Lincoln Electric COBRAMATIC IM597 User manual

Cobramatic®
For use with Push-Pull Torches Model K1589, K1590, K1591, K1592
World's Leader in Welding and Cutting Products
IM597
MK 091-0414
November 1999
Rev i
OPERATOR'S MANUAL
WIRE FEEDER
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 thoughful operation
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.
Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distibutors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com
OPERATOR'S MANUAL

K1587-1 Cobramatic® Owner's Manual - Page 7
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K1587-1 Cobramatic® Owner's Manual - Page 8
Table of Contents
Section 1 SPECIFICATIONS ........................................................... 10
Section 2 SUPPORT EQUIPMENT REQUIRED ................................ 10
Section 3 COOLANT RECOMMENDATIONS .................................... 10
Section 4 OPTIONAL ACCESSORIES .............................................. 10
Section 5 INSTALLATION .............................................................. 10
5.1 Location ................................................................................................. 10
5.2 42 VAC Input Power Connections ............................................................. 11
5.3 Posa Start Connection ............................................................................. 11
Section 6 WIRE THREADING PROCEDURE .................................... 11
6.1 Wire Spool Installation ............................................................................ 11
6.2 Threading Procedure ............................................................................... 11
6.3 Pre-Setting Slave Motor Tension ............................................................... 12
Section 7 OPERATION ................................................................... 12
7.1 General .................................................................................................. 12
7.2 Feeder Controls ...................................................................................... 12
7.3 CV/CC Posa Start Operating Procedure .................................................... 13
Section 8 MAINTENANCE............................................................... 14
8.1 Testing the Torch .................................................................................... 14
8.2 Relay K2 Operation ................................................................................. 15
8.3 Testing the Input Power Circuits ............................................................... 15
8.4 Testing the Speed Control ........................................................................ 15
MAIN PC BOARD CONNECTIONS ................................... 16
TROUBLE SHOOTING ..................................................... 17
DRAWINGS .................................................................... 18
K1587-1 Wire Feed Cabinet - Exploded View ............................................. 18
003-2016 Front Panel - Exploded View ...................................................... 20
003-0570 Spindle Brake Assembly - Exploded View .................................... 21
003-1232 Slave Motor Assembly - Exploded View ...................................... 22
Wire Harness for Input Power from Power Source ...................................... 23
Main PC Board Parts Placement................................................................ 24
Front Panel Circuit Board ......................................................................... 26
SCHEMATICS.................................................................. 27
Wiring Schematic .................................................................................... 27
Torch Connections .................................................................................. 28
Block Diagram ........................................................................................ 29
WARRANTY REPAIR STATIONS ..................................... 30

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K1587-1 Cobramatic® Owner's Manual - Page 10
Section 1 SPECIFICATIONS
Wire Diameter Capacity .................................... .030 - 1/16" ALL Types
Wire Capacity .................................................... 12" Standard
(Insulated or Non-Insulated)
Power Input ....................................................... 42 VAC 50/60 Hz,
............................................................................ 150 Watts Peak (3 amps)
Weight ................................................................ 31 pounds
Shipping Weight ............................................... 36 pounds
For Use with these Lincoln Torches ............... K1589,K1590,K1591,K1592
Section 2 SUPPORT EQUIPMENT REQUIRED
C.V. or C.C. Power Source of Sufficient Capacity for Your Needs.
Regulated Gas Supply and Hoses.
Properly Sized Power Leads from Power Source to Wire Feeder and Ground.
Water Source and Hose Capable of Providing a Minimum of 1 qt/min. at 45
p.s.i. when using water cooled torches.
Section 3 COOLANT RECOMMENDATIONS
1. Use a name-brand additive which does not contain reactive sulphur or
chlorine and does not react with copper, brass, or aluminum.
2. Check coolant periodically to remain within limits of the following:
A. Coolant Flow rate - 1 quart/minute at 45 p.s.i.
B. Resistivity - 10K ohms/centimeter
C. Ph Range - 5.5-8.5
D. Particle Size - .005"
Section 4 OPTIONAL ACCESSORIES
Replacement Plastic Guides for Slave Motor
Lincoln MK Products
Inlet Guide S23980-1 753-0062
Outlet Guide with Knob S23980-2 003-0428
Section 5 INSTALLATION
5.1 LOCATION
The cabinet should be placed in a location where it can be protected from
damage. Lead lengths and accessibility must also be considered when
installing the cabinet.

