Alfain PEGAS 160 E Smart User manual

ALFA IN a.s. © www.alfain.eu PEGAS 160-200 E Smart FOD anual EN 03
WELDING INVERTER
PEGAS 160 E Smart (FOD)
PEGAS 200 E Smart (FOD)
OPERATING MANUAL

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CONTENT:
1. INTRODUCTION .......................................................................................... 3
2. SAFETY INSTRUCTIONS AND WARNINGS ............................................. 4
3. TECHNICAL DATA ...................................................................................... 6
4. EQUIP ENT ................................................................................................ 8
5. OPERATOR CONTROLS ............................................................................ 9
6. GETTING STARTED ................................................................................. 10
7. ROUTINE AINTENANCE & INSPECTION ............................................. 11
8. STATE ENT OF WARRANTY .................................................................. 12
9. DISPOSAL ................................................................................................. 13
10. WARRANTY LIST ..................................................................................... 13

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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 anual 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 anual and your employer’s safety practices
before installing, operating, or servicing the equipment. While the information
contained in this anual represents the anufacturer's best judgement, the
anufacturer assumes no liability for its use.
PEGAS 160-200 E Smar (FOD) weld by those methods
a) E – ( A) coated electrodes up to 4,0 mm
b) TIG Lift arc.
Innovation FOD – Fan On Demand. This function ensures that after about 8
minutes of inactivity, the electronics will reduce the fan speed to about 30%. This
leads to less wear, less noise and power saving.
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. During 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. ake 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. Do not expose the welding machine to direct sunlight or to heavy rain. This
equipment conforms to protection rating IP23S.
11. During 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 RADIATION 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
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:

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20. Do not work in a damp or humid environment.
21. Do not use the welding machine if its cables are damaged in any way.
22. ake 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. During 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 50 V.
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
DC current: 113V
peak value
AC current: 68V
peak value and
48V effective
2 Places without increased risk
of electric shock
DC current: 113V
peak value
AC current: 113V
peak value and
80V effective
3
Torches held mechanically
with increased protection for
the operator
DC 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 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:
Device complies with IEC 61000-3-12.
Working ambient temperature between -10 and +40 °C.
Relative humidity below 90% at +20 °C.
Up to 3000 m altitude.

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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. During operation, the
device may be the source of interference.
Caution
We warn users, that they are responsible for possible interference from
welding.
3. TECHNICAL DATA
PEGAS 160 E smar (FOD)
ethod A TIG
ains voltage V/Hz 1x230/50-60
Welding current range A 10-160 10 - 160
Open-circuit voltage U20 V 50,0
ains protection A 16 @ (25 @)
ax. effective current I1eff A 16,0 (20,7) 13,6 (13,6)
Welding current (DC=100%) I2 A 85 (110) 110 (110)
Welding current (DC=60%) I2 A 110 (140) 140 (140)
Welding current (DC=x%) I2 A 25% = 160
(35%=160)
35% = 160
(35%=160)
Protection IP23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm 112 x 274 x 215
Weight kg 4,9
ethod A TIG
ains voltage V/Hz 1x230/50-60
Welding current range A 10 - 200 10 - 200
Open-circuit voltage U20 V 50,0
ains protection A 16 @ (25 @)
ax. effective current I1eff A 16,0 (22,7) 15,6 (15,6)
Welding current (DC=100%) I2 A 85 (120) 120 (120)
Welding current (DC=60%) I2 A 110 (150) 150 (150)

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Welding current (DC=x%) I2 A 15%=200 (30%=200) 30%=200 (30%=200)
Protection IP23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm 112 x 343 x 215
Weight kg 6,4
The machine is equipped with a 16 A plug for connection to a single phase
supply 1 x 230 V, the corresponding data for this 16 A plug (Duty Cycle = DC)
are in the table above without brackets.
In order to fully use the technical capabilities of the machine, the machine must
be connected to the industrial single phase networks with a blue plug 32 A with
the maximum permissible fuse of 25 A. The corresponding data for such a 32 A
plug are stated in the table above in brackets.
Another option is to connect the machine to the three-phase mains 3x400 / 230V
TN-S (CS). The condition is to use a 5 pin 32 A plugs for the supply cable and
connection to the phase voltage. Black (brown) wire connected to one phase
(e.g. L1), the blue wire to the neutral wire (N) and green-yellow wire to the
grounded conductor "PE". In this case, it is possible to connect the machine to
a three-phase socket, which may be protected by fuse max. 25 A.
Attention! Do not connect to the interconnected voltage (delta voltage) (between
2 phases)!
Replacement of the plug may only be performed by ALFA IN authorized service
personnel.
ALFA IN continuously strives to produce the best product possible and therefore
reserves the right to change, improve or revise the specifications or design of
this or any product without prior notice. Such updates or changes do not entitle
the buyer of equipment previously sold or shipped to the corresponding changes,
updates, improvements or replacement of such items.

