Lincoln Electric Python-Plus User manual

IM875

MK 091-0564

September 2005

Rev A.

OPERATOR'S MANUAL

GMAW

Push-Pull Gun

OPERATOR’S MANUAL

Model number K2447-1, K2447-2, K2447-3

C

opyrig

h

l

n G

l

o

b

a

l

Inc.

World's Leader in Welding and Cutting Products

Sales and Service through Subsidiaries and Distibutors Worldwide

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Safety Depends on You

Lincoln arc welding equipment

is designed and built with safety

in mind. However, your over-

all safety can be increased by

proper installation...and thoughtful

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.

Python

-Plus

®

n

P

yt

h

on is a registere

d

tra

d

emar

k

o

f

MK Pro

d

ucts

This manual covers equipment which is no

longer in production by The Lincoln Electric Co.

Specications and availability of optional

features may have changed.

Py

tho

n

-Plus Owner's Manual Pa

g

e i

Py

tho

n

-

Plus Owner's Manual Pa

g

e i

i

P

y

thon-Plus Owner's Manual Pa

g

e iii

 

         

        

      

7HEN THIS EQUIPMENT IS SHIPPED TITLE PASSES TO THE PURCHASER UPON RECEIPT BY THE

CARRIER #ONSEQUENTLY CLAIMS FOR MATERIAL DAMAGED IN SHIPMENT MUST BE MADE BY THE

PURCHASER AGAINST THE TRANSPORTATION COMPANY AT THE TIME THE SHIPMENT IS RECEIVED

0LEASE RECORD YOUR EQUIPMENT IDENTIFICATION INFORMATION BELOW FOR FUTURE REFERENCE 4HIS

INFORMATION CAN BE FOUND ON YOUR MACHINE NAMEPLATE

-ODEL .AME  .UMBER ?????????????????????

#ODE  3ERIAL .UMBER ?????????????????????

$ATE OF 0URCHASE ?????????????????????

7HENEVER YOU REQUEST REPLACEMENTS

PARTS FOR OR INFORMATION ON THIS EQUIPMENT ALWAYS

SUPPLY THE INFORMATION YOU HAVE RECORDED ABOVE

0LEASE %XAMINE #ARTON AND %QUIPMENT &OR $AMAGE )MMEDIATELY

2EAD THIS /WNERS -ANUAL COMPLETELY BEFORE ATTEMPTING TO USE THIS EQUIPMENT 3AVE THIS MANUAL

AND KEEP IT HANDY FOR QUICK REFERENCE 0AY PARTICULAR ATTENTION TO THE SAFETY INSTRUCTIONS WE

HAVE PROVIDED FOR YOUR PROTECTION

Table of

C

ontents

S

afet

y

Considerations ..............................................................

.

.......

.

i

-

iii

I

nsta

ll

at

i

on

...............................................................

................

S

ection

A

T

echnical S

p

eciﬁ cations

...............................................................

......................

1

Su

pp

ort E

q

ui

p

ment Re

q

uired

...............................................................

..............

1

G

un Lead Connections

...............................................................

.......................

1

O

peration

...............................................................

..................

S

ection B

G

eneral

.

.............................................................

.

.............................................

.

2

C

ontrols and Settings

.

.............................................................

.

........................

.

2

T

rigger Adjustment ..............................................................

.

.............................

.

2

D

riv

e

R

o

ll

a

n

d

I

d

l

e

r R

o

ll

s

.

.............................................................

.

..................

.

2

Accesso

r

ies

...............................................................

..............

S

ection

C

O

ptional Kits

.

.............................................................

.

......................................

.

4

Snake Skins

.

.............................................................

.

......................................

.

4

C

ontact Tips

.

.............................................................

.

......................................

.

5

G

as

C

ups ..............................................................

.

...........................................

.

5

Ba

rr

els

.

.............................................................

.

...............................................

.

