Alfain PEGAS 160 MIG MAN User manual

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ALFA IN a.s. © www.alfain.eu NA111-2
WELDING MACHINES
PEGAS 160 MIG MAN
PEGAS 160 MIG SYN
OPERATING MANUAL

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ALFA IN a.s. © www.alfain.eu
CONTENT:
1 INTRODUCTION ...................................................................................... 3
2 SAFETY INSTRUCTIONS AND WARNIN S 

 ..................................... 3
1.1 ELECTROMA NETIC COMPATIBILITY (EMC) ................................ 5
3 TECHNICAL DATA ................................................................................... 6
4 EQUIPMENT ............................................................................................ 6
4.1 MODELS ............................................................................................ 6
4.2 ACCESSORIES TO ORDER ............................................................. 6
4.2.1 Welding torches ............................................................................ 6
4.2.2 Other accessories ......................................................................... 7
5 OPERATOR CONTROLS ......................................................................... 7
5.1 FRONT PANEL .................................................................................. 7
5.2 REAR PANEL .................................................................................... 9
5.3 WIRE FEEDER AND SPOOL HOLDER ........................................... 10
6 ETTIN STARTED .............................................................................. 11
6.1 ETTIN STARTED MMA – COATED ELECTRODE ..................... 11
6.2 ETTIN STARTED TI LIFT ARC ................................................ 11
6.2.1 How to connect the gas cylinder ................................................. 12
6.2.2 Basic settings for TI welding – stainless steel, DC current ....... 12
6.3 ETTIN STARTED MI /MA ....................................................... 12
6.3.1 Model MAN setting ..................................................................... 13
6.3.2 Model SYN setting ...................................................................... 13
6.3.3 MI /MA welding parameters .................................................... 13
6.3.4 Feed rolls .................................................................................... 14
6.3.5 Inserting the wire ........................................................................ 14
6.3.6 Flux core wire – setting the polarity for MI /MA torch .............. 14
7 ROUTINE MAINTENANCE & INSPECTION ........................................... 15
8 STATEMENT OF WARRANTY ............................................................... 15
9 DISPOSAL .............................................................................................. 16

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ALFA IN a.s. © www.alfain.eu
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 Manual 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 Manual and your employer’s safety
practices before installing, operating, or servicing the equipment. While the
information contained in this Manual represents the Manufacturer's best
judgement, the Manufacturer assumes no liability for its use.
Both models of PE AS 160 MI are the multi-function inverter power
generators
welding by those methods
a) MI /MA in 2T, 4T, wires S 2 or stainless steel 0,6 - 1,0 mm, Al
wires 1,0 mm, flux cored wires shelf shielding or standard.
b) E – (MMA) coated electrodes up to 4,0 mm
c) TI lift arc.
2  SAFETY INSTRUCTIONS AND WARNINGS 
• Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
• This equipment must only be used by qualified personnel.
• During installation, any electric work must only be carried out by trained
personnel.
• The machine must be used in a dry place with good ventilation.
• Make sure that no metal dust can be drawn in by the fan inside the
machine, as this could cause damage to the electronic circuits.
• It is prohibited to connect more than one INVERTER generator in series or
in parallel.
• When installing the machine, follow the local regulations on safety.
• The position of the machine must allow easy access by the operator to the
controls and connectors.
• When the welding machine is operating, all its covers and doors must be
closed and well fixed.
• Do not expose the welding machine to direct sunlight or to heavy rain. This
equipment conforms to protection rating IP23S.
• During welding, the welding cables must be located near or at ground level.
They should be as short as possible.

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• 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.
• 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.
• 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.
• 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.
• The operator must ensure all flammable materials are removed from the
work area to avoid any risk of fire.
• 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 HI H RISK
OF EXPLOSION.
• 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.
• To prevent electric shock, we strongly suggest the following rules:
• Do not work in a damp or humid environment.
• Do not use the welding machine if its cables are damaged in any way.
• Make sure that the earthing system of the electric equipment is correctly
connected and operational.
• The operator must be insulated from the metal components connected to
the return wire.
• The earthing of the piece being worked could increase the risk of injury to
the operator.
• 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 58V.
• 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.
• The open-circuit voltage, for as many adjustments as possible, must never

