Alfain ALF 251 aXe User manual

ALFA IN a.s. © www.alfain.eu Version 1
MIG/MAG WELDING MACHINES
ALF 251 aXe
ALF 261 aXe
ALF 280 aXe
ALF 320 aXe
ALF 400 aXe
MINOR2 - MAJOR – SYNERGY
BASIC
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..........................................................................8
4. TECHNICAL DATA................................................................................8
5. ACCESSORIES...................................................................................10
6. DESCRIPTION OF THE APPLIANCE .................................................11
7. GETTING STARTED...........................................................................18
8. WELDING............................................................................................22
9. ROUTINE MAINTENANCE & INSPECTION........................................27
10. STATEMENT OF WARRANTY............................................................28
11. DISPOSAL...........................................................................................28

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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.
ALF 251/261/280/320/400 aXe are three phase sturdy welding machines for
MIG/MAG welding.
The machines are designed to produce maximum power output combined
with high reliability and efficiency.
The users interface is as simple as possible; however, there are secondary
parameters that can be set from the main front panel if suitable. All of them
are available in compact models, ALF 280, 320 and 400 can be ordered also
as sets consisting of the generator, interconnection cable bundle and
separate wire feeding unit. We will refer to the MINOR2-MAJOR and
SYNERGY controls as DIGITAL.
CONTROL MODEL BASIC MINOR2 MAJOR
SYNERGY
A + V meter optional NO YES YES
Wire initial speed (Soft Start) NO NO YES YES
Advice of the parameter settings
NO NO NO YES
Electronic feedback of the wire
speed NO YES YES YES
2 stoke / 4 stroke YES YES YES YES
Adjustable Post and Pre Gas
time NO YES YES YES
Spot and Interval welding YES YES YES YES
Adjustable Burn Back Time NO YES YES YES

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ALFA IN a.s. © www.alfain.eu
2. SAFETY INSTRUCTIONS AND WARNINGS
•OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN
BE DANGEROUS AND HAZARDOUS TO YOURHEALTH.
•Arc welding produces intense electric and magnetic emissions that may
interfere with the proper function of cardiac pacemakers, hearing aids, or
other electronic health equipment. Persons who work near arc welding
applications should consult their medical health professional and the
manufacturer of the health equipment to determine whether a hazard
exists.
•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 generator in series or in
parallel.
•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.
•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 cutting.
•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 arc 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.
•Keep all fumes and gases from the breathing area.
•Keep your head out of the fume plume.
•Use an air-supplied respirator if ventilation is not adequate to remove all
fumes and gases.
•The kinds of fumes and gases from the plasma arc depend on the kind of

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metal being used, coatings on the metal, and the different processes.
You must be very careful when welding any metals which may contain
one or more of the following:
Antimony Chromium Mercury
Nickel Cobalt Arsenic
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
•Always read the Material Safety Data Sheets (MSDS) that should be
supplied with the material you are using. These MSDSs will give you the
information regarding the kind and amount of fumes and gases that may
be dangerous to your health.
•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.
•Noise can cause permanent hearing loss. Welding arc processes can
cause noise levels to exceed safe limits. You must protect your ears from
loud noise to prevent permanent loss of hearing.
•To protect your hearing from loud noise, wear protective ear plugs and/or
ear muffs. Protect others in the workplace.
•Noise levels should be measured to be sure the decibels (sound) do not
exceed safe levels.
•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 cutting 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 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 clamps.
•The maximum open-circuit voltage of the plasma machines is
established by national and international standards (EN 60974-1)
depending on the type of 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
4 Plasma cutting DC current: 500V
peak value
•In case 1, the dc 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.
2.1 ELECTROMAGNETIC COMPATIBILITY (EMC)
This 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.).

