For appropriate control boxes see pages Also available in 100 length on Special Order

Transcription

1 AEC 200 1# Spool Gun STANDARD FEATURES Economical feeder/gun combination eliminates need for additional wire feeder Lightweight design reduces operator fatigue 50 hose/cable assembly offers maximum portability for remote operation Operation simplified by wire speed control on gun Mechanical pre-flow and post-flow control Operator safety provided by plastic housing and low voltage operation Model AEC 200 Ratings Current (D.C.R.P.) Duty Cycle Gas 200 Amps 100% Argon or Helium 250 Amps 50% Argon or Helium 275 Amps 30% Argon or Helium 300 Amps 100% Carbon Dioxide For appropriate control boxes see pages Also available in 100 length on Special Order Model AEC 200 comes complete with gun, nozzles, liners, contact tubes, a wrench and 50' of cable hose assembly. THE SELECTION CHART NO. WIRE SIZE TYPE MOTOR RATIO NOZZLE I.D. TIP & LINER AEC /64 Aluminum 36:1 11/16 3/ /64 Aluminum 64:1 11/16 3/64 AEC L*.030-3/64 Aluminum & 36:1 11/16 3/ Hard The AEC 200L is a modified gun to direct connect to the ESAB (L-TEC ) MigMaster 250 and the ESAB Mig-28A control module. DIRECT CONNECT Solid State Spool Gun The AEC 200-4DM Direct Connect is designed to give Solid State Performance to a Spool Gun that will connect to the Constant Voltage power sources listed below without the need of a control box. DESIGN FEATURES: Direct Connects to Miller, Thermal Arc and CompArc Constant Voltage power sources. No Control Box - Interfaces Direct to Power Source. Operates on 24 VAC One Motor for.030-1/16 Aluminum and Hard wires. No More Changing Motor Ratio s 20 to 800 ipm Speed Range. 50 Cable Length Standard. Solid State Control Provides: True Constant Speed Higher Motor Torque at all Speeds Compensates for Input Voltage Fluctuations Longer Motor Life Smoother Wire Feeding DIRECT CONNECT SPOOL GUN SYSTEMS NO. AEC 200-4DM DESCRIPTION Direct connect spool gun for Miller, Thermal Arc, and CompArc constant voltage power sources with the 14 pin wire feeder receptacle. Also available in 100 length on Special Order SPECIFICATIONS INPUT POWER WELD OUTPUT RATING ARGON WIRE CAPACITY WIRE SPEED RANGE 250 amps - 50% duty cycle.030-1/16 aluminum 24VAC 200 amps - 100% duty cycle hard wire 20 ipm to 800 ipm This system can be connected to any adequately sized constant voltage welding power source that provides 24 VAC auxiliary power and a contact 100 closure contactor circuit. See owners manual or consult factory for complete details.

2 Solid State Spool Gun & Control HAS GIVEN THE CLASSIC DESIGN OF THE AEC 200 SPOOL GUN A NEW SOLID STATE PUNCH. DESIGNED FOR CONSTANT VOLTAGE POWER SOURCES, THIS NEW PUNCH WILL PROVIDE: ONE MOTOR FOR.030 THROUGH 1/16 ALUMINUM AND.023 THROUGH.045 HARD WIRES. NO MORE CHANGING MOTOR RATIO'S NO MORE RHEOSTAT TO GET HOT OR BURN OUT 30 TO 800 INCH PER MINUTE CAPABILITY 50 GUN CABLE LENGTH STANDARD SOLID STATE CONTROL PROVIDES: TRUE CONSTANT SPEED HIGHER MOTOR TORQUE LONGER MOTOR LIFE SMOOTHER WIRE FEEDING SOLID STATE SPOOL GUN SYSTEM NO. AEC AEC 200-4C DESCRIPTION Spool Gun w/50' cable assembly for use w/ AEC 200-4C solid state control box Solid state control box for use w/ AEC Spool Gun Also available in 100 length on Special Order SPECIFICATIONS WELD OUTPUT RATING WEIGHT INPUT POWER ARGON or HELIUM WIRE CAPACITY WIRE SPEED RANGE DIMENSIONS 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" 4C Control 100% Duty Cycle.023 in. through 800 IPM Length 15" Net 7.5 lbs..045 Hard Wire Ship 9 lbs. The AEC Spool Gun and AEC 200-4C control are interfaced together to give the improved SOLID STATE motor control performance to the Classic AEC 200 Spool Gun 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. See owners and installation manual for complete details. 101

