Alfain aXe 400 IN User manual

ALFA IN a.s. ©www.alfain.eu aXe 400 500 IN manual EN 6
WELDING MACHINES
aXe 400 IN
aXe 500 IN
OPERATING MANUAL

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CONTENT:
1. INTRODUCTION ....................................................................................3
2. SAFETY PRECAUTIONS.......................................................................4
3. TECHNICAL DATA ................................................................................6
4. MAIN PARTS OF THE MACHINE..........................................................7
5. ACCESSORIES....................................................................................10
6. CONTROL PANEL...............................................................................11
7. BASIC SETTINGS................................................................................12
8. SAVE AND LOAD WELDING PROGRAMS - FLASH MEMORY.........13
9. MIG/MAG MANUAL .............................................................................13
10. MIG/MAG SYNERGY........................................................................13
11. MODE 2T/4T/STEPS.........................................................................14
12. SECONDARY PARAMETERS MENU ..............................................15
13. RESET..............................................................................................16
14. JOB MENU .......................................................................................17
15. REMOTE CONTROL ........................................................................18
16. ELECTRODE METHOD....................................................................19
17. ERROR MESSAGES ........................................................................20
18. GETTING STARTED.........................................................................20
19. GETTNG STARTED –COATED ELECTRODE................................25
20. ROUTINE MAINTENANCE & INSPECTION.....................................26
21. STATEMENT OF WARRANTY.........................................................27
22. DISPOSAL........................................................................................27

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1. INTRODUCTION
Dear consumer,
Company ALFA IN a.s. thanks you for buying our product and believe that
you will be satisfied with our machine.
Welding machine may be operated only by trained persons and only in the
technical provisions. Company ALFA IN a.s. accept no responsibility for
damage caused by improper use. Before commissioning please read
carefully this manual .
The machine complies with the appropriate CE mark.
For maintenance and repairs, use only original spare parts. There is of course
a complex of our services.
Welding machine aXe 400/500 IN is designed for MIG / MAG, MMA and
gouging. By the machine aXe 400/500 IN you can weld different types of
connections (butt, single-sided, double-sided, fillet, lap, etc.) using wire from
diameter 0.8 to 1.2 respectively to 1.6 mm of different metals and alloys
(carbon and alloy steels, aluminum alloys, etc.). They are designed primarily
to medium and large industrial facilities where are high demands on ease of
use, reliability and productivity with prolonged use.
Welding machines aXe 400/500 IN are available in:
1. aXe 400 IN COMPACT (H2O) - compact welding machine and the
option of a water cooled torch
2. aXe 500 IN COMPACT (H2O) - compact welding machine and the
option of a water cooled torch
3. aXe 400 IN (H2O) - welding machine with separate wire feeder and
the option of a water cooled torch
4. aXe 500 IN (H2O) - welding machine with separate wire feeder and
the option of a water cooled torch

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2. SAFETY PRECAUTIONS
1. Use and maintenance of welding and cutting machines can be
dangerous. Please draw user´s attention to follow the safety precau-
tions to avoid injuries. Welding and cutting machines must be used
appropriate and only by specialist staff. Please inform yourself
constantly about the valid safety precautions and regulations of
accident prevention by working with this machine*.
2. Remove all flammable material from the welding area for fire prevention
before welding.
3. Do not weld at containers which were filled up before with flammable
materials (fuel).
4. All inflammable material in the welding area which could be inflamed by
sparks must be removed.
5. Check after welding the place conforming UVV.
6. Do not expose the unit to rain, steam and do not spray water in it.
7. Do not weld without protection shield. Keep attention to protect other
persons in the welding area against arc-rays.
8. Please use absorbers or other systems to absorb the gases.
9. It is not possible to absorb all the gases correctly please use a
breathing apparatus.
10. Stop operation immediately at a defect or damaging of the mains
cable. Do not touch the cable. Unplug the unit before each service or
repair. Do not use the machine if the mains cable is defect.
11. Place an extinguisher near the welding area.
12. Check the welding area against fire after welding.
13. Never try to repair a defect pressure reducer. Replace the defect
one.
14. Keep attention to connect the ground cable near the welding
location. Welding current through chains, ball-bearing or steel-cables
may destruct or melt it.
15. Secure yourself and the unit at higher or inclinational places.
16. Connect the unit only at mains with correct connection to
ground/earth and at prolongations and sockets too.
17. Wear correct protective clothing, gloves and leather apron.
18. Protect the welding area with curtains or mobile walls against
rays.
19. Do not thaw frozen waterpipes or conductions with this unit.
20. In high electrical risk areas (in confined spaces) it is only allowed
to use machines with –sign S.
21. Switch off the machine at breaks and close the valve of the gas
cylinder.

