Alfain PEGAS 160 E PFC User manual

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ALFA IN a.s. © www.alfain.eu NA137-3
WELDING INVERTER
PEGAS 160 E PFC
OPERATING MANUAL

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ALFA IN a.s. © www.alfain.eu
CONTENT:
1 INTRODUCTION.......................................................................................3
2 SAFETY INSTRUCTIONS AND WARNINGS 

 .....................................3
3 ELECTROMAGNETIC COMPATIBILITY (EMC)........................................5
4 TECHNICAL DATA....................................................................................6
5 EQUIPMENT.............................................................................................7
5.1 ACCESSORIES TO ORDER..............................................................7
6 OPERATOR CONTROLS..........................................................................8
6.1 FRONT PANEL...................................................................................8
7 GETTING STARTED.................................................................................9
7.1 GETTING STARTED MMA – COATED ELECTRODE........................9
7.2 GETTING STARTED TIG LIFT ARC...................................................9
7.2.1 How to connect the gas cylinder....................................................9
7.2.2 Basic settings for TIG welding – stainless steel, DC current........10
8 ROUTINE MAINTENANCE & INSPECTION............................................10
9 STATEMENT OF WARRANTY................................................................11
10 DISPOSAL...............................................................................................11

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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 160 E PFC welds by those methods
a) E – (MMA) coated electrodes up to 4,0 mm
b) TIG lift arc.
PEGAS 160 E PFC is equipped by system of Power Factor Correction (PFC)
– which enables operating on AC power supply of 95V – 270V.
What are the advantages of PFC solution?
•Higher efficiency and less stress related to the circuit breaker (in other
words, circuit breaker will switch off later than the devices without PFC)
•The machine can be connected to the mains 110 V - 230 V + -15% Small
influence of under voltage and overvoltage mains power
•Smaller level of electromagnetic interference
•Minimum net reactive current loading
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.

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ALFA IN a.s. © www.alfain.eu
•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.
•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

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machine, the highest voltage, with which it is possible to come into contact,
is the open-circuit voltage between the welding clamps. In our generator
this voltage is 58V.
•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. The welding machines of this type can be marked with the
symbol:
S
•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.

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ALFA IN a.s. © www.alfain.eu
•All very sensitive electrical equipment.
•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
Method MMA TIG MMA TIG
Mains voltage V/Hz
1x110/50-60 1x230/50-60
Mains protection
A 20 T 16 T
Max. input power
I
1max
A 35,0 21,3 21,6 14,4
Max. effective
current I
1eff
A 19,1 15,1 13,7 9,1
Welding current
range A/V 8/20,3 - 125/25,0 8/10,3 - 125/15,0 10/20,4- 160/26,4 10/10,4 - 160/16,4
Open-circuit
voltage U
20
V 71,0** 71,0**
Welding current
(DC=100%) I
2
/U
2
A/V 60/22,4 100/14,0 80/23,2 100/14,0
Welding current
(DC=60%) I
2
/U
2
A/V 80/23,2 115/14,6 110/24,4 110/14,4
Welding current
(DC=x%) I
2
/U
2
A/V 30%=125/25,0
50%=125/15,0
40%=160/26,4
40%=160/16,4
Power factor
cosφ0,98
Insulation class F
Protection IP23S
Standards EN 60974-1
Dimensions (w x
l x h) mm
140x410x230
Weight kg 7,8
Max. input power
S
1max
kVA
3,8 2,6 5,0 3,3
Max. active input
power P
1max
kW 3,6 2,5 4,9 3,1
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.

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ALFA IN a.s. © www.alfain.eu
5 EQUIPMENT
5.1 ACCESSORIES TO ORDER
Item No. Description
VM0253 Welding Cable Set 2x 3m 35-50 160A
5.0110 Box blue
4281 Valve Red.AR /CO2, 2 manometers,MINI
S777a Light Reactive Welding Helmet ALFA IN S777a
GRAY
705.0307 Torch ABITIG 26 4m V 35-50
705.0308 Torch SR26 8m V 35-50
705.0172 Torch SR17 4m V 35-50
705.0173 Torch SR17 8m V 35-50
712.A011 Set SR17/18/26d=1,6
712.A012 Set SR17/18/26d=2,4
712.A013 Set SR17/18/26d=3,2
400P216175 Electrode T 2%Th 1.6x175
400P224175 ElectrodeT 2%Th 2.4x175
400P232175 Electrode T 2%Th 3.2x175

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6 OPERATOR CONTROLS
Fig . 1 Main parts
6.1 FRONT PANEL
Pos. Description
1 LED ON
2 LED over heating
3 Current potentiometer
4 Method switch MMA (electrode)/TIG
5 Cooling ribs
6 Panel quick connector +
7 Mains socket with a pulg
8 ON/OFF switch

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ALFA IN a.s. © www.alfain.eu
7 GETTING STARTED
Insert the mains plug into a suitable 1x230 V (or 1 x 110 V) mains socket. The
supply fuses or circuit breaker should correspond to the technical data in
section 3. Switch the machine on by the ON/OFF switch (7). LED (1) will
illuminate.
7.1 GETTING STARTED MMA – COATED ELECTRODE
•Connect the electrode holder and the work lead to terminals (5) and (6)
according the instructions on the electrode package. 

 NOTE 


Prevent touching the electrode any metal material for in this mode the
terminals (5) and (6) are under current.
•By means of the switch (2) select MMA .
•To select the current use potentiometer (3)
•Insert the coated electrode into the electrode holder.
7.2 GETTING STARTED TIG LIFT ARC
•Fit the TIG Torch to the minus terminal (5) and fasten it by turning the
connector to the right.
•Connect the work lead to positive terminal (6) and fasten it by turning the
connector to the right.
•Connect the work clamp to the work piece or at the welding table.
•By means of the switch (2) select TIG .
7.2.1 How to connect the gas cylinder
•Ensure that the gas cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
•Open the gas valve once to blow out possible dirt particles.
•Connect the gas regulator to the gas cylinder valve.
•Connect the gas hose of the TIG torch to the gas regulator.
•Open the gas cylinder valve, open the valve on the TIG torch and adjust
the gas flow on the gas regulator. The flow rate will be shown at the flow
meter. This should be done according the table below.

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ALFA IN a.s. © www.alfain.eu
7.2.2 Basic settings for TIG welding – stainless steel, DC
current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler material
diameter mm
Welding
current
A
Argon flow
l/min Gas
nozzle
mm
1 1 1,5 40-60 3 10
1,5 1,5 1,5 50-90 4 10
2 2 2 80-100 4 12
3 2-3 2-3 90-140 5 12
4-5 3-4 3-4 110-180 5 12
8 ROUTINE MAINTENANCE & INSPECTION
•The 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.


 CAUTION 


•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 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

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ALFA IN a.s. © www.alfain.eu
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.
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. 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:
•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.


 NOTE 


•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.
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

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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.