6

Ma

int

e

n

a

n

ce

...............................................................

.............

S

ection D

Pe

r

iodic

Mai

nt

e

n

a

n

ce

...............................................................

.........................

6

Recommended

S

pare Parts List

...............................................................

.........

7

T

roubleshooting

...............................................................

........

S

ection E

T

roubleshootin

g

G

uide

...............................................................

........................

9

T

estin

g

The

G

un

...............................................................

..................................

0

App

endices..............................................................

.

.............

.

S

ection F

D

ia

g

rams

/

Parts List

...............................................................

.........................

11

M

ec

h

an

i

ca

l

...............................................................

........................................

12

El

ectr

i

ca

l

...............................................................

............................................

16

M

K Re

p

air Stations

S

afet

y

Warnin

g

s

W

arrant

y

THIS PAGE INTENTIONALLY BLANK

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e

1

S

ection A

I

nsta

ll

at

i

o

n

Technical

Sp

eci

ﬁ

cation

s

Wire

C

apacit

y

.030" - .045"

(

0.6mm - 1.2mm

)

solid and hard wire

.030" - 1

/

16"

(

0.8mm - 1.6mm

)

aluminum and cored wire

Wire

S

pee

d

8

00 IPM

(

20.3 mpm

)

Max. at rated feeder Input Volta

g

e

(

120VAC / 42VAC

)

Duty Cycle - 100% (All ratings are using Argon Gas)

2

00 Amps

/

25 Volt

s

A

ir cooled standard

S

hippin

g

Wei

g

ht

(

approximate

)

- Air Cooled

15

f

t.

(

4.5m

)

.......................................

13

.

09

lbs.

(

5.94 Kg

)

25

f

t.

(

7.6m

)

.......................................

19

.

29

lbs.

(

8.29 K

g)

5

0ft.

(

15.2m

)

.....................................

2

9

.

9

lbs.

(

13.19 K

g)

T

orc

h

we

i

g

ht

(

less leads

)

A

ir

/

Water cooled - 2.5 lbs.

(

1.13 kilo

g

ram

)

S

u

pp

ort E

q

ui

p

ment Re

q

uire

d

•

C

.V. or C.C. Power Source of sufﬁ cient capacit

y

for

y

our needs.

•

R

egu

l

ate

d

gas supp

l

y an

d

h

oses.

•

P

roperly sized power leads

f

rom power source to wire

f

eeder and

g

round.

Gu

n L

ead

Co

nn

ect

i

o

n

s

P

o

w

e

r C

ab

l

e

A

#

2 AW

G

power cable is used on the Python-

Pl

us. The gun end o

f

the

cable has a

ﬁ

ttin

g

crimped to the copper cable strands. This

ﬁ

ttin

g

is

t

hen threaded into the

g

un bod

y

. The cabinet end of the power cable is

incor

p

orated into the Power

/G

as Ada

p

tor.

Co

n

du

i

t

Th

e

Py

t

h

on-

Plus

comes standard with a poly-lined conduit, for feeding

s

aluminum wire. The longer

ﬁ

tting with a shallow groove is used on the gun

end. A set screw located on top o

f

the

g

un handle secures the conduit in

p

lace. The cabinet end of the conduit is incor

p

orated into the Power/Gas

Ad

a

p

tor.

Gas

H

ose

T

he

g

as hose is pushed over a barbed ﬁ ttin

g

on the

g

un bod

y

and secured

with a plastic tie wrap. The cabinet end o

f

the gas hose is incorporated into

t

he Power

/G

as Adaptor.

El

ect

ri

c

C

ab

l

e

A

mu

l

t

i

-con

d

uctor contro

l

ca

bl

e

i

s use

d

on t

h

e

P

yt

h

on-

Pl

us. The gun end o

f

t

he cable is secured with a cable clamp and the wires are connected to the

potent

i

ometer, t

h

e m

i

cro sw

i

tc

h

, t

h

e motor an

d

t

h

e

g

un

b

o

dy

mec

h

an

i

ca

lly

.

