Alfain ALF 182 BASIC aXe User manual

ALFA IN a.s. © www.alfain.eu ALF 182-222 BASIC aXe MANUAL EN 06
MIG/MAG WELDING MACHINES
ALF 182 BASIC aXe
ALF 222 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
C ngratulati ns n y ur new ALFA IN pr duct. We are pr ud t have y u as
ur cust mer and will strive t pr vide y u with the best service and reliability
in the industry.
This Operating Manual has been designed t instruct y u n the c rrect use
and perati n f y ur ALFA IN pr duct. Y ur satisfacti n with this pr duct and
its safe perati n is ur ultimate c ncern. Theref re please take the time t
read the entire manual, especially the Safety Precauti ns. They will help y u
t av id p tential hazards that may exist when w rking with this pr duct.
Read and understand this entire Manual and y ur empl yer’s safety practices
bef re installing, perating, r servicing the equipment. While the inf rmati n
c ntained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes n liability f r its use.
Machines ALF 182 – 222 BASIC KTC aXe differ fr m the riginal versi n f
the machine by an ther kind f BASIC electr nics - descripti n f changes can
be f und bel w the table f the technical data.
ALF 182 and ALF 222 BASIC aXe are three phase sturdy welding machines
f r MIG/MAG welding.
The machines are designed t pr duce maximum p wer utput c mbined with
high reliability and efficiency.
We reserve the law f adjustments and changes in case f printing err rs,
change f technical paramaters, access ries etc. with ut previ us n tice.
These changes may n t be reflected in the manuals f r use in paper r
electr nic f rm.

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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 welding pr duces intense electric and magnetic emissi ns that may
interfere with the pr per functi n f cardiac pacemakers, hearing aids, r
ther electr nic health equipment. Pers ns wh w rk near arc welding
applicati ns sh uld c nsult their medical health pr fessi nal and the
manufacturer f the health equipment t determine whether a hazard exists.
3. Once the packing has been pened, make sure that the machine is n t
damaged. If in any d ubt, call the service centre.
4. This equipment must nly be used by qualified pers nnel.
5. During installati n, any electric w rk must nly be carried ut by trained
pers nnel.
6. The machine must be used in a dry place with g d ventilati n.
7. Make sure that n metal dust can be drawn in by the fan inside the machine,
as this c uld cause damage t the electr nic circuits.
8. It is pr hibited t c nnect m re than ne generat r in series r in parallel.
9. When installing the machine, f ll w the l cal regulati ns n safety.
10. The p siti n f the machine must all w easy access by the perat r t
the c ntr ls and c nnect rs.
11. When the welding machine is perating, all its c vers and d rs must be
cl sed and well fixed.
12. D n t exp se the welding machine t direct sunlight r t heavy rain.
This equipment c nf rms t pr tecti n rating IP23S.
13. The perat r must wear gl ves, cl thes, sh es, and a helmet r a
welder’s helmet, which pr tect and are fire-resistant in rder t pr tect him
against electric sh ck, flashes and sparks fr m cutting.
14. The perat r must pr tect his eyes with safety vis r r mask designed
f r welding, fitted with standard safety filters. He sh uld als be aware that
during arc welding ULTRAVIOLET RADIATION is emitted. Theref re it is
vital that his face is als pr tected fr m radiati n. Ultravi let rays pr duce
the same harmful effect as sun burning n unpr tected skin.
15. The perat r is bliged t warn any ne near the welding area f the risks
that welding inv lves and t arrange t pr vide adequate pr tecti n
equipment.
16. Keep all fumes and gases fr m the breathing area.
17. Keep y ur head ut f the fume plume.
18. Use an air-supplied respirat r if ventilati n is n t adequate t rem ve all
fumes and gases.
19. The kinds f fumes and gases fr m the plasma arc depend n the kind
f metal being used, c atings n the metal, and the different pr cesses.
Y u must be very careful when welding any metals which may c ntain ne
r m re f the f ll wing:

