Alfain ALFIN 300 AC/DC Operating instructions

ALFA IN a.s. © www.alfain.eu ALFIN 300 AC-DC manual EN 01
WELDING MACHINE
ALFIN 300 AC/DC
OPERATING AND MAINTENANCE MANUAL

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CONTENT:
1. INTRODUCTION...............................................................................3
2. WORK SAFETY................................................................................4
3. OPERATING CONDITIONS.............................................................5
4. TECHNICAL DATA...........................................................................7
5. ACCESSORIES................................................................................7
6. DESCRIPTION OF MACHINE AND FUNCTIONS...........................8
7. COMMISSIONING..........................................................................20
8. MMA WELDING..............................................................................25
9. DC TIG WELDING..........................................................................27
10. AC TIG WELDING ..........................................................................30
11. 2-STROKE (2T) AND 4-STROKE (4T) MODES.............................35
12. JOB MANAGEMENT ......................................................................37
13. RESET ............................................................................................38
14. MAINTENANCE AND SERVICE TESTS .......................................39
15. SERVICE ........................................................................................39
16. DISPOSAL OF ELECTRICAL WASTE...........................................41
17. WARRANTY....................................................................................41

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1.INTRODUCTION
Dear Consumer, ALFA IN a.s. thank you for purchasing our product, and
we hope you will be satisfied with our machine.
The welding machine may only be operated by trained persons within the
technical provisions. ALFA IN a.s. will not accept liability for damage
caused by improper use. Please read these operating instructions
carefully before putting the machine into operation.
The machines meet the requirements corresponding to the CE mark.
Use only original spare parts for maintenance and repairs. Our service
department is, of course, at your disposal.
If the machine is marked with the following mark
S
on the nameplate
or the control panel, it can be used for welding in areas with an increased
risk of electric shock.
The ALFIN 300 AC/DC is an inverter welding current generator that welds
in the following methods:
TIG AC
TIG DC
MMA
We reserve the right to make modifications and changes in case of printing
errors, changes in technical parameters, accessories, etc., without prior
notice. These changes may not be reflected in the instructions for use in
paper or electronic form.

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2. WORK SAFETY
PERSONAL PROTECTION
1. For safety reasons, protective gloves must be worn when welding.
These gloves protect you from electric shock (circuit voltage when idle).
They also protect you from heat radiation and splashing hot metal
droplets.
2. Wear sturdy, insulated footwear. Open shoes are not suitable as hot
metal droplets can cause burns.
3. Do not look into the welding arc without face and eye protection. Always
wear a good-quality welding hood with the protective filter intact.
4. Persons near the welding area must also be informed of the danger and
provided with protective equipment.
5. A sufficient supply of fresh air must be ensured when welding,
especially in small spaces, as welding produces harmful fumes.
6. Do not conduct welding near gas, oil, fuel, etc. tanks (even empty
ones), as there is a risk of explosion.
7. Special regulations apply in areas with explosion hazards.
8. Welded joints that are subjected to high stress must meet special safety
requirements. This applies in particular to rails, pressure vessels, etc.
These joints may only be made by qualified welders with the necessary
authorization.
9. Notice
Persons with implanted pacemakers must not work with the machines
or move close to them! There is a risk of impairing the function of the
pacemaker!
10. Stop welding immediately if the main cable is damaged. Do not touch
this cable. Pull it out of the socket.
SAFETY REGULATIONS
1. Before beginning any welding work, it is essential to become familiar
with the welding machine and the safety regulations for metal welding
and arc welding that are currently in effect in your country.
2. The CO2 bottle of mixed gases must be handled following the
regulations for working with pressure vessels.
3. The welder must use protective equipment.
4. When handling the machine using the lifting device, hang the machine
on all the suspension eyes (not standard equipment, not possible on
all ALFA IN machines). Other attachment methods are not permitted.
5. Before any intervention in the electrical part, removal of the cover or
cleaning, the device must be disconnected from the mains.