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22. Secure the gas cylinder with a chain against falling over.
23. Please take off the gas cylinder from the machine for trans-
portation.
24. Disconnect the plug from the mains before changing the welding
area or repairs at the machine.
*) Please follow the current safety regulations corresponding to your
country.
UNIT PROTECTION
1. This unit is protected electronically against overloading.
2. Close the side lid before welding.
3. Connect the workpiece with the groundcable to the unit.
4. Remove welding spatter from the inside of the gas nozzle with a special
pair of pliers. Spray with anti spatter spray inside the gas nozzle to
avoid adherence of spatters. Spray sloping to avoid the obstruction of
the gasoutlet.
5. At transportation of the unit only use the purposed transportation
facilities, do not use a fork-lift truck or something similar.
EMISSION OF SOUND
The sound level of the unit is smaller as 70 dB (A) measured at standard load
conforming EN 60 974 at the max. workpoint .
ELEKTROMAGNETIC COMPATIBILITY (EMC)
1. This product is manufactured conform to the current EMV standard.
Please notice following items:
2. The unit is for welding under commercial or industrial conditions. The
use in other surroundings (for example in residential areas) may disturb
other electric devices.
3. During welding electromagnetic problems can be caused at:
a) Mains cables, control cables, connections for telecommunication
b) TV/Radio
c) Computer and other similar devices
d) Protection devises as for example alarm systems
e) Pacemakers and hearing aids
f) Devices for measure and calibrate
g) Devices with less protection against disturbances
4. If other devices are disturbed it may be necessary to protect
additionally.
5. The affected area can be bigger than your premises/ property depends
of the building etc.
6. Please use the unit conform to the instructions of the manufacturer. The
user is responsible for installation and use of the machine. Furthermore

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the user is responsible to eliminate the disturbances caused by
electromagnetic fields.
3. TECHNICAL DATA
Technical data
aXe 400 IN
aXe 500 IN
Method
MIG/MAG
MMA
MIG/MAG
MMA
Mains voltage
V/Hz
3 x 400/50
Fuse
A
32 @
Max. effective
current I1eff
A
29,8
30,3
31,3
30,3
Welding current
range
A/V
40/16,0 -
400/34,0
10/20,4 -
400/36,0
40/16,0 -
500/39,0
10/20,4 -
400/36,0
Open circuit
voltage U20
V
92.0
Welding current
(DC=100%) I2
A
400
400
420
400
Welding current
(DC=60%) I2
A
---
---
500
---
Welding current
(DC=x%) I2
A
100%=400
100%=400
60%=500
100%=400
Protection
IP 23S
Standards
EN 60 974-1
Generator
Weight
kg
84,0
Dimensions (W x
D x H)
mm
474 x 846 x 956
Kompakt
Wire feed speed
m/min
1-25
Spool diameter
mm
300
Spool Weight
kg
18,0
Max. pressure of
the gas
Bar
5,0
Weight
kg
99,0
Dimensions (W x
D x H)
mm
474 x 876 x 1150
The drive unit
Wire feed speed
m/min
1-25
Spool diameter
mm
300
Spool Weight
kg
18,0
Max. pressure of
the gas
Bar
5,0
Weight
kg
21,5
Dimensions (W x
D x H)
mm
270 x 704 x 507
Protection
IP 23S
Standard
EN 60974-5
Cooling Unit

