Alfain aXe 500 IN PULSE Manual

ALFA IN a.s. © www.alfain.eu aXe 500 IN PULSE manual EN 01
PULSE WELDING MACHINE
aXe 500 IN PULSE
OPERATING AND MAINTENANCE
INSTRUCTIONS

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ALFA IN a.s. © www.alfain.eu
CONTENT
PERSONAL PROTECTION...........................................................................5
SAFETY REGULATIONS..............................................................................5
MACHINE PROTECTION..............................................................................5
ELECTROMAGNETIC COMPATIBILITY......................................................7
PART OF DELIVERY.....................................................................................8
ACCESSORIES TO ORDER.........................................................................8
TORCHS TO ORDER....................................................................................8
MAIN MACHINE PARTS ...............................................................................9
COLLING SYSTEM OF THE WATER TORCH (COOLANT)......................12
AIR BLEEDING TORCH COOLING SYSTEM............................................13
DESCRIPTION OF THE CONTROL PANEL..............................................13
MENU STRUCTURE...................................................................................14
QUICK JOB SELECTION - MEMORY ........................................................20
TORCH CONNECTION...............................................................................21
CONNECTING THE GROUNDING CABLE................................................21
ATTACHING THE GAS INLET....................................................................22
CONNECTION OF THE CONNECTING CABLE........................................23
CONNECTING TORCH...............................................................................23

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ALFA IN a.s. © www.alfain.eu
CONNECTING THE GROUNDING CABLE................................................23
CONNECTING THE EARTH CLAMP..........................................................23
CONNECTING TO THE MAINS..................................................................23
ATTACHING THE WIRE SPOOL................................................................24
GUIDING THE WIRE INTO THE FEED......................................................24
OVERVIEW OF WIRE FEED PULLEYS.....................................................25
MACHINE MODIFICATION FOR ALUMINIUM WELDING.........................26
ERROR MESSAGES...................................................................................32
PROVISION OF WARRANTY.....................................................................33
WARRANTY AND POST-WARRANTY REPAIRS......................................33
INFORMATION FOR USERS ON THE DISPOSAL OF ELECTRICAL AND
ELECTRONIC EQUIPMENT IN THE CZECH REPUBLIC .........................34

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ALFA IN a.s. © www.alfain.eu
INTRODUCTION
Dear consumer,
Company ALFA IN a.s. thank you for buying our product, and we believe you will
be satisfied with our machine.
Welding machines 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 this manual
carefully.
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.
The aXe 500 IN PULSE welding machine is a new generation of multifunctional
synergistic welding machines from ALFA IN. The device is designed for
MIG/MAG, MMA and AIR welding.
Note: The TIG method is not a standard feature of the welding machine.
With this machine, you can weld different types of connections (butt, single-
sided, double-sided, fillet, lap, etc.) using wire from diameters 0.8 to 1.2,
respectively to 1.6 mm of different metals and alloys (carbon and alloy steels,
aluminium alloys, etc.). They are designed not only for heavy industrial
operations but also for industries demanding precision and speed.
We reserve the law of adjustments and changes in case of printing errors,
changes of technical parameters, accessories etc., without previous notice.
These changes may not be reflected in the manuals for paper or electronic form.

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ALFA IN a.s. © www.alfain.eu
SAFETY PRECAUTIONS
PERSONAL PROTECTION
1. For safety reasons, protective gloves must be worn during welding. These
gloves protect you from electric shock (circuit voltage at no load). It also
saves you from heat radiation and splashing drops of hot metal.
2. Wear sturdy, insulated footwear. Open shoes are not suitable as droplets
of hot metal can cause burns.
3. Do not look into the welding arc without face and eye protection. Always
use a high-quality welding helmet with an intact protective filter.
4. Notice
Persons with implanted pacemakers must not work with the machine or
move in their immediate vicinity! There is a risk of the stimulator
malfunctioning!
5. Persons near the welding site must also be informed of the danger and
provided with protective equipment.
6. When welding, especially in small spaces, it is necessary to ensure a
sufficient supply of fresh air, as welding produces harmful emissions.
7. Do not perform welding work on gas, oil, fuel, etc. Tanks (even empty
ones) as there is a risk of explosion.
8. Special regulations apply in potentially explosive atmospheres.
9. Stop welding immediately if the power cord is damaged. Do not touch this
cable. Unplug it.
10. It is important to note that only machines marked with a symbol
should be used in areas with a higher risk of electric shock.
11. Welded joints that are subject to high stress must meet special safety
requirements. These are mainly rails, pressure vessels, etc. These joints
may only be made by qualified, trained welders with the necessary
authorisation.
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. Hitch the machine on all crane eyes when handling the machine with a
lifting device. Another mounting is not permitted!
5. Disconnect the device from the mains before working on the electrical
system, removing or cleaning the cover.
MACHINE PROTECTION
This machine is electronically protected against overload. Do not turn off the
main power switch while the machine is loaded.

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ALFA IN a.s. © www.alfain.eu
ACL-10 coolant is designed for ambient temperatures up to -10˚C.
Notice
Persons with implanted pacemakers must not work with the machines or move
close to them! There is a risk of impaired pacemaker function!
OPERATING CONDITIONS
1. aXe 500 IN PULSE welding machine is designed for welding steel,
aluminium, and alloys for commercial and industrial applications.
2. Use only the designated transport equipment to transport the welder. Do
not use a forklift or single crates for transport.
3. The device may only be operated by trained personnel within the
technical regulations. The manufacturer is not liable for damage caused
by improper use and operation. Only use original spare parts from ALFA
IN for maintenance and repairs.
4. The device complies with IEC 61000-3-12.
5. The welding machine is tested according to the standard for degree of
protection IP 23S, which protects against the intrusion of solids with a
diameter greater than 12 mm and protection against the intrusion of water
falling in a vertical to the oblique direction to a slope of 60˚.
6. Operating ambient temperature between -10 to +40 °C.
7. Relative humidity below 90% at +20 °C.
8. Altitudes of up to 3000 meters above sea level.
9. The machine must be located so the cooling air can enter and exit through
the cooling vents without restriction. Care must be taken to ensure that no
mechanical particles, especially metal particles, are sucked into the
machine (e.g. during grinding).
10. The handling handle is intended for travel only and is not designed
for lifting machines.
11. All interventions in the el. Equipment and repairs (disassembly of the
mains plug, replacement of fuses) may only be carried out by an
authorised person.
12. 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 regulations for welding and safety
provisions for metal arc welding. It is recommended that an authorised
employee performs the inspection. – See paragraph Maintenance and
service tests.
13. From the point of view of interference suppression, the welding
machine is designed primarily for industrial premises. Special measures
may be required if other premises are used (see EN 60974-10).
14. The machine must be protected against the following:
a. Moisture and rain
b. Mechanical damage
c. Drafts and possible ventilation of neighbouring machines

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ALFA IN a.s. © www.alfain.eu
d. Excessive overloading – exceeding tech. parameters
e. Rough treatment
ELECTROMAGNETIC COMPATIBILITY
Concerning interference suppression, the welding equipment is designed
primarily for industrial premises. It meets the requirements of EN EN 60974-10
class A and is not intended for use in residential areas where a public low-voltage
power supply network supplies electricity. Possible problems with ensuring
electromagnetic compatibility in these areas may be caused by line propagation
and radiated interference.
The device may be a source of interference during operation.
Notice
Due to the installed capacity's size, the distribution plants' approval must be
required to connect the equipment to the public distribution network. We warn
the user that he is responsible for any interference from welding.
TECHNICAL DATA
aXe 500 IN PULSE
Method MIG/MAG MMA TIG
Mains voltage V/Hz 3x400/50-60
Welding current
range A 20/15,0 - 500/39,0 10/20,4 - 500/40,0 10/10,4 - 500/30,0
Open-circuit voltage
U20 V94,0 103,0 100,0
Mains protection A32 @
Max. effective
current I1eff A32,0 31,4 27,0
Welding current
(DC=100%) I2A400 400 400
Welding current
(DC=60%) I
2
A500 450 500
Welding current
(DC=x%) I
2
A 60% = 500 55% = 500 60% = 500
Protection IP 23S
Standards EN IEC 60974-1, EN 60974-10 cl. A
Dimensions (w x l x
h) generator
mm 474 x 846 x 956
Compact weight kg 84
Wire-speed m/min 1,0 - 20,0 --- ---
Spool diameter mm 300 --- ---
Spool weight kg 18 --- ---
Feeder weight kg 21,5 --- ---
Cooling power
(Q=1l/min) kW 0,8 --- 0,8

