Alfain aXe 250 PULSE Smart (AL)GAS User manual

ALFA IN a.s. © www.alfain.eu aXe 250-320 PULSE smart (AL manual EN 04
WELDING MACHINES
aXe 250 PULSE Smart (AL)
GAS
aXe 320 PULSE Smart (AL)
GAS / H2O
aXe 250 Smart GAS
aXe 320 Smart GAS / H2O
INSTRUCTION MANUAL

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CONTENT
1. INTRODUCTION ...................................................................................................3
2. SAFETY PRECAUTIONS .........................................................................................4
3. OPERATING CONDITIONS .....................................................................................5
4. TECHNICAL DATA .................................................................................................6
5. ACCESSORIES .......................................................................................................8
6. DESCRIPTION OF THE APPLIANCE .........................................................................9
7. BASIC SETTINGS ................................................................................................. 17
8. MIG/MAG ELDING SYNERGY .......................................................................... 24
9. PULSED MODE ................................................................................................... 25
10. MIG/MAG ELDING MANUAL ........................................................................... 26
11. MMA ELDING (COATED ELECTRODE- ELE) ....................................................... 27
12. ROUTINE MAINTENANCE & INSPECTION ............................................................ 28
13. DISPOSAL ........................................................................................................... 31

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1. INTRODUCTION
Dear Consumers!
Company ALFA IN a.s. thanks you for buying our product and believe that you
will be satisfied with our machine.
Welding machines aXe 250 PULSE smart (AL GAS and aXe 320 PULSE
smart (AL GAS/H
2
O are IGBT invertors. They are designed for welding
method MMA, MIG (Metal Inert gas and MAG (Metal Active Gas . This is
welding in protective atmosphere (methods MIG, MAG . We are using inert
(impassive and active gases during welding. These methods are very
productive and particularly suitable for the connections of structural steels.
With welding machines aXe 250 PULSE smart (AL GAS and aXe 320 PULSE
smart (AL GAS/H
2
O it is possible to weld different types of connections (blunt,
single-sided, double-sided, fillet, lap etc. using wire diameter from 0,6 – 0,8
mm, or 1,0 – 1,2 mm of different metals and alloys (carbon and alloy steels,
aluminum alloys etc. .
Welding machines aXe 250 smart GAS and aXe 320 smart GAS/H
2
O haven’t
pulsed mode. But it is possible to extend these machines about pulsed mode.
S
The machines can be used for welding in areas with increased
danger of electric shock. Machines comply with the relevant requirements for
CE marking.
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. SAFET PRECAUTIONS
PERSONAL PROTECTION
1. For safety reasons, it is necessary to use welding gloves during welding.
These gloves will protect you before intervention of electric current
(open circuit voltage . It protects you against thermal radiation and
splashing drops of hot metal too. Wear sturdy isolated shoes. Do not
wear open shoes, because drops of hot metal can cause burns.
2. Do not look into the welding arc without eye and face protection. Always
use good quality welding helmet with intact protective filter.
3. The persons appearing in the vicinity of the welding must be informed of
the danger and must be equipped with protective equipment.
4. During welding, especially in small spaces, it is necessary to ensure an
adequate supply of fresh air, because during welding, harmful fumes
arise.
5. In tanks of gas, oil, fuel, etc., (even empty ones do not make welding,
because there is a chance of explosion.
6. In areas with chance of explosion special provisions are applied.
7. Welding machines that are subjected to great exertion must comply with
specific security requirements. These include the rail pressure of the
vessel etc. These connections may only be carried out by competently
trained welders with the necessary permissions.
SAFET REGULATIONS
1. Before starting work with welding machine it is necessary to get familiar
with the provisions of the ČSN 050601 and norm ČSN 050630.
2. With a bottle of CO2 or mixed gases should be handled according to the
regulations for working with pressure vessels contained in ČSN 07 83 05
and norm ČSN 07 85 09.
3. The welder must use protective equipment.
4. Before working on the electrical part, removing the cover or cleaning it is
necessary to disconnect the device from the network.

