AEC 200-4D DIRECT CONNECT SOLID STATE SPOOL GUN OPERATION AND PARTS MANUAL DIRECT CONNECTS TO: MILLER & PROFAX CV POWER SOURCES

AEC 200-4D DIRECT CONNECT SOLID STATE SPOOL GUN OPERATION AND PARTS MANUAL DIRECT CONNECTS TO: MILLER & PROFAX CV POWER SOURCES FOR CONSTANT VOLTAGE POWER SOURCES ONLY 00144OG050809 P.O. BOX 898 PEARLAND, TX 77588-0898 PH: 281-485-6258 FAX: 281-485-8030

CONTENT INDEX PAGE Warranty... i Safety... 1 Specifications and Installation... 2-3 Operation and Maintenance... 3 Consumable Parts... 4 Troubleshooting... 5 Replacement Parts... 6-7 Parts Replacement Procedures... 8-9 WARRANTY LIMITED WARRANTY - Subject to the terms and conditions stated below, PROFAX, Pearland, Texas warrants it s products to be free from defects in material and/or workmanship at the time of delivery by PROFAX. PROFAX - will honor warranty claims on products proven to have failed from a defect in material and/or workmanship, for the appropriate time period as listed below, beginning from the distributor s date of sale to the original end user. For warranty to apply, product must be sold by the distributor within 1 year from the original date of sale to the distributor. Products will not be covered if damage is determined to be caused by misuse, neglect and/or abuse. Consumable products manufactured by PROFAX.... 30 Days Resale consumable products.... Original Manufacturer s Warranty Flux Cored Guns, Mig Guns and Spool Guns.... 90 Days Arc Gouging Torches, Plasma Torches, Tig Torches and CO2 Heaters.... 90 Days Spool Gun Controls... 1 Year Wire Feeders and Welding Power Sources... 3 Year Shelf Life before Warranty Starts... 1 Year Upon return of the product, at users expense, PROFAX reserves the right to either repair or replace the product as necessary. This is the only warranty either expressed or implied covering PROFAX products. 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. WARNING! This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code 25249.5 ET. SEQ.) i

Form WSWC 594 WARNINGS AND SAFEGUARDS FOR WELDING AND CUTTING OPERATIONS 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 performed by qualified personnel. Retain these instructions for future use. Additional recommended safety and operating information is referenced in each section. ELECTRICAL SHOCK CAN CAUSE INJURY OR DEATH Electrical equipment must be installed and maintained in accordance with the National Electrical Code, NFPA 70, and all local codes. Maintain Mig-Guns, Electrode Holders, Tig Torches, Plasma Torches, Work Clamp, Welding Cable, and Welding Machines in good, safe operating condition. Replace worn or damaged insulation. Do not try to repair or service equipment while the power is still on. Do not service or repair equipment unless you are trained and qualified to do so. The Electrode and Work (or Ground) circuits are electrically HOT when equipment power is on. At no time should you touch the Electrode and Electrical Ground at the same time with bare skin or wet clothing while the power 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 part 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 200-4D SPECIFICATIONS Input Power Weld Output Rating Wire Capacity Wire Speed Range Dimensions Weight Argon or Helium Gun & Cables 250 Amps.030-1/16 20 ipm Height 8.25" Net 24VAC 50% Duty Cycle Aluminum to Width 3" 26.8 lbs. 200 Amps or 800 ipm Length 15" Ship 100% Duty Cycle.023 -.045 29.8 lbs. Hard Wire The AEC 200-4D Direct Connect Spoolgun gives the improved SOLID STATE motor control performance to the Classic AEC 200 Spoolgun design. This system can be direct connected to any Comparc, Miller, Thermal Arc, or PROFAX CONSTANT VOLTAGE welding power source of adequate size and with 24VAC auxiliary power available. DIRECT CONNECT SPOOL GUN SYSTEMS MODEL NO. AEC 200-4DM Direct Connect Spool Gun for Miller Constant Voltage power sources with the 14 pin wire feeder receptacle. AEC 200-4DMX Direct Connect Spool Gun for the Millermatic 250X. AEC 200-4DP DESCRIPTION Direct Connect Spool Gun for PROFAX power sources. INSTALLATION (For help see fig. 1) WARNING! DISCONNECT ALL ELECTRICAL POWER TO THE WELDING POWER SOURCE BEFORE INSTALLING THIS EQUIPMENT Connect the AEC 200-4D Direct Connect Spool Gun as follows: 1. Weld cable to the POSITIVE (+) terminal of the welding power source. 2. Control cable to the remote receptacle on the front of the welding power source. 3. Gas hose to the flowmeter/regulator at the gas supply. 2