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ALFA IN a.s. © www.alfain.eu
Total liquid content l 5,0 --- 5,0
Max. pressure Bar 3,5 --- 3,5
Max. flow l/min 9--- 9
Max. input power
I
1max
A41,2 42,3 34,6
Reduced Open-
circuit voltage U2R V16,0
Insulation class F
Max. příkon S1max kVA 28,6 29,1 24,4
Efficiency %89
Input power in idle
mode P10 W25
MACHINE ACCESSORIES
PART OF DELIVERY
1. Operating manual
2. Grounding cable 3 m 500 A 70 mm2with clamp
3. Pulley (s) for wire diameters 1,0 - 1,2 mm
4. 2x Reducer for wire spool
5. Hose for gas connection (in the separate version, the gas hose is
included in the link)
ACCESSORIES TO ORDER
See Catalog
TORCHS TO ORDER
1. Torch ARC M6W 3m DIGIMIG
2. Torch ARC M6W 4m DIGIMIG
3. Torch ARC M6W 5m DIGIMIG
4. Torch ARC M6W 3m DIGIMIG PISTOL
5. Torch ARC M6W 4m DIGIMIG PISTOL
6. Torch ARC M6W 5m DIGIMIG PISTOL
7. Torch ARC M6OSW 3m DIGIMIG
8. Torch ARC M6OSW 4m DIGIMIG
Assembly and maintenance instructions for M6WP/M6OSWP:
NoticeIf you decide to use a torch other than the one listed above, you

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ALFA IN a.s. © www.alfain.eu
need to choose according to the current range used and the load time of the
torch. ALFA IN a.s. is not responsible for damage to welding torches due to
overloading.
DESCRIPTION OF MACHINE AND FUNCTIONS
MAIN MACHINE PARTS

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ALFA IN a.s. © www.alfain.eu
Poz. Popis
A1 ON/OFF switch
A3
Quick connector (+)
A4
Quick connector (
-
)
A6 Control panel
A7 EURO connector
A8 Wire Feeder
A9 Spool holder
A10 Gas valve
A11 Mains cable
A12 Feeder Holder Feeder
A13 Feeder Holder Generator
A14 Quick connector
A15 Connector female
A16 Connector male panel
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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ALFA IN a.s. © www.alfain.eu
A30 CU aXe Cooling unit
A31 Cup
A32 Quick connector W (red)
COLLING SYSTEM OF THE WATER TORCH (COOLANT)
1. The cooling unit is located at the bottom of the machine.
2. The pump seal in this ALFA IN welder is specially designed for ACL-10 fluid
(pink, order no: 4600, 5 l canister.
Operating range - ambient temperature -10 °C to +40 °C).
3. Leakage of the cooling circuit may occur if other fluid is used.
A failure of the cooling circuit using a fluid other than ACL-10 cannot be
covered under the manufacturer's warranty. The liquid must not be mixed with
any other type of fluid.
4. Keep the coolant level in the coolant reservoir
within the permitted range (see illustration).
The fluid level is visually visible on the front of
the reservoir. Use the fluid prescribed by the
manufacturer.
5. Turn off the main switch if the error message
"ERR 2" illuminates during operation. After
switching on the machine, test the cooling unit.
If the error recurs, the cause of the fault must
be determined.
6. ACL-10 liquid is not poisonous. Please note that the fluid replaced in the
pump should be treated as hazardous waste. Do not pollute the
environment. In the worst case, please take it to a salvage yard in its
original canister. The safety data sheet can be found at
https://www.alfain.eu/static/_dokumenty/1/2/8/8/0/4/Bezpecnostni-list-ACL-
10.pdf.
7. Note: When connecting a gas-cooled torch, securing the quick water
couplings with the liquid circuit connection hose is necessary! Failure to do
so may result in damage to the pump!

