Series 500 Amp Mig Gun

STANDARD FEATURES:
Ergonomic handle
Spare switch leads
Extra flexible cable
Spring strain reliefs
Jacketed gooseneck
PROFAX NO.
500-3545-10
500-052-10
500-116-10
500-564-10
500-332-10
500-764-10

LENGTH
10
10
10
10
10
10

WIRE SIZE
.035-.045
.052
1/16
5/64
3/32
7/64

PROFAX NO.
500-3545-12
500-052-12
500-116-12
500-564-12
500-332-12
500-764-12

TO ORDER DIRECT CONNECT MIG GUNS

Lincoln Direct - Add an LN e.g. LN500-3545-15
Miller Direct
Add an M. e.g. M500-3545-15
SEE PAGES 71 for more details on direct connects.
SEE PAGES 78-79 for list of adapter kits

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LENGTH
12
12
12
12
12
12

WIRE SIZE
.035-.045
.052
1/16
5/64
3/32
7/64

PROFAX NO.
500-3545-15
500-052-15
500-116-15
500-564-15
500-332-15
500-764-15

LENGTH WIRE SIZE

15
.035-.045
15
.052
15
1/16
15
5/64
15
3/32
15
7/64

PROFAX NO.
500-3545-20
500-052-20
500-116-20
500-564-20
500-3545-25
500-052-25
500-116-25
500-564-25

LENGTH WIRE SIZE

20
.035-.045
20
.052
20
1/16
20
5/64
25
.035-.045
25
.052
25
1/16
25
5/64

500 Amp Mig Gun Parts List

NO.
1.

1a.
2.
2a.
3.

4.

5.
6.

6a.
7.

PROFAX NO.
25CT-50
25CT-62
25CT-75
25I-62
25I-75
35CT
35CT-HT
15H35
15H45
15H52
15H116
15H564
15H332
15H764
15AH364
15AH116
15HFC35
15HFC45
15HFC52
15HFC116
15HFC564
15HFC332
15HFC764
15AHFC364
15AHFC116
55
55SW
55H
44C
65-22J
65-45J
65-60J
65-60-3RJ
65-180J
65-45
65-60
65-60-3R
65-80
65-180
75
65N

DESCRIPTION
Nozzle 1/2, coarse thread
Nozzle 5/8, coarse thread (standard)
Nozzle 3/4, coarse thread
Nozzle 5/8, self insulated
Nozzle 3/4, self insulated
Insulator, use w/coarse thread nozzle (standard)
Insulator, high temp
Contact tip .035
Contact tip .045
Contact tip .052
Contact tip 1/16
Standard
Contact tip 5/64
tip series
Contact tip 3/32
Contact tip 7/64
Contact tip 3/64 (for aluminum)
Contact tip 1/16 (for aluminum)
Contact tip .035
Contact tip .045
Contact tip .052
Contact tip 1/16
Contact tip 5/64
Contact tip 3/32
Contact tip 7/64
Contact tip 3/64 (for aluminum)
Contact tip 1/16 (for aluminum)
Gas diffuser (use w/45-564 & 45N-116)
Gas diffuser (use w/45-3545, 45-116, 45N-3545)
Gas diffuser (use w/45H-332, & 45H-764)
Set screw for gas diffuser/conduit
Jacketed conductor tube 22
Jacketed conductor tube 45
Jacketed conductor tube 60 (standard)
Jacketed conductor tube 60, 3 radius
Jacketed conductor tube 180
Conductor tube 45
Conductor tube 60
Conductor tube 60, 3 radius
Conductor tube 80
Conductor tube 180
Replacement neoprene insulator
Nipple

CO2 Heated Regulator/FlowGauge

NO.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

27.

PROFAX NO.
114
A-532-24
104
155HD
85
124FM-SET
134-15
AL-300-25
44-25
94C
94R
145-6S
500-10
500-12
500-15
500-20
500-25
500CK
244
R185-S
134-15
194
R185-H
R185-SC
R175-UA
R175-UAG
44C

DESCRIPTION
Separator
9/16-18 ball point screws
Cable connector block assembly
Hanger
Handle w/binder screws
Binders (4 ea.) and screws (4 ea.) for handle
Clamp - handle
7/32 hex wrench
5/64 hex wrench
Switch contacts w/screws
Trigger switch assembly
Spring strain relief
10 replacement cable assembly
12 replacement cable assembly
15 replacement cable assembly
20 replacement cable assembly
25 replacement cable assembly
Cloth wrapped cable, bulk (per foot)
Terminal
Spring
Clamp - connector block
Connector tab assembly
Housing
Screws for housing (4)
Standard connector plug w/65N
Connector plug with gas hole w/65N
Set screw for conduit 8-32

28.

R175-L

Connector, Lincoln

R175-M
R175-T
225
45-3545-15
45-116-15
45-564-15
45H-332-15
45H-764-15
45-3545-25
45-116-25
45-564-25

Connector, Miller (with R175M-N nipple)

Connector, standard
O-ring
15 wire conduit assembly .035-.045
15 wire conduit assembly .052-1/16
15 wire conduit assembly 5/64
15 wire conduit assembly 3/32
15 wire conduit assembly 7/64
25 wire conduit assembly .035-.045
25 wire conduit assembly .052-1/16
25 wire conduit assembly 5/64

20a.
21.
22.
23.
24.
25.
26.

28a
29.

CO2 Heaters
Thermostat set at
174 F - 205 F

SPECIFICATIONS:
120V AC/190 watt
0 - 125 CFH flow-rate

High volume CO2 Regulator

FlowGauge with built in heater.
Prevents regulator freeze-up
Extends regulator/FlowGauge life
Eliminates porosity in welds due
to loss of gas coverage

120V AC 50/60hz100 Watt

The most ECONOMICAL Thermostatic controlled CO2 Heater, designed to prevent
CO2 regulator Freeze-Up. Extends life of regulator/flowmeter and prevents porosity in
welds from loss of shield gas in frozen regulator. Easily installed between CO2
cylinder valve and flowmeter.
Also Available In 240V AC 50/60hz.

Also Available In 240V AC 50/60hz.

PROFAX NO.
RFG-320-H

GAS SERVICE
CO2

CGA INLET
320

PROFAX NO.
CO2 HEATER

GAS SERVICE
CO2

CGA INLET
320

69

500 Amp Mig Gun

PROFAX NO.

DESCRIPTION

TIP I.D.

15H35
15H45
15H52
15H116
15H564
15H332
15H764
15H18
15AH364
15AH116

Contact tip .035

Contact tip .045
Contact tip .052
Contact tip 1/16
Contact tip 5/64
Contact tip 3/32
Contact tip 7/64
Contact tip 1/8
Contact tip 3/64
Contact tip 1/16

.044
.054
.064
.073
.090
.106
.120
.140
.059
.078

15HFC35
15HFC45
15HFC52
15HFC116
15HFC564
15HFC332
15HFC764
15HFC18
15AHFC364
15AHFC116

Contact tip .035

Contact tip .045
Contact tip .052
Contact tip 1/16
Contact tip 5/64
Contact tip 3/32
Contact tip 7/64
Contact tip 1/8
Contact tip 3/64
Contact tip 1/16

.044
.054
.064
.073
.090
.106
.120
.140
.059
.078

25CT-50

Nozzle 1/2

PROFAX NO. DESCRIPTION

25I-62

Nozzle 5/8

(Self Insulated Nozzle)

Standard tip series

25I-75

Nozzle 3/4

(Self Insulated Nozzle)

35CT

Insulator

(Coarse thread - fixed

nozzle - used with
35CT nozzle insulator)

25CT-62

Nozzle 5/8

(Used with coarse thread nozzles)

35CT-HT

Insulator

55

Gas diffuser
(Used with 45N-116,
45-564 conduits)
Gas Diffuser
(Used with 45-3545,
45-116 conduits)
Gas Diffuser
(Used with 45H-332,
45H-764 conduits)

(Coarse thread - fixed

nozzle - used with
35CT nozzle insulator)

25CT-75

Nozzle 3/4
(Coarse thread - fixed
nozzle - used with
35CT nozzle insulator)

PROFAX NO.
65-45
65-60
65-80
65-180
65-60-3R
65N

DESCRIPTION
Conductor tube 45
Conductor tube 60
Conductor tube 80
Conductor tube 180
Conductor tube 3 radius 60
Nipple - included

Special for hi temp applications.

55SW

55H

PROFAX NO.
65-22J
65-45J
65-60J
65-180J
65-60-3RJ
65N

DESCRIPTION
Jacketed conductor tube 22
Jacketed conductor tube 45
Jacketed conductor tube 60
Jacketed conductor tube 180
Jacketed conductor tube 3 radius 60
Nipple - included

Note:
15 wire conduit assembly (16 - 0 o.a.l.)
25 wire conduit assembly (26 - 0 o.a.l.)

70

PROFAX NO.
45-3545-15
45-116-15
45-564-15
45H-332-15
45H-764-15
45-3545-25
45-116-25
45-564-25

DESCRIPTION
15 wire conduit assembly used with .035-.045 diameter wire
15 wire conduit assembly used with .052-1/16" diameter wire
15 wire conduit assembly used with 5/64" diameter wire
15 wire conduit assembly used with 3/32" diameter wire
15 wire conduit assembly used with 7/64" diameter wire
25 wire conduit assembly used with .035-.045 diameter wire
25 wire conduit assembly used with .052-1/16" diameter wire
25 wire conduit assembly used with 5/64" diameter wire

Use with 55SW gas diffuser

Use with 55SW gas diffuser
Use with 55 gas diffuser
Use with 55H gas diffuser
Use with 55H gas diffuser
Use with 55SW gas diffuser
Use with 55SW gas diffuser
Use with 55 gas diffuser

I.D.
.067
.078
.105
.125
.135
.067
.078
.105

O.D.
.187
.187
.237
.267
.267
.187
.187
.237

Series 500 Amp Mig Gun

DirectConnects & Direct Mount Conversion Kits
The following direct connects are available by placing the letters shown below before the gun package number.
Example: add an M to 500-3545-10; eg M500-3545-10 is now a Miller direct connect gun.

Direct Connects

LN-Lincoln : LN7, LN8, LN9, LN25, LN742, and

Synergic 7. Also LN10, DH10, & STT10 with K1500-1
installed.

M-Miller : 8VS and 12VS, R115,

S21E, S22A, S32, Super 32,
and all 50, 60, 72, and 74 series feeders.

Direct Mount Conversion Kits

Standard: TAK-500
NO. PROFAX NO. DESCRIPTION
1. R175-T
Connector - Standard PROFAX
2. AK-354
Control cord

Miller : MAK-500
NO.
1.
2.
3.

PROFAX NO.
R175M-N
R175-M
MSAK-354

DESCRIPTION

Nipple for Miller connection

Connector for Miller

Control cord
Lincoln: LAK-500

NO.
1.
2.
3.
4.
5.
6.
7.

PROFAX NO.
R175-LC
35-170-5
MSAK-353
LAK-354
AK-353-2A
1245
1255

DESCRIPTION

Connector for Lincoln

Gas nipple
Gas hose w/grommet
Control cord
Gas hose clamp (2)
Gland
Nut
Conversion kits to convert the 500 amp mig gun to direct mount.
Includes connector plug, electrical cord w/plug, and gas hose (If required).

TAK-500 Lincoln: LN10, DH10, & STT10 w/O.E.M. K1500-3 Installed. (Requires LAK-354)
MAK-500 Miller: S21E, S22A, S32, Super 32, and all 50, 60, 72, and 74 series feeders.
LAK-500 Lincoln: LN7, LN8, LN9, LN25, LN742, and Synergic 7. Also Lincoln LN10, DH10, & STT10 w/O.E.M. K1500-1 installed.
*For adapter kits for other style feeders see page 78.

71