Figure 1 CONSTANT VOLTAGE POWER SOURCE WITH THE AEC 200-4D SPOOL GUN POWER SOURCE POSITIVE OUTPUT TERMINAL MULTI CONDUCTOR CABLE TO REMOTE RECEPTACLE ON POWER SOURCE WELDING CABLE TO POSITIVE OUTPUT TERMINAL ON POWER SOURCE GAS CYL. MODEL AEC 200-4D SPOOL GUN GAS & WELDING CABLE CABLE BOOT HOSE TO GAS SUPPLY WORK WELDING CABLE FROM NEGATIVE OUTPUT TERMINAL ON POWER SOURCE CONNECTION BLOCK PREWELD CHECK LIST 1. Make sure the AEC 200-4D Spool Gun is set up for wire size selected by having the proper liner, contact tube and nozzle. 2. Weld cable and hose is connected and tight. Control cable connection is fully inserted with the collar screwed on properly. 3. Mig wire is installed in a manner to allow the wire to feed from the top of the spool into the wire drive. 4. Proper shielding gas has been selected and the gas cylinder valve is on and backseated. Flowmeter properly set and hose line purged. 5. Power source on and correct voltage set. 6. Wire speed adjustment on Spool Gun is properly set. 7. Mig wire is through tip and extending just past end of nozzle. NOTE: It is recommended to perform trial welds on scrap metal similar to what is going to be welded for adjusting proper wire speed, amps and voltage settings. This will also familiarize you with the spool gun s operating characteristics. SHUTTING DOWN After your welding job is complete or work is stopped for any appreciable amount of time proceed as follows: 1. Turn power source off. 2. Turn shielding gas off at the cylinder valve. 3. Make sure cover is secured onto spool gun. MAINTENANCE NOTE: Before performing any maintenance on this spool gun, BE SURE all sources of power have been TURNED OFF. Check the following on a daily basis: 1. Inspect cables and hoses for frayed wiring or cracked insulation. Damaged wires and cable are hazardous and must be replaced. 2. Clean any spatter, grease or grime from the interior and/or exterior of the spool gun to prevent short circuits. 3. Check all mounting screws for tightness. 4. Keep cover on at all times to minimize dirt and contaminants from entering spool gun. 3

PART NO. WIRE SIZE I.D. 3123.023 Hard.031 3356.030-.035 Hard.044 3299.045-3/64 Alum..060 3300 1/16 Alum..078 45-070 3/64 Alum..073 4 1/4 1 4119 Bent nozzle kit 2 4346 Nut 3 4137 Nozzle 4 4300 Slip ring 5 4139 Adapter 6 4108 Barrel 7 4138 Assembly (5 & 6) 3136.030 Alum..040 3115.035-.047 Alum..064 3135 1/16 Alum..084 4 1/4 1 2 3 4 5 6 3067.030-.035 Hard.060 3068.045-3/64 Alum..084 3069 1/16 Alum..120 6-1/8 1/4 Note: Additional 4137 nozzle included 3150.030-.035 Hard.040 3223.045 Hard.053 3455 3/64 Alum..061 3456 1/16 Alum..081 1/4 1/4-20 Thd. 1-5/8 1 4638 New style assembly 2 4268 Nozzle 3 4269 Nozzle 1 2 4 5 4 4147 Nozzle body 5 4641 Spacer 6 4640 Adapter sleeve 6 3793.030-.035 Hard.040 3839.045 Hard.053 1/4 1/4-20 Thd. 1-27/32 3 PART NO. I.D. MATERIAL 4268 7/16 Brass 7/8-14 Thd. 1-1/2 1 1 4124 Old style assembly 2 4105 Adapter 3 4108 Barrel 4 4117 1/2 nozzle 4118 3/4 nozzle 4110 5/8 nozzle 7/8-14 Thd. 1-14 Thd. 4 1 2 3 4269 11/16 Brass 4572 11/16 Copper 1 1 1-1/2 1-5/8 7/8-14 Thd. 4270 11/16 Brass 1-5/8 1 1 4925 Flexible barrel 2 4580 Tip holder (included) 3 9635-8¼ Liner (cut to length) Included 7/8-14 Thd. 2 1 4552 9/16 Brass 1 10-3/4 1-1/2 3 4

TROUBLESHOOTING Figure 1 AEC 200-4D DIRECT CONNECT SPOOL GUN WIRING DIAGRAM Std. AEC 200-4DM Opt. AEC 200-4DMX Opt. AEC 200-DP REAR VIEWS BLACK Comparc, Miller Powcon,Thermal Arc 14 Pin K I B A J C L N H D M G E F Miller 10 Pin (MM250X) only F E D G J C H I B A PROFAX 10 Pin (P250SG & P300SG) only A C B G F E D J H K GREEN WHITE Speed Control CW Min. 2.5K POT 14 15 13 C1 C3 C5 C7 C9 C11 C12 C15 C17 C19 Motor Trigger (shown off) NO NO M NC NC BLACK RED YELLOW YELLOW WHITE WHITE Yellow Blue 1 2 3 1 2 3 2 1 4 2 3 1 Red White C2 C4 C6 C8 C10 C12 C14 C16 C18 C20 C21 C22 D9 R1 U1 C43 C44 R3 R4 C42 R5 C44 R6 C40 R7 R8 R9 R10 C39 U2 R11 C37 C36 R13 R12 C38 C24 C26 C32 C34 R14 C28 C30 D11 R15 D10 C23 C25 C35 C27 C33 C29 C31 TESTING INFORMATION TEST ITEM TEST POINT VALUE READING DESCRIPTION 1. Input Voltage Red - Term. 1 & 2 24VAC Primary power input to PC board. 2. Return Voltage Red - Term. 1 & 3 24VAC w/trigger activated 24VAC return for contactor operation. 3. Potentiometer Yellow - Term. 1 & 3 2.5K Gives reference value to PC board for speed control. Yellow - Term. 2 & 3 0 to 2.5K Should give smooth reading 0 through 2.5K when potentiometer is turned. 4. Motor Blue - Term. 1 & 2 1 to 27VDC DC power output to motor from PC board with Resistance 4.0 ohms reference to potentiometer setting. 5. Trigger Switch White - Term. 1 & 3 Norm. Closed Brakes motor when trigger is released. Opens to release brake when trigger is activated. White - Term. 2 & 4 Norm. Open Closes when trigger is activated completing circuit to motor. Also completes circuit from P1 - Term. 4 to P1 - Term. 5 for power source contactor activation. 5

6 PROFAX AEC 200-4D SPOOL GUN 96 1 51 18 26 27 28 24 25 33 17 32 31 30 35 34 36 37 38 56 41 39 40 44 45 48 50 88 87 86 85 84 83 82 89 91 92 81 91 72 93 90 73 76 75 74 95 71 77 72 80 79 71 70 49 47 46 42 43 29 64 94 65 66 67 62 68 69 59 63 57 34 57 58 61 62 60 14 55 54 53 52 2 3 11 4 12 5 6 13 7 14 8 15 9 16 18 19 22 23 20 21 10 78

