PROFAX PRO-1VS User manual

PM1190 REV. 1
E: 09-07-2020
R: 08-09-2020
PRO-1VS
VOLTAGE-SENSING WIRE FEEDER
OWNER´S
MANUAL
PROCESSES
MIG (GMAW)
FLUX CORED (FCAW)
READ THE MANUAL BEFORE OPERATING THE UNIT
GIVETHISMANUALTO OPERATOR.

TABLE OF CONTENTS
ARC WELDING SAFETY PRECAUTIONS...........................................................................i
SECTION 1 -- SAFETY SIGNAL WORDS ...........................................................................1
SECTION 2 -- SPECIFICATIONS.........................................................................................1
2 - 1 SERIAL NUMBER AND RATING LABEL LOCATION.................................................................. 1
2 - 2 UNITSPECIFICATIONS ............................................................................................................... 1
2 - 3 WIRE TYPE, SIZE, AND FEED SPEED CAPABILITY.....................................................1
2 - 4 GUN RECOMMENDATION.......................................................................................................... 2
2 - 4 ENVIRONMENTALSPECIFICATIONS ........................................................................................ 2
SECTION 3 -- INSTALLATION .............................................................................................3
3 - 1 EQUIPMENTCONNECTIONDIAGRAM ...................................................................................... 3
3 - 2 INSTALLING DRIVE ROLLS......................................................................................................... 3
3 - 3 CONNECTING WELDING GUN AND VOLTAGE SENSING CLAMP.......................................... 4
3 - 4 CONNECTINGSHIELDING GAS.................................................................................................. 5
3 - 5 CONNECTING WELD CABLE...................................................................................................... 5
3 - 6 SELECTING CABLE SIZES. ........................................................................................................ 6
3 - 7 INSTALLING AND THREADING WELDING WIRE ...................................................................... 7
SECTION 4 -- OPERATION...................................................................................................8
4 - 1 CONTROLSWITHMETERS......................................................................................................... 8
SECTION 5 -- MAINTENANCE AND TROUBLESHOOTING ...........................................9
5 - 1 ROUTINEMAINTENANCE ........................................................................................................... 9
5 - 2 OVERLOADPROTECTIONAND THERMOSTATPROTECTION................................................ 9
5 - 3 TROUBLESHOOTING .................................................................................................................10
SECTION 6 -- ELECTRICAL DIAGRAM ........................................................................... 11
SECTION 7 -- PARTS LIST ................................................................................................ 12
WARRANTY POLICY

PM1190

PM1190 i
SECTION1 - SAFETY PRECAUTIONS- READ BEFORE USING
WARNING
- DANGER! - Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards
are shown in the adjoining symbols or explained in the text
- Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown
in the adjoining symbols or explained in the text.
- The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is
only a summary of the more complete safety information found in the Safety Standards.
- Only qualified persons should install, operate, maintain, and
repair this unit.
- During operation, keep everybody, especially children, away.
ARC WELDING can be hazardous.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are electrically live.
Incorrectly installed or improperly grounded equiment is a hazard.
1.- Do not touch live electrical parts.
2.- Wear dry, hole-free insulating gloves and body protection.
3.- Insulate yourself from work and ground using dry insulating
mats or covers.
4.- Disconnect input power or stop engine before installing or
servicing this equipment.
5.- Properly install and ground this equipment according to this
Owner's Manual and national, state, and local codes.
6.- Turn off all equipment when not in use.
7.- Do not use worn, damaged, undersized, or poorly spliced cables.
8.- Do not wrap cables around your body.
9.- Ground the workpiece to a good electrical (earth) ground.
10.- Do not touch electrode while in contact with the work (ground)
circuit.
11.- Use only well-maintained equipment. Repair or replace damaged
parts at once.
12.- Wear a safety harness to prevent falling if working above floor
level.
13.- Keep all panels and cover securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes and
skin. Noise from some processes can damage hearing.
1.- Wear a welding helmet fitted with a proper shade
of filter (see ANSIZ49.1 listed in Safety Standards) to protect
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
1.- Keep your head out of the fumes. Do not breath the fumes.
2.- If inside, ventilate the area and / or use forced ventilation at the arc
to remove welding fumes and gases.
3.- If ventilation is poor, use an approved air-supplied respirator.
4.- Read the Material Safety Data Sheets (MSDSs) and the
manufacturer´s instruction for metal, consumables, coatings, and
cleaners.
5.- Work in a confined space only if it is well ventilated, or while wearing
an air-supplied respirator. Shielding gases used for welding can
displace air causing injury or death. Be sure the breathing air is safe.
6.- Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7.- Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the
area is well ventilated, and if necessary, while wearing an air-
supplied respirator. The coatings and any metals containing these
elements can give off toxic fumes if welded.
FLYING SPARK AND HOT METAL can
cause injury
Chipping and grinding cause flying metal . As welds
cool, they can throw off slag.
1.- Wear approved face shield or safety goggles. Side shields
recommended.
2.- Wear proper body protection to protect skin.
your face and eyes when welding or watching.
2.- Wear approved safety glasses. Side shields recommended.
3.- Use protective screens or barriers to protect others from flash and
glade; warn others not to watch the arc.
4.- Wear protective clothing made from durable, flame- resistant mate
rial (wool and leather) and foot protection.
5.- Use approved ear plugs or ear muffs if noise level is high.