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3.OPERATING CONDITIONS
1. Commissioning of the instrument may only be carried out by trained
personnel and only within the technical provisions. The manufacturer is
not liable for damage caused by improper use and operation. Only use
original ALFA IN spare parts for maintenance and repair.
2. The equipment complies with IEC 61000-3-12.
3. The welding machine is tested according to the IP23S degree of
protection standard, which protects against solid bodies with a diameter
greater than 12 mm and protection against water ingress falling in a
vertical to oblique direction up to a slope of 60°.
4. Operating ambient temperature between -10 and +40 °C.
5. Relative humidity below 90% at +20 °C.
6. Up to 3000 m altitude.
7. The machine must be positioned so cooling air can enter and exit
unhindered through the air slots. No electronic components are located
in the cooling duct area, but care must be taken to ensure no metallic
waste is drawn into the machine (e.g. during machining).
8. It is essential to conduct a regular inspection on the welding machine
every 6 to 12 months, as per the regulations for the revision of electrical
equipment in your country and the rules for welding and safety
provisions for metal arc welding. It is recommended that an authorized
employee perform the inspection.
9. All interventions in the electrical equipment and repairs (removal of the
mains plug, replacement of fuses) may only be carried out by an
authorized person.
10. The relevant mains voltage and power supply must correspond to
the mains plug.
NoticeIf the machine has been moved from an area with a low
temperature to a significantly warmer environment, condensation may
occur, especially inside the welder. This will reduce the electrical strength
and increase the risk of electrical flashover on voltage-stressed parts,
seriously damaging the machine. If this situation occurs, leaving the
welder at rest for about 1 hour is necessary until the temperature has
equilibrated with the environment. This will stop any condensation. Only
after this time has elapsed can the welder be connected to the mains and
started.
11. The machine must be protected from:
a. Moisture and rain - it must not be operated in the rain!
b. Mechanical damage
c. Draughts and possible ventilation of adjacent machines

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d. Excessive overloading – exceeding technical parameters
e. Rough handling
12. The handling handle on machines with wheeled chassis is designed
for travelling only and not for lifting the machine.
13. Use only the designated transport equipment to transport the welder.
Do not use a forklift or single crate to move.
14. The stability of the machine is guaranteed up to an inclination of 10°
if the following conditions are met:
a. The machine must be secured against spontaneous movement,
b. The feed unit must not be mounted on the generator,
c. A gas cylinder with a maximum height of 0.9 m may be placed
on the platform and properly anchored.
15. The extension cables must not have conductors with cross-sections
smaller than 3x2.5 mm2 for single-phase machines. The machine may
be operated on a single-phase power generator of 6 kVA
(1x230V/50Hz) or more, with a voltage stabilization of ± 10%.
Generators with lower power can damage the machine.
NoticeDue to the installed capacity's size, the distribution
companies' approval may be required to connect the equipment to the
public distribution network.
ELECTROMAGNETIC COMPATIBILITY
Welding equipment is primarily designed for industrial environments in
terms of EMI. It complies with EN 60974-10 class A requirements and is
not intended for use in residential areas where the public low-voltage
supply network supplies electricity. There may be potential problems with
ensuring electromagnetic compatibility in these areas caused by line-
propagated and radiated interference.
During operation, the equipment may be a source of interference.
NoticeThe user is advised that he is responsible for any interference
from welding.

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4.TECHNICAL DATA
Method MMA TIG
Mains voltage V/Hz 3X400/50-60
Welding current range A 10 - 300 5 - 300
Open-circuit voltage U20 V59,0 9,0
Mains protection A20 @
Max. effective current I1eff A12,0 8,7
Welding current (DZ=100%) I2A180 180
Welding current (DZ=60%) I2A220 220
Welding current (DZ=x%) I2A 30%=300 30%=300
Protection IP23
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm 230 x 460 x 325
Weight kg 23,0
5.ACCESSORIES
PART OF DELIVERY
Code Name
5.0275 Alfin 300 AC/DC Inverter Welder
021.004.3360 Connector Alfin Orig.
ACCESSORIES TO ORDER
Welding torches
Name Cooling Max. load DC Max. load AC
PARKER SGT
18
Fluid
320A/100%
230A/100%
PARKER SGT
20
Fluid
220A/100%
160A/100%
PARKER SGT
26
Gas
180A/35%
130A/35%
A torch equipped with a potentiometer for remote control of the welding
current can be connected to the machines.
NoticeThe torch must be selected according to the current
range. ALFA IN a.s. is not responsible for damage to welding
torches due to overload.

