MK Products Cobramatic Pro Series User manual

Cobramatic® Pro Series
Wire Feed Cabinet
Owner’s Manual
Product:
Cobramatic
®
Manual:
091-0756
Serial: 20010001
Voltage Rating:
24 VAC/42 VAC
115 VAC/230 VAC
Revision:
Jan 2020, Rev. A
Model Number:
150-008

Cobramatic
®
Pro Series Owner’s Manual
Safety Guidelines
Table of Contents
Installation ...............................................................................Section A
Technical Specifications.......................................................................................1
Machine Grounding..............................................................................................1
Machine Location.................................................................................................1
Input Power Connections.....................................................................................1
Wire Threading Procedure...................................................................................2
Welding Gun Connections ...................................................................................3
Operation................................................................................Section B
General Description .............................................................................................4
Recommended Processes and Equipment..........................................................4
Controls and Settings...........................................................................................5
POSA Start Operating Procedure.........................................................................6
Remote Operation................................................................................................7
Accessories............................................................................Section C
Optional Kits.........................................................................................................8
Maintenance...........................................................................Section D
Routine Maintenance...........................................................................................8
Testing the Feeder................................................................................................8
Testing the Gun....................................................................................................9
Troubleshooting......................................................................Section E
Troubleshooting Guide.......................................................................................10
Diagrams/Parts List................................................................. Section F
Main PC Boards.................................................................................................12
Mechanical.........................................................................................................15
Electrical ............................................................................................................26
Safety Warnings
Warranty

Cobramatic
®
Pro Series 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 and Standards:
Directives
Low Voltage Directive: 2006/95/EC
Electromagnetic Compatibility (EMC) Directive: 2004/108/EC
Standards
Electromagnetic Compatibility, (EMC): EN 60974-10: 2007
Torches And Guns For Arc Welding, EN 60974-7: 2005

Cobramatic
®
Pro Series Safety - Page iii
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 ruleswill
promote safe use of thisequipment.
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
ELECTRICARCWELDINGPRODUCES
H IGH IN TENSITY H EAT AN D
ULTRAVIOLET RADIANT ENERGY
WHICH MAY CAUSE SERIOUS AND
PERMANENT EYE DAMAGE AND
WHICHMAYDAMAGEANYEXPOSED
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)toprotecttheeyesfromradiant
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 beavailable foreach shift
unless medical facilities are close by for
immediatetreatmentofflashburnsofthe
eyes and skin burns.
Wear protective clothing - leather (or
asbestos) gauntlet gloves, hat, and high
safety-toe shoes. Button shirt collarand
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 ofCalifornia to cause cancer
and birth defects or other reproductive
harm.
Adequateventilation.Severediscomfort,
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
notbeheated unless coatingis removed
form the work surface, the area is well
ventilated, or the operator wears anair-
supplied respirator.
Work in a confined space only while it is
being ventilated and, if necessary, while
wearing an air-supplied 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
toxicgas,andotherlungandeyeirritating
products. The ultraviolet (radiant)
energy of the arc can also decompose
trichloroethylene andperchloroethylene
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 orperchloroethylene.
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.
BEAWARETHAT 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,
freeofoil,grease,and(inelectricalparts)
of metallic particles that can cause short
circuits.
Ifcombustiblesare inarea,doNOT weld
or cut. Move the work if practicable, to
anareafreeofcombustibles. Avoidpaint
spray rooms, dip tanks, storage areas,
ventilators. Iftheworkcannotbemoved,
movecombustiblesatleast35feetaway,
outofreachofsparksandheat;orprotect
against ignition with suitable and snug-
fitting, fire-resistant covers or shields.
Wallstouchingcombustiblesonopposite
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
than35feet,butcanbeignitedbysparks.
3. Openings (concealed or visible) in
floorsorwalls within35 feet may expose
combustibles to sparks.
4. Combustibles adjacent to walls,
ceilings, roofs, or metal partitions can
be ignited by radiant orconducted heat.
Hot work permit should be obtained
before operation to ensure supervisor’s
approval that adequate precautions
have been taken.
Afterworkisdone,checkthatareaisfree
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 industrystandards.
This includes: a thorough steam or
caustic cleaning (or a solvent of water
washing,dependingonthecombustible’s
solubility), followed by purging and
inerting with nitrogen or carbondioxide,
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.
Explosiveatmospheres. NEVERweldor
cut wherethe air may containflammable
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

Cobramatic
®
Pro Series Safety - Page iv
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
cylindervalve). Thefollowingsymptoms
indicate a faulty regulator:
Leaks - if gas leaks externally.
Excessive Creep - if delivery pressure
continues torise with downstreamvalve
closed.
Faulty Gauge - if gauge pointer does
notmove off stop pinwhenpressurized,
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
preventleaks anddamagetotheirwalls,
valves, or safety devices:
Avoid electrical circuit contact with
cylinders including third rails, electrical
wires, or welding circuits. They can
producedshortcircuitarcsthatmaylead
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,orothermarkingsonacylinder.
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,
usea securesupport suchas aplatform
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.)
Coolwith waterspraywheresuchexposure
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 yoursupplier.
Mixing gases. NEVER trytomixany 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 othersubstitute)
as a binding to connect hoses tofittings.
No copper tubing splices. Use only
standard brass fittings to splice hose.
Avoidlongruns topreventkinks and abuse.
Suspend hose off ground to keep it from
being run over, stepped on, or otherwise
damaged.
Coil excess hose to prevent kinks and
tangles.
Protecthosefrom damagebysharpedges,
and by sparks, slag, and open flame.
Examinehoseregularlyforleaks,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
Cleancylinder valveoutlet of impuritiesthat
may clog orifices and damage seats before
connecting regulator. Except forhydrogen,
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
wrenchestotightenadaptermarkedRIGHT
and LEFT HAND threads.
Regulator outlet (or hose) connections
may be identified by right hand threads for
oxygenand 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). Drainingprevents
excessive compression heat at high
pressure seat by allowing seat to open
on pressurization. Leave adjusting
screw engaged slightly on single-stage
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, opentoless 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.
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
fromserviceimmediatelyforrepair.Read
and follow user manual instructions.
F. Leaving Equipment Unattended
Close gas supply at source and drain
gas.
G. Rope Staging-Support
Rope staging-support should not be
used for welding or cutting operation;
rope may burn.
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; COMPLYWITH
PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing in addition to
gloves, hat, and shoes. As necessary,

Cobramatic
®
Pro Series Safety - Page v
use additional protective clothing such
as leather jacket or sleeves, flameproof
apron,andfire-resistantleggings. Avoid
outer garments of untreatedcotton.
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
Protecteyesfromexposuretoarc. Eyes
may be damaged by radiant energy
when exposed to the electric arc, even
when not looking in the direction of the
arc. Neverlookatanelectricarcwithout
protection.
Welding helmet or shield containing a
filter plate shade no. 12 or denser must
be used when welding. Place overface
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 withlow-
reflective, 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 in1-2B.
Generator engine exhaust must be
vented to the outside air. Carbon
monoxide can kill.
C. Fire and Explosion Prevention
Comply with precautions in1-2C.
Equipment’s rated capacity. Do not
overload arc welding equipment. Itmay
overheat cables and cause a fire.
Loose cable connections mayoverheat
or flash and cause afire.
Neverstrikeanarconacylinderorother
pressurevessel. Itcreatesabrittlearea
that can cause a violent rupture or lead to
such arupture later under rough handling.
D. Compressed Gas Equipment
Comply with precautions in1-2D.
E. Shock Prevention
Exposed electrically hot conductors or
otherbaremetalinthe welding circuit,orin
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 circulatorto
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
requirementofequipmentbeforeinstalling.
If only three-phase power is available,
connect single-phase equipment to only
two wires of the three-phase line. Do
NOT connect the equipment ground lead
to the third (live) wire, or the equipment
willbecomeelectricallyHOT- adangerous
condition that can shock, possiblyfatally.
Beforewelding,checkgroundforcontinuity.
Be sure conductors are touching bare
metalof equipmentframesatconnections.
Ifa 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
plugis addedfor connection toa grounded
matingreceptacle,thegroundleadmustbe
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
Frequently inspectcablesfor wear,cracks,
and damage. IMMEDIATELY REPLACE
those with excessively worn or damaged
insulation to avoid possibly lethal shock
frombaredcable. Cableswithdamaged
areas may be taped to give resistance
equivalent to original cable.
Keep cable dry, free of oil and grease,
and protected from hot metal and
sparks.
4. Terminals and Other Exposed
Parts
Terminals and other exposed parts of
electrical units should have insulating
covers secured before operation.
5. Electrode Wire
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 andother
HOT parts.
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 line-cord 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.
Leavingequipmentunattended. Always
shut OFF, and disconnect all power to
equipment.
Power disconnect switch must be
available near the welding power
source.

Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the
carrier. Consequently, claims for material damaged in shipment must be made by the
purchaser against the transportation company at the time the shipment is received.
Please record your equipment identification information below for future reference. This
information can be found on your machine nameplate.
Model Name & Number
Code & Serial Number
Date of Purchase
Whenever you request replacements parts for, or information on this equipment always
supply the information you have recorded above.
For selectinga quality product. We want you to take
pride in operating this product...as much pride as we
have in bringing the productto you!
Read this Owner’s Manual completely before attempting to use this equipment. Save this manual
and keep it handy for quick reference. Pay particular attention to the safety instructions we
have provided for your protection.
Cobramatic® Pro Series Owner’s Manual
ThankYou

Cobramatic
®
Pro Series Owner’s Manual - Page 1
Section A Installation
Technical Specifications
Wire Diameter Capacity................... .030 - 1/16”Aluminum
(0.8 mm - .063 mm)
.030” - .045” solid and hard wire
(0.8 mm - 1.2 mm)
Wire Spool Capacity 12” Standard
(Insulated or Non-Insulated)
Power Input ...................................... 230 / 115 / 42 / 24 VAC 50/60 Hz
........................................................... 150 Watts Peak
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.
Coolant Recommendations for Water Cooled Guns
Use Cobra Coolant (Aluminum Protection), P/N 931-0060. Cobra Coolant
does not contain reactive sulphur or chlorine and does not react with copper,
brass or aluminum.
The coolant flow rate should be a minimum of 15 GPH (1 qt/min) between 35
and 45psi. Contact the re-circulator manufacturer for specifications on pres-
sure.
Machine Grounding
The Cobramatic Pro Series is grounded with the power source through the
input power cable. The power source grounding terminal must be properly
connected to electrical ground per the power source operating manual.
Mounting 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.
Input Connections
Your Wire Feeder comes factory ready to connect into a 115 VAC.
The 24 VAC / 42 VAC / 115 VAC / 230 VAC is connected to the PC Board on
terminal strip J5 #1 (neutral) and #2 (hot) and Ground to the Cabinet chassis.
Brown Wire conected to 115VAC Brown Wire conected to 42 VAC
NOTE:
The Input Selector Wire must be at TB2-3 for 24 VAC, TB2-5 for 115 VAC,
TB2-4 for 42 VAC input, and at TB2-6 for 230 VAC.
Shielding Gas
In accordance with the required support equipment, the customer must pro-
vide a cylinder of shielding gas, a pressure regulator, a flow control valve,
and a hose from the flow control valve to the left bottom-most fitting on the
power block.

Cobramatic
®
Pro Series Owner’s Manual - Page 2
The end of the hose must have a male connector to fit the female 5/8-18
brass fitting. Use a 11/16” wrench to tighten.
Coolant Supply and Return for Water Cooled Guns
Using a recirculator with properly mixed coolant, as previously described,
connect the coolant RETURN hose to the left middle fitting on the power
block. Connect the coolant SUPPLY hose to the left top-most fitting on the
power block (See Cabinet and Gun Connections page 16).
The coolant hoses must have a male 5/8-18 left-hand thread to connect to
the power block fittings. Use an 11/16” wrench to tighten.
Welding Power
The electrode cable coming from the welding power supply should be affixed
with a 1/2” copper ring lug. Use a 9/16” wrench to tighten.
Cable from power supply MUST connect to bottom bolt of power block, with
crimp facing inward.
Reference Input Connections figure in the Appendix.
Wire Threading Procedure
Wire Spool Installation
Release latches, and open right side door of cabinet (Reference Cobramatic®
Pro Series Assembly drawing).
Remove spool retainer nut from spindle hub (Reference Cobramatic® Pro
Series Spindle Brake Assembly drawing).
Raise wire retainer bar to latched position (Reference Cobramatic® Pro
Series Assembly drawing).
Install wire spool onto spindle 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. The white dot on the end of the spindle will aid in this align-
ment.
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® Pro Series
front panel.
IN - All otherwires
Figure 1
OUT - .030/.035
Aluminum ONLY
Figure 2
Wire Spool Retainer In "Tool
Mode"; used to change
spindle drag.
Figure 3