PM1190
ii
CYLINDERS can explode if damaged.
Shieldinggas cylinders contain gas under high pressure.
If damaged, a cylinder can explode. Since gas cylinders
are normally part of the welding process, be sure to
treat them carefully.
1.- Protect compressed gas cylinders from excessive heat, mechanical
shocks, and arcs.
2.- Install and secure cylinders in an upright position by chaining them
to a stationary support or equipment cylinder rack to prevent falling
or tipping.
3.- Keep cylinders away from any welding or other electrical circuits.
4.- Never allow a welding electrode to touch any cylinder.
5.- Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6.- Turn face away from valve outlet when opening cylinder valve.
7.- Keep protective cap in place over valve except when cylinder is in
use or connected for use.
8.- Read and followinstructions on compressed gas cylinders, associated
equipment, and CGA publication P-1 listed in Safety Standards.
ENGINES can be hazardous.
WARNING
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1.- Use equipment outside in open, well-ventilated
areas.
2.- If used in a closed area, vent engine exhaust outside and away from
any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1.- Stop engine before checking or adding fuel.
2.- Do not add fuel while smoking or if unit is near any sparks or open
flames.
3.- Allow engine to cool before fueling. If possible, check and add fuel
to cold engine before beginning job.
4.- Do not overfill tank - allow room for fuel to expand.
5.- Do not spill fuel. If fuel is spilled, clean up before starting engine.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1.- Keep all doors, panels, covers, and guards closed
and securely in place.
2.- Stop engine before installing or connecting unit.
3.- Have only qualified people remove guards or covers for maintenance
and troubleshooting as necessary.
4.- To prevent accidental stating during servicing, disconnect negative
(-) battery cable from battery.
5.- Keep hands, hair, loose clothing, and tools away from moving parts.
6.- Reinstall panels or guards and close doors when servicing is finished
and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosive gases.
1.- Always wear a face shield when working on a
battery.
2.- Stop engine before disconnecting or connecting battery cables.
3.- Do not allow tools to cause sparks when working on a battery.
4.- Do not use welder to charge batteries or jump start vehicles.
5.- Observe correct polarity (+ and -) on batteries.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot workpiece,
and hot equipment can cause fires and burns. Acciden-
tal contact of electrode or welding wire to metal objects
can cause sparks, overheating, or fire.
1.- Protect yourself and others from flying sparks and hot metal.
2.- Do not weld where flying sparks can strike flammable material.
3.- Remove all flammables within 35ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
4.- Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5.- Watch for fire, and keep a fire extinguisher nearby.
6.- Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
7.- Do not weld on closed containers surch as tanks or drums.
8.- Connect work cable to the work as close to the welding areas as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9.- Do not use welder to thaw frozen pipes.
10.- Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11.- Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.