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Other accessories
Code
Name
VM0108
Welding Cable Set 2x 3m 35
-
50
315A
2307
Connector Set na HF complete
2368
Connector ALFIN remote cont 021.004.0602
5.0050
Remote CTRL
complete 4m
006.003.0110 Remote CTRL foot pedal ctrl 10 m ALFIN
5.0225
CS 601 W Cooling Unit ALFIN AC/DC+ALFIN T
VM0151-1 Hose Gas 3m G1/4-G1/4
3549 Pressure Reducer AR OXY MAXI PC 2 manometry
5.0028 Trolley TIG
6.DESCRIPTION OF MACHINE AND FUNCTIONS
FRONT PANEL
Fig. 1 Front panel
Po
s
.
Description
P1 (-) Welding cable quick connector
A2 Connector for torch gas hose connection
J2 Connector for control from the welding torch
P2 (+) Welding cable quick connector

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BACK PANEL
Fig. 2 Back panel
Po
s
.
Description
H1 Remote control connector
C1 Supply cable 4 x 2.5 mm23.5 m long
A1 Connector for connecting the gas hose from the gas cylinder
Z1 Connector for water cooling connection
(If the water cooling is not connected, keep the connector
covered with a cap, as the mains voltage is applied!)
I1
Main switch
(When the main switch is in position I - on and the machine is
switched in MMA mode, there is voltage between the + and -
output terminals!)

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CONTROL PANEL
Fig. 3 Control panel
Pos.
Symbol
Function description
L1
DC TIG light illuminates when the O-START function
has been activated.
AC TIG light is on when the AC WAVE IN MIX AC/DC
function has been activated.
L2
DC TIG light illuminates when the DYNAMIC ARC
function has been activated.
AC TIG light illuminates when the FUSIONE EXTRA
function has been activated.
L3
DC TIG light illuminates when the MULTI TACK
function has been activated.
AC TIG If the light is on, you can change the AC
FREQUENCY parameter.
AC TIG If the light is on, you can change the AC TIG
BALANCE parameter.
AC TIG If the light is on, you can change the
ELECTRODE DIAMETER parameter.
L4 Lights up when there is voltage at the output sockets.
L5 Lights up in case of error.

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L6 Lights up when TIG PULSED mode has been
selected.
L7 If lit, the TIG SYNERGY PULS method is selected.
L8 If it is lit, the arc ignition with high-frequency current is
selected.
L9 If it is lit, the remote current setting is selected. If not
lit, control panel adjustment is selected.
L10 If lit, 2T mode is selected. If the LED is flashing,
double scoring mode is selected.
L11 If lit, 4T mode is selected.
L12
If lit, 4T
BILEVEL mode is selected.
L13 If lit, MMA mode is selected...
L14 If lit, DC TIG mode is selected.
L15 If lit, AC TIG mode is selected.
D1
Displays welding current settings
Displays the welding current values in A during
welding.
After welding, it displays the last measured value of the
welding current
-
HOLD FUNCTION.
D2 Displays the selected parameters and their values
E1 Encoder Changes the values of the welding current or the
values of selected parameters.
S1
AC TIG:
Press the button to select the parameter you want to
set. EXTRA FUSION, AC FREQUENCY, AC TIG
BALANCE.
S2 One press of the button opens the JOB menu. Holding the button for 3 seconds opens access to
save/delete JOBs.
S3
One button press allows you to select the parameters
of the first MENU level.
Holding the button for 3 seconds opens access to the
second MENU level

