flow chart - MK Products

flow chart - MK Products
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
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