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Cooling capacity
(Q=1l/min)
kW
0,74
The total content
of liquid
l
3,5
Max. pressure
Bar
3,5
Max. flow rate
l/min
8,0
Input voltageU1
V/Hz
230/1~50
Protection
IP 23S
Standard
EN 60974-2
Attention 
Given the size of the installed capacity, the connection of the device to
the power supply must be approved by distribution companies.
Attention 
Users are reminded that they are responsible for any interference from
welding.
4. MAIN PARTS OF THE MACHINE

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Picture 1 - The main part of the machine aXe 400/500 IN

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Picture 2 - The main part of the machine aXe 400/500 IN COMPACT
A1
ON/OFF switch
A3
Quick connector (+)
A4
Quick connector (-)
A6
PCB control panel
A7
EURO connector
A8
Wire Feeder
A9
Spool Holder
A10
Solenoid Valve
A11
Mains Cable
A12
Feeder Holder Feede
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
A26
Quick connector W (red)
A27
Quick connector W (blue)

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A30
CU aXe Cooling unit
A31
Cup
A32
Quick connector W (red)
A33
Quick connector W (blue)
5. ACCESSORIES
SOFTWARE
The manual describes the fully equipped machine. All of these features may
not be available.
BASIC
1. MIG/MAG method - manual, synergy
2. possibility of connecting the remote control UP DOWN
EXTENSION
1. ELECTRODE method
2. 5 instant memories
3. Menu JOB functions –to store up to 99 JOBS.
INCLUDED IN DELIVERY
1. Power generator + drive unit / COMPACT
2. 3 m long earthing cable with clamps
3. Rolls for wire with diameters from 1.0 to 1.2 mm
4. Reducing for the spool wire 5 kg and 18 kg
5. Hose for gas connection
6. Water hose
ACCESSORIES ON REQUEST
1. Pressure regulator
2. Gas bottle
3. Wire cleaner
4. Torch holder
5. Spare parts for the torch
6. Remote control UP-DOWN
7. Earthing cable, lengths 4-5 m
8. Connecting cables 2, 5, 10, 15, 20 m
9. Rolls 0,6-0,8, 1,0-1,2, 1,4-1,6, 1,6-2,4
10. Welding cables for coated electrodes
TORCH ON REQUEST
1. torch PUSH-PULL up to 25 m
2. torch PARKER DIGIMIG 501W 3 m –5 m

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6. CONTROL PANEL
Picture 3 - Panel of the machine
T1
Instant JOB buttons (1-5)
T2
Current encoder
T3
Button for selecting the parameters to be displayed.
T4
Control light Material thickness (mm)
T5
Control light Wire speed (m/min)
T6
Control light Current (A)
T7
Left display
T8
Button for selecting the method
T9
Control light TIG –not active
T10
Control light Coated electrode - MMA
T11
Control light MIG/MAG Synergy
T12
Control light MIG/MAG Manual
T13
Control light Pre Gas Time (s)
T14
Control light Start Current (A)
T15
Control light Upslope (s) –not active yet

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T16
Control light Main Welding Current A (A)
T17
Control light Main Welding Current B (A)
T18
Control light Downslope (s) –not active yet
T19
Button for selecting parameters on the curveT13-T21
T20
Control light Final Current (A)
T21
Control light Post Gas Time (s)
T22
Button JOB
T23
Button Gas Test
T24
Button Wire Feeding
T25
Right display
T26
Control light of Voltage or Voltage Correction
T27
Control light of Wire Speed Correction
T28
Control light of Choke or Choke Correction
T29
Button for selecting the parameters to be displayed.
T30
Encoder Voltage or Correction
T31
Control light two stroke –2T
T32
Control light four stroke –4T
T33
Control light Steps
T34
Button for selecting the parameters to be displayed.
H1
Torch Remote Control Display
H2
UP-DOWN buttons
H3
Button for changing the function of the button H2
7. BASIC SETTINGS
SETTING THE METHOD - BUTTON T8
Function may not be available, depending on the software of the machine.
1. Short pressing switches between the manual or synergic method.
2. Long pressing (more than 4s) selects the ELECTRODE mode.
GAS TEST - BUTTON T23
1. Long pressing (more than 4s) opens the gas valve for 20 s.
2. To stop, press any button.
3. If you keep the button pressed for less than 4 s, when you release it the
gas valve will switch off the gas supply.
WIRE FEEDING- BUTTON T24
The wire feeder starts feeding at the speed 15 m/min.

