work lead connections can result in poor arc initiation, poor weld results and activation of the ground lead protector. Work Lead Lengths Current 60% Duty Cycle Up to 50ft. (15.2m) 10-100ft. (15.2-30.4m) 300A 400A 500A 600A 0 (53mm) 00 (67mm) 00 (67mm) 000 (85mm) 0 (67mm) 00 (85mm) 00 (85mm) 000 (107mm) Control Cable The 7-Pin “W” Clocked connector screws onto the mating receptacle on the front panel of the wire feeder. This provides all electrical signals (motor voltage, potentiometer control & trigger) to and from the feeder to the torch. CobraMig 260 Owner's Manual - Page 3 Wire Conduit Inlet Front panel access to attach conduit to front of slave motor assembly. Power Cable Inlet Front panel access to attach power cable (air or water) to top of power block. Gas Inlet Front panel access to attach gas hose to bottom fitting of power block. Water Inlet (For Water Cooled Torches) Front panel access to connect the water hose to the middle fitting on the power block. Shielding Gas Connection Remove the screws from the left hinged door, as viewed from the front, and open door. Route the gas hose from the regulator/flowmeter through the grommet on the back panel and into the 5/8-18 R.H. fitting on the power block. DANGER Welding gases can cause serious injury or death. Read manufacturer’s instructions before installing, using, or servicing the regulator, gas hose, or gas cylinder. Do not touch cylinder with electrode. Keep cylinder away from all electrical circuits. Keep gas cylinder secured so that it cannot move. CobraMig 260 Owner's Manual - Page 4 Coolant Connection (Water Cooled Torches Only) Connect the water return line from the recirculator through the grommet on the rear panel and into the 5/8" - 18 L.H. thread on the power block. The water “IN” hose connects directly to the torch water “IN” fitting; it does not pass through the power supply. Wire Threading Procedue Wire Spool Installation Release latches, and open right side door of cabinet. Remove spool retainer nut from spindle hub. Raise wire retainer bar to latched position. Install wire spool onto spindle hub so that wire feeds from bottom of spool towards slave motor. Make sure that the hole in the spool aligns with pin on spindle hub. The white dot on the end of the spindle hub will aid in this alignment. Replace the spool retainer nut. Lower the wire retainer bar onto the spool. Wire Spool Drag Setting NOTE: Standard factory setting of the Spindle Tension Knob is set for All Other Wires. There are two visible position settings for this Knob, IN - All Other Wires (Fig. 1) and, OUT - .030/.035 Al Only (Fig. 2). The Spindle Tension Knob must be set to match the Wire Size Selector Switch on the Cobramatic® front panel. To change this setting, it is easier done without the spool of wire on the spindle. Remove the wire spool retainer and re-install it reversed back onto the Spindle Tension Knob (Fig. 3). In the “Tool Mode”, the square shaped end of the retainer fits onto the Knob. Grab the retainer and turn in the COUNTER-CLOCKWISE direction until it stops. The Knob is now set to the OUT position (.030/.035 AL Only). IN - All other wires Figure 1 OUT - .030/.035 Aluminum ONLY Figure 2 Wire Spool Retainer In "Tool Mode"; used to change spindle drag. Figure 3 To reset the Knob back to the factory setting of All Other Wires, use the retainer as described above, and turn in the CLOCKWISE direction until it stops. The Knob is now set to the IN position. Turning the retainer and Knob in this direction may require more effort, since turning CLOCKWISE is working against a spring. Load wire spool onto spindle according to the previous instructions. Replace the spool retainer nut. CobraMig 260 Owner's Manual - Page 5 Lower the wire retainer bar onto the spool. Threading Procedure Place wire size selector switch on front panel to the correct position for the wire being used. Loosen end of wire from spool and cut off any kinked or bent portions. Unreel and straighten out first 6” to 8” of wire. Raise wire type lever to center position. Route wire into inlet guide, along drive roll groove, and into wire conduit. Flip wire type lever to show type of wire being used: ALUM or STEEL. Tighten the torch pressure adjusting knob so the wire will be picked up and fed through the contact tip. Proper tension is achieved when wire does not slip if a small amount of pressure is added to the wire as it exits the tip. Wire Retainer Bar The design of the patented Cobramatic® Wire Retainer Bar performs two very important and very basic functions of the wire feeder: a) spool drag tension, and b) wire maintenance on the spool. The spool drag tension is set by lowering the wire retainer bar onto the wire inside of the spool. The spring tension of the wire retainer bar applies enough pressure on the spool so that when the torch trigger is released, engaging the brake pall, the spool does not overrun kicking wire off the spool. Wire maintenance on the spool is performed by the applied pressure of the wire retainer bar spread across the coiled wire on the spool. The replaceable pad (P/N 437-0255) of the wire retainer bar is designed to hold the wire on the spool, maintaining the smooth layering of the wire and keeping it from jumping off, and possibly, electrically shorting to the cabinet chassis. Section B Operation General Description The CobraMig 260 is a constant voltage (CV) DC welding power supply with a built-in Cobramatic wire feeder which operates on the same basic principles as all other Cobramatics. The 115VAC slave motor in the feeder side runs at a fast, constant speed, but has very low torque. It is always trying to feed more wire than the torch motor wants, and when the torch motor gets all it wants, it slows the slave motor to the speed that the torch is running. Because of the low torque produced by the slave motor, a brake system is used to prevent wire overrun rather than tension. The drag adjustment in the spindle is used to keep the wire slightly taut, so it will not unspool while feeding wire. The high torque 24VDC torch pull motor is controlled by a solid state speed control, located on the main board, and the potentiometer located on the torch. The lower portion of the unit houses the power supply components. Power supply controls include a range switch and a variable voltage control. Controls and Settings ON/OFF SWITCH Placing the switch in the “ON” position energizes the power supply and places the unit in the ready-to-weld status. The power indicator light should be on at this time. CobraMig 260 Owner's Manual - Page 6 WELD VOLTAGE The weld voltage knob adjusts the power supply output voltage. It is infinitely variable between the ranges. The scale surrounding the WELD voltage control is a relative scale only; it does not represent actual voltage. RANGE SWITCH The “LO” range provides from 12 to 22 volts and the “HI” range provides from 22 to 32 volts. POLARITY JUMPER The polarity jumper allows for easy reversal of the electrode polarity. For Reverse polarity (DCRP) plug jumper into the plus (+) connector below jumper plug. For Straight polarity (DCSP) plug jumper into minus(-) connector below jumper plug. The work cable plugs into whichever connector is not used for the polarity jumper. COBRAMATIC CONTROLS ON/OFF SWITCH Placing the switch in the “ON” position energizes the feeder circuitry and the power indicator light. WIRE SIZE SELECTOR SWITCH The wire size selector switch changes the torque of the slave motor for the wire you are using. When in the ".030-.035" aluminum only position, the slave motor produces approximately 2 lbs. inches and approximately 3 lbs. inches when in the "all other wires" position. NOTE: Operating the cabinet with the switch in the wrong position will cause wire feed difficulties. POSA START CONTROLS The Posa Start Control selects a Run-in Speed which is slower than the actual welding speed. After arc initiation, the wire feed speed control is transfered to the potentiometer in the torch handle. The scale surrounding the Run-in Speed Control is a relative scale only; it does not represent actual inches per minute, but a percentage of the speed dialed by the torch potentiometer. REMOTE VOLTAGE (See Optional Kits) This option enables the weld voltage control to be adjusted from a remote hand pendant. TIMER KIT (See Optional Kits) This option provides Spot Welding or Stitch Welding operation from the Cobramig 260. In the Spot Mode, timing can be adjusted for a welding time of .5 to 4 seconds and a Burnback time of 0 to .25 seconds. In the Stitch Mode, the unit can be commanded to "Turn On" from .5 to 4 seconds and "Turn Off" from .25 to 1 second. DIGITAL VOLT/AMP METER (See Optional Kits) The LCD meter provides an alternating display of Volts and Amps during and after welding for up to 1 minute using a built-in memory. GAS CONTROL/TRIGGER LATCH (See Optional Kits) The Gas Purge/Trigger Latch Kit is a dual function kit. The kit includes an easy to install interface control PC board, a 24VAC solenoid for pre and post purge control, a modified valve stem for the welding torch and, a front panel switch for activating the Trigger Latch mechanism. The gas control times have been preset to 0.5 seconds pre-purge and 1.0 seconds post-purge. This offers an optimum amount of inert gas shielding prior to striking the arc and after the arc has been extinguished. CobraMig 260 Owner's Manual - Page 7 The Trigger Latch mechanism gives the operator the flexibility of normal trigger operation (pull trigger to weld - release trigger to stop). This also offers the comfort of latched trigger operation (pull trigger once to latch and weld - pull trigger again to unlatch and stop). POSA START OPERATING PROCEDURE General The Posa Start Run-in Speed Control, located on the front panel, provides adjustment for slow wire run-in. Once the arc has been established, the wire feed speed is automatically changed from the slow run-in speed to the welding speed set on the torch potentiometer. This slow run in speed helps to reduce “burn-backs” and “push-back” during arc start. Posa Start Operation Turn the Cobramatic to the “ON” position and the Posa Start to the “OFF” position. Adjust power source to desired voltage for your weld condition. Depress gun trigger and adjust wire feed speed at gun to match voltage setting. If approximate wire feed is not known, it is better to start with excess wire feed rather than too little, in order to prevent a “burn-back”. Turn the Posa Start switch to the “ON” position. Press torch trigger and, using Run-in Speed Control, adjust wire feed rate to approximately 10% of the welding wire speed. Strike an arc, and adjust wire feed rate at gun until correct condition is achieved. CobraMig 260 Owner's Manual - Page 8 PROCESS SETTINGS The following table is provided as a guide to assist you in setting up for standard welding processes. Please be aware that there are many variables associated with welding and conditions can change from day to day due to any number of external influences. MK Products' Customer Service Department is ready to assist you should you need help setting up your equipment in the field. Please be aware that we do not specialize in process parameter problems, but are willing to share our resources if it might help you achieve better quality welds. MK Products reserves the right to change any settings associated with this welding guide, you may request the most up to date guide by calling our Customer Service department during normal working hours. To use chart, locate material, thickness and wire diameter. Then read across for values to use, "REF" is the value dialed on the "Weld Voltage" knob on the front panel, this is only a reference value. CobraMig 260 Owner's Manual - Page 9 Sample Setup - Aluminum The procedure described below is designed to help you familiarize yourself with this equipment and also provide you with a known procedure so that you may perform a successful weld. Although these conditions may not be the exact ones needed for your specific application, it will provide an example of the proper use and operation of this equipment. MATERIALS NEEDED: 1 ea 1 ea 10 ea 1 ea 1 ea 1 ea 20 ea CobraMig 260 system with torch of your choice #6 Gas Cup (3/8") Contact Tips .044 (621-0001 spray arc) Spool of clean .035 4043 Wire Cylinder of Argon gas w/Regulator-Flowmeter and Hose Stainless Steel Wire Brush Weld coupons (2 X 6 X 1/8") 6061T-6 Aluminum PROCEDURE: Machine Set-up Hook-up the CobraMig 260 according to installation instructions in owners manual. Install wire onto spindle and thread wire through torch according to wire threading procedure. Make sure "Wire Type" switch is in the "030-035 ALUM" position. Press gun trigger and set gas flow to 25cfh. Set the “VOLTAGE” control on front panel to 8.4 and the “RANGE” switch to Lo. Turn the “POSA START” to the off position. Place the “POLARITY JUMPER” in the positive (+) connector and the ground clamp in the negative connector. Press the gun trigger for six (6) seconds. Adjust the wire feed speed until 32 inches of wire is measured in 6 seconds; this equals 320 ipm. Using the S/S brush, brush two weld coupons until the oxide is removed. Position Material and Tack Weld Position the coupons on the work table to form a ‘T’ fillet. Place the gas cup near the work piece and tack weld one end. Remember to provide pre-purge before each weld by cracking the torch trigger and holding it for a few seconds before fully pressing the trigger. This will reduce built-up pressure and aid in arc starting. Tack weld the other end. Deposit Weld Securely clamp the workpiece to the table so that you have a clear view of the arc, weld puddle, and unwelded portion of the joint at all times. Welding is done from right to left for a right handed operator and from left to right for a left handed operator (known as Push or Forehand). The torch CobraMig 260 Owner's Manual - Page 10 should bisect the 90 degree angle made by the joint and a push angle of from 10 to 15 degrees in the direction of travel is used. Strike an arc and move the torch progressively along the joint at a smooth steady rate. Most operators, unfamiliar with aluminum, tend to move too slow and consequently overheat the plate. A travel rate of 25 to 35 ipm should be used. The arc should sound smooth and the weld bead should be bright and shiny. If spatter occurs and the arc sounds like a short arc condition, decrease the wire feed speed or, if the weld looks cold, increase the voltage until a smooth spray transfer is achieved. The above condition provides 20 volts and 112 amps. If exact volts and amps are required, purchase meter kit P/N 005-0585. CobraMig 260 Owner's Manual - Page 11 Sample Setup - Stainless The procedure described below is designed to help you familiarize yourself with this equipment and also provide you with a known procedure so that you may perform a successful weld. Although these conditions may not be the exact ones needed for your specific application, it will provide an example of the proper use and operation of this equipment. MATERIALS NEEDED: 1 ea 1 ea 10 ea 1 ea 1 ea 20 ea CobraMig 260 system with torch of your choice #6 Gas Cup (3/8") Contact Tips .040 (621-0077 short arc) Spool of clean .035 stainless wire (E308L-SI) Cylinder of 90HE/7.5AR/2.5CO2 gas w/Regulator-Flowmeter and Hose Weld coupons (2 X 6 X 16 gauge) stainless steel PROCEDURE: Machine Set-up Hook-up the CobraMig 260 according to installation instructions in owners manual. Install wire onto spindle and thread wire through torch according to wire threading procedure. Make sure "Wire Type" switch is in the "All Others" position. Press gun trigger and set gas flow to 25cfh. Set the “VOLTAGE” control on front panel to 5 and the “RANGE” switch to Lo. Turn the “POSA START” to the off position. Place the “POLARITY JUMPER” in the positive (+) connector and the ground clamp in the negative connector. Press the gun trigger for six (6) seconds. Adjust the wire feed speed until 8 inches of wire is measured in 6 seconds; this equals 80 ipm. Position Material and Tack Weld Position the coupons on the work table to form a ‘T’ fillet. Place the gas cup near the work piece and tack weld one end. Remember to provide pre-purge before each weld by cracking the torch trigger and holding it for a few seconds before fully pressing the trigger. This will reduce built-up pressure and aid in arc starting. Tack weld the other end. Deposit Weld Securely clamp the workpiece to the table so that you have a clear view of the arc, weld puddle, and unwelded portion of the joint at all times. Welding is done from left to right for a right handed operator and from right to left for a left handed operator (known as Drag or Backhand). The torch CobraMig 260 Owner's Manual - Page 12 should bisect the 90 degree angle made by the joint and a drag angle of from 10 to 15 degrees is used. Strike an arc and move the torch progressively along the joint at a smooth steady rate. A travel rate of 20 to 25 ipm should be used. The arc should sound smooth and steady. If spatter occurs and the arc pops reduce the wire feed speed until the arc smooths out. The above condition provides 20 volts and 40 amps. If exact volts and amps are required, purchase meter kit P/N 005-0585. CobraMig 260 Owner's Manual - Page 13 Sample Setup - Steel The procedure described below is designed to help you familiarize yourself with this equipment and also provide you with a known procedure so that you may perform a successful weld. Although these conditions may not be the exact ones needed for your specific application, it will provide an example of the proper use and operation of this equipment. MATERIALS NEEDED: 1 ea 1 ea 10 ea 1 ea 1 ea 20 ea CobraMig 260 system with torch of your choice #6 Gas Cup (3/8") Contact Tips .040 (621-0077 short arc) Spool of clean .035 steel wire (E70-S6) Cylinder of 75Argon/25CO2 gas w/Regulator-Flowmeter and Hose Weld coupons (2 X 6 X 16 gauge) mild steel PROCEDURE: Machine Set-up Hook-up the CobraMig 260 according to installation instructions in owners manual. Install wire onto spindle and thread wire through torch according to wire threading procedure. Make sure "Wire Type" switch is in the "All Others" position. Press gun trigger and set gas flow to 25cfh. Set the “VOLTAGE” control on front panel to 5.8 and the “RANGE” switch to Lo. Turn the “POSA START” to the off position. Place the “POLARITY JUMPER” in the positive (+) connector and the ground clamp in the negative connector. Press the gun trigger for six (6) seconds. Adjust the wire feed speed until 13 inches of wire is measured in 6 seconds; this equals 130 ipm. Position Material and Tack Weld Position the coupons on the work table to form a ‘T’ fillet. Place the gas cup near the work piece and tack weld one end. Remember to provide pre-purge before each weld by cracking the torch trigger and holding it for a few seconds before fully pressing the trigger. This will reduce built-up pressure and aid in arc starting. Tack weld the other end. Deposit Weld Securely clamp the workpiece to the table so that you have a clear view of the arc, weld puddle, and unwelded portion of the joint at all times. Welding is done from left to right for a right handed operator and from right to left for a left handed operator (known as Drag or Backhand). The torch CobraMig 260 Owner's Manual - Page 14 should bisect the 90 degree angle made by the joint and a drag angle of from 10 to 15 degrees is used. 3. Strike an arc and move the torch progressively along the joint at a smooth steady rate. A travel rate of 25 to 35 ipm should be used. 4. The arc should sound smooth and steady. If spatter occurs and the arc pops reduce the wire feed speed until the arc smooths out. The above condition provides 16.5 volts and 89 amps. If exact volts and amps are required, purchase meter kit P/N 005-0585. CobraMig 260 Owner's Manual - Page 15 Section C Accessories Optional Kits Remote Voltage Kit ...........................................................................005-0584 Enables the power supply to be controlled from 25' pendant. LCD Meter Kit ...................................................................................005-0354 Digital Volt and AMp meters with memory feature to hold and alternately display volts and amps for 1 minute after welding. Timer Kit ...........................................................................................005-0586 Add on panel includes spot timer and stitch weld option. Torch Hanger Kit ...............................................................................005-0169 Allows you to hang torch on side of power supply. Easilly hooks on and off. Gas Control/Trigger Latch Kit ...........................................................005-0674 Adds Pre/Post Purge and Trigger function options. Water Flow Kit ..................................................................................005-0253 Monitors water pressure in torch. No water - no arc. Section D Maintenance Routine Maintenance Maintenance of the torch will normally consist of a general cleaning of the wire guide system, including tubes, drive rolls, and conduits at regular intervals. Remove spatter build-up from inside of nozzles with a hardwood stick. The only parts on the Cobramatic 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. Power Supply Periodically inspect all cables and hoses for damage or breaks in the insulation jacket, particularly at the plugs or ends. Repair or replace cables or hoses as necessary. Remove grease and dirt from components and remove moisture from electrical parts and cables. Be sure that all connections are clean and tight. WARNING: ELECTRIC SHOCK can kill. Shut-off disconnect and unplug unit before cleaning unit. Every six months blow out or vacuum dust and dirt from the internal components of the power supply. Remove the side panels and use a clean, dry air stream or vacuum suction for the cleaning operation. If repairs do become necessary, any part can easily be replaced by a qualified shop maintenance man. Your CobraMig 260 is designed to provide years of reliable service. Normal wear and component failure may require occasional service. The number of units in operation and the importance of minimal “down time” will determine to what extent spare parts should be stocked on hand. CobraMig 260 Owner's Manual - Page 16 Testing the Feeder Relay K2 Operation When the torch trigger is pressed, 24VAC is sent to the coil of relay K2. When K2 is energized, 115VAC is sent to the slave motor, spool brake, and the 115VAC contactor. Relay K2 is also responsible for sending 24VAC to the speed control circuit and shorting the torch motor leads together when the trigger is released for the dynamic braking system. K2 also provides the closing contactor signal. Testing the 115 VAC Circuits The 115 VAC circuit is protected by fuse F3. If F3 continually blows, remove J4 (Brake Solenoid), J7 (slave motor) and J5-3,4 (115 VAC Contactor) from the P.C. Board. Replace fuse, and retrigger system. If fuse does not blow; isolate the problem by plugging in J4, J7, and J5-3,4 one at a time until the fuse blows. Testing the Torch Motor Check Remove the amphenol connector from the cabinet. Using the torch amphenol, check the resistance across pins “A” and “B”(motor leads). The resistance across the motor should be between 5-10 ohms. If an open circuit or short exist, check the motor leads and motor independently. Testing the Potentiometer - “W” Clocked Using the torch amphenol, check the resistance across pin “D” (wiper) and pin “C”. The resistance should vary from 0 - 5K ohms. Check the resistance across pin “D” (wiper) and pin “G”. The resistance should vary from 5K - 0 ohms. Testing the Micro Switch Using the torch amphenol, check for continuity across pins “E” and “F” when the trigger is pressed. Testing the Speed Control NOTE: The torch should be tested first and the torch panel amphenol must be connected to the Cobramatic I to perform this test. Place a voltmeter across diode D10 and press torch trigger. A reading of 0 - 24VDC should be observed, as the potentiometer varied. Cobramtatic Main Board CobraMig 260 Owner's Manual - Page 17 Section E TROUBLESHOOTING WARNING Turn off input power switch, unplug primary power cord and wait 5 minutes before performing any service to this equipment. This will ensure that all storage capacitors have discharged to a relatively safe level. The following pages detail the trouble shooting section of this manual, please read carefully and use caution when performing service on any electrical equipment. All service is to be performed by a qualified service technician. Before calling for customer service, please go over the trouble shooting page to help solve your equipment problem. If the flow charts can not help you, please have the following information on hand before calling our service personnel: 1. 2. 3. 4. 5. 6. 7. Company name Your name Your phone number Power supply Model No. Primary power source Symptoms of failure Weld conditions CobraMig 260 Owner's Manual - Page 18 #OBRA-IG 4ROUBLESHOOTING 'UIDE 42/5",% #!53% #OBRA ) -AIN BOARD & FUSE BLOWN .O WIRE FEED AT TORCH FEEDER NOT OPERATING IE NO SLAVE MOTOR OR BRAKE SOLENOID "RAKE SOLENOID 3LAVE MOTOR INOPERATIVE .O WIRE FEED AT TORCH FEEDER OPERATING PROPERLY 7IRE FEEDS AT ONE SPEED ONLY .O WELD OUTPUT FAN MOTOR DOES NOT RUN EITHER 2EPLACE SWITCH #HECK SWITCH FOR OPERATION 2ELAY + ON #OBRA ) -AIN "OARD IS INOPERATIVE #HECK 2EPLACE + RELAY ,OOSE * * 0# "OARD CONNECTORS ON #OBRA ) "OARD #HECK * * CONNECTION "ROKEN ELECTRICAL CABLE #HECK FOR CONTINUITY REPLACE CABLE IF NEEDED 3OLENOID 3LAVE MOTOR DEFECTIVE 2ELAY + INOPERATIVE #HECK FOR OPEN CIRCUIT #HECK FOR 6!# ACROSS * "AD TORCH 0OTENTIOMETER #HECK POTENTIOMETER WITH METER "AD TORCH MOTOR "AD 3PEED CONTROL0#" #HECK 2EPLACE MOTOR #HECK MOTOR AND POTENTIOMETER WIRES FOR CONTINUITY #HECK 2EPLACE 0# "OARD 4ORCH POT IS DEFECTIVE OR TORCH CABLE IS SHORTED #HECK 2EPLACE TORCH POT #OBRA ) MAIN BOARD IS DEFECTIVE ,OOSE OR .O CABLE CONNECTIONS #HECK 2EPLACE #OBRA ) -AIN 0# "OARD #HECK ALL POWER CONNECTIONS #HECK 2EPLACE 0OWER 3UPPLY CONTROL BOARD #HECK RELAY + IF 6!# NOT PRESENT "ROKEN %LECTRICAL #ABLE ,OOSE CONNECTION AT THERMOSTAT TERMINALS #HECK CONNECTIONS TO THERMOSTAT 4HERMOSTAT IS DEFECTIVE + RELAY ON #OBRA ) MAIN BOARD IS NOT SENDING CLOSING CONTACT SIGNAL 4RIAC IS DEFECTIVE 2ELACE THERMOSTAT %RRATIC WELD OUTPUT #HECK 2EPLACE TRIAC #HECK POSITION OF 2EMOTE0ANEL *UMPERS .O PRIMARY POWER INPUT #ONNECT PRIMARY POWER #HECK FOR SECURE CONNECTIONS ON THE PRIMARY POWER 0RIMARY POWER CONNECTIONS ARE LOOSE 0RIMARY DISCONNECT SWITCH OFF OR FUSES OPEN #LOSE SWITCH OR REPLACE FUSE #OBRA-IG MAIN POWER SWITCH DEFECTIVE 2EPLACE POWER SWITCH ,OW INPUT VOLTAGE #HECK FOR PROPER INPUT VOLTAGE 6!# /NE OF TWO DIODES IS DEFECTIVE OR BLOWN 0LACE JUMPER IN POSITION TO MATCH INPUT VOLTAGE #HECK 2EPLACE POWER SWITCH 2ECIFIERS #APACITORS DAMAGED OR DEFECTIVE #HECK FOR SHORT * ON #OBRA ) MAIN BOARDS HOULD READ ABOUT OHMS 0OSA 3TART POT OR 0OSA 3TART SWITCH IS DEFECTIVE #URRENT SENSOR IS DEFECTIVE OR 0OSA 3TART CIRCUIT ON #OBRA ) MAIN BOARD IS DEFECTIVE 'ROUND CLAMP LOOSE AT WORK CONNECTION 2EPLACE RECTIFIERS CAPACITORS IF NECESSARY #HECK 2EPLACE IF NECESSARY #HECK 2EPLACE CURRENT SENSOR OR #OBRA ) MAIN BOARD #HECK GROUND CLAMP FOR SECURE ATTACHMENT )NPUT 6OLTAGE JUMPER IN WRONG POSITION 0OSA 3TART NOT OPERATING #HECK 2EPLACE RELAY + 2EMOTEPANEL VOLTAGE JUMPERS IN WRONG PLACE ,OW WELD VOLTAGE 7ALL DISCONNECT FUSE BLOWS WHEN TORCH TRIGGER IS DEPRESSED #HECK 6!# CIRCUIT REPLACE FUSE -ICROSWITCH DEFECTIVENOT BEING ACTIVATED 0OWER 3UPPLY CONTROL BOARD IS DEFECTIVE .O WELD OUTPUT WIRE FEEDS OK 2%-%$9 #APACITORS DEFECTIVE 2EPLACE CAPACITORS IF NECESSARY 6OLTAGE AND WIRE FEED SETTINGS ARE NOT CORRECT 2EADJUST AS NECESSARY CobraMig 260 Owner's Manual - Page 19 1 FLOW CHART 1 SYMPTOM NO WIRE FEED AT TORCH, FEEDER NOT OPERATING PROBLEM AREA COBRA I: MAIN BOARD, K2 RELAY TORCH: MOTOR, CABLE, MICRO SWITCH, SLAVE MOTOR, BRAKE SOLENOID START YES YES IS COBRA I MAIN BOARD F3 FUSE OK? NO NO BRAKE SOLENOID OR SLAVE MOTOR DEFECTIVE IS COBRA I MAIN BOARD F1 FUSE OK? MICRO SWITCH, TRANSFORMER RELAY, OR K2 RELAY ON COBRA I MAIN BOARD IS DEFECTIVE OR LOOSE J2, J3 ON COBRA I PC BOARD GO TO FLOW CHART #4 COBRA I MAIN BOARD, F1 AND F3 FUSES ARE OK BUT WIRE FEED AND TORCH NOT OPERATING MOTOR LEADS SHORTED OR TORCH MOTOR IS DEFECTIVE GO TO FLOW CHART # 3 COBRA I MAIN BOARD, F1 FUSE IS BLOWN GO TO FLOW CHART # 2 COBRA I MAIN BOARD, F3 FUSE IS BLOWN TROUBLE: No wire feed at torch, feeder not operating, ie. No slave motor or brake solenoid action. CAUSE: (F3) 2 amp Fuse on Main P.C. board on wire feeder. (F1) 4 amp Fuse on Main P.C. board on wire feeder. Micro Switch defective / Not being activated. Broken electrical cable. Transformer relay, Relay K2 inoperative. Loose J2, J3, Cobra I Main P.C. board connections. CobraMig 260 Owner's Manual - Page 20 2 FLOW CHART 2 SYMPTOM F3 FUSE ON COBRA I IS BLOWN WHEN TORCH IS TRIGGERED PROBLEM AREA COBRA: MAIN BOARD, SLAVE MOTOR OR BRAKE SOLENOID NOTE :The 115VAC on Cobra I Main P.C. Board is protected by Fuse F3. If F3 continually blows, unplug J4 (Brake Solenoid), J7 (Slave Motor) from the P.C. Board. Replace the fuse and retrigger. If fuse does not blow, isolate the problem by plugging in J4 and J7 one at a time until the fuse blows. START Resistance Check : a) Slave Motor J7-6 to J7-1 = 150 ohm J7-4 to J7-2 = 150 ohm b) Brake Solenoid J4-1 to J4-2 = 80 ohm F3 FUSE BLOWN COBRA MAIN BOARD UNPLUG CONNECTORS J4, BRAKE SOLENOID J7, SLAVE MOTOR RE-TRIGGER TORCH NO IS COBRA MAIN BOARD F3 FUSE OK ? GO TO FLOW CHART # 3 COBRA MAIN BOARD, F1 FUSE IS BLOWN YES PLUG IN J4 RE-TRIGGER TORCH YES IS COBRA I MAIN BOARD F3 FUSE OK ? NO SLAVE MOTOR IS OK SLAVE MOTOR IS DEFECTIVE PLUG IN J7 RE-TRIGGER TORCH YES BRAKE SOLENOID IS OK IS COBRA MAIN BOARD F3 FUSE OK ? NO BRAKE SOLENOID IS DEFECTIVE CobraMig 260 Owner's Manual - Page 21 3 FLOW CHART 3 SYMPTOM COBRA: MAIN BOARD, F1 FUSE IS BLOWN PROBLEM AREA COBRA: MAIN BOARD OR TORCH MOTOR START IS COBRA MAIN BOARD F1 FUSE OK? YES NO UNPLUG TORCH AMPHENOL FROM COBRA FRONT PANEL GO TO FLOW CHART #4 COBRA I MAIN BOARD, F1 AND F3 ARE OK, BUT WIRE FEED AND TORCH NOT OPERATIVE JUMPER "E" AND "F" ON EITHER OF THE COBRA FRONT PANEL AMPHENOL CONNECTORS IS COBRA MAIN BOARD F1 FUSE OK? NO COBRA I MAIN P.C. BOARD IS DEFECTIVE YES MOTOR LEADS ARE SHORTED OR MOTOR IS DEFECTIVE NOTE : MOTOR CHECK a. Remove the amphenol connector from the cabinet. b. Using an OHM meter, check the resistance across pins "A" and "B" (motor leads) on torch amphenol. The resistance across the motor should be between 5 and 10 ohms. c. If an open circuit or short circuit condition exists, check the motor leads and motor independently. CobraMig 260 Owner's Manual - Page 22 4 FLOW CHART 4 SYMPTOM COBRA MAIN BOARD, F1 AND F3 FUSES ARE OK BUT NO WIRE FEED AT TORCH AND FEEDER NOT OPERATING PROBLEM AREA K2 RELAY ON COBRA I MAIN BOARD, TRANSFORMER RELAY OR TORCH MOUNTED MICRO SWITCH START NO IS COBRA MAIN BOARD F1 FUSE OK? GO TO FLOW CHART #3 COBRA I MAIN BOARD, F1 FUSE IS BLOWN YES IS THE COBRA FRONT L.E.D. POWER LIGHT ON ? NO YES UNPLUG TORCH AMPHENOL FROM COBRA FRONT PANEL TRANSFORMER RELAY IS DEFECTIVE OR CABLE ASSEMBLY MISWIRED (SEE NOTE) IS WIRE FEEDING OK ? NO COBRA I MAIN P.C. BOARD, K2 RELAY IS INOPERATIVE OR LOOSE J2, J3 CONNECTORS ON MAIN BOARD JUMPER "E" AND "F" ON EITHER OF THE COBRA FRONT PANEL AMPHENOL CONNECTORS YES MICRO SWITCH IS DEFECTIVE NOTE : When the Cobra I front panel power switch is on, 115VAC is sent to the coil of Transformer Relay and 27 VAC is sent to Cobra I main board. When the torch is triggered, then K2 on Cobra I main board is energized. This action transfer 115 VAC to the slave motor, brake solenoid and controlled voltage to the torch motor. TRANSFORMER RELAY VOLTAGES : When torch trigger is depressed 115 VAC COM (White), Pin A to 115 VAC HOT (Neu), Pin B = 115 VAC 27 VAC COM (Brown), Pin 7 to 27 VAC HOT (Orange), Pin 9 = 27 VAC 27 VAC COM (Yellow), Pin 4 to 27 VAC HOT (Blue), Pin 6 = 27 VAC CobraMig 260 Owner's Manual - Page 23 5 FLOW CHART 5 SYMPTOM NO WIRE FEED AT TORCH, FEEDER OPERATING PROPERLY PROBLEM AREA COBRA MAIN BOARD, TORCH POT OR TORCH MOTOR START NO GO TO FLOW CHART #3 COBRA I MAIN BOARD, F1 FUSE IS BLOWN YES IS COBRA MAIN BOARD F1 FUSE OK? CHECK FOR LOOSE CABLES AT COBRA FRONT PANEL AND MAIN P.C. BOARD IS THE TORCH WORKING OK NOW ? (SEE NOTE 1 BELOW) WAS METER READING OK ? CABLE IS BROKEN OR TORCH POT IS DEFECTIVE NO NO CHECK TORCH POT SYSTEM OK NO YES YES CHECK TORCH MOTOR (SEE NOTE 2 BELOW) WAS METER READING OK ? CABLE IS BROKEN OR TORCH MOTOR IS DEFECTIVE YES COBRA MAIN BOARD IS DEFECTIVE NOTES: 2. Check TORCH MOTOR 1. Check TORCH POT at plug connector a. Testing the poteniometer - "W" Clocked. - Using Ohm Meter to check resistance across pin "D" (wiper) and pin "C" of Torch plug. Should vary from 0 to 5k ohm while turning pot. - Using Ohm Meter to check resistance across pin "D" (wiper) and pin "G" of Torch plug. Should vary from 0 to 5k ohm while turning pot. b. Testing the poteniometer - "S" Clocked. - Using Ohm Meter to check resistance across pin "D" (wiper) and pin "C" of Torch plug. Should vary from 0 to 5k ohm while turning pot.- Using Ohm Meter to check resistance across pin "D" (wiper) and pin "A" of Torch plug. Should vary from 0 to 5k ohm while turning pot. CobraMig 260 Owner's Manual - Page 24 a. Unplug the Torch from the front panel. b. Using the Ohm Meter, Check the resistance across pin "A" and pin "B" (motor leads) of Torch plug. The resistance should be about 5 to 10 ohms. c. If open of short circuit exists, then check motor leads and motor for additional problems. 6 FLOW CHART 6 SYMPTOM WIRE FEEDS AT ONE SPEED ONLY, NO CONTROL BY POT SETTING ON TORCH PROBLEM AREA TORCH MOTOR POTENIOMETER OR CABLE OR COBRA I MAIN BOARD START UNPLUG TORCH AMPHENOL FROM COBRA FRONT PANEL CHECK THE "W' CLOCKED / "S" CLOCKED POTENIOMETER PER NOTE BELOW WAS METER READING OK ? NO YES TORCH POT IS DEFECTIVE OR TORCH CABLE IS DEFECTIVE COBRA MAIN P.C. BOARD IS DEFECTIVE NOTES: 1. Check TORCH POT at plug connector a. Testing the poteniometer - "W" Clocked. - Using Ohm Meter to check resistance across pin "D" (wiper) and pin "C" of Torch plug. Should vary from 0 to 5k ohm while turning pot. - Using Ohm Meter to check resistance across pin "D" (wiper) and pin "G" of Torch plug. Should vary from 0 to 5k ohm while turning pot. b. Testing the poteniometer - "S" Clocked. - Using Ohm Meter to check resistance across pin "D" (wiper) and pin "C" of Torch plug. Should vary from 0 to 5k ohm while turning pot. - Using Ohm Meter to check resistance across pin "D" (wiper) and pin "A" of Torch plug. Should vary from 0 to 5k ohm while turning pot. CobraMig 260 Owner's Manual - Page 25 7 FLOW CHART 7 SYMPTOM NO WELD OUTPUT, NO VOLTAGE CONTROL PROBLEM AREA POWER SUPPLY CONTROL (PSCB), THERMOSTAT, TRIAC, CONTACTOR SIGNAL, PWR SWX BOARD START IS PSCB LED D7 ON ? (DOES IT HAVE 12 VOLTS) YES NO JUMPER TP1 TO TP5 ON PSCB IS PSCB F1 FUSE OK ? NO NO IS PSCB LED D12 ON ? YES YES PSCB IS DEFECTIVE TRANSFORMER RELAY IS DEFECTIVE OR NO AC INPUT, CHECK DISCONNECT FUSE PSCB IS DEFECTIVE REPOSITION JUMPER TO TP2 AND TP4 USING VOLTMETER, MEASURE WELD VOLTAGE AT COBRA I MAIN BOARD J6-1(+) AND J6-2(-) YES DOES OUTPUT VARY WHEN VOLTAGE KNOB IS TURNED APPROX :LO 10 - 32VDC HI 29 - 40VDC ADD SECOND JUMPER TO TP1 AND TP5 REPOSITION JUMPER TO TP2 AND TP3 YES DOES OUTPUT VARY WHEN VOLTAGE KNOB IS TURNED APPROX :LO 10 - 32VDC HI 29 - 40VDC NO YES IS WELD OUTPUT AT MAXIMUM (APPROX. 35 - 40VDC) PSCB IS DEFECTIVE K2 RELAY ON COBRA I MAIN BOARD DOES NOT SEND CLOSING CONTACT SIGNAL OR TORCH SWITCH IS DEFECTIVE NO THERMOSTAT TERMINALS LOOSE OR THERMOSTAT IS DEFECTIVE (OPEN ALL THE TIME) TRIAC RESISTANCE CHECK: Use meter in "Diode" mode. Pin 3 to Pin 4 : 2.3 Pin 1 to Pin 2 : open CobraMig 260 Owner's Manual - Page 26 NO TRIAC IS DEFECTIVE 8 FLOW CHART 8 SYMPTOM DISCONNECT FUSE BLOWS WHEN TORCH IS TRIGGERED PROBLEM AREA POWER TRANSFORMER "T1", DIODES, CAPACITORS START TURN OFF ALL POWER AND DISCONNECTS USING AN OHM METER, MEASURE THE RESISTANCE AT J6-1 (WELD VOLTS) AND J6-2 (WORK GROUND) ON COBRA I MAIN BOARD, READING SHOULD BE APPROX. 25 OHM NO IS READING OK ? DISCONNECT DIODES FROM POWER TRANSFORMER T1 : ANODE D1 FROM T1-6 ANODE D2 FROM T1-5 NO CAPACITORS SHORTED NO YES POWER TRANSFORMER "T1" IS DEFECTIVE IS READING AT J6-1 AND J6-2 APPROX. 25 OHM NOW ? YES SET OHM METER ON DIODE CHECK MODE MEASURE DIODE RESISTANCE : PLACE (+) LEAD ON ANODE AND (-) LEAD ON HEATSINK READING SHOULD BE APPROX. 300 TO 800 OHMS PLACE (-) LEAD ON ANODE AND (+) LEAD ON HEATSINK READING SHOULD BE OPEN. IS READING OK ? DIODE IS DEFECTIVE YES DIODE IS OK CobraMig 260 Owner's Manual - Page 27 9 FLOW CHART 9 SYMPTOM POSA START NO WORKING PROPERLY PROBLEM AREA CURRENT SENSOR, COBRA I MAIN BOARD, READ POSA START SECTION. START TO CHECK POSA START POT : REMOVE J2 ON COBRA I MAIN BOARD, TURN ON POSA START SWITCH USING OHM METER METER RESISTANCE AT J2-1 AND J2-2 RIBBON CABLE READING SHOULD VARY FROM 0 TO 100K OHM IS READING OK ? NO YES PLUG IN J2 REMOVE J1 ON COBRA I MAIN BOARD. USING OHM METER MEASURE RESISTANCE OF CURRENT SENSOR THE READING SHOULD BE OPEN POSA START POT OR POSA START SWITCH DEFECTIVE IS READING OK ? NO CURRENT SENSOR IS DEFECTIVE (CLOSED ALL THE TIME) YES USING A VOLT METER, MEASURE THE WELD VOLTAGE AT J6-2(-) AND J6-1(+) ON COBRA I MAIN BOARD SET POSA POT = 1/4 TURN ON SET TORCH POT = MAXIMUM (CW) TURN ON COBRAMIG 260 TRIGGER AND ADJUST WELD VOLTS TO APPROX 15V JUMPER J1-1 AND J1-2 ON COBRA 1 MAIN BOARD NO COBRA I MAIN BOARD IS DEFECTIVE DOES TORCH MOTOR SPEED INCREASE WHEN JUMPER IS ADDED? YES CURRENT SENSOR IS DEFECTIVE (OPEN ALL THE TIME) CobraMig 260 Owner's Manual - Page 28 10 FLOW CHART 10 SYMPTOM NO WELD OUTPUT, REMOTE VOLTAGE POT INSTALLED PROBLEM AREA JUMPER ON POWER SUPPLY CONTROL BOARD (PSCB) IN WRONG POSITION REMOTE PENDANT IS DEFECTIVE START IS REMOTE VOLTAGE KIT (005-0584) INSTALLED ? NO YES GO TO TO FLOW CHART #7 PANEL DO YOU WANT TO USE PENDANT OR FRONT PANEL VOLTAGE CONTROL KNOB SET JUMPER ON BACK OF WELD VOLTAGE CONTROL PANEL TO THE REMOTE POSITION AND CHECK THAT THE PENDANT IS PLUGGED INTO THE FRONT PANEL CONNECTOR SET JUMPER ON BACK OF WELD VOLTAGE CONTROL PANEL TO THE PANEL POSITION IS FRONT PANEL VOLTAGE KNOB WORKING NOW ? NO NO YES READY TO WELD PENDANT IS REMOTE VOLTAGE PENDANT WORKING NOW ? YES GO TO FLOW CHART #7 READY TO WELD NOTE : WHEN THE REMOTE VOLTAGE POT KIT IS INSTALLED AND THE JUMPER IS IN THE REMOTE POSITION, YOU MAY ONLY USE THE REMOTE POT, THE FRONT PANEL VOLTAGE POT IS DISABLED UNTIL YOU MOVE THE JUMPER BACK TO FRONT PANEL POSITION. CobraMig 260 Owner's Manual - Page 29 11 FLOW CHART 11 SYMPTOM CONTACTOR CLOSED, WIRE ALWAYS ENERGIZED PROBLEM AREA POWER SUPPLY CONTROL BOARD, K2 RELAY MAIN BOARD, TRIAC START IS PSCB LED D7 ON? YES NO JUMP TP1 TO TP5 NO IS PSCB LED D12 ON? PSCB IS DEFECTIVE REMOVE JUMPER FROM TP1:TP5 DISCONNECT J6 ON PSCB IS PSCB FUSE F1 OK? NO PSCB IS DEFECTIVE CONTACTOR STILL CLOSED? YES YES YES IS THE WELDING VOLTAGE CONTROLLABLE? PSCB IS DEFECTIVE USING OHMMETER, CHECK FOR CONTINUITY ACROSS J6-3 AND J6-4 ON MAIN PC BOARD NO DISCONNECT J5 ON THE PSCB PSCB IS DEFECTIVE REPLACE TRIAC TRANSFORMER RELAY IS DEFECTIVE OR NO AC INPUT, CHECK DISCONNECT FUSE NO NO YES YES IS THE WELDING WIRE STILL ENERGIZED? NO PSCB IS DEFECTIVE CobraMig 260 Owner's Manual - Page 30 CLOSED SIGNAL YES RESEAT K2 RELAY REPLACE IF NECESSARY Section F Appendices Diagrams/Parts List Main P.C. Board Connections .............................................. 32 001-3850 Top Level ........................................................... 33 003-2134 Power Supply Assembly ...................................... 34 003-1586 Multi-Tap Bracket Assembly ................................. 35 003-1584 Logic Transformer Assembly ................................ 36 003-2131 Wire Feeder Assembly ........................................ 37 003-2135 Front Panel Assembly ......................................... 38 003-2130 Back Panel Assembly .......................................... 39 003-2132 Deck Assembly ................................................... 40 003-1774 Heat Sink Assembly ............................................ 41 003-1714 Cap Bank Assembly ............................................ 42 003-1703 Control Panel Assembly ....................................... 43 003-2063 Cobramatic Power Block Assembly ....................... 44 003-2109 42 VAC Front Panel Assembly .............................. 45 003-2061 Cobramatic Spindle Brake Assembly ..................... 46 003-2078 Slave Motor Assembly ......................................... 47 071-0321 Universal Input................................................... 48 071-0390 Universal Input with Options ............................... 50 071-0370 Front Panel ........................................................ 51 071-0714 Power Supply Control Board ................................ 52 CobraMig 260 Owner's Manual - Page 31 STANDARD CONNECTIONS - MAIN PC BOARD CobraMig 260 Owner's Manual - Page 32 CobraMig 260 Owner's Manual - Page 33 Qty. 1 1 1 1 REF REF REF 38 2 2 4 2 1 1 1 1 2 1 1 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 003-1853 003-2131 003-2134 031-0171 071-0389 071-0390 327-0115 333-0043 336-0005 336-0039 336-0188 341-0018 405-0780 405-0887 405-0951 436-0044 445-0013 843-0528 003-1744 P/N Assy Top Cover CV-260 Assy Wire Feeder CV-260 Assy Power Supply CV-260 Test Procedure Final CV-260 Block Diagram CV-260 Block Diagram w/option CV-260 Scr Hw S T/B #14 x 1/2 St Washer Flat #6 Scr Pn Ph 6-32 x 3/8 Scr Pn P 10-32 x 3/8 ST Scr Pn P 6-32 x 3/8 ST HI Nut Hx Plain #1/2-13UNC Tag Owner Man CV-260 Decal Warning T13470 Decal Serial Plat CV-260 SS Fixed Door CV-260 Bolt Eye 1/2 - 13UNC Cable GND Power 20FT CV-260 Assy Gas Tank Chain CV-260 Description Multi-Tap CV 260 001-3850 CobraMig 260 Owner's Manual - Page 34 1 1 2 4 2 1 1 7 7 7 7 5 5 2 5 5 1 1 1 1 1 1 1 1 1 6 4 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Qty. 1 No. 431-3516 515-3693 331-0080 421-0410 137-0084 133-0007 329-0003 333-0009 331-0050 345-0051 329-0029 331-0025 515-3692 333-0010 341-0012 405-0801 405-0621 405-0862 185-0073 329-0219 345-0012 003-1586 003-1774 003-1706 327-0115 333-0027 003-1879 844-0066 438-0030 P/N Axle Back Wheel Wheel 08.00 Washer Flat 13/16x1.75 Pin 03/32 x 1.25 LG Transformer Power Choke Scr Hex 1/4-20x3/4LG Washer Spring Lock 1/4 Washer Flat 1/4x5/8x1/16 Nut Hex Lock 1/4-20 Scr Hex 5/16-18x3/4LG Washer Flat 5/16 Caster Washer Spring 5/16 Nut Hex 5/16-18 Decal Power Input Decal Warning Decal Voltage Terminal Ground Scr Hex 10-24x1/2LG Nut Hex 10-24 Assy Bracket Assy Heatsink Assy Fan Cooling Scr Sht Mtl #14 x 1/2 LG Washer LK Star-ln 1/4 Assy Cap Cable Choke to Receptable Base Paint Description Multi-Tap Power Supply Assembly 003-2134a CobraMig 260 Owner's Manual - Page 35 1 1 1 2 1 1 2 1 5 2.23ft 4 8 4 4 4 1.02ft 3.43ft 6 10 0.50ft 4 1 1 0.17ft 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 No. Qty. Description 003-1584 159-3590 1860075 405-0864 186-0069 437-0207 003-1772 411-0193 301-0081 335-0198 331-0004 333-0007 336-0195 331-0003 845-0058 845-0289 185-0077 185-0516 739-0007 336-0197 405-0869 124-0127 261-0019 Assy Xfmr Logic Switch, Power Terminal Strip 9 Pos Label TB1 Terminal Strip 2Pos Jumper, Capsulated Cable Power Supply Tie Wrap Grommet, Edge Potect Scr Hp Fil 10-32x1/2 Washer Flat #10 Washer Spring Lock #10 Scr Hp Fil 8-32x3/4 Washer Flat #8 Wire Bga White Wire 1Bga White Ring Lug Scr #10 8ga Ring Lug Scr #1022-1 8ga Tubing Heat Shrink 3/8 ID1.00 Scr Hp Fil 10-32x3/8 Label TB2 Var Rd 510V 110J 14mm Tubing Teflon White 18Ga 435-1515 Brackett, Multi-Tap P/N Multi-Tap Bracket Assembly 003-1586 CobraMig 260 Owner's Manual - Page 36 Qty. 1 8 2 2 1 .50ft 2.67ft No. 1 2 3 4 5 6 7 185-0003 185-0001 153-0910 153-0909 261-0469 261-0132 137-0085 P/N Term Lug #8 Scr 22-18ga Term Slpon Fem .187 22-18ga Con Term Crimp Pin 0.09 #18ga Conn Housing 3 Pin Tubing, Insulation 7/16 ID Tubing, Insulation 0.75 ID Logic Transformer Description Logic Transformer Assembly 003-1584 CobraMig 260 Owner's Manual - Page 37 1 1 1 1 14 1 1 2 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 No. Qty. 003-2130 003-2132 003-2135 327-0115 328-0063 328-0258 345-0015 419-0089 419-0090 431-1608 431-1609 435-1584 437-0242 437-0243 437-0255 003-1714 P/N Assy Back Panel CV-260 Assy Deck CV-260 Assy Front Panel Screw Sht Mtl #14-12 St T/B Screw Sch 1/4-20 x 1 3/4 Blk Screw Sch 1/4-20 x 3 1/2 Stl Nut Hex Lock 1/4-20 St Torsion Spring Restrainer Trosion Spring Catch Mandrel Catch Mandrel Restrainer Panel Restrainer CV-260 Restrainer Wire Pad Restrainer Catch Restrainer Assy Cap Blank Description 003-2131 Wire Feeder Assembly CobraMig 260 Owner's Manual - Page 38 1 2 12 12 1 1 1 1 1 1 1 1 2 2 1 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 No. Qty. 351-0089 351-0086 336-0005 003-1703 436-0093 436-0094 435-1588 351-0745 003-1780 351-0748 351-0101 351-0752 153-0754 844-0065 003-2110 351-0008 Thread Insert, #10-32 Thread Insert, #6-32 Screw, Ph Fil, #6-32 x 3/8" Control Panel Assy Screened Cover, Meter Kit Screened Cover, Timer Kit Cover PCB CV-260 Bushing, Snap 01.12 Pilot Lamp Assy Plug, Hole 01.12 Strain Relief, Cable Bushing, Snap 01.50 Con, Rcp, Pnl, Dinese, 400A Polarity Cable Cobra Panel Assy. Plug, Hold 03/8 Silkscreen Front Panel Description 003-2135a 436-0161 P/N Front Panel Assy. Back Panel Assembly 003-2130 No. Qty. P/N 1 1 438-0073 Paint Back panel CV-260 2 3 4 5 6 2 1 1 4 1 351-0089 351-0100 435-1499 327-0115 411-0165 Thread Insert #10-32 Bushing Snap 02.0 Hole Bracket Gas Tank Scr Hex Sht Mtl #14-12 x 1/2" Strain Relief Cable CobraMig 260 Owner's Manual - Page 39 Description CobraMig 260 Owner's Manual - Page 40 1 Description 003-2132a 438-0072 Paint Deck CV-260 P/N 2 1 438-0070 Paint Mid-Plate Assy. 3 4 329-0002 Scr Hex 1/4-20 x 5/8 4 1 261-0510 Spool Insulator 5 1 003-2078 Assy Slave Motor 115V 6 4 333-0009 Washer Spring Loc 01/4 ID 7 1 438-0044 Paint Panel Access Triac CV-260 8 1 329-0208 Scr Hex 3/8 -16 x 1.0 9 0.50ft 261-0505 Trim Protection Edge 10 1 003-0784 Assy Pawl Ratchet 11 1 003-2146 Assy Spindle CB 12 6 351-0086 Insert Thread #6-32 13 4 331-0002 Washer Flat #6 14 1 003-0593 Assy Relay 15 12 333-0043 Washer Star-In #6 16 12 336-0005 Scr Ph Phl St #6-32 x 3/8 17 2 411-0186 Strap Cable 18 2 305-0042 Pop Rivet 1/8 Al. 19 1 003-2096 Assy Sol Brk 115V 20 3 336-0037 Scr Ph Phl St #6 x 1/4 T/B 21 1 419-0080 Spring Extension 22 6 342-0410 Spacer #6-32 23 1 003-1628 Assy Pcb main Cb 115V 24 1 405-0072 Decal Elec Connection 25 1 405-0929 Decal Main Pcb Connections 26 2 351-0752 Bushing Snap 01.50 27 5 327-0115 Scr Hex Sht Mtl #14 x 1/2 28 1 003-2063 Assy Power Block CB 29 1 261-0109 Insulator Power Block 30 1 435-1502 Bracket Power Block 31 2 332-0009 Washer Shoulder 01/4 32 2 331-0049 Washer Flat 01/4 33 2 329-0003 Scr Hex 1/4-20 x 3/4 34 1 405-0930 Decal Hose Connections 35 4 329-0405 Scr Hexwshrhd Hi-Perf 8-32 x 3/8 36 1 405-0886 Decal Warning T13297 37 1 405-0887 Decal Warning T13470 1 No. Qty. Deck Assembly CobraMig 260 Owner's Manual - Page 41 1 Heat Sink Description 003-1774C 431-3102 P/N 2 4 431-3861 Spacer 3 4 333-0027 Washer, X-Star 1/4 4 8 329-0004 Screw, HEx 1/4-20 x 7/8 5 1 125-0033 Triac 660V 75A 7 4 333-0023 Washer, X-Star #6 8 2 336-0006 Screw Ph Ril #6-32 x 1/2 10 1 333-0011 Washer, Spring Lock 3/8 11 1 329-0053 Screw, Hex 3/8-16 x 1/2 12 1 844-0061 Cable, Triac Assy. 13 1 170-0003 Thermal Switch 15 2 333-0021 Washer, X-Star #4 16 2 336-0010 Screw, Ph Fil #4-40 x 3/8 17 1 003-1742 Cable, Triac & Ther. Sx. 18 2 124-0088 Diode 400V, 300A 19 4ft 261-0102 Sleeve, Fibre-glass 20 2 329-0029 Screw, Hex 5/16-18 x 