Alfain PEGAS 200 Bedienungsanleitung

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ALFA IN a.s. © www.alfain.eu NA156-6

WELDING INVERTER

PEGAS 200 AC/DC PULSE

OPERATING MANUAL

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ALFA IN a.s. © www.alfain.eu

CONTENT:

1INTRODUCTION ........................................................................................3

2SAFETY INSTRUCTIONS AND WARNINGS.............................................4

3ELECTROMAGNETIC COMPATIBILITY (EMC) ........................................5

4TECHNICAL DATA.....................................................................................6

5EQUIPMENT...............................................................................................7

5.1CONTENT OF DELIVERY...................................................................7

5.2ACCESSORIES TO ORDER...............................................................7

6OPERATOR CONTROLS...........................................................................8

6.1MAIN PARTS.......................................................................................8

7GETTING STARTED................................................................................10

7.1GETTING STARTED MMA – COATED ELECTRODE......................10

7.2GETTING STARTED TIG ..................................................................11

7.3REMOTE CONTROL.........................................................................12

8TWO STROKE AND FOUR STROKE IN TIG MODE...............................13

8.1TWO STROKE – 2T...........................................................................13

8.2FOUR STROKE – 4T.........................................................................13

8.3BILEVEL – SECOND WELDING CURRENT.....................................13

9BASIC SETTINGS FOR TIG WELDING...................................................13

10ROUTINE MAINTENANCE & INSPECTION ............................................14

11STATEMENT OF WARRANTY.................................................................15

12DISPOSAL................................................................................................15

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ALFA IN a.s. © www.alfain.eu

1 INTRODUCTION

Congratulations on your new ALFA IN product. We are proud to have you as

our customer and will strive to provide you with the best service and reliability

in the industry.

This Operating Manual has been designed to instruct you on the correct use

and operation of your ALFA IN product. Your satisfaction with this product and

its safe operation is our ultimate concern. Therefore please take the time to

read the entire manual, especially the Safety Precautions. They will help you to

avoid potential hazards that may exist when working with this product.

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment. While the information

contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

PEGAS 200 AC/DC PULSE welds by those methods

1. E – (MMA) DC coated electrodes up to 4,0 mm

2. E – (MMA) AC coated electrodes up to 4,0 mm

3. TIG DC (Lift arc or High Frequency ignition)

4. TIG AC (Lift arc or High Frequency ignition)

1. TIG AC 2. TIG DC 3. MMA

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ALFA IN a.s. © www.alfain.eu

2 SAFETY INSTRUCTIONS AND WARNINGS

Once the packing has been opened, make sure that the machine is not

damaged. If in any doubt, call the service centre.

This equipment must only be used by qualified personnel.

During installation, any electric work must only be carried out by trained

personnel.

The machine must be used in a dry place with good ventilation.

Make sure that no metal dust can be drawn in by the fan inside the machine,

as this could cause damage to the electronic circuits.

It is prohibited to connect more than one INVERTER generator in series or in

parallel.

When installing the machine, follow the local regulations on safety.

The position of the machine must allow easy access by the operator to the

controls and connectors.

When the welding machine is operating, all its covers and doors must be

closed and well fixed.

Do not expose the welding machine to direct sunlight or to heavy rain. This

equipment conforms to protection rating IP23S.

During welding, the welding cables must be located near or at ground level.

They should be as short as possible.

The operator must wear gloves, clothes, shoes, and a helmet or a welder’s

helmet, which protect and are fire-resistant in order to protect him against

electric shock, flashes and sparks from welding.

The operator must protect his eyes with safety visor or mask designed for

welding, fitted with standard safety filters. He should also be aware that during

electrical welding ULTRAVIOLET RADIATION is emitted. Therefore it is vital

that his face is also protected from radiation. Ultraviolet rays produce the same

harmful effect as sun burning on unprotected skin.

The operator is obliged to warn anyone near the welding area of the risks that

welding involves and to arrange to provide adequate protection equipment.

It is very important to arrange for sufficient ventilation, especially when welding

in enclosed spaces. We suggest using suitable fume extractors to prevent the

risk of intoxication by fumes or gas generated by the welding process.

The operator must ensure all flammable materials are removed from the work

area to avoid any risk of fire.

The operator must NEVER weld containers that have previously contained

petrol, lubricants, gas or similar flammable materials, even if the container has

been empty for a considerable time. THERE IS A VERY HIGH RISK OF

EXPLOSION.

The operator must be aware of all the special regulations which he needs to

conform to when welding in enclosed spaces with a high risk of explosion.

To prevent electric shock, we strongly suggest the following rules:

Do not work in a damp or humid environment.

Do not use the welding machine if its cables are damaged in any way.

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ALFA IN a.s. © www.alfain.eu

Make sure that the earthing system of the electric equipment is correctly

connected and operational.

The operator must be insulated from the metal components connected to the

return wire.

The earthing of the piece being worked could increase the risk of injury to the

operator.