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ALFA IN a.s. © www.alfain.eu
•Computers, robots, electro-medical instruments and life-support
systems.
•Radio-television transmitters and receivers.
•Pacemakers and hearing aids.
•All very sensitive electrical equipment.
The operator is responsible for the installation and use of the cutting
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.
2.2 PROTECTIVE UTTILITIES
•Welding helmet with filter shade at least 10
•Welding gloves
•Welding apron and cloth
•Welding boots
2.3 RISK OVERVIEW
•Risk of electric shock.
•Ultraviolet light and light radiation
•Risk of inhaling gas fumes and dust particles
•Burns
•Noise
 NOTE 
• It is forbidden to operate a machine with damaged insulation of the
welding torch or supply cable.
•Never operate the machine taken down or damaged covers.
• It is forbidden to operate the machine in wet environments and
outdoors in rain or snow.
• Ensure proper grounding clamping pliers, which also reduces the risk
of electric shock.
• Use prescribed protective utilities, keep them dry.
• Arc welding produces intense electric and magnetic emissions that
may interfere with the proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near
plasma arc cutting applications should consult their medical health
professional and the manufacturer of the health equipment to
determine whether a hazard exists.
•
Never aim the torch against the eyes, body or other person.

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3. CONDITIONS OF USE
•This equipment must only be used by qualified personnel.
•During installation, any electric work must only be carried out by trained
personnel.
•Do not expose the plasma machine to direct sunlight or to rain or snow.
This equipment conforms to protection rating IP23S.
•Place the machine the way that the cooling 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.
•Welding 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).
• The machine must be protected against
a) moisture and rain and snow
b) mechanical damage
c) draft and any ventilation of neighbouring machine
d) excessive overloading - crossing technical parameters
e) rough handling
4. TECHNICAL DATA
ALF 251 ALF 261
Mains voltage V/Hz
3x400/50 3x400/50
Mains protection A 16 16 T
Max. input power I1 A 17,0 17,9
Max. effective current
I1eff A 10,4 8,9
Welding current
range A/V 25/15,3 - 250/26,5 25/15,3 - 260/27,0
Open-circuit voltage
U20 V 17,9 - 45,2 17,9 - 45,2
Welding current
(DC=100%) I2 /U2 A/V 170/22,5 170/22,5
Welding current
(DC=60%) I2 /U2 A/V 200/24 200/24,0
Welding current
(DC=x%) I2 /U2 A/V x=30% 250/26,5 x=25% 260/27,0
Voltage steps 10 10
Insulation class F F
Protection IP 23S IP 23S
Standards EN 60 974-1 EN 60 974-1
Dimensions (w x l x h)
compact mm 500x868x806
500x868x806

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Dimensions (w x l x h)
generator mm x x
Weight compact kg 76 76
Weight generator kg x x
Wire speed m/min
1 - 19 1 - 19
Spool diameter mm 300 300
Spool weight kg 18 18
ALF 280 ALF 320 ALF 400
Mains voltage V/Hz
3x400/50 3x400/50 3x400/50
Mains protection A 16 T 16 T 20 T
Max. input power I1 A 16,7 21,5 27,3
Max. effective current
I1eff A 8,4 10,8 13,7
Welding current
range A/V 40/16,0 - 290/28,5 40/16,0 - 340/31,0 50/16,5 - 400/34,0
Open-circuit voltage
U20 V 18,3 - 40,1 18,2 - 44,9 19,4 - 49,8
Welding current
(DC=100%) I2 /U2 A/V 170/22,5 200/24,0 240/26,0
Welding current
(DC=60%) I2 /U2 A/V 210/24,5 230/25,5 290/28,5
Welding current
(DC=x%) I2 /U2 A/V 30%=290/28, 5 25%=340/31, 0 25% = 400/34,0
Voltage steps 10 12 2 x 10
Insulation class F F F
Protection IP 23S IP 23S IP 23S
Standards EN 60 974-1 EN 60 974-1 EN 60 974-1
Dimensions (w x l x h)
compact mm 500x868x806
500x868x806
500x868x806
Dimensions (w x l x h)
generator mm 500x868x889
500x868x889
500x868x889
Weight compact kg 88 99 109
Weight generator kg 83 94 103
Wire speed m/min
1 - 19 1 - 19 1 - 19
Spool diameter mm 300 300 300
Spool weight kg 18 18 18
Wire Feed Unit PS4 GAS aXe
Wire speed m/min
1 - 19
Input voltage U
1
V/Hz 24/1~50
Input current I
1
A 4
Welding current I
2
(DZ=100%) A 320

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Welding current I
2
(DZ=60%) A 400
Spool diameter mm 300
Spool weight kg 18
Protection IP 21S
Dimensions (w x l x
h) mm 264x704x507
Unit weight (without
wire and torch) Kg 21
Standards EN 60974-5
5. ACCESSORIES
5.1 DELIVERED WITH THE MACHINE
•Earthing cable 3m with a clamp
•Feed roll 0,8 - 1,0mm
•Gas hoses
5.2 ACCESSORIES TO ORDER
•Wire cleaner
•CO2 Gas pre heating cable
•Reduction valve KU 5, K 2
•Gay cylinder
•Torch consumables
•Earthing cable 4 - 5 m
•Feed rolls 0,6-0,8 1,0-1,2 1,4-1,6 for carbon steels, aluminium, flux
core wires
•Torches with UP-DOWN remote control
•Welding torches (see the table below)
Torch type Cooling Welder
MB 24KD Gas ALF 251-280 aXe
MB 36KD Gas ALF 320 aXe
MB 36KD Gas ALF 400 aXe

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6. DESCRIPTION OF THE APPLIANCE
6.1 MAIN PARTS
Fig. 1 - Main parts of ALF compact aXe
Fig. 2 - Main parts of ALF compact aXe

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Fig. 3 – Main parts of ALF Separate aXe
Fig. 4 - Main parts of ALF Separate aXe
A1 ON / OFF Switch
A2 Switch coarse
A3 Switch smooth

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A4 Quick connector -
A5 Quick connector - -
A6 PCB control panel
A7 EURO connector
A8 Wire Feeder
A9 Spool Holder
A10 Solenoid Valve
A11 Mains Cable
A12 Feeder Holder Feeder
A13 Feeder Holder Generator
A14 Quick Connector
A15 Connector female
A16 Connector male
A17 Quick Connector male
A18 Clamp for the cable Bundle
A19 Clamp for the cable Bundle
A20 Cable Bundle Inlet Feeder
A21 Cable Bundle
A22 Cable Bundle Generator
A23 LED ON Indicator
A24 Gas heater connector
6.2 CONTROL PANEL - OVERVIEW
Fig. 5 - ALF 400 aXe control panel
V1 PCB - encoder
V2 ON / OFF Switch
V3 Switch coarse
V4 Switch smooth

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6.3 DIGITAL CONTROL PANEL MINOR2-MAJOR-SYNERGY
Fig. 6 – MINOR2-MAJOR-SYNERGY digital control panel
Pos. Symbol Description
X1 Button •Wire insertion
•default RESET (together with button X2)
X2 Button •Gas test
•default RESET (together with button X1)
X3
Button
•Switches between 2S or 4S,
•Press more than 3s will initiate spot or interval
mode
•Enters secondary parameters (together with
button X5)
X4 Green LED 2 Stroke

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X5
Button
•In MANUAL disabled
•In SYNERGY switches among A, wire speed or
material thickness
•Enters secondary parameters (together with
button X3)
X6 Green LED – lights if on the display X8 are displayed
Amperes (required setting), (just SYNERGY).
X7
Green LED - lights if on the display X8 is displayed
Wire Speed in m/min (required setting), (just
SYNERGY).
X8
Left Display X8, shows:
•Amperage (real or required)
•Wire speed
•Material thickness
•Program No
•Secondary parameters:
- ISP – initial speed (soft start) [%]
- PrG – Pre gas time [s]
- PoG – Post gas time [s]
- brn – Burn back time [s]
- SPo – Time of tack welding [s]
- Int - Time of interval [s]
X9 LED - Cooling circuit error
X10 LED - Lights after finishing welding and signals the
HOLD function of A+V (last measured parameters)
X11 LED - Thermal overheating. Leave the machine on to
cool down by means of the fans.
X12
Right Display
•Voltage (real)
•Values of the secondary parameters
•Switches and choke settings (Just SYNERGY)
X13 Position of the coarse switch (just SYNERGY)
X14 Position of the smooth switch (just SYNERGY)
X15 Position of the choke (just SYNERGY)
X16 LED – The mode of selecting the program is active
(just SYNERGY).
X17 Green LED – lights if on the display X8 is displayed
material thickness, (just SYNERGY).

