AEC 200-4CSOLID STATE SPOOLGUN & CONTROL

OPERATION AND PARTS MANUAL

P.O. Box 898 • Pearland, TX 77588-0898 • (281) 485-6258 • Fax: (281) 485-8030

7190

®

Aluminum Case

FOR USE IN CONNECTING THE AEC 200-4 SPOOLGUNTO CONSTANT VOLTAGE POWER SOURCES ONLY.

WARNINGS AND SAFEGUARDS FOR WELDING AND CUTTING OPERATIONS Form WSWC 594Important - 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 and the power source manual used with this equipment. 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 per formed 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 in 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 on metal to be welded to a good electrical ground (earth). 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 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 no par t of the electrode circuit is touching the work or ground to prevent accidental contact. 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.

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 breath these fumes or gases. Ventilation must be adequate to remove smoke, fumes, and gases during welding procedure to protect operators and others in the immediate area. Do not weld in locations where chlorinated

hydrocarbon vapors 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 with proper lens that conform with 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 with noncombustible screens similarly painted. 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. Causes of fire and explosion are 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 such procedures will not cause flammable or toxic vapors from substances inside. Purging with inert gas is recommended. Use only inert gases or iner t gas mixes as required by the process. Special precautions should be used to prevent hazardous situations when using compressed gas. Never Use Oxygen in a Welding Torch. Use of combustible compressed gases can cause explosions resulting in personal injury or death. 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.

SAFETY AND OPERATING REFERENCESA) 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 10018D) 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 33135E) NFPA 51B, “Fire Prevention in Cutting and Welding Processes”F) NFPA-70, “National Electrical Code”

NFPA: National Fire Protection Association, Batterymarch Park, Quincy, MA 02269G) CGA P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”

CGA: Compressed Gas Association, 1235 Jefferson Davis Hwy., Arlington, Va 22202H) Code of Federal Regulations (OSHA) 29 CFR 1910

US: U.S. Government Printing Office, Washington, DC 20402I) CSA Standard W117.2, “Safety in Welding, Cutting and Allied Processes”

CSA: Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3

P.O. Box 898 • Pearland, Texas 77588-0898(281) 485-6258

Table of Contents

Warnings and Safeguards For Welding and Cutting Operations ........................................... 1

AEC 200-4C Specifications .............................................................................................. 2

Preweld Check List, Shutting Down, Maintenance ............................................................. 3

AEC 200-4 Spool Gun Isometric Exploded View ................................................................. 4

Replacement Parts for PROFAX AEC 200-4 Spool Gun ....................................................... 5

Removal and Replacement Information ............................................................................. 6

AEC-200 Contact Tips, Nozzles, and Adapters .................................................................. 7-8

AEC 200-4C Control Box Parts List .................................................................................. 9

AEC 200-4C Control Diagram ........................................................................................... 10

AEC 200-4 Gun Wiring ..................................................................................................... 10

CONTENTS PAGE

WARRANTY

LIMITED WARRANTY—Subject to the terms and conditions hereof, PROFAX, Pearland, Texas warrants its Model AEC 200 to be free from defect on workmanship and material at the time of delivery by PROFAX.

PROFAX will honor warranty claims on this equipment that result from a failure due to a defect for a time period as listed below beginning from date of sale to the original user.

AEC 200-4 Spool Gun — 90 daysAEC 200-4C Control Box — 1 year

Upon the return of this unit at users expense, PROFAX reserves the right to either repair or replace as necessary.

This is the only warranty either expressed or implied covering this unit.

CERTIFICATE OF QUALITY

This product was manufactured by PROFAX, Pearland, Texas using the highest quality of domestic components available. Each unit is tested to meet all industry standards to the maximum.

®

1

WARNINGS AND SAFEGUARDS FOR WELDING AND CUTTING OPERATIONS Form WSWC 594Important - 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 and the power source manual used with this equipment. 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 per formed 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 in 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 on metal to be welded to a good electrical ground (earth). 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 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 no par t of the electrode circuit is touching the work or ground to prevent accidental contact. 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.

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 breath these fumes or gases. Ventilation must be adequate to remove smoke, fumes, and gases during welding procedure to protect operators and others in the immediate area. Do not weld in locations where chlorinated

hydrocarbon vapors 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 with proper lens that conform with 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 with noncombustible screens similarly painted. 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. Causes of fire and explosion are 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 such procedures will not cause flammable or toxic vapors from substances inside. Purging with inert gas is recommended. Use only inert gases or iner t gas mixes as required by the process. Special precautions should be used to prevent hazardous situations when using compressed gas. Never Use Oxygen in a Welding Torch. Use of combustible compressed gases can cause explosions resulting in personal injury or death. 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.

SAFETY AND OPERATING REFERENCESA) 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 10018D) 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 33135E) NFPA 51B, “Fire Prevention in Cutting and Welding Processes”F) NFPA-70, “National Electrical Code”

NFPA: National Fire Protection Association, Batterymarch Park, Quincy, MA 02269G) CGA P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”

CGA: Compressed Gas Association, 1235 Jefferson Davis Hwy., Arlington, Va 22202H) Code of Federal Regulations (OSHA) 29 CFR 1910

US: U.S. Government Printing Office, Washington, DC 20402I) CSA Standard W117.2, “Safety in Welding, Cutting and Allied Processes”

CSA: Canadian Standards Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3

P.O. Box 898 • Pearland, Texas 77588-0898(281) 485-6258

Table of Contents

Warnings and Safeguards For Welding and Cutting Operations ........................................... 1

AEC 200-4C Specifications .............................................................................................. 2

Preweld Check List, Shutting Down, Maintenance ............................................................. 3

AEC 200-4 Spool Gun Isometric Exploded View ................................................................. 4

Replacement Parts for PROFAX AEC 200-4 Spool Gun ....................................................... 5

Removal and Replacement Information ............................................................................. 6

AEC-200 Contact Tips, Nozzles, and Adapters .................................................................. 7-8

AEC 200-4C Control Box Parts List .................................................................................. 9

AEC 200-4C Control Diagram ........................................................................................... 10

AEC 200-4 Gun Wiring ..................................................................................................... 10

CONTENTS PAGE

WARRANTY

LIMITED WARRANTY—Subject to the terms and conditions hereof, PROFAX, Pearland, Texas warrants its Model AEC 200 to be free from defect on workmanship and material at the time of delivery by PROFAX.

PROFAX will honor warranty claims on this equipment that result from a failure due to a defect for a time period as listed below beginning from date of sale to the original user.

AEC 200-4 Spool Gun — 90 daysAEC 200-4C Control Box — 1 year

Upon the return of this unit at users expense, PROFAX reserves the right to either repair or replace as necessary.

This is the only warranty either expressed or implied covering this unit.

CERTIFICATE OF QUALITY

This product was manufactured by PROFAX, Pearland, Texas using the highest quality of domestic components available. Each unit is tested to meet all industry standards to the maximum.

®

1

AEC 200-4C SPECIFICATIONSInput Power Weld Output Rating Wire Capacity Wire Speed Range Dimensions Weight

Argon or Helium Gun & Cables

250 Amps .023 in. through Net 26 lbs. 115VAC 50% Duty Cycle 1/16" Aluminum 30 IPM Height 8.25" Ship 29 lbs.

50/60 Hz. 200 Amps or to Width 3"100% Duty Cycle .023 in. through 800 IPM Length 15" 4C Control

.045 Hard WireNet 7.5 lbs.Ship 9 lbs.

The AEC 200-4 Spoolgun and AEC 200-4C control are interfaced together to give the improved SOLID STATE motor control performance to the Classic AEC 200 Spoolgun design. This system can be connected to any adequately sized CONSTANT VOLTAGE welding power source that provides 115V or 24V AC 50/60 Hz. auxiliary power and will operate 115 volt feedback or contact closure contactor circuits.

INSTALLATION (For help see fig. 2)

WARNING!DISCONNECT ALL ELECTRICAL POWER TOTHE WELDING POWER SOURCE BEFORE

INSTALLING THIS EQUIPMENT

1. Connect the two conductor contactor cord to the contactor receptacle of the welding power source. (See “Note” at bottom of page)

2. Connect the AEC 200-4 Spoolgun as follows:A. Weld cable to the POSITIVE (+) terminal of the welding power source.B. Gas hose to the flowmeter/regulator at the gas supply.C. Control cable to the receptacle on the front of the AEC 200-4C control box.

3. Connect the three conductor power cord to a 115 Volt 50/60 Hz. power source.(This control can also be connected to a 24 Volt AC power source. Contact the “PROFAX” technical service department if this is prefer red.)

NOTE!The AEC 200-4C control box is shipped with the contactor control cord connected to terminals 1 & 2 on “TS1”

terminal strip. This is for use with welding power sources requiring a normally open set of contacts to operate the contactor.

Power sources requiring 115 volt AC for contactor operation: (For help see fig.3)A. Remove the control box cover.B. Locate the four terminal strip “TS1”. Move the black and white wires from terminals 1 and 2 to

terminals 3 and 4. (color of wire to terminal does not matter)C. Install the top cover and secure.

FIGURE 2

CONSTANT VOLTAGE POWER SOURCE WITH THE AEC 200-4C GUN & CONTROL

PREWELD CHECK LISTA.) Make sure the AEC 200-4 Spoolgun is set up for wire size selected with, proper liner, contact tube and nozzle.B.) All control cable and hose connections are tight.C.) Mig wire installed for counter clockwise feed-off.D.) Proper shielding gas and flow selected and cylinder turned on and valve backseated.E.) Power source on and set for required voltage.F.) Welding wire extended from end of nozzle.

NOTE: We recommend using scrap metal for trial welds and adjusting gun speed, amps and voltage before your welding operation. This will familiarize you with the Spoolgun's operative characteristics.

SHUTTING DOWNAfter your welding job is complete or work is stopped for any appreciable time proceed as follows:A.) Turn power source off.B.) Disconnect 115VAC to the control box if separate from power source.C.) Turn shielding gas off.D.) Make sure cover is secured on spoolgun.

