MK Products CobraTig-150 Manual

CobraTig

150

Calibration Procedure

Document 031-0181 Rev

CAUTION

Performing

the

following

Tests and

Calibration

require the operator to

near HIGH VOLTAGES and HIGH CURRENTS. Operator must be

familia

with

working

in this

environment

and exercise caution during

this

procedure

to avoid any shock

hazards.

MK Products,

Inc.

16882 Armstrong Ave., Irvine, CA 92606 (949) 863-1234

1. EQUIPMENT NEEDED

o CobraTig 150 and Orbital Weldhead.

o Calibration Kit (p/n 005-0251)

o 30V / 5A DC External Power Supply and Banana Test Leads

o Digital MultiMeter (Fluke 8060A or Equivalent) and Test Leads

o Water Recirculator

o Small Plastic Flathead Screwdriver

o 1/4” Hex Wrench

o Glyptol Insulating Varnish

o Feeler Gauge

o Wire Brush

External DC Power Supply Digital Multi-Meter Glyptol

Calibration Kit ¼ Hex Wrench and Screw Driver

Please read this procedure in its entirety before

performing any work

2. EQUIPMENT SETUP

CobraTig150

Determine input power available and wire input power plug accordingly if not

already provided that way. See

Appendix

A for proper configuration of input

power and internal jumper selections.

Do not apply power to the CobraTig 150 until directed to do

so.

Calibration

Weld Box

Load

Adjust torch in load box for proper weld gap (.065~1/10 in) with feeler gauge and

ensure tungsten and plate surface are clean, use wire brush if necessary. Also

make sure the tungsten is 1/16

Do not connect load to CobraTig150 until directed to do

so.

3. COBRATIG-150

CALIBRA

TION

3.1

Current-Voltage-Demand

Offset

Adjustment

Before

starting Calibration,

print out the

current

Weldhead and Motor

Calibration

from

the

calibration

menu (Later this can be compared with your

new

calibration

ta.)

Meter (DMM) Setting

Scale: mV, Mode: DC

3.1.1 Using a ¼” hex wrench, remove all the screws from the cover of

the CobraTig150. Remove cover by pulling the sides slightly away

from the machine, and lifting upward. This is to ensure that the

louvers do not catch on any of the components or wires inside.

3.1.2 Locate the test points on the left side of the CobraTig150, on the

Power Supply Control Board (second board down from the top.)

Place the Meter GND(-) lead on TP1 and the Meter POS(+) lead

on TP3. (Figure 1)

Fig. 1 – TP3 Voltage adjustment

3.1.3 Apply input power to CobraTig150 and switch power on with

breaker on back of unit. Using the small plastic flathead

screwdriver, Adjust R24 (Current Offset) of the Power Supply

Control Board until a reading in the range of (-2 mV to +2mV) is

obtained on meter. (Figure 2)

Fig. 2 – Trimpot R24 is used to adjust voltage at TP3

NOTE If your CobraTig has only one Trimpot (instead of three, it is

an older model). The one

trimpot

is R24. After

completing

step 3.1.3, skip

ahead to step 3.1.9.

3.1.4 Leaving the Meter GND(-) lead on TP1, move the Meter POS(+) to

TP7. (Figure 3)

Fig. 3 – TP7 Voltage adjustment

R24

Location

3.1.5 Adjust R130 (Voltage offset) until a reading in the range of

(-2 mV to +2mV) is obtained on meter. (Figure 4)

Fig. 4 – Trimpot R130 is used to adjust voltage at TP7

3.1.6 Leaving the Meter GND(-) lead on TP1, move the Meter POS(+) to

TP8.(Figure 5)

Fig. 5 – TP8 Voltage adjustment

3.1.7 Adjust R139 (Demand Offset) until a reading in the range of

(-2 mV to +2mV) is obtained on meter. (Figure 6)

Fig. 6 – Trimpot R139 is used to adjust voltage at TP8

R130

Location

R139

Location

3.1.8 Re-Check all three test points (TP3, TP7, and TP8) to

verify that the settings are maintained. Make additional

adjustments if needed.

Notes:

R24 is used to adjust voltage at TP3

R130 is used to adjust voltage at TP7

R139 is used to adjust voltage at TP8

3.1.9 Remove all Meter leads from Test Points in CobraTig150. Use

Glyptol to seal the trimpot settings when done. (Figure 7)

Fig. 7 Use Glyptol to seal three (3) trimpot.