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4. EQUIPMENT
ACCESSORIES TO ORDER
I em No. Descrip ion Pic ure
V 0253 Welding Cable Set 2x 3m 35-
50 160A
5.0178 Box black 50x58,5x18 cm
6124
Pressure Reducer
BASECONTROL Ar 2
manometers
6125
Pressure Reducer
BASECONTROL CO2 2
manometers
706.1037 Torch SRT 17 4m V 35-50
S777c. Welding Helmet Barracuda
S777C Black

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5. OPERATOR CONTROLS
Fig . 1 ain parts
Pos. Descrip ion
1 LED ON
2 ethod switch A (electrode)/TIG
3 Current potentiometer
4 LED over heating
5 Panel quick connector (-)
6 Panel quick connector (+)
7 ains socket with a plug
8 ON/OFF switch

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6. GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
Insert the mains plug into a suitable 1x230 V (or 1x110 V) mains socket. The
supply fuses or circuit breaker should correspond to the technical data in section
3. Switch the machine on by the ON/OFF switch 7. LED 1 will illuminate.
GETTING STARTED MMA – COATED ELECTRODE
1. Connect the electrode holder and the work lead to terminals 5 and 6 according
the instructions on the electrode package. NOTE Preven
ouching he elec rode any me al ma erial for in his mode he erminals
5 and 6 are under curren .
2. By means of the switch 2 select A .
3. To select the current use potentiometer 3
4. Insert the coated electrode into the electrode holder.
TABLE OF ELECTRODE CONSUMPTION DURING WELDING
Elec rode
diame er
[mm]
Range of
welding
curren [A]
To al
elec rode
leng h [mm]
Weigh of
boiled
elec rode
wi hou slag
[g]
Boiled
elec rode
ime [s]
Weigh of
boiled
elec rode
wi hou slag
per 1 second
[g/s]
1,6 30 - 55 300 4 35 0,11
2,5 70 - 110 350 11 49 0,22
3,2 90 - 140 350 19 60 0,32
4,0 120 - 190 450 39 88 0,44
GETTING STARTED TIG LIFT ARC
1. Fit the TIG Torch to the minus terminal 5 and fasten it by turning the connector
to the right.
2. Connect the work lead to positive terminal 6 and fasten it by turning the
connector to the right.
3. Connect the work clamp to the work piece or at the welding table.
4. By means of the switch 2 select TIG .

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How o connec he gas cylinder
1. Ensure that the gas cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
2. Open the gas valve once to blow out possible dirt particles.
3. Connect the gas regulator to the gas cylinder valve.
4. Connect the gas hose of the TIG torch to the gas regulator.
5. Open the gas cylinder valve, open the valve on the TIG torch and adjust the
gas flow on the gas regulator. The flow rate will be shown at the flow meter.
This should be done according the table below.
TABLE OF CONSUMPTION DURING TIG WELDING
Wolfram elec rode diame er [mm]
Argon flow [l/min]
S eel / s ainless s eel
0,5 3 – 4
1,0 3 – 5
1,6 4 – 6
2,4 5 – 7
3,2 5 – 9
7. ROUTINE MAINTENANCE & INSPECTION
1. The only routine maintenance required for the PEGAS range of machines is
a thorough cleaning and inspection, with the frequency depending on the
usage and the operating environment.
 WARNING 
2. Disconnect the PEGAS from the mains supply voltage before disassembling.
3. Special maintenance is not necessary for the control unit parts in the Welder.
If these parts are damaged for any reason, replacement is recommended.
CAUTION 
4. Do not blow air into the welder during cleaning. Blowing air into the welder
can cause metal particles to interfere with sensitive electronic components
and cause damage to the welder.
5. To clean the welder, disconnect it from the mains supply voltage then open
the enclosure and use a vacuum cleaner to remove any accumulated dirt and
dust. The welder should also be wiped clean. If necessary, solvents that are
recommended for cleaning electrical apparatus may be used.

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6. Troubleshooting and repairing of PEGAS welding equipment should only be
carried out only by suitably qualified or competent person.
7. A ‘competent person’ must be a person who has acquired through training,
qualification or experience, or a combination of them, the knowledge and
skills enabling that person to safely carry out a risk assessment and repairs
to the electrical equipment in question.
8. The person carrying out the servicing needs and repairs must know what to
look at, what to look for and what to do.
8. STATEMENT OF WARRANTY
1. In accordance with the warranty periods stated below, ALFA IN guarantees
the proposed product to be free from defects in material or workmanship
when operated in accordance with the written instructions as defined in this
operating manual.
2. ALFA IN welding products are manufactured for use by commercial and
industrial users and trained personnel with experience in the use and
maintenance of electrical welding and cutting equipment.
3. ALFA IN will repair or replace, at its discretion, any warranted parts or
components that fail due to defects in material or workmanship within the
warranty period. The warranty period begins on the date of sale to the end
user.
4. If warranty is being sought, please contact your ALFA IN product supplier for
the warranty repair procedure.
5. ALFA IN warranty will not apply to:
 Equipment that has been modified by any other party other than ALFA
IN’s own service personnel or with prior written consent obtained from
ALFA IN Service Department.
 Equipment that has been used beyond the specifications established in
the operating manual.
 Installation not in accordance with the installation/operating manual.
 Any product that has been subjected to abuse, misuse, negligence or
accident.
 Failure to clean and maintain (including lack of lubrication, maintenance
and protection), the machine as set forth in the operating, installation or
service manual.
6. Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.
NOTE 
7. Warranty repairs must be performed by either an ALFA IN Service Centre, an
ALFA IN distributor or an Authorised Service Agent approved by the company
ALFA IN.
8. As a warranty list serves proof of purchase (invoice) on which is the serial
number of the machine, eventually a warranty list on the last page of this

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manual.
9. DISPOSAL
Only for EU countries. Do not dispose of electric tools together with
household waste material.
In accordance with European Council Directive 2002/96/EC on
electrical and electronic equipment waste and its implementation in accordance
with national law, electric tools that have reached the end of their service life
must be collected separately and returned to an environmentally compatible
recycling facility.
10. WARRANTY LIST
As a warranty list serves proof of purchase (invoice) on which is the serial
number of the machine, eventually a warranty list below, which is filled in by an
authorized dealer.
Serial number:
Day, month (written in words)
and year of sale:
Stamp and dealer signature: