Alfain 5.0238-2 User manual

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ALFA IN a.s. © www.alfain.eu PEGAS 200 AC-DC PULSE ovo manual ENG 11
WELDING INVERTER
PEGAS 200 AC/DC PULSE
OPERATING MANUAL

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ALFA IN a.s. © www.alfain.eu
CONTENT:
1. IN RODUC ION .......................................................................................... 3
2. SAFE Y INS RUC IONS AND WARNINGS ............................................. 4
3. ECHNICAL DA A ...................................................................................... 6
4. EQUIPMEN ................................................................................................ 7
5. OPERA OR CON ROLS ............................................................................ 8
6. GE ING S AR ED ................................................................................. 10
7. WO S ROKE AND FOUR S ROKE IN IG MODE ............................... 13
8. ROU INE MAIN ENANCE & INSPEC ION ............................................. 14
9. S A EMEN OF WARRAN Y .................................................................. 15
10. DISPOSAL ................................................................................................ 15
11. WARRAN Y LIS ..................................................................................... 16

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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.
his 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. herefore please take the time to read
the entire manual, especially the Safety Precautions. hey 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. IG DC (Lift arc or High Frequency ignition)
4. IG AC (Lift arc or High Frequency ignition)
We reserve the law of adjustments and changes in case of printing errors,
change of technical paramaters, accessories etc. without previous notice. hese
changes may not be reflected in the manuals for use in paper or electronic form.
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.
his equipment must only be used by qualified personnel.
During installation, any electric work must only be carried out by trained
personnel.
he 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 INVER ER generator in series or in
parallel.
When installing the machine, follow the local regulations on safety.
he 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. his
equipment conforms to protection rating IP23S.
During welding, the welding cables must be located near or at ground level. hey
should be as short as possible.
he 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.
he 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 UL RAVIOLE RADIA ION is emitted. herefore it is vital that
his face is also protected from radiation. Ultraviolet rays produce the same
harmful effect as sun burning on unprotected skin.
he 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.
he operator must ensure all flammable materials are removed from the work
area to avoid any risk of fire.
he 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. HERE IS A VERY HIGH RISK OF
EXPLOSION.
he 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.
o 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.
Make sure that the earthing system of the electric equipment is correctly

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ALFA IN a.s. © www.alfain.eu
connected and operational.
he operator must be insulated from the metal components connected to the
return wire.
he 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.
he 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. hese values are not applicable to the strike currents and those for
stabilisation of the arc that could be above it.
he 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
orches 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.
NOTE:
Device complies with IEC 61000-3-12.
Working ambient temperature between -10 and +40 °C.
Relative humidity below 90% at +20 °C.
Up to 3000 m altitude.
ELECTROMAGNETIC COMPATIBILITY
he welding device is in terms of interference designed primarily for industrial
areas. It meets the requirements of EN 60974-10 class A and it isn’t designed
for using in residential areas, where the electrical energy is supplied by public
low-voltage power supply network. It can be here potential problems with
ensuring of electromagnetic compatibility in this areas, due to interference

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caused by power lines as well as the radiated interference.
During operation, the device may be the source of interference.
Caution
We warn users, that they are responsible for possible interference from
welding.
3. TECHNICAL DATA
Method MMA - AC MMA - DC
Mains voltage V/Hz 1x230/50-60
Mains protection A 16 *)
Max. input power I1 A 40,3
Max. effective current I1eff A 20,2
Welding current range A 10 - 170 5 - 170
Open-circuit voltage U20 V 73 68
Welding current (DC=100%) I2
ta=40 °C A 70 80
Welding current (DC=60%) I2
ta=40 °C A 90 110
Welding current (DC=x%) I2
ta=40 °C A 20%=170 25%=170
Welding current (DC=100%) I2
ta=25 °C A 90 110
Welding current (DC=60%) I2
ta=25 °C A 110 130
Welding current (DC=x%) I2
ta=25 °C A 25%=170 30%=170
Insulation class F
Protection IP23S
Standards EN 60 974-1, EN 60 974-10 cl.A
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 10 - 20 5 - 200
Open-circuit voltage U20 V 73 68
Welding current (DC=100%) I2
ta=40 °C 70 80
Welding current (DC=60%) I2
ta=40 °C A 90 110
Welding current (DC=x%) I2
ta=40 °C A 20%=200 25%=200

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ALFA IN a.s. © www.alfain.eu
Welding current (DC=100%) I2
ta=25
°
C
A 90 11
Welding current (DC=60%) I2
ta=25
°
C
A 110 13
Welding current (DC=x%) I2
ta=25
°
C
A 25%=200 30%=200
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.
4. E UIPMENT
CONTENT OF DELIVERY
Item No.
Description
uantity
5.0238-2 PEGAS 200 AC/DC PULSE 1
5.0189 Set of Connectors for PEGAS AC/DC 1
ACCESSORIES TO ORDER
Item No. Description
VM0410 Hose Gas 3m Pegas quick connector G1/4 AERO
VM0253 Welding Cable Set 2x 3m 35-50 200A
5.0216 CS 601 W Cooling Unit PEGAS
5.0508 Welders Cart P 80
26FSL4A orch PARKER SG 26 4m 35-50 FX AERO
26FSL4AUD orch PARKER SG 26 4m 35-50 FX AERO UD
26FSL8A orch PARKER SG 26 8m 35-50 FX AERO
26FSL8AUD orch PARKER SG 26 8m 35-50 FX AERO UD
6008 Pressure Reducer FIXICON ROL Ar 2 manometers GCE
5.0174 Foot Pedal Remote C RL 3 m PEGAS incl. Connector

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5. OPERATOR CONTROLS
MAIN PARTS
Fig . 1 Main parts
Pos
.
Description
1 Button IG 2 or 4 (two stroke, four stroke)
2 LED Pregas. 0,1 – 1 s, default 0,3 s
3
Current Display
4 LED start current (just 4 ). 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 IG DC, 10 – 200 IG 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 IG AC

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10 LED Pulse Base Current. 5 – 200 A DC, 10 -200 A AC.
11 LED ime (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
8.
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 and if there are faulty output diodes and
transistors on main board.
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 4 .
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 HO S AR , 0 – 10.
25 Button for moving to the right on the parameters curve.
26 LED Balance (just IG 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 IG AC). Range: 50-250 Hz. he higher
current, the more the maximal frequency decreases. he 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/LIF 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 est. If illuminated the mode of setting the gas flow was

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selected (by means of the gas valve on the gas cylinder). o turn it
off press the button 31 again or it will go off this mode after 10 s.
37 LED Four Stroke (4 ).
38 LED wo Stroke (2 ).
39 LED DC
40 LED AC
41 Button switch AC/DC mode.
42 Quick connector +
43 orch 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
6. GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
GETTING STARTED MMA – COATED ELECTRODE
1. Insert the mains plug 41 into a suitable 1x230 V
mains socket. he supply fuses or circuit breaker should
correspond to the technical data stated in this manual.
2. Connect the welding cables to the panel quick
connectors (+) 42 and (-) 44 according the instruction on
the electrodes packing.
3. Switch the machine on by the ON/OFF switch 48.
4. Set the welding current by means of Encoder 28. he values will be
showed on the display 3.
5. It is possible to change the settings of the HO S AR (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.
6. hen switch to the MMA mode by means of the button 21. LEDs 20, 23 or
24 may not illuminate.
7. NO E Prevent touching the electrode any metal material for in this
mode the terminals 42 and 44 are under current.
8. 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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TABLE OF ELECTRODE CONSUMPTION DURING WELDING
Electrode
diameter
[mm]
Range of
welding
current [A]
Total
electrode
length [mm]
Weight of
boiled
electrode
without slag
[g]
Boiled
electrode
time [s]
Weight of
boiled
electrode
without slag
per 1 second
[g/s]
1,6 30 - 55 300 4 35 0,11
2,5 70 - 110 350 11 49 0,22
3,2 90 - 140 350 19 60 0,32
4,0 120 - 190 450 39 88 0,44
GETTING STARTED TIG
1. Insert the mains plug 41 into a suitable 1x230 V
mains socket. he supply fuses or circuit breaker should
correspond to the technical data stated in this manual.
2. Fit the IG orch to the Panel quick connector (-)
44 and fasten it by turning the connector to the right.
3. Connect the gas hose of the IG torch onto Gas
outlet connector 45.
4. Connect the torch control connector onto the matching connector 43.
5. Connect the work lead to Panel quick connector (+) 42 and fasten it by
turning the connector to the right.
6. Connect the gas hose to the reduction valve on the gas cylinder and on
the Gas inlet connector 46 on the rear panel.
7. Switch the machine on by the ON/OFF switch 48.
8. Select the Gas setting mode by means of pressing the button 31, LED 36
will illuminate. Set the flow of the argon gas by means of the pressure
reduction valve on the gas cylinder.
9. Select 2 (two stroke) or 4 (four stroke) mode by means of switch 1. he
corresponding LED will light up.
10. Select the method desired IG DC or AC method by means of the
button 41. he corresponding LED will light up.
11. In the welding torch must be installed a corresponding tungsten
electrode (for AC green or golden). he electrode should be sharpened
also corresponding to the AC or DC mode.
12. Select HF or list arc ignition by means or switch 4.
13. Set the welding current by means of Encoder 28. he values will be
showed on the display 3.
14. Other parameters may be set by means of buttons 30 and 25 and
the encoder 28. he corresponding LEDs will light up. he set parameter
will be automatically memorised when you move to another parameter of
after 3 s. More in the table MAIN PAR S above.
15. Connect the work clamp to the work piece or at the welding table and
you can start welding.
16. he following table describes the influence setting the clearance

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effect.
Clearance effect
Value 20
-
30%
Value
50%
Shape of the current
curve
Penetration
Shallow
Deep
Level of wear of the of
tungsten electrode
Smaller Bigger
TABLE OF CONSUMPTION DURING TIG WELDING
Wolfram electrode diameter [mm]
Argon flow [l/min]
Steel / stainless steel
0,5 3 – 4
1,0 3 – 5
1,6 4 – 6
2,4 5 – 7
3,2 5 – 9
REMOTE CONTROL
he PEGAS 200 AC/DC PULSE supports three kinds of remote controls.
1. IG torch with UP-DOWN buttons
2. Foot pedal
3. Standard separate remote control for changing the value of the welding
current.
All three models of remote controls can be connected by means of the front panel
connector 43.
Fig . 2 Foot pedal remote control

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Pos.
Description
P1
Stepping surface
P2
Potentiometer of setting the limit of maximal welding current
P3
Connector (connect to matching connector 13 on the front panel)
1. When you connect the P3 connector to matching connector on the front
panel 43 the function setting the current from the front panel will blocked,
instead of that the max. current is limited by the potentiometer P2.
2. By pressing the stepping surface down you start the welding process. he
value of the welding current depends on the level of pressing the stepping
surface. o reach the maximal current limited by potentiometer P2 requires
to gently pressing to the lowest position of the stepping surface P1. he
set current will be displayed on the current display 3.
3. he welding process ends after releasing the stepping surface P1.
7. TWO STROKE AND FOUR STROKE IN TIG MODE
TWO STROKE – 2T
FOUR STROKE – 4T
Gas
Pregas Postgas
Down slope
Welding current
Current

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BILEVEL – SECOND WELDING CURRENT
When the machine is in 4 mode, there is always active the BILEVEL function.
he value of the second current is automatically set to 50% of the pre-set value
of the main welding current. o enter the second welding current press the torch
button for a short time and release it. o get back to the main welding current
press the torch button for a short time and release it.
8. ROUTINE MAINTENANCE & INSPECTION
he only routine maintenance required for the PEGAS range of machines is a
thorough cleaning and inspection, with the frequency depending on the usage
and the operating environment.
 WARNING Disconnect the PEGAS 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.
CAU ION 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.
o 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.
he welder should also be wiped clean. If necessary, solvents that are
recommended for cleaning electrical apparatus may be used.
roubleshooting and repairing of PEGAS 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.
he person carrying out the servicing needs and repairs must know what to look
at, what to look for and what to do.
Gas
Down slope
Post
gas
Up slope
Pregas
Welding current
Current

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9. 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 of 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. he 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:
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.
Equipment that has been used beyond the specifications established in the
operating manual.
Installation not in accordance with the installation/operating manual.
Any product that has been subjected to abuse, misuse, negligence or accident.
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.
NO 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.
As a warranty list serves proof of purchase (invoice) on which is the serial
number of the machine, eventually a warranty list on the last page of this manual.
10. DISPOSAL
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.

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11. WARRANTY LIST
As a warranty list serves proof of purchase (invoice) on which is the serial
number of the machine, eventually a warranty list below, which is filled in by an
authorized dealer.
Serial number:
Day, month (written in words)
and year of sale:
Stamp and dealer signature: