Alfain PEGAS 200 AC/DC PULSE Smart User manual

ALFA IN a.s. © www.alfain.eu PEGAS 200 AC-DC (Pulse) Smart manual ENG 03
WELDING INVERTER
PEGAS 200 AC/DC PULSE Smart
PEGAS 200 AC/DC Smart
OPERATING MANUAL

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CONTENT
1 INTRODUCTION ....................................................................................... 3
2 SAFETY INSTRUCTIONS AND WARNINGS ............................................
3 TECHNICAL DATA .................................................................................... 6
EQUIPMENT ............................................................................................. 7
5 OPERATOR CONTROLS .......................................................................... 8
6 GETTING STARTED ............................................................................... 11
7 TWO STROKE AND FOUR STROKE IN TIG MODE ............................... 15
8 BASIC SETTINGS FOR TIG WELDING .................................................. 16
9 GENERAL INFORMATION ON THE WELDING MODES ........................ 17
10 ROUTINE MAINTENANCE & INSPECTION ............................................ 18
11 STATEMENT OF WARRANTY ................................................................ 19
12 DISPOSAL ............................................................................................... 19

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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 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.
PEGAS 200 AC/DC PULSE Smart welds by those methods
1. E – (MMA) DC coated electrodes
2. E – (MMA) AC coated electrodes
3. TIG DC (Lift arc or High Frequency ignition)
. TIG AC (Lift arc or High Frequency ignition)
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.
. The 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 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.
1 . 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

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explosion.
19. To 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. The operator must be insulated from the metal components
connected to the return wire.
2 . The earthing of the piece being worked could increase the risk of
injury to the operator.
EN 6097 -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.
The maximum open-circuit voltage of the welding machines is established by
national and international standards (EN 6097 -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
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
8V 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: 1 1V
peak value
AC current: 1 1V
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.
25. Before opening the machine switch off the machine and disconnect
it from the power socket.
26. Only personnel authorised by this company can carry out
maintenance on the machine.
NOTE
Device complies with IEC 61000-3-12 with following conditions:
Short-circuit power Ssc of network in place at an interface between the user's
supply and the public network (PCC) must be least 99 kW.
User is obliged to consult with the electricity supplier if the impedance of the
network at this point is that required short-circuit capacity Zmax = 36 mΩ and

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whether the device can be connected with a public low-voltage network.
On the nameplate are the following symbols: .
ELECTROMAGNETIC COMPATIBILITY
The welding device is in terms of interference designed primarily for industrial
areas. It meets the requirements of EN 6097 -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
Met od MMA - AC MMA - DC TIG - AC TIG - DC
Mains voltage V/Hz
1x230/50-60
Welding current range A/V
10 - 170 10 - 170 10 -200 10 - 170
Open-circuit voltage U20 V 53,0 63,0 53,0 63,0
Mains protection A 16 @ (25 @)
Max. effective current I1eff A 16,0 (22,5) 16,0 (16,6)
Welding current (DZ=100%)
I2 ta=40 oC A 80 (110) 80 (110) 120 (120) 120(120)
Welding current (DZ=60%)
I2 ta=40 oC A 100 (140) 100 (140) 140 (140) 140 (140)
Welding current (DZ=x%) I2
ta=40 oC A 20%=170 (40%=170)
20%=170
(40%=170)
30%=200
(35%=200)
40%=170
(40%=170)
Protection IP23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (W x L x H) mm
130 x 430 x 230
Weig t kg 8,5
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.

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Another option is to connect the machine to the three-phase mains 3x 00 /
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.
4 EQUIPMENT
CONTENT OF DELIVERY
Item No. Description Qu ntity
5.0279 PEGAS 200 AC/DC PULSE SMART 1
5.0278 PEGAS 200 AC/DC SMART 1
58 7 Set of Connectors for PEGAS AC/DC Smart 1
8. 62.12 Quick connector Pegas 160 female 1
In case you order a torch with the connector on, the set 5756 would be used
for that purpose and will not be delivered then. In case you order a Gas Hose,
the quick connector 8. 62.12 would be used for that purpose and will not be
delivered then.
ACCESSORIES TO ORDER
Item No. Description
VM0321-2 Hose Gas PEGAS OVO 3m G1/
VM0253 Welding Cable Set 2x 3m 35-50 200A
5.0508 Welders Cart P 80
17FSL S Torch PARKER SGT 17 m 35-50 FX S
17FSL SUD Torch PARKER SGT 17 m 35-50 FX S UD
17FSL8S Torch PARKER SGT 17 8m 35-50 FX S
17FSL8SUD Torch PARKER SGT 17 8m 35-50 FX S UD
26FSL S Torch PARKER SGT 26 m 35-50 FX S

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26FSL SUD Torch PARKER SGT 26 m 35-50 FX S UD
26FSL8S Torch PARKER SGT 26 8m 35-50 FX S
26FSL8SUD Torch PARKER SGT 26 8m 35-50 FX S UD
6008 Pressure Reducer FIXICONTROL Ar 2 manometers
5.017 ST Foot Pedal Remote CTRL 3 m PEGAS incl. Connector ST
5 OPERATOR CONTROLS
MAIN PARTS
Fig . 1 Main parts
Pos. Description
A1 Operating panel
A2 Quick connector +
A3 Gas connector of the welding torch
A Torch control connector
A5 Quick connector -
A6 ON/OFF switch
A7 Gas inlet
A8 Mains cable and plug

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OPERATING PANEL
Fig. 2 PEGAS 200 AC/DC Pulse Smart
Fig. 3 PEGAS 200 AC/DC Smart
Pos. Description
1 LED MMA
2 LED TIG LA – Lift Arc ignition
3 Button switch MMA/TIG HF/TIG LIFT ARC.
LED HF. If illuminated the HF ignition was set.

