Alfain ALF 181 BASIC aXe User manual

ALFA IN a.s. © www.alfain.eu ALF 181-221 BASIC aXe MANUAL EN 08
MIG/MAG WELDING MACHINES
ALF 181 BASIC aXe
ALF 221 BASIC aXe
INSTRUCTION MANUAL

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ALFA IN a.s. © www.alfain.eu
CONTENT
1. INTRODUCTION .......................................................................................... 3
2. SAFETY INSTRUCTIONS AND WARNINGS ..................................................... 4
3. CONDITIONS OF USE................................................................................... 7
4. TECHNICAL DATA ....................................................................................... 8
5. ACCESSORIES ............................................................................................. 9
6. DESCRIPTION OF THE APPLIANCE ............................................................... 10
7. GETTING STARTED ..................................................................................... 13
8. WELDING .................................................................................................. 16
9. ROUTINE MAINTENANCE INSPECTION .................................................... 21
10. STATEMENT OF WARRANTY ...................................................................... 21
11. DISPOSAL .................................................................................................. 22
12. WARRANTY LIST ........................................................................................ 23

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ALFA IN a.s. © www.alfain.eu
1. INTRODUCTION
Con ratulations 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 Operatin Manual has been desi ned 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 workin with this product.
Read and understand this entire Manual and your employer’s safety practices
before installin , operatin , or servicin the equipment. While the information
contained in this Manual represents the Manufacturer's best jud ement, the
Manufacturer assumes no liability for its use.
ALF 181 and ALF 221 BASIC aXe are three phase sturdy weldin machines
for MIG/MAG weldin .
The machines are desi ned to produce maximum power output combined with
hi h reliability and efficiency.
We reserve the law of adjustments and chan es in case of printin errors,
chan e of technical paramaters, accessories etc. without previous notice.
These chan es may not be reflected in the manuals for use in paper or
electronic form.

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ALFA IN a.s. © www.alfain.eu
2. SAFETY INSTRUCTIONS AND WARNINGS
1. OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN BE
DANGEROUS AND HAZARDOUS TO YOURHEALTH.
2. Arc weldin produces intense electric and ma netic emissions that may
interfere with the proper function of cardiac pacemakers, hearin aids, or
other electronic health equipment. Persons who work near arc weldin
applications should consult their medical health professional and the
manufacturer of the health equipment to determine whether a hazard exists.
3. Once the packin has been opened, make sure that the machine is not
dama ed. If in any doubt, call the service centre.
4. This equipment must only be used by qualified personnel.
5. Durin installation, any electric work must only be carried out by trained
personnel.
6. The machine must be used in a dry place with ood ventilation.
7. Make sure that no metal dust can be drawn in by the fan inside the machine,
as this could cause dama e to the electronic circuits.
8. It is prohibited to connect more than one enerator in series or in parallel.
9. When installin the machine, follow the local re ulations on safety.
10. The position of the machine must allow easy access by the operator to
the controls and connectors.
11. When the weldin machine is operatin , all its covers and doors must be
closed and well fixed.
12. Do not expose the weldin machine to direct sunli ht or to heavy rain.
This equipment conforms to protection ratin IP23S.
13. The operator must wear loves, clothes, shoes, and a helmet or a
welder’s helmet, which protect and are fire-resistant in order to protect him
a ainst electric shock, flashes and sparks from cuttin .
14. The operator must protect his eyes with safety visor or mask desi ned
for weldin , fitted with standard safety filters. He should also be aware that
durin arc weldin 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 burnin on unprotected skin.
15. The operator is obli ed to warn anyone near the weldin area of the risks
that weldin involves and to arran e to provide adequate protection
equipment.
16. Keep all fumes and ases from the breathin 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 ases.
19. The kinds of fumes and ases from the plasma arc depend on the kind
of metal bein used, coatin s on the metal, and the different processes.
You must be very careful when weldin any metals which may contain one
or more of the followin :