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COOLING TEST: +
When long pressing (more than 4s) buttons T23 and T24 at the same time
the fan and pump will start running. To stop, press any button.
8. SAVE AND LOAD WELDING PROGRAMS -
FLASH MEMORY
, , , ,
Function may not be available, depending on the software of the machine.
1. To save a JOB, keep the button T1 pressed until the display starts
flashing.
2. To load JOB press shortly T1 button
9. MIG/MAG MANUAL
1. The left display T7 shows the wire feed speed T5 , the right
display T25 shows voltage T26 or choke T27 .
2. Wire feed speed is set by the encoder T2.
3. Voltage or choke is adjusted via the encoder T30.
4. Voltage or choke can be displayed and set by long-pressing T29.
5. If the torch with remote control is connected, the display on the torch
will show the wire speed, voltage or choke. Use UP-DOWN rocker
button to set the displayed value, round button changes the function. In
case the JOB function is sellected, it is possible switch among the
active JOBs by means of the UD buttons of th torch.
10. MIG/MAG SYNERGY
1. Press and hold the encoder T2 to enter the menu, where u can select
the synergistic curve. The left display T7 shows SYN, the right display
T25 shows No. of the synergy curve as P.xx
2. By means of turning the encoder T2 select your synergy curve and
confirm by pressing the encoder T2.
P.00 - Material: SG / Fe wire diameter: 1.0 mm, gas: ArCO2 (82/18).
P.01 - Material: SG / Fe wire diameter: 1.2 mm, gas: ArCO2 (82/18).

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P.02 - Material: SG/Fe, wire diameter: 1,0 mm, gas: CO2.
P.03 - Material: SG/Fe, wire diameter: 1,2 mm, gas: CO2.
P.04 - Material: CrNi 308, wire diameter: 1,0 mm, gas: ArCO2 (97,5/2,5).
P.05 - Material: CrNi 308, wire diameter: 1,2 mm, gas: ArCO2 (97,5/2,5).
P.06 - Material: CrNi 316, wire diameter: 1,0 mm, gas: ArCO2 (97,5/2,5).
P.07 - Material: CrNi 316, wire diameter: 1,2 mm, gas: ArCO2 (97,5/2,5).
3. The left display T7 shows the machine performance (current ,
wire feed speed , material thickness ). The right display
T25 shows voltage.
4. The value of the correction (Voltage , wire speed ) or the
value of the choke is shown on the display T25 only at the time
of selecting the values. (Changing the method using the wire correction
is possible by pressing and holding the button T13). (When you change
the welding power by turning the encoder T2 it will reset the correction,
in other words the machine uses parameters from the factory stored
synergic curves. The machine supports the possibility of maintaining a
user-defined correction when changing the welding power. Switching to
such arrangements must be made by the manufacturer or an
authorized service center.)
5. If the correction is zero, the display T25 on would show voltage value.
6. Button T3 selects the parameters to be displayed on T7 display
(current, wire speed, material thickness).
7. Machine output (current, wire feed speed, material thickness) is set by
the encoder T2.
8. Button T29 to switches between correction of voltage (or wire speed)
and correction fo the choke. (To change the meaning of the correction
from Voltage to Wire speed, keep the button T29 pressed for 4
seconds).
9. The correction (of Voltage, wire speed) of the value of the choke can be
set by means of the encoder T30.
10. If the torch with remote control is connected, the display on the
torch will show the wire speed, voltage or choke. Use UP-DOWN rocker
button to set the displayed value, round button changes the function. In
case the JOB function is sellected, it is possible switch among the
active JOBs by means of the UD buttons of the torch.
11. MODE 2T/4T/STEPS
1. Press the buton T34 to switch the mode 2T / 4T / steps (synergy only).
2T /4T / steps (only in synergy mode) .
2. In steps mode it is possible to set values of the current and pre and post