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3. OPERATING CONDITIONS
1. Putting the machine into operation can be performed only by trained
personnel and only within the technical provisions. The manufacturer is
not liable for damages resulting from improper use or handling. For
maintenance and repair, use only original spare parts from ALFA IN.
2. Device complies with IEC 61000-3-12 with following conditions:
Short-circuit power S
sc
of network in place at an interface between the
user's supply and the public network (PCC must be least 4106 kW.
User is obliged to consult with the electricity supplier if the impedance of
the network at this point is that required short-circuit capacity Z
max
= 36
mΩ and whether the device can be connected with a public low-voltage
network.
On the nameplate are the following symbols: .
3. The welding machine is tested according to the degree of protection IP
23S, which provides protection against the intrusion of solid bodies with a
diameter greater than 12 mm and protection against ingress of water,
falling on the machine in a vertical direction or max degree of 60°.
4. The machine must be positioned so that cooling air can enter and leave
through cooling vents with no problem. It is necessary to ensure that
there are no mechanical equipment, especially metal particles (e.g.
during grinding drawn into the machine.
5. Handling handle is intended for movement, it is not designed to lifting the
machine.
6. In case of overheating of the machine welding is automatically stopped
and this condition is signalized by pilot light.
7. All interventions in the el. equipment as well as repair (removal of the
plug, fuse replacement should be performed by an authorized person.
8. With competent mains voltage and input must match the plug.
9. Do not use the machine for other purposes, such as defrosting pipes,
starter source, etc.
10. It is necessary for welding machine to undergo a periodic
inspection every 6/12 months by an authorized officer according to ČSN
331500 and ČSN 050630 – see Maintenance and service tests.
11. The welding machine is designed especially for industrial areas. In
case of using it in other areas there may exist special measures (see EN
60974-10 .
12. It is necessary to protect the machine against:
a. Moisture and rain
b. Mechanical damage
c. Draft and possibly ventilation of neighboring machines
d. Excessive overloading – exceeding tech. parameters
e. Rough treatment
f. Chemically aggressive environments

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ELECTROMAGNETIC COMPATIBILIT
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.
During operation, the device may be the source of interference.
 Caution 
We warn users, that they are responsible for possible interference from
welding.
4. TECHNICAL DATA
Model aXe 250 PULSE smart (AL) GAS
Method MIG/MAG MMA
Mains voltage V/Hz 3x400/50-60
Welding current range A 20 - 250 10 - 250
Open-circuit voltage U
20
V 63,1
Mains protection A 16 @
Max. effective current I
1eff
A 12,9 13,0
Welding current (DZ=100% I
2
A 210 190
Welding current (DZ=60% I
2
A 250 230
Welding current (DZ=x% I
2
A 60%=250 50%=250
Protection IP 23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h generator mm 474 x 911 x 670
Weight - generator /compact kg 47,6
Wire speed m/min 1,0 - 20,0 ---
Spool diameter mm 300 ---
Spool weight kg 18 ---

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Model
aXe 320 PULSE
smart
(AL)
H
2
O
aXe 320 PULSE
smart
(AL)
GAS
Method MIG/MAG
MMA MIG/MAG
MMA
Mains voltage V/Hz
3 x 400/50-60 3 x 400/50-60
Welding current range A 20 - 315 10 - 300 20 - 315 10 - 300
Open-circuit voltage U
20
V 63,1 63,1
Mains protection A 16 @ 16 @
Max. effective current I
1eff
A 13,3 12,8 12,9 12,8
Welding current (DZ=100% I
2
A 210 190 210 190
Welding current (DZ=60% I
2
A 250 230 250 230
Welding current (DZ=x% I
2
A 25%=315 20%=300
25%=315 20%=300
Protection IP 23S
Standards EN 60974-1; EN 60974-10 cl. A
Dimensions (w x l x h generator
mm 474 x 902 x 884 474 x 911 x 670
Weight - generator /compact kg 72,5 47,6
Wire speed m/min
1,0 - 20,0 --- 1,0 - 20,0 ---
Spool diameter mm 300 --- 300 ---
Spool weight kg 18 --- 18 ---
Cooling power (Q=1l/min kW 0,74 --- --- ---
Total liquid content l 4,0 --- --- ---
Max. pressure Bar 3,5 --- --- ---
Max. flow l/min 8,0 --- --- ---
S
The machine marked with this symbol can be used for welding in areas with
an increased risk of electric shock.
The machine structure is designed so that, in any case, even if the failure
rectifier does not exceed the permitted peak value of the open circuit voltage
according to EN 60974-1, i.e., 113 V direct current or 68 V alternating.

