ALF 251-261-280-320-400 BASIC-MINOR2-MAJOR
Contents
1. Weight compact 76 76 Weight generator X X Wire speed m min 1 19 1 19 Spool diameter mm 300 300 Spool weight kg 18 18 ALF 280 ALF 320 ALF 400 Mains voltage V Hz 3x400 50 3x400 50 3x400 50 Mains protection A 16 16 20 ae effective current A 84 10 8 13 7 Welding current 40 16 0 40 16 0 50 16 5 range 290 28 5 340 31 0 400 34 0 open circuit voltage y 183 401 182 449 194 498 Welding current DC 100 12 A 170 200 240 Welding current DC 60 12 A 210 230 290 Welding current es ae Sipe DC x 12 A 30 290 25 340 25 400 Voltage steps 10 12 2x10 Protection IP 235 IP 235 IP 295 Standards EN 60 974 1 EN 60 974 1 EN 60 974 1 Dimensions nm 500x868x806 500x868x806 500x868x806 compact Dimensions wx xh nm 500 868 889 500x868x889 500x868x889 generator Weight compact kg 88 99 109 Weight generator kg 83 94 103 Wire speed m min 1 19 1 19 1 19 Spool diameter mm 300 300 300 Spool weight kg 18 18 18 Wire Feed Unit PS4 GAS aXe Wire speed m min 1 19 Input voltage U 24 1 50 Input current A 4 Welding current 2 DZ 100 4 Welding current l2 DZ 60 A 400 Spool diameter mm 300 Spool weight kg 18 ALFA IN a s www alfain eu 10 29 Protection IP 215 WxIX 264x704x507 Unit weight without wire and torch Kg 2l Standards EN 60974 5 5 ACCESSORIES 5 1 DELIVERED WITH THE MACHINE 1 Ea2. PrG Pre gas time s PoG Post gas time 5 brn Burn back time 5 Time of tack welding 5 Int Time of interval s X9 Me LED Cooling circuit error us LED Lights after finishing welding and signals the AIG HOLD function of A V last measured parameters LED Thermal overheating Leave the machine on to at ei cool down by means of the fans Right Display X12 e Voltage real e Values of the secondary parameters e Switches and choke settings Just SYNERGY X13 Position of the coarse switch just SYNERGY X14 Position of the smooth switch just SYNERGY X15 Position of the choke just SYNERGY X16 n LED The mode of selecting the program is active just SYNERGY 17 z Green LED lights if on the display X8 is displayed material thickness just SYNERGY ALFA IN a s www alfain eu 16 29 X18 LED 4 Stroke LED When flashes the interval welding mode has X19 ceceo been selected When illuminated the spot welding mode has been selected Encoder e Sets wire speed all models Amperage or X20 material thickness just SYNERGY e Selects program No just SYNERGY e Sets secondary parameters 6 4 BASIC CONTROL PANEL V8 Vi0 _ V9 ViR Via Via Fig 7 BASIC control panel V2 Switch V3 Switch Coarse V4 Swit
3. Do not blow air into the welder during cleaning Blowing air into the welder can cause metal particles to interfere with sensitive electronic components and cause damage to the welder To clean the welder disconnect it from the mains supply voltage then open the enclosure and use a vacuum Cleaner to remove any accumulated dirt and dust The welder should also be wiped clean If necessary solvents that are recommended for cleaning electrical apparatus may be used Troubleshooting and repairing of ALF welding equipment should only be carried out only by suitably qualified or competent person A competent person must be a person who has acquired through training qualification or experience or a combination of them the knowledge and skills enabling that person to safely carry out a risk assessment and repairs to the electrical equipment in question ALFA IN a s www alfain eu 28 29 8 The person carrying out the servicing needs and repairs must know what to look at what to look for and what to do 10 STATEMENT OF WARRANTY In accordance with the warranty periods stated below ALFA IN guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with the written instructions as defined in this operating manual ALFA IN welding products are manufactured for use by commercial and industrial users and trained personnel with experience in the use and maintenance o
4. Cable Bundle Generator A23 ILED ON Indicator A24 Gas heater connector 6 2 CONTROL PANEL OVERVIEW V1 V2 Fig 5 ALF 400 aXe control panel V1 PCB encoder V2 OFF Switch V3 Switch coarse V4 Switch smooth ALFA IN a s www alfain eu 14 29 6 3 DIGITAL CONTROL PANEL MINOR2 MAJOR SYNERGY X9 X8 X7 X6 X5 X4 X3 X2 X1 Fig 6 MINOR2 MAJOR SYNERGY digital control panel Pos Symbol Description Button X1 e Wire insertion e default RESET together with button X2 Button X2 Fal Gas test e default RESET together with button X1 Button e Switches between 2S or 4S X3 0 Press more than 3s will initiate spot or interval mode Enters secondary parameters together with button X5 X4 Green LED 2 Stroke ALFA IN a s www alfain eu 15 29 X5 D Button In MANUAL disabled e In SYNERGY switches among A wire speed or material thickness e Enters secondary parameters together with button X3 Green LED lights if on the display X8 are displayed A 6 Amperes required setting just SYNERGY Green LED lights if on the display X8 is displayed X7 8 Wire Speed in m min required setting just SYNERGY e Left Display X8 shows e Amperage real or required Wire speed Material thickness Program No Secondary parameters ISP initial speed soft start
