Alfain PEGAS 201 MIG SYN PFC User manual

ALFA IN a.s. © www.alfain.eu PEGAS 201 MIG SYN PFC manual EN 04
WELDING MACHINE
PEGAS 201 MIG SYN PFC
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. MAIN PAR S OF HE MACHINE ............................................................. 8
6. MAIN MENU ............................................................................................ 10
7. GE ING S AR ED MIG/MAG .............................................................. 13
8. GE ING S AR ED IG ........................................................................ 20
9. GE ING S AR ED MMA ...................................................................... 21
10. ROU INE MAIN ENANCE & INSPEC ION .......................................... 21
11. S A EMEN OF WARRAN Y .............................................................. 22
12. DISPOSAL ............................................................................................. 23

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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.
he model of PEGAS 201 MIG SYN PFC is the multi-function inverter power
generators welding by those methods:
a) MIG/MAG in 2 , 4 , manually or synergic wires G3Si1 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) IG Lift arc
PEGAS 201 MIG SYN PFC is equipped by system of Power Factor Correction
(PFC).
What are the adva tages of PFC solutio ?
1. Higher efficiency and less stress related to the circuit breaker (in other
words, circuit breaker will switch off later than the devices without PFC).
2. he machine can be connected to the mains 110 V - 230 V + -15% small
influence of under voltage and overvoltage mains power.
3. Smaller level of electromagnetic interference.
4. Minimum net reactive current loading.
We reserve the law of adjustments and changes in case of printing errors,
change of technical parameters, 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. 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. 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.
19. o prevent electric shock, we strongly suggest the following rules:
a. Do not work in a damp or humid environment.

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b. Do not use the welding machine if its cables are damaged in any way.
c. Make sure that the grounding system of the electric equipment is
correctly connected and operational.
d. he operator must be insulated from the metal components connected
to the return wire.
e. he grounding of the piece being worked could increase the risk of
injury to the operator.
20. 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 67V.
21. 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.
22. 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 operator
DC current: 141V
peak value
AC current: 141V
peak value and
100V effective
23. 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
24. Before opening the machine switch off the machine and disconnect it from
the power socket.
25. Only personnel authorised by this company can carry out maintenance on
the machine.
NOTE:
Device complies with IEC 61000-3-12.
ELECTROMAGNETIC COMPATIBILITY
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

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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 MIG/
MAG MMA IG MIG/ MAG MMA IG
Mains voltage V/Hz
1x110/50-60 1x230/50-60
Welding current range A 20 - 130
10 - 100
10 - 140
20 - 200
10 - 200
10 - 200
Open-circuit voltage U20
V 67,0 67,0
Mains protection A 25 @ 16 @
Max. effective current
I1eff A 22,0 17,5 18,0 14,9 15,7 12,0
Welding current
(DC=100%) I2 A 85 65 95 130 120 140
Welding current
(DC=60%) I2 A 110 80 125 150 140 150
Welding current
(DC=x%) I2 A 35%=
130
30%=
100
40%=
140
30%=
200
25%=
200
35%=
200
Protection
IP 23S
Standards
EN 60974-1; EN 60974-10 cl. A
Dimensions (w x l x h) mm 215 x 540 x 410
Weight kg 17,7
Wire speed m/mi
n 1,5 - 4,5
--- --- 1,5 -
17,0 --- ---
Spool diameter mm 200 --- --- 200 --- ---
Spool weight kg 5 --- --- 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.