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5 Button switch AC/DC mode
6 LED AC
7 LED DC
8 LED Two Stroke (2T).
9 Button TIG 2T or T (two stroke, four stroke)
10 LED Four Stroke ( T)
11 Encoder
12 LED Pregas. 0,0 – 2,0 s
13 LED start current (just T), 10 – 170 A DC, 10 – 200 A AC.
1 LED Up slope. 0 – 10 s.
15
LED – non pulse mode. To change, turn the encoder 11 and
confirm by means of pressing the encoder 11 down. Display 31
shows ---
16 LED Main Welding Current. 10 - 170 A (TIG-DC)；10 - 200 A (TIG-
AC)； 10 – 170 A (MMA-AC/DC)
17 LED – PULSE selected To change, turn the encoder 11 and confirm
by means of pressing the encoder 11 down. Display 31 shows -P-
18 LED lower current, 10 – 170 A (TIG-DC)；10 – 200 A (TIG-AC)；
10 – 170 A (MMA-AC/DC)
19 LED ratio of the pulse current and the base current . 5 – 95 %. Just
for the pulse mode.
20 LED Pulse Frequency. 0,5 – 200 Hz. Just for the pulse mode.
21 LED Down Slope, 0 – 10 s
22 LED Balance (just TIG AC). Used for elimination of the aluminium
oxides. Range +5 to -5, (more in the text below).
23 LED end current, 10 – 170 A DC, 10 – 200 A AC, just in T.
2 LED Post Gas, 0 – 10 s.
25 LED Time (s). If illuminated there are values in s on the display.
26 LED %. If illuminated there are values in % on the display.
27 LED Hz. If illuminated there are values in Hz on the display.
28 LED HOT START, just for MMA, 0 – 100. LED lights up after
pressing the encoder 11.
29 LED welding current MMA 10 – 170 A, just for MMA. LED lights up
after pressing the encoder 11.
30 LED ARC FORCE just for MMA, 0 – 100. LED lights up after
pressing the encoder 11.

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31 Display
32 LED ALARM. If illuminated there is under or over voltage in the
mains or the machine is overheated
33 LED Voltage (V). If illuminated there are values in V on the display
3 LED current (A)
35 LED ON
6 GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
GETTING STARTED MMA – COATED ELECTRODE
Fig. Ways of connecting the welding cables. Follow the instructions on the
packing of the welding electrodes.
1. Insert the mains plug A8 into a suitable 1x230 V mains socket.
2. Connect the welding cables to the panel quick connectors (+) A2 and (-)
A5 according the instruction on the electrodes packing.
3. Switch the machine on by the ON/OFF switch A6.
. Then switch to the MMA mode by means of the button 3.
5. Set the welding current by means of encoder 11. The values will be
showed on the display.
6. Press button 5 to select AC or DC welding current.
7. It is possible to change the settings of the HOT START (increase of
current during arc ignition time), ARC FORCE (an automatic increase of
the welding current in case the electrode touches the welding piece) by
means of the Encoder 11.
NOTE Prevent touching the electrode any metal material for in this
mode the terminals A2 and A5 are under current.
8. Insert the coated electrode into the electrode holder, connect the clamps
of the ground cable to the welding piece and you may start welding.

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GETTING STARTED TIG
Fig. 5 TIG welding set up
1. Insert the mains plug A8 into a suitable 1x230 V mains socket.
2. Fit the TIG Torch to the Panel quick connector (-) A5.
3. Connect the gas hose of the TIG torch onto Gas outlet connector A3.
. Connect the torch control connector onto the matching connector A4.
5. Connect the work lead to Panel quick connector (+) A2.
6. Connect the gas hose to the reduction valve on the gas cylinder and on
the Gas inlet connector A7 on the rear panel.
7. Switch the machine on by the ON/OFF switch A6.
8. Press the torch trigger, the solenoid valve will open; set the desired gas
flow (pure argon).
9. Select TIG LA or HF mode by means of switch 3. The corresponding
LED will light up.
10. Select 2T (two stroke) or T (four stroke) mode by means of switch
9. The corresponding LED will light up.
11. Select the method desired DC or AC method by means of the
button 5. The corresponding LED will light up.
12. In the welding torch must be installed a corresponding tungsten