Cobramatic
®
Pro Series Owner’s Manual - Page 3
To change this setting, it is easily done without the spool of wire on the spin-
dle. Remove the wire spool retainer nut 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 nut and turn in the
COUNTER-CLOCKWISE direction until it stops. The Knob is now set to the
OUT position (.030/.035 AL Only).
To reset the Knob back to the factory setting of all other wires, use the
retainer nut as described above, and turn in the CLOCKWISE direction until
it stops. The Spindle Knob is now set to the IN position. Turning the retainer
nut and Spindle 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.
Reinstall the spool retainer nut.
Lower the wire retainer bar onto the spool.
Wire 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 on the slave motor assembly of feeder to center posi-
tion.
Route wire into inlet guide, along drive roll groove, and into wire conduit.
Flip wire type lever to display name of wire type being used.
Proper tension is achieved when wire does not slip if a small amount of pres-
sure is added to the wire between thumb and forefinger as wire exits the tip.
Adjust gun idler arm tension screw as necessary.
Wire Retainer Bar
The design of the patented Cobramatic® Pro Series Wire Retainer Bar per-
forms 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 gun 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
surface of the wire retainer bar spread across the coiled wire on the spool.
The replaceable pad 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.
Welding Gun Connections
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 volt-
age, potentiometer control & trigger) to and from the feeder to the gun.
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.
Guns with ring lugs, MUST connect to top bolt of power block with crimp
facing inward.

Cobramatic
®
Pro Series Owner’s Manual - Page 4
Section B
Gas Inlet
Front panel access to attach gas hose to bottom fitting of power block.
Work Cable (Ground)
Connect a work lead of sufficient size and length between the proper output
stud on the power source and the work. Be sure the connection to the work
ground makes tight metal to metal electrical contact. Improper work lead
connections can result in poor arc initiation, and unsatisfactory weld results.
Consult welding power supply manufacturer for proper work lead size.
Operation
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 gun motor wants,
and when the gun motor gets all the wire it wants, the slave motor automati-
cally slows, preventing a bird’s nest. Because of the low torque produced
by the slave motor, a combination drag and electric brake system is used to
prevent wire overrun rather than relying on spindle tension alone. The spool
drag tension is produced by the patented Wire Retainer Bar mechanism to
keep the wire slightly taut. The 24 VDC gun “pull” motor is controlled by a
solid state speed control in the cabinet and through a potentiometer located
in the gun.
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. The blue Arc On LED (LED) illuminates as the arc is established. When
the trigger is released the normal LED operating sequence is blue, green and
red (L4, L3, & L2) turn off simultaneously followed by the yellow (L1) after the
postpurge time has elasped (Figure 4).
Green LED
when triggered.
L3
Yellow LED
when gas
solenoid opens.
L1
Red LED when
wire feeds/
contactor closes.
L2
Blue LED
when arcestablished
L4
Figure 4 - L1, L2, L3 & L4
For reference, see Main PC Board Connections picture in Section F
Recommended Processes and Equipment
The Cobramatic® Pro Series feeder is recommended for use with GMAW and
FCAW welding applications. It is recommended for use with constant voltage
power sources but will also work with CC machines. The Cobramatic® Pro
Series feeder is capable of feeding wires (diameter capacity) ranging from
.030” through .045” solid/cored and .030” through 1/16” aluminum.
Controls and Settings
On/Off Switch
Placing the switch in the “ON” position energizes the feeder circuitry and the
power indicator light.

