Alfain PEGAS 200 User manual

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ALFA IN a.s. © www.alfain.eu NA156-6
WELDING INVERTER
PEGAS 200 AC/DC PULSE
OPERATING MANUAL

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ALFA IN a.s. © www.alfain.eu
CONTENT:
1INTRODUCTION ........................................................................................3
2SAFETY INSTRUCTIONS AND WARNINGS.............................................4
3ELECTROMAGNETIC COMPATIBILITY (EMC) ........................................5
4TECHNICAL DATA.....................................................................................6
5EQUIPMENT...............................................................................................7
5.1CONTENT OF DELIVERY...................................................................7
5.2ACCESSORIES TO ORDER...............................................................7
6OPERATOR CONTROLS...........................................................................8
6.1MAIN PARTS.......................................................................................8
7GETTING STARTED................................................................................10
7.1GETTING STARTED MMA – COATED ELECTRODE......................10
7.2GETTING STARTED TIG ..................................................................11
7.3REMOTE CONTROL.........................................................................12
8TWO STROKE AND FOUR STROKE IN TIG MODE...............................13
8.1TWO STROKE – 2T...........................................................................13
8.2FOUR STROKE – 4T.........................................................................13
8.3BILEVEL – SECOND WELDING CURRENT.....................................13
9BASIC SETTINGS FOR TIG WELDING...................................................13
10ROUTINE MAINTENANCE & INSPECTION ............................................14
11STATEMENT OF WARRANTY.................................................................15
12DISPOSAL................................................................................................15

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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 welds by those methods
1. E – (MMA) DC coated electrodes up to 4,0 mm
2. E – (MMA) AC coated electrodes up to 4,0 mm
3. TIG DC (Lift arc or High Frequency ignition)
4. TIG AC (Lift arc or High Frequency ignition)
1. TIG AC 2. TIG DC 3. MMA

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ALFA IN a.s. © www.alfain.eu
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.
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 HIGH 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.

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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.
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
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.
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.
3 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.

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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.
4 TECHNICAL DATA
Units
Method MMA - AC MMA - DC
Mains voltage V/Hz 1x230/50-60
Mains protection A 16T *)
Max. input power I1 A 40,3
Max. effective current I1eff A 20,2
Welding current range A/V 10/20,4 - 170/26,8 5/20,2 - 170/26,8
Open-circuit voltage U20 V 73 68
Welding current (DC=100%) I2 /U2
ta=40 oC A/V 70/22,8 80/23,2
Welding current (DC=60%) I2/U2
ta=40 oC A/V 90/23,6 110/24,4
Welding current (DC=x%) I2/U2
ta=40 oC A/V 20%=170/26,8 25%=170/26,8
Welding current (DC=100%) I2 /U2
ta=25 oC A/V 90/23,6 110/24,4
Welding current (DC=60%) I2/U2
ta=25 oC A/V 110/24,4 130/25,2
Welding current (DC=x%) I2/U2
ta=25 oC A/V 25%=170/26,8 30%=170/26,8
Insulation class F
Protection IP23S
Standards EN 60974-1
Dimensions (w x l x h) mm 250 x 470 x 400
Weight kg 21,8
Method TIG - AC TIG - DC
Mains voltage V/Hz 1x230/50-60
Welding current range A/V 10/10,4 - 200/18,0 5/10,2 - 200/18,0
Open-circuit voltage U20 V 73 68
Welding current (DC=100%) I2 /U2
ta=40 oC A/V 70/12,8 80/13,2
Welding current (DC=60%) I2/U2
ta=40 oC A/V 90/13,6 110/14,4