PM1190
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
1.- Do not remove radiator cap when engine is hot. Allow engine to cool.
2.- Wear gloves and put a rag over cap area when removing cap.
3.- Allow pressure to escape before completely removing cap.
- Additional Symbols For Installation, Operation, And Maintenance
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
- Wear approved ear protection if noise level is high.
FALLING EQUIPMENT can injure
-Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
-Use equipment of adequate capacity to lift and support unit.
-If using lift forks to move unit, be sure forks arelong enough to extend
beyond opposite side of unit.
-Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
OVERUSE can cause OVERHEATING
-Allow cooling period; follow rated duty cycle.
-Reduce current or reduce duty cycle before starting to
weldagain.
-Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
-Put on grounded wrist strap BEFORE handling boards or parts.
-Use proper static-proof bags and boxes to store, move, or ship PC boards.
ARC WELDING can cause interference.
-Electromagnetic energy can interfere with sensitive
electronic equipment such as microprocessors, computers,
and computer-driven equipment such as robots.
-Be sure all equipment in the welding area is
electromagnetically compatible.
- To reduce possible interference, keep weld cables as short as possible, close
together, and down low, such as on the floor.
-Locate welding operation 100 meters from anysensitive electronic equipment.
-Besurethisweldingmachineisinstalledandgroundedaccordingtothismanual.
-If interference still occurs, the user must take extra measures such as moving
thewelding machine, using shielded cables, usingline filters, or shielding thework
area.
-Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit.
Read the safety information at the beginning of the manual and in each section.
- Definitions
iii

PM1190

PM1190
SECTION 1 SAFETY SIGNAL WORDS
IMPORTANT: Statements identify special instructionsnecessaryforthemostefficientoperation
ofthisequipment.
WARNING WARNINGstatementsidentifyproceduresorpracticeswhichmustbefollowedto
avoid serious personal injury or loss of life.
CAUTION CAUTIONstatementsidentifyproceduresorpracticeswhichmustbefollowedto
avoid minor personal injury or damage to this equipment.
Thefollowingsafetyalertsymbolandsignalwordsareusedthroughoutthismanualtocallattention
toandidentifydifferentlevelsofhazardandspecialinstructions.
SECTION 2 SPECIFICATIONS
Imagesshown in this manualmust betakenas a referenceand thereal unitmay
changeslightly.
CAUTION
2-1 Serial Number And Rating Label Location
Theserialnumberandratinginformationforthisproductislocatedinsidethedoor.Useratinglabel
todetermineinputpowerrequirementsand/orratedoutput.Forfuturereference,writeserialnumber
inspaceprovidedonbackcoverofthismanual.
2-2. Unit Specifications
Type of
Input
Power
Welding
Power
Source
Type
Wire Feed
Speed
Wire
Diameter
Range
Input Welding
Circuit Rating
Max. Wire
Spool
Capacity
Overall
Dimensions Weight
Open-Circuit/
Arc Voltage,
14 - 110
Volts DC
Constant
Voltage (CV)
Or Constant
Current (CC)
DC Power
Source Only
60 50- 8 ipm
( - 21.52 1.6
mpm) Depending
On Arc Voltage
Solid Wire:
.023 - .052 in.
(0.6 To 1.3 mm)
Flux Cored:
.030 - 5/64 in.
(0.8 To 2 mm)
300AmperesAt
100% Duty Cycle
4 AmperesAt00
60% Duty Cycle
45 lb (20.4 kg),
12 in. (304 mm)
Length: 21 in..5
(5 mm)46
Width: in.8.5
(2 mm)16
Height: 1 in.7
( mm)432
3 lb3
(15 kg)
See Section -3 for detailed wire type, size, and rated speed range2
TABLE 2-1 Unit Specifications
2-3 Wire Type, Size, and Feed Speed Capability
Motor Speed Wire Type Wire Size
Rated Speed Range
Standard All .023To 5/64 in.
(0.6 To 2 mm)
50 to 780 ipm
(1.3 -19.8 mpm)
TABLE 2-2 Wire Type, Size, and Feed Speed Capability
1

PM1190
2-4 Gun Recommendation
Process
GMAW - Hard or Cored Wires: M400-15, HDM400-15
FCAW - Self-Shielding Wires: 1260-15MLR, 1150-15MRL
2-5 Environmental Specifications
IP Rating
Operating Temperature Range
Storage Temperature Range
14 to 104  F (-10 to 40  C) -4 to 131  F (- 20 to 55°C)
This equipment is designed for outdoor use but not intended to be used outside during precipitationunless
Sheltered.
2
A. IP Rating
B. Temperature Specifications

