PROFAX PRO II User manual
7198
®
®JANUARY 2005 EFFECTIVE
WITH SERIAL NUMBER
PRO II A-1001
PRO IV A-5001
PRO
& PRO
OWNER’S MANUAL
IVIV
II
®
INDEX
P.O. BOX 898
PEARLAND, TX 77588-0898
(281) 485-6258
AVAILABLE THROUGH YOUR
WELDING SUPPLY DISTRIBUTOR
Copyright 2005 by PROFAX; Pearland, Texas
All Rights Reserved
No page or part of any page in this catalog may be reproduced in
any form without permission of copyright owner shown above.
®
®
SECTION 1 SAFETY
Safety Symbols and Words ........................................................................................... 1
Safety Precautions ........................................................................................................ 2 - 3
SECTION 2
Specifications & Warranty ............................................................................................. 4
SECTION 3 INSTALLATION
Connecting the Wire Feeder & Welding Gun .................................................................... 5
Control Panel ............................................................................................................... 6
Threading Welding Wire and Adjusting Tension .............................................................. 6
Spool Brake Adjustment ............................................................................................... 6
Optional 115/24 VAC Transformer Installation ............................................................... 7
TS1 Contactor Terminal Strip Operation ......................................................................... 7
SECTION 4 CHARTS & TABLES
Drive Roll Kit and Guide Chart ...................................................................................... 8
Welding Cable Selection Table ...................................................................................... 8
RC1 Pin Reference ....................................................................................................... 9
Interconnecting and Extension Cords ............................................................................ 9
SECTION 5
Maintenance ................................................................................................................ 10
Overload Protection ...................................................................................................... 10
SECTION 6
Troubleshooting .......................................................................................................... 11
Circuit Diagram ........................................................................................................... 12
SECTION 7
Parts List ........................................................................................................................ 13 - 17
FIGURE A PARTS LIST PRO II WIRE DRIVE 2 ROLL ASSEMBLY P/N 9004
ITEM PART NO. DESCRIPTION QTY.
1 9143 WIRE DRIVE HOUSING 1
2 9144 SCREW, guide retention, and motor mounting 5
3 9145 PRESSURE ARM 1
4 9134 AXLE, pressure roll 1
5 9136 GEAR, pressure roll 1
6 9052 PRESSURE ROLL, flat smooth 1
7 9053 PRESSURE ROLL, knurled ( optional ) 1
8 9135 CIRCLE CLIP, pressure roll axle 1
9 9146 PIVOT PIN, pressure arm 1
10 9147 SPACER 1
11 9148 SPRING, lift 1
12 9149 CIRCLE CLIP, pressure arm pivot pin 1
13 9150 TENSION AJUSTER 1
14 9151 RETAINING PIN, tension adjuster 1
15 9129 GEAR, drive 1
16 9130 SCREW, drive roll retention 2
17 9126 SCREW, drive gear retention 1
18 9128 KEY, motor shaft (Not Shown) 1
19 9152 SNAP RING, motor shaft (Not Shown) 1
FIGURE B PARTS LIST PRO IV WIRE DRIVE 4 ROLL ASSEMBLY P/N 9005
ITEM PART NO. DESCRIPTION QTY.
1 9153 WIRE DRIVE HOUSING 1
2 9154 SCREW, guide retention 3
3 9145 PRESSURE ARM 2
4 9155 PIVOT PIN, pressure arms 1
5 9149 CIRCLE CLIP, pressure arm pivot pin 4
6 9156 SPRING, lift 1
7 9147 SPACER 2
8 9134 AXLE, pressure roll 2
9 9135 CIRCLE CLIP, pressure roll axle 2
10 9136 GEAR, feed and pressure roll 4
11 9052 PRESSURE ROLL, flat smooth 2
12 9053 PRESSURE ROLL, knurled ( optional ) 2
13 9132 AXLE, drive roll 2
14 9133 WASHER, drive roll retention 2
15 9127 SCREW, gear retention 3
16 9150 TENSION ADJUSTER 2
17 9151 RETAINING PIN, tention adjuster 2
18 9131 INTERMEDIATE GUIDE (see Drive Roll, Kit and Guide Chart) 1
19 9137 GEAR, main drive 1
20 9128 KEY, motor shaft (Not Shown) 1
21 9152 SNAP RING, motor shaft (Not Shown) 1
22 9138 SCREW, motor mounting (Not Shown) 3
Parts List
®
17
®
Safety Section 1
®
1
ALERT - Read carefully - used with warning and caution words
WARNING - Serious injury or death can happen
CAUTION - Minor injury or equipment damage can happen
NOTE - Gives instructions for proper operation of equipment.
IMPORTANT - PROTECT YOURSELF AND OTHERS!
REMEMBER THAT SAFETY DEPENDS ON YOU.
The operator, supervisor, and helper must read and understand all warning and safety information provided in these
instructions. Serious injury or death could result if welding and cutting equipment is not properly installed, used, and
maintained. Training and proper supervision are most important for a safe work place. Installation, operation, repair work, and
maintenance must be performed by qualified personnel. Retain these instructions for future use. Additional recommended safety
and operating information is referenced in each section.
ELECTRICAL SHOCK CAN CAUSE INJURY OR DEATH
Electrical equipment must be installed and maintained in accordance with the National Electrical Code, NFPA 70, and all local codes. Maintain Mig-
Guns, Electrode Holders, Tig Torches, Plasma Torches, Work Clamp, Welding Cable, and Welding Machines in good, safe operating condition. Replace
worn or damaged insulation. Do not try to repair or service equipment while the power is still on. Do not service or repair equipment unless you are
trained and qualified to do so. The Electrode and Work (or Ground) circuits are electrically “HOT” when equipment power is on. At no time should you touch the
Electrode and Electrical Ground at the same time with bare skin or wet clothing while the power is on. Insulate yourself from work and ground using dry insulation.
When welding in damp locations make certain the insulation is large enough to cover your full area of physical contact with work and ground. Ground the work (metal
to be welded) to a good electrical earth ground. Keep gas cylinders, chains, wire ropes, hoists, cranes, and elevators away from any part of the electrical path.
Always be sure the work cable makes a good electrical connection with the metal being welded. Occasionally check all ground connections to determine if they are
mechanically strong and electrically adequate for the current required. The ground connection should be as close as possible to the area being welded. Never touch
electrically “HOT” parts of electrode holders connected to two welding power sources at the same time. The voltage between the two can be the total of the open
circuit voltage of both power sources. When the welding or cutting process requires values of open circuit voltages in alternating current machines higher than 80
volts, and direct current machines higher than 100 volts, adequate insulation or other means must be provided to prevent the operator from making accidental contact
with the high voltage. The use of reliable automatic controls for reducing no load voltage is recommended to reduce shock hazard. When not welding for any
substantial period of time, make certain that no par t of the electrode circuit will accidentally make contact with the work or ground. Never immerse Mig-Guns,
Electrode Holders, Tig Torches, Plasma Torches, or Electrodes in water for cooling.
REFERENCES: See Safety and Operating References A,F,H, and I.
Electrical shock
can kill
Smoke, fumes,
and gases
Arc rays, molten
materials, and sparks
Welding can
cause fires
Moving parts
can main
Falling equipment
can injure
Electromagnetic
fields
Cylinders can
explode
Hot parts can burn
Flying debris can
injure eyes
Welding wire can
puncture skin
® ®
®
Safety
®
32
Safety
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Keep smoke, fumes, and gases from your breathing zone and the general area. Smoke, fumes, and gases from the welding or cutting process are of
various types and strengths, depending on the kind of base metal being welded on. To ensure your safety, do not breathe these fumes or gases.
Ventilation must be adequate to remove smoke, fumes, and gases during the welding procedure to protect operators and others in the immediate area.
Do not weld in locations where chlorinated hydrocarbon vapors are coming from degreasing, cleaning, or spraying operations. Vapors of chlorinated solvents can form
the toxic gas “phosgene” when exposed to ultraviolet radiation from an electric arc. All solvents, degreasers, and potential sources of these vapors must be removed
from the welding area. Shielding gases used for arc welding can displace air and cause injury or death. Fumes produced by welding or cutting, especially in confined
areas, can cause discomfort and physical harm if inhaled over an extended period of time.
Always provide adequate ventilation in the welding and cutting area to insure breathing air is safe. Use air-supplied respirators if ventilation is not adequate to remove
all fumes and gases. Never Ventilate with Oxygen, because oxygen supports and vigorously accelerates fire.
REFERENCES: See Safety and Operating References A,B,C,H, and I.