REPLACEMENT PARTS FOR PROFAX AEC 200-4D SPOOL GUN PROFAX ESAB /AIRCO PROFAX ESAB /AIRCO NO. PART NO. PART 1 4147 2360-7147 Nozzle Body 51 1093 2360-2093 Trigger Pin 2 4641 2360-7641 Spacer 52 1097D Trigger 3 1102 2360-2102 Grommet 53 1682 9204-9682 Set Screw 4 4640 2360-7640 Adapter Sleeve 54 1134 9204-4134 Screw 5 1614 2360-0614 Nut 55 1126 9205-6126 Lock Washer 6 1613 2360-0613 Fitting 56 9338 Hole Plug 7 1058 2360-2058 Inner Barrel 57 1167 9204-4167 Screw 8 1103 2360-2103 Guide Tube 58 1579D Cable Clamp 9 1111 2360-2111 O-ring 59 1715 9201-6715 Nut 10 5133 2360-2133 Green Liner.030-.035 60 1059 2360-2059 Sleeve 5109 2360-2109 Red Liner.045-3/64 61 1215 9204-2715 Screw 5134 2360-2134 White Liner 1/16 62 1027 9205-6027 Washer 11 1743 9201-6743 Pal Nut 63 1012 9201-8012 Nut 12 1100 2360-2100 Guide 64 1091D Post 13 1754 831-1754 Retainer 65 1090 2360-2090 Spindle 14 1117 2360-2117 Spring 66 1089 2360-2089 Washer 15 1107 2360-2107 Valve Pin 67 1118 2360-2118 Spring 16 1953 831-1953 Diaphragm 68 1624 9204-2624 Screw 17 1098 2360-2098 Housing 69 1092AD Screw 18 1388 2360-3388 C-Clip 70 1060DM Cable w/miller 14 Pin 19 1077 2360-2077 Pin 1060DMX Cable w/miller 10 Pin 20 1076 2360-2076 Spacer 1060DP Cable w/profax 10 Pin 21 1072 2360-2072 Driven Roll 71 1057 2360-2057 Hose Cable Assy. 22 1122 2360-2122 Adjusting Screw 72 1255 803-0255 Nut 23 1075 2360-2075 Swingout Arm only 73 1052 9226-0052 C-Clip 1078 Swingout Arm w/roll 74 1116 2360-2116 Washer 24 1741 9201-6741 Pal Nut 75 1083 2360-2083 Thum Screw 25 1080 2360-2080 Drive Roll 76 1104 2360-2104 Dial Decal 26 1130 9204-4130 Screw 77 6459 Profax 10 Pin Plug 27 1082 2360-2082 Spring Catch 9214 Miller 10 Pin Plug 28 1094 2360-2094 Inlet Bushing 136-961 Miller 14 Pin Plug 29 1709 2389-3709 O-ring 78 9252 PC Board 30 1079 2360-2079 Drive Roll Spring 79 1433 2360-3433 Ferrule 31 1987 2360-6987 Pivot Screw 80 1832 2360-0832 Fitting 32 1930 2360-2130 Insulating Insert 81 1074 2360-2074 Boot 33 1127 9204-4127 Screw 82 1087 2360-2087 Block 34 1081 2360-2081 Motor Insulator 83 1972 9228-0072 Terminal 35 1071 831-2071 O-ring 84 1009 9205-6009 Washer 36 1004 9220-0004 Key 85 1742 9201-6742 Nut 37 1886D Motor 86 1086 2360-2086 Cable Assy. 38 1066D Handle 87 1923 2360-2123 Terminal 39 1014 9218-0014 Insert 6-32 88 05304 Lenco Dinse Connector 40 1037 9218-0037 Insert ¼-20 89 1273 803-0273 Nipple 41 1036 9218-0036 Insert 4-40 90 1277 803-0277 Nut 42 1606D Potentiometer 91 1206 803-9206 Ferrule 43 9251 Potentiometer Brake 92 1085 2360-2085 Hose Assy. 44 1095 2360-2095 Bracket 93 1245 803-0245 Nipple 45 1993 9204-3093 Screw 94 1065RD Rear Cover 46 1131 9204-4131 Set Screw 95 1064RD Front Cover 47 1096 2360-2096 Knob 96 1264 832-9264 Wrench 48 1280D Micro Switch 49 1113D Insulator 50 1018 9205-6018 Screw 7

PARTS REPLACEMENT PROCEDURES A. DRIVE ROLL 1. Unlatch swing-out arm and rotate out away from drive roll. 2. Remove palnut from end of motor shaft. 3. Remove drive roll from shaft. 4. Install new drive roll by aligning keyway and pushing roll down onto motor shaft fully against stop. 5. Replace palnut. 6. Close swing-out arm and adjust tension. B. DRIVEN ROLL 1. Unlatch swing-out arm and rotate out away from drive roll. 2. Remove one of the C-clips from the driven roll bearing pin. 3. Remove the bearing pin and driven roll. 4. Remove the nylon bushings from the old roll and install into the new roll. 5. Install the new driven roll by inserting the bearing pin and replacing the C-clip. 6. Close swing-out arm and adjust tension. C. MOTOR 2. Remove the four screws on the rear cover to release the gun housing and handle. 3. Unplug the motor from the PC board. 4. Remove the three screws holding the handle to the drive housing and separate. Retain the motor insulator and O-ring. 5. Remove the motor from the gun handle. 6. Remove the drive roll from the old motor and install onto the new motor. 7. Install the new motor into the gun handle and replace the O-ring and insulator. 8. Assemble the gun handle and housing together making sure that the motor wires fit into the groove provided in the handle. 9. Reassemble the spool gun making sure that the motor wires do not get pinched between the housing and the rear cover. 10. Plug the motor onto the PC board at the Blue terminal. D. PC BOARD 2. Unplug the four plugs from the PC board. 3. Remove the three nylon PC board securing screws and lift the PC board from the spool gun. 4. Install the new PC board and secure with the three nylon screws removed in step 3. 5. Reconnect the plugs to the PC board as follows: a. Motor plug to Blue terminal. b. Pot plug to Yellow terminal. c. Control cord plug to Red terminal. d. Switch plug to White terminal. E. MICRO SWITCH 2. Remove the two switch securing screws and insulator. 3. Remove the four screws on the rear cover to release the housing and handle. 4. Unplug the switch from the PC board. P2 pins 3,4,5 & 6. 5. Remove the three screws holding the handle to the drive housing and sperate enough to remove the switch and wires. 6. Place the new switch wires into the handle wire groove and assemble the handle and drive housing back together using the screws removed in step 5. 7. Secure the switch insulator and new switch to the handle using the screws removed in step 2. 8. Plug the switch to the PC board at the White terminal. F. POTENTIOMETER 2. Unplug the potentiometer from the PC board. 3. Remove the knob and brake nut from the potentiometer and remove the potentiometer from the holding bracket. 4. Install the new potentiometer into the holding bracket and secure with the brake nut. 5. Install the potentiometer knob so that it will point to 0 when the potentiometer is at minimum. 6. Plug the potentiometer to the PC board at the Yellow terminal. 8

G. GAS VALVE 2. Remove the four screws on the rear cover to release the gun housing and handle. 3. Remove the C-clip from either end of the trigger retaining pin and remove the pin, trigger and tension spring. 4. Remove the brass valve retaining body and diaphragm from the drive housing. 5. Install the new diaphragm and valve retaining body into the drive housing. 6. Reinstall the trigger tension spring, trigger and trigger pin onto the gun handle and secure with the C-clip removed in step 3. Make sure that the trigger is connected to the gas valve. 7. The gas valve should activate and gas should flow before the micro switch starts the motor. This allows for a preflow and postflow of shielding gas to prevent cratering and porosity. Adjust when the micro switch activates with the adjusting set screw beneath the metal trigger tab or by bending the tab itself or both. The micro switch should activate approximately 1/8 before the trigger bottoms out against the handle. 8. Reinstall the housing and handle to the rear cover with the four screws removed in step 2 making sure not to pinch any wiring. H. CONTROL CABLE 2. Remove the four screws on the rear cover to release the gun housing and handle 3. Unplug the control cord from the PC board. 4. Remove the cable /hose from the drive housing. 5. Remove the control cord clamp. 6. Remove the screw securing the rubber support sleeve and carefully remove the sleeve with the cable /hose and control cord. 7. Pull the cable/hose out of the rubber support sleeve and then remove the control cord. 8. Push the PC board plug end of the new control cord through the rubber support sleeve. Then slide the cable/hose through the sleeve. NOTE: A lubricant may be necessary on the cable/hose to allow easier insertion. 9. Connect the cable/hose to the drive housing and tighten. 10. Secure the new control cable to the rear cover with the control cord clamp removed in step 5. 11. Route the new control cord under the cable/hose and connect the plug to the PC board at Red terminal. 12. Slide the rubber support sleeve up and carefully insert into the rear cover and secure with the screw removed in step 6. 13. Reinstall the gun housing and handle to the rear cover using the four screw removed in step 2. Be careful not to pinch any wiring. I. CABLE / HOSE 2. Remove the four screws on the rear cover to release the gun housing and handle 3. Unplug the control cord from the PC board. 4. Remove the cable /hose from the drive housing. 5. Remove the control cord clamp. 6. Remove the screw securing the rubber support sleeve and carefully remove the sleeve with the cable /hose and control cord. 7. Pull the old cable/hose out of the rubber support sleeve. 8. Slide the new cable/hose through the rubber support sleeve. NOTE: A lubricant may be necessary on the cable/hose to allow easier insertion. 9. Connect the cable/hose to the drive housing and tighten. 10. Secure the control cable to the rear cover with the control cord clamp removed in step 5. 11. Route the control cord under the cable/hose and connect the plug to the PC board at Red terminal. 12. Slide the rubber support sleeve up and carefully insert into the rear cover and secure with the screw removed in step 6. 13. Reinstall the gun housing and handle to the rear cover using the four screw removed in step 2. Be careful not to pinch any wiring. J. MULTIPIN CONTROL CORD CONNECTORS 1. CompArc, Miller and Thermal Arc 14 pin connectors. 3. PROFAX P250SG & P300SG only 10 pin connector. a. Black wire to pin G a. Black wire to pin E b. White wire to pin A b. White wire to pin C c. Green wire to pin B c. Green wire to pin D 2. Millermatic 250X only 10 pin connector. a. Black wire to pin J b. White wire to pin D c. Green wire to pin G 9