PM1190
Installing Drive Rolls:
1 Drive Roll Securing Nut
2 Drive Roll Carrier
Turn nut one click until lobes of nut
line up with lobes of drive roll carrier.
3 Drive Roll
Slide drive roll onto drive roll carrier.
Turn nut one click.
Repeat procedure for top drive roll.
Cleaning Drive Rolls:
Remove drive rolls, and clean
grooves using a wire brush.
1
2
3
3-2 Installing Drive Rolls
FIGURE 3-1 Equipment Connection Diagram
Turn Off wire feeder and welding
power source.
Do not move or operate
equipment where it could tip.
Use only with CC/CV DC Power
Sources.
1 Constant Current (CC) or
Constant Voltage (CV) Welding
Power Supply
2 Weld Cable To Feeder
3 Work Cable To Workpiece
Weld cable and work cable connections
to power source (DCEN/ DCEP) are
dependant on wire type.
Since feeder is not polarity sensitive,
there is no need for an electrode
polarity switch.
4 Workpiece
5 Voltage Sensing Clamp
Connect voltage sensing clamp to
workpiece.
6 Gun
7 Gun Trigger Receptacle
8 Wire Feeder
9 Gas Hose
10 Gas Cylinder
Use of shielding gas is dependant on
wire type.
Shielding gas pressure not to exceed
100 psi (689 kPa).
SECTION 3 INSTALLATION
CAUTION READ SAFETY BLOCKS at beginning of manual before
proceeding.
3-1 Equipment Connection Diagram
1
2
3
4
8
9
10
6
7
5
FIGURE 3-2 Installing Drive Rolls 3

PM1190
1 Gun Securing Knob
2 Power Pin Receiver Block
3 Gun Power Pin
4 Power Pin Tip
5 Gun Locking Tab
Loosen gunsecuringknoband
seat the gun power pin fully into
powerpinreceiverblock.Align
thegunpowerpin groovewiththe
gunlocking tab. If the gunpower
pindoesnothaveagroove,
loosenknob. The gun lockingtab will
preventthetabfrominterferingwhen
the gun powerpin doesnot havea
groove.Tightengunsecuring
knob.
6 Gun Trigger Plug
7 Gun TriggerReceptacle
Connect guntrigger plug togun
triggerreceptacle.
8 Voltage Sensing Clamp
Connectvoltagesensingclamp
toworkpiece.
3-3 Connecting Welding Gun And Voltage Sensing Clamp
FIGURE 3-3 Connecting Welding Gun And Voltage Sensing Clamp
4
3
6
8
1
2
5
7
Turn Off wire feeder and
welding power source.
Weld voltage is present at
voltage sensing clamp
when wire feeder and
welding power source are
on. This condition exists
even if wire feeder lights
and meters are off.
Turn off wire feeder or
welding power source before
handling or moving
voltage sensing clamp.

PM1190
3-5 Connecting Weld Cable
FIGURE 3-4 Connecting Shielding Gas
1 Gas Hose With 5/8-18
Right-handThreadFittings
(User-Supplied)
Tighten gashose fittingto a
maximum of 100 in. lbs (12
N.m).
2 Shielding Gas Cylinder
Shielding gas pressure not to
exceed100 psi (689 kPa).
3 Valve
4 Flowmeter
Closevalveoncylinderwhen
finishedwelding.
3-4 Connecting Shielding Gas
FIGURE 3-5 Connecting Weld
1
Rear View
2
3
4
Turn Off wire feeder and
welding power source.
1 User-SuppliedWeldCable
Followwiremanufacturer’s
recommendations
forweldcablepolarity.
2 MaleConnector
3 User-Supplied Female
Connector
Connectmaleandfemale
connectors.
2
3
1
5

PM1190
6
TABLE 3-1 Selecting Cable Sizes
3-6. Selecting Cable Sizes
Turn off power before connecting to weld output terminals.
Do not use worn, damaged, undersized, or repaired cables.
NOTICE - The Total Cable Length in Weld Circuit (see table below) is the combined length of both
weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable
length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size
100
150
200
250
300
350
4
3
3
2
1
1/0
4
3
2
1
1/0
2/0
4
2
1
1/0
2/0
3/0
3
1
1/0
2/0
3/0
4/0
2
1/0
2/0
3/0
4/0
2-2/0
1
2/0
3/0
4/0
2-2/0
2-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
3/0
4/0
2-2/0
2-3/0
2-4/0
WELDING
AMPERAGE 10 TO 60%
Duty Cycle.
60 Thru
100%
Duty Cycle.
100 Ft (30 m) or less 150Ft (45 m) 200Ft (60 m) 250Ft (70 m) 300Ft (90 m) 400Ft (120 m)350Ft (105 m)
10 thru 100% Duty Cycle
TOTALCABLE(COPPER)LENGHTINWELDCIRCUITNOTEXCEEDING.*
* Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of not more than 300 circular mils per ampere.
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
CAUTION SEE SAFETY SIGNAL AT THE BEGINING THIS
MAN UAL