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ALFA IN a.s. © www.alfain.eu
Antim ny
Chr mium
Mercury
Nickel
C balt
Arsenic
Barium C pper Selenium
Beryllium
Lead
Silver
Cadmium
Manganese
Vanadium
20. Always read the Material Safety Data Sheets (MSDS) that sh uld be
supplied with the material y u are using. These MSDSs will give y u the
inf rmati n regarding the kind and am unt f fumes and gases that may be
danger us t y ur health.
21. It is very imp rtant t arrange f r sufficient ventilati n, especially when
welding in encl sed spaces. We suggest using suitable fume extract rs t
prevent the risk f int xicati n by fumes r gas generated by the welding
pr cess.
22. N ise can cause permanent hearing l ss. Welding arc pr cesses can
cause n ise levels t exceed safe limits. Y u must pr tect y ur ears fr m
l ud n ise t prevent permanent l ss f hearing.
23. T pr tect y ur hearing fr m l ud n ise, wear pr tective ear plugs and/ r
ear muffs. Pr tect thers in the w rkplace.
24. N ise levels sh uld be measured t be sure the decibels (s und) d n t
exceed safe levels.
25. The perat r must ensure all flammable materials are rem ved fr m the
w rk area t av id any risk f fire.
26. The perat r must NEVER weld c ntainers that have previ usly
c ntained petr l, lubricants, gas r similar flammable materials, even if the
c ntainer has been empty f r a c nsiderable time. THERE IS A VERY HIGH
RISK OF EXPLOSION.
27. The perat r must be aware f all the special regulati ns which he needs
t c nf rm t when cutting in encl sed spaces with a high risk f expl si n.
28. T prevent electric sh ck, we str ngly suggest the f ll wing rules:
29. D n t w rk in a damp r humid envir nment.
30. D n t use the machine if its cables are damaged in any way.
31. Make sure that the earthing system f the electric equipment is c rrectly
c nnected and perati nal.
32. The perat r must be insulated fr m the metal c mp nents c nnected
t the return wire.
33. The earthing f the piece being w rked c uld increase the risk f injury
t the perat r.
34. EN 60974-1 Standard: Open-circuit v ltage. During the perati n f the
machine, the highest v ltage, with which it is p ssible t c me int c ntact,
is the pen-circuit v ltage between the clamps.
35. The maximum pen-circuit v ltage f the plasma machines is
established by nati nal and internati nal standards (EN 60974-1)
depending n the type f current t be used, n its wavef rm and n the

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ALFA IN a.s. © www.alfain.eu
hazards arising fr m the w rk place. These values are n t applicable t the
strike currents and th se f r stabilisati n f the arc that c uld be ab ve it.
36. The pen-circuit v ltage, f r as many adjustments as p ssible, must
never exceed the values relating t the vari us cases sh wn in the f ll wing
table:
Case W rking c nditi ns Open-circuit v ltage
1 Places with increased
risk f electric sh ck
DC current: 113V
peak value
AC current: 68V
peak value and 48V
effective
2 Places with ut increased
risk f electric sh ck
DC current: 113V
peak value
AC current: 113V
peak value and 80V
effective
3
T rches held
mechanically with
increased pr tecti n f r
the perat r
DC current: 141V
peak value
AC current: 141V
peak value and
100V effective
4 Plasma cutting DC current: 500V
peak value
37. In case 1, the dc machines with rectifier must be built in such a way that,
in case f a fault devel ping in the rectifier (f r example pen circuit, sh rt
circuit r lack f p wer), the permitted values cann t be exceeded. The
welding machines f this type can be marked with the symb l:
S
38. Bef re pening the machine switch ff the machine and disc nnect it
fr m the p wer s cket.
39. Only pers nnel auth rised by this c mpany can carry ut maintenance
n the machine.
WELDING.PROTECTIVE UTTILITIES
1. Welding helmet with filter shade at least 10
2. Welding gl ves
3. Welding apr n and cl th
4. Welding b ts
RISK OVERVIEW
1. Risk f electric sh ck.
2. Ultravi let light and light radiati n
3. Risk f inhaling gas fumes and dust particles
4. Burns
5. N ise

