Lincoln Electric Cobramatic K2259-1 Operator's Manual
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Lincoln Electric Cobramatic K2259-1 Operator's Manual

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IM775-A

WIRE FEEDER

MK 091-0612
October 2007
RETURN TO MAIN MENU
OPERATOR'S MANUAL
Cobramatic
®
K2259-1
For use with code 11480
Safety Depends on You
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 INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Copyright © 2007 Lincoln Global Inc.
®
World's Leader in Welding and Cutting Products
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric Cobramatic K2259-1

  • Page 1: Wire Feeder

    IM775-A WIRE FEEDER MK 091-0612 October 2007 RETURN TO MAIN MENU OPERATOR’S MANUAL Cobramatic ® K2259-1 For use with code 11480 Safety Depends on You 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.

  • Page 3: Table Of Contents

    Table of Contents Safety Guidelines ....................i-vi Installation ....................Section A Technical Specifications ....................... 1 Machine Grounding........................1 Mounting Location........................1 Input Power Connections ......................1 Wire Threading Procedure ......................1 Welding Gun Connections ......................3 Operations ....................Section B General Description ........................3 Recommended Processes and Equipment..................
  • Page 4 Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). MK Products, Inc. Manufacturer’s Name: 16882 Armstrong Ave. Irvine, CA 92606 ® Cobramatic Declares that the product: conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC...
  • Page 5 Cobramatic Safety - page i ®...
  • Page 6 Cobramatic Safety - page ii ®...
  • Page 7 Cobramatic Safety - page iii ®...
  • Page 8 Cobramatic Safety - page iv ®...
  • Page 9 Cobramatic Safety - page v ®...
  • Page 10 Cobramatic Safety - page vi ®...

  • Page 11: Installation

    Section A Installation Technical Specifications Wire Diameter Capacity ......030” - .045” Solid and Hard wire ...............030” - 1/16” Aluminum Wire Capacity ............12” Standard (Insulated or Non-Insulated) Power Input ............42 VAC 50/60 Hz, ................150 Watts Peak (3 amps) Weight ..............
  • Page 12 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.

  • Page 13: Welding Gun Connections

    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.

  • Page 14: Recommended Processes And Equipment

    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 Trigger LED (L3) and the yellow Gas Solenoid LED (L1) illuminate simultane- ously. The red Contactor/Wire Feed LED (L2) illuminates after the prepurge time.
  • Page 15 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 (top right) across pins. Changing the position of the JP3 jumper changes the configuration of the pre &...

  • Page 16: Posa Start Operating Procedure

    Middle/Bottom: 0-5 sec. Top/Middle: 2 sec fixed Figure 6b Timing adjustment for the variable settings are as follows: Move the jumpers to variable setting location. Turn potentiometer screw (Small flat or cross- head) half way. Upon release of gun trigger, count time between yellow Gas Solenoid LED (L1) and green Trigger LED (L3).

  • Page 17: Remote Operation

    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.

  • Page 18: Testing The Feeder

    Testing the Feeder Testing 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) and J5-3 &...

  • Page 19: Troubleshooting

    Section E Troubleshooting Troubleshooting Symptom Cause Remedy No wire feed at gun, feeder not oper- F1 & F2 fuse(s) in feeder failed. Check AC circuit. Replace fuse(s). ating, i.e., no slave motor or brake F3 (4 amp) fuse in feeder failed. Check motor leads for shorts then solenoid.
  • Page 20 THIS PAGE INTENTIONALLY BLANK Cobramatic Owner’s Manual ®...

  • Page 21: Diagrams/Parts List

    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 Front Panel Assembly ......17 ® 003-2068 Cobramatic Slave Motor Assembly......18 ® 003-2063 Cobramatic Power Block Assembly ......
  • Page 22 THIS PAGE INTENTIONALLY BLANK Cobramatic Owner’s Manual ®...

  • Page 23: Main P.c. Board Connections

    Main P.C. Board Connections Post-Purge Pre-Purge Trim Pot Trim Pot Lit: Weld Speed Motor (blue) Demand JP1 & JP2 Remote Input/Output Adj. Gas Purge Jumper Gas Purge Jumper Green (Trigger “on”) Gas Solenoid Test Point MTR VDC Test Point GROUND Gas “on”...

  • Page 24: Cabinet And Gun Hook-Up

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

  • Page 27: 003-2237 Cobramatic Front Panel Assembly

    003-2237 Front Panel Assembly Cobramatic Owner’s Manual - page 17 ®...

  • Page 28: 003-2068 Cobramatic Slave Motor Assembly

    003-2068 Slave Motor Assembly Cobramatic Owner’s Manual - page 18 ®...

  • Page 29: 003-2063 Cobramatic Power Block Assembly

    003-2063 Power Block Assembly Cobramatic Owner’s Manual - page 19 ®...

  • Page 30: 003-2146 Cobramatic Spindle Assembly

    003-2146 Spindle Assembly Cobramatic Owner’s Manual - page 20 ®...

  • Page 31: 003-2137 Gas Solenoid Assembly

    003-2137 Gas Solenoid Assembly Cobramatic Owner’s Manual - page 21 ®...

  • Page 32: 843-0496 Le Cobramatic Control Cable

    ® 843-0496 LE Cobramatic Control Cable Cobramatic Owner’s Manual - page 22 ®...

  • Page 33: Electrical

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

  • Page 34: 071-0400 Cobramatic Main Pc Board

    ® 071-0400 Cobramatic Main PC Board Cobramatic Owner’s Manual - page 24 ®...
  • Page 35 ® 071-0400 Cobramatic Main PC Board Cobramatic Owner’s Manual - page 25 ®...

  • Page 36: 071-0367 Cobramatic Gun Connections

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

  • Page 37: Input/Output Configuration For Tb1

    Input / Output Configuration for TB1 Monitor Wire Feed Speed Use digital volt meter between: TB1 – 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 MSPD VOLT METER Remote/External Trigger...
  • Page 38 Cobramatic Owner’s Manual - page 28 ®...
  • Page 39 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 –...
  • Page 40 Manual Gas Purge Jumper from TB1-7 to TB1-1 to externally operate the gas solenoid in the cabinet Cobramatic Owner’s Manual - page 30 ®...
  • Page 41 Cobramatic Owner’s Manual - page 31 ®...
  • Page 42 Copyright © 2002 Lincoln Global Inc. Cobramatic Owner’s Manual - page 32 ®...
  • Page 43 THIS PAGE INTENTIONALLY BLANK Cobramatic Owner’s Manual ®...

  • Page 44: Limited Warranty

    LIMITED WARRANTY Effective October 1, 2006 This warranty supersedes all previous MK Products warranties and is exclusive, with no other guarantees or warranties expressed or implied. Classification of any item into the foregoing categories shall be at LIMITED WARRANTY - MK Products Inc., Irvine, California the sole discretion of MK Products.

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