Alfain 5.0291 User manual

ALFA IN a.s. © www.alfain.eu PERUN 200 MIG SYN PFC manual EN 06
WELDING MACHINE
PERUN 200 MIG SYN PFC
OPERATING MANUAL

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CONTENT
1. INTRODUCTION .......................................................................................... 3
2. SAFETY INSTRUCTIONS AND WARNINGS ............................................. 4
3. TECHNICAL DATA ...................................................................................... 6
4. EQUIPMENT ................................................................................................
5. MAIN PARTS OF THE MACHINE ............................................................... 9
6. MAIN MENU ............................................................................................... 12
. GETTING STARTED MIG/MAG ................................................................ 16
8. GETTING STARTED TIG .......................................................................... 23
9. GETTING STARTED MMA ........................................................................ 25
10. ROUTINE MAINTENANCE & INSPECTION ............................................ 25
11. STATEMENT OF WARRANTY ................................................................ 26
12. DISPOSAL ................................................................................................ 2
13. WARRANTY LIST ..................................................................................... 2

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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.
The model of PERUN 200 MIG SYN PFC is the multi-function inverter power
generators welding by those methods:
a) MIG/MAG in 2T, 4T, manually or synergic wires G3Si1 or stainless steel
0,6 - 1,0 mm, Al wires 1,0 mm, flux cored wires shelf shielding or standard
b) E – (MMA) coated electrodes up to 4,0 mm
c) TIG Lift arc
PERUN 200 MIG SYN PFC is equipped by system of Power Factor Correction
(PFC).
What are the adva tages of PFC solutio ?
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 parameters, accessories etc. without previous notice. These
changes may not be reflected in the manuals for use in paper or electronic form.

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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.
6. It is prohibited to connect more than one INVERTER generator in series or in
parallel.
. 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.
16. The operator must ensure all flammable materials are removed from the
work area to avoid any risk of fire.
1 . 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.
19. To prevent electric shock, we strongly suggest the following rules:
a. Do not work in a damp or humid environment.

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b. Do not use the welding machine if its cables are damaged in any way.
c. Make sure that the grounding system of the electric equipment is
correctly connected and operational.
d. The operator must be insulated from the metal components connected
to the return wire.
e. The grounding of the piece being worked could increase the risk of
injury to the operator.
20. EN 609 4-1 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. In our generator this
voltage is 6 V.
21. The maximum open-circuit voltage of the welding machines is established
by national and international standards (EN 609 4-1) 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.
22. 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
23. 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
24. Before opening the machine switch off the machine and disconnect it from
the power socket.
25. 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.

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ELECTROMAGNETIC COMPATIBILITY
The welding device is in terms of interference designed primarily for industrial
areas. It meets the requirements of EN 609 4-10 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
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 MIG/
MAG
MMA TIG MIG/
MAG
MMA TIG
Mains voltage V/Hz 1x110/50-60 1x230/50-60
Welding current
range A 25 - 130 10 - 100 10 - 140 25 - 200 10 - 200 10 - 200
Open-circuit
voltage U20 V 6 ,0 6 ,0
Mains protection A 25 @ 16 @
Max. effective
current I1eff A 22,0 1 ,5 18,0 14,5 16,0 12,0
Welding current
(DC=100%) I2 A 85 65 95 130 120 140
Welding current
(DC=60%) I2 A 110 80 125 150 140 160
Welding current
(DC=x%) I2 A 35%=130
30%=100 40%=140 30%=200 25%=200 35%=200
Protection IP 23S
Standards EN 609 4-1, EN 609 4-10 cl. A
Dimensions (w x
l x h)
compact
mm 230 x 640 x 420
Weight -
compact
kg 18,4
Wire speed m/min 1,5 - 4,5 --- --- 1,5 - 16,5 --- ---
Spool diameter mm 200 --- --- 200 --- ---
Spool weight kg 5 --- --- 5 --- ---
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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4. EQUIPMENT
MODELS
Item No Descriptio Picture
5.0291 PERUN 200 MIG SYN PFC
ACCESSORIES TO ORDER
Item No. Descriptio Picture
SGB25-3 Torch PARKER SGB 250 3m
SGB25-4 Torch PARKER SGB 250 4m
SGB25-5 Torch PARKER SGB 250 5m
T24ST Torch T2 4m 35-50 arc ST
T28ST Torch T2 8m 35-50 arc ST
584 Set Connectors ST 12 PIN
VM0151-1 Hose Gas 3m G1/4-G1/4
VM0253 Welding Cable Set 2x 3m
35-50 200A

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Rolls – see section WIRE
FEEDER
S C Welding Helmet Barracuda
S C Black
S SUN9B Welding Helmet S9B
Shooting Blue Shark
4488
Wire 0.8 Coreshield 15 A
D200 Self Shielding 4,5kg
spool
SGL2 Small Gas Lens Body Starter
Kit 1.6mm
-
1/16"
SGL4 Small Gas Lens Body Starter
Kit 2.4mm
-
3/32"
SGL5 Small Gas Lens Body Starter
Kit 3.2mm
-
1/8"
00.0306.10 Electrode wolf.1.6x1 5-Violet
00.0308.10 Electrode wolf.2.4x1 5-Violet
00.0310.10
Electrode wolfram E3
3.2x1 5
-
violet