ARC RAYS, MOLTEN MATERIAL, AND SPARKS CAN CAUSE EYE AND SKIN INJURY
Always wear approved eye, ear, and body protection. Remove any and all combustible material from the work area. Never attempt to weld or cut
without a proper head shield, and lens, that conforms to federal guidelines. A number 12 to 14 shade filter lens provides the best protection from arc
radiation. A cover plate protects your eyes from sparks. Protect other nearby personnel from arc rays and sparks. Use approved shielding curtains and
appropriate goggles. Warn them not to watch the arc or expose themselves to arc rays, sparks, or molten material.
Always wear protective clothing and gloves which will not allow skin to become exposed to arc rays, heat, or molten material. Wear ear plugs to protect ears from
sparks. Flammable hair preparations should not be used when welding or cutting. If possible, welding should be done in a booth that has been painted with an
ultraviolet absorbing material such as zinc oxide and a low reflective finish such as lamp black, or shall be enclosed by similarly painted and noncombustible screens.
REFERENCES: See Safety and Operating References A,B,H, and I.
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS
Remove any and all combustible materials from the work area. If this is not possible, cover them to prevent the welding sparks from starting a fire.
Fires & explosions are caused by any combustibles reached by the arc, flame, flying sparks, hot slag, or heated materials. Do not wear any gloves or
clothing that has oil or a fuel type material on it. Always have a properly working and OSHA approved Fire Extinguisher near and be sure everyone has
proper training in its use.
Do not weld, heat, or cut drums or containers that have held combustibles. All hollow spaces, cavities, and containers should be vented prior to cutting, welding, or
heating for they may explode. Make sure proper steps have been taken to insure that venting procedures will not form flammable or toxic vapors from substances
inside containers. Purging with inert gas is recommended. Use only iner t gases or inert gas mixes as required by the process.
Special precautions should be used to prevent hazardous situations when using compressed gas. Use of combustible compressed gases can cause
explosions resulting in personal injury or death. Never Use Oxygen for Cleaning or Purging. Arcing against any compressed gas cylinder can cause cylinder damage
or explosion. Read and follow the instructions on compressed gas cylinders, Associated Equipment, and CEA Publication P-1, “Precautions for safe handling of
compressed gases in Cylinders” available from the Compressed Gas Association, 1235 Jefferson Davis Hwy, Arlington, Va. 22202.
REFERENCES: See Safety and Operating References A,D,E,F,G, and H.
FALLING EQUIPMENT
Lift only the unit to be moved without any running gear, accessories or gas cylinders that may be attached to it. Use equipment of a proper size to lift
and move the unit. Falling equipment can cause personal injury and equipment damage.
MOVING PARTS MAY CAUSE INJURY
Have only qualified people remove guards or covers for performing maintenance and troubleshooting. Moving par ts such as cooling fans can maim
fingers or hands and catch loose clothing. Keep tools, hands, hair and clothing away from moving parts. Be sure to reinstall all panels and guards before
operating equipment.
"EMF" ELECTRO MAGNETIC FIELDS
The study of the biological effects of low frequency electric and magnetic fields does not yet let us interpret the results in a single coherent context.
However, there now seems to be an extremely large amount of scientific analysis based on experimentation, at the cellular level and from studies on
animals and humans, that clearly show low frequency magnetic fields interacting with and producing changes in biological systems. Current scientific
understanding of the evidence does not allow definite conclusions concerning advise on avoiding risks. Therefore, the current procedures recommended for
*pacemaker users are also recommended for all humans and other biological systems. To reduce the effects of low frequency electric and magnetic fields, use the
following recommendations:
1. Welding cables should be kept close together by twisting or taping together.
2. Draping or coiling welding cables around the body should be avoided.
3. Welding cables should be kept away from the operator to one side.
4. Work clamp should be connected as close as possible to the area being welded.
5. Operator should not be between the work clamp and the location of the weld being made.
6. Welding power source and cables should be kept as far away as practically possible.
*Note: Pacemaker Wearers - Consult your doctor for complete information.
REFERENCES: See Safety and Operating Reference J.
CYLINDERS
Shielding gas cylinders are under high pressure and if damaged can explode. Protect from welding and electrical arcs, excessive heat and mechanical
shocks. Secure cylinders in an upright position by changing to a cylinder rack or stationary support. Use only the cor rect shielding gas for the process.
Never use unmarked cylinders or rely on color markings to denote contents. Keep cylinder caps securely on cylinders unless in use. Turn face away
when opening a cylinder valve. Open cylinder valves slowly then backseat or fully open valve to prevent valve body leaks. Use regulators and hose of a sufficient type
for the compressed gas used. Never connect a regulator to a cylinder with a gas it is not compatible with. Do not transfill cylinders and keep valves closed and
cylinder caps installed on empty cylinders. Never use a cylinder for other than its intended use.
REFERENCES: See Safety and Operating Reference G.
HOT PARTS
Hot parts can cause serious burns. The area at and near the work being welded should be handled with proper gloves. Proper clothing should be worn
to prevent spatter or chipped slag from causing burns. Never pick up welded material until it has properly cooled.
REFERENCES: See Safety and Operating References A, B, H, & I.
FLYING DEBRIS CAN INJURE EYES
Wearing proper eye protective lenses can prevent debris from damaging the eye. Wear safety glasses with side shields or face shields.
REFERENCES: See Safety and Operating References B.
WELDING WIRE CAN PUNCTURE SKIN
Position the unit away from any part of the body, other people, and metal when threading.
REFERENCES: See Safety and Operating References A.
Safety and Operating References
A) ANSI Z49.1, “Safety in Welding and Cutting”
B) ANSI Z87.1, “Practice for Occupational and Educational Eye and Face Protection”
C) ANSI Z88.2, “Standard Practice for Respiratory Protection”
ANSI: American National Standard Institute, 1430 Broadway, New York, NY 10018
D) AWS F4.1, “Recommended Safe Practices for Welding and Cutting Containers”
AWS: The American Welding Society, P.O. Box 351040, 550 NW Lejeune Rd., Miami, FL 33135
E) NFPA 51B, “Fire Prevention in Cutting and Welding Processes”
F) NFPA-70, “National Electrical Code”
NFPA: National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
G) CGA P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”
CGA: Compressed Gas Association, 1235 Jefferson Davis Hwy., Arlington, Va 22202
H) Code of Federal Regulations (OSHA) 29 CFR 1910
US: U.S. Government Printing Office, Washington, DC 20402
I) CSA Standard W117.2, “Safety in Welding, Cutting and Allied Processes”
CSA: Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3
J) OTA-BP-E-53 Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper US Congress,
Office of Technology Assessment, General Conclusions Section, Washington D.C: US Government Printing Office, May 1989.
® ®
®
Safety
®
32
Safety
SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH
Keep smoke, fumes, and gases from your breathing zone and the general area. Smoke, fumes, and gases from the welding or cutting process are of
various types and strengths, depending on the kind of base metal being welded on. To ensure your safety, do not breathe these fumes or gases.
Ventilation must be adequate to remove smoke, fumes, and gases during the welding procedure to protect operators and others in the immediate area.
Do not weld in locations where chlorinated hydrocarbon vapors are coming from degreasing, cleaning, or spraying operations. Vapors of chlorinated solvents can form
the toxic gas “phosgene” when exposed to ultraviolet radiation from an electric arc. All solvents, degreasers, and potential sources of these vapors must be removed
from the welding area. Shielding gases used for arc welding can displace air and cause injury or death. Fumes produced by welding or cutting, especially in confined
areas, can cause discomfort and physical harm if inhaled over an extended period of time.
Always provide adequate ventilation in the welding and cutting area to insure breathing air is safe. Use air-supplied respirators if ventilation is not adequate to remove
all fumes and gases. Never Ventilate with Oxygen, because oxygen supports and vigorously accelerates fire.
REFERENCES: See Safety and Operating References A,B,C,H, and I.
ARC RAYS, MOLTEN MATERIAL, AND SPARKS CAN CAUSE EYE AND SKIN INJURY
Always wear approved eye, ear, and body protection. Remove any and all combustible material from the work area. Never attempt to weld or cut
without a proper head shield, and lens, that conforms to federal guidelines. A number 12 to 14 shade filter lens provides the best protection from arc
radiation. A cover plate protects your eyes from sparks. Protect other nearby personnel from arc rays and sparks. Use approved shielding curtains and
appropriate goggles. Warn them not to watch the arc or expose themselves to arc rays, sparks, or molten material.
Always wear protective clothing and gloves which will not allow skin to become exposed to arc rays, heat, or molten material. Wear ear plugs to protect ears from
sparks. Flammable hair preparations should not be used when welding or cutting. If possible, welding should be done in a booth that has been painted with an
ultraviolet absorbing material such as zinc oxide and a low reflective finish such as lamp black, or shall be enclosed by similarly painted and noncombustible screens.
REFERENCES: See Safety and Operating References A,B,H, and I.
WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS
Remove any and all combustible materials from the work area. If this is not possible, cover them to prevent the welding sparks from starting a fire.
Fires & explosions are caused by any combustibles reached by the arc, flame, flying sparks, hot slag, or heated materials. Do not wear any gloves or
clothing that has oil or a fuel type material on it. Always have a properly working and OSHA approved Fire Extinguisher near and be sure everyone has
proper training in its use.
Do not weld, heat, or cut drums or containers that have held combustibles. All hollow spaces, cavities, and containers should be vented prior to cutting, welding, or
heating for they may explode. Make sure proper steps have been taken to insure that venting procedures will not form flammable or toxic vapors from substances
inside containers. Purging with inert gas is recommended. Use only iner t gases or inert gas mixes as required by the process.
Special precautions should be used to prevent hazardous situations when using compressed gas. Use of combustible compressed gases can cause
explosions resulting in personal injury or death. Never Use Oxygen for Cleaning or Purging. Arcing against any compressed gas cylinder can cause cylinder damage
or explosion. Read and follow the instructions on compressed gas cylinders, Associated Equipment, and CEA Publication P-1, “Precautions for safe handling of
compressed gases in Cylinders” available from the Compressed Gas Association, 1235 Jefferson Davis Hwy, Arlington, Va. 22202.
REFERENCES: See Safety and Operating References A,D,E,F,G, and H.
FALLING EQUIPMENT
Lift only the unit to be moved without any running gear, accessories or gas cylinders that may be attached to it. Use equipment of a proper size to lift
and move the unit. Falling equipment can cause personal injury and equipment damage.
MOVING PARTS MAY CAUSE INJURY
Have only qualified people remove guards or covers for performing maintenance and troubleshooting. Moving par ts such as cooling fans can maim
fingers or hands and catch loose clothing. Keep tools, hands, hair and clothing away from moving parts. Be sure to reinstall all panels and guards before
operating equipment.
"EMF" ELECTRO MAGNETIC FIELDS
The study of the biological effects of low frequency electric and magnetic fields does not yet let us interpret the results in a single coherent context.
However, there now seems to be an extremely large amount of scientific analysis based on experimentation, at the cellular level and from studies on
animals and humans, that clearly show low frequency magnetic fields interacting with and producing changes in biological systems. Current scientific
understanding of the evidence does not allow definite conclusions concerning advise on avoiding risks. Therefore, the current procedures recommended for
*pacemaker users are also recommended for all humans and other biological systems. To reduce the effects of low frequency electric and magnetic fields, use the
following recommendations:
1. Welding cables should be kept close together by twisting or taping together.
2. Draping or coiling welding cables around the body should be avoided.
3. Welding cables should be kept away from the operator to one side.
4. Work clamp should be connected as close as possible to the area being welded.
5. Operator should not be between the work clamp and the location of the weld being made.
6. Welding power source and cables should be kept as far away as practically possible.
*Note: Pacemaker Wearers - Consult your doctor for complete information.
REFERENCES: See Safety and Operating Reference J.
CYLINDERS
Shielding gas cylinders are under high pressure and if damaged can explode. Protect from welding and electrical arcs, excessive heat and mechanical
shocks. Secure cylinders in an upright position by changing to a cylinder rack or stationary support. Use only the cor rect shielding gas for the process.
Never use unmarked cylinders or rely on color markings to denote contents. Keep cylinder caps securely on cylinders unless in use. Turn face away
when opening a cylinder valve. Open cylinder valves slowly then backseat or fully open valve to prevent valve body leaks. Use regulators and hose of a sufficient type
for the compressed gas used. Never connect a regulator to a cylinder with a gas it is not compatible with. Do not transfill cylinders and keep valves closed and
cylinder caps installed on empty cylinders. Never use a cylinder for other than its intended use.
REFERENCES: See Safety and Operating Reference G.
HOT PARTS
Hot parts can cause serious burns. The area at and near the work being welded should be handled with proper gloves. Proper clothing should be worn
to prevent spatter or chipped slag from causing burns. Never pick up welded material until it has properly cooled.
REFERENCES: See Safety and Operating References A, B, H, & I.
FLYING DEBRIS CAN INJURE EYES
Wearing proper eye protective lenses can prevent debris from damaging the eye. Wear safety glasses with side shields or face shields.
REFERENCES: See Safety and Operating References B.
WELDING WIRE CAN PUNCTURE SKIN
Position the unit away from any part of the body, other people, and metal when threading.
REFERENCES: See Safety and Operating References A.
Safety and Operating References
A) ANSI Z49.1, “Safety in Welding and Cutting”
B) ANSI Z87.1, “Practice for Occupational and Educational Eye and Face Protection”
C) ANSI Z88.2, “Standard Practice for Respiratory Protection”
ANSI: American National Standard Institute, 1430 Broadway, New York, NY 10018
D) AWS F4.1, “Recommended Safe Practices for Welding and Cutting Containers”
AWS: The American Welding Society, P.O. Box 351040, 550 NW Lejeune Rd., Miami, FL 33135
E) NFPA 51B, “Fire Prevention in Cutting and Welding Processes”
F) NFPA-70, “National Electrical Code”
NFPA: National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
G) CGA P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”
CGA: Compressed Gas Association, 1235 Jefferson Davis Hwy., Arlington, Va 22202
H) Code of Federal Regulations (OSHA) 29 CFR 1910
US: U.S. Government Printing Office, Washington, DC 20402
I) CSA Standard W117.2, “Safety in Welding, Cutting and Allied Processes”
CSA: Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3
J) OTA-BP-E-53 Biological Effects of Power Frequency Electric & Magnetic Fields - Background Paper US Congress,
Office of Technology Assessment, General Conclusions Section, Washington D.C: US Government Printing Office, May 1989.
® ®
®
Section 3 Installation
®
54
Section 2
Specifications & Warranty
SPECIFICATIONS
Type of input power required Single-Phase 24 VAC, 7 Amperes, 50/60 Hertz. (If the power source has only
from power source. 115 VAC power available, use the optional (St./No. 9045) 115/24 VAC transformer)
Maximum weld circuit rating. 100 Volts, 500 Amperes, 100% Duty Cycle
Required welding power source. (CV) Constant Voltage with contactor
Wire feed speed 30 to 650 IPM
Wire size range .023 (.6mm) to 1/16 in. (1.6mm)
Dimensions Length: 20 in. (508mm) x Width: 10 in. (254mm) x Height 11 in. (279mm)
PRO II Net: 28 lbs. (12.7 Kg.) Ship: 30 lbs. (13.6 Kg.)
Weight PRO IV Net: 30 lbs. (13.6 Kg.) Ship: 32 lbs. (14.5 Kg.)
(Add 4 lbs. (1.8 Kg.) If optional 115/24V transformer (p/n 9045) is factory installed.)
WARRANTY
LIMITED WARRANTY - Subject to the terms and conditions hereof, PROFAX, Pearland, TX warrants its products to be
free from defects in workmanship and material at the time of delivery by PROFAX.
PROFAX will honor warranty claims on products as a result of failure from a defect for a time period as listed below for
the particular product line, from date of sale to the original user.
Consumable products manufactured by PROFAX ....................................................... 30 days
Contactors, Meters and Resale consumable products ................................................ Original Manufacturer's Warranty
Mig Guns, Flux Cored Guns, and Spool Guns .............................................................. 90 days
Gouging, Plasma, Tig Torches and CO2Heaters .......................................................... 90 days
Control, Extension, Interconnect and Adapter Cords ................................................... 90 days
Twist-lock, Multi-pin Plugs, and Connectors ............................................................... 90 days
®®®
Esab , Lincoln , Miller and PROFAX Drive Rolls ........................................................ 90 days
Remote Fingertip, Hand and Foot Controls ................................................................. 90 days
Fan Motors, Rheostats, Diodes and Brushes .............................................................. 90 days
Spool Gun Controls ................................................................................................... 1 year
Pro II Tig ................................................................................................................... 1 year
Welding Power Sources and Wire Feeders ................................................................. 3 years
Shelf Life before Warranty Starts ................................................................................ 1 year
Upon the return of the merchandise at user's expense, PROFAX reserves the right to either repair or replace as
necessary.
This is the only warranty either expressed or implied covering our products.
MAILING SHIPPING
P.O. Box 898 1603 North Main
Pearland, TX 77588-0898 Pearland, TX 77581-2803
CAUTION!
NOTE: Read and understand the safety information in Section 1 before attempting installation.
CONNECTING THE WIRE FEEDER
CONNECTING THE WELDING GUN
Note: Route all cables and hoses through cable
clamp.
1. Attach weld cable from power source to
power block.
2. Attach gas hose from flowmeter regulator
to gas inlet fitting.