K1587-1 Cobramatic® Owner's Manual - Page 11
5.2 42 VAC INPUT POWER CONNECTIONS
Your Wire Feeder comes factory ready with a harness to plug directly into all 14 pin
Lincoln Power Sources equipped with 42 VAC auxiliary.
The 42 VAC is connected to the PC Board on terminal strip J5 #1 (neutral) and #2
(hot) and Ground to the Cabinet chassis.
5.3 POSA START CONNECTIONS
Posa Start circuitry aids welding starts by sensing arc establish signals. A
weld ground signal is required for this to circuit to work, which is provided
through the Power Harness to the Power Source and is internally connected
to the P.C. board on terminal strip J6 terminal 2.
Note: Place polarity switch to DCEP. Refer to scetion 7.3 for
power supply settings to insure proper Posa Start operation.
WARNING: TURN THE INPUT POWER TO THE POWER SOURCE OFF
AT THE DISCONNECT SWITCH BEFORE PERFORMING ANY WORK.
Section 6 WIRE THREADING PROCEDURE
6.1 WIRE SPOOL INSTALLATION
Release latches, and open right side door of cabinet.
Remove spool retainer from spindle hub.
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.
6.2 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.
Release tension from slave motor drive rolls.
Route wire into inlet guide, along drive roll groove, and into wire conduit.
Prevent the wire spool from turning with the palm of the right hand, and at the
same time grasp the slave motor pressure adjusting knob.
Pull the torch trigger and slowly tighten the slave motor pressure adjusting
knob until the slave motor stalls.
CAUTION:
EXCESSIVE DRIVE ROLL TENSION WILL REDUCE RATHER
THAN IMPROVE WIRE FEED PERFORMANCE.

K1587-1 Cobramatic® Owner's Manual - Page 12
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.
6.3 PRE-SETTING SLAVE MOTOR TENSION
All Cobramatics have preset adjusting nuts which enables spools of the same
wire diameter and type to be changed without further pressure adjustment
after initial set-up.
To preset the slave motor tension bottom out the pressure adjusting knob by
turning it completely clockwise.
Prevent the wire spool from turning and using a 9/16" wrench adjust the
preset nut until the slave motor stalls.
Correct pressure will now be achieved by simply bottoming out the pressure
adjusting knob.
6.4 WIRE GUARD
The Cobramatic® Wire Guard is designed to keep the welding wire from
jumping off the spool inside the wire feed cabinet. When the trigger is
released and the brake engages, especially when using a new spool that is
heavier towards the outside, the spool will tend to rotate more against the
spindle drag adjustment.
However since the wire is held by the slave motor it will not move and could
subsequently jump off the back of the spool and become lodged in the brake
mechanism, or jump off the front of the spool and electrically short-out to the
cabinet chassis. The wire guard will keep the wire from doing either.
The wire guard is designed to run inside the spool on top of the wire, and
when the brake is engaged the wire guard will hold the wire onto the spool.
The wire guard is made of a heavy woven nylon material that is resistant to
wear and will not contaminate the surface of the wire.
Section 7 OPERATION
7.1 GENERAL
The AC slave motor in the feeder runs at a fast, constant speed, but has very
low torque. It is always trying to feed more wire than the torch motor wants,
and when the motor gets all it wants, it slows the slave motor preventing a
bird’s nest. Because of the low torque produced by the slave motor, a brake
system is used to prevent wire overrun rather than tension. The drag
adjustment in the spindle is used to keep the wire slightly taut, so it will not
unspool while feeding wire. The 24 VDC torch pull motor is controlled by a
solid state speed control and a potentiometer located in the torch.
7.2 FEEDER CONTROLS
7.2.1 ON/OFF SWITCH
Placing the switch in the “ON” position energizes the feeder circuitry and the
power indicator light.
7.2.2 WIRE SIZE SELECTOR SWITCH
The wire size selector switch changes the torque of the slave motor for the

