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SAFETY CONSIDERATIONSELECTRIC ARC WELDING EQUIPMENTCAUTION : READ BEFORE ATTEMPTING INSTALLATION, OPERATION ORMAINTENANCE OF THIS EQUIPMENT1-1 INTRODUCTIONThis equipment is intended for ultimate applicationby commercial/industrial users and foroperation by persons trained and experiencedin the use and maintenance of welding equipment.Operation should not be undertaken withoutadequate training in the use of such equipment.Training is available from many publicand private schools or similar facilities.Safe practices in the installation, operation andmaintenance of this equipment requires propertraining in the art, a careful study of the informationprovided with the equipment, and the useof common sense. Rules for safe use are generallyprovided by suppliers of welding powersources, compressed gas suppliers, and electrodesuppliers. Careful compliance with theserules will promote safe use of this equipment.The following Safety Rules cover some of themore generally found situations. READ THEMCAREFULLY. In case of any doubt, obtain qualified help before proceeding.1-2 GENERAL PRECAUTIONSA. Burn PreventionELECTRIC ARC WELDING PRODUCES HIGHINTENSITY HEAT AND ULTRAVIOLETRADIANT ENERGY WHICH MAY CAUSESERIOUS AND PERMANENT EYE DAMAGEAND WHICH MAY DAMAGE ANY EXPOSEDSKIN AREAS.Wear helmet with safety goggles or glasses withside shields underneath, appropriate fi lter lensesor plates (protected by clear cover glass). Thisis a must for welding or cutting (and chipping) toprotect the eyes from radiant energy and fl yingmetal. Replace cover glass when broken, pitted,or spattered.Medical fi rst aid and eye treatment. First aidfacilities and a qualifi ed fi rst aid person shouldbe available for each shift unless medical facilitiesare close by for immediate treatment of fl ashburns of the eyes and skin burns.Wear protective clothing - leather (or asbestos)gauntlet gloves, hat, and high safety-toe shoes.Button shirt collar and pocket fl aps, and wearcuffl ess trousers to avoid entry of sparks andslag.Avoid oily or greasy clothing. A spark may ignitethem.Flammable hair preparations should not be usedby persons intending to weld or cut.Hot metal such as electrode stubs and workpieces should never be handled without gloves.Ear plugs should be worn when working onoverhead or in a confi ned space. A hard hatshould be worn when others work overhead.B. Toxic Fume PreventionWARNING: The use of this product may resultin exposure to chemicals known to the State ofCalifornia to cause cancer and birth defects orother reproductive harm.Adequate ventilation. Severe discomfort, illnessor death can result from fumes, vapors, heat, oroxygen enrichment or depletion that welding (orcutting) may produce. Prevent them with adequateventilation. NEVER ventilate with oxygen.Lead-, cadmium-, zinc-, mercury-, beryllium-bearingand similar materials, when welded or cut,may produce harmful concentrations of toxic fumes.Adequate local exhaust ventilation must be used, oreach 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 emittoxic fumes should not be heated unless coatingis removed form the work surface, the area is wellventilated, or the operator wears an air-suppliedrespirator.Work in a confi ned space only while it is beingventilated and, if necessary, while wearing an airsuppliedrespirator.Gas leaks in a confi ned space should be avoided.Leaked gas in large quantities can change oxygenconcentration dangerously. Do not bring gas cylindersinto a confi ned space.Leaving confi ned space, shut OFF gas supply atsource to prevent possible accumulation of gases inthe space if downstream valves have been accidentallyopened or left open. Check to be sure that thespace is safe before reentering it.Vapors from chlorinated solvents can be decomposedby the heat of the arc (or fl ame) to formPHOSGENE, a highly toxic gas, and other lungand eye irritating products. The ultraviolet (radiant)energy of the arc can also decompose trichloroethyleneand perchloroethylene vapors to form phosgene.DO NOT WELD or cut where solvent vaporscan be drawn into the