3 AEC 200 STANDARD SPOOL GUNS NO. WIRE SIZE CONNECTION TYPE AEC AEC P P AEC L AEC AEC 200-4DM AEC 200-4DMX AEC AEC 200-1P AEC AEC 200-3A AEC 200-4C.030-3/64 ALUMINUM.035-3/64 ALUMINUM.030-3/64 ALUMINUM.035-3/64 ALUMINUM.030-3/64 ALUMINUM HARD WIRE.030-1/16 ALUMINUM HARD WIRE.030-1/16 ALUMINUM HARD WIRE.030-1/16 ALUMINUM HARD WIRE FOR USE WITH THE AEC ON CONSTANT VOLTAGE POWER SOURCES OR WITH THE AEC AND AEC 200-3A ON CONSTANT CURRENT POWER SOURCES. FOR USE WITH THE AEC 200-1P CONTOL BOX ON CONSTANT VOLTAGE POWER SOURCES. DIRECT CONNECTS TO THE AIRCO POWER SOURCES WITH 10 PIN RECEPTACLE. SOLID STATE SPOOL GUNS DIRECT CONNECTS TO AN ESAB MIGMASTER 250 AND TO THE ST-28A CONTROL BOX. MUST BE USED IN CONJUNCTION WITH THE AEC 200-4C CONTROL BOX. FOR USE ON CONSTANT VOLTAGE POWER SOURCES ONLY. DIRECT CONNECTS TO MILLER OR COMPARC CONSTANT VOLTAGE POWER SOURCE WITH THE 14 PIN RECEPTACLE. CAN ALSO BE USED WITH THE AEC-LVC CONTACTOR BOX ON CV MACHINES WITHOUT A CONTACTOR. DIRECT CONNECTS TO A MILLERMATIC 250X, TO THE MILLERMATIC 300 (BEGINNING WITH SERIAL # LA000202) AND THE HOBART IRONMAN 275. STANDARD CONTROL BOXES FOR USE WITH ANY STANDARD SPOOL GUN BEING USED ON A CONSTANT VOLTAGE POWER SOURCE. (SEE CONTACTOR BOX). FOR USE WITH ANY STANDARD (P) SPOOL GUN BEING USED ON A CONSTANT VOLTAGE POWER SOURCE. (SEE CONTACTOR BOX). FOR USE WITH ANY STANDARD SPOOL GUN BEING USED ON A CONSTANT CURRENT POWER SOURCE. (SEE CONTACTOR BOX). FOR USE WITH A STANDARD SPOOL GUN ON A CONSTANT CURRENT DC POWER SOURCE. RECOMMENDED FOR INDUSTRIAL SIZED ELECTRIC MACHINES AND ENGINE DRIVES OF 3 CYLINDERS OR MORE. OPERATES ON 115V AC OR DC. SOLID STATE CONTROL BOXES FOR USE WITH AN AEC BEING USED ON A CONSTANT VOLTAGE WELDING POWER SOURCE. (SEE CONTACTOR BOX). CONTACTOR BOX AEC 200-C FOR USE ON POWER SOURCES WITHOUT A CONTACTOR. USED IN CONJUNCTION WITH AN AEC 200-1, AEC 200-1P OR AEC 200-4C ON CONSTANT VOLTAGE POWER SOURCES AND WITH THE AEC ON CONSTANT CURRENT POWER SOURCES. AEC 200-LVC FOR USE WITH THE AEC 200-4DM WHERE AN EXTERNAL CONTACTOR IS REQUIRED. AEC NON SOLID STATE AEC 200-4C SOLID STATE AEC AEC 200-C CONTACTOR AEC NON SOLID STATE 102

4 AEC 200 AEC 200-C CONTACTOR AEC 200-4C SOLID STATE AEC AEC NON SOLID STATE AEC NON SOLID STATE AEC 200-C CONTACTOR AEC 200-3A CONTROL WITH INTERNAL CONTACTOR AEC 200-4DM AEC-LVC CONTACTOR AEC 200-4DM AEC L 103