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ALFA IN a.s. © www.alfain.eu
NOTE
1. It is f rbidden t perate a machine with damaged insulati n f the
welding t rch r supply cable.
2. Never perate the machine taken d wn r damaged c vers.
3. It is f rbidden t perate the machine in wet envir nments and utd rs
in rain r sn w.
4. Ensure pr per gr unding clamping pliers, which als reduces the risk f
electric sh ck.
5. Use prescribed pr tective utilities, keep them dry.
6. Arc welding pr duces intense electric and magnetic emissi ns that may
interfere with the pr per functi n f cardiac pacemakers, hearing aids, r
ther electr nic health equipment. Pers ns wh w rk near plasma arc
cutting applicati ns sh uld c nsult their medical health pr fessi nal and
the manufacturer f the health equipment t determine whether a hazard
exists.
7. Never aim the t rch against the eyes, b dy r ther pers n.
. CONDITIONS OF USE
1. This equipment must nly be used by qualified pers nnel.
2. During installati n, any electric w rk must nly be carried ut by trained
pers nnel.
3. Device c mplies with IEC 61000-3-12.
4. D n t exp se the plasma machine t direct sunlight r t rain r sn w. This
equipment c nf rms t pr tecti n rating IP23S.
5. W rking ambient temperature between -10 and +40 °C.
6. Relative humidity bel w 90% at +20 °C.
7. Up t 3000 m altitude.
8. Place the machine the way that the c ling air can enter the vents with ut
restricti n t . It is necessary t ensure that n impurities, especially metal
particles are n t drawn int the machine.
9. Welding machine in terms f interference suppressi n is intended primarily
f r industrial premises. In the case f use f ther areas may be need f r
special measures (see EN 60974-10).
10. The stability f the machine is guaranteed up t 10° inclinati n under
the f ll wing c nditi ns:
a. The machine must be secured against r lling away
b. The gas b ttle with a maximum height f 0.9 m may be placed and
pr perly anch red n the platf rm
11. The machine must be pr tected against
a. M isture and rain and sn w
b. Mechanical damage

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ALFA IN a.s. © www.alfain.eu
c. Draft and any ventilati n f neighb uring machine
d. Excessive verl ading - cr ssing technical parameters
e. R ugh handling
ELECTROMAGNETIC COMPATIBILITY
The welding device is in terms f interference designed primarily f r industrial
areas. It meets the requirements f EN 60974-10 class A and it isn’t designed
f r using in residential areas, where the electrical energy is supplied by public
l w-v ltage p wer supply netw rk. It can be here p tential pr blems with
ensuring f electr magnetic c mpatibility in this areas, due t interference
caused by p wer lines as well as the radiated interference. During perati n,
the device may be the s urce f interference.
Cauti n
We warn users, that they are resp nsible f r p ssible interference fr m
welding.
4. TECHNICAL DATA
ALF 182 BASIC AXE
Meth d MIG/MAG
Mains v ltage V/Hz 3 x 400/50
Welding current range A 60 - 180
Open-circuit v ltage U20 V 22,8 - 37,9
Mains pr tecti n A 10 @
Max. effective current I1eff A 5,9
Welding current (DC=100%) I2 A 130
Welding current (DC=60%) I2 A 150
Welding current (DC=x%) I2 A 40%=180
V ltage steps 7
Pr tecti n IP 23S
Standards EN 60 974-1, EN 60 974-10 cl.A
Dimensi ns (w x l x h) mm 474 x 888 x 561
Weight kg 61
Wire speed m/min 1 - 17
Wire speed (f r KTC versi n) m/min 1,5 - 10
Sp l diameter mm 300
Sp l weight kg 18

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ALFA IN a.s. © www.alfain.eu
ALF 222 BASIC AXE
Meth d MIG/MAG
Mains v ltage V/Hz 3 x 400/50
Welding current range A 60 - 210
Open-circuit v ltage U20 V 24,1 - 42,8
Mains pr tecti n A 16 @
Max. effective current I1eff A 7,7
Welding current (DC=100%) I2 A 150
Welding current (DC=60%) I2 A 170
Welding current (DC=x%) I2 A 40%=210
V ltage steps 7
Pr tecti n IP 23S
Standards EN 60 974-1, EN 60 974-10 cl.A
Dimensi ns (w x l x h) mm 474 x 888 x 561
Weight kg 65
Wire speed m/min 1 - 17
Wire speed (f r KTC versi n) m/min 1,5 - 16
Sp l diameter mm 300
Sp l weight kg 18
Machines ALF 182 – 222 BASIC KTC aXe differ fr m the riginal versi n f
the machine in parameter values f pregas time and p stgas time:
 Pregas time 0,1 s
 P stgas time 0,5 s
5. ACCESSORIES
DELIVERED WITH THE MACHINE
1. Earthing cable 3m with a clamp
2. Feed r ll 0,6 - 0,8 mm f r ALF 182; 0,8 – 1,0 mm f r ALF 222
3. Gas h ses
ACCESSORIES TO ORDER
1. Wire cleaner
2. CO2 Gas pre heating cable
3. Reducti n valve KU 5, K 2
4. Gay cylinder
5. T rch c nsumables
6. Earthing cable 4 - 5 m