S

lack is le

f

t in the electric cable as it exits the back o

f

the gun to prevent

cable and

/

or wire breaka

g

e. The cabinet end o

f

the control cable uses a

7-

Pi

n,

A

m

ph

eno

l

connector

.

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e

2

S

ection B

Op

eratio

n

G

eneral

T

he P

y

thon

g

un maintains a constant, stead

y

, uni

f

orm wire

f

eed speed,

re

g

ardless of curved or looped wire conduit. The constant push exerted b

y

t

he slave motor in the cabinet, combined with the pull o

f

the torch motor,

causes the wire to literall

y

ﬂ

oat

f

riction-

f

ree throu

g

h the wire conduit. The

24VDC torch motor is controlled b

y

a three and three-quarter

(

3 3/4

)

turn

potent

i

ometer

i

n t

h

e torc

h

an

dl

e.

C

ontrols and Settin

gs

Potentiomete

r

T

he laterall

y

-positioned potentiometer is located in the lower end of the

handle, providing up to 800 ipm with 3 3/4 turns.

M

icro

S

witc

h

T

he micro switch assembl

y

consists of the micro switch, and leads.

Trigger Sensitivity

T

he amount o

f

trigger level travel can

be shortened

f

or a "

q

uicker" or "more

res

p

ons

i

ve

"

act

i

on.

A

more sensitive trigger lever is produced

b

y

reducin

g

the

g

ap between the

t

r

i

gger

l

ever an

d

t

h

e m

i

cro-sw

i

tc

h

l

ever.

By turning-in the Trigger

S

ensitivity

A

d

j

ustment

S

crew, it closed the

g

ap

b

etween t

h

e tr

i

gger

l

ever an

d

t

h

e m

i

cro-

sw

i

tc

h

l

ever.

T

his well enable the o

p

erator to increase

t

he sensitivity of the trigger lever.

S

ensitivit

y

Ad

j

ustmen

t

With the wire feeder turned on (with or

without welding wire loaded

)

, turn the

sc

r

e

w in

u

ntil th

e

mi

c

r

o

-

s

wit

c

h i

s

ac

tiv

a

t

ed

.

Once activated, the gun and wire feeder

motors will begin

f

eeding wire. Retract

t

he screw accordin

g

l

y

until the s

y

stem is

d

eact

i

vate

d

an

d

a

dj

uste

d

to t

h

e operators

'

liki

ng.

D

r

i

ve

R

o

ll

an

d

Idl

er

R

o

lls

Ge

n

e

r

al

Th

e

Py

t

h

on

g

un comes stan

d

ar

d

w

i

t

h

a

k

nur

l

e

d

r

i

ve ro

ll

an

d

a

g

roove

d

idl

er

roll

,

which will handle both steel and aluminum wire with diameters

f

rom

.030-1

/

16 inch.

O

ptional insulated V-

g

roove drive rolls are also available

f

or

aluminum wire if desired

(

see Optional Kits

)

.

D

r

i

ve ro

ll

tens

i

on

i

s accomp

li

s

h

e

d

w

i

t

h

a un

i

que spr

i

ng-

l

oa

d

e

d

pressure

screw. The P

y

thon comes

f

rom the

f

actor

y

with the pressure ad

j

ustment

screw

p

reset.

N

O ADJUSTMENT IS RE

Q

UIRED FOR ALL SIZES

AND TYPE

S

O

F WIRE

S

.

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e

3

Driv

e

R

o

ll In

sta

ll

at

i

o

n/R

e

m

o

v

al

N

O

TE: N

e

i

t

h

e

r

of

t

h

e

h

a

n

d

l

es

n

eeds

to

be

r

e

m

o

v

ed

to

access

t

h

e

Driv

e

o

r I

d

l

e

r R

o

ll

s

.