K1587-1 Cobramatic® Owner's Manual - Page 13
wire you are using. When in the .030-.035 aluminum only position, the slave
motor produces approximately 1 1/2 lbs. inches and approximately 4 1/2 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.)
7.2.3 POSA START CONTROLS
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.
7.2.4 TORCH AMPHENOL CONNECTORS
The Cobramatic® contains a 7 pin “W” clocked amphenol.
7.2.5 CONDUIT INLET
The Conduit Inlet provides access to the slave motor outlet guide.
7.2.6 GAS INLET
Provides access to the gas fitting inside the cabinet.
7.2.7 POWER INLET
The Power Inlet provides access to the power block inside the cabinet.
7.3 CV/CC POSA START OPERATING PROCEDURE
7.3.1 GENERAL
The Posa Start feature allows the Cobramatic® to be used in combination
with constant current DC welding power sources of open circuit voltage in
excess of 55 volts - also, any constant voltage welding power source capable
of a minimum of 50 amps.
(NOTE: Reverse polarity MUST be used.)
CAUTION:
DO NOT OPERATE A COBRAMATIC® ON A POWER SOURCE HAVING A
HIGH-FREQUENCY STARTING CIRCUIT BEFORE MAKING SURE THAT THE
HIGH-FREQUENCY PORTION OF THE POWER SOURCE IS TURNED OFF.
FAILURE TO TAKE THIS PRECAUTION WILL CAUSE PERMANENT DAMAGE
TO THE POSA START CIRCUITRY.
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.
7.3.2 CV POSA START OPERATION
Attach Cobramatic® to CV power source according to the installation
instructions.
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
welding wire speed set at torch.
Strike an arc, and adjust wire feed rate at gun until correct condition is
achieved.

K1587-1 Cobramatic® Owner's Manual - Page 14
7.3.3 CC POSA START OPERATION
Attach the Cobramatic® to a CC power source according to the installation
instructions.
Insure power supply high frequency switch is in the “OFF” position, and
power supply is set to DC reverse polarity.
The power supply contactor should be set to “Remote” or “Tig” and the
amperage control set to “Panel” or “Standard” depending on power supply.
Turn the Cobramatic® power switch to the “ON” position and the Posa Start
switch to the “OFF” position.
Adjust power source to desired amperage for your weld condition.
Press gun trigger and adjust wire feed speed at gun to match current setting.
If approximate wire feed speed is not known, it is better to start with excess
wire feed rather than too little, in order to prevent possible damage to the
contact tip.
Turn Posa Start switch to the “ON” position. Press torch trigger and, using
Run-in Speed Control, adjust wire feed speed to approximately 10% of
welding wire speed set at torch.
Strike an arc; if the wire stubs out, reduce wire feed rate at gun, or increase
amperage setting on power source.
NOTE: Because the Posa Start Run-in Speed always remains a percentage of the
actual welding wire feed rate, the Posa Start run-in speed will always slow down or
speed up proportional to any adjustment you now make at the gun. Therefore, if you
slow down the welding wire feed speed, you will have to increase the Run-in Speed
setting.
Section 8 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.
If repairs do become necessary, any part can easily be replaced by a qualified
shop maintenance man.
Your Cobramatic® 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.
8.1 TESTING THE TORCH
8.1.1 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.