(5/8-18 right hand inert gas)
3. Attach control cable from power source to
RC1 receptacle.
SEE SECTION 4 FOR DRIVE ROLL AND CONTROL CABLE SELECTION
1. Gun Securing Thumbscrew
2. Trigger Plug
3. Connector Plug
4. Adapter Block
5. Trigger Plug Receptacle
Loosen the gun securing thumbscrew on the side of the adapter block. Insert the mig gun connector plug fully into the adapter block. Secure
by tightening the gun securing thumbscrew. Connect the trigger plug to the trigger plug receptacle by aligning the plug until it inserts into the
receptacle then turning the plug collar to the right to lock in place.
2
3
1
1
4
5
2
3
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Section 3 Installation
®
54
Section 2
Specifications & Warranty
SPECIFICATIONS
Type of input power required Single-Phase 24 VAC, 7 Amperes, 50/60 Hertz. (If the power source has only
from power source. 115 VAC power available, use the optional (St./No. 9045) 115/24 VAC transformer)
Maximum weld circuit rating. 100 Volts, 500 Amperes, 100% Duty Cycle
Required welding power source. (CV) Constant Voltage with contactor
Wire feed speed 30 to 650 IPM
Wire size range .023 (.6mm) to 1/16 in. (1.6mm)
Dimensions Length: 20 in. (508mm) x Width: 10 in. (254mm) x Height 11 in. (279mm)
PRO II Net: 28 lbs. (12.7 Kg.) Ship: 30 lbs. (13.6 Kg.)
Weight PRO IV Net: 30 lbs. (13.6 Kg.) Ship: 32 lbs. (14.5 Kg.)
(Add 4 lbs. (1.8 Kg.) If optional 115/24V transformer (p/n 9045) is factory installed.)
WARRANTY
LIMITED WARRANTY - Subject to the terms and conditions hereof, PROFAX, Pearland, TX warrants its products to be
free from defects in workmanship and material at the time of delivery by PROFAX.
PROFAX will honor warranty claims on products as a result of failure from a defect for a time period as listed below for
the particular product line, from date of sale to the original user.
Consumable products manufactured by PROFAX ....................................................... 30 days
Contactors, Meters and Resale consumable products ................................................ Original Manufacturer's Warranty
Mig Guns, Flux Cored Guns, and Spool Guns .............................................................. 90 days
Gouging, Plasma, Tig Torches and CO2Heaters .......................................................... 90 days
Control, Extension, Interconnect and Adapter Cords ................................................... 90 days
Twist-lock, Multi-pin Plugs, and Connectors ............................................................... 90 days
®®®
Esab , Lincoln , Miller and PROFAX Drive Rolls ........................................................ 90 days
Remote Fingertip, Hand and Foot Controls ................................................................. 90 days
Fan Motors, Rheostats, Diodes and Brushes .............................................................. 90 days
Spool Gun Controls ................................................................................................... 1 year
Pro II Tig ................................................................................................................... 1 year
Welding Power Sources and Wire Feeders ................................................................. 3 years
Shelf Life before Warranty Starts ................................................................................ 1 year
Upon the return of the merchandise at user's expense, PROFAX reserves the right to either repair or replace as
necessary.
This is the only warranty either expressed or implied covering our products.
MAILING SHIPPING
P.O. Box 898 1603 North Main
Pearland, TX 77588-0898 Pearland, TX 77581-2803
CAUTION!
NOTE: Read and understand the safety information in Section 1 before attempting installation.
CONNECTING THE WIRE FEEDER
CONNECTING THE WELDING GUN
Note: Route all cables and hoses through cable
clamp.
1. Attach weld cable from power source to
power block.
2. Attach gas hose from flowmeter regulator
to gas inlet fitting.
(5/8-18 right hand inert gas)
3. Attach control cable from power source to
RC1 receptacle.
SEE SECTION 4 FOR DRIVE ROLL AND CONTROL CABLE SELECTION
1. Gun Securing Thumbscrew
2. Trigger Plug
3. Connector Plug
4. Adapter Block
5. Trigger Plug Receptacle
Loosen the gun securing thumbscrew on the side of the adapter block. Insert the mig gun connector plug fully into the adapter block. Secure
by tightening the gun securing thumbscrew. Connect the trigger plug to the trigger plug receptacle by aligning the plug until it inserts into the
receptacle then turning the plug collar to the right to lock in place.
2
3
1
1
4
5
2
3
1. Remove hinged cover.
2. Locate TS2 terminal strip.
3. Remove the two jumper links from TS2.
4. Install the 115/24 VAC transformer (St./No. 9045) onto it's mounting holes using the supplied four 8/32 screws, washers,
lockwashers and nuts.
5. Cut the transformer wires back so as to neatly reach their respective TS2 terminal listed in step 6.
6. Install the supplied spade wire terminals to the transformer wires.
7. Connect the transformer wires to terminal strip TS2 as follows:
White to Terminal 1
Yellow to Terminal 2
Yellow to Terminal 3
Black to Terminal 4
8. Install the hinged cover making sure not to trap and or pinch any wiring.
® ®
® ®
76
InstallationInstallation
1. Wire Speed Control
2. Power Switch and Power "ON" Light
3. Trigger Receptacle
4. Mig Gun Receptacle
CONTROL PANEL
THREADING WELDING WIRE AND ADJUSTING TENSION
OPTIONAL 115/24 VAC TRANSFORMER INSTALLATION
TS1 CONTACTOR TERMINAL STRIP OPERATION
SPOOL BRAKE ADJUSTMENT
1. Release pressure arm(s) by sliding the tension 5. Holding the mig gun out straight, feed the welding wire
adjustment lever(s)down. through the mig gun by using the gun trigger.
2. Route the welding wire through the inlet guide 6. Reinstall the contact tip.
across the drive roll(s) and into the outlet guide. 7. To adjust drive roll pressure - hold the mig gun no less
Slide at least six inches of wire into the outlet guide. than four inches up from a wood surface. Press the
3. Close pressure arm(s) and secure by sliding the gun trigger to feed wire and tighten the wire tension adjust
tension adjustment lever(s) up until locked in place. ment knob to the point where the wire does not slip.
4. Remove the mig gun contact tip. 8. Cut off wire and close cover.
NOTE: Too much wire tension will damage motor, cause erratic feeding and excessively wear drive rolls
1. Tension should be adjusted with wire spool on feeder.
2. Remove wire spool securing nut.
3. Turn the tension adjustment nut to the right to increase braking tension.
4. Adjust until a slight force is felt as you turn the spool by hand.
5. Install wire spool securing nut.
NOTE: Too much brake tension will cause erratic feeding.
WOOD
TIGHTEN
SPOOL
SECURING NUT
TIGHTEN
TENSION
NUT
SPINDLE
ASSY.
4
1
2
3
TS2 SET FOR
115 VAC OPERATION
TS2 SET FOR
24 VAC OPERATION
JUMPER
LINKS
YELLOW
YELLOW
WHITE
BLACK
CONTACT CLOSURE OPERATION
This setting is for welding power sources that require a normally open set of
contacts to operate the contactor. When the normally open set of contacts on K1
relay close it completes the circuit and energizes the contactor. Pins F and E on RC1
will give contact closure operation by the wire feeder when the TS1 jumper is from
terminal 1to 2.
VOLTAGE FEEDBACK CONTACTOR OPERATION
This setting is for power sources that require voltage feedback to operate the
contactor. When K1 relay closes voltage will be sent back to the welding power
source to energize the contactor. This setting is normally used with the 115/24 VAC
transformer option (St./No. 9045) to send 115 VAC back to the welding power
source to operate the contactor circuit. Pins F and B on RC1 will give voltage
feedback operation by the wire feeder when the TS1 jumper is from terminal 2 to 3.
1 2 3
CONTACT
CLOSURE
VOLTAGE
FEEDBACK
1
CONTACT
CLOSURE
2 3
VOLTAGE
FEEDBACK
CAUTION!
Jumper links on TS2 must be removed when
installing the 9045 115V transformer option.
Failure to remove links will cause the pc board
to fail and void warranty.
1. Remove hinged cover.
2. Locate TS2 terminal strip.
3. Remove the two jumper links from TS2.
4. Install the 115/24 VAC transformer (St./No. 9045) onto it's mounting holes using the supplied four 8/32 screws, washers,
lockwashers and nuts.
5. Cut the transformer wires back so as to neatly reach their respective TS2 terminal listed in step 6.
6. Install the supplied spade wire terminals to the transformer wires.
7. Connect the transformer wires to terminal strip TS2 as follows:
White to Terminal 1
Yellow to Terminal 2
Yellow to Terminal 3
Black to Terminal 4
8. Install the hinged cover making sure not to trap and or pinch any wiring.
® ®
® ®
76
InstallationInstallation
1. Wire Speed Control
2. Power Switch and Power "ON" Light
3. Trigger Receptacle
4. Mig Gun Receptacle
CONTROL PANEL
THREADING WELDING WIRE AND ADJUSTING TENSION
OPTIONAL 115/24 VAC TRANSFORMER INSTALLATION
TS1 CONTACTOR TERMINAL STRIP OPERATION
SPOOL BRAKE ADJUSTMENT
1. Release pressure arm(s) by sliding the tension 5. Holding the mig gun out straight, feed the welding wire
adjustment lever(s)down. through the mig gun by using the gun trigger.
2. Route the welding wire through the inlet guide 6. Reinstall the contact tip.
across the drive roll(s) and into the outlet guide. 7. To adjust drive roll pressure - hold the mig gun no less
Slide at least six inches of wire into the outlet guide. than four inches up from a wood surface. Press the
3. Close pressure arm(s) and secure by sliding the gun trigger to feed wire and tighten the wire tension adjust
tension adjustment lever(s) up until locked in place. ment knob to the point where the wire does not slip.
4. Remove the mig gun contact tip. 8. Cut off wire and close cover.
NOTE: Too much wire tension will damage motor, cause erratic feeding and excessively wear drive rolls
1. Tension should be adjusted with wire spool on feeder.
2. Remove wire spool securing nut.
3. Turn the tension adjustment nut to the right to increase braking tension.
4. Adjust until a slight force is felt as you turn the spool by hand.
5. Install wire spool securing nut.
NOTE: Too much brake tension will cause erratic feeding.
WOOD
TIGHTEN
SPOOL
SECURING NUT
TIGHTEN
TENSION
NUT
SPINDLE
ASSY.
4
1
2
3
TS2 SET FOR
115 VAC OPERATION
TS2 SET FOR
24 VAC OPERATION
JUMPER
LINKS
YELLOW
YELLOW
WHITE
BLACK
CONTACT CLOSURE OPERATION
This setting is for welding power sources that require a normally open set of
contacts to operate the contactor. When the normally open set of contacts on K1
relay close it completes the circuit and energizes the contactor. Pins F and E on RC1
will give contact closure operation by the wire feeder when the TS1 jumper is from
terminal 1to 2.
VOLTAGE FEEDBACK CONTACTOR OPERATION
This setting is for power sources that require voltage feedback to operate the
contactor. When K1 relay closes voltage will be sent back to the welding power
source to energize the contactor. This setting is normally used with the 115/24 VAC
transformer option (St./No. 9045) to send 115 VAC back to the welding power
source to operate the contactor circuit. Pins F and B on RC1 will give voltage
feedback operation by the wire feeder when the TS1 jumper is from terminal 2 to 3.
1 2 3
CONTACT
CLOSURE
VOLTAGE
FEEDBACK
1
CONTACT
CLOSURE
2 3
VOLTAGE
FEEDBACK
CAUTION!
Jumper links on TS2 must be removed when
installing the 9045 115V transformer option.
Failure to remove links will cause the pc board
to fail and void warranty.
® ®
® ®
98
Charts & Tables
Section 4
Charts & Tables
DRIVE ROLL, KIT AND GUIDE CHART
RC 1 PIN REFERENCE
INTERCONNECTING & EXTENSION CORDS
PRO II PRO IV
WIRE DIAMETER KIT NO. KIT NO. TYPE DRIVE ROLL INLET GUIDE OUTLET GUIDE INTER. GUIDE
.023/.025(.6mm ) 9095 9110 V 9054 9070 9080 9131
.030 (.8mm ) 9095 9110 V 9054 9070 9080 9131
.035 (.9mm ) 9096 9111 V 9055 9071 9081 9131
.045 (1.2mm ) 9097 9112 V 9056 9071 9081 9131
V - KNURLED
.030 (.6mm ) 9098 9113 VK 9057 9070 9080 9131
.035 (.8mm ) 9099 9114 VK 9057 9071 9081 9131
.045 (1.2mm ) 9100 9115 VK 9058 9071 9081 9131
.052 (1.4mm ) 9101 9116 VK 9059 9072 9082 9131
1/16 in. (1.6mm ) 9101 9116 VK 9059 9072 9082 9131
PRESSURE ROLLS
FLAT SMOOTH --- --- --- 9052 STANDARD - FURNISHED WITH WIRE FEEDER -
CAN BE USED WITH V & V-KNURLED FEED ROLLS
FLAT KNURLED --- --- --- 9053 OPTIONAL - USED WHEN EXTRA DRIVE IS
NEEDED ON CORED WIRES
WELDING CABLE SELECTION TABLE
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft. 150 ft. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.
(30m) or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Welding 10 To 60% 60 Thru 100% 10 Thru 100%
Amperes Duty Cycle Duty Cycle Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
* CAUTION! - 115 VAC should not be connected to pins A & G unless the 115/24 VAC transformer option (p/n 9045) is installed.
PIN PIN INFORMATION
A* 115 VAC power input through fuse F3 in respect to pin G
B Voltage return from pins A or D.
C Not used
D 24 VAC power input through fuse F2 in respect to pin G
E Contact closure to pin F in respect to TS1 jumper on terminals 1 & 2.
F Relay common to pins B & E in respect to TS1 jumper position.
G Circuit common for 24 and 115 VAC input power.
H Case ground
H
G
F
C
A
B
D
E
As viewed facing
rear of feeder.
NOTE: Control Cords come in 10 ft., 25 ft., 50 f t. & 100 ft. lengths and consist of an 8 Socket Plug,
Multi-conductor Cord(s) and necessary Wires or Plugs to connect to the power source.
When ordering - Add the length required to the end of the part number. (Example: 9225-10)
POWER SOURCE CORD END PLUG DESCRIPTION
FOR CONNECTION TO ST./NO. FROM WIRE FEEDER TO:
PLUG ONLY 9046 8 Socket Plug Only - Connects to rear of wire feeder
EXTENSION CORD 9240 8 Socket Free Hanging Plug to 8 Pin Free Hanging Female Receptacle.
( Extends between the wire feeder and the interconnecting cord. )
UNIVERSAL CORD 9225 7 Individual wires
PROFAX 9237 10 Pin Plug
®
AIRCO 9234 115V Male Plug on Power Cord and 2 Prong Twistlock Female on Contactor Cord
9226 3 Prong Male Twistlock on Power Cord and 2 Prong Twistlock Female on Contactor Cord
®
HOBART 9232 115V Male Plug on Power Cord and 5 Pin Plug on Contactor Cord
9233 19 Pin Plug
®
L - TEC 9230 7 Flat Pin Male Plug (AMP Style)
9231 19 Pin Plug
®
LINCOLN 9228 5 Individual Wires with Spade Connectors for Terminal Strip Hookup
9229 14 Pin Plug
®
MILLER 9226 3 Prong Male Twistlock on Power Cord and 2 Prong Twistlock Female on Contactor Cord
9227 14 Pin Plug
®
POWCON 9235 14 Pin Plug (only power sources w/115 VAC available at plug.)
®
THERMAL DYNAMICS 9227 14 Pin Plug
® ®
® ®
98
Charts & Tables
Section 4
Charts & Tables
DRIVE ROLL, KIT AND GUIDE CHART
RC 1 PIN REFERENCE
INTERCONNECTING & EXTENSION CORDS
PRO II PRO IV
WIRE DIAMETER KIT NO. KIT NO. TYPE DRIVE ROLL INLET GUIDE OUTLET GUIDE INTER. GUIDE
.023/.025(.6mm ) 9095 9110 V 9054 9070 9080 9131
.030 (.8mm ) 9095 9110 V 9054 9070 9080 9131
.035 (.9mm ) 9096 9111 V 9055 9071 9081 9131
.045 (1.2mm ) 9097 9112 V 9056 9071 9081 9131
V - KNURLED
.030 (.6mm ) 9098 9113 VK 9057 9070 9080 9131
.035 (.8mm ) 9099 9114 VK 9057 9071 9081 9131
.045 (1.2mm ) 9100 9115 VK 9058 9071 9081 9131
.052 (1.4mm ) 9101 9116 VK 9059 9072 9082 9131
1/16 in. (1.6mm ) 9101 9116 VK 9059 9072 9082 9131
PRESSURE ROLLS
FLAT SMOOTH --- --- --- 9052 STANDARD - FURNISHED WITH WIRE FEEDER -
CAN BE USED WITH V & V-KNURLED FEED ROLLS
FLAT KNURLED --- --- --- 9053 OPTIONAL - USED WHEN EXTRA DRIVE IS
NEEDED ON CORED WIRES
WELDING CABLE SELECTION TABLE
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft. 150 ft. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.