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4. EQUIPMENT
MODELS
Item No Descriptio
5.0284 PEGAS 201 MIG SYN PFC
ACCESSORIES TO ORDER
Item No. Descriptio
SGB25-3 orch PARKER SGB 250 3m
SGB25-4 orch PARKER SGB 250 4m
SGB25-5 orch PARKER SGB 250 5m
17FSL4S orch PARKER SG 17 4m 35-50 FX S
5847 Set Connectors PEGAS AC/DC Smart, 201 MIG SYN PFC,
aXe 200 IN PFC
VM0321-3 Hose Gas 3m Pegas MIG without G1/4
4314 Quick connector Pegas 160/40
(part of hose VM0321-3)
VM0253 Welding Cable Set 2x 3m 35-50 200A
Rolls – see section WIRE FEEDER
4281 Pressure Reducer AR 2 manometers MINI
S777a Welding Helmet ALFA IN S777a Black
4488 Wire 0.8 Coreshield 15 A D200 Self Shielding 4,5kg spool
5950 Set SG , SR 17/18/26d=1,6
5951 Set SG , SR 17/18/26d=2,4
5952 Set SG , SR 17/18/26d=3,2
700.0306.10 Electrode wolf.1.6x175-Violet
700.0308.10 Electrode wolf.2.4x175-Violet
700.0310.10 Electrode wolfram E3 3.2x175 - violet

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5. MAIN PARTS OF THE MACHINE
Fig. 1. PEGAS 201
MIG SYN PFC
Pos. Descriptio
A1 MIG/MAG torch connector
A2 Quick connector (-) of welding cables or IG torch
A3 Gas connector for IG torch
A4 Knob
A5 Display
A6 Knob
A7 IG torch control connector

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A8 Quick connector (+) of welding cables
A9 Switch ON/OFF
A10 Mains cable
A11 Gas connector
A12 Handle
A13 Spool holder
A14 Switch Spool Gun
A15 erminals of change polarity MIG/MAG torch
A16 Wire feeder
WIRE FEEDER
Fig. 2 Wire feeder
Pos.
Descriptio
E1
Nut of pressure arm
E2
Pressure arm
E3
Inlet liner
E4
EURO c
o
nnec
tor
E5
Roll

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OVERVIEW OF ROLLS FOR WIRE FEED
ab
a = 22 mm
b = 30 mm
Groove type
Wire diameter
Item No
Steel
0,6
-
0,8
2187
0,8-1,0 2188
Aluminium
0,8
-
1,0
2270
Flux core
0,8
-
1,0
2318
1,0
-
1,2
2319
6. MAIN MENU
Fig. 3 Main Menu

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Pos.
Descriptio
1
Method selection
2 Synergic parameters selection
3
Welding parameters settings
4
System settings
5
Chosen function icon
6
Chosen mode icon
7 Synergic parameter
(from left: program number, material of welding
wire, protective gas and wire diameter)
8
M
ultifunctional
window
Press MENU button to move between submenus.
METHOD SELECTION
Rotate and then press the knob A4 for method selection.
Fig. 4 Submenu of method selection
Use the button in the upper right part of the panel to get to the settings of welding
current and voltage. o change these parameters rotate knobs A4 and A6.
Fig. 5 Welding parameters selection

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SYNERGIC PARAMETERS SELECTION
Submenu of synergic parameters is available only when the method MIG/MAG
Synergy is chosen.
Rotate and then press the knob A4 for synergic parameter selection.
Fig. 6 Synergic parameters selection
SECONDARY WELDING PARAMETERS SELECTION
Rotate the knob A4 and then press the knob A6 for parameters settings.
Fig. 7 Secondary welding parameters selection
Secondary welding
parameters
MIG/MAG
welding
parameters
(Default)
IG welding
parameters
(Default)
MMA welding
parameters
(Default)
wo/four Stroke
2 /4
(2 )
2 /4
(2 )
-
Burn Back
0
-
10
(0)
-
-
Slow Feed
0
-
10
(0)
-
-
Pre
F
low
0
-
2 s
(0 s)
-
-
Post Flow 0-10 (0 s) 0-10 (0 s) -

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Inductance
0
-
10
(5)
-
-
Down slope
-
0
-
10 s (0 s)
Hot Start
-
-
0
-
10 (0)
Arc Force
-
-
0
-
10
(0)
SYSTEM SETTINGS
Rotate the knob A4 and then press the knob A6 for parameters settings.
he last position in submenu of system settings is Factory reset.
Press the knob A6 for Factory reset performance.
Fig. 8 Submenu of system settings
7. GETTING STARTED MIG/MAG
Getting started must be consistent with technical data and conditions of use.
CHOOSING THE FEEDING ROLL
In all machines (ALFA IN MIG / MAG) rolls with two grooves are used. hese
grooves are intended for two different wire diameters (e.g. 0,8 and 1,0 mm).
Rolls for wire feed must comply with the diameter and material of the welding
wire. Only this way a smooth wire feed can be achieved. Irregularities of the wire
feed leads to a poor quality of welding and deformation of the wire.

 
ABC
Fig. 9 he influence of the roll groove on the welding wire
A Correct
B Wrong
C Wrong

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INSERTING THE WIRE
1. Open the side cover of the wire feeder space.
2. Put the wire spool on the wire spool holder D1 and fix it with the fixing nut
D2.
3. Cut off the curved or damaged end of welding wire and lead it through the
inlet liner E3, and the roll into the liner inside the EURO torch connector
(about 5 cm). Make sure, that you use the suitable groove.
4. Put the pressure arm E2 down in that way, that the teeth or the gear fit and
fix it by setting the lever E1 into vertical position.
5. Adjust the pressure nut that way that it provides constant movement of
wire but it does not deform wire. he adjusting screw is located under the
plastic screw E1.
6. he spool brake is set by the manufacturer. If necessary, the brake can be
adjusted by a screw D1 so that while stopping the feed, spool will be
stopped on time (it will avoid excessive release of wire). However, too tight
brake needlessly strains the feeding mechanism and thus slippage may
occur in the wire rolls.
Fig. 10 Spool holder
Pos.
Descriptio
D1
Spool Holde
r
D2
Nut Spool Holder
D3
It is not
for this
welder

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INSERTING THE WIRE TO THE TORCH AND CONNECTION OF GROUND
CABLE
Fig. 11 Co ecti g the grou d cable a d the torch (illustrative picture)
1. Connect the torch B6 to connector B8 on the machine while the machine
is turned off.
2. Connect the ground cable B4 to the quick connector (-) of welding cables.
3. Connect the ground clamps B5 to the weldment B7 or to the welding table.
4. Notice When inserting the wire do not point with torch to the eyes!
5. Remove the gas nozzle from the torch.
6. Unscrew the current nozzle.
7. Connect the machine to power supply.
8. urn the main switch A9 on the rear panel to ON.
9. With MENU button and knob A4 select the mode MIG/MAG.
10. In submenu of welding parameters selection choose 2 or 4 .
11. Press the torch button and the welding wire is fed into the torch. After
coming off from the torch tube, screw the current nozzle and gas nozzle
on.
12. Before welding, spray the area in a gas hose and current nozzle with
a separation spray, to prevent damage.

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ADJUSTMENT OF GAS FLOW
he electric arc and the weld must be perfectly shielded by gas. oo small
amount of gas does not perform the protective atmosphere and on the other
hand to big amount of the gas brings air into the electric arc.
Notice Gas bottle must be well secured against fall. his manual does
not solve the safe securing of gas bottle. Information can be obtained from a
supplier of industrial gases.
1. Connect the gas hose to gas outlet F8 on the valve and the gas inlet to the
gas connector A11.
2. Press the torch button.
3. urn the adjusting screw F7 at the bottom side pressure reducing valve,
until the meter F6 shows the required flow, then release the button. he
optimum flow is 10-15l/min.
4. After long-term shutdown of the machine or replacement of the torch it is
suitable to blow the pipes with protective gas before welding.
Fig. 12 Gas flow setting
Pos. Descriptio
F1
Gas bottle
F2
Cylinder Valve
F4
Pressure Reducer
F5
High Pressure Manometer
F6
Low Pressure Manometer
F7
Adjusting Screw
F8
Gas outlet
ADJUSTING WELDING PARAMETERS FOR MIG SYN
1. Find the appropriate program number in submenu of synergic parameters.
(For example, if you want to weld steel by full wire with diameter 0,8 mm
and if you have available mixed gas 82% Ar + 8% CO2. his is program
number 01).
2. Select the synergic parameter by knob A4 and then press the knob A4 for
confirmation.