3/4 21 2 333-0010 Washer Spring Lock 5/16 22 2 331-0099 Washer, Flat 5/16 23 2 341-0012 Nut, hex 5/16-18 24 A/R 823-0032 Compound Alcoa #2 25 1 844-0067 Cable, Triac (long) 26 2 333-0025 Wsher, X-Star #10 27 1 261-0516 Insulator, Heat Sink 29 2 336-0030 Screw Ph Fil #8-32 x 1/2 30 6 333-0024 Washer X-Star #8 31 4 333-0009 Washer Spring Lock 1/4 32 1.6ft 261-0505 Protective Trim 33 1 435-1064 Upper Baffler 34 2 336-0091 Screw Ph Fil #8-32x1 3/4 35 1 435-1063 Lower Baffler 36 2 341-0006 Nut, Hex #8-32 Items 6, 9, 14 & 28 are not used. 1 No. Qty. Heat Sink Assembly CobraMig 260 Owner's Manual - Page 42 1 4 8 8 8 8 4 1 4 4 4 4 1 1 2 2 4 4 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 No. Qty. 104-0081 333-0045 325-0225 329-0001 333-0027 431-4029 844-0058 331-0099 329-0029 333-0010 341-0012 844-0059 113-0056 333-0041 327-0109 332-0009 331-0005 435-1061 844-0084 Capacitor 300000uF Lock Washer #10 Internal Tooth Screw Pan Slotted #10-32x3/8 Bolt Hex Head 1/4-20x1/2 Lock Washer 1/4" Ext. Tooth Spacer Cap Bank Cable Jumper Positive Washer Flat 5/16" Bolt Hex Head 5/16-18 x 3/4 Lock Washer #5/16 Slit Spring Nut 5/16-18 Hex Cable Power & Posa Resistor 15 Ohm, 55W Lock Washer #4 Int-Tooth Scr Pan Phil T/B #4-40x1/4 Washer 0.265ID Shoulder Washer Flat #1/4 Bracket Mounting Plus Cable 12" Power Bracket Mounting, Minus Description 003-1714D 435-1062 P/N Cap Bank Assembly CobraMig 260 Owner's Manual - Page 43 Qty. 1 2 1 1 1 1 No. 1 2 3 4 5 6 331-0087 003-1311 401-0075 003-1741 301-0023 436-0045 P/N Washer Flat Neoprene Closing Contact Cable Knob 2.00 Dia Pcb Control Assy. Grommet Pnl. Led Screened Panel Description Control Panel Assembly 003-1703 CobraMig 260 Owner's Manual - Page 44 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 A/R A/R A/R 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 No. Qty. Description 003-2063a 313-0021 329-0054 331-0002 331-0777 333-0252 336-0005 342-0395 351-0066 431-1612 435-3038 753-0112 753-0114 753-0115 753-0466 753-0475 823-0029 823-0043 823-0044 333-0011 Stud Receiver Push-On Scr hex 3/8-16 x 5/8 Washer Flat #6 Stl Washer flat 0.391ID x 0.875OD Wshr Lk Star-In #6 St Scr Pn Ph 6-32 x .375 Stl Spacer Current Sensor Plug Hole 05/16 Block Power CB2K Bracket Current Sensor Ftg 1/4NPT Male to 5/8-18 Male Aptr 1/8NPT x 1/8NPS Bush 1/4NPT Male to 1/8NPT Fem Aptr 1/4NPT Male to 5/8-18 Fem Aptr 1/4NPT M to 5/8-18 Fem Lh Anti-Corrosion Compound Removable Threadlock Compound Pipe Thread Sealant Washer Spring Lock 3/8 003-1243 Assy Sensor Posa-Start P/N Power Block Assembly CobraMig 260 Owner's Manual - Page 45 1 1 1 1 1 2 1 1 1 1 1 2 3 4 5 6 7 8 9 10 No. Qty. 003-1631 003-2024 301-0023 341-0050 345-0004 401-0012 436-0144 003-1642 351-0835 003-1332 P/N Cable Power Assy. Assy Pcb Fr Pnl CB 110V Grommet Panel Mount Nut 3/8-32 St Nut Hex Lock 4-40 Knob 01.0 Blk SS Pnl Fr Cobramatic Assy Con 7P "w" CB Snap Btn 01/2 Hole Blk Assy Cbl Rbn 26c Description 42 VAC Front Panel Assembly 003-2110b CobraMig 260 Owner's Manual - Page 46 1 3 3 1 1 1 3 1 1 1 1 1 1 1 1 1 A/R 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 No. Qty. Description 003-2146 330-3063 331-0063 331-0095 331-0313 345-0018 419-0059 419-0095 431-1266 431-3726 437-0258 437-0259 437-0260 437-0645 723-0059 751-0018 823-0049 Scr Shldr Mod .25 x .63 10-24 Wshr Flt .355 x .505 Wshr Flt 11/32 x 3/4 Sst Wshr Leather .75ID x .125 Thk Nut Hex Lock 5/16-18 St Spg Comp .468 x .437 x .056 Spg Comp .85 x .69 x .75 Plate Back-up Ring Adapter Spiral Spindle Retainer Spool Spindle Knob Tension Spindle Spacer Spindle Spindle Disk Ratchet Brake Cap .5 .5 Lg Vinyl Black Thread Locking Permanent 003-2139 Assy Bearing Spindle P/N Spindle Assembly CobraMig 260 Owner's Manual - Page 47 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A/R A/R A/R REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 No. Qty. Description 003-2078 003-2069 328-0024 328-0259 330-0258 345-0018 419-0085 419-0211 431-1576 435-1582 437-0230 437-0231 437-0232 437-0245 437-0254 501-0118 501-0156 501-0207 507-0130 511-0206 753-0210 823-0043 835-0001 823-0051 031-0167 Assy Torque Motor 115V Scr Shc 8-32 x 3/8 Stl Scr Shc 8-32 x 1-1/8 Stl Scr Shldr 1/4 x 1/4 x 10-24 Nut Lock 5/16-18 Spring Comp 1/32 x OD .40 Spring Comp OD 5/8 x 1/16 Bolt Swing Mod Plate Locate Slave Motor Housing Slave Motor Mold Handle Mold Slave Motor Arm Idler Mold Slave Motor Cap Bearing Mold Sleeve Spring Bearing 1.125 x .50 x .31 Bearing .875 x .38 x .28 Bearing Idler Roll Shaft Gear Drive Roll Guide Wire Inlet Loctile Threadlocking Grease Mobilux 2 Loctile Retaining Compound Test Procedure 003-0176 Assy Knob Conduit P/N Slave Motor Assembly CobraMig 260 Owner's Manual - Page 48 NO 9 A B 6 4 AC NE U 3 GROUND LUG P/N 186- 0071 GRN 1706 SW1 40A / 600 V P/N 159- 3590 4 2 #18GA BLK FAN P/N 003 27VAC IN (HOT) ORN 27VAC IN (COM) BRN VR1 510V Q1 4 WHT #8GA 75A / 600V P/N 125-0033 POWER TRIAC 3 2 1 TB1 INPUT SELECTOR P/N 186 0075 CW CCW J13 1 2 3 3 2A 4A TB2 INPUT SELECTOR P/N 186-0075 123456789 WHT #8GA 1 235V YEL 1 2 4 10 11 12 13 14 15 BLK RED 3 J6 9 208V CONT + ORN BLK 130V 10 11 12 13 THERMAL SW P/N 170 0003 584 WHT BRN 0V BRN 0V ORG 28V 0V ORG 28V WELD VOLT (-) #18GA WELD VOLT (+) #18GA 2 D1 2 D2 P/N 137- 0084 1 P/N 124-0088 HEAT SINK 29V 1 NC NO1 POWER DIODE 0V 29V 2 (-) (+) -1311 POWER INDICATOR LED (N) POWER INDICATOR LED (H) TORCH MOTOR (-) TORCH MOTOR (+) TORCH TRIGGER 27V (RTN) TORCH TRIGGER 27V (SRC) TORCH POT CCW TORCH POT WIPER TORCH POT CW POSASTART (RETURN) POSASTART (SOURCE) J2 27VAC REMOTE 2&3 12VDC 2A F1 C1 + + C3 CONT + .1u/1KV 1742 METER 007 C5 1 2 R1 25/55W P/N 113 0056 BLK #2GA C4 BLK #2GA 1.2 mH P/N 133 0 L1 CABLE 003- T.SWX. & TRIAC 1 2 3 4 5 J4 REMOTE 1 2 3 J6 J3 POWER SUPPLY ( 30000 uF, 50 VDC) X 4 P/N 104 0081 + TRIAC (-) YEL C2 THERMAL SW. RED TRIAC (+) ORN J5 P/N 003 1741 FOR 60 HZ UNITS P/N 003 1795 FOR 50 HZ UNITS 1332 CONT+ CONT- CABLE 003 POWER SUPPLY CONTROL BOARD JP1 JP2 THERMAL SW. BRN PANEL JP3 WELD VOLTAGE JUMPER TO WELD VOLT (-) J1 T ORQUE SWITCH (SOURCE), BLU T ORQUE SWITCH (RETURN), GRN MAIN SWITCH AC OUT (H), ORG MAIN SWITCH AC IN (H), YEL MAIN SWITCH AC OUT (N), RED TO WELD VOLT (+) 3 2 1 1631 MAIN SWITCH AC IN (N), BRN CABLE 003 003 12 43 (TO POWER BLOCK) CABLE 003 POWER TRANSFORMER 1 5 235V 2 0V 8 6 235V 208V 0V P/N 003 1 1 1 CONT - YEL J2 J3 LOGIC XFMR 9 208V 5 0V BRN ORG 2 8 6 235V 208V 4 GRY VIO 0V 115V H BLK #18 2 GRN 1 J5 115VAC 27VAC 1628 RELAY K2 157-00 22 F3 F1 P/N 003 1 2 J1 COBRAMATIC I MAIN BOARD J14 115V N WHT #18 123456789 HEAT SINK 1 P/N 003 1780 1 1 2 3 4 5 6 J8 1 2 J4 J7 1 2 3 4 5 6 W/ LEADS PILOT LAMP TRANSFORMER RELAY 003-05 93 115VAC (COM) WHT 115VAC (HOT) BLK 27VAC (HOT) BLU CABL E 003-1 772 #8GA WHT #8 003-20 96 27VAC (COM) YEL AC HO T 1 WHT #8GA J4-2 115V (N) J4-1 115V (H) BRAKE SOLENOID POWER TERMINAL BLOCK P/N 186- 0069 120VAC RE LAY P/N 157- 0149 K1 NO 7 003-20 78 SLAVE MOTOR TO COBRA I PCB J6-1 (+) J7-6 115V (N) BLU J7-4 115V (N) WHT J7-3 WELD VOLT RED J7-2 115V (H) BLK J7-1 115V (H) RED 1 2 3 WELDING CURREN T SENSOR 1 2 W 1 2 1 2 3 4 JUMPER CABLE 003 1307 C6 .1u/1KV J2 4&5 003-20 63 POWER BL OCK WELD VOLT (-) WELD VOLT (+) TO COBRA I J6-2 (ZONE C6) - + (-) (+) J4 J3 COBRAMATIC I FRONT PANEL P/N 003- 2024 J1 TO COBRA I J6-1 (ZONE C6) 1 1 - REV TERMINAL AND WORK GROUND CLAMP C Size Title Document Number 071- 0389 STANDARD M. K. PRODUCTS INC. CM260 UNIVERSAL INPUT, TO (+) TERMINAL TERMINAL AND WORK GROUND CLAMP DCSP, PLUG PIGTAIL POWER BLOCK TO (-) 5K 1 (-) WER SUPPLY REMOTE VOLTAGE CONTROL, TO (-) TERMINAL 5. FOR 3 CW DCRP, PLUG PIGTAIL POWER BLOCK TO (+) 4. FOR JUMPER JP1 TO JP2 3. FOR PO (+) WER SUPPLY PANEL VOLTAGE CONTROL, JUMPER JP1 TO JP3 2. FOR PO G F E D C B A DATE 02/01 - Rev TORCH TRIGG ER TORCH POT TORCH MOTOR TORCH "W" CLK 003 16 42 MS "W" AMPHENOL CONNECTOR APPR. ELECTOR: SEE CM260 UNIVERSAL INPUT A B C D E F G A B C D E F G PRN 3253 DESCRIPTION / DCN WIRING DIAGRAM 1. INPUT S NOTES 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 P/ZONE 2 CobraMig 260 Owner's