Alfain aXe 200 IN PFC User manual

ALFA IN a.s. © www.alfain.eu aXe 200 IN PFC manual EN 03
WELDING MACHINE
aXe 200 IN PFC
OPERATING MANUAL

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CONTENT
1. INTRO UCTION ....................................................................................... 3
2. SAFETY INSTRUCTIONS AN WARNINGS ............................................ 4
3. TECHNICAL ATA .................................................................................... 7
4. EQUIPMENT ............................................................................................. 7
5. OPERATOR CONTROLS .......................................................................... 9
6. GETTING STARTE MIG/MAG .............................................................. 14
7. GETTING STARTE TIG ........................................................................ 20
8. GETTING STARTE MMA ...................................................................... 22
9. ROUTINE MAINTENANCE & INSPECTION ............................................ 22
10. STATEMENT OF WARRANTY .............................................................. 23
11. ISPOSAL ............................................................................................. 24

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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 aXe 200 IN PFC is the multi-function inverter power generators
welding by those methods
a) MIG/MAG in 2T, 4T, manually or synergistically with 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
aXe 200 IN PFC is equipped by system of Power Factor Correction (PFC) –
which enables operating on AC power supply of 95V – 270V.
What are the advanta es 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.

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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. uring 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.
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. o not expose the welding machine to direct sunlight or to heavy rain. This
equipment conforms to protection rating IP23S.
11. uring 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 RA IATION 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.
17. The operator must NEVER weld containers that have previously contained
petrol, lubricants, gas or similar flammable materials, even if the container

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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:
20. o not work in a damp or humid environment.
21. o 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.
25. EN 60974-1 Standard: Open-circuit voltage. uring 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 68V.
26. The maximum open-circuit voltage of the welding machines is established
by national and international standards (EN 60974-1) 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.
27. 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
C current: 113V
peak value
AC current: 68V
peak value and
48V effective
2 Places without increased risk
of electric shock
C current: 113V
peak value
AC current: 113V
peak value and
80V effective
3
Torches held mechanically
with increased protection for
the operator
C current: 141V
peak value
AC current: 141V
peak value and
100V effective
28. 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

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symbol:
S
29. Before opening the machine switch off the machine and disconnect it from
the power socket.
30. Only personnel authorised by this company can carry out maintenance on
the machine.
NOTE:
evice complies with IEC 61000-3-12.
ELECTROMAGNETIC COMPATIBILITY
The welding device is in terms of interference designed primarily for industrial
areas. It meets the requirements of EN 60974-10 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. uring operation, the
device may be the source of interference.
Caution
We warn users, that they are responsible for possible interference from
welding.

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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 - 140
10 - 120
10 - 120
25 - 200
10 - 200
10 - 200
Open-circuit voltage
U
20
V 68,0 68,0
Mains protection A 20 @ 16 @
Max. effective current
I
1eff
A 17,0 18,0 17,0 15,8 16,0 13,2
Welding current
( Z=100%) I
2
A 90 80 90 140 120 150
Welding current
( Z=60%) I
2
A 120 100 110 170 140 180
Welding current
( Z=x%) I
2
A 30%
=
140
30%
=
120
35%
=
120
35%
=
200
30%
=
200
40%
=
200
Protection
IP 23S
Standards
EN 60974-1, EN 60974-10 cl. A
imensions (w x l x
h) generator
mm 474 x 911 x 670
Weight kg 44,5
Wire speed m/min
1,5 -
16,5
--- --- 1,5 -
16,5
--- ---
Spool diameter mm 300 --- --- 300 --- ---
Spool weight kg 18 --- --- 18 --- ---
4. EQUIPMENT
PART OF DELIVERY
Item No. Description
5.0286 aXe 200 IN PFC
VM0321-2 Hose Gas 3m Pegas quick connector G1/4
VM0023 Earthing Cable 3 m 400 A 35mm2 35-50
K910-1 Adapter up to 18 kg
ACCESSORIES TO ORDER
Item No. Description
SGB25-3 Torch PARKER SGB 250 3m (MIG/MAG)
SGB25-4 Torch PARKER SGB 250 4m (MIG/MAG)
SGB25-5 Torch PARKER SGB 250 5m (MIG/MAG)
STH24-3 Torch PARKER STH 240AE 3m Hybrid (MIG/MAG)

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STH24-4 Torch PARKER STH 240AE 4m Hybrid (MIG/MAG)
STH24-5 Torch PARKER STH 240AE 5m Hybrid (MIG/MAG)
17FSL4ST Torch PARKER SGT 17 4m 35-50 FX ST (TIG)
5847 Set Connectors PEGAS AC/ C Smart, 201 MIG SYN PFC,
aXe 200 IN PFC
VM0253 Welding Cable Set 2x 3m 35-50 200A
Rolls – see
OVERVIEW OF ROLLS FOR WIRE FEE
6008 Pressure Reducer FIXICONTROL Ar 2 manometers
6124 Pressure Reducer BASECONTROL Ar 2 manometers
6125 Pressure Reducer BASECONTROL CO2 2 manometers
S777a Welding Helmet ALFA IN S777a Black
4488 Wire 0.8 Coreshield 15 A 200 Self Shielding 4,5kg spool
6050 Set for Aluminium with roll AL 22/30 0,8-1,0
5950 Set SGT, SR 17/18/26d=1,6
5951 Set SGT, SR 17/18/26d=2,4
5952 Set SGT, SR 17/18/26d=3,2
700.0306.10 Electrode wolf.1.6x175-Violet
700.0308.10 Electrode wolf.2.4x175-Violet
700.0310.10 Electrode wolfram E3 3.2x175 - violet

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5. OPERATOR CONTROLS
MAIN PARTS OF THE MACHINE
1.Fig. Main parts of the machine

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Pos. Description
A1 Main switch
A2 PCB control panel
A3 Quick connector (+)
A4 Quick connector (-)
A5 EURO connector
A6 Wire feeder
A7 Spool holder
A8 Gas valve
A9 Mains cable
A10 TIG torch control connector
B1 EURO connector
B2 EURO connector male
B3 Torch
C1 Quick connector male
C2 Earthing clamps
C3 Quick connector (+)
C4 Quick connector (-)
F1 Gas bottle
F2 Cylinder valve
F3 Pressure reducer
F4 High pressure manometer
F5 Low pressure manometer
F6 Adjusting screw
F7 Gas outlet
F8 Soneloid valve
F9 Chain

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CONTROL PANEL
Fig. 2. Control panel
Pos. Description
V1 LE . If it lights, the mode 4T has been selected.
V2 Button: 2T / 4T
V3 LE . If it lights, the mode 2T has been selected.
V4
Encoder
Wire speed for MIG/MAG
Current for MMA and TIG
V5 Button: method selection (MIG/MAG, MMA, TIG)
V6 isplay
V7 LE . If it lights, on the left display is shown welding current in A.
V8 LE . If it lights, on the left display is shown wire feed speed in
m/min.
V9 isplay

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V10 LE . If it lights, on the right display is shown voltage in V.
V11 LE . If it lights, on the right display is shown value of ARC FORCE.
V12 LE . If it lights, on the right display is shown time of OWN SLOPE
in s.
V13 LE . If it lights, the machine is switched on.
V14 LE alarm (If it lights, in mains is overvoltage or undervoltage, or
the machine is overheated.)
V15
Encoder
Voltage for MIG/MAG
Correction for MMA
OWN SLOPE for TIG
V16 Choke potentiometer
V17 Main switch
Fig. 3. Secondary control panel – panel in the space of the wire feeder
Pos. Description
32 Switch Remote. ON – on the remote control
OFF – of the remote control
33 Switch Spool Gun. In the ON position one can weld with the Spool
Gun
34 Potentiometer for the BURNBACK time setting
35 Potentiometer for the initial wire speed setting
36 Potentiometer for the PRE GAS time setting

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37 Potentiometer for the POST GAS time setting
38 Gas setting button
39 Wire feeding button
WIRE FEEDER
Fig. 4. Wire feeder
Pos. Description
E1 Nut of pressure arm
E2 Pressure arms
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
2187
0,8-1,0 2188
Aluminum
0,8-1,0 2270
Flux core
0,8
-
1,0
2318
1,0
-
1,2
2319
6. 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. 5. The influence of the roll groove on the welding wire
A Correct
B Wrong
C Wrong

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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. 6. Spool holder
INSERTING THE WIRE TO THE TORCH AND CONNECTION OF EARTHING
CABLE
1. Connect the MIG/MAG torch to the EURO connector A5 on the machine
while the machine is turned off.
2. Connect the earthing cable to the quick connector A4 (-).
3. Connect the earthing clamps to the welder 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.
7. Connect the machine to power supply.
8. Turn the main switch A1 on the front panel to ON.
9. By means of the button V5 and encoder V15 select required MIG/MAG
program.
10. By means of the button V2 select 2T or 4T, appropriate LE V1 or
V3 will light.
11. Press the button 39 in the space of the wire feeder. The welding wire
is fed into the torch. After coming off from the torch tube, screw the current
Pos.
Description
1
Spool Holder
2 Nut Spool Holder
3
It is not
for this
welder

