Alfain PEGAS 161 E softswitch User manual

ALFA IN a.s. © www.alfain.eu PEGAS 161 E softswitch Manual EN 02
WELDING INVERTER
PEGAS 161 E softswitch
OPERATING MANUAL

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CONTENT:
1 IN RODUC ION ....................................................................................... 3
2 SAFE Y INS RUC IONS AND WARNINGS ............................................ 4
3 ECHNICAL DA A .................................................................................... 6
4 EQUIPMEN ............................................................................................. 7
5 OPERA OR CON ROLS .......................................................................... 8
6 GE ING S AR ED ................................................................................. 9
7 ROU INE MAIN ENANCE & INSPEC ION ............................................ 10
8 S A EMEN OF WARRAN Y ................................................................ 10
9 DISPOSAL ............................................................................................... 11
10 WARRAN Y LIS .................................................................................... 11

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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.
his 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. herefore please take the time to
read the entire manual, especially the Safety Precautions. hey 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.
PEGAS 161 E softswitch is an inverter welding power source using softswitch
technology. he softswitch technology - simply said - ensures the opening and
closing of the IGB s at zero voltage and current. he inverter then has less
power consumption, and less cooling requirements, and it is possible
significantly reduce the size of the welder while maintaining considerable
power. PEGAS 161 E softswitch at ambient temperature 25 ° C Duty Cycle
100% provides160 A welding current. he machine is light and small.
PEGAS 161 E softswitch welds by those methods
a) E – (MMA) coated electrodes up to 4,0 mm
b) IG lift arc.
We reserve the law of adjustments and changes in case of printing errors,
change of technical paramaters, accessories etc. without previous notice.
hese changes may not be reflected in the manuals for use in paper or
electronic form.

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2 SAFET 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. his equipment must only be used by qualified personnel.
3. During installation, any electric work must only be carried out by trained
personnel.
4. he machine must be used in a dry place with good ventilation.
5. 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.
6. It is prohibited to connect more than one INVER ER generator in series or
in parallel.
7. When installing the machine, follow the local regulations on safety.
8. he 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.
his equipment conforms to protection rating IP23S.
11. During welding, the welding cables must be located near or at ground
level. hey should be as short as possible.
12. he 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. he 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 UL RAVIOLE RADIA ION is emitted. herefore 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. he 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. he operator must ensure all flammable materials are removed from the
work area to avoid any risk of fire.
17. he 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. HERE IS A VERY
HIGH RISK OF EXPLOSION.
18. he 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.

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19. o prevent electric shock, we strongly suggest the following rules:
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. Make sure that the earthing system of the electric equipment is correctly
connected and operational.
23. he operator must be insulated from the metal components connected to
the return wire.
24. he 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 50,9 V.
26. he 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. hese values are not applicable to the strike
currents and those for stabilisation of the arc that could be above it.
27. he 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 orches held mechanically
with increased protection for
the operato
r
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. he 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.

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ELECTROMAGNETIC COMPATIBILIT
he 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
Method MMA IG
Mains voltage V/Hz 1x230/50-60
Welding current range A 5 - 160 5 - 160
Open-circuit voltage U20 V 51,0
Mains protection A 16 @ (25 @)
Max. effective current I1eff A 16,0 (22,1) 14,5 (14,5)
Welding current (DC=100%) I2 A 80 (110) 110 (110)
Welding current (DC=60%) I2 A 100 (140) 140 (140)
Welding current (DC=x%) I2 A 20% = 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 4,5
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.
he machine is equipped as standard with a 16 A plug for connection to
a single-phase network of 1 x 230 V. For this 16A plug the loaders in front of
the brackets apply.
When the machine is operated in higher load areas where the effective current
drawn from the mains exceeds 16 A, it is necessary to replace the standard
plug with a 32 A industrial plug.

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Protection of the mains socket with the same design, to which the machine will
be connected, it must be max. 25 A.
For this power supply with 25 A protection the loaders in the brackets apply.
Modification of the connection may only be carried out by a qualified
electrician, which at the same time assesses the state of the network at the
connection point and decides whether it will be possible to connect the
machine in this way.
4 EQUIPMENT
ACCESSORIES TO ORDER
Item No. Description
V9030034 Welding Cable Set 2x3m 10-25 150A
5.0110 Box blue
6124 Pressure Reducer BASECON ROL Ar 2 manometers
S777c. Welding Helmet Barracuda S777C Black
706.1057 orch SR 17 V 4m BSB10-25
712.A011 Set SR17/18/26d=1,6
712.A012 Set SR17/18/26d=2,4
712.A013 Set SR17/18/26d=3,2
700.1184 Electrode wolf.WL15 1.6x175 gold
700.1186 Electrode wolf.WL15 2.4x175 gold
700.1187 Electrode wolf.WL15 3.2175 gold

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5 OPERATOR CONTROLS
FRONT PANEL
Fig . 1 Main parts
Pos. Description
1 LED ON
2 LED over heating
3
Current potentiometer
4 Method switch MMA (electrode)/ IG
5
Panel quick connector
-
6
Panel quick connector
+
7
Mains sock
et with a p
l
ug
8
ON/OFF switch

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6 GETTING STARTED
Insert the mains plug into a suitable 1x230 V mains socket. he supply fuses
or circuit breaker should correspond to the technical data in section 4. Switch
the machine on by the ON/OFF switch 8. 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
Prevent touching the electrode any metal material for in this mode the
terminals 5 and 6 are under current.
2. By means of the switch 4 select MMA .
3. o select the current use potentiometer 3
4. Insert the coated electrode into the electrode holder.
GETTING STARTED TIG LIFT ARC
1. Fit the IG orch 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 4 select IG .
How to connect the 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 IG torch to the gas regulator.
5. Open the gas cylinder valve, open the valve on the IG torch and adjust the
gas flow on the gas regulator. he flow rate will be shown at the flow meter.
his should be done according the table below.

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7 ROUTINE MAINTENANCE & INSPECTION
1. he 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.
CAU ION 
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. o 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. he welder should also be wiped clean. If necessary, solvents that
are recommended for cleaning electrical apparatus may be used.
6. roubleshooting 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. he 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 WARRANT
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. he 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:

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6. 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.
7. Equipment that has been used beyond the specifications established in the
operating manual.
8. Installation not in accordance with the installation/operating manual.
9. Any product that has been subjected to abuse, misuse, negligence or
accident.
10. Failure to clean and maintain (including lack of lubrication, maintenance
and protection), the machine as set forth in the operating, installation or
service manual.
11. Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.
NO E 
12. 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.
1. 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 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 WARRANT 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: