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Lincoln International K2259-1 manual

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Table of contents for the manual

  • Page 1

    WIRE FEEDER IM775-A MK 091-0612 October 2007 OPERA T OR’S MANUAL Cobramatic ® K2259-1 For use with code 11480 Safety Depends on Y ou Lincoln arc welding equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation...and thoughtful oper- ation on your part. DO NOT INST ALL, OPERA TE OR[...]

  • Page 2

    [...]

  • Page 3

    Cobramatic ® Owner’ s Manual T able of Contents Safety Guidelines ................................................................................................. i-vi Installation ................................................................................................. Section A T echnical Specifications ..............................[...]

  • Page 4

    Cobramatic ® Owner’ s Manual Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Manufacturer ’s Name: MK Products, Inc. 16882 Armstrong Ave. Irvine, CA 92606 Declares that the product: Cobramatic ® conforms to the following Directives an[...]

  • Page 5

    Cobramatic ® Safety - page i[...]

  • Page 6

    Cobramatic ® Safety - page ii                         ?[...]

  • Page 7

    Cobramatic ® Safety - page iii 2   "$ +" " )           '  ?[...]

  • Page 8

    Cobramatic ® Safety - page iv[...]

  • Page 9

    Cobramatic ® Safety - page v[...]

  • Page 10

    Cobramatic ® Safety - page vi     83 : 9/       :[...]

  • Page 11

    Cobramatic ® Owner’ s Manual - page 1 Section A Installation T echnical Specifications Wire Diameter Capacity ............................. .030” - .045” Solid and Hard wire ...................................................................... .030” - 1/16” Aluminum Wire Capacity ...................................................... 1[...]

  • Page 12

    Cobramatic ® Owner’ s Manual - page 2 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 wire 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 re[...]

  • Page 13

    Cobramatic ® Owner’ s Manual - page 3 sure 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 [...]

  • Page 14

    Cobramatic ® Owner’ s Manual - page 4 The normal operating sequence of the wire feeder can be viewed on the board itself via sequence LED’s. When the system is triggered, the green T rigger LED (L3) and the yellow Gas Solenoid LED (L1) illuminate simultane- ously . The red Contactor/Wire Feed LED (L2) illuminates after the prepurge time. The b[...]

  • Page 15

    Cobramatic ® Owner’ s Manual - page 5 release trigger to start welding functions - pull trigger again and release to stop welding functions. The Prepurge/Postpurge functions are pre-configured to provide a preset amount of pre & postpurge gas time; 0.25 and 2.0 second respectively . The default factory position of this jumper is horizontal [...]

  • Page 16

    Cobramatic ® Owner’ s Manual - page 6 T iming adjustment for the variable settings are as follows: Move the jumpers to variable setting location. T urn potentiometer screw (Small flat or cross- head) half way . Upon release of gun trigger , count time between yellow Gas Solenoid LED (L1) and green T rigger LED (L3). Adjust as necessary . Posa S[...]

  • Page 17

    Cobramatic ® Owner’ s Manual - page 7 using Run-in Speed Control, adjust wire feed rate to approximately 50% of welding wire speed set at gun. Initiate an arc, and adjust wire feed speed at gun until correct condition is achieved. At the moment when welding wire speed transition occurs, L4 will illuminate. POSA ST ART WIRE SPEED NOTE: Because th[...]

  • Page 18

    Cobramatic ® Owner’ s Manual - page 8 T esting the Feeder T esting the Input Power Circuits The AC circuits are protected by pico-fuses F1 and F2 (see page 13 for location). If these continually fail, especially when powering up the cabi- net, remove the connectors for the components that draw on this power , J6 (Brake Solenoid), J7 (Slave Motor[...]

  • Page 19

    Cobramatic ® Owner’ s Manual - page 9 Section E T roubleshooting T roubleshooting Symptom Cause Remedy No wire feed at gun, feeder not oper- ating, i.e., no slave motor or brake solenoid. F1 & F2 fuse(s) in feeder failed. Check AC circuit. Replace fuse(s). F3 (4 amp) fuse in feeder failed. Check motor leads for shorts then replace fuse. Micr[...]

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    Cobramatic ® Owner’ s Manual THIS P AGE INTENTIONALL Y BLANK[...]

  • Page 21

    Cobramatic ® Owner’ s Manual - page 11 Section F Appendices Diagrams/Parts List Main P .C. Board Connections................................................... 13 Cabinet and Gun Connections ................................................. 14 001-4022 Cobramatic ® Assembly ............................................. 15 003-2237 Cobramatic ®[...]

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    Cobramatic ® Owner’ s Manual THIS P AGE INTENTIONALL Y BLANK[...]

  • Page 23

    Cobramatic ® Owner’ s Manual - page 13 Main P .C. Board Connections J7 Slave Motor J10 T ransformer J8 Current Sensor J4 Front Panel J9 Brake Solenoid J5 T erminal Strip J6 T erminal Strip JP3 Gas Purge Jumper P1 Pre-Purge T rim Pot Control Cable LE P/N L10708-1 MK P/N 843-0496 Input Power - 42 V AC Hot-Black Input Power - 42 V AC Neutral-White [...]

  • Page 24

    Cobramatic ® Owner’ s Manual - page 14 Cabinet and Gun Connections Coolant Supply Coolant Return Shielding Gas Welding Power Gas Coolant Return Power/ Coolant In Gas Shielding Gas Power Cable Welding Power Input Gun Air Cooled Input Connections Gun Connections W ater Cooled[...]