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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 valve A8.
2. Press the button 38 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. 7. Gas flow setting
Pos. Description
F1 Gas bottle
F2 Cylinder Valve
F4 Pressure Reducer
F5 High Pressure Manometer
F6 Low Pressure Manometer
F7 Adjusting Screw
F8 Gas outlet

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ADJUSTING WELDING PARAMETERS FOR MIG SYN
Synergic curves are created for PA welding positions - horizontally from above.
Perform the correction of welding arc for welding in other positions.
Program No. 13 is created for wire 0,8 Coreshield 15A 200/4,5 kg self-shielding
(Order No. 4488). You don’t need protective gas for welding with this wire (in this
case you weld without gas nozzle on the torch).
Recommendation – For perfect manual tack welding (for example for car
bodywork repairs) use the machine in the MIG Manual mode.
1. Open the door of wire feeder space. On the door is program table (program
table is in the text below, too).
2. Select the program number according to the work, which you will do. (For
example: if you want to weld steel with solid wire (solid wire has diameter
0,8) and you have available the mixed gas 82% Ar + 8% CO2. This
corresponds to the program number 8.)
3. Press the button V5 and by means of the encoder V15 choose program
number.
4. By pressing the button V5 confirm the choice.
5. By means of the encoder V4 choose the appropriate welding current.
6. By means of the encoder V15 modify the voltage correction (if needed).
7. By means of the potentiometer V16 modify the welding arc by changing
the level of choke.
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

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relationship, we can determine the required voltage. When setting the
voltage, we expect the decline in voltage during load. The voltage drop is
approximately 4,8 V at 100 A.
2. By means of the encoder V15 select voltage.
3. Then by means of the encoder V4 select the appropriate wire speed.
4. By means of the potentiometer V16 tune the arc by changing the levels of
choke.
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 - 7,0
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 forward (at 4-rolls wire feeder), pressure rolls E2
will be opened upward.
2. Unscrew the plastic locking element 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.
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 K3 is connected to the central EURO connector of the
MIG/MAG torch. We supply the welder with K3 connected by means of the
bridge K2 to (+) K1.
4. In case of welding with flux core wire with negative polarity, connect K3 by
means of the bridge K2 with K4 (-) terminal.
5. Make sure you fasten the terminals properly.

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6. Connect the earthing cable to the quick connector (+), fig. 1, pos. A3.
Fig. 8. Terminals for changing the polarity of the MIG/MAG torch
Pos.
Description
K1
Upper terminal (+)
K2
Bridge
K3
Middle terminal
K4
Lower terminal (
-
)
ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
For feeding the AL wire it is necessary to use roll with the “U” profile - see
paragraph

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OVERVIEW OF ROLLS FOR WIRE FEE . To prevent problems with feeding
use wires with diameter 1,0 mm of AIMg3 or AlMg5. Wire of alloy Al99,5 or AlSi5
are too soft and easily will cause problems with movement.
For the aluminium welding it is also necessary to provide the torch tefl. liner and
special current nipple. We do not recommend you to use the torch longer than 3
m. Great attention must be paid to adjust the contact power of rolls – it must not
be too high, otherwise there is a deformation of the wire.
As a protective atmosphere is necessary to use argon.
Fig. 9. Customization of the feed for the aluminium wire
Pos. Order No. Description
6050 Set for Aluminium with roll AL 22/30 0,8-1,0
G1 EURO connector
G2 Rolls
G3 Liner terminal (part of liner G6)
G4 O-ring 3,5 x 1,5mm to prevent escape of gas
(part of liner G6)
G5 Nut (part of EURO connector G1)
G6 Liner tefl.
G7 Support tube 4,4/5,0 200mm
7. GETTING STARTED TIG
Getting started must be consistent with technical data and conditions of use.
1. Connect the TIG torch to the quick connector A4 (-), next connect the gas
connector and torch connector.
2. Connect the earthing cable to the quick connector A3 (+) and the earthing
clamps to the welder or to the welding table.
3. Connect the machine to power supply and turn the main switch A1 on the
front panel to ON.
4. Connect the gas hose and gas flow adjustment described in A JUSTMENT
OF GAS FLOW.
5. Press the button V5 and by means of the encoder V15 choose the program
number 3.