PM1190
FIGURE 3-7 Installing And Threading Welding Wire
Installing Wire And Adjusting Hub
Tension:
1 Retaining Nut
2 Hub Tension Adjustment Knob
Removeretainingnut,andinstallspool
so hub pin fits spool hole. Reinstall
retainingnut.
Adjust tension knob so only a slight
force is needed to turn spool.
Do not over tighten tension knob. It
is not necessary to use any tools to
tighten the knob.
Threading Welding Wire:
3 Pressure Adjustment Knob
Lay gun cable out straight.
Openpressureassembly. Holdwire
tightly andcutoff end.Guidewire
throughinletguide,intodriveroll
grooves,andintogunliner.
Closepressure assembly and tighten
pressureadjustmentknobenoughto
feed wire. Press jog switch until wire
comesout of gun.
Tosetproperdriverollpressure,
releasethepressureonthedriverolls
by loosening thepressureadjustment
knob. Position gunat about a 45
degreeangle, with nozzleabout two
inchesfromawoodensurface.While
feedingthewireagainstthewooden
surface, increasethe pressure to one
half turn pastthe point where thewire
stops slipping. If the wire slips at
maximumhand-tightpressure,there
may beother problems. Checkthe gun
liner, spool tension, contact tip and
drive rollwear, asall thesecan cause
wirefeedingproblems.
Cut off wire, and closedoor.
3-7 Installing And Threading Welding Wire
1
2
3
7
WARNING SEE SAFETY PRECAUTIONS at the beginning of manual for basic welding
information.

PM1190
FIGURE 4-1 Controls With Meters
1 Power Control Switch
2 Wire Speed / Amperage Meter
Displays preset wire speed. While welding in CC mode,
actual wire speed is dependant on arc voltage.
Amperage displayed at the feeder is approximate.
Refer to power source for actual amperage.
3 Voltmeter
Displays actual arc voltage or open circuit voltage at the
feeder.
4 Wire Speed Control
Use control to adjust wire speed within the speed range
selected by the wire speed range switch, located on the
inner control panel. Maximum wire speed may be limited by
arc voltage.
5 CC/CV Switch
Use switch to match feeder with the output of the power
source.
While welding in CC mode, actual wire speed is dependent
on arc voltage.
While welding in CV mode, the wire feeder remains at
constant speed and the wire speed is not dependent on arc
voltage. Maximum wire speed may be limited by arc voltage.
6 HI/LO Speed Range Switch
Use switch to select speed range. High range is 100 to 800
Inches per Minute (2.5 to 20.3 Meters per Minute). Low range
is 25 to 200 Inches per Minute (0.6 to 5.1 Meters per Minute).
7 Display speed / inches per minute
Wire Speed / Amperage Meter will display only Wire Speed
in Inches per Minute.
Display amperage
Wire Speed / Amperage Meter will display Amps while
welding.
8 Trigger Hold Switch
Trigger hold allows operator to weld without holding gun
trigger.
To use trigger hold function, place trigger hold switch in the I
position.
Press and hold the trigger. Welding will continue when
trigger is released.
To stop welding, press and release the trigger.
9 Jog Switch
Pressing the Jog switch allows the operator to jog wire
without energizing the contactor or gas valve.
10 Purge Switch
Pressing the Purge switch allows the operator to
purge gas lines before welding and to preset gas
flow rate at the flowmeter.
4.1 Controls With Meters
SECTION4 OPERATION
8
1
2
3
4
9
10
5
6
7
8
CAUTION SEE SAFETY BLOCKS at beginning of manual
before proceeding.

PM1190
5-2 Overload Protection And Thermostat Protection
SECTION 5 - MAINTENANCE & TROUBLESHOOTING
5-1 Routine Maintenance
FIGURE 5-1 Overload Protection And Thermostat Protection
= Check = Change = Clean = Replace
Every
3
Months
Replace
Damaged
Or
Unreadable
Labels
Replace
Damaged Gas
Hose
Repair Or Replace
Cracked CablesAnd
Cords
Every
6
Months Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
Turn Off wire feeder and
welding power source.
1 Supplementary Protector CB1
CB1 protects wire feeder from overload.
Correct problem and reset
CB1.
Close and latch door.
Thermostat Protection
Unit has internal thermostat protection
and will not feed wire if overheating
occurs.
9
CAUTION SEE SAFETY BLOCKS at beginning of manual
before proceeding.