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ALFA IN a.s. © www.alfain.eu
Antimony
Chromium
Mercury
Nickel
Cobalt
Arsenic
Barium Copper Selenium
Beryllium
Lead
Silver
Cadmium
Man anese
Vanadium
20. Always read the Material Safety Data Sheets (MSDS) that should be
supplied with the material you are usin . These MSDSs will ive you the
information re ardin the kind and amount of fumes and ases that may be
dan erous to your health.
21. It is very important to arran e for sufficient ventilation, especially when
weldin in enclosed spaces. We su est usin suitable fume extractors to
prevent the risk of intoxication by fumes or as enerated by the weldin
process.
22. Noise can cause permanent hearin loss. Weldin arc processes can
cause noise levels to exceed safe limits. You must protect your ears from
loud noise to prevent permanent loss of hearin .
23. To protect your hearin from loud noise, wear protective ear plu s 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, as or similar flammable materials, even if the
container has been empty for a considerable time. THERE IS A VERY HIGH
RISK OF EXPLOSION.
27. The operator must be aware of all the special re ulations which he needs
to conform to when cuttin in enclosed spaces with a hi h risk of explosion.
28. To prevent electric shock, we stron ly su est the followin rules:
29. Do not work in a damp or humid environment.
30. Do not use the machine if its cables are dama ed in any way.
31. Make sure that the earthin system of the electric equipment is correctly
connected and operational.
32. The operator must be insulated from the metal components connected
to the return wire.
33. The earthin of the piece bein worked could increase the risk of injury
to the operator.
34. EN 60974-1 Standard: Open-circuit volta e. Durin the operation of the
machine, the hi hest volta e, with which it is possible to come into contact,
is the open-circuit volta e between the clamps.
35. The maximum open-circuit volta e of the plasma machines is
established by national and international standards (EN 60974-1)
dependin on the type of current to be used, on its waveform and on the

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ALFA IN a.s. © www.alfain.eu
hazards arisin 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.
36. The open-circuit volta e, for as many adjustments as possible, must
never exceed the values relatin to the various cases shown in the followin
table:
Case Workin conditions Open-circuit volta e
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
4 Plasma cuttin DC current: 500V
peak value
37. In case 1, the dc machines with rectifier must be built in such a way that,
in case of a fault developin in the rectifier (for example open circuit, short
circuit or lack of power), the permitted values cannot be exceeded. The
weldin machines of this type can be marked with the symbol:
S
38. Before openin the machine switch off the machine and disconnect it
from the power socket.
39. Only personnel authorised by this company can carry out maintenance
on the machine.
WELDING.PROTECTIVE UTTILITIES
1. Weldin helmet with filter shade at least 10
2. Weldin loves
3. Weldin apron and cloth
4. Weldin boots
RISK OVERVIEW
1. Risk of electric shock.
2. Ultraviolet li ht and li ht radiation
3. Risk of inhalin as fumes and dust particles
4. Burns
5. Noise

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ALFA IN a.s. © www.alfain.eu
NOTE
1. It is forbidden to operate a machine with dama ed insulation of the
weldin torch or supply cable.
2. Never operate the machine taken down or dama ed covers.
3. It is forbidden to operate the machine in wet environments and outdoors
in rain or snow.
4. Ensure proper roundin clampin pliers, which also reduces the risk of
electric shock.
5. Use prescribed protective utilities, keep them dry.
6. Arc weldin produces intense electric and ma netic emissions that may
interfere with the proper function of cardiac pacemakers, hearin aids, or
other electronic health equipment. Persons who work near plasma arc
cuttin 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 a ainst the eyes, body or other person.
. CONDITIONS OF USE
1. This equipment must only be used by qualified personnel.
2. Durin installation, any electric work must only be carried out by trained
personnel.
3. Device complies with IEC 61000-3-12.
4. Do not expose the plasma machine to direct sunli ht or to rain or snow. This
equipment conforms to protection ratin IP23S.
5. Workin ambient temperature between -10 and +40 °C.
6. Relative humidity below 90% at +20 °C.
7. Up to 3000 m altitude.
8. Place the machine the way that the coolin 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.
9. Weldin 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).
10. The stability of the machine is uaranteed up to 10° inclination under
the followin conditions:
a. The machine must be secured a ainst rollin away
b. The as bottle with a maximum hei ht of 0.9 m may be placed and
properly anchored on the platform
11. The machine must be protected a ainst
a. Moisture and rain and snow
b. Mechanical dama e