K1587-1 Cobramatic® Owner's Manual - Page 15
8.1.2 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.
8.1.3 TESTING THE MICRO SWITCH
Using the torch amphenol, check for continuity across pins “E” and “F” when
the trigger is pressed.
8.2 RELAY K2 OPERATION
When the torch trigger is pressed, 24VAC is sent to the coil of relay K2.
When K2 is energized, AC is sent to the slave motor, spool brake, and the AC
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.
8.3 TESTING THE INPUT POWER CIRCUITS
The AC circuits are protected by fuses F2 and F3. If F2 and F3 continually
blow, remove J4 (Brake Solenoid), J7 (slave motor) and J5-3,4 (AC
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.
8.4 TESTING THE SPEED CONTROL
NOTE: The torch should be tested first and the amphenol must be connected to the
Cobramatic® to perform this test.
Place a voltmeter across diode D10 and press torch trigger. A reading of 0 -
24VDC should be observed, as the torch potentiometer varied.
+_
24.024.0
24.024.0
24.0
VDC
D10

K1587-1 Cobramatic® Owner's Manual - Page 16
MAIN P.C. BOARD CONNECTIONS
J1
J8
TRANSFORMER
J7
SLAVE MOTOR
CURRENT SENSOR
(Posa Start)
Input Power - 42VAC
Input Power - 42VAC
Chasis Ground
Closing Contacts Out
Closing Contacts Out
Weld Connection Ref (-)
Not Used
J5J6
J13
Note: For Cabinet -
Remote Pot Kit, Remove
Jumper from J13-J14. Plug
Remote Pot Kit into J14.
J14
Control
Cable
LE P/N L10708-1
MK P/N 843-0496
1 12 2 33 4 4
J2
FRONT PANEL
J3
FRONT PANEL
BRAKE SOLENOID
J4

K1587-1 Cobramatic® Owner's Manual - Page 17
TROUBLESHOOTING
TROUBLE CAUSE REMEDY
No wire feed at torch, feeder
not operating, i.e., no slave
motor or brake soleniod.
F2 & F3 (MDA7 7A Slow Blow)
fuse in feeder blown.
Check AC circuit. Replace fuse
F1 (4 amp) fuse in feeder blown. Check motor leads for shorts, then
replace fuse
Micro-switch defective/not being
activated. Broken electrical cable.
Replace switch. Check switch for
operation. Check micro switch wires for
continuity.
Relay K2 inoperative. Check/Replace relay K2.
Loose J2, J3, P.C. board
connector
Check J2, J3 connectors.
Brake soleniod inoperative.
Soleniod defective. Replace soleniod.
Relay K2 inoperative. Check for 42VAC across J4-1 and J4-2
Check relay K2 for AC not present.
No wire feed at torch, feeder
operating properly.
Bad potentiometer. Check potentiometer with meter.
Bad torch motor. Check/Replace motor.
Broken electrical cable. Check motor and potentiometer wires
for continuity.
Bad speed control/PCB. Check/Replace P.C. Board.
Wire feeds, but welding wire
is not energized.
Loose or no cable connections. Check all power connections.
Relay K2 not sending contactor
signal.
Check/Replace relay K2.
Contactor control cable loose or in
wrong position.
Check power supply owners manual for
location and type of contactor signal
required, i.e. closing contacts or AC.
Welding power source not working
right.
Check power supply for proper
operation.
Wire feeds erratically.
Excessive spool drag pressure. Decrease spool drag pressure inside
hub.
Dirty or worn conduit. Blow out or replace conduit.
Incorrect pressure on drive rolls. Adjust pressure at both feeder and
torch.
Idler roll stuck. Check for lock washer under idler roll, or
replace if damaged or worn.
Wrong size contact tip. See contact tip table.
Wire feeds one speed only
Bad potentiometer. Check with meter.
Broken electrical cable in lead
assy.
Check potentiometer wires for continuity
or shorts.
Bad speed control. Check/Replace P.C. Board.
Wire walks out of drive rolls
Idler roll upside-down. Place groove in idler roll towards top.
Rear wire guide missing. Replace wire guide.