  • Page 25

    Cobramatic ® Owner’ s Manual - page 15 Cobramatic 42 V Assembly 001-4022 No. Qty . Part No. Description 1 1 003-0784 Assy Pawl Cobramatic 2 1 003-2118 Assy PCB Main 42V 3 1 003-1723 Assy Xfmr 42V 4- - - 5 1 003-2146 Assy Spindle Cobramatic 6 1 003-2063 Assy Power Block 7 1 003-2068 Assy Slave Motor 42V LE 8 1 003-2095 Assy Sol Brk 42V T op 9 1 0[...]

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    Cobramatic ® Owner’ s Manual THIS P AGE INTENTIONAL Y BLANK[...]

  • Page 27

    Cobramatic ® Owner’ s Manual - page 17 Front Panel Assembly 003-2176 No. Qty . Part No. Description 1 1 003-1332 Assy Cable Ribbon 26C 2 1 003-1631 Cable Power Assy . 3 1 003-2001 PCB Front Panel 42V CB 4 1 301-0023 Gromment Panel Mount 5 1 341-0050 Nut 3/8-32 St. 6 2 345-0004 Nut Hex Lock 4-40 7 1 401-0012 Knob 1.0 Blk 8 1 436-0153 Silkscreen P[...]

  • Page 28

    Cobramatic ® Owner’ s Manual - page 18 Slave Motor Assembly 003-2068 No. Qty . Part No. Description 1 1 003-0176 Assy Knob Conduit 2 1 003-21 13 Assy T orque Mtor 42V 3 1 328-0024 Scr Shc B-32 x 3/B Stl 4 4 328-0259 Scr Shc B-32 x 1-1/B Stl 5 1 330-0258 Scr Shldr 1/4 x 1/4 x 10-24 6 1 333-0006 W asher Spring Lock #8 7 1 345-0018 Nut lock 5-16-18[...]

  • Page 29

    Cobramatic ® Owner’ s Manual - page 19 003-2063 Power Block Assembly A A A A B A A Apply pipe thread sealant Apply anti-corrosive compound T orque: 140 in-lb to 150 in-lb T orque: 92 in-lb to 108 in-lb A B Power Block Assembly 003-2063 No. Qty . Part No. Description 1 1 003-1243 Assy Sensor Posa-Start 2 1 313-0021 Stud Receiver Push-on 3 2 329-0[...]

  • Page 30

    Cobramatic ® Owner’ s Manual - page 20 Spindle Assembly 003-2146 No. Qty . Part No. Description 1 1 003-2139 Assy Bearing Spindle 2 3 330-3063 Scr Shldr Mod .25 x .63 10-24 3 3 331-0063 Wshr Flt .355 x .505 4 1 331-0095 Wshr Flt 1 1/32 x 3/4 sst 5 1 331-0313 Wshr Leather .75 ID x .125 Thk 6 1 345-0018 Nut Hex Lock 5/16-18 St 7 3 419-0059 Spg Com[...]

  • Page 31

    Cobramatic ® Owner’ s Manual - page 21 Gas Solenoid Assy 003-2137 No. Qty . Part No. Description 1 2 153-0853 Pin Crimp 2 1 153-0868 Conn single row 3P 3 2 185-0476 T erm slip-on female 4 1 405-0762 Label self-lam .8 x 1.4 5 1 552-0205 Assy gas connector 6 1 561-0017 Gas solenoid 24V 7 1 753-3285 Adptr FE 5/8-18 to M 1/8 NPT 8 2.50 FT 844-0089 C[...]

  • Page 32

    Cobramatic ® Owner’ s Manual - page 22               ! "     #        ?[...]

  • Page 33

    Cobramatic ® Owner’ s Manual - page 23 071-0402 Cobramatic ® Block Diagram[...]

  • Page 34

    Cobramatic ® Owner’ s Manual - page 24 071-0400 Cobramatic ® Main PC Board[...]

  • Page 35

    Cobramatic ® Owner’ s Manual - page 25 071-0400 Cobramatic ® Main PC Board[...]

  • Page 36

    Cobramatic ® Owner’ s Manual - page 26 071-0367 Cobramatic ® Gun Connections and Front Panel Schematic[...]

  • Page 37

    Cobramatic ® Owner’ s Manual - page 27 Monitor Wire Feed Speed Use digital volt meter between: TB 1 – 1(GND) and TB1 – 2(MSPD). Measured value defined as: Reading x 100 = Wire Feed Speed. Example: 3.54 VDC is equivalent to 354 IPM GN D MS P D TB 1 1 2 3 4 5 6 7 8 VOLT METER Remote/External Trigger Install jumper between: TB1 – 1(GND) and T[...]

  • Page 38

    Cobramatic ® Owner’ s Manual - page 28[...]

  • Page 39

    Cobramatic ® Owner’ s Manual - page 29 Torch Pot Output Some power supplies can utilize a variable DC voltage signal from the gun potentiometer adjustment as their external voltage control. Adjusting the potentiometer at the gun will give 0 to 10VDC output between TB1 – 1 (GND) and TB1 – 6 (POT). GN D PO T TB1 1 2 3 4 5 6 7 8 A common “syn[...]

  • Page 40

    Cobramatic ® Owner’ s Manual - page 30 Manual Gas Purge Jumper from TB1-7 to TB1-1 to externally operate the gas solenoid in the cabinet[...]

  • Page 41

    Cobramatic ® Owner’ s Manual - page 31[...]

  • Page 42

    Cobramatic ® Owner’ s Manual - page 32 Copyright © 2002 Lincoln Global Inc.[...]

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    Cobramatic ® Owner’ s Manual THIS P AGE INTENTIONALL Y BLANK[...]

  • Page 44

    Sales and Service through Subsidiaries and Distributors W orldwide Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www.lincolnelectric.com W orld’s Leader in W elding and Cutting Prodcuts   ® Copyright © 2007 Lincoln Global Inc. 16882 Armstrong Ave. Irvine, CA 92606 T[...]