PM1190
5-3 Troubleshooting
10
Trouble Remedy
Check power switch S1 and connections, and replace if necessary.
Check supplementary protector CB1. Reset CB1.
Unit overheated. Allow unit to cool.
Check sensing lead connection.
Check gun trigger plug connection.
Check gun trigger. See gun Owner’s Manual.
Have Factory Authorized Service Agent check Motor Control Board (PC1).
Readjust hub tension (see Section 3-7).
Readjust drive roll pressure (see Section 3-7).
Clean or replace dirty or worn drive roll (see Section 3-2).
Remove weld spatter around gun nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Change to correct size and type drive roll (see Section 3-2)
Check that Power Pin Tip is correct size (see Section 3-3).
Have Factory Authorized Service Agent check Motor Control Board (PC1).
Readjust hub tension (see Section 3-7).
Check and replace contact tip or liner if necessary. See gun Owner’s Manual
Have Factory Authorized Service Agent check Motor Control Board (PC1).
Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch.
See gun Owner’s
Have Factory Authorized Service Agent check Motor Control Board (PC1).
Make sure CC/CV switch is in CC position (see Section 4-1).
Increase power source inductance setting if available.
Increase output setting of power source or decrease wire feed speed.
Clear blockage in gas hose or replace hose.
Clear blockage in welding gun.
Check gas valve.
Check coil voltage and connections ofgas valve GS1. Check continuity of coil.
Replace GS1 if necessary.
Have Factory Authorized Service Agent check Motor Control Board (PC1).
Check setting of trigger hold switch, if applicable.
Check contactor W1 to see if contacts are frozen closed.
Wire remains energized after trigger is released.
Wire does not feed; open-circuit voltage available.
Wire feeds erratically.
Wire feeds when Jog switch is pressed but not when
gun trigger is pressed.
Wire stubbing on lowend using a constant current
power source or feeder resets.
Gas does not flow or does not stop flowing; wire
feeds.
Motor runs slowly.

PM1190 11
SECTION 6 ELECTRICAL DIAGRAM
17
TP1 TP2
+
M
20 22
C100 C101
++SR1
42
41
40
RC4-C
RC4-B RC4-A RC6-A
1
P5
2
P6 RC6-B
S2
CC
S3A
VC
47
48 49
RC4-H
RC4-J RC4-K
CC
S3B
VC
46
44 RC4-G
RC4-E
44
RC4-F
45
43 RC4-D
P2 P3 P4
P7
52 W1
31
34
35 32 30
GS1
S4B
S4A
14 16
+AC
AC
OFF
ON
S1
55
11 12 HD1 W1
56
11
CB1
CW
MAX
R100
RC2-A
RC2-C
RC1-E
RC1-G
RC1-B
RC1-C
RC3-F
RC3-E
RC3-B
RC3-C
RC3-A
PC1
MOTOR BOARD
RC1 / PLG1 RC2 / PLG2 RC3 / PLG3 RC4 / PLG4 RC5 / PLG5 RC6 / PLG6
8
9
S
6
A
M
P
/
S
P
1
4
3
2
RC -
RC - RC -
7
6
+
C102
RC5-B
RC5-A
B
D
A
1
RC
-
1
2
2
D
R
C
-
R
C
-
R
C
-
R
C
-
1
2
1
2
9
3
1
5
2
4
2
5
1
0
1
3
7
7
7
5
7
6
7
8
7
9
8
1
8
0
T
R
I
G
G
E
R
H
O
L
D
(
S
7
)
OFF
ON
RC1-7
RC1-2
RC1-8
RC1-4
RC1-5
RC1-11
RC2-2
RC2-6
RC2-8
RC2-4
ADJ
+ V
- V
N L
FMW +24V
RC1-12
RC1-6
RC01-2 RC01-1 RC01-3 RC01-4 RC01-5
RC01-6
RC02-1 RC02-3 RC02-2
4
5
3
4 5 3
4
5
3
14
16
PC3
R
C
2
/
P
L
G
8
R
C
1
/
P
L
G
7
RC02 / PLG 10
RC01 / PLG 9
P
C
2
4
R
C
4
0
-
2
R
C
4
0
-
1
1
2
RC1-10
7
4
G
U
N
V
O
L
T
S
E
N
S
E
L
E
A
D
W
E
L
D
C
A
B
L
E
W
I
R
E
D
R
I
V
E
R
H
O
U
S
I
N
G
WIRE
PURGE
CC/CV SWITCH
HIGH/LOW
SPEED RANGE SWITCH
LOW
S5A
HIGH
LOW
S5B
HIGH
IT
S7 = OFF (NO OPERATION 2T)
IS SHOWN IN DIAGRAM THE
CONTROLS AT NEXT POSSITION
S1 = OFF ( INOPERATIVE FEEDER ) S2 = DEFUSED ( DO NOT OPERATES WIRE PURGE ) S3 = CC ( SET AS CC MODE ) S4 = DEFUSED ( DO NOT OPERATES GAS PURGE ) S5 = LOW ( SET AS LOW RANGE ) S6 = SP ( SHOWS SPEED ON DISPLAY SCREEN )
AMPERAGE
SPEED
METER BO
A
R
D
TRIG
G
E
R
(G
U
N
)
GAS PURGE