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ALFA IN a.s. © www.alfain.eu
c. Draft and any ventilation of nei hbourin machine
d. Excessive overloadin - crossin technical parameters
e. Rou h handlin
ELECTROMAGNETIC COMPATIBILITY
The weldin device is in terms of interference desi ned primarily for industrial
areas. It meets the requirements of EN 60974-10 class A and it isn’t desi ned
for usin in residential areas, where the electrical ener y is supplied by public
low-volta e power supply network. It can be here potential problems with
ensurin of electroma netic compatibility in this areas, due to interference
caused by power lines as well as the radiated interference. Durin operation,
the device may be the source of interference.
Caution
We warn users, that they are responsible for possible interference from
weldin .
4. TECHNICAL DATA
ALF 181 BASIC AXE
Method MIG/MAG
Mains volta e V/Hz 3 x 400/50
Weldin current ran e A 30 - 180
Open-circuit volta e U20 V 19,3 - 37,7
Mains protection A 10 @
Max. effective current I1eff A 5,9
Weldin current (DC=100%) I2 A 130
Weldin current (DC=60%) I2 A 150
Weldin current (DC=x%) I2 A 40%=180
Volta e steps 7
Protection IP 23S
Standards EN 60 974-1, EN 60 974-10 cl.A
Dimensions (w x l x h) mm 474 x 888 x 561
Wei ht k 61
Wire speed m/min 1-17
Spool diameter mm 300
Spool wei ht k 18

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ALFA IN a.s. © www.alfain.eu
ALF 221 BASIC AXE
Method MIG/MAG
Mains volta e V/Hz 3 x 400/50
Weldin current ran e A 30 - 210
Open-circuit volta e U20 V 20,8 - 43,6
Mains protection A 16 @
Max. effective current I1eff A 7,7
Weldin current (DC=100%) I2 A 150
Weldin current (DC=60%) I2 A 170
Weldin current (DC=x%) I2 A 40%=210
Volta e steps 7
Protection IP 23S
Standards EN 60 974-1, EN 60 974-10 cl.A
Dimensions (w x l x h) mm 474 x 888 x 561
Wei ht k 65
Wire speed m/min 1 - 17
Spool diameter mm 300
Spool wei ht k 18
5. ACCESSORIES
DELIVERED WITH THE MACHINE
1. Earthin cable 3m with a clamp
2. Feed roll 0,6 - 0,8 mm for ALF 181; 0,8 – 1,0 mm for ALF 221
3. Gas hoses
ACCESSORIES TO ORDER
1. Wire cleaner
2. CO2 Gas pre heatin cable
3. Reduction valve KU 5, K 2
4. Gay cylinder
5. Torch consumables
6. Earthin cable 4 - 5 m
7. Feed rolls 0,6-0,8, for carbon steels, aluminium, flux core wires
8. Weldin torches

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ALFA IN a.s. © www.alfain.eu
6. DESCRIPTION OF THE APPLIANCE
MAIN PARTS
Fi . 1 - Main parts
A1
ON / OFF Switch
A2
Volta e switch
A3
LED ON Indicator
A4
Work leads
A5
LED
over heatin indicator
A6
Wire speed potentiometer
A7
EURO connec
tor
A8
Gas heater connector
A9
Solenoid Valve
–
as connector
A10
Mains cable
A11
Chain for fixin the as cylinder
A12
Wire Feeder
A13
Spool Holder

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ALFA IN a.s. © www.alfain.eu
CONTROL PANEL - OVERVIEW
Fi . 2 - Control panel
A1
PCB
-
encoder ON / OFF Switch
A2
Volta e switch
A3
LED ON Indicator
A5
LED over heatin indicator
P1
Wire speed potentiometer
P2
Spot time potentiometer
P3
Interval time
potentiometer
WIRE FEEDER
Fi 3 – Wire feeder
Pos.
Description
E1
Fixin shaft
E2
Pressure arm
E3
Liner
-
Feeder
E4
EURO connector
E5 Roll, Plastic cup

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ALFA IN a.s. © www.alfain.eu
ab
PS 2(W)
PS 4(W)
2
-
rolls
4
-
rolls
a = 22 mm
a = 22 mm
b = 30 mm
b = 30 mm
Grove type
Wire diameter
Item No
Steel
0,6
-
0,8
2187
0,8
-
1,0
2188
Aluminium
0,8
-
1,0
2270
1,0
-
1,2
2269
1,6
-
2,0
2513
Flux core
0,8-1,0 2318
1,0
-
1,2
2319