MAINTENANCENOTE: Before performing any maintenance on spoolgun, BE SURE all sources of power are TURNED OFF.It is important to periodically inspect and clean if necessary the AEC 200-4 Spoolgun. Inspect as follows:1.) Inspect cable/hose assembly, (power cords, control cables & gas hose) for frayed or cracked insulation. Damaged wires and cables

are hazardous to your health and should be repaired or replaced immediately.2.) Look for and clean if necessary any grease or grime from spoolgun. Grease containing metallic par ticles can cause short circuits.3.) Check all mounting screws and nuts for tightness.4.) Front cover should be in place during any welding operation. This keeps weld spatter from causing short circuits.

32

115 VOLT ACPOWER CABLE

115 VOLT AC*PLUG NOT INCLUDED

CONTACTOR CONTROLCABLE TO CONTACTORCONTROL RECEPTACLEON POWER SOURCE(see installation instructions)

POWERSOURCE

HOSE TO GASSUPPLY

CONNECTIONBLOCK

CABLEBOOT

GASCYLINDER

POSITIVEOUTPUTTERMINAL

WELDING CABLE TOPOSITIVE OUTPUT TERMINALON POWER SOURCE

MODELAEC 200-4CCONTROL

MODELAEC 200-4SPOOL GUN

GAS & WELDING CABLE

WELDING CABLE FROMNEGATIVE OUTPUT TERMINALON POWER SOURCE

WORK

MULTI CONDUCTORCABLE TO TERMINALSTRIP IN CONTROL BOX

AEC 200-4C SPECIFICATIONSInput Power Weld Output Rating Wire Capacity Wire Speed Range Dimensions Weight

Argon or Helium Gun & Cables

250 Amps .023 in. through Net 26 lbs. 115VAC 50% Duty Cycle 1/16" Aluminum 30 IPM Height 8.25" Ship 29 lbs.

50/60 Hz. 200 Amps or to Width 3"100% Duty Cycle .023 in. through 800 IPM Length 15" 4C Control

.045 Hard WireNet 7.5 lbs.Ship 9 lbs.

The AEC 200-4 Spoolgun and AEC 200-4C control are interfaced together to give the improved SOLID STATE motor control performance to the Classic AEC 200 Spoolgun design. This system can be connected to any adequately sized CONSTANT VOLTAGE welding power source that provides 115V or 24V AC 50/60 Hz. auxiliary power and will operate 115 volt feedback or contact closure contactor circuits.

INSTALLATION (For help see fig. 2)

WARNING!DISCONNECT ALL ELECTRICAL POWER TOTHE WELDING POWER SOURCE BEFORE

INSTALLING THIS EQUIPMENT

1. Connect the two conductor contactor cord to the contactor receptacle of the welding power source. (See “Note” at bottom of page)

2. Connect the AEC 200-4 Spoolgun as follows:A. Weld cable to the POSITIVE (+) terminal of the welding power source.B. Gas hose to the flowmeter/regulator at the gas supply.C. Control cable to the receptacle on the front of the AEC 200-4C control box.

3. Connect the three conductor power cord to a 115 Volt 50/60 Hz. power source.(This control can also be connected to a 24 Volt AC power source. Contact the “PROFAX” technical service department if this is prefer red.)

NOTE!The AEC 200-4C control box is shipped with the contactor control cord connected to terminals 1 & 2 on “TS1”

terminal strip. This is for use with welding power sources requiring a normally open set of contacts to operate the contactor.

Power sources requiring 115 volt AC for contactor operation: (For help see fig.3)A. Remove the control box cover.B. Locate the four terminal strip “TS1”. Move the black and white wires from terminals 1 and 2 to

terminals 3 and 4. (color of wire to terminal does not matter)C. Install the top cover and secure.

FIGURE 2

CONSTANT VOLTAGE POWER SOURCE WITH THE AEC 200-4C GUN & CONTROL

PREWELD CHECK LISTA.) Make sure the AEC 200-4 Spoolgun is set up for wire size selected with, proper liner, contact tube and nozzle.B.) All control cable and hose connections are tight.C.) Mig wire installed for counter clockwise feed-off.D.) Proper shielding gas and flow selected and cylinder turned on and valve backseated.E.) Power source on and set for required voltage.F.) Welding wire extended from end of nozzle.

NOTE: We recommend using scrap metal for trial welds and adjusting gun speed, amps and voltage before your welding operation. This will familiarize you with the Spoolgun's operative characteristics.

SHUTTING DOWNAfter your welding job is complete or work is stopped for any appreciable time proceed as follows:A.) Turn power source off.B.) Disconnect 115VAC to the control box if separate from power source.C.) Turn shielding gas off.D.) Make sure cover is secured on spoolgun.

MAINTENANCENOTE: Before performing any maintenance on spoolgun, BE SURE all sources of power are TURNED OFF.It is important to periodically inspect and clean if necessary the AEC 200-4 Spoolgun. Inspect as follows:1.) Inspect cable/hose assembly, (power cords, control cables & gas hose) for frayed or cracked insulation. Damaged wires and cables

are hazardous to your health and should be repaired or replaced immediately.2.) Look for and clean if necessary any grease or grime from spoolgun. Grease containing metallic par ticles can cause short circuits.3.) Check all mounting screws and nuts for tightness.4.) Front cover should be in place during any welding operation. This keeps weld spatter from causing short circuits.