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If the button is held down with the machine switched off
and then switched on (button held down), the SETUP
MENU will open
S4 Mode selection button via torch button
Selects 2T, 4T and BILEVEL
S5 Welding method selection button
Select
MMA, TIG DC and TIG AC
DESCRIPTION OF FUNCTIONS AND TERMS
I1
Main welding current
t1
SLOPE
UP
I2
BASE CURRENT
t2
PEAK CURRENT TIME
I3
Final
current
t3
BASE CURRENT TIME
I4 Starting current t4 SLOPE DOWN
1/t2+t3 Pulse frequency
Welding parameters
Welding current
Welding current output.
Maximum welding current
Maximum welding current that can be achieved with the remote control.
Hot-start
It facilitates ignition; the risk of high values is the burning of weaker
materials, spattering during ignition and a large ignition area. A low value
makes it harder to ignite the arc.

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Arc-force
It helps to reduce the risk of the electrode getting stuck in the welding
bath. The weld is very fluid, and the arc is stable. The electrode
penetrates more into the weldment, causing more spatter.
Consequences of a low value: The arc goes out more quickly. Less
spatter.
VRD
It reduces the voltage at the output when it is not welding. If the function
is on, touching the weldment with the electrode is necessary when
welding starts. Voltage is then delayed. The welding voltage will then be
on the electrode for a few seconds.
Long arc voltage
It maintains the arc even if the distance of the electrode from the
weldment is more significant than usual. Consequences of high value:
The arc is maintained even at a relatively large distance from the welding
electrode. The consequence of a low value is that the arc is more easily
extinguished.
Remote control
Allows you to set the welding current from the remote control.
Dynamic Arc
The welding current is maintained at the set value, even if the distance
between the electrode and the weldment changes. The consequence of
the high value is a constant welding power, preventing the electrode from
sticking. The weldment can deform more easily.
Second BILEVEL current
By quickly pressing and releasing the torch button during welding (for less
than 0.5 seconds), the main welding current changes to the BILEVEL
welding current.
In TIG DC welding, the BILEVEL welding current is helpful when welding
materials of different thicknesses.
The BILEVEL welding current is useful in changing the heat output in
TIG AC welding. When the weldment is heated to the point where there

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is a risk of deformation, it is possible to reduce the current value by
simply pressing the torch.
Base current
Minimum pulse current. The consequence of the high value is a faster
formation of the melt bath. The thermally affected area is increased.
Peak time
The time for which the pulse current is at its maximum. The
consequence of a high value is a higher penetration; the consequence of
a lower value is a smaller thermally affected area, and it is harder to form
a melt bath.
Base time
The time for which the pulse current is at its maximum. The
consequence of a high value is a higher penetration; the consequence of
a lower value is a smaller thermally affected area, and it is harder to form
a melt bath.
Pulse frequency
The high-value results from a slower fusion rate and a smaller heat-
affected area.
Slope down
The time it takes to reduce the welding current to the end current
gradually.
End current
It allows the same appearance of the weld at the beginning and the end.
POST-GAS time
The time for which the shielding gas supply is ensured after the welding
arc is extinguished.

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PRE-GAS time
The time for which the shielding gas supply is ensured before the
welding arc is ignited.
Starting current
Current after arc ignition.
Slope UP
The time it takes to gradually increase the welding current from the
starting current to the main welding current.
TIG spot time
The arc is lit for a set period. The result is a very precise, unoxidized
weld without deformation of the sheet metal.
HF arc start
It ignites the TIG arc using HF current discharge. Prevents tungsten from
entering the weldment. HF discharges can damage electronic devices.
Minimum pedal current
Determines the minimum welding current achieved using the remote
control or foot pedal. It is set as a percentage of the maximum welding
current.
Q-start
Creates a faster welding bath. The function is particularly suitable for
spot joints on thin sheets.
Multi-tack
Allows welding of thin sheets without deformation. The consequence of
high values is the possibility to weld thin sheets without deformation.
Less material is melted, and the welding process is slower.