Cobramatic
®
Pro Series Owner’s Manual - Page 5
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 1 1/2 lbs/inch of torque and approximately 4
1/2 lbs/inch when in the all other wires position.
NOTE:
Operating the cabinet with the switch in the wrong
position will cause wire feed difficulties.
PosaStart Switch & Run In Speed Setting
The Posa Start Run-in Speed Control, located on the front panel, provides
wire speed adjustment for slow wire run-in. This setting tracks as a percent-
age of the welding wire speed setting. Once the arc has been established,
the wire feed speed automatically changes from the slow run-in speed to the
welding wire speed set on the gun potentiometer.
PosaStart operation and configuration is explained later in this section.
Trigger Normal/Trigger Latched
This switch configures the electronic Trigger Latching mechanism. In the
Trigger “Normal” mode, pull and hold the trigger to start welding functions -
release trigger to stop welding functions. In the Trigger “Latched” mode pull
and release trigger, to start welding functions- pull trigger again and release,
to stop welding functions.
NOTE:
Most guns require Modified Gas Valve Assy (p/n 003-2199) for
Pre & Postpurge functions.
The Pre-Purge/Post-Purge 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) acrosspins.
Changing the position of the JP3 jumper changes the configuration of the pre
& postpurge sequences. Refer to Figure 5 for the desired pre and postpurge
sequence. Once the desired sequence is selected, relocate on JP3 jumper
from its horizontal default pattern (top right) to its new vertical sequence posi-
turn.
Figure 5
Pre-Purge Settings & Adjustments (JP2)
The Pre-Purge Jumper/Pot Configuration at JP2 has 3 available settings:
0.25 sec. fixed, variable from 0-1 sec. or variable from 0-5 seconds.
By default, the twin two-pin jumpers, across rows 1 & 3, are configured for
0.25 sec. Just to the left of the jumpers is a ¾-turn potentiometer (pot) which
is used with both variable settings. For the 0-1 sec. range, move the jumpers
across rows 3 & 5. For the 0-5 second range, move the jumpers across rows
5 & 7 (Figure 6a).
Timing adjustment for the variable settings are as follows: Move the jumpers
to either variable setting location. Turn potentiometer screw (Small flat or
cross-head) half way. Pull gun trigger and count time between red contactor

Cobramatic
®
Pro Series Owner’s Manual - Page 6
wire feed LED (L2) and yellow Gas Solenoid LED (L1). Adjust pot screw as
necessary.
Rows 1 & 3: 0.25 sec. fixed Rows 3 & 5: 0-1 sec. Rows 5 & 7: 0-5 sec.
Figure 6a
Post-Purge Settings & Adjustments (JP1)
The Post-Purge Jumper/Pot Configuration at JP1 has 2 available settings: 2
sec. fixed and variable from 0-5 seconds.
By default, the two-pin jumper across the top-and-middle pins, is configured
for 2 sec. Just to the left of the jumper is a ¾-turn pot which is used with the
variable setting. For the 0-5 second range, move the jumper from the top-
and-middle to the middle-and-bottom pins (Figure 6b).
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). Adjust as necessary.
Wire Inch
Wire Inch momentary switch causes wire feed at the weld feed rate indepen-
dent of Posa Start and may be used to observe or time the weld wire feed
rate without turning Posa Start off. The contactor is not activated during “Wire
Inch.”
Gas Purge
The Gas Purge momentary switch operates the gas solenoid in the cabinet.
Meter
The LED Meter provides a continuous reading of wire feed speed in inches
per minutes. While welding, the meter will display weld voltage.
NOTE:
The Work Ground Wire must be at Work Ground Table in order to dis-
play weld voltage.
Posa Start Operating Procedure
CAUTION:
Do not operate this wire feeder on a power source having a high-fre-
quency (HF) starting circuit until the high frequency feature has been
turned off or disabled. Failure to disable the HF will result in damage
to the PosaStart circuitry of the main board.
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

Cobramatic
®
Pro Series Owner’s Manual - Page 7
feed speed is automatically changed from the slow run-in speed to the weld-
ing speed set on the gun potentiometer.
The Posa Start feature allows the Cobramatic® Pro Series feeder and gun to
be used in conjunction 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.
Once the PosaStart circuit has transferred from slow run-in to weld speed,
the blue LED (L4) illuminates (Figure 7). Blue LED
when PosaStart engages.
L4
CV/CC Posa Start Operations
Figure 7
NOTE:
CV Posa Start does not need welding voltage sensing lead.
The default factory setting is CV mode. Attach Cobramatic® Pro Series cabi-
net to CV power source according to the installation instructions.
Turn the Cobramatic® Pro Series cabinet 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.
Turn the Posa Start switch to the “ON” position. Depress gun trigger and,
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 START WIRE SPEED NOTE:
Because the Posa Start Run-in Speed always remains apercentage
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.
Remote Operation: Input/Ouput
The terminal strip TB1(reference Appendix pages) allows for external input
signals for remote operation of the feeder as well as output signals for volt-
age and wire speed measurements, for a wide variety of automatic andsemi-
automatic applications. By making connections across specific points of
TB1, such functions as the trigger and motor speed control can be controlled
using an external source, such as a controller interface or a PLC (program-
mable logic controller).
Figure 8