(30m) or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
Welding 10 To 60% 60 Thru 100% 10 Thru 100%
Amperes Duty Cycle Duty Cycle Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
* CAUTION! - 115 VAC should not be connected to pins A & G unless the 115/24 VAC transformer option (p/n 9045) is installed.
PIN PIN INFORMATION
A* 115 VAC power input through fuse F3 in respect to pin G
B Voltage return from pins A or D.
C Not used
D 24 VAC power input through fuse F2 in respect to pin G
E Contact closure to pin F in respect to TS1 jumper on terminals 1 & 2.
F Relay common to pins B & E in respect to TS1 jumper position.
G Circuit common for 24 and 115 VAC input power.
H Case ground
H
G
F
C
A
B
D
E
As viewed facing
rear of feeder.
NOTE: Control Cords come in 10 ft., 25 ft., 50 f t. & 100 ft. lengths and consist of an 8 Socket Plug,
Multi-conductor Cord(s) and necessary Wires or Plugs to connect to the power source.
When ordering - Add the length required to the end of the part number. (Example: 9225-10)
POWER SOURCE CORD END PLUG DESCRIPTION
FOR CONNECTION TO ST./NO. FROM WIRE FEEDER TO:
PLUG ONLY 9046 8 Socket Plug Only - Connects to rear of wire feeder
EXTENSION CORD 9240 8 Socket Free Hanging Plug to 8 Pin Free Hanging Female Receptacle.
( Extends between the wire feeder and the interconnecting cord. )
UNIVERSAL CORD 9225 7 Individual wires
PROFAX 9237 10 Pin Plug
®
AIRCO 9234 115V Male Plug on Power Cord and 2 Prong Twistlock Female on Contactor Cord
9226 3 Prong Male Twistlock on Power Cord and 2 Prong Twistlock Female on Contactor Cord
®
HOBART 9232 115V Male Plug on Power Cord and 5 Pin Plug on Contactor Cord
9233 19 Pin Plug
®
L - TEC 9230 7 Flat Pin Male Plug (AMP Style)
9231 19 Pin Plug
®
LINCOLN 9228 5 Individual Wires with Spade Connectors for Terminal Strip Hookup
9229 14 Pin Plug
®
MILLER 9226 3 Prong Male Twistlock on Power Cord and 2 Prong Twistlock Female on Contactor Cord
9227 14 Pin Plug
®
POWCON 9235 14 Pin Plug (only power sources w/115 VAC available at plug.)
®
THERMAL DYNAMICS 9227 14 Pin Plug
TROUBLE REMEDY
Unit completely inoperative. 1. Turn power switch on.
2. Check F3 fuse if using 115/24 VAC transformer option.
3. If using 115/24 VAC transformer option check to see if transformer was
installed properly.
4. Check F2 fuse if operating from a 24 VAC power source.
5. Check control cord plugs and connections.
6. Check input power to feeder.
Wire does not feed. 1. Check for proper drive roll size and proper drive roll tension.
2. Check for drive roll obstructions.
3. Check mig gun trigger, trigger leads, cord and plug.
4. Check fuses
5. Have an authorized service station check motor and PC board.
Wire feeds as soon as power is turned on. 1. Check mig gun trigger, trigger leads, cord and plug for shorted wires.
2. Check for shorted or frayed wires touching in RC2 receptacle.
Wire feeds erratically. 1. Readjust drive roll tension.
2. Spool brake too tight.
3. Wrong size drive rolls and or wire guides.
4. Worn drive rolls and or guides.
5. Inlet or outlet guide touching drive rolls preventing proper tension
adjustment.
5. Dirty mig gun liner.
6. Improperly installed mig gun liner.
7. Worn contact tube.
8. Worn drive roll axles and or drive gear bushings.
9. Have an authorized service station check motor and PC board.
Gas valve rattles loudly with erratic 1. Check for a short between the weld cable and the mig gun trigger leads.
or slow wire speed. 2. Check gas valve components for tightness.
Gas does not flow but wire feeds OK. 1. Check gas supply and flowmeter to see if they are on and allowing gas to flow.
2. Check to see if gas flow is reaching gas solenoid connection at feeder.
3. Check gas solenoid valve.
Motor runs slowly. 1. Check for correct input voltage.
2. Check for correct voltage to motor.
3. Have an authorized service station check the motor and PC board.
Wire feeder operates OK but will not weld. 1. Ground cable not or badly connected.
2. Weld cable not connected to wire feeder.
3. Power cable not connected to power block.
4. Contactor not being energized in power source.
Check:
A. K1 relay
B. TS1 jumper placement
C. Control cord wiring
® ®
® ®
1110
Section 5
Maintenance
Section 6
Troubleshooting
WARNING WARNING
Electrical shock can kill
A. DO NOT TOUCH LIVE
electrical parts.
B. Disconnect input power
before servicing.
Moving parts can main
Disconnect input power
before servicing.
Hot parts can burn
Allow for cooling periods.
Read and understand the safety information in Section 1 of this manual.
CAUTION Maintenance should be performed by qualified personnel only.
DAILY
1. Clean drive rolls.
A. Clean with a towel and wire brush.
B. If a solvent is required use one that will leave NO residue.
C. DO NOT USE - penetrating oils or anti-spatter spray on drive rolls.
2. Inspect all connections to make sure that they are clean and tight.
3. Inspect all cables and hose for cracks, tears and frayed wires. Repair as necessary.
MONTHLY
1. Inspect and repair any cables or hoses that are cracked or frayed.
2. Replace any cables or hoses that have been overheated or that have more than one repair in any six foot section.
3. Blow out or vacuum any particles from the wire drive area.
4. Clean any buildup of metal particles on or around the drive roll shafts.
5. Replace any terminal connections that show to have arced out or cannot be tightened.
3 MONTHS
1. Remove hinged cover and blow out or vacuum component area
2. Inspect for wear and replace if necessary, drive and pressure rolls, roll axles, gears and gear bushings.
3. Disassemble ,inspect and repair or replace if necessary all control cord multi-pin plugs with frayed wire or deteriorated wire
insulation.
4. Replace inlet, intermediate and outlet guides.
5. Replace mig gun liner and connector plug "O" rings
6. Replace unreadable labels.
OVERLOAD PROTECTION Disconnect all electrical power before checking fuses.
FUSES:
F1 - 7A -Fast Acting
Protects motor from overload
F2 - 7A - Slo-Blo
For wire feeder overload protection when operating on
24VAC power.
F3 - 3A - Slo-Blo
USED ONLY WITH 115/24 VAC TRANSFORMER INSTALLED
Protects wire feeder from overload
Troubleshooting should only be done by qualified personnel
with a working knowledge of electrical circuits.
TROUBLE REMEDY
Unit completely inoperative. 1. Turn power switch on.
2. Check F3 fuse if using 115/24 VAC transformer option.
3. If using 115/24 VAC transformer option check to see if transformer was
installed properly.
4. Check F2 fuse if operating from a 24 VAC power source.
5. Check control cord plugs and connections.
6. Check input power to feeder.
Wire does not feed. 1. Check for proper drive roll size and proper drive roll tension.
2. Check for drive roll obstructions.
3. Check mig gun trigger, trigger leads, cord and plug.
4. Check fuses
5. Have an authorized service station check motor and PC board.
Wire feeds as soon as power is turned on. 1. Check mig gun trigger, trigger leads, cord and plug for shorted wires.
2. Check for shorted or frayed wires touching in RC2 receptacle.
Wire feeds erratically. 1. Readjust drive roll tension.
2. Spool brake too tight.
3. Wrong size drive rolls and or wire guides.
4. Worn drive rolls and or guides.
5. Inlet or outlet guide touching drive rolls preventing proper tension
adjustment.
5. Dirty mig gun liner.
6. Improperly installed mig gun liner.
7. Worn contact tube.
8. Worn drive roll axles and or drive gear bushings.
9. Have an authorized service station check motor and PC board.
Gas valve rattles loudly with erratic 1. Check for a short between the weld cable and the mig gun trigger leads.
or slow wire speed. 2. Check gas valve components for tightness.
Gas does not flow but wire feeds OK. 1. Check gas supply and flowmeter to see if they are on and allowing gas to flow.
2. Check to see if gas flow is reaching gas solenoid connection at feeder.
3. Check gas solenoid valve.
Motor runs slowly. 1. Check for correct input voltage.
2. Check for correct voltage to motor.
3. Have an authorized service station check the motor and PC board.
Wire feeder operates OK but will not weld. 1. Ground cable not or badly connected.
2. Weld cable not connected to wire feeder.
3. Power cable not connected to power block.
4. Contactor not being energized in power source.
Check:
A. K1 relay
B. TS1 jumper placement
C. Control cord wiring
® ®
® ®
1110
Section 5
Maintenance
Section 6
Troubleshooting
WARNING WARNING
Electrical shock can kill
A. DO NOT TOUCH LIVE
electrical parts.