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electrode (for AC green or golden). The electrode should be sharpened
also corresponding to the AC or DC mode.
13. Set the welding current by means of Encoder 11.
1 . Other parameters may be set by means of the encoder 11.
Illuminate the appropriate LED by means of pressing the encoder 11, by
means of turning the encoder 11 set the parameter and save it by means
of pressing the encoder 11. After that a next LED will illuminate and you
may set that parameter the same way. The set parameter will be
automatically memorised when you move to another parameter of after 3
s. At every turning of the encoder 11 the last selected parameter will be
offered to be changed.
15. Connect the work clamp to the work piece or at the welding table
and you can start welding.
16. The following table describes the influence setting the clearance
effect.
Clearance effect Value -5 to 0 Value +1 to +5
Shape of the current
curve
Penetration Deep Shallow
Level of wear of the of
tungsten electrode Smaller Bigger

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REMOTE CONTROL
The PEGAS 200 AC/DC PULSE supports three kinds of remote controls.
1. TIG torch with UP-DOWN buttons
2. Foot pedal
3. Standard separate remote control for changing the value of the welding
current.
All three models of remote controls can be connected by means of the front
panel connector A4.
Fig . 6 Foot pedal remote control
Pos. Description
P1 Stepping surface
P3 Connector (connect to matching connector A4 on the front panel)
1. When you connect the P3 connector to matching connector on the front
panel A4 the function setting the current from the front panel will blocked.
2. Set by the encoder 11 the maximal required value of the current.
3. Set the machine to the mode 2T.
. By pressing the stepping surface P1 down you start the welding process.
The value of the welding current depends on the level of pressing the
stepping surface. To reach the maximal current, set by encoder 11,
requires to gently pressing to the lowest position of the stepping surface
P1. The set current will be displayed on the display 31.
5. The welding process ends after releasing the stepping surface P1.

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7 TWO STROKE AND FOUR STROKE IN TIG MODE
TWO STROKE – 2T
FOUR STROKE – 4T
Gas
Down slope
Post
gas
Up slope
Pregas
Welding current
Current
Gas
Pregas Postgas
Down slope
Welding current
Current

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8 BASIC SETTINGS FOR TIG WELDING
Table for stainless steel, DC current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler material
diameter mm
Welding
current
A
Argon flow
l/min
Gas
nozzle
mm
1 1 1,5 0-60 3 10
1,5 1,5 1,5 50-90 10
2 2 2 80-100 12
3 2-3 2-3 90-1 0 5 12
-5 3- 3- 110-180 5 12
Table for Aluminium and aluminium alloys, AC current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler
material
diameter
mm
Welding
current
A
Argon
flow
l/min
Gas
nozzle
mm
Pre
heating
°C
1 2 1,6 5-60 7-9 8 -
1,5 2 1,6-2 50-80 7-9 8 -
2 2,5 2-2,5 90-120 8-12 8-12 -
3 3 3 150-180
8-12 8-12 -
180-200
10-15 8-12 -
5 3- 180-2 0
10-15 10-12 -
Table for Cuprum, DC current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler
material
diameter
mm
Welding
current
A
Argon
flow
l/min
Gas
nozzle
mm
Pre
heating
°C
1 1,5 2 70-80 10 150
2 2,5 3 120-1 0
5 10 150
3 3 3 130-160
5 10 200

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GENERAL INFORMATION ON THE WELDING MODES
MMA welding
The manufacturers of the electrodes specify the optimum welding current for
each type of electrode. The type of electrode to be used depends on the
thickness of the material to be welded and on its position.
Insert the chosen electrode into the electrode holder. To strike the electric arc,
rub the electrode against the material to be welded connected to the earth
(ground) clamp. Once the arc is struck, lift the electrode holder slowly to the
normal welding distance.
To strike the arc better, an initial current is supplied which is higher (hot-start)
compared to the welding current. The electrode on melting deposits in the form
of drops onto the piece to be welded and its outer coating is consumed
supplying the shielding gas for the welding. To facilitate the fluidity of the
welding arc, while the drops are coming off, which can cause a short circuit
between the electrode and the weld pool, a momentary increase in the welding
current (arc-force) is given, thus preventing the arc from going out. If the
electrode stays stuck to the piece to be welded, there is an anti-stick function
that, after a certain short-circuit time, cuts off the power to the generator. Thus
you can detach the electrode without damaging it.
When the coating electrodes are used, you need to remove the dross from the
welding after every pass.
TIG welding
In TIG (Tungsten Inert Gas) welding the electric arc is struck between a non-
consumable electrode (pure tungsten or an alloy) and the workpiece in an
atmosphere protected by an inert gas (argon).
The TIG lift-arc process is struck by contact. A low short-circuit welding current
is set to limit the tungsten inclusion on the workpiece. This process does not
guarantee a weld of high quality at the start of the bead.
To completely prevent the tungsten being included, you must not let the
electrode touch the piece to be welded. However you use a start-up with high
frequency (HF) discharge, that allows striking of the electric arc at a distance.

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10 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 Disconnect the PEGAS from the mains supply voltage before
disassembling.
2. 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.
3. 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 PEGAS welding equipment should only
be carried out only by suitably qualified or competent person.
5. 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.
6. The person carrying out the servicing needs and repairs must know what
to look at, what to look for and what to do.

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11 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.
. 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:
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.
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.
12 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.