welding or cutting atmosphereor where the radiant energy can penetrateto atmospheres containing even minute amounts oftrichloroethylene or perchloroethylene.C. Fire and Explosion PreventionCauses of fi re and explosion are: combustiblesreached by the arc, fl ame, fl ying sparks, hot slag, orheated material, misuse of compressed gases andcylinders, and short circuits.BE AWARE THAT fl ying sparks or falling slag canpass through cracks, along pipes, through windowsor doors, and through wall or fl oor openings, outof sight of the goggled operator. Sparks can fl ymany feet.To prevent fi res and explosion:Keep equipment clean and operable, free of oil,grease, and (in electrical parts) of metallic particlesthat can cause short circuits.If combustibles are in area, do NOT weld or cut.Move the work if practicable, to an area free ofcombustibles. Avoid paint spray rooms, diptanks, storage areas, ventilators. If the workcannot be moved, move combustibles at least35 feet away, out of reach of sparks and heat; orprotect against ignition with suitable and snugfitting, fi re-resistant covers or shields.Walls touching combustibles on opposite sidesshould not be welded on (or cut). Walls, ceilings,and fl oor near work should be protected byheat-resistant covers or shields.Fire watcher must be standing by with suitablefi re extinguishing equipment during and forsome time after welding or cutting if:1. Appreciable combustibles (including buildingconstruction) are within 35 feet.2. Appreciable combustibles are further than 35feet, but can be ignited by sparks.3. Openings (concealed or visible) in fl oors orwalls within 35 feet may expose combustibles tosparks.4. Combustibles adjacent to walls, ceilings,roofs, or metal partitions can be ignited by radiantor conducted heat.Hot work permit should be obtained before operationto ensure supervisor’s approval that adequateprecautions have been taken.After work is done, check that area is free ofsparks, glowing embers, and fl ames.An empty container that held combustibles, orthat can produce fl ammable or toxic vaporswhen heated, must never be welded on or cut,unless container has fi rst been cleaned in accordancewith industry standards.This includes: a thorough steam or causticcleaning (or a solvent of water washing, dependingon the combustible’s solubility), followed bypurging and inerting with nitrogen or carbondioxide, and using protective equipment.Water-fi lling just below working level may substitutefor inerting.A container with unknown contents should becleaned (see paragraph above). Do NOTdepend on sense of smell or sight to determine ifit is safe to weld or cut.Hollow castings or containers must be ventedbefore welding or cutting. They can explode.Explosive atmospheres. NEVER weld or cutwhere the air may contain fl ammable dust, gas,or liquid vapors (such as gasoline).D. Compressed Gas EquipmentThe safe handling of compressed gas equipmentis detailed in numerous industry publications.The following general rules cover many ofthe most common situations.1. Pressure RegulatorsRegulator relief valve is designed to protectonly the regulator from overpressure; it is not
intended to protect any downstream equipment.Provide such protection with one or more reliefdevices.Never connect a regulator to a cylinder containinggas other than that for which the regulatorwas designed.Remove faulty regulator from service immediatelyfor repair (fi rst close cylinder valve). Thefollowing symptoms indicate a faulty regulator:Leaks - if gas leaks externally.Excessive Creep - if delivery pressure continuesto rise with downstream valve closed.Faulty Gauge - if gauge pointer does not moveoff stop pin when pressurized, nor returns tostop pin after pressure release.Repair. Do NOT attempt repair. Send faultyregulators for repair to manufacturer’s designatedrepair center, where special techniquesand tools are used by trained personnel.2. CylindersCylinders must be handled carefully to preventleaks and damage to their walls, valves, orsafety devices:Avoid electrical circuit contact with cylindersincluding third rails, electrical wires, or weldingcircuits. They can produced short circuit arcsthat may lead to a serious accident. (See 1-3C)ICC or DOT marking must be on each cylinder.It is an assurance of safety when the cylinder isproperly handled.Identifying gas content. Use only cylinders withname of gas marked on them; do not rely oncolor to identify gas content. Notify supplierif unmarked. NEVER DEFACE or alter name,number, or other markings on a cylinder. It isillegal and hazardous.Empties: Keep valves closed, replace capssecurely; mark MT; keep them separate fromFULLS, and return promptly.Prohibited use. Never use a cylinder or its contentsfor other than its intended use, NEVER asa support or roller.Locate or secure cylinders so they cannot beknocked over.Passageways and work areas. Keep cylindersclear of areas where they may be stuck.Transporting cylinders. With a crane, use asecure support such as a platform or cradle. DoNOT lift cylinders off the ground by their valvesor caps, or by chains, slings, or magnets.Do NOT expose cylinders to excessive heat,sparks, slag, and fl ame, etc. that may causerupture. Do not allow contents to exceed 55degrees C (130 degrees F.) Cool with waterspray where such exposure exists.Protect cylinders, particularly valves frombumps, falls, falling objects, and weather.Replace caps securely when moving cylinders.Stuck valve. Do NOT use a hammer or wrenchto open a cylinder valve that cannot be openedby hand. Notify your supplier.Mixing gases. NEVER try to mix any gases ina cylinder.NEVER refi ll any cylinder.Cylinder fi ttings should never be modifi ed orexchanged.3. HoseProhibited use. Never use hose other than thatdesigned for the specifi ed gas. A general hoseidentifi cation rule is: red for fuel gas, green foroxygen, and black for inert gases.Use ferrules or clamps designed for the hose (notordinary wire or other substitute) as a binding toconnect hoses to fi ttings.No copper tubing splices. Use only standard brassfi ttings to splice hose.Avoid long runs to prevent kinks and abuse.Suspend hose off ground to keep it from being runover, stepped on, or otherwise damaged.Coil excess hose to prevent kinks and tangles.Protect hose from damage by sharp edges, and bysparks, slag, and open fl ame.Examine hose regularly for leaks, wear, and looseconnections. Immerse pressured hose in water;bubbles indicate leaksRepair leaky or worn hose by cutting area out andsplicing. Do NOT use tape.4. Proper ConnectionsClean cylinder valve outlet of impurities thatmay clog orifi ces and damage seats before connectingregulator. Except for hydrogen, crack valvemomentarily, pointing outlet away from people andsources of ignition. Wipe with a clean, lintlesscloth.Match regulator to cylinder. Before connecting,check that the regulator label and cylinder markingagree, and that the regulator inlet and cylinderoutlet match. NEVER Connect a regulatordesigned for a particular gas or gases to a cylindercontaining any other gas.Tighten connections. When assembling threadedconnections, clean and smooth seats where necessary.Tighten. If connection leaks, disassemble,clean, and retighten, using properly fi tting wrench.Adapters. Use a CGA adapter (available from yoursupplier) between cylinder and regulator, if one isrequired. Use two wrenches to tighten adaptermarked RIGHT and LEFT HAND threads.Regulator outlet (or hose) connections may beidentifi ed by right hand threads for oxygen and lefthand threads (with grooved hex on nut or shank)for fuel gas.5. Pressurizing Steps:Drain regulator of residual gas through suitable ventbefore opening cylinder (or manifold valve) by turningadjusting screw in (clockwise). Draining preventsexcessive compression heat at high pressureseat by allowing seat to open on pressurization.Leave adjusting screw engaged slightly on singlestageregulators.Stand to side of regulator while opening cylindervalve.Open cylinder valve slowly so that regulator pressureincreases slowly. When gauge is pressurized(gauge reaches regulator maximum) leave cylindervalve in following position: for oxygen and inertgases, open fully to seal stem against possibleleak; for fuel gas, open to less than one turn topermit quick emergency shut-off.Use pressure <strong>chart</strong>s (available from your supplier)for safe and effi cient recommended pressure settingson regulators.Check for leaks on fi rst pressurization and regularlythereafter. Brush with soap solution.Bubbles indicate leaks. Clean off soapy waterafter test; dried soap is combustible.E. User ResponsibilitiesFollow all Safety Rules.Remove leaky or defective equipment from serviceimmediately for repair. Read and followuser manual instructions.F. Leaving Equipment UnattendedClose gas supply at source and drain gas.G. Rope Staging-SupportRope staging-support should not be used forwelding or cutting operation; rope may burn.1-3 ARC WELDINGComply with precautions in 1-1, 1-2, and thissection. Arc Welding, properly done, is a safeprocess, but a careless operator invites trouble.The equipment carries high currents at signifi -cant voltages. The arc is very bright and hot.Sparks fl y, fumes rise, ultraviolet and infraredenergy radiates, weldments are hot, and compressedgases may be used. The wise operatoravoids unnecessary risks and protects himselfand others from accidents.A. Burn ProtectionComply with precautions in 1-2.The welding arc is intense and visibly bright.Its radiation can damage eyes, penetrate lightweightclothing, refl ect from light-colored surfaces,and burn the skin and eyes. Skinburns resemble acute sunburn; those fromgas-shielded arcs are more severe andpainful. DON’T GET BURNED; COMPLY WITHPRECAUTIONS.1. Protective ClothingWear long-sleeve clothing in addition to gloves,hat, and shoes. As necessary, use additionalprotective clothing such as leather jacket orsleeves, fl ameproof apron, and fi re-resistant leggings.Avoid outer garments of untreated cotton.Bare skin protection. Wear dark, substantialclothing. Button collar to protect chest and neck,and button pockets to prevent entry of sparks.2. Eye and Head ProtectionProtect eyes from exposure to arc. Eyes maybe damaged by radiant energy when exposedto the electric arc, even when not looking in thedirection of the arc. Never look at an electric arcwithout protection.Welding helmet or shield containing a fi lter plateshade no. 12 or denser must be used whenwelding. Place over face before striking arc.Protect fi lter plate with a clear cover plate.Cracked or broken helmet or shield should NOTbe worn; radiation can be passed through tocause burns.Cracked, broken, or loose fi lter plates must bereplaced IMMEDIATELY. Replace clear coverplate when broken, pitted, or spattered.Flash goggles with side shields MUST be wornunder the helmet to give some protection to theeyes should the helmet not be lowered over theface before an arc is struck. Looking at an arc
Page 4: momentarily with unprotected eyes (
Page 7 and 8: Section AInstallationTechnical Spec
Page 9 and 10: Route input cable through strain re
Page 11 and 12: Coolant Connection (Water Cooled To
Page 13 and 14: WELD VOLTAGEThe weld voltage knob a
Page 15 and 16: PROCESS SETTINGSThe following table
Page 17 and 18: should bisect the 90 degree angle m
Page 23 and 24: Testing the FeederRelay K2 Operatio
Page 25 and 26: CobraMig 260 Owner's Manual - Page
Page 27 and 28: 2 FLOW CHART 2SYMPTOMF3 FUSE ON COB
Page 29 and 30: 4 FLOW CHART 4SYMPTOMCOBRA MAIN BOA
Page 31 and 32: 6 FLOW CHART 6SYMPTOMWIRE FEEDS AT
Page 33 and 34: 8 FLOW CHART 8SYMPTOMDISCONNECT FUS
Page 35 and 36: 10 FLOW CHART 10SYMPTOMNO WELD OUTP
Page 37 and 38: Section FAppendicesDiagrams/Parts L
Page 39 and 40: Multi-Tap CV 260001-3850No. Qty. P/
Page 41 and 42: Multi-Tap Bracket Assembly003-1586N
Page 43 and 44: Wire Feeder Assembly003-2131No. Qty
Page 45 and 46: Back Panel Assembly003-2130No. Qty.
Page 47 and 48: Heat Sink Assembly003-1774CNo. Qty.
Page 49 and 50: Control Panel Assembly003-1703No. Q
Page 51 and 52: 42 VAC Front Panel Assembly003-2110
Page 53 and 54:
Slave Motor Assembly003-2078No. Qty
Page 55 and 56:
CobraMig 260 Owner's Manual - Page
Page 57 and 58:
J1910P10J29101112131415161718192021
Page 61 and 62:
LIMITED WARRANTYEffective March 1,
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