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AC pulse in AC/DC mode
Allows you to set the percentage time of the AC pulse relative to the DC.
Consequences: more weld penetration, less deformation, faster weld
bath formation, the "white" strip that forms next to the weld is narrower,
and the arc extinguishes more easily.
Extra Fusion
This parameter sets the percentage of the subtracted positive wave and
added to the negative wave. Consequences of higher values: more stable
arc, greater penetration, reduced cleaning ability, less electrode
deformation.
The following figure shows part of the positive wave after subtraction from
the positive wave and addition to the negative wave. The resulting wave
is dashed.
AC frequency
Allows you to adjust the AC frequency.
Consequences of higher values: concentrated arc, reduced heat affected
zone, slower melting speed.
The following figures show an example where the wave in the second
graph has twice the wave's frequency in the first graph.

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AC balance
Allows you to adjust the balance of the positive to negative part of the
wave.
Consequences of higher values: larger weld, the white stripe that appears
next to the weld is narrower.
The following figures show graphs with different wave balances. The first
graph represents a current curve with a more negative balance (larger
sag), where the percentage of the positive part of the wave is low
compared to the negative part.
The second graph represents a current curve with a more positive balance
(more clearing). In this case, there is a higher percentage of the positive
part of the wave than the negative part.
PARAMETER ACTIVATION
Some welding parameters are only possible in a particular welding mode
and when others are enabled. The table shows the possible settings of
each parameter.
always available
1: Available with an active user interface
2: Available with "remote control" = ON setting and remote control
connected
3: Available with setting "HF ARC START "= ON
4: Not available with active parameter "MULTI TACK "
5: Available with parameter "PULSE TYPE "= slow
6: Available with parameter "PULSE TYPE "= fast

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1
3
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5
4
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5
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5
4
1
2
3
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5
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1
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3
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6
5
4
1
3
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3
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4
4
1
2
3
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4
4
1
2
3
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4
4
1
2
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MODE

PROCEDURE

PARAMETER

WELDING CURRENT
MAX. WELDING CURRENT
HOT
-START
ARC
-FORCE
PRE
-GAS
STARTING CURRENT
SLOPE UP
SECOND BILEVEL CURRENT
BASE CURRENT
P
EAK TIME
PULSE
FREQUENCY
BASE
TIME
SLOPE DOWN
MENU

1°
1°
1°
1°
1°
1°
1°
1°
1°
1°
1°
1°
1°

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
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4
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4
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4
2
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4
2
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4
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4
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4
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2
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2
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4
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4
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4
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2
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4
2
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3
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4
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3 + 4
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4
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3 + 4
4
3
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2
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2
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3 + 4
4
3
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4
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3 + 4
4
3
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4
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2
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4
2
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3 + 4
4
3

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
MODE

PROCEDURE

PARAMETER

POST
-GAS
VRD
LONG ARC VOLTAGE
REMOTE CONTROL
FINAL
CURRENT
TIG
SPOT TIME
MINIMUM PEDAL CURRENT
HF ARC START
AC WAVE + FORM
Q
-START
DYNAMIC ARC
MULTI
-TACK
AC PULS IN AC
-DC MODE
EXTRA
FUSION
AC FREQUENCY
AC BALANCE
ELECTRODE DIAMETER
MENU

1°
2°
2°
2°
2°
2°
2°
2°
2°
SPECIAL
SPECIAL
SPECIAL
SPECIAL
SPECIAL
SPECIAL
SPECIAL
SPECIAL

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7.COMMISSIONING
The commissioning of the machine must be in accordance with the
technical data and operating conditions.
NOTICEOnly adequately trained persons may operate the
machine.
CONNECTION TO THE POWER GRID
Connect the machine using the supplied mains plug to a power source in
accordance with the technical data and operating conditions given in this
manual.
MACHINE PREPARATION FOR MMA MODE
1. Connect the electrode holder and ground cable to the quick
connectors P1 (-) and P2 (+) following the polarity required by the
electrode manufacturer on the electrode packaging.
2. Insert the electrode into the electrode holder.
3. Connect the cable with grounding clamps to the quick connector on
the front panel.
4. Attach the pliers to the weldment.
5. Turn on the machine with the main switch on the rear panel and start
welding.
NoticeBe careful that the electrode does not touch any
metallic material because in this mode when the machine is
switched on, the welding voltage is permanently applied to the
quick couplers of the welding machine.