NOTE: Connect the

Calibration

Kit Weld Power & Gas Cables

and

Weldhead Control Cable to the back of the Cobratig150. (See

Appendix B)

(Figure 8)

Fig. 8 - Calibration Setup

3.2 Weldhead Motor

Calibration

The COBRATIG-150 Software allows push-button adjustments of the

COBRATIG-150 calibration parameters.

3.2.1 From the MAIN MENU, press the CALIB MENU [F7] key.

3.2.2 From the CALIBRATION MENU, Press the MOTOR CALIB

[F6]

key. The default settings are High=6 and Low=2. Leave these

speeds as they are for most cases.

3.2.3 Then press the START CALIB [F8] key. Verify visually that the

weldhead rotor is turning. The CobraTig150 motor compensation

circuit will automatically calibrate for that Weldhead connected.

NOTE: The Motor

Calibration

data is updated after two complete passes

the rotor,

aborting

at any time before this will cause the Weldhead to be

un-

calibrated.

3.3 Arc Voltage

Calibration

Connect the DC power supply to the Input Voltage connectors of the Calibration Kit

shunt box. (POS to RED+, NEG to BLACK-). Connect voltage meter DMM

(Digital Multi Meter) across supply leads to monitor voltage if your DC supply does

not have a digital display.(See

App

ndix

C / Figure 9)

Meter (DMM) Setting

Scale: Volts (V), Mode: DC

Fig. 9 – Voltage Calibration Setup

3.3.1 From the MAIN MENU, Press the CALIB MENU [F7] key.

3.3.2 Inject exactly 1.80VDC from the DC power supply with digital display

or inject 1.80VDC +/-1% or [1.782VDC to 1.818VDC] from DC power

supply without digital display. Then press the 1.8VDC CALIB [F3]

key to accept input.

3.3.3 Inject exactly 18.00 VDC from the DC power supply with digital

display or inject 18.00VDC +/-0.5% or [17.9VDC to 18.1VDC] from

DC power supply without digital display. Then press the 18VDC

CALIB [F4] key to accept input.

NOTE: Arc Voltage

Calibration

is updated only after

pressing

the 18VDC

CALIB [F4] key,

aborting

at any time before this will cause the Arc

Voltag

to be

un-c

librated.

3.4 Current

Calibration

CAUTION:

Disconnect

DC power supply and/or DMM from their

power

source until an Arc is

established.

3.4.1 Connect leads from the DMM (POS to RED+) (NEG to BLACK-)

to the Current Shunt of the Calibration Kit Shunt Box, make sure

meter is off until weld arc is started. Verify that the Calibration Kit is

connected to the CobraTig150 weld terminals. (See

Appendix

3.4.2 From the CALIBRATION MENU, press the CURRENT START

[F7] key to start the Current Calibration sequence. Once an Arc is

established, turn the DMM back on.

Meter (DMM) Setting - Scale: mV, Mode: DC

3.4.3 The current output should now be at approximate 10 Amps. Adjust

the output current as read across the Calibration Kit shunt with the

DMM by pressing ADJUST UP [F5] or ADJUST DOWN [F10]

keys until it is in the range of (2.50mV to 2.59mV). The voltage

reading should be as close to 2.59mV as possible without going

over. Then press the 10A CALIB [F8] key to accept when right.

3.4.4 The current output should now be at approximate 80 Amps. Adjust

the output current as read across the Calibration Kit shunt with the

DMM by pressing ADJUST UP [F5] or ADJUST DOWN [F10]

keys until it is in the range of 19.97mV to 20.034mV. Then press

the

80A

CALIB [F9]key to accept when right.

Repeat 3.4.3 ~ 3.4.4 for second time, unit should acknowledge completion.

NOTE: The Current

Calibration

is updated only after

pressing

the

80A

CALIB [F9]key the second time.

Aborting

at any time before this will

cause

the Weld Current to be

un-calibrated.

3.4.5 Press the MAIN MENU [F2] key. Press the PRINT MENU

[F6

]

key. Press CALIB REPORT [F9] key. Save the printout

for reference.

Disconnect all Test Equipment from CobraTig150, your MK Welder is now

calibrated and ready to weld.

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