Profax AEC 200-4C User Manual

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AEC 200-4C

SOLID STATE SPOOLGUN & CONTROL

OPERATION AND PARTS MANUAL

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7190

FOR USE IN CONNECTING THE AEC 200-4 SPOOLGUN

TO CONSTANT VOLTAGE POWER SOURCES ONLY.

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P.O. Box 898 • Pearland, TX 77588-0898 • [phone] • Fax: [phone]

P.O. Box 898 • Pearland, Texas 77588-0898

®

[phone]

Table of Contents

CONTENTS PAGE

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

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 days
AEC 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.

WARNINGS AND SAFEGUARDS FOR WELDING AND CUTTING OPERATIONS Form WSWC 594

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 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.

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.

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.

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

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

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

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.

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.

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”

D) AWS F4.1, “Recommended Safe Practices for Welding and Cutting Containers”

E) NFPA 51B, “Fire Prevention in Cutting and Welding Processes”
F) NFPA-70, “National Electrical Code”

G) CGA P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”

H) Code of Federal Regulations (OSHA) 29 CFR 1910

I) CSA Standard W117.2, “Safety in Welding, Cutting and Allied Processes”

protects your eyes from sparks. Protect other nearby personnel from arc rays and sparks. Use approved shielding curtains and appropriate goggles. Warn them

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,

SAFETY AND OPERATING REFERENCES

ANSI: American National Standard Institute, 1430 Broadway, New York, NY 10018

AWS: The American Welding Society, P.O. Box 351040, 550 NW Lejeune Rd., Miami, Fl 33135

NFPA: National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

CGA: Compressed Gas Association, 1235 Jefferson Davis Hwy., Arlington, Va 22202

US: U.S. Government Printing Office, Washington, DC 20402

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

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AEC 200-4C SPECIFICATIONS

Input 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 Wire

Net 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 TO

THE 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 preferred.)

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.