AEC 200-4C

AEC 200-4C
SOLID STATE SPOOLGUN & CONTROL
OPERATION AND PARTS MANUAL
m
inu
m
Alu
se
Ca
FOR USE IN CONNECTING THE AEC 200-4 SPOOLGUN
TO CONSTANT VOLTAGE POWER SOURCES ONLY.
®
P.O. Box 898 • Pearland, TX 77588-0898 • (281) 485-6258 • Fax: (281) 485-8030
7190
®
P.O. Box 898 • Pearland, Texas 77588-0898
(281) 485-6258
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.
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 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
1
AEC 200-4C SPECIFICATIONS
Input Power
Weld Output Rating
Wire Capacity
Wire Speed Range
Dimensions
Argon or Helium
115VAC
50/60 Hz.
250 Amps
50% Duty Cycle
200 Amps
100% Duty Cycle
Weight
Gun & Cables
.023 in. through
1/16" Aluminum
or
.023 in. through
.045 Hard Wire
30 IPM
to
800 IPM
Height 8.25"
Width 3"
Length 15"
Net 26 lbs.
Ship 29 lbs.
4C Control
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 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.
2
FIGURE 2
CONSTANT VOLTAGE POWER SOURCE WITH THE AEC 200-4C GUN & CONTROL
POWER
SOURCE
115 VOLT AC
POWER CABLE
CONTACTOR CONTROL
CABLE TO CONTACTOR
CONTROL RECEPTACLE
ON POWER SOURCE
(see installation instructions)
115 VOLT AC
*PLUG NOT INCLUDED
POSITIVE
OUTPUT
TERMINAL
MODEL
AEC 200-4C
CONTROL
MULTI CONDUCTOR
CABLE TO TERMINAL
STRIP IN CONTROL BOX
WELDING CABLE TO
POSITIVE OUTPUT TERMINAL
ON POWER SOURCE
GAS
CYLINDER
MODEL
AEC 200-4
SPOOL GUN
GAS & WELDING
CABLE
HOSE TO GAS
SUPPLY
CABLE
BOOT
CONNECTION
BLOCK
WELDING CABLE FROM
NEGATIVE OUTPUT TERMINAL
ON POWER SOURCE
WORK
PREWELD CHECK LIST
A.)
B.)
C.)
D.)
E.)
F.)
Make sure the AEC 200-4 Spoolgun is set up for wire size selected with, proper liner, contact tube and nozzle.
All control cable and hose connections are tight.
Mig wire installed for counter clockwise feed-off.
Proper shielding gas and flow selected and cylinder turned on and valve backseated.
Power source on and set for required voltage.
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 DOWN
After 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.
MAINTENANCE
NOTE: Before performing any maintenance on spoolgun, BE SURE all sources of power are TURNED OFF.
It is important to periodically inspect and clean if necessar y 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.
3
11
4
12
97
13
5
14
6
15
7
4
52
1
16
51
20
21
8
53
18
18
2
9
19
10
23
34
14
3
22
54
55
39
38
17
26
25
98
40
33
30
28
42
37
36
35
27
41
44
29
31
45
96
56
48
99
32
34
47
46
43
56
49
65
50
66
74
94
64
92
63
58
57
89
68
67
93
69
61
24
62
59
88
92
70
75
91
90
61
84
60
87
86
85
78
79
71
76
83
96
77
80
72
82
73
74
81
73
PROFAX AEC 200-4 SPOOL GUN
REPLACEMENT PARTS FOR PROFAX AEC 200-4 SPOOL GUN
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
PROFAX
PART NO.
ESAB®/AIRCO®
PART NO.
4147
4641
1102
4640
1614
1613
1058
1103
1111
1078
5133
5109
5134
1743
1100
1754
1117
1107
1953
1098
1388
1077
1076
1072
1122
1171
9260
1741
1080
1130
1082
1094
1709
1079
1987
1930
1127
1081
1071
1004
1061
1066
1014
1037
1036
1606L
1095
1993
1131
1096
1280
2360-7147
2360-7641
2360-2102
2360-7640
2360-0614
2360-0613
2360-2058
2360-2103
2360-2111
2360-2078
2360-2133
2360-2109
2360-2134
9201-6743
2360-2100
831-1754
2360-2117
2360-2107
831-1953
2360-2098
2360-3388
2360-2077
2360-2076
2360-2072
2360-2122
2360-6171
9201-6741
2360-2080
9204-4130
2360-2082
2360-2094
2389-3709
2360-2079
2360-6987
2360-2130
9204-4127
2360-2081
831-2071
9220-0004
2360-2061
2360-2066
9218-0014
9218-0037
9218-0036
636202
2360-2095
9204-3093
9204-4131
2360-2096
2310-0280
DESCRIPTION
NO.
PROFAX
PART NO.
Nozzle Body
Spacer
Grommet
Adapter Sleeve
Nut
Fitting
Inner Barrel
Guide Tube
O-ring
Arm Assembly
Green Liner .030-.035
Red Liner .045-3/64"
White Liner 1/16"
Pal Nut
Guide
Retainer
Spring
Valve Pin
Diaphragm
Housing
Retaining Ring
Pin
Spacer
Driven Roll
Adjusting Screw
Pressure Arm
Terminal Cover
Pal Nut
Drive Roll
Screw
Spring Catch
Inlet Bushing
O-ring
Drive Roll Spring
Pivot Screw
Insulating Insert
Screw
Motor Insulator
O-ring
Key
Motor
Handle
Insert 6-32
Insert 1/4"-20
Insert 4-40
Potentiometer
Bracket
Screw
Set Screw
Knob
Micro Switch
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
1113
1018
1093
1097
1682
1134
1126
1167
1579
1715
1059
1215
1027
1012
1121
1114
1091
1090
1089
1118
1624
1092
1969
1060-4
1057
1255
1052
1116
1083
1104
1607L
1608L
1433
1832
1074
1087
1972
1009
1742
1086
1923
1273
1277
1206
1085
1245
1065
1064
1264
9338
9251
ESAB®/AIRCO®
PART NO.
2360-2113
9205-6018
2360-2093
2360-2097
9204-9682
9204-4134
9205-6126
9204-4167
834-0098
9201-6715
2360-2059
9204-2715
9205-6027
9201-8012
2360-2121
2360-2114
2360-2091
2360-2090
2360-2089
2360-2118
9204-2624
2360-2092
2360-2069
2360-2060-4
2360-2057
803-0255
9226-0052
2360-2116
2360-2083
2360-2104
647257
2360-3433
2360-0832
2360-2074
2360-2087
9228-0072
9205-6009
9201-6742
2360-2086
2360-2123
803-0273
803-0277
803-9206
2360-2085
803-0245
2360-2065
2360-2064
832-9264
DESCRIPTION
Insulator
Screw
Trigger Pin
Trigger
Set Screw
Screw
Lockwasher
Screw
Cable Clamp
Nut
Sleeve
Rd. Head Screw
Washer
Speednut
Terminal Strip
Marker Strip
Post
Spindle
Washer
Spindle Spring
Screw
Spindle Screw
Spade Terminal
Control Cable Assy. w/Plug
Hose Cable Assembly
Connection Nut
Retaining Ring
Thrust Washer
Lock Screw
Dial Plate
8 Pin Male Plug
Clamp Only
Ferrule
Fitting
Cable Boot
Block
Terminal
Washer
Nut
Cable Assembly
Cable Lug
Gland
Nut
Ferrule
Hose Assembly
Gland
Rear Cover
Front Cover
Wrench
Hole Plug
Pot Brake
®
®
®
®
®
PROFAX is in no way affiliated with ESAB /AIRCO®. The parts advertised for sale are not genuine ESAB /AIRCO parts, but are parts made for and by PROFAX. References to ESAB /AIRCO machines,
®
®
torches, and numbers are for your convenience only. We reserve the right to substitute genuine ESAB /AIRCO parts in place of PROFAX parts.
5
REMOVAL & REPLACEMENT INFORMATION
A.) DRIVE ROLL
1.) 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 ROLL
1.) 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.) MOTOR
1.) 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 VALVE
1.) 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.) MICROSWITCH
1.) 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 POTENTIOMETER
1.) 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.
6
AEC-200 Contact Tips, Nozzles, & Adapters
PART NO.
WIRE SIZE
I.D.