K1587-1 Cobramatic® Owner's Manual - Page 18
Exploded View - K1587-1 Wire Feed Cabinet

K1587-1 Cobramatic® Owner's Manual - Page 19
PARTS LIST - K1587-1 Wire Feed Cabinet
No. Qty. Part Number Description
1 1 436-0122 Base, Cabinet, Screened, Lincoln
2 1 438-0019 Cover, Front, PCB, Lincoln
3 14 336-0038 Screw, PH Fil T/B #6-32 x 3/8
4 4 301-0103 Rubber Feet
5 16 333-0043 Washer, Int-Star #6
6 4 336-0006 Screw, PH Fil #6-32 x 1/2
7 6 341-0005 Nut, Hex #6-32
8 2 329-0003 Screw, Hex1/4-20 x 3/4
9 2 332-0009 Washer, Shoulder 0.265 ID
10 1 261-0105 Insulator Power Block
11 1 003-1674 Power Block Assy.
12 1 261-0104 Insulator, Spool
13 2 336-0037 Screw, PH Fil T/B #6-32 x 1/4
14 2 329-0005 Screw, Hex 1/4-20 x 1.00 LG
15 1 261-0372 Insulator, Slave Motor
16 2 331-0005 Washer, Flat 1/4
17 2 333-0009 Washer, Spring Lock 1/4
18 2 341-0010 Nut, Hex 1/4-20
19 1 001-1232 Slave Mtor 42V Assy.
20 1 003-0570 Spindle Brake Assy.
21 1 328-0112 Screw, Socket HD 3/8-16 x 1.00 LG
22 1 003-0784 Pawl Ratchet Assy.
23 1 405-0886 Decal, Warning (T13297)
24 2 327-0012 Screw, ST T/F #6-32 x 1/4 LG
25 1 419-0080 Spring Extension
26 1 003-2095 Brake Solenoid, 42V Assy.
27 1 003-1723 Transformer, 42V Assy.
28 16 336-0005 Screw, PH, Fil, #6-32 x 3/8 LG
29 5 331-0002 Washer, Flat #6
30 4 345-0008 Nut, Self-Locking #6-32
31 1 405-0909 Decal, Electronic Connection
32 1 003-1721 PCB, Main Assy.
33 6 342-0410 Apcer, Stacking #6-32 x 0.534 LG
34 4 336-0039 Screw, PH. Fil. #10-32 x 3/8 LG
35 1 003-2016 Assy, Panel, Front, Lincoln
36 1 351-0752 Bushing Snap 1.12ID, 1.50 Dia Mtg. Hole
37 1 351-0744 Bushing Snap 1.00ID, 1.375 Dia Mtg. Hole
38 4 351-0745 Bushing Snap 15/16ID, 1.125 Dia Mtg. Hole
39 1 351-0082 Cap Plug 7/8 Dia Mtg. Hole
40 1 411-0157 Clamp Cable Strain Rel.
41 1 003-2015 Assy, Doors, Lincoln
42 1 415-0243 Handle Carry
43 4 329-0219 Screw, Hex #10-24 x 1/2 LG
44 4 331-0067 Washer, Flat #10
45 4 333-0007 Washer, Spring Lock #10
46 4 341-0007 Nut, Hex #10-24
47 1 L10708-1 Control Cable, Lincoln 42V
48 1 435-3121 Holder Capacitor
49 0.25ft 261-0446 Mylar Tape
50 4 351-0086 Thread Insert #6-32
51 1 405-0894 Serial Number ID Plate, Lincoln
52 4 351-0089 Thread Insert #10-32
53 2 331-0049 Washer, Flat 1/4
54 4 411-0020 Tie Wrap
55 1 003-1798 External Cap Assy
56 1 351-0758 Bushing, Snap. dia3/4, Black
57 1 301-0087 Wire Guard

K1587-1 Cobramatic® Owner's Manual - Page 20
Exploded View - MK P/N 003-2016 Front Panel