Cobramatic
®
Pro Series Owner’s Manual - Page 8
Section C
Section D
Optional Kits
The following is a list of Optional Power Supply Interface Cable Kits available
for the Cobramatic® Pro Series Wire Feeder.
8ft Interface Cable for Miller 14-Pin, 24VAC ........................................005-0816
25ft Interface Cable for Miller 14-Pin, 24VAC......................................005-0817
8ft Interface Cable for Miller 14-Pin, 115VAC ......................................005-0316
25ft Interface Cable for Miller 14-Pin, 115VAC....................................005-0658
When properly connected, these interface cables will supply all the neces-
sary signals and power needed, from most Miller welding power supplies: a
Closing Contact signal and 115VAC input power.
8ft Interface Cable for Lincoln 14-Pin, 115VAC..................................005-0608
25ft Interface Cable for Lincoln 14-Pin, 115VAC ...............................005-0659
When properly connected, these interface cables will supply all the neces-
sary signals and power needed, from most Lincoln Electric welding power
supplies: a Closing Contact signal and 115VAC input power.
8ft Interface Cable for Thermal Arc 19-Pin, 115VAC.........................005-0630
When properly connected, these interface cables will supply all the neces-
sary signals and power needed, from most Thermal Arc welding power sup-
plies: a Closing Contact signal and 115VAC input power.
8ft Interface Cable for ESAB 19-Pin, 115VAC......................................005-0705
When properly connected, these interface cables will supply all the neces-
sary signals and power needed, from most ESAB welding power supplies: a
Closing Contact signal and 115VAC input power.
NOTE:
The Input Wire Selector must be at TB2-5 for 115VAC input.
Maintenance
Routine Maintenance
Your Cobramatic® Pro Series system is designed to provide years of reliable
service. Normal wear and component mortality may require occasional ser-
vice.
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.
If repairs do become necessary, any part can easily be replaced by qualified
shop maintenance personnel.
Maintenance of the gun 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® Pro Series system that are subject to
normal wear are the conduit, contact tips, gas cups, front body liners, wire
guides, drive and idler rolls (parts that contact the welding wire). A supply of
these parts should be maintained.
Testing the Feeder
Testing the Input Power Circuits
The AC circuits are protected by fuses F1 and F2 (see page 12 for location).
If these fail, especially when powering up the cabinet, remove the connectors
for the components that draw on this power, J6 (Brake Solenoid), J7 (Slave
Motor) and J5-3 & 4 (AC Contactor - if used) from the PC Board. Replace
fuses and retrigger system. If fuses do not fail, isolate the problem by plug-
ging in J4, J7, and J5-3,4 one at a time until the fuses fail.

Cobramatic
®
Pro Series Owner’s Manual - Page 9
Testing the Speed Control NOTE:
The gun should be tested prior to testing circuitry on the main board.
Gun amphenol must be connected to the Cobramatic® Pro Series cabi-
net to perform the following tests.
To test the motor voltage circuit and measure how much voltage is being
delivered to the gun motor, place a voltmeter across diode test points TP1
& TP2 and depress gun trigger. A reading between 0 - 30 VDC should be
observed, as the gun potentiometer is varied.
Motor Voltage
Test Point
TP1
Figure 9
Motor Voltage
Test Point
TP2
For reference, see Main PC Board Connections picture in Section F
Testing the Gun
Motor Check
Remove the connector from the cabinet.
Using the Amphenol connector, check the resistance across pins “A” and “B”
(motor leads).
If an open circuit (more than K ohms) or short (less than 2 ohms) exists, check
the motor leads and motor independently.
Testing the Potentiometer - “W” Clocked Amphenol Connector
Using the gun amphenol, check the resistance across pin “D” (wiper) and
pin “C”. The resistance should vary from 0 - 5K ohms as you turn pot..
Check the resistance across pin “D” (wiper) and pin “G”. The resistance
should vary from 5K - 0 ohms as you turn pot.
Testing the Micro Switch
Using the gun amphenol, check for continuity across pins “E” and “F” when
the trigger is pressed.