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5. MAIN PARTS OF THE MACHINE
Fig. 1 - PERUN 200 MIG SYN PFC – main parts
Pos. Descriptio
A1 Display
A2 Knob
A3 Quick connector (+) of welding cables

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A4 MIG/MAG torch connector
A5 Knob
A6 TIG torch control connector
A Gas connector for TIG torch
A8 Quick connector (-) of welding cables or TIG torch
A9 Handle
A10 Mains cable
A11 Switch Spool Gun
A12 Wire feeder
A13 MENU button
A14 Button for setting the welding current and voltage
A15 Wire feeding button
A16 Gas setting button
WIRE FEEDER
Fig. 2 - Wire feeder
Pos. Descriptio
E1 Nut of pressure arm
E2 Pressure arm
E3 Inlet liner
E4 EURO connector
E5 Roll

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OVERVIEW OF ROLLS FOR WIRE FEED
ab
a = 22 mm
b = 30 mm
Groove type
Wire diameter
Item No
Steel
0,6
-
0,8
218
0,8
-
1,0
2188
Aluminium
0,8
-
1,0
22 0
Flux core
0,8
-
1,0
2318
1,0
-
1,2
2319

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6. MAIN MENU
Fig. 3 - Main Menu
Pos. Descriptio
1 Method selection
2 Synergic parameters selection
3 Welding parameters settings
4 System settings
5 Chosen function icon
6 Chosen mode icon
Multifunctional window
8 Synergic
parameter (from left: program number, material of welding
wire, protective gas and wire diameter)
Press MENU button A13 to move between submenus.

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METHOD SELECTION
Rotate and then press the knob A2 for method selection.
Fig. 4 - Submenu of method selection
Use the button for setting the welding current and voltage A14 in the upper right
part of the panel to get to the settings of welding current and voltage. To change
these parameters rotate knobs A2 and A5.
Fig. 5 - Welding parameters selection

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SYNERGIC PARAMETERS SELECTION
Submenu of synergic parameters is available only when the method MIG/MAG
Synergy is chosen.
Rotate and then press the knob A2 for synergic parameter selection.
Fig. 6 - Synergic parameters selection
SECONDARY WELDING PARAMETERS SELECTION
Rotate the knob A2 and then press the knob A5 for parameters settings.
Fig. - Secondary welding parameters selection

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Secondary welding
parameters
MIG/MAG
welding
parameters
(Default)
TIG welding
parameters
(Default)
MMA welding
parameters
(Default)
Two/four Stroke
2T
/
4T
(2T)
2T
/
4T
(2T)
-
Burn Back
0
-
10
(0)
-
-
Slow Feed 0 - 10 (0) - -
Pre
F
low
0
-
2 s
(0 s)
-
-
Post Flow
0
-
10
(0 s)
0
-
10
(0 s)
-
Inductance
0
-
10
(5)
-
-
Down slope - 0 - 10 s (0 s)
Hot Start
-
-
0
-
10 (0)
Arc Force
-
-
0
-
10 (0)
SYSTEM SETTINGS
Rotate the knob A2 and then press the knob A5 for parameters settings.
The last position in submenu of system settings is Factory reset.
Press the knob A5 for Factory reset performance.
Fig. 8 - Submenu of system settings

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7. GETTING STARTED MIG/MAG
Getting started must be consistent with technical data and conditions of use.
CHOOSING THE FEEDING ROLL
In all machines (ALFA IN MIG / MAG) rolls with two grooves are used. These
grooves are intended for two different wire diameters (e.g. 0,8 and 1,0 mm).
Rolls for wire feed must comply with the diameter and material of the welding
wire. Only this way a smooth wire feed can be achieved. Irregularities of the wire
feed leads to a poor quality of welding and deformation of the wire.

 
ABC
Fig. 9 - The influence of the roll groove on the welding wire
INSERTING THE WIRE
1. Open the side cover of the wire feeder space.
2. Put the wire spool on the wire spool holder D1 and fix it with the fixing nut
D2.
3. 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.
4. 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.
5. Adjust the pressure nut that way that it provides constant movement of
wire but it does not deform wire. The adjusting screw is located under the
plastic screw E1.
6. The spool brake is set by the manufacturer. If necessary, the brake can be
adjusted by a screw D1 so that while stopping the feed, spool will be
stopped on time (it will avoid excessive release of wire). However, too tight
brake needlessly strains the feeding mechanism and thus slippage may
occur in the wire rolls.
Fig. 10 - Spool holder
A Correct
B Wrong
C Wrong
Pos. Descriptio
D1 Spool Holder
D2 Nut Spool Holder
D3 It is not for this welder

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INSERTING THE WIRE TO THE TORCH AND CONNECTION OF GROUND
CABLE
Fig. 11 - Connection of the main MIG/MAG components
1. Connect the torch B6 to connector A4 on the machine while the machine
is turned off.
2. Connect the ground cable B4 to the quick connector (-) A8 of welding
cables.
3. Connect the ground clamps B5 to the weldment B7 or to the welding table.
4. Notice When inserting the wire do not point with torch to the eyes!
5. Remove the gas nozzle from the torch.
6. Unscrew the current nozzle.
. Connect the machine to power supply.
8. Turn the main switch on the rear panel to ON.
9. With MENU button A13 and knob A2 select the mode MIG/MAG.
10. In submenu of welding parameters selection choose 2T or 4T.

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11. Press the button A15 in the space of the wire feeder and the welding
wire is fed into the torch. After coming off from the torch tube, screw the
current nozzle and gas nozzle on.
12. Before welding, spray the area in a gas hose and current nozzle with
a separation spray, to prevent damage.
ADJUSTMENT OF GAS FLOW
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.
Notice Gas bottle must be well secured against fall. This manual does
not solve the safe securing of gas bottle. Information can be obtained from a
supplier of industrial gases.
1. Connect the gas hose to gas outlet F8 on the valve and the gas inlet to the
gas connector.
2. Press the button A16 in the space of the wire feeder.
3. Turn the adjusting screw F7 at the bottom side pressure reducing valve,
until the meter F6 shows the required flow, then release the button. The
optimum flow is 10-15l/min.
4. After long-term shutdown of the machine or replacement of the torch it is
suitable to blow the pipes with protective gas before welding.
Fig. 12 - Gas flow setting
Pos. Descriptio
F1 Gas bottle
F2 Cylinder Valve
F4 Pressure Reducer
F5 High Pressure Manometer
F6 Low Pressure Manometer
F Adjusting Screw
F8 Gas outlet

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ADJUSTING WELDING PARAMETERS FOR MIG SYN
1. Find the appropriate program number in submenu of synergic parameters.
2. Select the synergic parameter by knob A2 and then press the knob A2 for
confirmation.
3. After that, choose the appropriate welding parameters by knobs A2 and
A5.
4. Recommendation – For perfect manual tack welding (for example for car
bodywork repairs) use the machine in the MIG Manual mode.
ADJUSTING WELDING PARAMETERS FOR MIG MAN
1. Approximate setting for the MIG / MAG welding current and voltage
corresponds the empirical relationship U2 = 14 +0.05 I2. According to this
relationship, we can determine the required voltage. When setting the
voltage, we expect the decline in voltage during load. The voltage drop is
approximately 4,8V at 100 A.
2. Select voltage.
3. Then select the appropriate wire speed.
4. Tune the arc by changing the levels of the choke in submenu of welding
parameters settings.
Wire diameter (mm) Welding current (A) Material thickness (mm)
0,6 25 - 110 1,0 - 1,6
0,8 35 - 160 1,0 - 2,3
0,9 45 - 160 1,0 - 2,3
1,0 45 - 200 1,2 - ,0
Table of approximate parameter settings
ADJUSTING THE MACHINE FOR ANOTHER WIRE DIAMETER
In all machines ALFA IN MIG / MAG are used rolls with two grooves. These
grooves are intended for two different wire diameters (e.g. 0,8 a 1,0 mm). Groove
can be replaced by removing the rolls and rotating them, or use a different roll
grooves with required dimensions.
1. Open the nut E1 to the left, pressure roll E2 will be opened upward.
2. Unscrew the plastic locking element E5 and remove the roll.
3. If there is a suitable groove on the roll, rotate the roll and place it back on
the shaft and secure it by screwing the element E5.

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FLUX CORE WIRE – SETTING THE POLARITY FOR MIG/MAG TORCH
1. It is desirable to have positive polarity on the MIG/MAG torch while welding
with solid wire in majority of cases. The welder is supplied from the
production with positive polarity on the MIG/MAG torch.
2. For welding with flux cored wires it may be necessary to have negative
polarity on the MIG/MAG torch.
3. The middle terminal K2 is connected to the central euro connector of the
MIG/MAG torch. We supply the welder with K2 connected by means of the
bridge K3 to terminal (+) K1.
4. In case of welding with flux core wire with (-) polarity, connect K2 by means
of the bridge K3 with K4 terminal (-). Use Phillips screwdriver.
5. Make sure you fasten the terminals properly.
6. Connect the ground cable B4 to the quick connector (+) A3.
Fig. 13 - Terminals for changing the polarity of the MIG/MAG torch
Pos. Descriptio
K1 Upper terminal (+)
K2 Middle terminal
K3 Bridge
K4 Lower terminal (-)
Notice
In case, that you want to weld with flux core wire, it is first necessary to remove
the gas nozzle of the torch before starting welding. Furthermore, during the
welding process, you must not touch the weldment with the die. There would be
a risk of baking the wire.