5. with European Council Directive 2002 96 EC on electrical and electronic equipment waste and its implementation in accordance with national law electric tools that have reached the end of their service life must be collected separately and returned to an environmentally compatible recycling facility ALFA IN a s www alfain eu
6. MIG MAG WELDING MACHINES ALF 251 aXe ALF 261 aXe ALF 280 aXe ALF 320 aXe ALF 400 aXe MINOR2 MAJOR SYNERGY BASIC INSTRUCTION MANUAL ALFA IN a s www alfain eu ALF 251 261 280 320 400 BASIC MINOR2 MAJOR SYNERGY AXE MANUAL EN1 2 29 Content INTRODUETION saisissant 3 SAFETY INSTRUCTIONS AND WARNINGS ssccssccssccssccscescccsccesscesscessonseens 4 5 8 TECHNICAL DATA sims 8 ACCESSORIES sien mesrine aiaiai aana Aa erkan 10 DESCRIPTION OF THE APPLIANCE ssssssssssssisssssssesssnnesssssoneessanssnsennensiesnse 11 18 WELDING sc nioi iais 22 ROUTINE MAINTENANCE INSPECTION cccsccssscccssccsssccsssccescecssseceseees 27 STATEMENT OF WARRANT HY sissssosssssssncsssecssccsssscssansssascensacnsenssssesnessacsasesseesas 28 A 28 ALFA IN a s www alfain eu 1 INTRODUCTION 3 29 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 concer
7. YES ALFA IN a s www alfain eu 4 29 SAFETY INSTRUCTIONS AND WARNINGS 1 OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS YOURHEALTH 2 Arc welding produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near arc welding applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists 3 Once the packing has been opened make sure that the machine is not damaged If in any doubt call the service centre 4 This equipment must only be used by qualified personnel 5 During installation any electric work must only be carried out by trained personnel 6 The machine must be used in a dry place with good ventilation 7 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 8 It is prohibited to connect more than one generator in series or in parallel 9 When installing the machine follow the local regulations on safety 10 The position of the machine must allow easy access by the operator to the controls and connectors 11 When the welding machine is operating all its covers and doors must be closed and well fixed 12 Do not expose the welding machine to direct sunlight or to heavy rain This equip
8. anual program PO and on the left display will be the wire speed in m min or the last parameters of previous settings On the right display will appear symbol in manual PO program or the recommended settings in programs P1 P9 not on BASIC INSERTING THE WIRE Spool Holder Nut Spool Holder Fig 10 Spool holder 1 2 3 7 2 Open the side cover of the wire feeder space Put the wire spool on the wire spool holder D1 using the adapter D3 and fix it with the fixing nut D2 Cut off the curved or damaged end of welding wire and lead it through the inlet liner E3 and the roll into the liner inside the EURO torch connector about 5 cm Make sure that you use the suitable groove Put the pressure arm E2 down in that way that the teeth or the gear fit and fix it by setting the lever E1 into vertical position Adjust the pressure nut that way that it provides constant movement of wire but it does not deform wire INSERTING THE WELDING WIRE INTO THE WELDING TORCH Fig 11 Welding torch connecting ALFA IN a s www alfain eu 20 29 B1 EURO connector B2 EURO connector male B3 Torch 1 Connect the torch B3 to the EURO connector 1 onthe 2 It is recommended to use torches form 2 up to 5 m long 3 Take off the torch gas cup 4 Take off the torch tip 5 Press the button inlet wire X1 for digital V11 for BASIC 6 When the wire reaches the end of the torch release
9. by trained 8 29 This equipment conforms to protection rating IP23S 4 Place the machine the way that the cooling air can enter the vents without restriction to It is necessary to ensure that no impurities especially metal particles are not drawn into the machine 5 Welding machine in terms of interference suppression is intended primarily for industrial premises In the case of use of other areas may be need for special measures see EN 60974 10 6 The machine must be protected against a moisture and rain and snow b mechanical damage c draft and any ventilation of neighbouring machine d excessive overloading crossing technical parameters e rough handling 4 TECHNICAL DATA ALF 251 ALF 261 Mains voltage V Hz 3x400 50 3x400 50 Mains protection A 16 16 Max effective current A 10 4 89 16 Welding current AN 25 15 3 25 15 3 range 250 26 5 260 27 0 Open circuit voltage 179 459 179 459 U20 J 3 J 3 Welding current DC 100 12 1 Welding current DC 60 12 A 200 200 Welding current LOFO DC x 12 A x 30 250 x 25 260 Voltage steps 10 10 Protection IP 23S IP 23S Standards EN 60 974 1 EN 60 974 1 Dimensions wxIxh mm 500x868x806 500x868x806 compact Dimensions w x x h ean generator ALFA IN a s www alfain eu 9 29
10. ch Fine V5 Wire speed V6 Spot time V7 Interval time V8 LED ON ALFA IN a s www alfain eu V9 17 29 LED thermal protection V10 Switch 2T 4T optional V11 Wire insertion V12 Gas test V13 A meter optional V14 V meter optional 6 5 WIRE FEEDER Fig 8 Wire feeder 4 rolls 2 rolls Pos Description E Fixing shaft E2 Pressure arm E3 Liner Feeder E4 EURO connector E5 Roll Plastic cup PS 2 W PS 4 W 2 rolls 4 rolls S S YYW a 22mm ALFA IN a s b 30 mm www alfain eu 18 29 Steel Au Flux core 7 GETTING STARTED Fig 9 Earthing cable connecting C1 Quick Connector Male C2 Earthing Clamp C3 Quick Connector C4 Quick Connector 1 Connect the quick connector C1 into C3 or C4 according the welding current 2 Connect the earthing clamp C2 to the welding piece 3 In case your appliance is a model with separate wire feeder connect the feeder with the generator by means of cable bundle A21 ALFA IN a s www alfain eu 5 19 29 Plug the mains plug to 3x400 V mains Switch the machine on by the ON OFF switch A1 There will appear type of the machine and software version on the displays for ca 3 5 time not on BASIC Then the machine will enter the m
11. elding Burn Post Pre gas speed process back gas EE FA Torch button SPOT AND INTERVAL WELDING DIGITAL Keep pressing the button x3 2 4 for at least 3s ALFA IN a s www alfain eu 24 29 If led LED 16 MB continuously lights the spot mode has been selected If led 16 flashes the interval mode has been selected You can have spot or interval welding both in 2 stroke and in 4 stroke mode A 4 by means of short pressing the button X 30 LEDs X4 and X18 indicate the mode Those modes are available in 2T or 4T mode To get out of those modes keep pressing the button 3 for more than 3 s SPOT AND INTERVAL WELDING BASIC SPOT and INTERWAL welding in BASIC are just in 2T SPOT WELDING The potentiometer V7 must be in 0 position By means of potentiometer V6 select the time of a spot INTERVAL WELDING By means of potentiometer V6 select the time of a spot and by means of potentiometer V7 select the time of an interval the period during which the machines do not weld The spot welding mode is being used for welding short welds of the same length The pressing the torch button activates the time circuit that starts and end the welding procedure Initial Arc Welding Burn Post Pre gas speed ignition process back gas 00000 MINT 1 Length of the spot Torch button ALFA IN a s www alfain eu 25 29 Initial Welding Burn Post Pre gas speed p
12. en installed and gas had been set it is possible to start welding The appliance must be plugged into the mains the ON OFF switch V2 on I To select the voltage use step switches V3 V4 ALF 400 ALF 280 and 320 only V3 To select the current that is linked to the wire speed use the encoder V1 8 2 WELDING MODES Machines works in four modes 1 continuous two stroke 2T 2 continuous four stroke 4T 3 spot welding 4 interval welding ALFA IN a s www alfain eu 23 29 TWO STROKE DIGITAL Press the button X3 0 2 4 and select the LED X4 Welding procedure starts by pressing the button in the torch handle It is necessary to keep the button pressed all the time during welding The welding stops by releasing the torch button TWO STROKE BASIC Potentiometers V6 and V7 must be in 0 position Initial Welding Burn Posi Pre gas speed proces back gas gt Torch button FOUR STROKE DIGITAL Press the button X3 2T 4T and select the LED X18 The four stroke mode is being used mostly for long welds when there is no need to hold the torch button pressed The welding procedure start by pressing the torch button after releasing the torch button the welding continues The welding stops after the second pressing and releasing the torch button then FOUR STROKE BASIC Set the potentiometers V7 into any position 1 10 Potentiometer V6 must be in 0 position Initial W