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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
• 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
• Before opening the machine switch off the machine and disconnect it from
the power socket.
• Only personnel authorised by this company can carry out maintenance on
the machine.
1.1 ELECTROMAGNETIC COMPATIBILITY (EMC)
• This welding machine conforms to EN 60974-10 standard. However, the
electromagnetic emissions generated could prove not be compatible with
the maximum permitted levels for some classes of electrical equipment,
such as the following:
• Domestic electronic appliances (radios, TVs, videos, telephones,
burglar alarms, etc.).
• Computers, robots, electro-medical instruments and life-support
systems.
• Radio-television transmitters and receivers.
• Pacemakers and hearing aids.
• All very sensitive electrical equipment.
• The operator is responsible for the installation and use of the welding
machine. If there should be any fault in operations of other systems located
in the immediate vicinity of the generator, we recommend suspending
operations and consulting the manufacturers.

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3 TECHNICAL DATA
Method MI /MA MMA TI
Mains voltage V/Hz 1x230/50-60
Mains protection A 16 T
Max. input power I
1
A 25,9 33,3 22,1
Max. effective current
I
1eff
A 14,2 18,2 12,1
Welding current range A/V 25/15,3 - 160/22 10/20,4 - 160/26,4 10/10,4 - 160/16,4
Open-circuit voltage
U
20
V 58
Welding current
(DC=100%) I
2
/U
2
A/V 90/18,5 90/23,6 90/13,6
Welding current
(DC=60%) I
2
/U
2
A/V 115/19,8 115/24,6 115/14,6
Welding current
(DC=x%) I
2
/U
2
A/V 30%=160/22 30%=160/26,4 30%=160/16,4
Power factor cosφ 0,83
Insulation class F
Protection IP 23S
Standards EN 60974-1
Dimensions (w x l x h)
generator mm 210x470x380
Weight -
compact/generator kg 11,5
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.
4 E UIPMENT
4.1 MODELS
Item No Description
5.0144 PE AS 160 MI MAN
5.0145 PE AS 160 MI SYN
4.2 ACCESSORIES TO ORDER
4.2.1
Welding torches
Item No. Description
BD-14040 Torch ER 140 4m EURO (MI /MA )
5.0155 Torch SR17 4m PE AS 160 MAN-SYN (TI )

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4.2.2 Other accessories
Item No. Description
VM0253 Welding Cable Set 2x 3m 35-50 160A
5.0156 Roll 0.6-0.8/1.0 Pegas MI
4281 Valve Red.AR /CO2, 2 manometers,MINI
S777a Light Reactive Welding Helmet ALFA IN S777a
RAY
3177 Wire 0.9 PN D200 Self Shielding
712.A011 Set SR17/18/26d=1,6
712.A012 Set SR17/18/26d=2,4
712.A013 Set SR17/18/26d=3,2
400P216175 Electrode T 2%Th 1.6x175
400P224175 ElectrodeT 2%Th 2.4x175
400P232175 Electrode T 2%Th 3.2x175
5 OPERATOR CONTROLS
Fig . 1 PE AS 160 MI MAN Fig . 2 PE AS 160 MI SYN
5.1 FRONT PANEL
Pos. Description
1 Display - Current
2 LED is on, when the machine is switched on by the mains switch

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3 Display - Voltage
4
LED. If the LED illuminates the thermo-switch is disconnected. In
such a case leave the machine on to cool down. Second function of
this LED: The LED illuminates for 5 s after the machines is switched
on1. During this time there is no current on the socket 18 and 20.
5 LED. If it illuminates, the method MI /MA has been selected by
the button 8.
6 LED. If it illuminates, the method TI has been selected by the
button 8.
7 LED. If it illuminates, the method MMA has been selected by the
button 8.
8 Button for selecting the welding method.
9 LED. If it illuminates the mode 2 stroke has been selected by the
button 10.
10 Button for selecting the 2T or 4T mode.
11 LED. If it lights the mode 4 stroke has been selected by the button
10.
12 Choke potentiometer
13
Potentiometer:
• Voltage for MI /MA MAN, Correction of Voltage for
MI /MA SYN
• Down Slope for TI
• ARC FORCE for MMA
14 Current potentiometer (for MI /MA wire speed)
15 Button for material selection (only SYN)
16 Button for wire diameter selection. The last LED signed MAN is for
manual mode (only SYN)
17 Central MI /MA torch connector
18 (+) terminal of welding cables
19 TI torch control connector
20
• (-)terminal of welding cables
• TI torch connector

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5.2 REAR PANEL
Fig. 3 – Rear panel elements
Pos. Descriptions
21 ON/OFF switch
22 as connector
23 Mains supply cable
24 Stowage space (for instance torch tips, nozzles etc.)
25 Vents

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5.3 WIRE FEEDER AND SPOOL HOLDER
Fig. 4 – Feeding mechanism and spool holder
Pos. Description
26 Motor gear box
27 Motor
28 Feeding roll
29 Feed roll fixing
30 Inner wall
31 Minus terminal of the MI torch
32 Plus terminal of the MI torch

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33 Burn back time potentiometer
34 MI /MA torch central connector
35 Nut
36 Nut
37 Feeder body
38 Fixing Arm
39 Tightening nut of the spool holder
40 Spring
41 Fixing nut of the spool holder
42 Washer
43 Liner for Feeder
44 Spool holder body
45 Pivot
46 Brake
6 GETTING STARTED
Insert the mains plug into a suitable 1x230 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 (21). LED (2) and displays (1)
and (3) will light on.
6.1 GETTING STARTED MMA – COATED ELECTRODE
• Connect the electrode holder and the work lead to terminals (18) and (20)
according the instructions on the electrode package.
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
 NOTE 


Prevent touching the electrode any metal material for in this mode the
terminals (18) and (20) are under current.
• By means of the button (8) select MMA . LED (7) will light on.
• To select the current use potentiometer (14)
• To select the voltage use potentiometer (13)
• Insert the coated electrode into the electrode holder.
• It is possible to change the level of ARC FORCE by means of
potentiometer (12)
6.2 GETTING STARTED TIG LIFT ARC
• Fit the TI Torch to the minus terminal (20), its connector fit to connector
(19).

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• Connect the work lead to positive terminal (18) and fasten it by turning the
connector to the right. Connect the work clamp to the work piece or at the
welding table.
6.2.1
How to connect the gas cylinder
• Ensure that the gas cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
• Open the gas valve once to blow out possible dirt particles.
• Connect the gas regulator to the gas cylinder valve.
• Connect the gas hose VM0321 to the gas regulator and the quick
connector fit to connector (22).
• Open the gas cylinder valve and adjust the gas flow on the gas regulator
while pressing the torch trigger. The flow rate will be shown at the flow
meter. This should be done according the table below.
• By means of the button (8) select TI . LED (6) will illuminate.
• To select the current use potentiometer (14).
• To select the slope down time use the potentiometer (13).
6.2.2
Basic settings for TIG welding – stainless steel, DC
current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler material
diameter mm
Welding
current
A
Argon flow
l/min
as
nozzle
mm
1 1 1,5 40-60 3 10
1,5 1,5 1,5 50-90 4 10
2 2 2 80-100 4 12
3 2-3 2-3 90-140 5 12
4-5 3-4 3-4 110-180 5 12
6.3 GETTING STARTED MIG/MAG
• Fit the MI Torch to the Euro adaptor (17) by pushing the torch connector
into the brass torch adaptor and screwing the plastic torch nut clockwise to
secure the torch to the torch adaptor. Remove the contact tip from the torch
handset.
• Connect the work lead to negative terminal (20) and fasten it by turning the
connector to the right. Connect the work clamp to the work piece or at the
welding table.
• Ensure that the gas cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
• Open the gas valve once to blow out possible dirt particles.
• Connect the gas regulator to the gas cylinder valve.

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• Connect the gas hose VM0321 to the gas regulator and the quick
connector fit to connector (22).
• Open the gas cylinder valve and adjust the gas flow on the gas regulator
while pressing the torch trigger. The flow rate will be shown at the flow
meter. This should be approximately wire diameter x 10 l/min.
• By means of the button (8) select MI /MA , LED (5) will illuminate.
• To select 2 stroke or 4 stroke modes press button (10). Appropriate LED
(9) or (11) will illuminate.
6.3.1
Model MAN setting
• To select the current/wire speed use potentiometer (14).
• To select the voltage use potentiometer (13).
• To set the level of the choke use potentiometer (12).
• To change the time of burn back (0,1 – 0,6 s) use potentiometer (33) in the
space of the wire feeder.
6.3.2
Model SYN setting
• By means of the button (15) set the material to be welded with. (Fe – steel
S 2/S 3, Al-aluminium, Ss – stainless steel).
• By means of the button (16) set the wire diameter to be welded with. In
case of setting MAN follow the instructions in the article above.
• To set the welding power use potentiometer (14).
• To make correction of the voltage use potentiometer (13). On position 5 is
no correction.
• To make correction of the choke level use potentiometer (12). On position
5 is no correction.
• To change the time of burn back (0,1 – 0,6 s) use potentiometer (33) in the
space of the wire feeder.
Note: The synergy curves are for PA welding position. The gas for Fe is 80%
Ar+20%CO2, for Ss 98% Ar + 2% CO2, for Al 100% Ar. If you weld in different
conditions it may be necessary to make correction by potentiometers (13) and
(12) .
6.3.3
MIG/MAG welding parameters
For orientating adjusting of the welding current and voltage you can use
empirical relation U2 = 14+0.05 2. From that you can specify desired
voltage
.
Wire diameter (mm) Welding current (A) Material thickness (mm)
0,6 25-110 1,0-1,6
0,8 35-160 1,0-2,3
0,9 45-160 1,0-2,3

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1,0 45-160 1,2-6,0
Table of approximate parameter settings
6.3.4 Feed rolls
• The wire feed rolls can be used for two different diameters of welding wire
– the rolls have two grooves - 0,6 and 0,8-1,0 mm (The larger groove is
aimed for three wire diameters 0,8-0,9 and 1,0 mm).
• To change the groove move the Fixing Arm (38) towards you and the
spring loaded pressure roll arms will pop down.
• Unscrew the plastic Feed roll fixing (29) and take off the roll.
• Turn the feed roll around or replace with size required.
• The groove 0,8-1,0 mm can be used also for flux cored wires.
6.3.5
Inserting the wire
• Open the wire feed compartment lid on the machine and un-screw the
Fixing nut of the spool holder (41).
• Place wire spool on the Spool holder body (44) and ensure that its drive
dog-pin engages the mating hole in the wire spool.
• Screw back the Fixing nut of the spool holder (41).
• Un-screw the contact tip in the MI torch.
• Cut off the curved or damaged end of welding wire and feed it through the
Liner for Feeder (43). The diameter of the wire should correspond to the
diameter of the feed roll. The wire size is on the face of the feed roll (28).
• Move the Fixing Arm (38) towards you and the spring loaded pressure roll
arms will pop down.
• Thread the wire through the Liner for Feeder (43) past the rollers and then
through the outlet guide in the MI /MA torch central connector (34).
• Put the pressure arm roll back ensuring that it fit together and fix by setting
the Fixing Arm (38) into vertical position.
• Adjust the pressure by of Fixing Arm (38) so that it provides constant
movement. Do not over tighten pressure arm setting as damage to motor
gearbox may occur.
• You may brake the spool by means of tightening nut of the spool holder
(39), the wire spool should not continue to run on when the feed motor
stops.
• Press the torch trigger till the wire appears approximately 20 mm out of the
torch neck. Screw in the contact tip corresponding to the wire diameter and
cut off the wire stick out.
6.3.6
Flux core wire – setting the polarity for MIG/MAG torch
It is desirable to have positive polarity on the MI /MA torch while
welding with solid wire in majority of cases. The welder is supplied from the

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production with positive polarity on the MI /MA torch. For welding with flux
cored wires it may be necessary to have negative polarity on the MI /MA
torch (refer to the welding wire maker´s recommendations).
• Unscrew nut (32) and remove the cable off the terminal (+) (32).
• Connect the cable into the (-) terminal (31) - do not leave out the washers.
• Connect the work lead to (+) terminal of welding cables (18).
7 ROUTINE MAINTENANCE & INSPECTION
• The only routine maintenance required for the PE AS range of machines
is a thorough cleaning and inspection, with the frequency depending on the
usage and the operating environment.


 WARNIN 


• Disconnect the PE AS from the mains supply voltage before
disassembling.
• 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 


• 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.
• 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.
• Troubleshooting and repairing of PE AS welding equipment should only
be carried out only by suitably qualified or competent person.
• 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.
• 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
• 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.
• ALFA IN welding products are manufactured for use by commercial and
industrial users and trained personnel with experience in the use and

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maintenance of electrical welding and cutting equipment.
• 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.
• If warranty is being sought, please contact your ALFA IN product supplier
for the warranty repair procedure.
• 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.
• Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.


 NOTE 


• 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.
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.