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gas by pressing the button T19.
3. Press the switch T19 to switch individual parameters, the parameter is
signalized by LED on the curve.
4. During the steps mode, encoder T2 sets the machine performance.
5. The main current MAIN A = B, the starting current START = 1.2 x A
and the final current FINAL = 0.7 x A.
6. During welding, the display T7 shows measured value of welding
current and the the display T25 shows voltage .
7. After welding, on the display will remain measured value (HOLD) for 4
secs.
2T TWO STROKE:
1. Tact –press and hold the button
the machine will start welding
2. Tact –release the torch button
the machine will stop
4T FOUR STROKE:
1. Tact –press and hold the button
the machine will start welding
2. Tact –release the torch button
the machine will continue
3. Tact - press the torch button
the machine will stop
4. tact - release the torch button
FOUR STROKE STEPS: (ONLY IN SYNERGY MODE)
A = B (MAINS CURRENTS ARE EGUAL)
1. Tact –press and hold the button
the machine will start
welding with the START
current
2. Tact –release the torch button
the machine will continue
with the MAIN current
3. Tact - press the torch button
the machine will start
welding with the FINAL
current
4. tact - release the torch button
the machine will stop
A ≠ B (MAIN CURRENTS ARE DIFFERENT) BILEVEL
The difference from A = B is in the second tact, quickly pressing and
releasing the torch switches between two main welding currents.
12. SECONDARY PARAMETERS MENU
+

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1. Simultaneously pressing T34 and T2 encoder enters the menu for
secondary parameters.
2. T2 encoder selects a parameter (ISP, PRG, PoG, brn), T30 encoder
sets the desired value.
3. The secondary parameters are the same for either manual or synergy
modes.
Symbol
Meaining
Range (Default)
ISP (Initial speed)
Approaching speed
10 - 100 % (30 %).
PrG (Pre gas time)
Pre gas
0 - 20 s (0,1 sec).
PoG (Post gas time)
Post gas
0 - 20 s (0,5 sec).
brn (Burnback)
Burnback
0 - 75 ms (35 ms)
CAL (Calibrarion menu)
Calibrarion menu
x.xx (software version
–for service use only)
4. Press the encoder T2 to confirm the change.
5. Press any button to exit the menu without saving changes.
6. Long pressing of the button T1(1) will show the configuration of the
motor PCB CFG (--- basic, E-- - electrode, --5-5 easy Jobs, E-5 –
electrode + 5 easy Jobs, -99 –5 easy Jobs + 99 Jobs, E99 –full
configuration)
7. Long pressing the button T1(2) will show the configuration of the
Control PCB (on the left display T7 to machine power, on the right
display T25 0/1 –the function of cutting the ball off at the end of welding
is OFF/ON.
8. Long pressing of the button T1(3) will show the welding time in hours.
13. RESET
”LARGE RESET“
+
1. Pressing T34+T19 at the same time more than 4 s makes RESET –
default parameters will be restored.
2. It will delete saved JOBs!
”SMALL RESET“
+
Pressing T34+T1[5] at the same time more than 4 s makes RESET –default
parameters will be restored. Saved JOB remain.