5 AEC 200 Consumables NO. WIRE SIZE / / / STANDARD CONTACT TIPS I.D Bent nozzle kit Nut Nozzle Slip ring BENT NOZZLE KIT & TIPS Adapter Barrel Assembly (5 & 6) / Note: Additional 4137 nozzle included NO. I.D. MATERIAL STANDARD NOZZLES NO. WIRE SIZE I.D / / /16 Brass 4137 Copper 5/ /16 Brass (Used on AH-20E) FLEXIBLE BARREL ASSEMBLY & TIPS /16 Brass /16 Brass /16 Copper Flexible barrel Tip holder (included) Nozzles 4268, 4269, and 4270 Shown above in left column NO. WIRE SIZE I.D Hard Hard / /16 Alum ¼ Liner (cut to length) Included Contact Tips 3150, 3223, and 3456 Shown below NEW STYLE BARREL ASSEMBLY New style assy Nozzle Nozzle Nozzle body Spacer Adapter sleeve OLD STYLE BARREL ASSEMBLY Old style assembly /2 nozzle Adapter /4 nozzle Barrel /8 nozzle 104

6 AEC 200 HEAVY DUTY Consumables Optional AEC 200 Heavy Duty Consumables Heavy Duty Flexible Barrel NO.: 4675 Assembly with 180 Gooseneck NO.: 4975 (Assembly) NO.: 4676 Assembly with 45 Gooseneck series Nozzles series Tip 2a. 17ST series Tip 3. 57HD Gas diffuser 4. 44C Screw Retaining ring O-ring NO. DESCRIPTION TIP I.D. 17S-35 Contact tip S-40 Contact tip S-45 Contact tip AS-364 Contact tip 3/64 aluminum S-52 Contact tip S-116 Contact tip 1/ AS-116 Contact tip 1/16 aluminum SW Shock washer Barrel adapter 8a O-ring Gooseneck - straight 9a Gooseneck Liner (phos-bronze) Locking nut series Nozzles series Tip 2a. 17ST series Tip HDF Liner (phos-bronze) 4. 57HD Gas diffuser 5. 44C Screw NO. DESCRIPTION 27S62 H.D. Nozzle 5/ Spring O-ring 8. 17SW Shock washer HD HD Flexible Barrel HD HD Guide Tube 10a O-ring 17ST-35 Contact tip ST-40 Contact tip ST-45 Contact tip ST-52 Contact tip ST-116 Contact tip 1/ S75 H.D. Nozzle 3/4 27S50GL H.D. Nozzle 1/2 Cut View 27K50 M.D. Nozzle 1/2 (Use with 17ST series tips) (Use with 17ST series tips) 27S62GL H.D. Nozzle 5/8 Cut View 27S50 H.D. Nozzle 1/2 27S75GL H.D. Nozzle 3/4 (Use with 17ST series tips) Cut View 105

7 106 AEC 200 1# Spool Gun Breakdown

8 Replacement Parts for the AEC 200 1# Spool Gun Nozzle Trigger Contact tip 55a 1097D Trigger (200-4DM) Nozzle body Trigger pin Spacer Set screw Grommet Screw Adapter sleeve Lock washer Nut Screw Fitting Cable clamp Inner barrel 61a 1579D Cable clamp (200-4DM) Guide tube Nut O-ring Sleeve Green liner Round head screw 5109 Red liner.045-3/64" Washer 5134 White liner 1/16" Speed nut Pal nut Terminal strip Guide 67a 9252 PC board (200-4DM) Retainer Marker strip Spring Post Valve pin Spindle Diaphragm Washer Housing Spindle spring Arm assembly (consists of # S 21-25) Screw Retaining ring Spindle screw Pin Spade terminal Spacer Control cable assembly Driven roll 76a 1060DM Cable w/miller 14 Pin (200-4DM) Driven roll for.023 wire only L Control cable assembly Pressure Arm 77a Control cable assembly Adjusting screw 1060P Control cable assembly Terminal Cover Hose cable assembly Pal nut L Hose cable assembly 30' Drive roll Connection nut Screw Retaining ring Spring catch Thrust washer Inlet bushing Lock screw O-ring Dial plate Drive roll spring pin plug for DM gun Pivot screw pin male plug for P gun Insulating insert 1607L 8 pin male plug for L & #4 gun Screw Motor insulator O-ring Key Motor (36:1 ratio) 1886 Motor (64:1 ratio) 41a 1886D Motor (200-4DM) Handle 42a 1066D Handle (200-4DM) Insert Insert 1/4" Insert Rheostat assembly D Potentiometer (200-4DM) 47a 1606L Bracket Screw Set screw Knob Micro switch Potentiometer for L & #4 gun 52a 1280D Micro switch (200-4DM) Insulator 53a 1113D Insulator (200-4DM) Screw Spade terminal Ferrule Fitting Cable boot Block Terminal Washer Nut Cable assembly Cable lug 97 LDP-50M Dinse connector Gland Nut Ferrule Hose assembly Gland Rear cover(orange) 103a 1065RD Rear cover (200-4DM)(Red) Front cover(orange) 104a 1064RD Front cover (200-4DM)(Red) Wrench 107