PM1190
SECTION 7 PARTS LIST
LIST 7-1 Part List Wire Feeder
12
IT. No. PART No. QUANTITY
1 PM0851 1
2 PC2123 1
3 PM1240 1
4 PS1612 1
5 MP08414 1
6 PS1618 1
7 MC10209 1
8 PS1399 1
9 PS1630 1
10 MM04279 1
11 PA0940 1
12 MC10885 2
13 PA0936 1
14 PA0957 1
15 MC10895 1
16 PA0941 1
17 PA1056 1
18 MS03964 1
19 MV01050 1
20 PT1071 1
21 MP08335 1
22 MT08470 1
23 MT08503 2
24 PT2143 1
25 PT2145 1
26 126693 1
27 PT2547 2
28 PT2566 1
29 PP3591 1
30 MR09816 1
31 MI01227 4
32 PP3592 1
33 MC11467 1
34 MP02512 1
35 PF0925 1
36 MI01281 2
37 MI01178 1
38 MP08416 1
39 PA0928 6
40 PA0929 8
41 PS1634 1
42 PS1636 1
43 MS03965 14
44 PC1864 1
45 PT3477 1
46 PR1144 VALVE REINFORCEMENT 1
47 PR1145 2
48 PA1197 1
49 MF02383 1
50 LC-40HD 1
AUXILIARY SOURSE, CLAMP
AUXILIARY SOURSE
WELD CABLE
SCREW GROMMENT
MOTORGEAR SEPARATOR
VALVE PLATE, CLAMP
CIRCUIT CARD, VOLTAGE SELECTOR
HUB SUPPORT
CIRCUIT CARD, CONTROL
THERMOSTAT
STRAIN RELIEF
HUB
RECTIFIER, BRIDGE
RETAINING NUT FOR SOLENOID VALVE
SOLENOID VALVE
ELECTROLITIC CAPACITOR
CAPACITOR, INSULATOR
CAPACITOR, CLAMP
ELECTROLITIC CAPACITOR
CONTACTOR
GEARMOTOR INSULATOR
CAPACITOR, CLAMP
MOTORGEAR SEPARATOR
FEMALE ISOLATOR
MALE INSULATOR
PLATE, CONTROLS
KNOB
CIRCUIT CARD, DIGITAL METER
VALVE PLATE
SWITCH DPDT
THERMAL CIRCUIT BREAKER
SWITCH SPST
SWITCH DPDT
POTENTIOMETER
WELD LEAD CONNECTION
DESCRIPTION
CASE
CHASSIS
CAPACITOR, INSULATOR
GAS HOSE
BUS-BAR OUTPUT
SPOOL, HUB SUPPORT
COVER, COMPONENTS
HEEL, SUPPORT
WORK CLAMP AND LEAD
MOTOR INSULATOR
PLATE, INNER CONTROLS
CURRENT TRANSDUCER
GEARMOTOR
BUS-BAR INPUT

PM1190 13
FIGURE 7-1 General Assembly
5
4
3
1
0
2
6
9
4
3
24
17
35
25
3
8
37
34
33
40
42
41
45
14
16
23
7
8
22
21 6
15
32 47
13
11
12
48
49 20
18
19
39
31
44
28
2
2
7
1
46
29
30
36
50