13. f electrical welding and cutting equipment ALFA IN will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the warranty period The warranty period begins on the date of sale to the end user If warranty is being sought please contact your ALFA IN product supplier for the warranty repair procedure ALFA IN warranty will not apply to a Equipment that has been modified by any other party other than ALFA IN s own service personnel or with prior written consent obtained from ALFA IN Service Department b Equipment that has been used beyond the specifications established in the operating manual c Installation not in accordance with the installation operating manual d Any product that has been subjected to abuse misuse negligence or accident e Failure to clean and maintain including lack of lubrication maintenance and protection the machine as set forth in the operating installation or service manual Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation W NOTE W Warranty repairs must be performed by either an ALFA IN Service Centre an ALFA IN distributor or an Authorised Service Agent approved by the company ALFA IN 11 DISPOSAL Only for EU countries Do not dispose of electric tools together with household waste material ALFA IN a s www alfain eu 29 29 In accordance
14. hine if its cables are damaged in any way c Make sure that the earthing system of the electric equipment is correctly connected and operational d The operator must be insulated from the metal components connected to the return wire e The earthing of the piece being worked could increase the risk of injury to the operator 29 EN 60974 1 Standard Open circuit voltage During the ALFA IN a s www alfain eu 6 29 operation of the machine the highest voltage with which it is possible to come into contact is the open circuit voltage between the clamps The maximum open circuit voltage of the plasma machines is established by national and international standards EN 60974 1 depending on the type of 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 30 31 Case Working conditions Open circuit voltage 1 Places with increased DC current 113V AC current 68V risk of electric shock peak value peak value and 48V effective 2 Places without increased DC current 113V AC current 113V risk of electric shock peak value peak value and 80V effective 3 Torches held DC current 141V AC current 141V
15. ld be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health 21 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 22 Noise can cause permanent hearing loss Welding arc processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing 23 To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace 24 Noise levels should be measured to be sure the decibels Sound do not exceed safe levels 25 The operator must ensure all flammable materials are removed from the work area to avoid any risk of fire 26 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 ISA VERY HIGH RISK OF EXPLOSION 27 The operator must be aware of all the special regulations which he needs to conform to when cutting in enclosed spaces with a high risk of explosion 28 To prevent electric shock we strongly suggest the following rules a Do not work in a damp or humid environment b Do not use the mac
16. mechanically with peak value peak value and increased protection for 100V effective the operator 4 Plasma cutting DC current 500V peak value 32 In case 1 the dc 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 The welding machines of this type can be marked with the symbol Before opening the machine switch off the machine and disconnect it from the power socket Only personnel authorised by this company can carry out 33 34 maintenance on the machine 2 1 ELECTROMAGNETIC COMPATIBILITY EMC This 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 1 Domestic electronic appliances radios TVs videos telephones ALFA IN a s www alfain eu 7 29 burglar alarms etc 2 Computers robots electro medical instruments and life support systems 3 Radio television transmitters and receivers 4 Pacemakers and hearing aids 5 All very sensitive electrical equipment The operator is responsible for the installation and use of the cutting machine If there should be any fault in operations of other systems located in the immediate vicinity of the generator we recommend suspending ope
17. ment conforms to protection rating 235 13 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 cutting 14 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 arc 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 15 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 16 Keep all fumes and gases from the breathing area 17 Keep your head out of the fume plume 18 Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases 19 The kinds of fumes and gases from the plasma arc depend on ALFA IN a s www alfain eu 5 29 the kind of metal being used coatings on the metal and the different processes You must be very careful when welding any metals which may contain one or more of the following Antimony Chromium Mercury Nickel Cobalt Arsenic Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium 20 Always read the Material Safety Data Sheets MSDS that shou
18. n 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 ALF 251 261 280 320 400 aXe are three phase sturdy welding machines for MIG MAG welding The machines are designed to produce maximum power output combined with high reliability and efficiency The users interface is as simple as possible however there are secondary parameters that can be set from the main front panel if suitable All of them are available in compact models ALF 280 320 and 400 can be ordered also as sets consisting of the generator interconnection cable bundle and separate wire feeding unit We will refer to the MINOR2 MAJOR and SYNERGY controls as DIGITAL CONTROL MODEL BASIC MINOR2 MAJOR SYNERGY V meter optional NO YES YES Wire initial soeed Soft Start NO NO YES YES Advice of the parameter settings NO NO NO YES feedback of the wire NO YES YES YES 2 stoke 4 stroke YES YES YES YES Post and Pre Gas NO YES YES YES Spot and Interval welding YES YES YES YES Adjustable Burn Back Time NO YES YES
19. protective atmosphere and on the other hand to big amount of the gas brings air into the electric arc F6 F8 F7 F1 F10 Fig 14 Gas fitting F1 Gas Cylinder F2 Cylinder Valve F3 Gas heater connector F4 Pressure Reducer F5 High Pressure Manometer F6 Low Pressure Manometer F7 Adjusting Screw ALFA IN a s www alfain eu 22 29 F8 Gas outlet FQ Solenoid Valve F10 Chain 1 Place the gas cylinder on the platform and fix it properly by the fixing chain We recommend using bolts and nuts to fix it more safely 2 Connect the pressure reduction valve on the gas cylinder 3 Connect the gas hose to gas outlet F8 on the valve and the gas inlet F9 on the machine 4 In case you use gas CO2 it may be needed to use suitable gas heater only above 6 l min Connect the heater to the F3 heater connector optional Use type corresponding to voltage and current given on the shield Open the F2 cylinder valve Press the button Gas test X2 for digital V12 for BASIC Adjust the amount of gas on the reduction gas valve it is not a part of the welding machine by the F7 adjusting screw 8 Release the button X2 for digital V12 for BASIC 8 WELDING For orientating adjusting of the welding current and voltage you can use empirical relation U2 14 0 05 2 From that you can specify desired voltage N O O 8 1 SETTING WELDING CURRENT AND VOLTAGE When the wire had be
20. rations and consulting the manufacturers 2 2 PROTECTIVE UTTILITIES 1 Welding helmet with filter shade at least 10 2 Welding gloves 3 Welding apron and cloth 4 Welding boots 2 3 RISK OVERVIEW 1 Risk of electric shock 2 Ultraviolet light and light radiation 3 Risk of inhaling gas fumes and dust particles 4 Burns 5 Noise NOTE 1 It is forbidden to operate a machine with damaged insulation of the welding torch or supply cable 2 Never operate the machine taken down or damaged covers 3 It is forbidden to operate the machine in wet environments and outdoors in rain or snow 4 Ensure proper grounding clamping pliers which also reduces the risk of electric shock 5 Use prescribed protective utilities keep them dry 6 Arc welding produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists 7 Never aim the torch against the eyes body or other person ALFA IN a s www alfain eu personnel 3 Do not expose the plasma machine to direct sunlight or to rain or snow CONDITIONS OF USE This equipment must only be used by qualified personnel 2 During installation any electric work must only be carried out
21. rocess back gas EE D mm 1 a Length of the spot Length of the interval Torch button 8 3 SECONDARY PARAMETERS If necessary it is possible to change the secondary parameters Initial wire speed soft start ISP Pre gas time PrG Post gas time PoG Burn back time brn Time of spots tack or interval welding SPo Time of intervals interval welding Int Press buttons X3 and X5 at the same time for at least On left display will appear ISP On the right display will appear value of the chosen parameter By means of the Encoder you can change the parameter Use the button X3 to select the next parameter When you press the button X3 the value of the previous parameter had been stored 8 4 SYNERGY MODE ONLY FOR THE SYNERGY MODELS Synergy machines can advise the welder the optimum settings Please keep in mind that those machines are not equipped with incremental sensors and therefore the advised settings are always approximate 1 3 steps on the fine voltage step It depends also on welding position kind of welding wire gas and mains voltage The optimal setting has been determined for welding position PA The welder select the parameter that he knows by means the button X5 and the encoder X20 Current in A wire speed in m min or material thickness Then the welder can the recommended settings see on the right display see Fig 17 ALFA IN a s www alfain e
22. rthing cable 3m with a clamp 2 Feed roll 0 8 1 0mm 3 Gas hoses 5 2 ACCESSORIES TO ORDER 1 Wire cleaner 2 CO2 Gas pre heating cable 3 Reduction valve KU 5 K 2 4 Gay cylinder 5 Torch consumables 6 Earthing cable 4 5 m 7 Feed rolls 0 6 0 8 1 0 1 2 1 4 1 6 for carbon steels aluminium flux core wires 8 Torches with UP DOWN remote control 9 Welding torches see the table below Torch type Cooling Welder MB 24KD Gas ALF 251 280 aXe MB 36KD Gas ALF 320 aXe MB 36KD Gas ALF 400 aXe ALFA IN a s www alfain eu 11 29 6 DESCRIPTION OF THE APPLIANCE 6 1 MAIN PARTS Fig 2 Main parts of ALF compact aXe ALFA IN a s www alfain eu 12 29 A6 A7 A20 A13 A23 A16 A10 A17 A18 A21 A15 A14 A19 Fig 4 Main parts of ALF Separate aXe A1 ON OFF Switch A2 Switch coarse A3 Switch smooth ALFA IN a s www alfain eu 13 29 A4 Quick connector A5 Quick connector A6 PCB control panel A7 EURO connector A8 Wire Feeder A9 Spool Holder A10 Solenoid Valve A11 Mains Cable A12 Feeder Holder Feeder A13 Feeder Holder Generator A14 Quick Connector A15 Connector female A16 Connector male A17 Quick Connector male A18 Clamp for the cable Bundle A19 _ Clamp for the cable Bundle A20 Cable Bundle Inlet Feeder A21 Cable Bundle A22
23. the button X1 V11 screw on the tip and open nozzle 7 3 CHANGING THE WIRE FEEDER ROLL 1 Every wire feeding roll in ALFA IN machines can be used for two different diameters of welding wire the rolls have two grooves 2 When the machine is equipped with two roll wire feeder move the lever E1 to the right 2 roll feeder forward 4 roll feeder The pressure arm shall pop up 3 Unscrew the plastic fixing cup E5 and take off the roll 4 In case there is suitable groove on the roll turn it around and fix it back to the feeder A B C 1 0 0 8 1 2 P Fig 12 The influence of the roll groove on the wire Correct B Wrong C Wrong 7 4 ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM For feeding the AL wire it is necessary to use roll with the U profile of the groove To prevent problems with feeding use wires with diameter 1 0 or more mm AIMg3 or AIMg5 The torch must be equipped with Teflon liner and special tip As shielding atmosphere use Argon ALFA IN a s www alfain eu 21 29 G3 G5 G7 G2 G1 G4 G6 Fig 13 Set for welding aluminium G1 EURO connector G2 Rolls G3 Liner terminal for 4 0mm 4 7mm outer diameter G4 O ring 3 5x1 5mm G5 Nut G6 Teflon Liner G7__ Sustain pipe for teflon and plastic liner 7 5 GAS FLOW SETTING The electric arc and the weld must be perfectly shielded by gas Too small amount of gas does not perform the
24. u 26 29 SELECTING PROGRAM 1 press button X3 for3s 2 LED X16 will illuminate On left display X8 No of the last program will appear 3 Selects the desired program see the table below by means of Encoder X20 and confirm by pressing button X3 If within 10 s is not selected program and confirmed by button X3 LED X16 would turn off and program has not been selected Ar 82 CO 18 carbon steel carbon steel Ar 97 5 CO 2 5 CrNi 308 Fig 15 Table of programs ALF320 ALF400 Ar 82 CO 18 carbon steel CO 100 carbon steel Fig 16 Table of programs ALF280 8 5 SYSTEM OF ADVICES ON DISPLAY X12 JUST SYNERGY 1 First left figure coarse voltage A B JUST ALF 400 2 Second left figure fine voltage 1 9 the tenth position of the switch is signed as 0 ALF 320 shows numbers 1 12 3 Third left figure choke position ALFA IN a s www alfain eu 27 29 Fig 17 Synergy advice 9 ROUTINE MAINTENANCE amp INSPECTION The only routine maintenance required for the ALF range of machines is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment UWARNING Disconnect the ALF from the mains supply voltage before disassembling Special maintenance is not necessary for the control unit parts in the Welder If these parts are damaged for any reason replacement is recommended YCAUTION amp
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