32

115 VOLT ACPOWER CABLE

115 VOLT AC*PLUG NOT INCLUDED

CONTACTOR CONTROLCABLE TO CONTACTORCONTROL RECEPTACLEON POWER SOURCE(see installation instructions)

POWERSOURCE

HOSE TO GASSUPPLY

CONNECTIONBLOCK

CABLEBOOT

GASCYLINDER

POSITIVEOUTPUTTERMINAL

WELDING CABLE TOPOSITIVE OUTPUT TERMINALON POWER SOURCE

MODELAEC 200-4CCONTROL

MODELAEC 200-4SPOOL GUN

GAS & WELDING CABLE

WELDING CABLE FROMNEGATIVE OUTPUT TERMINALON POWER SOURCE

WORK

MULTI CONDUCTORCABLE TO TERMINALSTRIP IN CONTROL BOX

PROFAX AEC 200-4 SPOOL GUN REPLACEMENT PARTS FOR PROFAX AEC 200-4 SPOOL GUN

1 4147 2360-7147 Nozzle Body

2 4641 2360-7641 Spacer

3 1102 2360-2102 Grommet

4 4640 2360-7640 Adapter Sleeve

5 1614 2360-0614 Nut

6 1613 2360-0613 Fitting

7 1058 2360-2058 Inner Barrel

8 1103 2360-2103 Guide Tube

9 1111 2360-2111 O-ring

1078 2360-2078 Arm Assembly

10 5133 2360-2133 Green Liner .030-.035

5109 2360-2109 Red Liner .045-3/64"

5134 2360-2134 White Liner 1/16"

11 1743 9201-6743 Pal Nut

12 1100 2360-2100 Guide

13 1754 831-1754 Retainer

14 1117 2360-2117 Spring

15 1107 2360-2107 Valve Pin

16 1953 831-1953 Diaphragm

17 1098 2360-2098 Housing

18 1388 2360-3388 Retaining Ring

19 1077 2360-2077 Pin

20 1076 2360-2076 Spacer

21 1072 2360-2072 Driven Roll

22 1122 2360-2122 Adjusting Screw

23 1171 2360-6171 Pressure Arm

24 9260 Terminal Cover

25 1741 9201-6741 Pal Nut

26 1080 2360-2080 Drive Roll

27 1130 9204-4130 Screw

28 1082 2360-2082 Spring Catch

29 1094 2360-2094 Inlet Bushing

30 1709 2389-3709 O-ring

31 1079 2360-2079 Drive Roll Spring

32 1987 2360-6987 Pivot Screw

33 1930 2360-2130 Insulating Insert

34 1127 9204-4127 Screw

35 1081 2360-2081 Motor Insulator

36 1071 831-2071 O-ring

37 1004 9220-0004 Key

38 1061 2360-2061 Motor

39 1066 2360-2066 Handle

40 1014 9218-0014 Insert 6-32

41 1037 9218-0037 Insert 1/4"-20

42 1036 9218-0036 Insert 4-40

43 1606L 636202 Potentiometer

44 1095 2360-2095 Bracket

45 1993 9204-3093 Screw

46 1131 9204-4131 Set Screw

47 1096 2360-2096 Knob

48 1280 2310-0280 Micro Switch

49 1113 2360-2113 Insulator

50 1018 9205-6018 Screw

51 1093 2360-2093 Trigger Pin

52 1097 2360-2097 Trigger

53 1682 9204-9682 Set Screw

54 1134 9204-4134 Screw

55 1126 9205-6126 Lockwasher

56 1167 9204-4167 Screw

57 1579 834-0098 Cable Clamp

58 1715 9201-6715 Nut

59 1059 2360-2059 Sleeve

60 1215 9204-2715 Rd. Head Screw

61 1027 9205-6027 Washer

62 1012 9201-8012 Speednut

63 1121 2360-2121 Terminal Strip

64 1114 2360-2114 Marker Strip

65 1091 2360-2091 Post

66 1090 2360-2090 Spindle

67 1089 2360-2089 Washer

68 1118 2360-2118 Spindle Spring

69 1624 9204-2624 Screw

70 1092 2360-2092 Spindle Screw

71 1969 2360-2069 Spade Terminal

72 1060-4 2360-2060-4 Control Cable Assy. w/Plug

73 1057 2360-2057 Hose Cable Assembly

74 1255 803-0255 Connection Nut

75 1052 9226-0052 Retaining Ring

76 1116 2360-2116 Thrust Washer

77 1083 2360-2083 Lock Screw

78 1104 2360-2104 Dial Plate

79 1607L 647257 8 Pin Male Plug

80 1608L Clamp Only

81 1433 2360-3433 Ferrule

82 1832 2360-0832 Fitting

83 1074 2360-2074 Cable Boot

84 1087 2360-2087 Block

85 1972 9228-0072 Terminal

86 1009 9205-6009 Washer

87 1742 9201-6742 Nut

88 1086 2360-2086 Cable Assembly

89 1923 2360-2123 Cable Lug

90 1273 803-0273 Gland

91 1277 803-0277 Nut

92 1206 803-9206 Ferrule

93 1085 2360-2085 Hose Assembly

94 1245 803-0245 Gland

95 1065 2360-2065 Rear Cover

96 1064 2360-2064 Front Cover

97 1264 832-9264 Wrench

98 9338 Hole Plug

99 9251 Pot Brake

® ®PROFAX ESAB /AIRCONO. PART NO. PART NO. DESCRIPTION

® ®PROFAX ESAB /AIRCONO. PART NO. PART NO. DESCRIPTION

54

®PROFAX is in no way affiliated with ESAB /AIRCO . The parts advertised for sale are not genuine parts, but are parts made for and by PROFAX. References to machines, torches, and numbers are for your convenience only. We reserve the right to substitute genuine parts in place of PROFAX parts.