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ALFA IN a.s. © www.alfain.eu
7. GETTING STARTED
Gettin started must be consistent with technical data and conditions of use.
Fi 4 – Earthin cable connectin
B1
Euro connector female
B2
Torch Euro connector
B3
Weldin torch
C1
Work lead
C2
Earthin c
lamp
1. Connect the earthin clamp C2 to the weldin piece.
2. Connect the B1 and B2 torch connectors to ether. Screw them up properly
by mean turnin the B2 clockwise.
3. Plu the mains plu to 3x400 V mains.
4. Switch the machine on by the ON/OFF switch A1.
INSERTING THE WIRE
Fi . 5 – Spool holder
1. Open the side cover of the wire feeder space.
2. Put the wire spool on the wire spool holder D1 usin the adapter D and fix
it with the fixin nut D2.
3. Cut off the curved or dama ed end of weldin wire and lead it throu h the
inlet liner E , and the roll into the liner inside the EURO torch connector
D1
Spool h
older
D2
Nut
spool h
older
D3
Adapter

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ALFA IN a.s. © www.alfain.eu
(about 5 cm). Make sure, that you use the suitable roove.
4. Put the pressure arm E2 down in that way, that the teeth or the ear fit and
fix it by settin the lever E1 into vertical position.
5. 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
1. See the manual of the weldin torch.
2. Take off the torch as cup.
3. Take off the torch tip.
4. Press the torch tri er, the wire will start feedin into the torch.
5. When the wire reaches the end of the torch, release the tri er, screw on
the tip and the nozzle.
CHANGING THE WIRE FEEDER ROLL
1. Every wire feedin roll in ALFA IN machines can be used for two different
diameters of weldin wire – the rolls have two rooves.
2. When the machine is equipped with two roll wire feeder move the lever E1
to the ri ht (2 roll feeder)/ forward (4 roll feeder). The pressure arm shall
pop up.
3. Unscrew the plastic fixin cup E5 and take off the roll
4. In case there is suitable roove on the roll, turn it around and fix it back to
the feeder.

 
ABC
Fi . 6- The influence of the roll roove on the wire
A Correct
B
Wron
C
Wron

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ALFA IN a.s. © www.alfain.eu
ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
1. For feedin the AL wire it is necessary to use roll with the “U” profile of the
roove. To prevent problems with feedin use wires with diameter 1,0 or
more mm of AlM 3 or AlM 5. The torch must be equipped with Teflon liner
and special tip. As shieldin atmosphere use Ar on.
Fi 7 – Set for weldin aluminium
G1
EURO connector
G2
Rolls
G3
Liner terminal for 4,0mm, 4,7mm outer diameter
G4 O – rin 3,5x1,5mm
G5
Nut
G6
Teflon Liner
G7
Sustain pipe for teflon and plastic liner
GAS FLOW SETTING
The electric arc and the weld must be perfectly shielded by as. Too small
amount of as does not perform the protective atmosphere and on the other
hand to bi amount of the as brin s air into the electric arc.
Fi . 8 – Gas fittin

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ALFA IN a.s. © www.alfain.eu
F1
Gas Cylinder
F2
Cylinder
Valve
F3 Gas heater connector
F4
Pressure Reducer
F5
Hi h Pressure Manometer
F6
Low Pressure Manometer
F7
Adjustin Screw
F8
Gas outlet
F9
Solenoid Valve
F10
Chain
1. Place the as cylinder on the platform and fix it properly by the fixin chain.
We recommend usin bolts and nuts to fix it more safely.
2. Connect the pressure reduction valve on the as cylinder.
3. Connect the as hose to as outlet F8 on the valve and the as inlet F9 on
the machine.
4. In case you use as CO2 it may be needed to use suitable as heater (only
above 6 l/min). Connect the heater to the F heater connector (optional).
Use type correspondin to volta e and current iven on the shield.
5. Open the F2 cylinder valve.
6. Press the torch tri er.
7. Adjust the amount of as on the reduction as valve (it is not a part of the
weldin machine) by the F7 adjustin screw.
8. Release the torch tri er.
8. WELDING
For orientatin adjustin of the weldin current and volta e you can use
empirical relation U2 = 14+0,05 2. From that you can specify desired volta e.
SETTING WELDING CURRENT AND VOLTAGE
When the wire had been installed and as had been set it is possible to start
weldin .
The appliance must be plu ed into the mains, the ON/OFF switch A1 on "I".
To select the volta e use step switch A2.
To select the current (that is linked to the wire speed) use the potentiometer
A6 (P1).

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ALFA IN a.s. © www.alfain.eu
WELDING MODES
Machines works in four modes:
1. Ccontinuous two stroke (2T)
2. Continuous four stroke (4T)
3. Spot weldin
4. Interval weldin
TWO STROKE
P2
P3
Both potentiometers P2, P are in the OFF position. Weldin
procedure starts by pressin the button in the torch handle. It is necessary to
keep the button pressed all the time durin weldin . The weldin stops by
releasin the torch button.
1
2
Weldin proces
FOUR STROKE
P2
P3
The four stroke mode is bein used mostly for lon welds, when
there is no need to hold the torch button pressed. The left potentiometer P2 is
in the OFF position, the ri ht potentiometer P is in the ON position. The
weldin procedure start by pressin the torch button; after releasin the torch
button the weldin continues. The weldin stops after the second pressin and
releasin the torch button then.
1- 2
3 - 4
Weldin proces

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ALFA IN a.s. © www.alfain.eu
SPOT WELDING
P2
P3
The spot weldin mode is bein used for weldin short welds of
the same len th. The len th (weldin time) can be set by the left potentiometer
P2, the ri ht potentiometer P must be in the OFF position. The pressin the
torch button activates the time circuit that starts and end the weldin
procedure.
1
2
Weldin proces
1
2
Weldin proces
INTERVAL WELDING
P2
P3
The interval weldin mode is bein used for weldin repeated
short welds of the same len th of weldin time and the pause time. The len th
of weldin time can be set by the left potentiometer P2, the pause by the ri ht
potentiometer P . By pressin the torch button activate the time circuit that
starts and end the weldin procedure.
1Weldin proces
2
Weldin proces
Pause

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ALFA IN a.s. © www.alfain.eu
BURN BACK SETTING
1234568 79101112
t
300ms
max
t
20 ms
min
Burn back time
Fi . 9 – Burn back time trimmer
The burn back function if set suitably prevents stickin the weldin wire into
the weldin tip. The default time is 50-80 ms. I tis possible to chan e the burn
back time by means of a trimmer placed on the rear side of the control board.
It is necessary to take off the front panel. Only a qualified person may curry
out this operation.

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ALFA IN a.s. © www.alfain.eu
TABLE OF WIRE CONSUMPTION DURING WELDING
Wire
diameter
[mm]
Range of
wire feed
speed
[m/min]
Maximal
wire feed
speed
[m/min]
Weight of
1 m wire
[g]
Wire consumption
per 1 minute of
welding
[g/min]
Wire
consumption
per 1 hour of
welding
[g/hour]
Steel wire
0,6 2 - 5 5 2,3 11,5 690
0,8 3 - 6 6 4 24 1440
1,0 3 - 12 12 6 72 4320
1,2 4 -18 18 9 162 9720
Stainless steel wire
0,6 2 - 5 5 2,3 11,5 690
0,8 3 - 6 6 4 24 1440
1,0 3 - 12 12 6 72 4320
1,2 4 -18 18 9 162 9720
Aluminum wire
0,6 2 - 5 5 0,8 4 240
0,8 3 - 6 6 1,3 7,8 468
1,0 3 - 12 12 2 24 1440
1,2 4 -18 18 3 54 3240
TABLE OF GAS CONSUMPTION DURING WELDING
Wire diameter [mm] Gas flow [l/min] Gas consumption per 1 hour
of welding [l/hour]
0,6 6 6 * 60 = 360
0,8 8 8 * 60 = 480
1,0 10 10 * 60 = 600
1,2 12 12 * 60 = 720
1,6 16 16 * 60 = 960
2,0 20 20 * 60 = 1200