1

.

P

ull the

C

am Lever away

f

rom

t

h

e

i

d

l

e

r r

o

ll. Thi

s

will r

e

li

e

v

e

th

e

pressure against the drive roll (as

shown in Figure 1

)

.

2.

Ali

gn t

h

e

D

r

i

ve

R

o

ll

R

emova

l

T

oo

l

(

P

/

N 931-0100

)

over the

ﬂ

ats o

f

the

d

rive roll

(

as shown in Fi

g

ure 2

)

.

Hold

t

he

t

o

r

ch

w

i

t

h

o

n

e

ha

n

d

o

r

o

n

a table top, with the other hand give

t

he Removal Tool a quick snap-turn

i

n t

he

CLOCKWISE DIRECTIO

N

.

3. Once the drive roll is loose, continue to s

p

in drive roll in the clockwise

d

irection to remove the drive roll

f

rom the torch.

4

. In

s

t

a

ll

a

n

e

w

d

riv

e

r

o

ll

o

n th

e

l

ef

t-h

a

n

d

thr

eaded

s

h

af

t. Th

e

d

riv

e

r

o

ll will

self-tighten when it is feeding wire.

Id

l

e

r R

o

ll In

sta

ll

at

i

o

n

a

n

d

R

e

m

o

v

al

(

Re

f

erence Fi

g

ure 3

)

1

.

U

s

i

ng a s

l

ot type screw

d

r

i

ver,

l

oosen

idl

er screw, ta

ki

ng care not to

l

ose

l

oc

k w

as

h

e

r

u

n

de

r i

d

l

e

r r

o

ll.

2.

I

nsert new

idl

er ro

ll

an

d

l

oc

k

was

h

er onto screw,

i

nsur

i

ng t

h

at

idl

er groove

i

s towar

d

top an

d

l

oc

k

was

h

er

i

s

b

eneat

h

.

3

.

T

ighten.

N

OTE: Lock washer must be under idler roll or it will not turn freel

y

.

C

am Lever

Figure

2

F

igure

1

F

igure

3

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e 4

S

ection

C

Accessories/

Op

tions

L

E P

/

N

M

K P

/N

In

su

l

a

t

ed

Driv

e

R

o

ll Kit

s

are used to prevent preheatin

g

of the wire which

may soften it and clog the liner. This picking up of current at the drive rolls

rather than at the contact tip is usually not a problem unless using too large

o

f a contact tip or excessivel

y

oxidized aluminum wire.

I

nsulated Groove Drive Roll Ki

t

..........................

K

P1594-030

......

005-0640

Fo

r

.

030

"

(

0.8mm

)

dia. aluminum wire. Includes insulated g

roo

v

e

drive roll

a

n

d

i

nsu

l

a

t

ed

idler roll ass

y

.

I

nsulated Groove Drive Roll Ki

t

..........................

K

P1594-035

......

005-0641

Fo

r

.

035

"

(

0.9mm

)

dia. aluminum wire. Includes insulated g

roo

v

e

drive roll

a

n

d

i

nsu

l

a

t

ed

idler roll ass

y

.

I

nsulated Groove Drive Roll Ki

t

..............................

n

/a

................

005-0642

Fo

r

.

0

4

0

"

(

1.0mm

)

dia. aluminum wire. Includes insulated g

roo

v

e

drive roll

a

n

d

i

nsu

l

a

t

ed

idler roll ass

y

.

I

nsulated Groove Drive Roll Ki

t

.........................

KP1594-3/64

......

005-0643

Fo

r

.

0

4

5

"

(

1.2mm

)

dia. aluminum wire. Includes insulated g

roo

v

e

drive roll

a

n

d

i

nsu

l

a

t

ed

idler roll ass

y

.

I

nsulated Groove Drive Roll Ki

t

.........................

K

P1594-1/16

.......

005-0644

Fo

r

.

062

"

(

1.6mm

)

dia. aluminum wire. Includes insulated g

roo

v

e

drive roll

and insulated idler roll ass

y

.

H

a

n

d

l

e

Ki

t

.........................................................................................

005

-

0699

I

n

cludes

left and ri

g

ht handles, screws and drive roll door.

Tri

gg

er Kit.........................................................................................

00

5-

0694

T

ri

gg

er ad

j

ustment kit includes a sprin

g

and sensitivit

y

ad

j

ustment screw

replacement for all Python

-Plus

guns.

s

M

i

c

r

o

S

wi

tc

h Ki

t

...............................................................................

005

-

0

7

01

R

eplacement micro switch assembl

y

for all P

y

thon

g

uns.

P

ote

n

t

i

o

m

ete

r Ki

t

.............................................................................

005

-

0695

R

eplacement potentiometer assembly for all Python guns.

S

nake

S

kin

s

®

S

nake

S

kin

®

protective covers are now standard on all guns. You may order

®

spare replacement covers to protect the lead assy of the torch when the

f

actory one becomes damaged or worn. It can easily be replaced in the

ﬁ

eld

b

y

means o

f

Velcro

©

.

Snake Skin Cover 13ft (for 15ft leads)

........................................

931-011

0

S

nake

S

kin

C

over 23

f

t

(f

or 25

f

t leads

)

.

.....................................

.

931

-

0122

Snake Skin Cover 48ft

(

for 50ft leads

)

.......................................

931

-

0123

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e 5

Contact Tip - 3/8" Diameter

LE P/N MK P/N Wire Size Tip ID Arc Tip Length

KP2217

-

1B1

621-0390

.

030"(0.8mm) .040"(1.0mm) Spra

y

1

.57"(39.9mm)

--

621-0396

.

030"(0.8mm) .040"(1.0mm) Short

1

-7/8"(47.6mm)

KP2217

-

2B1

621-0391

.

035"(0.9mm) .045"(1.1mm) Spra

y

1

.57"(39.9mm)

--

621-0397

.

035"(0.9mm) .045"(1.1mm) Short

1

.82"(46.2mm)

--

621-0392

.

047"(1.2mm)

.

054"(1.37mm) Spra

y

1

.57"(39.9mm)

--

621-0398

.

047"(1.2mm)

.

054"(1.37mm) Short

1

.82"(46.2mm)

KP2217

-

4B1

621-0393*

.

047"(1.2mm) .060"(1.5mm) Spra

y

1

.57"(39.9mm)

--

621-0399

.

045" or .052" .060"(1.5mm) Short

1

-7/8"(47.6mm)

K

P2217-5B1 621-0394

1

/16"(1.6mm) .074"(1.9mm) Spra

y

1

.57"(39.9mm)

--

621-0400

1

/16"(1.6mm) .074"(1.9mm) Short

1

-7/8"(47.6mm)

--

621-0395

1

/16"(1.6mm)

.

085"(2.16mm) Spra

y

1

-5/8"(41.3mm)

*

Standard - furnished with torch.

To Remove contact tip when using full water cooled gas cup

(

P/N 621-0065

)

, contact tip removal tool

(

P/N 931-0002

)

must

be

use

d

.

Contact Tip

s

Finned Copper Cup

s

Finned Copper Gas Cups

Cup Size Cup I.D. MK P/N LE P/N

No.

6

3/

8"

(

9.25mm

)

621

-

02

4

8

K

P

2213

-

1

No.

8

1/2" (12.7mm

)

6

21-0249

KP2214

-

1

No. 1

0*

5

/8"

(

15.8mm

)

6

21-

0

2

50

K

P221

5

-1

Heavy Duty Finned Copper Gas Cups

Cup Size Cup I.D. MK P/N LE P/N

No.

10

5

/

8"

(

15.8mm

)

621

-

0251

K

P

2216

-

1

No.

12

3

/

4"

(

19.0mm

)

621

-

02

5

2

--

*

Stan

d

ar

d

-

f

urnis

h

e

d

wit

h

torc

h

Torch Barrel Liners

Part Number Description

LE KP

22

44-

1

M

K

6

21-

0

424

Tip Extender (Air/Water cooled barrel only)

615

-

01

7

8

Bulk Te

ﬂ

on Liner

LE KP

2226

-

1

M

K

931

-

013

7

Li

ner

P

ac

k

age, 5 p

i

eces

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e

6

B

arre

l

A

ssem

bli

es

A

ll barrels are rated at 100% dut

y

c

y

cle

B

a

rr

e

l

s

Air Cooled

Th

e

P

yt

h

on

-Pl

u

s

guns come standard with a 60˚ curved barrel. The barrel

s

assembl

y

locks to the P

y

thon

®

body using the patented EZ Lock™ system.

®

B

a

rr

e

l R

e

m

o

v

a

l

a

n

d

In

sta

ll

at

i

on

T

o remove t

h

e

b

arre

l

assem

bl

y,

l

oosen t

h

e patente

d

EZ

L

oc

k™

T

aper

l

oc

k

nut until it is clear o

f

the threads. Pull barrel out o

f

the gun body.

T

o replace a barrel assembl

y

, open the drive and idler roll door and seat the

b

arre

l

assem

bl

y unt

il

t

h

e

i

n

l

et gu

id

e

i

s a

l

most touc

hi

ng t

h

e

d

r

i

ve an

d

idl

er ro

ll

and the rear

f

ace o

f

the barrel is

ﬂ

ush with the aluminum body block. Take

care not to dama

g

e the “O” rin

g

s when insertin

g

into the bod

y

. Ti

g

hten taper

lock nut assembly ﬁ rmly so that barrel cannot rotate.

B

arre

l

R

otat

i

o

n

T

o rotate a barrel assembl

y

, loosen the patented EZ Lock™ Taper lock nut

assembly no more than 1 turn. Rotate barrel to the position of your choice

and retighten taper lock nut assembly

ﬁ

rmly so that the barrel cannot rotate.

WARNIN

G

: Do not attempt to weld without the barrel bein

g

ti

g

htl

y

s

ecure

d

i

n t

h

e torc

h

b

o

d

y, or

d

amage to t

h

e

b

arre

l

or

b

o

d

y may resu

l

t

.

Section D Maintenance

P

e

ri

od

i

c

M

a

in

te

n

a

n

ce

Your

C

obramatic

®

System is designed to provide years of reliable

®

service.Maintenance of the torch will normally consist of a general cleaning

of

the wire guide system, including barrels, drive rolls, and conduits at regular

int

e

rv

a

l

s

.

R

emove s

p

atter build-u

p

from inside of nozzles with a hardwood stick.

T

he only parts on the

C

obramatic

®

system that are subject to normal wear

®

are the conduit, contact tips,

g

as cups, front bod

y

liners, wire

g

uides, drive

and idler rolls. A supply of these parts should be maintained on hand.

T

he number o

f

units in operation and the importance o

f

minimal

“

down time”

will determine to what extent s

p

are

p

arts should be stocked on hand. See

t

he “Recommended Spare Parts List” for the most commonly replaced parts.

I

f

repairs do become necessary, quali

ﬁ

ed shop maintenance personnel can

easil

y

replace an

y

part.