® ® ® ® ®ESAB /AIRCO ESAB /AIRCO® ®ESAB /AIRCO

97

1

51

18

27

28

29

25

26

34

1733

32

31

36

35 37

38

39

42

4041

4445

4850

89

88878685

84

9092

93

83

9274 94

91

75

78

77

76

96

73

7980

74

82

8173

72

71

49

47

4699

43

30

65

96

66

67 68

61 6970

64

63

58

62

5634

56

5760

61

59

14

55 5498

53

52

2

3

11

412

56

13

7

14

8

15

9

16

18

19

24

22

23

20

21

10

PROFAX AEC 200-4 SPOOL GUN REPLACEMENT PARTS FOR PROFAX AEC 200-4 SPOOL GUN

1 4147 2360-7147 Nozzle Body

2 4641 2360-7641 Spacer

3 1102 2360-2102 Grommet

4 4640 2360-7640 Adapter Sleeve

5 1614 2360-0614 Nut

6 1613 2360-0613 Fitting

7 1058 2360-2058 Inner Barrel

8 1103 2360-2103 Guide Tube

9 1111 2360-2111 O-ring

1078 2360-2078 Arm Assembly

10 5133 2360-2133 Green Liner .030-.035

5109 2360-2109 Red Liner .045-3/64"

5134 2360-2134 White Liner 1/16"