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5. ACCESSORIES
PART OF DELIVER
1. Roll (rolls for wire with diameters 0,8 – 1,0 mm
2. Instruction manual
3. Reducing for the spool wire 5 kg and 15 kg
4. Earthing cable 3 m with clamp
5. Hose for gas connection
ACCESSORIES ON REQUEST
1. Pressure regulator
2. Spare parts for torch
3. Rolls 0,6-0,8 and 1,0-1,2 with different grooves
4. Torch PARKER SGA-LW305A Ultralight 3 m – 5 m
5. Torch PARKER DIGIMIG 305 aXe IN UD Ultralight 3 m – 5 m
6. Torch PARKER SGB 240W délka 3 m – 5 m
7. Torch PARKER DIGIMIG 240W aXe IN UD 3 m – 5 m
8. Set for aluminium welding
9. Wire cleaner
NOTICE If you decide to use a different torch than the above, it is
necessary to choose one, according to your current range and load time of the
torch. ALFA IN a.s. is not liable for damage caused by overload welding
torches.

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6. DESCRIPTION OF THE APPLIANCE
MAIN PARTS
Fig. 1 – Main parts of the machine

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Fig. 2 – Main parts of the machine with
cooling unit

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Pos.
Description
A1 ON/OFF switch
A2
PCB
control panel
A3
Quic
k connector
(
+
A4 Quick connector (-
A5
EURO
connector
A6
Wire feeder
A7
Spool holder
A8
Soneloid valve
A9
Mains cable
A10
Cooling unit
A11
Remote control connector for MMA method
A12
LED
A13
Button of inserting the wire
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
p
ressure
m
anometer
F5
Low
p
ressure
m
anometer
F6 Adjusting Screw
F7
Gas outlet
F8
Soneloid valve
F9 Chain
 NOTICE 
If the machine is equipped with the connector A11, the machine can be
controlled in MMA method by the remote control.

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WIRE FEEDER
Fig. 3 - Wire feeder 4 rolls
Pos.
Description
E1
Nut of pressur
e arm
E2 Pressure arm
E3
I
nlet liner
E4
EURO connector
E5 Roll
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. 4 - The influence of the roll groove on the welding wire
A Correct
B Wrong
C Wrong

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OVERVIEW OF ROLLS FOR WIRE FEED
ab
4 rolls
a =
19
mm
b = 3
7
mm
Groove type
Wire diameter
It
em No
Steel
0,6
-
0,8
4299
0,8-1,0 4300
1,0
-
1,2
4301
1,2
-
1,6
4302
Aluminum
1,0
-
1,2
4306
1,2
-
1,6
4307
1,6-2,0 4308
2,4
-
3,2
4309
Flux core
1,0-1,2 4303
1,2
-
1,6
4304
2,4
-
3,2
4305
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, pressure rolls E2 will be opened upward.
2. Unscrew the 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.
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 FEED. To prevent problems with feeding
use wires with diameter 1,0 mm of AIMg3 or AlMg. Wire of alloy Al99, 5 or
AlSi5 are too soft and easily will cause problems with movement.
For the aluminum 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. 5 – Customization of the feed for the aluminium wire
Pos. Description
G1
EURO
connector
G2
Roll
s
G3 Liner terminal for 4,0mm, 4,7mm outer diameter
G4
O
-
ri
ng 3,5 x1, 5mm to prevent escape of gas
G5
Nut
G6
Liner tefl.
G7
Sustain pipe
for teflon and plastic liner
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. If a spool (size of 15 or 18 kg is used, put on each side of the spool
adapter D3. The hole in the back of the adapter must fit into the pin on
the wire spool holder!
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. By pressing the button A13, placed in
the space of the wire feeder, turn on the motor of the feeder. The
adjusting screw is located under the plastic screws 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

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may occur in the wire rolls.
Fig. 6 - Spool holder
ADJUSTING PRESSURE FORCE OF FEED ROLLS
Important thing for reliable operation of the feeding mechanism is the size of
pressure force of feed rolls.
The amount of force depends on the type of welding wire, for aluminum or tube
wire, we choose a smaller pressure force.
If the pressure force is too small, slippage may occur and thus irregular wire
feeding speed.
If the pressure force is too high, it will lead to increased mechanical wear of
bearings and it can damage the machine. Before putting into operation, clean
the rolls from preservative oil.
INSERTING THE WIRE TO THE TORCH AND CONNECTION OF EARTH
CABLE
1. Connect the earthling clamps to the welder or to the welding table.
2.  Notice  When inserting the wire do not point with torch to the eyes!
3. Screw the central end of the torch B2 to connector B1 on the machine
while the machine is turned off.
4. Remove the gas nozzle from the torch.
5. Unscrew the current nozzle.
6. Connect the machine to power supply.
7. Turn the ON/OFF switch to ON.
8. Press button A13 in the space of wire feeder to run the motor of the
feeder. The welding wire is fed into the torch. After coming off from the
torch tube, screw the current nozzle and gas nozzle on.
9. Before welding, spray the area in a gas hose and current nozzle with a
separation spray, to prevent damage.
Pos. Description
D1
Spool Holder
D2
Nut Spool Holder
D3
Adapter

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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. Fit the gas hose to the outlet on the back panel of the machine.
2. Press button V1 (pic. 8 on the main panel to the switching of the gas
valve. If you hold the button for less than 3 s, after releasing the button,
the gas valve will turn off. If you hold the button for more than 3 s, it will
turn off the gas valve after about 20 s, or after pressing any button.
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. 2 – Gas flow setting
Pos.
Description
F1
Gas b
ottle
F2
Cylinder Valve
F4
Pressure Reducer
F5 High Pressure Manometer
F6
Low Pressure Manometer
F7
Adjusting Screw
F8 Gas outlet

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7. BASIC SETTINGS
CONTROL PANEL
Fig. 8 – Control panel
Pos.
Description
V
1
Button
:
G
as
test
V2
Button:
P
ulsed mode
V3
LED
-
I
f it illuminates
, when Pulsed mode was chosen
V4 Instant JOB buttons 1-6
V5
Current encoder
V6
LED
-
Material thickness (mm
V7 LED - Wire speed (m/min
V8
Button for selecting
the parameters to be displayed
V9
LED
-
Current (A
V10
Left display shows:
1. Welding current
2. Welding current in the MMA mode
3. Speed of the wire
4. Material thickness
5.
Sign
of
the
secondary parameter
V11
Right display shows:
1. Welding voltage
2. Correction
3.
Choke
V12
LED
-
V
oltage or
v
oltage
c
orrection
V13
Button for selecting the parameters to be displayed

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V14
LED
-
Wire
s
peed
c
orrection
V15
LED
-
Choke or
c
hoke
c
orrection
V16
Encoder
v
oltage or
c
orrection
V17
LED
-
T
wo stroke
–
2T
V18
LED
-
F
our stroke
–
4T
V19
Button for selecting the parameters to be displayed
SETTING THE METHOD OF WELDING
1. By long-pressing the encoder V5 open the menu.
2. By turning the encoder V5 choose the method ELE (covered electrode
MMA , MAN (MIG/MAG manual or SYN (MIG/MAG synergistic . Confirm
your choice by pressing the button V5.
WELDING METHOD S NERG
Synergic curves are welded in PB position (fillet connection, horizontal,
obliquely from above . It is necessary to perform the parameters correction for
welding in other positions.
AXE 250-320 PULSE SMART (AL ø 0.8 ø 1.0 ø 1.2
SG/Fe Ar 82 % CO
2
18 % 0 * 1 * 2 *
SG/Fe Ar 92 % CO
2
8 % 3 * 4 * 5 *
SG/Fe CO
2
100 % 6 7 8
Cr/Ni 308 Ar 97,5 % CO
2
2,5 % 9 * 10 * 11 *
Cr/Ni 316 Ar 97,5 % CO
2
2,5 % 12 * 13 * 14 *
AlMg Ar 100 % x 15 ** 16 **
AlSi Ar 100 % x 17 ** 18 **
Table of synergic parameters
* You can switch on/off the pulsed mode by means of the button V2.
** Can be welded only in the pulsed mode, and it is available only for AL
variant of the machine.
1. Left display V10 shows SYN, right display V11 shows the number of
synergistic curve.
2. Selects the synergic curve (program number using the encoder V16
according to the table, which is located inside. To confirm the program
number press the encoder V5.
3. If you press any button other than V5, or after 10 s, you exit the menu.