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14. JOB MENU
Features may not be available (depending on the software of the machine).
SAVING THE JOB (JOB SAV)
1. Long pressing the button T22 (more than 4 s) enters the Jobs Save
Menu.
2. The left display T7 shows JOB, the right display T25 shows the number
of the JOB.
3. T30 encoder sets the number of JOB.
Symbol before the number means:
E. - (empty) - JOB is empty.
n. - inactive JOB (can not switch with the remote control).
A. - active JOB (can be switched by remote control).
4. Press the encoder T2 to confirm the saving of the JOB.
5. Press any button to exit the JOB menu without saving.
LOADING THE JOB (JOB LOA)
1. Short pressing the button T22 enters JOBs Load Menu.
2. The left display T7 shows JOB, the right display T25 shows the number
of the JOB.
3. T30 encoder sets the number of JOB.
Symbol before the number means:
E. - (empty) - JOB is empty.
n. - inactive JOB (can not switch with the remote control).
A. - active JOB (can be switched by remote control).
4. With the encoder T2 you can set the JOB as active (A.) or inactive (n.)
5. Confirm by pressing the encoder T2.
6. Press any button to exit the menu.
When loading the JOB, the display goes off. If everything is OK, the screen
will display stored values. If an error occurs during the loading (e.g. JOB is
empty), the display will show JOB Err.
When the JOB is saving, display blinks several times. JOBs are stored as
inactive (n.).

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15. REMOTE CONTROL
JOB SELECTION WITH REMOTE CONTROL
+
Features may not be available (depending on the software of the machine).
1. When the machine starts, this feature is automatically disabled.
2. Pressing T34 +T22 at the same time for more than 4 s activates
operating JOBs by means of remote control on the torch. The display
shows JOB.
3. Pressing T34 +T22 at the same time for short time deactivates
operating JOBs by means of remote control on the torch. The display
shows JOB off.
REMOTE CONTROL FROM THE TORCH PARKER
Picture 4 - Remote control from the torch
H1
Display of remote control
H2
Display
H3
Torch button M for choosing the function
MAN: Wire speed, Voltage/Choke, JOB (See How to switch on
the remote control of JOBs on below)
SYN: Power, Correction/Choke, JOB
H4
Torch button LOCK lock/unlock the buttons UP/DOWN and M
The UP/DOWN and M buttons get automatically locked when
the torch trigger is pressed.

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H5
When the LED is on it indicates UP/DOWN and M button are
functioning.
H6
Torch button UP
H7
Torch button DOWN
Symbols on the torch display H1
Symbol
Description
A synergic program is running on the welding machine
Amperage setting (SYN)
Wire speed setting
No symbol
Material thickness setting (SYN)
Voltage setting (MAN)
Correction (SYN)
Symbols on the torch display H2
J.xx
JOBs (xx –JOB No)
I.xx
Choke level (SYN/MAN).
(Only with firmware 2015 and newer)
ELE
Machine is in MMA (Electrode) mode
16. ELECTRODE METHOD
Features may not be available (depending on the software of the
machine).
1. Control light. When illuminates the MELECTRODE mode has been
selected.
2. The welding current is set by the encoder T2.
3. During welding, the display shows measured values of welding current
.
4. After welding, on the display will remain measured value (HOLD) for 4
secs.
5. If the torch with a remote control is connected, is shown on the display

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ELE.
6. If the MIG/MAG torch stays connected, the welding voltage will be on it.
17. ERROR MESSAGES
1. The left diplay T7 shows Err, the right display T25 shows number of the
error.
2. To remove the error message, press the encoder T2.
3. ERR 1 - Overheating of the machine. Let the engine cool down, DO
NOT POWER OFF THE MACHINE!. Error message can be cleared
after the machine is cooled down by pressing the encoder T2.
4. ERR 2 - Small water pressure. Check the fluid level in the tank or clean
water circuit.
18. GETTING STARTED
TORCH INSTALATION
1. Never connect the torch in the machine if it’s still running!
2. Connect the EURO connector male B2 to EURO connector B1. Then,
connect Quick connector torch W (red) B6 to the Quick connector W
(red) B4 and the Quick connector torch W (blue) B7 to the Quick
connector W (blue) B5
3. When connecting a gas-cooled torch, it is necessary to interconnect the
quick connectors with water hose of the hydraulic circuit. If this
condition is not met, it may result in damage to the pump.
Picture 5 –Torch INSTALATION
COOLING SYSTEM OF WATER TORCH
1. CU aXe Cooling unit A30 is located in the lower part of the machine.