11 1743 9201-6743 Pal Nut

12 1100 2360-2100 Guide

13 1754 831-1754 Retainer

14 1117 2360-2117 Spring

15 1107 2360-2107 Valve Pin

16 1953 831-1953 Diaphragm

17 1098 2360-2098 Housing

18 1388 2360-3388 Retaining Ring

19 1077 2360-2077 Pin

20 1076 2360-2076 Spacer

21 1072 2360-2072 Driven Roll

22 1122 2360-2122 Adjusting Screw

23 1171 2360-6171 Pressure Arm

24 9260 Terminal Cover

25 1741 9201-6741 Pal Nut

26 1080 2360-2080 Drive Roll

27 1130 9204-4130 Screw

28 1082 2360-2082 Spring Catch

29 1094 2360-2094 Inlet Bushing

30 1709 2389-3709 O-ring

31 1079 2360-2079 Drive Roll Spring

32 1987 2360-6987 Pivot Screw

33 1930 2360-2130 Insulating Insert

34 1127 9204-4127 Screw

35 1081 2360-2081 Motor Insulator

36 1071 831-2071 O-ring

37 1004 9220-0004 Key

38 1061 2360-2061 Motor

39 1066 2360-2066 Handle

40 1014 9218-0014 Insert 6-32

41 1037 9218-0037 Insert 1/4"-20

42 1036 9218-0036 Insert 4-40

43 1606L 636202 Potentiometer

44 1095 2360-2095 Bracket

45 1993 9204-3093 Screw

46 1131 9204-4131 Set Screw

47 1096 2360-2096 Knob

48 1280 2310-0280 Micro Switch

49 1113 2360-2113 Insulator

50 1018 9205-6018 Screw

51 1093 2360-2093 Trigger Pin

52 1097 2360-2097 Trigger

53 1682 9204-9682 Set Screw

54 1134 9204-4134 Screw

55 1126 9205-6126 Lockwasher

56 1167 9204-4167 Screw

57 1579 834-0098 Cable Clamp

58 1715 9201-6715 Nut

59 1059 2360-2059 Sleeve

60 1215 9204-2715 Rd. Head Screw

61 1027 9205-6027 Washer

62 1012 9201-8012 Speednut

63 1121 2360-2121 Terminal Strip

64 1114 2360-2114 Marker Strip

65 1091 2360-2091 Post

66 1090 2360-2090 Spindle

67 1089 2360-2089 Washer

68 1118 2360-2118 Spindle Spring

69 1624 9204-2624 Screw

70 1092 2360-2092 Spindle Screw

71 1969 2360-2069 Spade Terminal

72 1060-4 2360-2060-4 Control Cable Assy. w/Plug

73 1057 2360-2057 Hose Cable Assembly

74 1255 803-0255 Connection Nut

75 1052 9226-0052 Retaining Ring

76 1116 2360-2116 Thrust Washer

77 1083 2360-2083 Lock Screw

78 1104 2360-2104 Dial Plate

79 1607L 647257 8 Pin Male Plug

80 1608L Clamp Only

81 1433 2360-3433 Ferrule

82 1832 2360-0832 Fitting

83 1074 2360-2074 Cable Boot

84 1087 2360-2087 Block

85 1972 9228-0072 Terminal

86 1009 9205-6009 Washer

87 1742 9201-6742 Nut

88 1086 2360-2086 Cable Assembly

89 1923 2360-2123 Cable Lug

90 1273 803-0273 Gland

91 1277 803-0277 Nut

92 1206 803-9206 Ferrule

93 1085 2360-2085 Hose Assembly

94 1245 803-0245 Gland

95 1065 2360-2065 Rear Cover

96 1064 2360-2064 Front Cover

97 1264 832-9264 Wrench

98 9338 Hole Plug

99 9251 Pot Brake

® ®PROFAX ESAB /AIRCONO. PART NO. PART NO. DESCRIPTION

® ®PROFAX ESAB /AIRCONO. PART NO. PART NO. DESCRIPTION

54

®PROFAX is in no way affiliated with ESAB /AIRCO . The parts advertised for sale are not genuine parts, but are parts made for and by PROFAX. References to machines, torches, and numbers are for your convenience only. We reserve the right to substitute genuine parts in place of PROFAX parts.

® ® ® ® ®ESAB /AIRCO ESAB /AIRCO® ®ESAB /AIRCO

97

1

51

18

27

28

29

25

26

34

1733

32

31

36

35 37

38

39

42

4041

4445

4850

89

88878685

84

9092

93

83

9274 94

91

75

78

77

76

96

73

7980

74

82

8173

72

71

49

47

4699

43

30

65

96

66

67 68

61 6970

64

63

58

62

5634

56

5760

61

59

14

55 5498

53

52

2

3

11

412

56

13

7

14

8

15

9

16

18

19

24

22

23

20

21

10

REMOVAL & REPLACEMENT INFORMATION

A.) DRIVE ROLL1.) Unlatch swing out arm and rotate out away from drive roll.2.) Remove palnut from end of motor shaft.3.) Lift drive roll off shaft.4.) Install new drive roll making sure key way lines up with woodruff key.5.) Replace palnut.6.) Readjust tension on swing out arm.

B.) DRIVEN ROLL1.) Unlatch swing out arm and rotate out away from drive roll.2.) Remove one of the retaining rings on the driven roll bearing pin.3.) Remove pin and driven roll.4.) Install the replacement driven roll, inserting pin and replace retaining ring.5.) Return and readjust tension on swing out arm.

C.) MOTOR1.) Remove front cover.2.) Remove the four screws on rear cover to release housing.3.) Remove motor leads on terminal strip. (16 black and 23 red)4.) Remove the three screws holding gun handle to housing.5.) Remove handle assembly from housing. Remove the motor insulator and O-ring, set them aside for use when

reassembling.6.) Remove motor from gun handle.7.) Remove drive roll and place on replacement motor making sure key way lines up with woodruff key, replace palnut.8.) Install new motor in handle, making sure motor lead wires are in the groove provided in the handle. Replace motor insulator and

O-ring in proper place.9.) Reassemble gun making sure motor leads are out of way of the movable arm on the rheostat.

D.) GAS VALVE1.) Remove front and rear covers.2.) Remove retaining ring from trigger pin, remove palnut from valve pin, remove the pin, trigger, trigger spring and the valve guide.3.) Remove retaining nut on diaphragm assembly, remove pin and diaghram.

*IMPORTANT: Before gun assembly adjust gas valve as follows:A.) Attach shielding gas supply hose from AEC 200-4 gun to the flowmeter regulator on gas supply source.B.) Full gas flow must be attained before microswitch is actuated. Pull the trigger and adjust the palnut to achieve proper gas

flow. An allen screw in the trigger casting allows for proper gas flow adjustments before microswitch is actuated.C.) With the gun trigger fully depressed adjust the microswitch actuating screw, in the trigger casting, until the microswitch

makes first click. While still holding the gun trigger fully depressed, check for at least 0.30” of movement in the microswitch actuating button.

D.) Reassemble the Gun.4.) Install new valve components.

E.) MICROSWITCH1.) Remove the microswitch insulator and microswitch.2.) Remove electrical lead wires.3.) Connect electrical lead wires to new microswitch.4.) Replace microswitch and insulator to housing.

F.) WIRE FEED SPEED POTENTIOMETER1.) Remove front cover.2.) Disconnect electrical lead wires from terminal strip inside rear cover. (Lead's #13, 14 & 15)3.) Remove potentiometer screws from housing and remove potentiometer.4.) Replace new potentiometer with screws previously removed.5.) Reconnect the marked lead wires to corresponding terminals on terminal strip in rear cover.

AEC-200 Contact Tips, Nozzles, & AdaptersPART NO. WIRE SIZE I.D.

3356 .030-.035 Hard .0443299 .045-3/64” Aluminum .0603300 1/16” Aluminum .07845-070 3/64” Aluminum .073

3136 .030 Aluminum .0403115 .035-.047 Aluminum .0643135 1/16” Aluminum .084

3067 .030-.035 Hard .0603068 .045-3/64” Aluminum .0843069 1/16” Aluminum .120

PART NO. I.D. MATERIAL

4137 5/8” Copper

4268 7/16” Brass

4117 1/2” Copper4118 3/4” Copper4110 5/8” Copper

These nozzles are used with the old style assembly see 4124 page 8.

4269 11/16” Brass4572 11/16” Copper

4270 11/16” Brass

4552 9/16” Brass

Available Through YourWelding Supply Distributor

76

4”

6-1/8”

4”

1/4”

1/4”

1/4”

1-1/2”

3/4”

1”

7/8 - 14 Thd.

1-5/8”

1”

7/8 - 14 Thd.

1-1/2”

1”

1”

7/8 - 14 Thd.

7/8 - 14 Thd.

1-1/2”1-5/8”

1”

1 - 14 Thd.

®

PART NO. I.D. MATERIAL

REMOVAL & REPLACEMENT INFORMATION

A.) DRIVE ROLL1.) Unlatch swing out arm and rotate out away from drive roll.2.) Remove palnut from end of motor shaft.3.) Lift drive roll off shaft.4.) Install new drive roll making sure key way lines up with woodruff key.5.) Replace palnut.6.) Readjust tension on swing out arm.

B.) DRIVEN ROLL1.) Unlatch swing out arm and rotate out away from drive roll.2.) Remove one of the retaining rings on the driven roll bearing pin.3.) Remove pin and driven roll.4.) Install the replacement driven roll, inserting pin and replace retaining ring.5.) Return and readjust tension on swing out arm.

C.) MOTOR1.) Remove front cover.2.) Remove the four screws on rear cover to release housing.3.) Remove motor leads on terminal strip. (16 black and 23 red)4.) Remove the three screws holding gun handle to housing.5.) Remove handle assembly from housing. Remove the motor insulator and O-ring, set them aside for use when

reassembling.6.) Remove motor from gun handle.7.) Remove drive roll and place on replacement motor making sure key way lines up with woodruff key, replace palnut.8.) Install new motor in handle, making sure motor lead wires are in the groove provided in the handle. Replace motor insulator and

O-ring in proper place.9.) Reassemble gun making sure motor leads are out of way of the movable arm on the rheostat.

D.) GAS VALVE1.) Remove front and rear covers.2.) Remove retaining ring from trigger pin, remove palnut from valve pin, remove the pin, trigger, trigger spring and the valve guide.3.) Remove retaining nut on diaphragm assembly, remove pin and diaghram.

*IMPORTANT: Before gun assembly adjust gas valve as follows:A.) Attach shielding gas supply hose from AEC 200-4 gun to the flowmeter regulator on gas supply source.B.) Full gas flow must be attained before microswitch is actuated. Pull the trigger and adjust the palnut to achieve proper gas

flow. An allen screw in the trigger casting allows for proper gas flow adjustments before microswitch is actuated.C.) With the gun trigger fully depressed adjust the microswitch actuating screw, in the trigger casting, until the microswitch

makes first click. While still holding the gun trigger fully depressed, check for at least 0.30” of movement in the microswitch actuating button.

D.) Reassemble the Gun.4.) Install new valve components.

E.) MICROSWITCH1.) Remove the microswitch insulator and microswitch.2.) Remove electrical lead wires.3.) Connect electrical lead wires to new microswitch.4.) Replace microswitch and insulator to housing.

F.) WIRE FEED SPEED POTENTIOMETER1.) Remove front cover.2.) Disconnect electrical lead wires from terminal strip inside rear cover. (Lead's #13, 14 & 15)3.) Remove potentiometer screws from housing and remove potentiometer.4.) Replace new potentiometer with screws previously removed.5.) Reconnect the marked lead wires to corresponding terminals on terminal strip in rear cover.

AEC-200 Contact Tips, Nozzles, & AdaptersPART NO. WIRE SIZE I.D.

3356 .030-.035 Hard .0443299 .045-3/64” Aluminum .0603300 1/16” Aluminum .07845-070 3/64” Aluminum .073

3136 .030 Aluminum .0403115 .035-.047 Aluminum .0643135 1/16” Aluminum .084

3067 .030-.035 Hard .0603068 .045-3/64” Aluminum .0843069 1/16” Aluminum .120

PART NO. I.D. MATERIAL

4137 5/8” Copper

4268 7/16” Brass

4117 1/2” Copper4118 3/4” Copper4110 5/8” Copper

These nozzles are used with the old style assembly see 4124 page 8.

4269 11/16” Brass4572 11/16” Copper

4270 11/16” Brass

4552 9/16” Brass

Available Through YourWelding Supply Distributor

76

4”

6-1/8”

4”

1/4”

1/4”

1/4”

1-1/2”

3/4”

1”

7/8 - 14 Thd.

1-5/8”

1”

7/8 - 14 Thd.

1-1/2”

1”

1”

7/8 - 14 Thd.

7/8 - 14 Thd.

1-1/2”1-5/8”

1”

1 - 14 Thd.