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CALIBRATION OF THE WELDING CIRCUIT
Welding features of the synergic curve depends on many factors, for example:
on the torch length, ground cable length, qrounding quality, weldment distance
from the grounding place etc. Therefore, it is appropriate to perform the
calibration of the welding circuit for actual welding conditions.
1. Simultaneously press V20 and V5 encoder and you will enter the menu
for secondary parameters.
2. Choose CAL parameter by the encoder V5 and press it to confirm.
3. Set CrE by the encoder V5 and press it to confirm.
4. Unscrew the gas nozzle of the welding torch.
5. Cut off the welding wire tightly at the welding jet.
6. Piece of the welding wire (about 50 mm give to the wire feeder.
In the current jet cannot be now any welding wire.
7. Place the welding tip of welding torch on a clean or cleaned place of the
workpiece by the gentle pressure, press and hold the torch button for 2 s.
For a moment flows the short-circuit current. Short-circuit current helps to
determine and screen the new resistence. (Value can be from 0 mΩ to 60
mΩ – for users aren’t these values important, factory reset CrE = 10 mΩ,
you can set this value by the encoder V16 .
8. Right display V11 shows Err, if an error occurs. You must repeat the
measurement.
9. Screw back the gas nozzle of the welding torch.
10. Insert the welding wire.
QUICK SETTING THE JOB - MEMOR
Works for all welding methods.
1. Long press (4s one of the buttons V4 (1,2,3,4,5,6 to save set
parameters to memory.
2. Short press one of the buttons V4 (1,2,3,4,5,6 to load parameters from
memory.
3. Display shows no Job, if at the desired position isn’t saved any JOB.
WELDING MODE 2T – TWO STROKE
Works for both welding methods MIG/MAG.
Press the button V20 to switch between the modes 2T , 4T and
. The two stroke mode is signalized by LED V17. First tact: press and
hold the torch button, the machine will start welding. Second tact: release the
torch button, the machine will stop welding.

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WELDING MODE 4T – FOUR STROKE
Works for both welding methods MIG/MAG.
Press the button V20 to switch between the modes 2T , 4T and
. The four stroke mode is signalized by LED V18. First tact: press and
hold the torch button, the machine will start welding. Second tact: release the
torch button, the machine will continue welding. Third tact: press the torch
button, the machine will continue welding. Fourth tact: release the torch button,
the machine will stop welding.
WELDING MODE 2T – TWO STROKE STAIRS
Works for both welding methods MIG/MAG.
Press the button V20 to switch between the modes 2T , 4T and
. The two stroke stairs mode is signalized by LEDs V17 and V19.
First tact: press and hold the torch button, the machine will start welding with
the Start current SCu during the time START t S. Then after the time UP tuP
start the machine welding with the main welding current (100 % . Second tact:
release the torch button, after the time DOWN tdo start the machine welding
with the End current ECu during the time END t E. After this time the machine
will stop welding.
WELDING MODE 4T – FOUR STROKE STAIRS
Works for both welding methods MIG/MAG.
Press the button V20 to switch between the modes 2T , 4T and
. The four stroke mode is signalized by LEDs V18 and V19.
First tact: press and hold the torch button, the machine will start welding with
the Start current SCu. Second tact: release the torch button, after the time UP
tuP start the machine welding with the main welding current (100 % . Third
tact: press the torch button, after the time DOWN tdo start the machine
welding with the End current ECu. Fourth tact: release the torch button, the
machine will stop welding.
BILEVEL BCU ≠ 100 %
The difference of BILEVEL compared with classical stairs is in the second tact.
When you quickly press and release the torch button, the machine switches
between two set main welding currents.