Maintenance Tools

Tool Part Number

D

riv

e

R

o

ll R

e

m

o

v

a

l T

oo

l

931

-

0100

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e 7

K

n

u

r

led

D

r

i

v

e

Roll

L

E P

/

N KP221

9

-1

M

K P

/

N

5

11-

0

1

0

1

Driv

e

R

o

ll R

e

m

o

v

a

l T

ool

93

1-

0

1

00

Micro

S

witch Assembl

y

005

-

0

7

0

1

I

d

l

e

r R

o

ll Ki

t

LE P/N KP2220-1

M

K P/N 005-0686

Recommended Spare Parts List

Qty. Part No. Description

1

L

E KP24

63

-1

M

K

6

1

5

-

0603

-1

5

C

onduit - 1

5

ft

1

L

E KP2463-2

M

K 615-0603-25

Conduit - 25 ft

1

L

E KP24

63

-

3

M

K

6

1

5

-

0603

-

50

Conduit - 50 ft

1

4

3

7-

02

5

3

D

r

i

ve

R

o

ll

D

oor

2

00

5-

069

4

T

r

i

gger

A

ssy.

Kit

2

00

5-

069

5

P

otent

i

ometer

A

ssy.

Kit

1

00

5-

0699

H

an

dl

e

Ki

t

2

00

5-

0

7

01

Micro-

S

witch Assy. Ki

t

10

L

E KP221

9

-1

M

K

5

11-

0

1

0

1

Driv

e

R

o

ll

5

L

E KP222

0

-1

MK

005

-

0686

I

d

l

e

r R

o

ll Kit

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e

8

Section E Troubleshooting

Trouble Cause Remedy

N

o wire

f

eed at

t

orch, feeder not

o

perat

i

ng,

i

.e. no

s

lave motor or brake

so

l

e

n

o

i

d

.

115

/

42 VA

C

ontrol

f

use in

feeder

/C

ontrol box blown.

R

e

p

lace fuse.

Micro-switch de

f

ective

/

not

bein

g

activated.

R

eplace switch.

C

heck

s

witch for o

p

eration.

Br

o

k

e

n

e

l

ec

tri

ca

l

cab

l

e

.

C

heck micro-switch

wires for continuit

y

.

N

o wire

f

eed at

t

orch, feeder

o

perat

i

ng proper

l

y.

24 VA

C

ontrol fuse in

feeder/Control box blown.

C

heck motor leads for

sh

orts; t

h

en re

pl

ace

f

use

.

B

a

d

p

otent

i

ometer

.

C

heck potentiometer

with meter.

Broken Electrical

C

able.

C

heck motor and

potentiometer wires for

c

ont

i

nu

i

ty.

Bad S

p

eed control/PCB

See s

p

eciﬁ c cabinet

/

c

ontro

l

b

ox owners

manual

f

or speed

c

ontro

l

o

p

erat

i

on.

Wire

f

eeds

,

but

weldin

g

wire is not

energ

i

ze

d

.

L

oose

o

r n

o

cab

l

e

co

nn

ec

t

io

n

s

.

C

heck all

p

ower

co

nn

ec

t

io

n

s

.

C

ontactor control cable

l

oose or

i

n wrong pos

i

t

i

on.

C

heck power suppl

y

o

wners manual for

location and type

o

f contactor si

g

nal

re

q

u

i

re

d

.

W

e

ldi

n

g

power source.

C

heck

p

ower source.

Wir

e

f

eeds

errat

i

ca

ll

y

.

D

irt

y

or worn conduit.

Blow out or re

p

lace

c

on

d

u

i

t.

W

ron

g

s

i

ze contact t

i

p. See Contact ti

p

table.

Idle

r r

oll

s

t

uck

.

C

heck for lock washer

un

d

er

idl

er ro

ll,

or

replace i

f

damaged.

Wir

e

feeds

o

n

e

s

pee

d

on

l

y

.

B

a

d

p

otent

i

ometer

.

C

heck with meter.

B

ro

k

en e

l

ectr

i

ca

l

ca

bl

e.

C

heck

p

otentiometer

wires

f

or continuity or

s

h

o

rt

.

Bad speed control.

S

ee speci

ﬁ

c cabinet

/

co

ntr

o

l

o

wn

e

r

s

m

a

n

ua

l

for s

p

eed control

o

peration.