Manual - Page 49 CobraMig 260 Owner's Manual - Page 50 NO 9 A B 6 4 P/N 003-1706 FAN GROUND LUG P/N 186-0071 GRN WHT #8 #8GA 4 510 V VR1 2 1 4 J13 1 2 3 3 1 0V 130V 0V 0V 28V 28V WHT BLK BRN BRN ORG ORG 13 2 2 D1 NO 1 (-) (+) J1 TB1 INPUT SELECTOR P/N 186-0075 123456789 1 9 5 2 8 6 10 11 12 P/N 137-0084 NC 1 2 D2 1 P/N 124-0088 HEAT SINK 29V POWER DIODE 0V 29V POWER XFMR 235V 208V 0V 235V 208V 0V TIMER J3 27VAC 3 2 1 J2 REMOTE PSCB 2&3 J1 12VDC 12VDC 2A + + C3 + CONT L1 1 1.2 mH R1 25/55W P/N 113 0056 BLK #2GA C4 BLK #2GA 2 (-) P/N 133-0007 1 2 3 J3 S H U NT GND 12VDC 7 9 2 WELD(+) CABLE 003 1758 WELD(-) CW ( OPTIONAL ) BLK CCW P/N 003 1762 WHT W GRN VOLT 4&5 88.88 ( OPTIONAL ) METER 1K P/ZONE (-) (+) G F E D C B A 1 1 APPR. A B C DE F G (+) 3 CW 5K 1 (-) K M. K. PRODUCTS INC Document Number Thursday July 26 2001 Date: C . , N 071- 0390 Sheet 1 of C M 260 UNIVERSAL INPUT, WITH OPTIONS Size Title TIMER PCB, J2 RIBBON CABLE FROM COBRA 1 FRONT PANEL, J2, TO 6. WITHOUT GAS/TRIGGER HOLD KIT, PLUG 26 PIN TO (+) TERMINAL TO (-) TERMINAL AND WORK GROUND CLAMP 5. FOR DCSP, PLUG PIGTAIL POWER BLOCK TO (-) TERMINAL TO (+) TERMINAL AND WORK GROUND CLAMP 4. FOR DCRP, PLUG PIGTAIL POWER BLOCK JUMPER JP1 TO JP2 3. FOR POWER SUPPLY REMOTE VOLTAGE CONTROL, JUMPER JP1 TO JP3 2. FOR POWER SUPPLY PANEL VOLTAGE CONTROL, , 2 - Rev O TORCH TRIGGER TORCH POT TORCH MOTOR TORCH "W" CLK P/N 003-1642 MS "W" AMPHENOL CONNECTOR A B C DE F G J3 Bd P/N 003-2024 02/01 DATE J4 J2 COBRAMATIC I FRONT PANEL J1 PRN #3253 DESCRIPTION / DCN 1. INPUT SELECTOR: SEE CM260 UNIVERSAL INPUT WIRING NOTES Bd P/N 003-1324 KIT P/N 005-0585 POWER BLOCK P/N 003-2063 C6 .1u/1KV WELD VOLT (-) WELD VOLT (+) TO COBRA I J6-2 (ZONE C6) - + 2 AMP TO COBRA I J6-1 (ZONE C6) METER 1 2 3 4 5 6 7 8 J1 KIT P/N 005 0584 TO COBRA I J6-1 (ZONE C6) + J3 1 - REV REMOTE WELD VOLT WF(+) WF(-) (OPTIONAL) Bd P/N 003-2136 KIT P/N 005-0674 J4 SHUNT(-) 2 (+) C5 .1u/1KV P/N 002-0481 1 METER 1 2 3 4 5 J4 NORMAL/LATCH SW. 1 2 3 J1 GAS TRIGGER /HOLD J2 1 P/N #003-2137 REMOTE CABLE 003 1742 T.SWX. & TRIAC J6 POWER SUPP LY P/N 104-0081 ( 30000 uF, 50 VDC) X 4 + C1 THERMAL SW P/N 170-0003 C2 THERMAL SW. RED J5 P/N 003 1741 FOR 60 HZ UNITS P/N 003 1795 FOR 50 HZ UNITS F1 6 GAS SOLENOID CONT+ CABLE 003 1756 CONTGND 1 POWER SUPPLY CONTROL BOARD JP1 THERMAL SW. BRN PANEL JP2 WELD VOLTAGE JUMPER TO WELD VOLT (-) TO WELD VOLT (+) JP3 J2 Bd P/N 003-1755 KIT P/N 005-0586 ( OPTIONAL ) SPOT TIME BURN BACK & PULSE TRIAC (-) YEL 10 11 12 13 14 15 WELD VOLT (-) #18GA WELD VOLT (+) #18GA WIRE FORWARD (+) WIRE FORWARD (-) POWER INDICATOR LED (N) POWER INDICATOR LED (H) 1 TRIAC (+) ORN 1 BLK RED 4 TORCH MOTOR (-) TORCH MOTOR (+) TORCH TRIGGER 27V (RTN) TORCH TRIGGER 27V (SRC) TORCH POT CCW TORCH POT WIPER TORCH POT CW POSASTART (RETURN) POSASTART (SOURCE) TORQUE SWITCH (SOURCE), BLU MAIN SWITCH AC IN (H), YEL TORQUE SWITCH (RETURN), GRN MAIN SWITCH AC OUT (H), ORG MAIN SWITCH AC OUT (N), RED MAIN SWITCH AC IN (N), BRN P/N 003-1584 235V YEL 9 5 2 8 6 J6 1 1 CABLE P/N 003-1631 (TO POWER BLOCK) P/N 003-1243 WELDING CURRENT SENSOR LOGIC XFMR 208V 0V ORG BRN 235V 208V VIO GRY 0V GRN 2 115V H BLK #18 2 3 4 J2 J1 J3 1 2 3 115VAC RELAY K2 4A 2A 27VAC P/N 157-0022 F3 F1 P/N 003-1628 J5 HEAT SINK Q1 POWER TRIAC 75A / 600V P/N 125-0033 WHT #8GA #8GA WHT #18GA SW 1 40A / 600 V P/N 159-3590 AC NEU 3 P/N 003-1772 CABLE WHT #8GA AC HOT 1 1 TB2 INPUT SELECTOR P/N 186-0075 BLK CW CCW 1 2 COBRAMATIC I MAIN BOARD J14 115V N WHT #18 1 2 3 4 5 6 J8 1 2 J4 J7 1 2 3 4 5 6 123456789 #18GA 1 BLK P/N 003-1780 PILOT LA MP 27VAC IN (HOT) ORN P/N 003-0593 27VAC IN (COM) BRN TRANSFORMER RELAY W/ LEADS 115VAC (COM) WHT 115VAC (HOT) BLK 27VAC (HOT) BLU 27VAC (COM) YEL P/N 003-2096 BRAKE SOLENOID J4-2 115V (N) J4-1 115V (H) J6-1 TO COBRA I PCB (+) J7-6 115V (N) BLU J7-4 115V (N) WHT J7-3 WELD VOLT RED J7-2 115V (H) BLK J7-1 115V (H) RED POWER TERMINAL BLOCK P/N 186-0069 P/N 157-0149 120VAC RELAY K1 NO 7 P/N 003-2078 SLAVE MOTOR TO J14 (OPTIONAL) 1 2 3 W 1 2 3 4 JUMPER CABLE P/N 003-1307 1 2 3 4 5 CABINET POT KIT P/N 005-0167 1 2 1 2 3 4 5 6 7 8 2 1 2 1 2 3 4 1 3 1 2 3 4 5 6 7 8 G CobraMig 260 Owner's Manual - Page 51 P26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 J2 P10 1 2 3 4 5 6 7 8 9 10 J1 (N) (N) (H) (H) POWER INDICATOR LED (H) POWER INDICATOR LED (N) TORCH MOTOR (-) TORCH MOTOR (+) TORCH TRIGGER 27VAC (H) TORCH TRIGGER 27VAC (H) TORCH POT CCW TORCH POT WIPER TORCH POT CW POSA START POSA START 115VAC 115VAC 115VAC 115VAC TORQUE TORQUE 2.7K 1/2W R3 CW SW3 SW SPDT 5 2 R2 100K SW SPDT SW2 SW1B SW1A GREEN D1 6 3 4 1 8W R1 300 OHM FOR ALL OTHER FOR 0.030 - 0.035 J3 P8 1 2 3 4 5 6 7 8 J4 P8 1 2 3 4 5 6 7 8 A B C D E F G A B C D E F G A G F E D C B (+) R 5K POT (-) TORCH TRIGGER TORCH POT TORCH MOTOR TORCH "W" CLOCK DCN 12472 DCN 12582 B C 2/01 12/98 12/00 DCN 11559 DATE 01/98 DESCRIPTION/DCN # PRN 2886 P/ZONE A REV. REVISIONS DT DT DT CKT APPRV. CobraMig 260 Owner's Manual - Page 52 LIMITED WARRANTY Effective March 1, 2001 This warranty supersedes all previous MK Products warranties and is exclusive, with no other guarantees or warranties expressed or implied. LIMITED WARRANTY - MK Products,Inc.,Irvine,California warrants that all new and unused equipment furnished by MK Products is free from defect in workmanship and material as of the time and place of delivery by MK Products. No warranty is made by MK Products with respect to trade accessories or other items manufactured by others. Such trade accessories and other items are sold subject to the warranties of their respective manufacturers, if any. MK Products’ warranty does not apply to components having normal useful life of less than one (1) year, such as relay points, wire conduit, tungsten, and welding torch parts that come in contact with the welding wire, including nozzles, nozzle insulators, and contact tips where failure does not result from defect in workmanship or material. In the case of MK Products’ breach of warranty or any other duty with respect to the quality of any goods, the exclusive remedies therefore shall be at MK Products’ option: (1) repair; (2) replacement; (3) where authorized in writing by MK Products, the reasonable cost of repair or replacement at our Irvine, California plant; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Upon receipt of notice of apparent defect or failure, MK Products shall instruct the claimant on the warranty claim procedures to be followed. As a matter of general policy only, MK Products may honor an original user’s warranty claims on warranted equipment in the event of failure resulting from a defect within the following periods from the date of delivery of equipment to the original user: 1. Torches, Weldheads & Water Recirculators ..........1 year 2. All Other Equipment ...............................................3 years 3. Repairs .................................................................. 90 days MK Products, Inc. 16882 Armstrong Ave. Irvine, CA 92606 Tel (949)863-1234 Fax (949)474-1428 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. Normal surface transportation charges (both ways) for products returned for warranty repair or replacement will be borne by MK Products, except for products sold to foreign markets. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE, OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MK PRODUCTS, IS EXCLUDED AND DISCLAIMED BY MK PRODUCTS. EXCEPT AS EXPRESSLY PROVIDED BY MK PRODUCTS IN WRITING, MK PRODUCTS ARE INTENDED FOR ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS AND FOR OPERATION BY PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT AND NOT FOR CONSUMERS OR CONSUMER USE. MK PRODUCTS WARRANTIES DO NOT EXTEND TO, AND NO RE-SELLER IS AUTHORIZED TO EXTEND MK PRODUCTS’ WARRANTIES TO ANY CONSUMER. DATE : March 1, 2001 MK PRODUCTS, INC. 16882 ARMSTRONG AVE. IRVINE,CALIFORNIA 92606 (949) 863-1234 FAX (949) 474-1428
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
Related manuals
advertisement