PEGAS 250-320 MIG MAN manual EN
Contents
1. if illuminated the display shows the welding current 8 LED indicator if illuminated the machine is ON 9 LED indicator if illuminated the welder is over heated or the mains voltage is out of range 10 2stroke 4 stroke switch 11 Wire feeding button 12 Choke potentiometer 13 Quick connector Earthing cable 6 2 WIRE FEEDER Fig 2 Wire feeder 2 rolls 2 rolls 4 rolls ay J i O a 22 mm b 30 mm Grove type Wire diameter Item No 0 6 0 8 2187 5434 Steel 0 8 1 0 2188 5435 1 0 1 2 2189 5436 0 8 1 0 2270 5437 Aluminium 1 0 1 2 2269 5438 ALFA IN a s www alfain eu Page 10 of 15 lll 0 8 1 0 2318 5439 Flux core 1 0 1 2 2319 5440 1 2 1 4 2320 5441 lg 7 GETTING STARTED Fig 3 Earthing cable and Welding Torch connecting The picture is just for illustration for the real position use Fig 1 C1 Quick connector Earthing cable Fig 1 13 C2__ Earthing clamp Bi EURO connector Fig 1 1 B2 Torch Euro Connector Male B3 Welding Torch e Connect the earthing clamp C2 to the welding piece e Connect the B1 and B2 torch connectors together Screw them up properly by mean turning the B2 clockwise e Plug the mains plug to 3x400 V mains e Switch the machine on by the ON OFF switch at the rear panel of the welder 7 1 INSERTING THE WIRE Spool Holder N2. telephones burglar alarms etc e Computers robots electro medical instruments and life support systems e Radio television transmitters and receivers e Pacemakers and hearing aids e 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 operations and consulting the manufacturers 2 2 PROTECTIVE UTTILITIES Welding helmet with filter shade at least 10 Welding gloves Welding apron and cloth Welding boots 2 3 RISK OVERVIEW e Risk of electric shock e Ultraviolet light and light radiation ALFAIN a s O www alfain eu Page 6 of 15 Risk of inhaling gas fumes and dust particles Burns Noise 9NOTEd a b c d e It is forbidden to operate a machine with damaged insulation of the welding torch or supply cable Never operate the machine taken down or damaged covers It is forbidden to operate the machine in wet environments and outdoors in rain or snow Ensure proper grounding clamping pliers which also reduces the risk of electric shock Use prescribed protective utilities keep them dry 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 cuttin
3. values relating to the various cases shown in the following table 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 mechanically with peak value peak value and ALFA IN a s www alfain eu Page 5 of 15 increased protection for 100V effective the operator 4 Plasma cutting DC current 500V peak value e Incase 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 e Before opening the machine switch off the machine and disconnect it from the power socket e Only personnel authorised by this company can carry out 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 e Domestic electronic appliances radios TVs videos
4. AL Only for EU countries Do not dispose of electric tools together with household waste material In accordance 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
5. MIG MAG WELDING MACHINES PEGAS 250 MIG MAN PEGAS 320 MIG MAN INSTRUCTION MANUAL Content 1 INTRODUCTION siisaiisviiewscaecstwddccssaciuagssisdsdaisuvidasavessigeidenscsinuinuasaisscidasassadedassunds 2 2 SAFETY INSTRUCTIONS AND WARNINGS cccscsssccssccssccscessccssccesscescossconss 2 3 CONDITIONS OF USE wivciesisassidavencssvessasvaiiinessursneasciiaanvenesineatsusiccucanweessuceca iowa 6 A TECHNICAL DAU A isisisssicasssncciasanccncsiavereaadsansxissannseissnssnscsnseantaaegouncinvssanianssancien 7 Be ACCESSORIES mana AANI tase isin niwasaseorveasanausbvadruresseinenisiasaendanewseustats 7 6 DESCRIPTION OF THE APPLIANCE Jana AGA 8 7 GETTING STARTED masa NA ANAH AKUIN 10 8 WELDING GUAGUA KAKAIBABE 13 9 ROUTINE MAINTENANCE amp INSPECTION ccccssscccsssccsscccsssccsscesscensseeees 14 10 STATEMENT OF WARRANTY osssssnssssssssessesssssssssonsssnscenscssscssscnsssossassecassenssenses 14 11 DISPOSAL saa G KAKAININ 15 ALFA IN a s 2013 www alfain eu PEGAS 250 320 MIG MAN manual EN Page 2 of 15 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 re
6. ad 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 250 320 MIG MAN 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 2 SAFETY INSTRUCTIONS AND WARNINGS e OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOURHEALTH e 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 e Once the packing has been opened make sure that the machine is not damaged If in any doubt call the service centre e This equipment must only be used by qualified personnel e During installation any electric work must only be carried out by trained personnel e The machine must be used in a dry place with good ventilation e Make sure that n
7. entilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on 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 Always read the Material Safety Data Sheets MSDS that should 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 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 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 To protect your hearing from loud noise wear protective ear plugs and or ALFA IN a s www alfain eu Page 4 of 15 ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels Sound do not exceed safe levels The operator must ensure all flammable materials are removed from the work area to avoid any risk of
8. es with diameter 1 0 or more mm of AlMg3 or AlMg5 The torch must be equipped with Teflon liner and special tip As shielding atmosphere use Argon G3 G5 G7 G2 G1 G4 G6 Fig 6 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 74 GAS FLOW SETTING The electric arc and the weld must be perfectly shielded by gas Too small amount of gas does not perform the protective atmosphere and on the other hand to big amount of the gas brings air into the electric arc F4 PG F6 F8 F7 F1 F10 Fig 7 Gas fitting The picture is just for illustration The portable PEGAS 250 320 MIG MAN are not equipped to support the gas cylinders The gas cylinders must be well fitted in another gadget in accordance with the appropriate safety rules ALFA IN a s www alfain eu Page 13 of 15 F1 Gas Cylinder F2 Cylinder Valve F3 Gas heater connector F4 Pressure Reducer F5 High Pressure Manometer F6 Low Pressure Manometer F7 Adjusting Screw F8 Gas outlet F9 Solenoid Valve F10 Chain e 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 e Connect the pressure reduction valve on the gas cylinder e Connect the gas hose to gas outlet F8 on the valve and