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Welding current (DC=x%) I2/U2
ta=40 oC A/V 20%=200/18,0 25%=200/18,0
Welding current (DC=100%) I2 /U2
ta=25 oC A/V 90/13,6 110/14,4
Welding current (DC=60%) I2/U2
ta=25 oC A/V 110/14,4 130/15,2
Welding current (DC=x%) I2/U2
ta=25 oC A/V 25%=200/18,0 30%=200/18,0
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.
5 EQUIPMENT
5.1 CONTENT OF DELIVERY
Item No. Description Quantity
5.0172 PEGAS 200 AC/DC PULSE 1
5.0189 Set of Connectors for PEGAS AC/DC 1
5.2 ACCESSORIES TO ORDER
Item No. Description
VM0184-1 Hose Gas ATA PULSE 3m G1/4, D 9.5 HD
VM0253 Welding Cable Set 2x 3m 35-50 200A
5.0216 CS 601 W Cooling Unit PEGAS
5.0228 Welders Cart
WP17121RBAA Torch WP 17 4m 35-50 with Connector AERO
5.0201A Torch WP 26 4m 35-50 with connector AERO
5.0202A Torch WP 26 8m 35-50 with connector AERO
7S3.A005A Torch ABITIG 26 4m 35-50 HiF Leather UD AERO
7S3.A006A Torch ABITIG 26 8m 35-50 HiF Leather UD AERO
7S4.A003AA Torch ABITIG 18 4m 35-50 leather W AERO
3549 Valve Red.AR OXY MAXI PC 2
5.0174 Foot Pedal Remote CTRL 3 m PEGAS incl. Connector

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6 OPERATOR CONTROLS
6.1 MAIN PARTS
Fig . 1 Main parts
Pos. Description
1 Button TIG 2T or 4T (two stroke, four stroke)
2 LED Pregas. 0,1 – 1 s, default 0,3 s
3 Current Display
4 LED start current (just 4T). 5 – 100 % of the main welding current.
DC, 10 – 100 % AC, Default 5%.
5 LED Up slope. 0 – 10 s, default 0 s.
6 LED Main Welding Current. 5 – 200 TIG DC, 10 – 200 TIG AC, 5 –
170 MMA DC, 10 – 170 MMA AC
7 LED ratio of the pulse current and the base current . 5 – 100 %.
Default 5 %.Just for the pulse mode.
8 Display Voltage, %, time and Hz.
9 LED Main Welding Current in the pulse mode. 5 – 200 A DC, 10 –
200 TIG AC
10 LED Pulse Base Current. 5 – 200 A DC, 10 -200 A AC.

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11 LED Time (s). If illuminated there are values in s on the display 8.
12 LED Voltage (V). If illuminated there are values in V on the display
8.
13 LED %. If illuminated there are values in % on the display 8.
14 LED ON
15 LED ALARM. If illuminated there is under or over voltage in the
mains or the machine is overheated. At the same time the displays
show Err 001.
16 LED Hz. If illuminated there are values in Hz on the display 8.
17 LED Down Slope, 0 – 10 s, default 0 s.
18 LED Post Gas, 0,1 – 10 s, default 3 s.
19 LED end current, 5 – 100 % of the Main Welding Current DC, 10 –
100 % of the Main Welding Current AC, default 5 %. Just in 4T.
20 LED ARC FORCE for MMA, 0 – 10.
21 MMA switch
22 LED MMA. Can be turned off by means of pressing button 1.
23 LED Arc Length, 0 – 10.
24 LED HOT START, 0 – 10.
25 Button for moving to the right on the parameters curve.
26 LED Balance (just TIG AC). Used for elimination of the aluminium
oxides. Range 15 – 50 %, default 15% (more in the text below).
27 LED Pulse Frequency. 0,5 – 200 Hz, default 0,5 Hz. Just in the
pulse mode.
28 Encoder
29 LED AC Frequency (just TIG AC). Range: 50-250 Hz. The higher
current, the more the maximal frequency decreases. The range of
frequency at the maximal current is 50 – 100 Hz.
30 Button for moving to the left on the parameters curve.
31 Gas test.
32 Button switch HF/LIFT ARC.
33 Button switch Pulse/Non pulse mode.
34 LED Pulse. If illuminated the Pulse mode was set.
35 LED HF. If illuminated the HF ignition was set.
36 LED Gas Test. If illuminated the mode of setting the gas flow was
selected (by means of the gas valve on the gas cylinder). To turn it
off press the button 31 again or it will go off this mode after 10 s.