®

PART NO. I.D. MATERIAL

1 43462 4300

4119 Bent Nozzle Kit 3 4137For AEC-200 4 4139

5 4108

4124 Old Style Assembly 1 4105For AEC-200 2 4108

1a 42684638 New Style Assembly 1 4269

For AEC-200 2 41473 46414 4640

3150 .030-.035 Hard .0403223 .045 Hard .0533575 .052 .0683019 1/16" Hard .0783455 3/64" .0613456 1/16" Alum. .081

3793 .030-.035 .0403839 .045 .0533020 1/16" .078

4925 Flexible Barrel 14580 Tip Holder (Included) 29635-8¼ Liner (Cut to length) 3

Note: Additional 4137 Nozzle Included

Note: This assembly uses the 4110 Nozzle

FIGURE 3

DIA.NO. PART NO. MKG. DESCRIPTION QTY.

1 8328A Top Cover N/S* 1

2 8336A Base 1

3 9250 PC1 PC Board 1

4 6416 T1 Transformer 115/24 50VA 1

5 9044 K1 Relay, 3PDT 24VAC 1

6 6461 RC1 8 Pin Receptacle 1

7 6100 Fuse Holder 1

8 6101 F1 Fuse, 1.25A 250V* 1

9 7004 TS1 Terminal Strip 1

10 6182 Contactor Cord, 5ft. 18/2 1

11 6183 Primary Cord, 5ft. 18/3 1

12 7026 Strain Relief 1

13 8004 Decal, 4 Pole Terminal Strip 1

14 8999 Terminal Tool 1

* NOT SHOWN

98

1 2 34

5

1 2

21a

3

1

4

6

12

3

10-3/4”

1-5/8”

1-27/32”

1/4”

1/4”

1/4 - 20 Thd.

1/4 - 20 Thd.

ITEMPART NO. DESCRIPTION NO. PART NO. 2 9 13

3 5 14 4 7 11

10

12

1 43462 4300

4119 Bent Nozzle Kit 3 4137For AEC-200 4 4139

5 4108

4124 Old Style Assembly 1 4105For AEC-200 2 4108

1a 42684638 New Style Assembly 1 4269

For AEC-200 2 41473 46414 4640

3150 .030-.035 Hard .0403223 .045 Hard .0533575 .052 .0683019 1/16" Hard .0783455 3/64" .0613456 1/16" Alum. .081

3793 .030-.035 .0403839 .045 .0533020 1/16" .078

4925 Flexible Barrel 14580 Tip Holder (Included) 29635-8¼ Liner (Cut to length) 3

Note: Additional 4137 Nozzle Included

Note: This assembly uses the 4110 Nozzle

FIGURE 3

DIA.NO. PART NO. MKG. DESCRIPTION QTY.

1 8328A Top Cover N/S* 1

2 8336A Base 1

3 9250 PC1 PC Board 1

4 6416 T1 Transformer 115/24 50VA 1

5 9044 K1 Relay, 3PDT 24VAC 1

6 6461 RC1 8 Pin Receptacle 1

7 6100 Fuse Holder 1

8 6101 F1 Fuse, 1.25A 250V* 1

9 7004 TS1 Terminal Strip 1

10 6182 Contactor Cord, 5ft. 18/2 1

11 6183 Primary Cord, 5ft. 18/3 1

12 7026 Strain Relief 1

13 8004 Decal, 4 Pole Terminal Strip 1

14 8999 Terminal Tool 1

* NOT SHOWN

98

1 2 34

5

1 2

21a

3

1

4

6

12

3

10-3/4”

1-5/8”

1-27/32”

1/4”

1/4”

1/4 - 20 Thd.

1/4 - 20 Thd.

ITEMPART NO. DESCRIPTION NO. PART NO. 2 9 13

3 5 14 4 7 11

10

12

FIGURE 1

AEC 200-4C

CONTROL

DIAGRAM

DESCRIPTION WIRE COLOR PIN#

MOTOR 23 RED E

MOTOR 16 BLACK D

MICRO SWITCH 21 ORANGE A

MICRO SWITCH 22 PURPLE B

RHEOSTAT (HIGH SPEED) 13 YELLOW H

RHOESTAT (MED. SPEED) 15 GREEN G

RHEOSTAT (LOW SPEED) 14 BLUE F

AEC 200-4 GUN WIRING

10

16 23

21

14

22

1513

1415

1322

2120

1623

TERMINALSTRIP

TO CONNECTORBLOCK

MOTOR(24V DC)

MICROSWITCH

RHEOSTAT

TO CONTROL

ELECTRODE

HOUSING

REAR VIEW MALE PLUGPROFAX P/N 1607L (PLUG & CLAMP ASSY.)

ED

2316

G

B R

HB

13

6 7 8 9 10 11 12 13

1421 22 15

G (GND)

B

AEC 200-4 SPOOLGUN

W

B

B S NW

NSB UGYPYU

TRIGGER

W

1 2 3 4 5

K1

CW

R2M

K1

F1

14 3 2

24VAC

IN

PROFAX 9250

PC BOARD

Min. Wipper Max

Neg. Pos.

1 to 27VDC to motor

with reference to R2

when trigger closed

115VAC

2.5K OHM

TS1

24VAC

IN

24VAC

Trigger

Return

COLOR CODE

B BLACK

G GREEN

N BROWN

O ORANGE

P PURPLE

S GRAY

U BLUE

W WHITE

O

24VAC

B

RC1FA

T1

GA

B

C D

E

F

H