B. Disconnect input power
before servicing.
Moving parts can main
Disconnect input power
before servicing.
Hot parts can burn
Allow for cooling periods.
Read and understand the safety information in Section 1 of this manual.
CAUTION Maintenance should be performed by qualified personnel only.
DAILY
1. Clean drive rolls.
A. Clean with a towel and wire brush.
B. If a solvent is required use one that will leave NO residue.
C. DO NOT USE - penetrating oils or anti-spatter spray on drive rolls.
2. Inspect all connections to make sure that they are clean and tight.
3. Inspect all cables and hose for cracks, tears and frayed wires. Repair as necessary.
MONTHLY
1. Inspect and repair any cables or hoses that are cracked or frayed.
2. Replace any cables or hoses that have been overheated or that have more than one repair in any six foot section.
3. Blow out or vacuum any particles from the wire drive area.
4. Clean any buildup of metal particles on or around the drive roll shafts.
5. Replace any terminal connections that show to have arced out or cannot be tightened.
3 MONTHS
1. Remove hinged cover and blow out or vacuum component area
2. Inspect for wear and replace if necessary, drive and pressure rolls, roll axles, gears and gear bushings.
3. Disassemble ,inspect and repair or replace if necessary all control cord multi-pin plugs with frayed wire or deteriorated wire
insulation.
4. Replace inlet, intermediate and outlet guides.
5. Replace mig gun liner and connector plug "O" rings
6. Replace unreadable labels.
OVERLOAD PROTECTION Disconnect all electrical power before checking fuses.
FUSES:
F1 - 7A -Fast Acting
Protects motor from overload
F2 - 7A - Slo-Blo
For wire feeder overload protection when operating on
24VAC power.
F3 - 3A - Slo-Blo
USED ONLY WITH 115/24 VAC TRANSFORMER INSTALLED
Protects wire feeder from overload
Troubleshooting should only be done by qualified personnel
with a working knowledge of electrical circuits.
® ®
® ®
1312
Troubleshooting
Section 6
Parts
PARTS
MANUAL
SW1
2
1
4
3
115vac
TS2
T2
OPTIONAL
Required for 115VAC operation
F
E
B
H
G
D
A
GND
24V
RC1
115V
COMMON
GS
1 2 345 6 9 10 11 127 8
K1
PROFAX 9001
PC BOARD
F2
F3
RC2
(Trigger Recpt.) CW
R2
F1
24vac
TS1
32
1
YB
N
O
W
W
PU
R
GW
UW
S
YB
Y
BW YB
OB
PW
PW SB
S
S
RB
W
G
R
B
24VAC OUT
WHEN RC2
IS CLOSED
0-27VDC
OUT WITH
REF. TO R2
WHEN RC2
IS CLOSED
24VAC IN
WITH SW1
ON
CIRCUIT DIAGRAM
M
P
B = BLACK
G = GREEN
N = BROWN
O = ORANGE
P = PURPLE
R = RED
S = GRAY
U = BLUE
W = WHITE
Y = YELLOW
WIRE COLOR CODE
BW = BLACK/WHITE
GW = GREEN/WHITE
OB = ORANGE/BLACK
PW = PURPLE/WHITE
RB = RED/BLACK
SB = GRAY/BLACK
UW = BLUE/WHITE
YB = YELLOW/BLACK
Contact closure operation
between F & E with TS1
jumper on terminals 1 & 2
Voltage feedback operation
between F & B with TS1
jumper on terminals 2 & 3
Jumper links on TS2
must be removed when
installing this option.
® ®
® ®
1312
Troubleshooting
Section 6
Parts
PARTS
MANUAL
SW1
2
1
4
3
115vac
TS2
T2
OPTIONAL
Required for 115VAC operation
F
E
B
H
G
D
A
GND
24V
RC1
115V
COMMON
GS
1 2 345 6 9 10 11 127 8
K1
PROFAX 9001
PC BOARD
F2
F3
RC2
(Trigger Recpt.) CW
R2
F1
24vac
TS1
32
1
YB
N
O
W
W
PU
R
GW
UW
S
YB
Y
BW YB
OB
PW
PW SB
S
S
RB
W
G
R
B
24VAC OUT
WHEN RC2
IS CLOSED
0-27VDC
OUT WITH
REF. TO R2
WHEN RC2
IS CLOSED
24VAC IN
WITH SW1
ON
CIRCUIT DIAGRAM
M
P
B = BLACK
G = GREEN
N = BROWN
O = ORANGE
P = PURPLE
R = RED
S = GRAY
U = BLUE
W = WHITE
Y = YELLOW
WIRE COLOR CODE
BW = BLACK/WHITE
GW = GREEN/WHITE
OB = ORANGE/BLACK
PW = PURPLE/WHITE
RB = RED/BLACK
SB = GRAY/BLACK
UW = BLUE/WHITE
YB = YELLOW/BLACK
Contact closure operation
between F & E with TS1
jumper on terminals 1 & 2
Voltage feedback operation
between F & B with TS1
jumper on terminals 2 & 3
Jumper links on TS2
must be removed when
installing this option.
® ®
® ®
1514
PartsParts
PART ELEC. QTY.
ITEM NO. MKGS. DESCRIPTION PRO II PRO IV
1 9002 M MOTOR, 24VDC 160 RPM 1
2 9003 M MOTOR, 24VDC 160 RPM 1
3 9004 WIRE DRIVE ASSY. 2 ROLL (see figure A) 1
4 9005 WIRE DRIVE ASSY. 4 ROLL (see figure B) 1
5 9012A BASE 1 1
6 9014A DIVIDER PANEL 1 1
7 9016A FRONT PANEL 1 1
8 9013A HINGED COVER 1 1
9 9015 COVER HASP 1 1
10 9019 FACEPLATE 1
11 9139 FACEPLATE 1
12 9018 SPOOL SUPPORT 1 1
13 9017 SPINDLE ASSY. 1 1
14 9001 PC BOARD 1 1
15 8999 TERMINAL TOOL, PC Board (Not Shown) 1 1
16 9007 INLET GUIDE HOLDER 1 1
17 INLET GUIDE LINER (see DRIVE ROLL, KIT and GUIDE chart ) 1 1
18 9028 R2 POTENTIOMETER, 10K, 1T, 2W 1 1
19 9029 INSULATOR, potentiometer 1 1
20 9008 DRIVE MOUNT INSULATOR 1 1
21 9006 ADAPTER BLOCK 1 1
22 LINER, adapter block (see DRIVE ROLL, KIT and GUIDE chart ) 1 1
23 9170 NIPPLE, adapter block 1 1
24 9171 THUMB SCREW, adapter block 1 1
25 9020 GS GAS SOLENOID, 24VAC 1 1
26 9172 HOSE, gas solenoid 1 1
27 9021 FITTING, gas solenoid inlet 1 1
28 9173 CLAMP, gas solenoid hose 2 2
29 9022 SW1 POWER SWITCH 1 1
30 9030 KNOB, potentiometer 1 1
31 9031 BRAKE, felt 1 1
32 9032 OUTLET INSULATOR 1 1
33 9033 RC1 POWER RECEPTACLE, amphenol 1 1
34 9034 RC2 TRIGGER RECEPTACLE, amp 1 1
35 9035 TERMINAL, trigger receptacle (Not Shown) 2 2
36 9010 POWER BLOCK 1 1
37 9011 POWER CABLE 1 1
38 9024 FOOT, rubber 4 4
39 6100 FUSE HOLDER 3 3
40 9038 F1 FUSE, 7 amp, 250V fast acting (Not Shown) 1 1
41 9039 F2 FUSE, 7 amp, 250V Slo-Blo (Not Shown) 1 1
42 9040 F3 FUSE, 3 amp, 250V Slo-Blo (Not Shown) 1 1
43 9041 TS1 TERMINAL STRIP, 3 pole 1 1
44 9042 TS2 TERMINAL STRIP, 4 pole 1 1
45 9043 JUMPER, terminal strip (Not Shown) 3 3
46 9025 SCREW INSULATOR, wire drive 2 2
47 9026 INSULATING WASHER, wire drive 2
48 9009 CLAMP, cable 1 1
49 9023 SPACER BLOCK 1
50 9027 GROMMET, rubber 2 2
52 9045 T2 TRANSFORMER, (optional) 115/24VAC 100VA 1 1
53 9047 LABEL, TS2 1 1
54 9048 LABEL, TS1 1 1
55 9049 LABEL, fuses 1 1
56 9051 LABEL, schematic 1 1
57 9142 LABEL, PROFAX 22
58 9036 LABEL, safty 1 1
59 9177 DIVIDER PANEL, Insulator 1
60 9176 TOP COVER, Insulator 1
58
57
9
56
8
14
54
27
25 28
26 30
31
29
10
7
32
4
3
16
37
23
36
5
21
22
24
17
12
47
34
18
19
11
33 50
6
55
53
12
13
48
44
52
38
46
49
20
39
59
43
60
(See Figure B)
(See Figure A)
(Optional)
® ®
® ®
1514
PartsParts
PART ELEC. QTY.