3356
3299
3300
45-070
.030-.035
.045-3/64”
1/16”
3/64”
Hard
Aluminum
Aluminum
Aluminum
.044
.060
.078
.073
3136
3115
3135
.030
.035-.047
1/16”
Aluminum
Aluminum
Aluminum
.040
.064
.084
1/4”
4”
1/4”
4”
1/4”
3067
3068
3069
.030-.035
.045-3/64”
1/16”
Hard
Aluminum
Aluminum
.060
.084
.120
6-1/8”
PART NO.
I.D.
MATERIAL
PART NO.
I.D.
MATERIAL
7/8 - 14 Thd.
4137
5/8”
4269
4572
Copper
11/16” Brass
11/16” Copper
1-1/2”
3/4”
7/8 - 14 Thd.
7/8 - 14 Thd.
4268
7/16”
1”
Brass
1”
4270
1”
11/16” Brass
1-1/2”
1-5/8”
1 - 14 Thd.
7/8 - 14 Thd.
4117
4118
4110
1/2”
3/4”
5/8”
Copper
Copper
Copper
1”
4552
1-5/8”
9/16”
Brass
1”
1-1/2”
These nozzles are used with the old style assembly see 4124 page 8.
Available Through Your
Welding Supply Distributor
®
7
PART NO. DESCRIPTION
ITEM
NO.
PART NO.
1
2
3
4
5
4346
4300
4137
4139
4108
1
4119
Bent Nozzle Kit
For AEC-200
2
4
3
5
Note: Additional 4137 Nozzle Included
1
4124
Old Style Assembly
For AEC-200
1
2
2
4105
4108
Note: This assembly uses the 4110 Nozzle
4638
New Style Assembly
For AEC-200
1a
1
2
3
4
1a
4268
4269
4147
4641
4640
3150
3223
3575
3019
3455
3456
.030-.035 Hard
.045 Hard
.052
1/16" Hard
3/64"
1/16" Alum.
.040
.053
.068
.078
.061
.081
3793
3839
3020
.030-.035
.045
1/16"
.040
.053
.078
3
2
1
1/4 - 20 Thd.
1/4”
1-5/8”
1/4 - 20 Thd.
1/4”
1-27/32”
4925
4580
9635-8¼
Flexible Barrel
Tip Holder (Included)
Liner (Cut to length)
2
1
2
3
1
10-3/4”
3
8
4
FIGURE 3
6
2
9
13
10
12
3
5
14
4
DIA.
MKG.
DESCRIPTION
7
11
NO.
PART NO.
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
9
QTY.
FIGURE 1
COLOR CODE
B
G
N
O
P
S
U
W
AEC 200-4C
PROFAX 9250
PC BOARD
BLACK
GREEN
BROWN
ORANGE
PURPLE
GRAY
BLUE
WHITE
1 to 27VDC to motor
with reference to R2
when trigger closed
Neg.
K1
24VAC
IN
24VAC
IN
5
6
Pos.
2.5K OHM
Min. Wipper Max
24VAC
Trigger
Return
K1
CONTROL
1
DIAGRAM
2
B
3
B
4
N
S
Y
U
7
O
9
8
B
P
10
11
12
13
R
Y
G
U
24VAC
T1
G (GND)
A
B
B
F1
W
115VAC
21
B
22
D
E
16
23
W
W
B
3
4
2
TS1
14
CW
TRIGGER
1
RC1
R2
M
N
S
15
13
F
G
H
AEC 200-4 SPOOLGUN
HOUSING
TO CONTROL
ELECTRODE
23 6
1
22
21
TO CONNECTOR
BLOCK
20
21
22 3
1
13
15
14
MICRO
SWITCH
15
TERMINAL
STRIP
14
G
A
B
MOTOR
(24V DC)
16
23
C
RHEOSTAT
F
H
E
D
REAR VIEW MALE PLUG
PROFAX P/N 1607L (PLUG & CLAMP ASSY.)
DESCRIPTION
WIRE
MOTOR
23
MOTOR
16
MICRO SWITCH
21
MICRO SWITCH
22
RHEOSTAT (HIGH SPEED) 13
RHOESTAT (MED. SPEED) 15
RHEOSTAT (LOW SPEED) 14
AEC 200-4 GUN WIRING
10
COLOR
RED
BLACK
ORANGE
PURPLE
YELLOW
GREEN
BLUE
PIN#
E
D
A
B
H
G
F