Cobramatic
®
Pro Series Owner’s Manual - Page 10
Section E Troubleshooting
Troubleshooting
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.
Micro-switch defective/not being acti-
vated. Broken electrical cable. Replace switch. Check switch for operation. Check micro switch wires
for continuity.
Loose board connectors. Check board connectors.
Brake solenoid inoperative. Solenoid defective. Replace solenoid.
Loose Brake Solenoid connector. Check Brake Solenoid connector.
No wire feed at gun, feeder operating
properly. Bad potentiometer. Check potentiometer with meter.
Bad gun motor.
Check/Replace motor.
Broken electrical cable.
Check motor and potentiometer wires
for continuity.
Bad speed control/PCB. Check/Replace PC board.
Wire feeds, but welding wire is not
energized.
Loose or no power supply cable con-
nections.
Check all power connections.
Contactor control cable loose or in
wrong position. Check power supply owner’s manual for location and type of contactor signal
required, i.e. closing contacts or AC.
Welding power source not working
correctly. Check power supply for proper operation.
Wire feeds erratically.
Dirty or worn conduit.
Blow out or replace conduit.
Incorrect pressure on drive rolls. Adjust pressure at gun (Gold or Prince)
Idler roll stuck in gun. 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 continu-
ity or shorts.
Bad speed control.
Check/Replace PC boards.
Wire walks out of drive rolls. Idler roll upside-down. Place groove in idler roll toward the
top.
Rear wire guide missing.
Replace wire guide.
Trigger inoperable or not operating
correctly.
Trigger mode configuration.
Check front panel Trigger Normal/
Latched toggle switch.
Purge not operating correctly. Jumper incorrectly configured. Gas
solenoid malfunctioning. Check jumper location per Jumper Table in Appendix. Check cable con-
nections to gas solenoid Check valve
in gun.
No PosaStart Wire Speed Transition
Welding power cable and/or gun power
cable connected to wrong bolt on
power block.
Welding power cable to bottom bolt.
Gun power cable to top bolt.
Welding current not being sensed.
Check current sensor in power block.
Remote Functions Not Working Wires not connected at TB1 Reseat all wire connections at TB1.

Cobramatic
®
Pro Series Owner’s Manual - Page 11
Section F Appendices
Diagrams/Parts List
Main PC Board Connections ............................................................12
Main PC Board: Jumper Functions...................................................13
Cabinet and Gun Connections..........................................................15
Cabinet Assembly ............................................................................16
003-2454 Control Module Assembly.................................................17
003-2078 Slave Motor Assembly......................................................18
003-2451 Power Block Assembly, MK Connection ...........................19
003-2455 Spindle Brake Assembly...................................................20
003-2452 Gas Solenoid Assembly, MK Connection..........................21
071-0413 Block Diagram..................................................................22
071-0400 Main PC Board.................................................................23
071-0412 Gun and Front Panel Connections....................................25
Input/Output Configuration for TB1...................................................26

Cobramatic
®
Pro Series Owner’s Manual - Page 12
Main PC Board Connections
JP5
Int/Ext.
JP1
Adj. Gas Post-Purge Jumper
P2
P1 Post-Purge Trim Pot
L4
Posa JP6
Torch Select
TB1
Remote
Input/Output L3
Pre-Purge Trim Pot JP2 Start “on” P3 Trigger “on”
JP3
Gas Purge Jumper
J2
Gas Solenoid
Adj. Gas Pre-Purge Jumper (blue) Digital Meter
Adjustment (green) J11
Front Panel
TP2
Test Point - MTR VDC
TP1
L1
Gas “on” (yellow)
J1
Trigger Normal/Latch
J10
Transformer
J8
Current Sensor
F3
Motor Fuse
J6
Test Point - GROUND
TP3
Motor Demand
L2
Contactor Signal
“on” (red)
J4
Front Panel
F2
Line Fuse
J7
Slave Motor
F1
Line Fuse
J9
Brake Solenoid
J5
Terminal Strip Terminal Strip
Work Ground
Closing Contacts Out
Closing Contacts Out
Chassis
Ground
(Green)
Opt. Contactor - 115 VAC Out - Hot - Black
Opt. Contactor - 115 VAC Out - Neutral - White
Input Power - 24/42/115/230 VAC - Hot - Black
Input Power - 24/42/115/230 VAC Neutral - White
Fuse P/N
F1, F2, & F3:151-0046