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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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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