Wire walks out o

f

d

rive rolls.

Idl

er ro

ll

u

p

s

id

e-

d

own.

Pl

ace groove

i

n

idl

er

roll toward top.

R

ear wire guide missing.

R

eplace wire guide.

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e

9

Troubleshootin

g

G

uid

e

R

e

g

ardless o

f

which torch or

f

eeder used, all MK Products’ push-pull

g

uns

op

erate on the same

p

rinci

p

le. The slave motor in the feeder runs at a fast,

constant speed, but has very low torque. It is always trying to

f

eed more wire

t

han the torch motor wants, and when the motor

g

ets all it wants, it slows the

slave motor, preventin

g

a bird’s nest. Because of the low torque produced b

y

th

e s

l

ave motor, a

b

ra

k

e system

i

s use

d

to prevent w

i

re overrun rat

h

er t

h

an

t

ension. The dra

g

ad

j

ustment in the

f

eeder is used simpl

y

to keep the wire

sli

g

htl

y

taut, so it will not pull off the spool while feedin

g

wire.

T

he high torque 24VD

C

torch motor is controlled by a solid state speed

control located in the feeder, and a

p

ot located in the torch. The torch motor,

p

otentiometer, and micro switch are connected to the cabinet/control box via

a control cable and Amphenol connector. I

f

this cable becomes dama

g

ed, a

variet

y

of s

y

mptoms can occur, dependin

g

on which wire

(

s

)

break. To test,

check each wire for continuity and shorts.

R

emember, the micro switch in the torch activates both the slave motor and

t

orch motor circuits in the cabinet. Therefore

,

if the slave motor and brake

solenoid operate, but the torch does not, look more toward the torch motor’s

24V circuits, speed control, control cable, or the torch motor. If nothin

g

op

erates, look more toward the slave motor

’

s in

p

ut, micro switch leads, or

micro switch.

Testing The

G

u

n

R

e

f

erence the "W" clocked torch wiring diagram on

t

h

e

P

yt

h

on

®

Electrical Diagram for information

®

a

b

out p

i

n-outs an

d

l

ocat

i

ons.

M

otor Chec

k

R

emove the torch connector

f

rom the cabinet.

U

sin

g

the torch Amphenol connector, check the resistance across pins

“

A”

an

d

“B

” (motor leads). The resistance across the motor should be between

5

-

10

o

hm

s

as the potentiometer is turned.

If an o

p

en circuit or short exist, check the motor leads and motor

i

n

d

epen

d

ent

l

y.

Testing the Potentiometer - “W”

C

locke

d

U

sin

g

the torch Amphenol connector, check the resistance across pin

“

D”

(

wiper) and pin “C

”

. The resistance should vary from

0

- 5K ohm

s

as t

h

e

potentiometer is turned.

C

heck the resistance across

p

in

“

D

”

(

wiper

)

and pin “

G”

. Th

e

r

es

i

s

t

a

n

ce

should vary from 5K - 0 ohms as t

h

e

p

otent

i

ometer

i

s turne

d

.

Testing the Micro

S

witc

h

U

sin

g

the torch Amphenol connector, check for continuit

y

across pins

“

E”

a

n

d

“

F

”

when the tri

gg

er is pressed.

THIS PAGE INTENTIONALLY BLANK

Py

thon-

P

lus

O

wner's Manual -

P

a

g

e

11

S

ection

F

App

en

di

ce

s

Diagrams / Parts List

P

y

thon-

P

l

us

Exploded View

s

...............................................................

...........

12

Py

t

h

on-

Plus

Bill of Material

s

...............................................................

............

1

3

P

yt

h

on

F

ront

B

o

d

y

A

ssem

bl

y

...............................................................

........

14

A/

W Barrel Assembl

y

...............................................................

......................

15

Py

t

h

on-

Plus

Electrical

s

...............................................................

....................

1

6

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