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3. After that, choose the appropriate welding parameters by knobs A4 and
A6.
4. Recommendation – For perfect manual tack welding (for example for car
bodywork repairs) use the machine in the MIG Manual mode.
ADJUSTING WELDING PARAMETERS FOR MIG MAN
1. Approximate setting for the MIG / MAG welding current and voltage
corresponds the empirical relationship U2 = 14 +0.05 I2. According to this
relationship, we can determine the required voltage. When setting the
voltage, we expect the decline in voltage during load. he voltage drop is
approximately 4,8V at 100 A.
2. Select voltage.
3. hen select the appropriate wire speed.
4. une the arc by changing the levels of the choke in submenu of welding
parameters settings.
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
1,0 45 - 200 1,2 - 7,0
able of approximate parameter settings
ADJUSTING THE MACHINE FOR ANOTHER WIRE DIAMETER
In all machines ALFA IN MIG / MAG are used rolls with two grooves. hese
grooves are intended for two different wire diameters (e.g. 0,8 a 1,0 mm). Groove
can be replaced by removing the rolls and rotating them, or use a different roll
grooves with required dimensions.
1. Open the nut E1 to the left, pressure roll E2 will be opened upward.
2. Unscrew the plastic locking element E5 and remove the roll.
3. If there is a suitable groove on the roll, rotate the roll and place it back on
the shaft and secure it by screwing the element E5.
FLUX CORE WIRE – SETTING THE POLARITY FOR MIG/MAG TORCH
1. It is desirable to have positive polarity on the MIG/MAG torch while welding
with solid wire in majority of cases. he welder is supplied from the
production with positive polarity on the MIG/MAG torch.
2. For welding with flux cored wires it may be necessary to have negative
polarity on the MIG/MAG torch.
3. he middle terminal K2 is connected to the central euro connector of the
MIG/MAG torch. We supply the welder with K2 connected to terminal (+)
K1.

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4. In case of welding with flux core wire with (-) polarity, connect K2 by means
the bridge K3 with K4 terminal. Use Phillips screwdriver.
5. Make sure you fasten the terminals properly.
6. Connect the ground cable to the quick connector (+).
Fig. 13 erminals for changing the polarity of the MIG/MAG torch
Pos.
Descriptio
K1
Upper terminal (
+
)
K2
Middle terminal
K3
Bridge
K4
Lower terminal (
-
)

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ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
For feeding the AL wire it is necessary to use roll with the “U” profile - see
paragraph OVERVIEW ROLLS WIRE FEED. o prevent problems with feeding
use wires with diameter. 1.0 mm of AIMg3 or AlMg. Wire of alloy Al99, 5 or AlSi5
are too soft and easily will cause problems with movement.
For the aluminium welding it is also necessary to provide the torch tefl. liner and
special current nipple. We do not recommend you to use the torch longer than 3
m. Great attention must be paid to adjust the contact power of rolls – it must not
be too high, otherwise there is a deformation of the wire.
As a protective atmosphere is necessary to use argon.
Fig. 14 Customization of the feed for the aluminium wire
Pos. Descriptio
G1
EURO connector
G2
Rolls
G3
Liner
terminal for 4,0mm, 4,7mm outer diameter
G4
O
-
ring 3,5 x1, 5mm to prevent escape of gas
G5
Nut
G6
Liner tefl.
G7
Sustain pipe for teflon and plastic liner

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8. GETTING STARTED TIG
Getting started must be consistent with technical data and conditions of use.
Fig. 15 Connecting the ground cable and the torch (illustrative picture)
1. Connect the torch B12 to the quick connector (-) B13 of welding cables to
the gas connector B14 and connector B10.
2. Connect the ground cable to the quick connector (+) B9 of welding cables
and the ground clamps B11 to the weldment B7 or to the welding table.
3. Connect the machine to power supply and turn the main switch on the back
panel to ON.
4. Connect the gas hose and gas flow adjustment described in
ADJUS MEN OF GAS FLOW.
5. In submenu of method selection select TIG Lift, see part 6. MAIN MENU.
6. Use the knob A4 to adjust the welding current.
7. Use the potentiometer 30 to adjust the time of Slope down.
8. In submenu of welding parameters settings you can change values of Pre
Gas time and Post Gas time.