ITEM NO. MKGS. DESCRIPTION PRO II PRO IV
1 9002 M MOTOR, 24VDC 160 RPM 1
2 9003 M MOTOR, 24VDC 160 RPM 1
3 9004 WIRE DRIVE ASSY. 2 ROLL (see figure A) 1
4 9005 WIRE DRIVE ASSY. 4 ROLL (see figure B) 1
5 9012A BASE 1 1
6 9014A DIVIDER PANEL 1 1
7 9016A FRONT PANEL 1 1
8 9013A HINGED COVER 1 1
9 9015 COVER HASP 1 1
10 9019 FACEPLATE 1
11 9139 FACEPLATE 1
12 9018 SPOOL SUPPORT 1 1
13 9017 SPINDLE ASSY. 1 1
14 9001 PC BOARD 1 1
15 8999 TERMINAL TOOL, PC Board (Not Shown) 1 1
16 9007 INLET GUIDE HOLDER 1 1
17 INLET GUIDE LINER (see DRIVE ROLL, KIT and GUIDE chart ) 1 1
18 9028 R2 POTENTIOMETER, 10K, 1T, 2W 1 1
19 9029 INSULATOR, potentiometer 1 1
20 9008 DRIVE MOUNT INSULATOR 1 1
21 9006 ADAPTER BLOCK 1 1
22 LINER, adapter block (see DRIVE ROLL, KIT and GUIDE chart ) 1 1
23 9170 NIPPLE, adapter block 1 1
24 9171 THUMB SCREW, adapter block 1 1
25 9020 GS GAS SOLENOID, 24VAC 1 1
26 9172 HOSE, gas solenoid 1 1
27 9021 FITTING, gas solenoid inlet 1 1
28 9173 CLAMP, gas solenoid hose 2 2
29 9022 SW1 POWER SWITCH 1 1
30 9030 KNOB, potentiometer 1 1
31 9031 BRAKE, felt 1 1
32 9032 OUTLET INSULATOR 1 1
33 9033 RC1 POWER RECEPTACLE, amphenol 1 1
34 9034 RC2 TRIGGER RECEPTACLE, amp 1 1
35 9035 TERMINAL, trigger receptacle (Not Shown) 2 2
36 9010 POWER BLOCK 1 1
37 9011 POWER CABLE 1 1
38 9024 FOOT, rubber 4 4
39 6100 FUSE HOLDER 3 3
40 9038 F1 FUSE, 7 amp, 250V fast acting (Not Shown) 1 1
41 9039 F2 FUSE, 7 amp, 250V Slo-Blo (Not Shown) 1 1
42 9040 F3 FUSE, 3 amp, 250V Slo-Blo (Not Shown) 1 1
43 9041 TS1 TERMINAL STRIP, 3 pole 1 1
44 9042 TS2 TERMINAL STRIP, 4 pole 1 1
45 9043 JUMPER, terminal strip (Not Shown) 3 3
46 9025 SCREW INSULATOR, wire drive 2 2
47 9026 INSULATING WASHER, wire drive 2
48 9009 CLAMP, cable 1 1
49 9023 SPACER BLOCK 1
50 9027 GROMMET, rubber 2 2
52 9045 T2 TRANSFORMER, (optional) 115/24VAC 100VA 1 1
53 9047 LABEL, TS2 1 1
54 9048 LABEL, TS1 1 1
55 9049 LABEL, fuses 1 1
56 9051 LABEL, schematic 1 1
57 9142 LABEL, PROFAX 22
58 9036 LABEL, safty 1 1
59 9177 DIVIDER PANEL, Insulator 1
60 9176 TOP COVER, Insulator 1
58
57
9
56
8
14
54
27
25 28
26 30
31
29
10
7
32
4
3
16
37
23
36
5
21
22
24
17
12
47
34
18
19
11
33 50
6
55
53
12
13
48
44
52
38
46
49
20
39
59
43
60
(See Figure B)
(See Figure A)
(Optional)
®
®
16
Parts
FIGURE A
FIGURE B
17
11 12
8
5
4
7
6
9
18
1
3
10
16
15
14
2
17
19
13
16
15
2
14
13
8
67
5
4
10
9
1
12
11
3
®
INDEX
P.O. BOX 898
PEARLAND, TX 77588-0898
(281) 485-6258
AVAILABLE THROUGH YOUR
WELDING SUPPLY DISTRIBUTOR
Copyright 2005 by PROFAX; Pearland, Texas
All Rights Reserved
No page or part of any page in this catalog may be reproduced in
any form without permission of copyright owner shown above.
®
®
SECTION 1 SAFETY
Safety Symbols and Words ........................................................................................... 1
Safety Precautions ........................................................................................................ 2 - 3
SECTION 2
Specifications & Warranty ............................................................................................. 4
SECTION 3 INSTALLATION
Connecting the Wire Feeder & Welding Gun .................................................................... 5
Control Panel ............................................................................................................... 6
Threading Welding Wire and Adjusting Tension .............................................................. 6
Spool Brake Adjustment ............................................................................................... 6
Optional 115/24 VAC Transformer Installation ............................................................... 7
TS1 Contactor Terminal Strip Operation ......................................................................... 7
SECTION 4 CHARTS & TABLES
Drive Roll Kit and Guide Chart ...................................................................................... 8
Welding Cable Selection Table ...................................................................................... 8
RC1 Pin Reference ....................................................................................................... 9
Interconnecting and Extension Cords ............................................................................ 9
SECTION 5
Maintenance ................................................................................................................ 10
Overload Protection ...................................................................................................... 10
SECTION 6
Troubleshooting .......................................................................................................... 11
Circuit Diagram ........................................................................................................... 12
SECTION 7
Parts List ........................................................................................................................ 13 - 17
FIGURE A PARTS LIST PRO II WIRE DRIVE 2 ROLL ASSEMBLY P/N 9004
ITEM PART NO. DESCRIPTION QTY.
1 9143 WIRE DRIVE HOUSING 1
2 9144 SCREW, guide retention, and motor mounting 5
3 9145 PRESSURE ARM 1
4 9134 AXLE, pressure roll 1
5 9136 GEAR, pressure roll 1
6 9052 PRESSURE ROLL, flat smooth 1
7 9053 PRESSURE ROLL, knurled ( optional ) 1
8 9135 CIRCLE CLIP, pressure roll axle 1
9 9146 PIVOT PIN, pressure arm 1
10 9147 SPACER 1
11 9148 SPRING, lift 1
12 9149 CIRCLE CLIP, pressure arm pivot pin 1
13 9150 TENSION AJUSTER 1
14 9151 RETAINING PIN, tension adjuster 1
15 9129 GEAR, drive 1
16 9130 SCREW, drive roll retention 2
17 9126 SCREW, drive gear retention 1
18 9128 KEY, motor shaft (Not Shown) 1
19 9152 SNAP RING, motor shaft (Not Shown) 1
FIGURE B PARTS LIST PRO IV WIRE DRIVE 4 ROLL ASSEMBLY P/N 9005
ITEM PART NO. DESCRIPTION QTY.
1 9153 WIRE DRIVE HOUSING 1
2 9154 SCREW, guide retention 3
3 9145 PRESSURE ARM 2
4 9155 PIVOT PIN, pressure arms 1
5 9149 CIRCLE CLIP, pressure arm pivot pin 4
6 9156 SPRING, lift 1
7 9147 SPACER 2
8 9134 AXLE, pressure roll 2
9 9135 CIRCLE CLIP, pressure roll axle 2
10 9136 GEAR, feed and pressure roll 4
11 9052 PRESSURE ROLL, flat smooth 2
12 9053 PRESSURE ROLL, knurled ( optional ) 2
13 9132 AXLE, drive roll 2
14 9133 WASHER, drive roll retention 2
15 9127 SCREW, gear retention 3
16 9150 TENSION ADJUSTER 2
17 9151 RETAINING PIN, tention adjuster 2
18 9131 INTERMEDIATE GUIDE (see Drive Roll, Kit and Guide Chart) 1
19 9137 GEAR, main drive 1
20 9128 KEY, motor shaft (Not Shown) 1
21 9152 SNAP RING, motor shaft (Not Shown) 1
22 9138 SCREW, motor mounting (Not Shown) 3
Parts List
®
17
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