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ALFA IN a.s. © www.alfain.eu
7. Feed r lls 0,6-0,8 f r carb n steels, aluminium, flux c re wires
8. Welding t rches
6. DESCRIPTION OF THE APPLIANCE
MAIN PARTS
Fig. 1 - Main parts
A1
ON / OFF Switch
A2
V ltage switch
A3
LED ON Indicat r
A4
W rk leads
A5
LED ver heating indicat r
A6
Wire speed p tenti meter
A7
EURO c nnec
t r
A8
Gas heater c nnect r
A9
S len id Valve
–
gas c nnect r
A10
Mains cable
A11
Chain f r fixing the gas cylinder

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ALFA IN a.s. © www.alfain.eu
A12
Wire Feeder
A13
Sp l H lder
CONTROL PANEL - OVERVIEW
Fig. 2 - C ntr l panel
A1
PCB
-
enc der ON / OFF Switch
A2 V ltage switch
A3
LED ON Indicat r
A5
LED ver heating indicat r
P1
Wire speed p tenti meter
P2
Sp t
time p tenti meter
P3
Interval time p tenti meter
WIRE FEEDER
Fig 3 – Wire feeder
P s.
Descripti n
E1
Fixing shaft
E2
Pressure arm

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ALFA IN a.s. © www.alfain.eu
E3
Liner
-
Feeder
E4
EURO c nnect r
E5 R ll, Plastic cup
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
1,6
-
2,0
2513
Flux c re
0,8
-
1,0
2318
N te: Largest permissible diameter f the wire is 1,0 mm.

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ALFA IN a.s. © www.alfain.eu
7. GETTING STARTED
Getting started must be c nsistent with technical data and c nditi ns f use.
Fig 4 – Earthing cable c nnecting
B1
Eur c nnect r female
B2
T rch Eur c nnect r
B3
Welding t rch
C1
W rk lead
C2
Earthing c
lamp
1. C nnect the earthing clamp C2 t the welding piece.
2. C nnect the B1 and B2 t rch c nnect rs t gether. Screw them up pr perly
by mean turning the B2 cl ckwise.
3. Plug the mains plug t 3x400 V mains.
4. Switch the machine n by the ON/OFF switch A1.
INSERTING THE WIRE
Fig. 5 – Sp l h lder
1. Open the side c ver f the wire feeder space.
2. Put the wire sp l n the wire sp l h lder D1 using the adapter D and fix
it with the fixing nut D2.
3. Cut ff the curved r damaged end f welding wire and lead it thr ugh the
inlet liner E , and the r ll int the liner inside the EURO t rch c nnect r
D1
Sp l h
lder
D2
Nut
sp l h
lder
D3
Adapter

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ALFA IN a.s. © www.alfain.eu
(ab ut 5 cm). Make sure, that y u use the suitable gr ve.
4. Put the pressure arm E2 d wn in that way, that the teeth r the gear fit and
fix it by setting the lever E1 int vertical p siti n.
5. Adjust the pressure nut that way that it pr vides c nstant m vement f wire
but it d es n t def rm wire.
INSERTING THE WELDING WIRE INTO THE WELDING TORCH
1. See the manual f the welding t rch.
2. Take ff the t rch gas cup.
3. Take ff the t rch tip.
4. Press the t rch trigger, the wire will start feeding int the t rch.
5. When the wire reaches the end f the t rch, release the trigger, screw n
the tip and the n zzle.
CHANGING THE WIRE FEEDER ROLL
1. Every wire feeding r ll in ALFA IN machines can be used f r tw different
diameters f welding wire – the r lls have tw gr ves.
2. When the machine is equipped with tw r ll wire feeder m ve the lever E1
t the right (2 r ll feeder)/ f rward (4 r ll feeder). The pressure arm shall
p p up.
3. Unscrew the plastic fixing cup E5 and take ff the r ll
4. In case there is suitable gr ve n the r ll, turn it ar und and fix it back t
the feeder.

 
ABC
Fig. 6- The influence f the r ll gr ve n the wire
A
C rrect
B
Wr ng
C
Wr ng

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ALFA IN a.s. © www.alfain.eu
ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
1. F r feeding the AL wire it is necessary t use r ll with the “U” pr file f the
gr ve. T prevent pr blems with feeding use wires with diameter 1,0 r
m re mm f AlMg3 r AlMg5. The t rch must be equipped with Tefl n liner
and special tip. As shielding atm sphere use Arg n.
Fig 7 – Set f r welding aluminium
G1
EURO c nnect r
G2
R lls
G3
Liner terminal f r 4,0mm, 4,7mm uter diameter
G4 O – ring 3,5x1,5mm
G5
Nut
G6
Tefl n Liner
G7
Sustain pipe f r tefl n and plastic liner
GAS FLOW SETTING
The electric arc and the weld must be perfectly shielded by gas. T small
am unt f gas d es n t perf rm the pr tective atm sphere and n the ther
hand t big am unt f the gas brings air int the electric arc.
Fig. 8 – Gas fitting

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ALFA IN a.s. © www.alfain.eu
F1
Gas Cylinder
F2
Cylinder
Valve
F3 Gas heater c nnect r
F4
Pressure Reducer
F5
High Pressure Man meter
F6
L w Pressure Man meter
F7
Adjusting Screw
F8
Gas utlet
F9
S len id Valve
F10
Chain
1. Place the gas cylinder n the platf rm and fix it pr perly by the fixing chain.
We rec mmend using b lts and nuts t fix it m re safely.
2. C nnect the pressure reducti n valve n the gas cylinder.
3. C nnect the gas h se t gas utlet F8 n the valve and the gas inlet F9 n
the machine.
4. In case y u use gas CO2 it may be needed t use suitable gas heater ( nly
ab ve 6 l/min). C nnect the heater t the F heater c nnect r ( pti nal).
Use type c rresp nding t v ltage and current given n the shield.
5. Open the F2 cylinder valve.
6. Press the t rch trigger.
7. Adjust the am unt f gas n the reducti n gas valve (it is n t a part f the
welding machine) by the F7 adjusting screw.
8. Release the t rch trigger.
8. WELDING
F r rientating adjusting f the welding current and v ltage y u can use
empirical relati n U2 = 14+0,05 2. Fr m that y u can specify desired v ltage.
SETTING WELDING CURRENT AND VOLTAGE
When the wire had been installed and gas had been set it is p ssible t start
welding.
The appliance must be plugged int the mains, the ON/OFF switch A1 n "I".
T select the v ltage use step switch A2.
T select the current (that is linked t the wire speed) use the p tenti meter
A6 (P1).

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ALFA IN a.s. © www.alfain.eu
WELDING MODES
Machines w rks in f ur m des:
1. Cc ntinu us tw str ke (2T)
2. C ntinu us f ur str ke (4T)
3. Sp t welding
4. Interval welding
TWO STROKE
P2
P3
B th p tenti meters P2, P are in the OFF p siti n. Welding
pr cedure starts by pressing the butt n in the t rch handle. It is necessary t
keep the butt n pressed all the time during welding. The welding st ps by
releasing the t rch butt n.
1
2
Welding pr ces
FOUR STROKE
P2
P3
The f ur str ke m de is being used m stly f r l ng welds, when
there is n need t h ld the t rch butt n pressed. The left p tenti meter P2 is
in the OFF p siti n, the right p tenti meter P is in the ON p siti n. The
welding pr cedure start by pressing the t rch butt n; after releasing the t rch
butt n the welding c ntinues. The welding st ps after the sec nd pressing and
releasing the t rch butt n then.
1- 2
3 - 4
Welding pr ces

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ALFA IN a.s. © www.alfain.eu
SPOT WELDING
P2
P3
The sp t welding m de is being used f r welding sh rt welds f
the same length. The length (welding time) can be set by the left p tenti meter
P2, the right p tenti meter P must be in the OFF p siti n. The pressing the
t rch butt n activates the time circuit that starts and end the welding
pr cedure.
1
2
Welding pr ces
1
2
Welding pr ces
INTERVAL WELDING
P2
P3
The interval welding m de is being used f r welding repeated
sh rt welds f the same length f welding time and the pause time. The length
f welding time can be set by the left p tenti meter P2, the pause by the right
p tenti meter P . By pressing the t rch butt n activate the time circuit that
starts and end the welding pr cedure.
1Welding pr ces
2
Welding pr ces
Pause

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ALFA IN a.s. © www.alfain.eu
BURN BACK SETTING
(n t applicable t KTC machine versi n)
1234568 79101112
t
300ms
max
t
20 ms
min
Burn back time
Fig. 9 – Burn back time trimmer
The burn back functi n if set suitably prevents sticking the welding wire int
the welding tip. The default time is 50-80 ms. I tis p ssible t change the burn
back time by means f a trimmer placed n the rear side f the c ntr l b ard.
It is necessary t take ff the fr nt panel. Only a qualified pers n may curry
ut this perati n.

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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