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ALFA IN a.s. © www.alfain.eu
AIR BLEEDING TORCH COOLING SYSTEM
1. After filling the empty cooling system of the torch or replenishing the fluid after
a substantial leak and aeration, it is necessary to perform a complete air
bleeding of the circuit.
2. Remove the coolant reservoir cap and connect the quick water couplers with
the fluid circuit jumper hose.
3. Run the cooling test for about 30 seconds.
4. Connect the torch and start the cooling test for about 30 seconds.
5. The procedure must be repeated if the error message "ERR 2" - low water
pressure lights up after pressing the torch button.
DESCRIPTION OF THE CONTROL PANEL

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ALFA IN a.s. © www.alfain.eu
Poz. Popis
V1 Button: Wire Feeding
V2 Button: Gas Test
V3 LED: feed rate (m/min)
V4 LED: material thickness (mm)
V5 Button: JOB
V6 LED: lights up when the control panel is locked
V7 LED: Hold
V8 LED: Error
V9 LED: Cooling unit error
V10 LED: voltage or voltage correction
V11 Display for selecting methods
V12 Display for voltage, choke and feed rate correction.
V13 Button: correction selection
V14 LED: choke or choke correction
V15 LED: feed rate correction
V16 Encoder for voltage setting/voltage correction/chokes/short press -
enter the method setting menu
V17 Button: 1-5 - Quick JOB selection
V18 Button: Synergy, Pulse
V19 LED: lights up when pulse mode is selected
V22 Button: mode selection
V23 LED: Two-stroke 2T
V24 LED: Four-stroke 4T
V25 LED: Steps
V26 LED lit: interval welding
LED flashing: spot welding
V27 Encoder for setting current and feed rate / short press - access to
MENU 1 (menu of secondary parameters)
V28 LED: lights up when the left display shows the current - the
expected value the welder wants.
V29 Button: Select synergy display
V30 Display: shows the current, feed rate and material thickness
V31 LEDs: for displaying choke values
MENU STRUCTURE
METHOS SETTINGS MENU
Press the V16 encoder briefly to enter the method selection.
Set the AIR/ELE/TIG/MAN/SYN method with encoder V16. In synergic welding

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mode, select the synergic program number - the selection is shown on display
V11 (displays V30 and V12 are off). Confirm the selection by pressing encoder
V16 or V27. Press another button to exit the menu.
You can switch between the synergy and pulse synergy programs using the
V18 button. The selected method or synergy program number is displayed on
the V11 display.
MENU 1 (MENU OF SECONDARY PARAMETERS)
Press the V27 encoder briefly to enter the secondary parameters menu.
The secondary parameter menu varies depending on the selected method
selected.
Use encoder V27 to select the parameter and encoder V16 to set the desired
value. Press any button to exit the menu.
Display V30 shows "parametr ", display V12 shows the set value and display
V11 shows the default value.
MENU 1 STRUCTURE ELE
Parameter
tag
Parameter Range Default settings
VRD
Voltage reduce device
(on/off)
[on]
ASt
Antisti
c
k
(on/off)
[on]
HS
HotStart
(100
-
250%)
[150]
AF
ArcForce
(100
-
250%)
[130]
PdC
Second (lower) current
(1
-
99%)
[60]
dut Duty cycle (1-99%) [50]
FrE
Frequency
(0,5
-
250Hz)
[1,0]
MENU 1 STRUCTURE TIG - (if the machine is equipped with the TIG method)
Parameter
tag
Parameter Range Default settings
LA
LiftArc
(on/off)
[on]
PoG
Post Gas
(0
-
20s)
[
3,0
]
tuP
Time Up
(0
-
20s)
[0]
Tdo
Time Down
(0
-
20s)
[0,5]
SCu
Start current
(10
-
100%)
[
100
]
bCu
Second
(BiLevel)
Current
(10
-
100%)
[100]
ECu
End Current
(10
-
100%)
[10]
PdC
Second Current
(1
-
99%)
[40]
dut
Duty cycle
(1
-
99%)
[50]
FrE
Frequency
(0,5
-
250Hz)
[1,0]
MENU 1 STRUCTURE MAN
Parameter
tag
Parameter Range Default settings

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ISP Initial Speed (10-100%) [30]
PrG
Pre Gas
(0
-
20s)
[
0,1
]
PoG
Post Gas
(0
-
20s)
[0
,5
]
Brn Burnback (0-150ms) [60]
SPo
Spot
(0,5
-
20s)
[
2,0
]
Int
Interval
(0,5
-
20s)
[
2,0
]

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ALFA IN a.s. © www.alfain.eu
DP PARAMETERS
FdP – frequency of alternating main vs. lower current
dut – Main vs. secondary current duration ratio
bAL – the percentage of how much will be the secondary current
compared to the main current (smaller number = more significant
difference between main and secondary current)
dPC – side current correction
– LEDs below the right display show the currently selected
correction
MENU 2 (CALIBRATION MENU)
Long press encoder V27 to enter the calibration menu.
Cu1 - Cooling unit
oFF - Cooling unit permanently switched off
on - Cooling unit permanently switched on
Aut - Automatic start-up of the cooling unit
Cu2 – Flow sensor
0 - without sensor
1 - pressure switch/flow sensor
2 - flow meter (Hall-Effect)
Cor - Resetting of correction (1 - resetting of correction and choke when
changing the power value).
LoC - Machine lock menu (control panel lock level)
- Cannot enter MENU 3 (calibration menu)
- Cannot save JOBs
- Cannot calibrate the torch
- Cannot switch methods (only by loading JOB)
- Cannot use the reset
1 - Cannot switch JOBs
- Cannot enter the secondary parameters menu
- Cannot change set parameters, only correction in synergy
2 – The machine can only be operated from the remote control
u-I - Voltage and current calibration menu (password protected)
toC – Menu for entering a token
tIM – Menu of counters for machine start-up time, total welding time and
working time in individual modes
By long pressing button 1 (V17) in this mode, the PAS menu is called up, where
after entering the password (123), the counter can be reset.
Long press button 2 (V17) to display the software version of each board:
(V30) – Control PCB (7130)
(V12) – Motor PCB (7131)
(V11) – Display PCB (7132)

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ALFA IN a.s. © www.alfain.eu
Press button 3 (V17) to display the machine's serial number.
Long press button 4 (V17) to display the current machine configuration
(V30) – Machine power
(V12) – Current configuration
Long press button 5 (V17) to test the display.
TOKEN
The token is a unique combination of characters for each machine and is
generated by the manufacturer based on the required features or a purchased
configuration extension. The token can unlock features and configure the
machine without reloading the software. In case of a change request (purchase
of functions), the supplier sends a new token and the procedure for using the
token.
GAS TEST
Press the V2 button to turn on the gas valve. If the button is pressed for less
than 3 seconds, the gas valve switches off when the button is released. If the
button press time is longer than 3 s, the gas valve switches off after approx—20
seconds or after pressing any button.
WIRE FEEDING
Press the V1 button to start the feed motor. Releasing the button stops the feed
motor.
The V30 display shows the wire feed speed. The wire feed speed is set with
encoder V27.INS is displayed on display V11, and display V12 is off. Press
button A36 (wire feeding) inside the feed to start the feed motor. Releasing the
button stops the feed motor.
WIRE LOAD (optional)
Press the V1 and V29 buttons simultaneously to start the feed motor. Releasing
the V1 button stops the feed motor.
The V30 display shows the wire feed speed. V27. Na displeji V11 je zobrazeno
RET, displej V12 je zhasnutý.
COOLING UNIT TEST
Start the cooling unit by pressing the V1 and V2 buttons simultaneously (for more
than 3 seconds). To end the test, press any button. The display V11 shows CU.
Display V30 shows the number of half-pumps from the flow sensor, and V12
shows the flow rate in l/min.
If the flow rate is insufficient, the V9 indicator lights up, and the ERR message
appears on the V30 display.

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FAST LOCK
Long press encoder V16 to lock/unlock the machine.
The lock is not under the password and is signalled by the V6 light.
A locked machine cannot be operated from the control panel; a remote control
can be used.
SMALL RESET
Simultaneously, briefly press the V18 and V22 buttons to reset the selected
method to factory settings. The JOBs will not be deleted – the values in the
calibration menu will remain.
BIG RESET
Long press buttons V18 and V22 simultaneously to set the machine to factory
settings. All JOBs will be deleted. The values in the calibration menu will remain.
JOBs
JOB means the saved welding machine settings (programs) for a specific
welding job. JOBs work only for the MIG method (manual, synergic, pulse)
SAVING JOBs
Long press the V5 button to enter the menu to save the JOB.
The V30 display shows SAV, the V12 display shows the JOB number and the
V11 display shows Job.
Symboly před číslem znamenají:
E. - empty JOB.
n. - inactive JOB (cannot be switched by remote control).
A. - Active JOB (can be switched by remote control).
Use encoder V16 to set the JOBs number.
Press encoder V27 or V16 to store the desired JOB.
Press another button to exit the menu to load the job.
LOADING JOBU (JOB LOA)
Short press the V5 buttons to enter the JOB load menu.
The V30 display will be shown LoA, the V12 display will indicate the JOB
number and the V11 display will offer Job.
The symbol in front of the number means:
E. - empty JOB.
n. - inactive JOB (cannot be switched by remote control).
A. - Active JOB (can be switched by remote control).
Use encoder V16 to set the JOBs number.
Use encoder V27 to set the JOB as active inactive or delete the selected JOB.
Press encoder V27 or V16 to load the desired JOB.
Press another button to exit the menu to load the job.

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QUICK JOB SELECTION - MEMORY
JOBs work only for the MIG method (manual, synergic, pulse). Values, including
secondary Parameters, are stored. JOBs are stored as active (can be switched
by remote control on the torch).
Long press buttons 1-5 (position V17) to save the set parameters to memory.
Short press buttons 1-5 (position V17) to retrieve the stored parameters from
memory.
If no JOB is stored at the desired position, an error (ERR 6) appears on the
display.
MACHINE PREPARATION FOR GROOVING (AIR)
CONNECTION OF THE GROOVING TORCH
Connect the groove torch quick coupler to the plus quick coupler A3 on the
generator, carefully forcefully secure by turning clockwise.
CONNECT THE EARTH CABLE
Connect the earth cable quick coupler to the minus quick coupler A4 on the
generator, and secure carefully by forcefully turning clockwise. Attach the earth
clamp to the weldment.
AIR CONNECTION TO THE GROOVE TORCH
Connect the torch to a compressed air source and ensure the pressure is
minimally 5 Bar.
GROOVING (AIR)
1. In the PROGRAM menu, select the AIR method (See page 14).
2. AIR is shown on display V11. The current setpoint is shown on the left
display V30. Display V12 is off.
3. Use encoder V27 to set the current spline value.
4. During welding, the measured value of the welding current is displayed on
display V30. The measured voltage value is displayed on display V12.
5. After the welding is finished, the measured value HOLD remains on
display. The illumination of V7 indicates the HOLD value.
6. If a torch with a remote control is connected, the display shows: ---.
7. If the MIG/MAG torch remains connected, the welding voltage will be
displayed on the