9 AEC Control Boxes A Cover, top N/S* A Base Fuse holder Fuse 1¼ amp slo blo N/S* Strain relief (2) Terminal strip 8 pole Decal, 8 pole terminal strip Terminal strip 4 pole AEC Decal, 4 pole terminal strip Bridge rectifier Relay, 3 PDT-24VAC Transformer, step down Resistor, 10 ohm 25 watt Cable, 5 18/ Cable, 5 18/3 For use in connecting the AEC 200 welding gun to a constant voltage welding power source A Cover, top N/S* A Base Fuse holder Fuse 1¼ amp slo blo N/S* Strain relief (2) Terminal strip 8 pole Decal, 8 pole terminal strip Terminal strip 4 pole AEC 200-1P Decal, 4 pole terminal strip Bridge rectifier Relay, 3 PDT-24VAC Transformer, step down Resistor, 10 ohm 25 watt Cable, 5 18/ Cable, 5 18/ pin amphenol receptacle For use in connecting the AEC 200P welding gun to a constant voltage welding power source. AEC A Cover, top N/S* Relay, 3 PDT-24VAC (2) A Base Transformer, step down Fuse holder Resistor, 10 ohm 25 watt Fuse 1¼ amp slo blo N/S* Current relay w/reed switch Strain relief (2) Dinse panel mount (2) Terminal strip 8 pole Cable, 5 18/ Decal, 8 pole terminal strip Reed switch only Terminal strip 4 pole Sensor lead Decal, 4 pole terminal strip Relay diode assembly Bridge rectifier (8 amp 600 volt) *N/S - Not Shown For use in connecting the AEC 200 welding gun to a constant current welding power source. Requires two each LENCO LDP-50 Dinse type cable connectors A Cover, top N/S* A Base Relay 110V DC B Buss cable Contactor A Bus bar Dinse panel mount (2) Resistor 10 ohm 25 watt Resistor 100 ohm 50 watt AEC 200-3A Fuse holder Fuse, 1¼ amp slo blo N/S* Fuse, 2 amp slo blo N/S* Sensor lead Strain relief (2) Line cord BCKPrinted circuit board assy FS Flash suppressor 108 For use in connecting the AEC 200 welding gun to a constant current stationary or engine driven welding power source not having a contactor. Recommended for aluminum welding only. Requires two each LENCO LDP-50 Dinse type cable connectors.

10 AEC Control Boxes A Top cover N/S* A Base PC board Transformer 115/24 50VA Relay, 3PDT - 24VAC pin receptacle Fuse holder AEC 200-4C Fuse, 1.25 amp 250V* Terminal strip Contactor cord, 5 ft. 18/ Primary cord, 5 ft. 18/ Strain relief Decal, 4 pole terminal strip Terminal tool For use in connecting the AEC spoolgun to constant voltage power sources A Cover, top N/S* A Base Fuse holder Fuse 1¼ amp slo blo N/S* Strain relief Bridge rectifier AEC 200-C Dinse panel mount (2) Contactor Varistor assembly Bus bar (2) Cable, 5 18/3 For use with the AEC 200 welding gun and related controls, however, it may also be used in any application requiring a welding contactor, as long as operating parameters are observed A Cover, top N/S* A Base Relay 24VAC Buss bar C Bus bar Transformer Contactor Bridge rectifier Dinse panel mount (2) AEC 200-LVC Fuse holder Fuse, 1¼ amp slo blo N/S* socket panel receptacle Varistor assembly Strain relief Line cord FS Flash suppressor assembly Requires two each LENCO LDP-50 Dinse type cable connectors. For use with the AEC 200-4DM spoolgun on constant voltage power sources without an internal contactor. Requires two each LENCO LDP-50 Dinse type cable connectors. *N/S - Not Shown 109