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37 LED Four Stroke (4T).
38 LED Two Stroke (2T).
39 LED DC
40 LED AC
41 Button switch AC/DC mode.
42 Quick connector +
43 Torch control connector (pin 8 and 9)
44 Quick connector -
45 Gas connector of the welding torch
46 Gas inlet
47 Mains cable and plug
48 ON/OFF switch
7 GETTING STARTED
7.1 GETTING STARTED MMA – COATED ELECTRODE
Insert the mains plug 41 into a suitable 1x230 V
mains socket. The supply fuses or circuit breaker
should correspond to the technical data stated in
this manual.
Connect the welding cables to the panel quick
connectors (+) 42 and (-) 44 according the instruction on the electrodes
packing.
Switch the machine on by the ON/OFF switch 48.
Set the welding current by means of Encoder 28. The values will be showed on
the display 3.
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) and Arc Length by
means of the Button 21 and the Encoder 28.
Then switch to the MMA mode by means of the button 21. LEDs 20, 23 or 24
may not illuminate.
NOTEPrevent touching the electrode any metal material for in this
mode the terminals 42 and 44 are under current.
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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7.2 GETTING STARTED TIG
Insert the mains plug 41 into a suitable 1x230 V
mains socket. The supply fuses or circuit breaker
should correspond to the technical data stated in this
manual.
Fit the TIG Torch to the Panel quick connector (-) 44
and fasten it by turning the connector to the right.
Connect the gas hose of the TIG torch onto Gas
outlet connector 45.
Connect the torch control connector onto the matching connector 43.
Connect the work lead to Panel quick connector (+) 42 and fasten it by
turning the connector to the right.
Connect the gas hose to the reduction valve on the gas cylinder and on the
Gas inlet connector 46 on the rear panel.
Switch the machine on by the ON/OFF switch 48.
Select the Gas setting mode by means of pressing the button 31, LED 36
will illuminate. Set the flow of the argon gas by means of the pressure
reduction valve on the gas cylinder.
Select 2T (two stroke) or 4T (four stroke) mode by means of switch 1. The
corresponding LED will light up.
Select the method desired TIG DC or AC method by means of the button
41. The corresponding LED will light up.
In the welding torch must be installed a corresponding tungsten electrode
(for AC green or golden). The electrode should be sharpened also
corresponding to the AC or DC mode.
Select HF or list arc ignition by means or switch 4.
Set the welding current by means of Encoder 28. The values will be
showed on the display 3.
Other parameters may be set by means of buttons 30 and 25 and the
encoder 28. The corresponding LEDs will light up. The set parameter will
be automatically memorised when you move to another parameter of after
3 s. More in the table MAIN PARTS above.
Connect the work clamp to the work piece or at the welding table and you
can start welding.
The following table describes the influence setting the clearance effect.
Clearance effect Value 20-30% Value 50%
Shape of the current
curve
Penetration Deep Shallow

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Level of wear of the of
tungsten electrode Smaller Bigger
7.3 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 43.
Fig . 2 Foot pedal remote control
Pos. Description
P1 Stepping surface
P2 Potentiometer of setting the limit of maximal welding current
P3 Connector (connect to matching connector 13 on the front panel)
When you connect the P3 connector to matching connector on the front panel
43 the function setting the current from the front panel will blocked, instead of
that the max. current is limited by the potentiometer P2.
By pressing the stepping surface 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 limited by potentiometer P2 requires to
gently pressing to the lowest position of the stepping surface P1. The set
current will be displayed on the current display 3.
The welding process ends after releasing the stepping surface P1.

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8 TWO STROKE AND FOUR STROKE IN TIG MODE
8.1 TWO STROKE – 2T
8.2 FOUR STROKE – 4T
8.3 BILEVEL – SECOND WELDING CURRENT
When the machine is in 4T mode, there is always active the BILEVEL function.
The value of the second current is automatically set to 50% of the pre-set value
of the main welding current. To enter the second welding current press the
torch button for a short time and release it. To get back to the main welding
current press the torch button for a short time and release it.
9 BASIC SETTINGS FOR TIG WELDING
Table for stainless steel, DC current
Material
thickness Tungsten electrode Filler material diameter mm Welding current Argon flow l/min Gas nozzle
Gas
Down slope
Post
gas
Up slope
Pregas
Welding current
Current
Gas Pregas Postgas
Down slope
Welding current
Current

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mm diameter
mm A 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
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
0C
1 2 1,6 45-60 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 -
4 4 4 180-200 10-15 8-12 -
5 4 3-4 180-240 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
0C
1 1,5 2 70-80 4 10 150
2 2,5 3 120-140 5 10 150
3 3 3 130-160 5 10 200
10 ROUTINE MAINTENANCE & INSPECTION
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.
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 PEGAS welding equipment should only be
carried out only by suitably qualified or competent person.

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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.
11 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
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.
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

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compatible recycling facility.