9. 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 cutting 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 machine if its cables are damaged in any way 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 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
10. g applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists Never aim the torch against the eyes body or other person CONDITIONS OF USE This equipment must only be used by qualified personnel During installation any electric work must only be carried out by trained personnel Do not expose the plasma machine to direct sunlight or to rain or snow This equipment conforms to protection rating IP23S 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 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 The machine must be protected against moisture and rain and snow mechanical damage draft and any ventilation of neighbouring machine excessive overloading crossing technical parameters rough handling ALFAIN a s O www alfain eu 4 TECHNICAL DATA Page 7 of 15 Model PEGAS 250 PEGAS 320 Method MIG MAG MIG MAG Mains voltage V Hz 3 x 400 50 60 3 x 400 50 60 Mains protection A 16 slow 16 slow Max input power l A 16 4 23 4 Max effective current lett A 12 9 12 9 Welding current range A V HAAN 5 Br EAR O
11. ng 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 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 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
12. o metal dust can be drawn in by the fan inside the machine as this could cause damage to the electronic circuits e It is prohibited to connect more than one generator in series or in parallel e When installing the machine follow the local regulations on safety ALFA IN a s www alfain eu Page 3 of 15 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 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 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 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 Keep all fumes and gases from the breathing area Keep your head out of the fume plume Use an air supplied respirator if v
13. pen circuit voltage U20 V 54 4 63 1 Welding current DC 100 I2 U2 A V 210 24 5 210 24 5 Welding current DC 60 l2 U2 A V 250 26 5 250 26 5 Welding current DC x l2 U2 A V 60 250 26 5 25 315 29 8 Voltage setting continuous continuous Insulation class F F Protection IP 23S IP 23S Standards EN 60974 1 EN 60974 1 Dimensions w x x h generator mm 240 x 640x438 240 x 650 x 438 Weight compact generator kg 25 8 26 6 5 ACCESSORIES 5 1 e Feed roll 0 8 1 0mm 5 2 ACCESSORIES TO ORDER Gas hose Wire cleaner CO2 Gas pre heating cable Reduction valve Gas cylinder ALFA IN a s Earthing cable 3 5 m with a clamp DELIVERED WITH THE MACHINE www alfain eu Page 8 of 15 Torch consumables Feed rolls 0 6 0 8 1 0 1 2 for carbon steels aluminium flux core wires Torches with UP DOWN remote control Welding torches see the table below Ordering No 018 D975 1 Torch ABIMIG AT 305 C LW 3m 018 D976 1 Torch ABIMIG AT 305 C LW 4m 018 D977 1 Torch ABIMIG AT 305 C LW 5m 6 DESCRIPTION OF THE APPLIANCE 6 1 MAIN PARTS 134 Ja Fig 1 Main parts 1 EURO connector 2 Voltage potentiometer ALFAIN a s O www alfain eu Page 9 of 15 3 Voltage Display 4 Wire Speed potentiometer 5 Current Display 6 LED indicator if illuminated the display shows the wire speed 7 LED indicator
14. the gas inlet F9 on the machine e Open the F2 cylinder valve e Press the button Gas test 11 e Adjust the amount of gas on the reduction gas valve it is not a part of the welding machine by the F7 adjusting screw e Release the button 11 for digital 8 WELDING For orie ntating adjusting of the welding current and voltage you can use empirical relation U2 14 0 05 2 From that you can specify desired voltage 8 1 SETTING WELDING CURRENT AND VOLTAGE When the wire had been installed and gas had been set it is possible to start welding The appliance must be plugged into the mains the ON OFF switch on I You will find the ON OFF switch on the rear panel of the welder To select the voltage potentiometer 2 To select the current that is linked to the wire speed use the voltage potentiometer 3 To modify the arc characteristic use the chope potentiometer 12 8 2 WELDING MODES Machines works in four modes ALFA IN a s www alfain eu Page 14 of 15 continuous two stroke 2T continuous four stroke 4T To select the mode switch the 2T 4T switch into the appropriate position 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 v WARNING amp Disconnect the ALF from the mains supply voltage before disassembli
15. use by commercial and industrial users and trained personnel with experience in the use and maintenance of electrical welding and cutting equipment ALFA IN will repair or replace at its discretion any warranted parts or ALFAIN a s O www alfain eu Page 15 of 15 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 e f warranty is being sought please contact your ALFA IN product supplier for the warranty repair procedure e ALFA IN warranty will not apply to e 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 e Equipment that has been used beyond the specifications established in the operating manual e Installation not in accordance with the installation operating manual e 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 e Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation wy NOTE wy e 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 DISPOS
16. ut Spool Holder www alfain eu Page 11 of 15 Fig 4 Spool holder 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 7 2 CHANGING THE WIRE FEEDER ROLL Every wire feeding roll in ALFA IN machines can be used for two different diameters of welding wire the rolls have two grooves 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 Unscrew the plastic fixing cup E5 and take off the roll 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 C P A Correct B 1C Wrong 7 3 ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM For feeding the AL wire it is necessary to use roll with the U profile of the ALFA IN a s www alfain eu Page 12 of 15 groove To prevent problems with feeding use wir
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