EN 60974-1 Standard: Open-circuit voltage. During the operation of the

machine, the highest voltage, with which it is possible to come into contact, is

the open-circuit voltage between the welding clamps.

The maximum open-circuit voltage of the welding machines is established by

national and international standards (EN 60974-1) depending on the type of

weld current to be used, on its waveform and on the hazards arising from the

work place. These values are not applicable to the strike currents and those for

stabilisation of the arc that could be above it.

The open-circuit voltage, for as many adjustments as possible, must never

exceed the values relating to the various cases shown in the following table:

Case Working conditions Open-circuit voltage

1 Places with increased risk of

electric shock DC current: 113V

peak value AC current: 68V

peak value and

48V effective

2 Places without increased risk

of electric shock DC current: 113V

peak value AC current: 113V

peak value and

80V effective

3 Torches held mechanically

with increased protection for

the operator

DC current: 141V

peak value AC current: 141V

peak value and

100V effective

In case 1, the dc welding machines with rectifier must be built in such a way

that, in case of a fault developing in the rectifier (for example open circuit, short

circuit or lack of power), the permitted values cannot be exceeded.

Before opening the machine switch off the machine and disconnect it from the

power socket.

Only personnel authorised by this company can carry out maintenance on the

machine.

3 ELECTROMAGNETIC COMPATIBILITY (EMC)

This welding machine conforms to EN 60974-10 standard. However, the

electromagnetic emissions generated could prove not be compatible with the

maximum permitted levels for some classes of electrical equipment, such as

the following:

Domestic electronic appliances (radios, TVs, videos, telephones, burglar

alarms, etc.).

Computers, robots, electro-medical instruments and life-support systems.

Radio-television transmitters and receivers.

Pacemakers and hearing aids.

All very sensitive electrical equipment.

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ALFA IN a.s. © www.alfain.eu

The operator is responsible for the installation and use of the welding machine.

If there should be any fault in operations of other systems located in the

immediate vicinity of the generator, we recommend suspending operations and

consulting the manufacturers.

4 TECHNICAL DATA

Units

Method MMA - AC MMA - DC

Mains voltage V/Hz 1x230/50-60

Mains protection A 16T *)

Max. input power I1 A 40,3

Max. effective current I1eff A 20,2

Welding current range A/V 10/20,4 - 170/26,8 5/20,2 - 170/26,8

Open-circuit voltage U20 V 73 68

Welding current (DC=100%) I2 /U2

ta=40 oC A/V 70/22,8 80/23,2

Welding current (DC=60%) I2/U2

ta=40 oC A/V 90/23,6 110/24,4

Welding current (DC=x%) I2/U2

ta=40 oC A/V 20%=170/26,8 25%=170/26,8

Welding current (DC=100%) I2 /U2

ta=25 oC A/V 90/23,6 110/24,4

Welding current (DC=60%) I2/U2

ta=25 oC A/V 110/24,4 130/25,2

Welding current (DC=x%) I2/U2

ta=25 oC A/V 25%=170/26,8 30%=170/26,8

Insulation class F

Protection IP23S

Standards EN 60974-1

Dimensions (w x l x h) mm 250 x 470 x 400

Weight kg 21,8

Method TIG - AC TIG - DC

Mains voltage V/Hz 1x230/50-60

Welding current range A/V 10/10,4 - 200/18,0 5/10,2 - 200/18,0

Open-circuit voltage U20 V 73 68

Welding current (DC=100%) I2 /U2

ta=40 oC A/V 70/12,8 80/13,2

Welding current (DC=60%) I2/U2

ta=40 oC A/V 90/13,6 110/14,4

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ALFA IN a.s. © www.alfain.eu

Welding current (DC=x%) I2/U2

ta=40 oC A/V 20%=200/18,0 25%=200/18,0

Welding current (DC=100%) I2 /U2

ta=25 oC A/V 90/13,6 110/14,4

Welding current (DC=60%) I2/U2

ta=25 oC A/V 110/14,4 130/15,2

Welding current (DC=x%) I2/U2

ta=25 oC A/V 25%=200/18,0 30%=200/18,0

ALFA IN continuously strives to produce the best product possible and

therefore reserves the right to change, improve or revise the specifications or

design of this or any product without prior notice. Such updates or changes do

not entitle the buyer of equipment previously sold or shipped to the

corresponding changes, updates, improvements or replacement of such items.

5 EQUIPMENT

5.1 CONTENT OF DELIVERY

Item No. Description Quantity

5.0172 PEGAS 200 AC/DC PULSE 1

5.0189 Set of Connectors for PEGAS AC/DC 1

5.2 ACCESSORIES TO ORDER

Item No. Description

VM0184-1 Hose Gas ATA PULSE 3m G1/4, D 9.5 HD

VM0253 Welding Cable Set 2x 3m 35-50 200A

5.0216 CS 601 W Cooling Unit PEGAS

5.0228 Welders Cart

WP17121RBAA Torch WP 17 4m 35-50 with Connector AERO

5.0201A Torch WP 26 4m 35-50 with connector AERO

5.0202A Torch WP 26 8m 35-50 with connector AERO

7S3.A005A Torch ABITIG 26 4m 35-50 HiF Leather UD AERO

7S3.A006A Torch ABITIG 26 8m 35-50 HiF Leather UD AERO

7S4.A003AA Torch ABITIG 18 4m 35-50 leather W AERO

3549 Valve Red.AR OXY MAXI PC 2

5.0174 Foot Pedal Remote CTRL 3 m PEGAS incl. Connector

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ALFA IN a.s. © www.alfain.eu

6 OPERATOR CONTROLS

6.1 MAIN PARTS

Fig . 1 Main parts

Pos. Description

1 Button TIG 2T or 4T (two stroke, four stroke)

2 LED Pregas. 0,1 – 1 s, default 0,3 s

3 Current Display

4 LED start current (just 4T). 5 – 100 % of the main welding current.

DC, 10 – 100 % AC, Default 5%.

5 LED Up slope. 0 – 10 s, default 0 s.

6 LED Main Welding Current. 5 – 200 TIG DC, 10 – 200 TIG AC, 5 –

170 MMA DC, 10 – 170 MMA AC

7 LED ratio of the pulse current and the base current . 5 – 100 %.

Default 5 %.Just for the pulse mode.

8 Display Voltage, %, time and Hz.

9 LED Main Welding Current in the pulse mode. 5 – 200 A DC, 10 –

200 TIG AC

10 LED Pulse Base Current. 5 – 200 A DC, 10 -200 A AC.

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ALFA IN a.s. © www.alfain.eu

11 LED Time (s). If illuminated there are values in s on the display 8.

12 LED Voltage (V). If illuminated there are values in V on the display

13 LED %. If illuminated there are values in % on the display 8.

14 LED ON

15 LED ALARM. If illuminated there is under or over voltage in the

mains or the machine is overheated. At the same time the displays

show Err 001.

16 LED Hz. If illuminated there are values in Hz on the display 8.

17 LED Down Slope, 0 – 10 s, default 0 s.

18 LED Post Gas, 0,1 – 10 s, default 3 s.

19 LED end current, 5 – 100 % of the Main Welding Current DC, 10 –

100 % of the Main Welding Current AC, default 5 %. Just in 4T.

20 LED ARC FORCE for MMA, 0 – 10.

21 MMA switch

22 LED MMA. Can be turned off by means of pressing button 1.

23 LED Arc Length, 0 – 10.

24 LED HOT START, 0 – 10.

25 Button for moving to the right on the parameters curve.

26 LED Balance (just TIG AC). Used for elimination of the aluminium

oxides. Range 15 – 50 %, default 15% (more in the text below).

27 LED Pulse Frequency. 0,5 – 200 Hz, default 0,5 Hz. Just in the

pulse mode.

28 Encoder

29 LED AC Frequency (just TIG AC). Range: 50-250 Hz. The higher

current, the more the maximal frequency decreases. The range of

frequency at the maximal current is 50 – 100 Hz.

30 Button for moving to the left on the parameters curve.

31 Gas test.

32 Button switch HF/LIFT ARC.

33 Button switch Pulse/Non pulse mode.

34 LED Pulse. If illuminated the Pulse mode was set.

35 LED HF. If illuminated the HF ignition was set.

36 LED Gas Test. If illuminated the mode of setting the gas flow was

selected (by means of the gas valve on the gas cylinder). To turn it

off press the button 31 again or it will go off this mode after 10 s.

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ALFA IN a.s. © www.alfain.eu

37 LED Four Stroke (4T).

38 LED Two Stroke (2T).

39 LED DC

40 LED AC

41 Button switch AC/DC mode.

42 Quick connector +

43 Torch control connector (pin 8 and 9)

44 Quick connector -

45 Gas connector of the welding torch

46 Gas inlet

47 Mains cable and plug

48 ON/OFF switch

7 GETTING STARTED

7.1 GETTING STARTED MMA – COATED ELECTRODE

Insert the mains plug 41 into a suitable 1x230 V

mains socket. The supply fuses or circuit breaker

should correspond to the technical data stated in

this manual.

Connect the welding cables to the panel quick

connectors (+) 42 and (-) 44 according the instruction on the electrodes

packing.

Switch the machine on by the ON/OFF switch 48.

Set the welding current by means of Encoder 28. The values will be showed on

the display 3.

It is possible to change the settings of the HOT START (increase of current

during arc ignition time), ARC FORCE (an automatic increase of the welding

current in case the electrode touches the welding piece) and Arc Length by

means of the Button 21 and the Encoder 28.

Then switch to the MMA mode by means of the button 21. LEDs 20, 23 or 24

may not illuminate.

NOTEPrevent touching the electrode any metal material for in this

mode the terminals 42 and 44 are under current.

Insert the coated electrode into the electrode holder, connect the clamps of the

ground cable to the welding piece and you may start welding.

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