Alfain 5.0238-3 User manual

ALFA IN a.s. © www.alfain.eu PEGAS 200 AC-DC PULSE PFC manual ENG 03
WELDING INVERTER
PEGAS 200 AC/DC PULSE PFC
OPERATING MANUAL

2/1
ALFA IN a.s. © www.alfain.eu
CONTENT:
1. INTRODUCTION ....................................................................................... 3
2. SAFETY INSTRUCTIONS AND WARNINGS ............................................ 4
3. TECHNICAL DATA ....................................................................................
4. EQUIPMENT ............................................................................................. 7
5. OPERATOR CONTROLS .......................................................................... 8
. GETTING STARTED ............................................................................... 10
7. TWO STROKE AND FOUR STROKE IN TIG MODE ............................... 13
8. BASIC SETTINGS FOR TIG WELDING .................................................. 14
9. ROUTINE MAINTENANCE & INSPECTION ............................................ 14
10. STATEMENT OF WARRANTY .............................................................. 15
11. DISPOSAL ............................................................................................. 1

3/1
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 200 AC/DC PULSE PFC 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. TIG DC (Lift arc or High Frequency ignition)
4. TIG AC (Lift arc or High Frequency ignition)
1. TIG AC
2. TIG DC
3. MMA
PEGAS 200 AC/DC PULSE PFC is equipped by system of Power Factor
Correction (PFC) – which enables operating on AC power supply of 95V – 270V.
What are the a vantages of PFC solution?
1. Higher efficiency and less stress related to the circuit breaker (in other
words, circuit breaker will switch off later than the devices without PFC)
2. The machine can be connected to the mains 110 V - 230 V + -15% Small
influence of under voltage and overvoltage mains power
3. Smaller level of electromagnetic interference
4. Minimum net reactive current loading
We reserve the law of adjustments and changes in case of printing errors,
change of technical paramaters, accessories etc. without previous notice. These
changes may not be reflected in the manuals for use in paper or electronic form.

4/1
ALFA IN a.s. © www.alfain.eu
2. SAFETY INSTRUCTIONS AND WARNINGS
1. Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
2. This equipment must only be used by qualified personnel.
3. During installation, any electric work must only be carried out by trained
personnel.
4. The machine must be used in a dry place with good ventilation.
5. 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.
7. When installing the machine, follow the local regulations on safety.
8. The position of the machine must allow easy access by the operator to the
controls and connectors.
9. When the welding machine is operating, all its covers and doors must be
closed and well fixed.
10. Do not expose the welding machine to direct sunlight or to heavy
rain. This equipment conforms to protection rating IP23S.
11. During welding, the welding cables must be located near or at ground
level. They should be as short as possible.
12. 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.
13. 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.
14. 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.
15. 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.
1 . The operator must ensure all flammable materials are removed from
the work area to avoid any risk of fire.
17. 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.
18. 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.

5/1
ALFA IN a.s. © www.alfain.eu
19. To prevent electric shock, we strongly suggest the following rules:
20. Do not work in a damp or humid environment.
21. Do not use the welding machine if its cables are damaged in any
way.
22. Make sure that the earthing system of the electric equipment is
correctly connected and operational.
23. The operator must be insulated from the metal components
connected to the return wire.
24. The earthing of the piece being worked could increase the risk of
injury to the operator.
EN 0974-1 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.
The maximum open-circuit voltage of the welding machines is established by
national and international standards (EN 0974-1) 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: 8V
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.
25. Before opening the machine switch off the machine and disconnect
it from the power socket.
2 . Only personnel authorised by this company can carry out
maintenance on the machine.
NOTE:
Device complies with IEC 1000-3-12.
ELECTROMAGNETIC COMPATIBILITY
The welding device is in terms of interference designed primarily for industrial
areas. It meets the requirements of EN 0974-10 class A and it isn’t designed
for using in residential areas, where the electrical energy is supplied by public

/1
ALFA IN a.s. © www.alfain.eu
low-voltage power supply network. It can be here potential problems with
ensuring of electromagnetic compatibility in this areas, due to interference
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- 0
Welding current range A 10 - 170 5 - 170
Open-circuit voltage U20 V 4,0
Mains protection A 1 @
Max. effective current I1eff A 14,1
Welding current (DC=100%) I2
ta=40
°
C
A 70 90
Welding current (DC= 0%) I2
ta=40
°
C
A 90 110
Welding current (DC=x%) I2
ta=40
°
C
A 25%=170 25%=170
Protection IP23S
Standards EN 0 974-1, EN 0 974-10 cl.A
Dimensions (w x l x h) mm 250 x 470 x 400
Weight kg 21
Method TIG - AC TIG - DC
Mains voltage V/Hz 1x230/50- 0
Welding current range A 10 - 200 5 - 200
Open-circuit voltage U20 V 4
Welding current (DC=100%) I2
ta=40
°
C
A 70 90
Welding current (DC= 0%) I2
ta=40
°
C
A 90 110
Welding current (DC=x%) I2
ta=40
°
C
A 25%=200 25%=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.

7/1
ALFA IN a.s. © www.alfain.eu
4. EQUIPMENT
CONTENT OF DELIVERY
Item No.
Description
Quantity
5.0238-3 PEGAS 200 AC/DC PULSE PFC 1
5.0189 Set of Connectors for PEGAS AC/DC 1
ACCESSORIES TO ORDER
Item No. Description
VM0410 Hose Gas PEGAS OVO 3m G1/4
VM0253 Welding Cable Set 2x 3m 35-50 200A
5.021 -2 CS 01 W Cooling Unit PEGAS
5.0228 Welders Cart
2 FSL4A Torch PARKER SGT 2 4m 35-50 FX AERO
2 FSL4AUD Torch PARKER SGT 2 4m 35-50 FX AERO UD
2 FSL8A Torch PARKER SGT 2 8m 35-50 FX AERO
2 FSL8AUD Torch PARKER SGT 2 8m 35-50 FX AERO UD
008 Pressure Reducer FIXICONTROL Ar 2 manometers GCE
5.0174 Foot Pedal Remote CTRL 3 m PEGAS incl. Connector

8/1
ALFA IN a.s. © www.alfain.eu
5. OPERATOR CONTROLS
MAIN PARTS
Fig . 1 Main parts
Pos
.
Description
1 Button TIG 2T or 4T (two stroke, four stroke)
2 LED Pregas. 0,1 – 1 s, default 0,3 s
3
Current Display
4 LED start current (just 4T). 5 – 100 % of the main welding current.
DC, 10 – 100 % AC, Default 5%.
5 LED Up slope. 0 – 10 s, default 0 s.
LED Main Welding Current. 5 – 200 TIG DC, 10 – 200 TIG 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 TIG AC

9/1
ALFA IN a.s. © www.alfain.eu
10 LED Pulse Base Current. 5 – 200 A DC, 10 -200 A AC.
11 LED Time (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. At the same time the displays show
Err 001.
1 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 4T.
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 HOT START, 0 – 10.
25 Button for moving to the right on the parameters curve.
2 LED Balance (just TIG 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 TIG AC). Range: 50-250 Hz. The higher
current, the more the maximal frequency decreases. The 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/LIFT 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.
3 LED Gas Test. If illuminated the mode of setting the gas flow was
selected (by means of the gas valve on the gas cylinder).
To turn it

10/1
ALFA IN a.s. © www.alfain.eu
off press the button 31 again or it will go off this mode after 10 s.
37 LED Four Stroke (4T).
38 LED Two Stroke (2T).
39 LED DC
40 LED AC
41 Button switch AC/DC mode.
42 Quick connector +
43 Torch control connector (pin 8 and 9)
44 Quick connector -
45 Gas connector of the welding torch
4 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 47 into a suitable 1x230 V
mains socket. The 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. The values will be
showed on the display 3.
5. It is possible to change the settings of the HOT START (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.
. Then switch to the MMA mode by means of the button 21. LEDs 20, 23 or
24 may not illuminate.
NOTE Prevent touching the electrode any metal material for in this mode
the terminals 42 and 44 are under current.
7. Insert the coated electrode into the electrode holder, connect the clamps
of the ground cable to the welding piece and you may start welding.

11/1
ALFA IN a.s. © www.alfain.eu
GETTING STARTED TIG
1. Insert the mains plug 47 into a suitable 1x230 V mains
socket. The supply fuses or circuit breaker should
correspond to the technical data stated in this manual.
2. Fit the TIG Torch to the Panel quick connector (-) 44 and
fasten it by turning the connector to the right.
3. Connect the gas hose of the TIG 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.
. 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 2T (two stroke) or 4T (four stroke) mode by means of switch 1. The
corresponding LED will light up.
10. Select the method desired TIG DC or AC method by means of the
button 41. The corresponding LED will light up.
11. In the welding torch must be installed a corresponding tungsten
electrode (for AC green or golden). The 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. The 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. The corresponding LEDs will light up. The set parameter
will be automatically memorised when you move to another parameter of
after 3 s. More in the table MAIN PARTS above.
15. Connect the work clamp to the work piece or at the welding table and
you can start welding.
1 . The following table describes the influence setting the clearance
effect.
Clearance effect
Value 20
-
30%
Value
50%
Shape of the current
curve
Penetration
Deep
Shallow
Level of wear of the of
Smaller
Bigger

12/1
ALFA IN a.s. © www.alfain.eu
tungsten electrode
REMOTE CONTROL
The PEGAS 200 AC/DC PULSE supports three kinds of remote controls.
1. TIG 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
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. The
value of the welding current depends on the level of pressing the stepping
surface. To reach the maximal current limited by potentiometer P2 requires
to gently pressing to the lowest position of the stepping surface P1. The
set current will be displayed on the current display 3.
3. The welding process ends after releasing the stepping surface P1.

13/1
ALFA IN a.s. © www.alfain.eu
7. TWO STROKE AND FOUR STROKE IN TIG MODE
TWO STROKE – 2T
FOUR STROKE – 4T
BILEVEL – SECOND WELDING CURRENT
When the machine is in 4T mode, there is always active the BILEVEL function.
The value of the second current is automatically set to 50% of the pre-set value
of the main welding current. To enter the second welding current press the torch
button for a short time and release it. To get back to the main welding current
press the torch button for a short time and release it.
Gas
Pregas Postgas
Down slope
Welding current
Current
Gas
Down slope
Post
gas
Up slope
Pregas
Welding current
Current

14/1
ALFA IN a.s. © www.alfain.eu
8. BASIC SETTINGS FOR TIG WELDING
Table for 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
-
0
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
Table for Aluminium and aluminium alloys, AC current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler
material
diameter
mm
Welding
current
A
Argon flow
l/min
Gas
nozzle
mm
Pre
heating
°C
1
2
1,
45
-
0
7
-
9
8
-
1,5
2
1,
-
2
50
-
80
7
-
9
8
-
2 2,5 2-2,5 90-120 8-12 8-12 -
3
3
3
150
-
180
8
-
12
8
-
12
-
4
4
4
180
-
200
10
-
15
8
-
12
-
5
4
3
-
4
180
-
240
10
-
15
10
-
12
-
Table for Cuprum, DC current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler
material
diameter
mm
Welding
current
A
Argon flow
l/min
Gas
nozzle
mm
Pre
heating
°C
1
1,5
2
70
-
80
4
10
150
2
2,5
3
120
-
140
5
10
150
3
3
3
130
-
1 0
5
10
200
9. ROUTINE MAINTENANCE & INSPECTION
1. 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.
2. 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

15/1
ALFA IN a.s. © www.alfain.eu
components and cause damage to the welder.
3. 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.
4. Troubleshooting and repairing of PEGAS welding equipment should only
be carried out only by suitably qualified or competent person.
5. 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
1. 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.
2. 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.
3. 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.
4. If warranty is being sought, please contact your ALFA IN product supplier
for the warranty repair procedure.
5. 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.
7. Equipment that has been used beyond the specifications established in
the operating manual.
8. Installation not in accordance with the installation/operating manual.
9. Any product that has been subjected to abuse, misuse, negligence or
accident.
10. Failure to clean and maintain (including lack of lubrication,
maintenance and protection), the machine as set forth in the operating,
installation or service manual.
11. 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.

1 /1
ALFA IN a.s. © www.alfain.eu
12. As a warranty list serves proof of purchase (invoice) on which is the
serial number of the machine.
11. DISPOSAL
Only for EU countries. Do not dispose of electric tools together with
household waste material.
In accordance with European Council Directive 2002/9 /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.