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X18 LED - 4 Stroke
X19
LED
•When flashes, the interval welding mode has
been selected
•When illuminated, the spot welding mode has
been selected
X20
Encoder
•Sets wire speed (all models) , Amperage or
material thickness (just SYNERGY)
•Selects program No (just SYNERGY)
•Sets secondary parameters
6.4 BASIC CONTROL PANEL
Fig. 7 – BASIC control panel
V2 On/Off Switch
V3 Switch Coarse
V4 Switch Fine
V5 Wire speed
V6 Spot time
V7 Interval time
V8 LED ON

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V9 LED thermal protection
V10 Switch 2T/4T (optional)
V11 Wire insertion
V12 Gas test
V13 A meter (optional)
V14 V meter (optional)
6.5 WIRE FEEDER
Fig 8 – Wire feeder 4 rolls, 2 rolls
Pos. Description
E1 Fixing shaft
E2 Pressure arm
E3 Liner- Feeder
E4 EURO connector
E5 Roll, Plastic cup
PS 2(W) PS 4(W)
2-rolls 4-rolls
a = 22 mm a = 22 mm
ab
b = 30 mm b = 30 mm

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ALFA IN a.s. © www.alfain.eu
Grove type Wire diameter Item No
0,6-0,8 2187
0,8-1,0 2188
1,0-1,2 2189
1,4-1,6 2176
1,2-1,6 2511
Steel
2,0-2,4 2512
0,8-1,0 2270
1,0-1,2 2269
1,4-1,6 2315
1,2-1,6 2316
Aluminium
1,6-2,0 2513
0,8-1,0 2318
1,0-1,2 2319
1,2-1,4 2320
1,2-1,6 2321
1,6-2,0 2514
Flux core
2,0-2,4 2515
7. GETTING STARTED
Fig 9 – Earthing cable connecting
C1 Quick Connector Male
C2 Earthing Clamp
C3 Quick Connector -
C4 Quick Connector - -
•Connect the quick connector C1 into C3 or C4 (according the welding
current).
•Connect the earthing clamp C2 to the welding piece
•In case your appliance is a model with separate wire feeder connect the

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feeder with the generator by means of cable bundle A21.
•Plug the mains plug to 3x400 V mains.
•Switch the machine on by the ON/OFF switch A1
•There will appear type of the machine and software version on the
displays for ca 3 s time – not on BASIC.
•Then the machine will enter the manual program (P0) and on the left
display will be the wire speed in m/min (or the last parameters of previous
settings). On the right display will appear symbol --- (in manual P0
program) or the recommended settings (in programs P1 – P9) - not on
BASIC
7.1 INSERTING THE WIRE
Fig. 10 – Spool holder
•Open the side cover of the wire feeder space
•Put the wire spool on the wire spool holder D1 using the adapter D3 and
fix it with the fixing nut D2
•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.
•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.
•Adjust the pressure nut that way that it provides constant movement of
wire but it does not deform wire.
7.2 INSERTING THE WELDING WIRE INTO THE WELDING TORCH
D1 Spool Holder
D2 Nut Spool Holder
D3 Adapter

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Fig. 11 – Welding torch connecting
B1 EURO connector
B2 EURO connector male
B3 Torch
•Connect the torch B3 to the EURO connector B1 on the
•It is recommended to use torches form 2 up to 5 m long.
•Take off the torch gas cup
•Take off the torch tip
•Press the button inlet wire X1 for digital, V11 for BASIC
•When the wire reaches the end of the torch, release the button X1/V11,
screw on the tip and open nozzle.
7.3 CHANGING THE WIRE FEEDER ROLL
•Every wire feeding roll in ALFA IN machines can be used for two different
diameters of welding wire – the rolls have two grooves.
•When the machine is equipped with two roll wire feeder move the lever E1
to the right (2 roll feeder)/ forward (4 roll feeder). The pressure arm shall
pop up.
•Unscrew the plastic fixing cup E5 and take off the roll
•In case there is suitable groove on the roll, turn it around and fix it back to
the feeder.
∅ 1,0
1,0 1,20,8
ABC
Fig. 12- The influence of the roll groove on the wire
7.4 ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
•For feeding the AL wire it is necessary to use roll with the “U” profile of the
groove. To prevent problems with feeding use wires with diameter 1,0 or
more mm of AlMg3 or AlMg5. The torch must be equipped with Teflon
A Correct
B Wrong
C Wrong