Profax AEC 200-4D - Manual (Page 2)

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 CO
2
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.)
CONTENT PAGE
INDEX
1
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
i
Form WSWC 594