Alfain PEGAS 250 MIG MAN User manual

ALFA IN a.s. © 2013 www.alfain.eu PEGAS 250-320 MIG MAN manual EN
MIG/MAG WELDING MACHINES
PEGAS 250 MIG MAN
PEGAS 320 MIG MAN
INSTRUCTION MANUAL
Content:
1. INTRODUCTION ............................................................................................. 2
2. SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 2
3. CONDITIONS OF USE ...................................................................................... 6
4. TECHNICAL DATA ........................................................................................... 7
5. ACCESSORIES ................................................................................................. 7
6. DESCRIPTION OF THE APPLIANCE .................................................................. 8
7. GETTING STARTED ....................................................................................... 10
8. WELDING ..................................................................................................... 13
9. ROUTINE MAINTENANCE INSPECTION ...................................................... 14
10. STATEMENT OF WARRANTY ........................................................................ 14
11. 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 250/320 MIG MAN are three phase sturdy welding machines for
MIG/MAG welding.
The machines are designed to produce maximum power output combined
with high reliability and efficiency.
2. SAFETY INSTRUCTIONS AND WARNINGS
•OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN
BE DANGEROUS AND HAZARDOUS TO YOURHEALTH.
•Arc welding produces intense electric and magnetic emissions that may
interfere with the proper function of cardiac pacemakers, hearing aids, or
other electronic health equipment. Persons who work near arc welding
applications should consult their medical health professional and the
manufacturer of the health equipment to determine whether a hazard
exists.
•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 generator in series or in
parallel.
•When installing the machine, follow the local regulations on safety.

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•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.
•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 cutting.
•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 arc 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.
•Keep all fumes and gases from the breathing area.
•Keep your head out of the fume plume.
•Use an air-supplied respirator if ventilation is not adequate to remove all
fumes and gases.
•The kinds of fumes and gases from the plasma arc depend on the kind of
metal being used, coatings on the metal, and the different processes.
You must be very careful when welding any metals which may contain
one or more of the following:
Antimony Chromium Mercury
Nickel Cobalt Arsenic
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
•Always read the Material Safety Data Sheets (MSDS) that should be
supplied with the material you are using. These MSDSs will give you the
information regarding the kind and amount of fumes and gases that may
be dangerous to your health.
•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.
•Noise can cause permanent hearing loss. Welding arc processes can
cause noise levels to exceed safe limits. You must protect your ears from
loud noise to prevent permanent loss of hearing.
•To protect your hearing from loud noise, wear protective ear plugs and/or

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ear muffs. Protect others in the workplace.
•Noise levels should be measured to be sure the decibels (sound) do not
exceed safe levels.
•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 cutting 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 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 clamps.
•The maximum open-circuit voltage of the plasma machines is
established by national and international standards (EN 60974-1)
depending on the type of 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 DC current: 141V peak value AC current: 141V peak value and

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increased protection for
the operator 100V effective
4 Plasma cutting DC current: 500V
peak value
•In case 1, the dc 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.
2.1 ELECTROMAGNETIC COMPATIBILITY (EMC)
This 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 cutting
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.
2.2 PROTECTIVE UTTILITIES
•Welding helmet with filter shade at least 10
•Welding gloves
•Welding apron and cloth
•Welding boots
2.3 RISK OVERVIEW
•Risk of electric shock.
•Ultraviolet light and light radiation

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•Risk of inhaling gas fumes and dust particles
•Burns
•Noise
 NOTE 
• It is forbidden to operate a machine with damaged insulation of the
welding torch or supply cable.
•Never operate the machine taken down or damaged covers.
• It is forbidden to operate the machine in wet environments and
outdoors in rain or snow.
• Ensure proper grounding clamping pliers, which also reduces the risk
of electric shock.
• Use prescribed protective utilities, keep them dry.
• Arc welding produces intense electric and magnetic emissions that
may interfere with the proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near
plasma arc cutting applications should consult their medical health
professional and the manufacturer of the health equipment to
determine whether a hazard exists.
• Never aim the torch against the eyes, body or other person.
3. CONDITIONS OF USE
•This equipment must only be used by qualified personnel.
•During installation, any electric work must only be carried out by trained
personnel.
•Do not expose the plasma machine to direct sunlight or to rain or snow.
This equipment conforms to protection rating IP23S.
•Place the machine the way that the cooling air can enter the vents
without restriction to. It is necessary to ensure that no impurities,
especially metal particles, are not drawn into the machine.
•Welding machine in terms of interference suppression is intended
primarily for industrial premises. In the case of use of other areas may be
need for special measures (see EN 60974-10).
• The machine must be protected against
a) moisture and rain and snow
b) mechanical damage
c) draft and any ventilation of neighbouring machine
d) excessive overloading - crossing technical parameters
e) rough handling

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4. TECHNICAL DATA
Model
PEGAS 250 PEGAS 320
Method
MIG/MAG MIG/MAG
Mains voltage
V/Hz 3 x 400/50-60 3 x 400/50-60
Mains protection
A 16 slow 16 slow
Max. input power I
1
A 16,4 23,4
Max. effective current I
1eff
A 12,9 12,9
Welding current range
A/V 20/15,0 -
250/26,5 40/16,0 - 315/29,8
Open-circuit voltage U
20
V 54,4 63,1
Welding current (DC=100%) I
2
/U
2
A/V 210/24,5 210/24,5
Welding current (DC=60%) I
2
/U
2
A/V 250/26,5 250/26,5
Welding current (DC=x%) I
2
/U
2
A/V 60%=250/26,5 25%=315/29,8
Voltage setting
continuous continuous
Insulation class
F F
Protection
IP 23S IP 23S
Standards
EN 60974-1 EN 60974-1
Dimensions (w x l x h) generator
mm 240 x 640 x 438 240 x 650 x 438
Weight - compact/generator
kg 25,8 26,6
5. ACCESSORIES
5.1 DELIVERED WITH THE MACHINE
•Feed roll 0,8 - 1,0mm
5.2 ACCESSORIES TO ORDER
•Earthing cable 3 5 m with a clamp
•Gas hose
•Wire cleaner
•CO2 Gas pre heating cable
•Reduction valve
•Gas cylinder

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•Torch consumables
•Feed rolls 0,6-0,8 1,0-1,2 for carbon steels, aluminium, flux core wires
•Torches with UP-DOWN remote control
•Welding torches (see the table below)
Ordering No
018.D975.1 Torch ABIMIG AT 305-C LW 3m
018.D976.1 Torch ABIMIG AT 305-C LW 4m
018.D977.1 Torch ABIMIG AT 305-C LW 5m
6. DESCRIPTION OF THE APPLIANCE
6.1 MAIN PARTS
Fig. 1 - Main parts
1 EURO connector
2 Voltage potentiometer

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3 Voltage Display
4 Wire Speed potentiometer
5 Current Display
6 LED indicator – if illuminated, the display shows the wire speed
7 LED indicator – if illuminated, the display shows the welding
current
8 LED indicator - if illuminated, the machine is ON
9 LED indicator – if illuminated, the welder is over heated or the
mains voltage is out of range
10 2 stroke/4 stroke switch
11 Wire feeding button
12 Choke potentiometer
13 Quick connector - (Earthing cable)
6.2 WIRE FEEDER
Fig. 2 - Wire feeder 2 rolls
ab
2 rolls 4 rolls
a = 22 mm a = 10 mm
b = 30 mm b = 30 mm
Grove type Wire diameter Item No
Steel
0,6-0,8 2187 5434
0,8-1,0 2188 5435
1,0-1,2 2189 5436
Aluminium 0,8-1,0 2270 5437 1,0-1,2 2269 5438

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Flux core
0,8-1,0 2318 5439
1,0-1,2 2319 5440
1,2-1,4 2320 5441
7. GETTING STARTED
Fig 3 – Earthing cable and Welding Torch connecting (The picture is just for
illustration, for the real position use Fig. 1)
C1 Quick connector - (Earthing cable) (Fig. 1, 13)
C2 Earthing clamp
B1 EURO connector (Fig. 1, 1)
B2 Torch Euro Connector Male
B3 Welding Torch
•Connect the earthing clamp C2 to the welding piece
•Connect the B1 and B2 torch connectors together. Screw them up
properly by mean turning the B2 clockwise.
•Plug the mains plug to 3x400 V mains.
•Switch the machine on by the ON/OFF switch at the rear panel of the
welder
7.1 INSERTING THE WIRE
D1 Spool Holder
D2 Nut Spool Holder
D3 Adapter

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Fig. 4 – Spool holder
•Open the side cover of the wire feeder space
•Put the wire spool on the wire spool holder D1 using the adapter D3 and
fix it with the fixing nut D2
•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.
•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.
•Adjust the pressure nut that way that it provides constant movement of
wire but it does not deform wire.
7.2 CHANGING THE WIRE FEEDER ROLL
•Every wire feeding roll in ALFA IN machines can be used for two different
diameters of welding wire – the rolls have two grooves.
•When the machine is equipped with two roll wire feeder move the lever E1
to the right (2 roll feeder)/ forward (4 roll feeder). The pressure arm shall
pop up.
•Unscrew the plastic fixing cup E5 and take off the roll
•In case there is suitable groove on the roll, turn it around and fix it back to
the feeder.
∅ 1,0
1,0 1,20,8
ABC
Fig. 5- The influence of the roll groove on the wire
7.3 ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
•For feeding the AL wire it is necessary to use roll with the “U” profile of the
A Correct
B Wrong
C Wrong

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groove. To prevent problems with feeding use wires with diameter 1,0 or
more mm of AlMg3 or AlMg5. The torch must be equipped with Teflon
liner and special tip. As shielding atmosphere use Argon.
Fig 6 – Set for welding aluminium
G1 EURO connector
G2 Rolls
G3 Liner terminal for 4,0mm, 4,7mm outer diameter
G4 O – ring 3,5x1,5mm
G5 Nut
G6 Teflon Liner
G7 Sustain pipe for teflon and plastic liner
7.4 GAS FLOW SETTING
The electric arc and the weld must be perfectly shielded by gas. Too 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.
Fig. 7 – Gas fitting. The picture is just for illustration. The portable PEGAS
250/320 MIG MAN are not equipped to support the gas cylinders. The gas
cylinders must be well fitted in another gadget in accordance with the
appropriate safety rules.

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F1
Gas Cylinder
F2
Cylinder Valve
F3
Gas heater connector
F4
Pressure Reducer
F5
High Pressure Manometer
F6
Low Pressure Manometer
F7
Adjusting Screw
F8
Gas outlet
F9
Solenoid Valve
F10
Chain
•Place the gas cylinder on the platform and fix it properly by the fixing
chain. We recommend using bolts and nuts to fix it more safely.
•Connect the pressure reduction valve on the gas cylinder.
•Connect the gas hose to gas outlet F8 on the valve and the gas inlet F9
on the machine
•Open the F2 cylinder valve
•Press the button Gas test 11
•Adjust the amount of gas on the reduction gas valve (it is not a part of the
welding machine) by the F7 adjusting screw
•Release the button 11 for digital
8. WELDING
For orie ntating adjusting of the welding current and voltage you can use
empirical relation U2 = 14+0,05 2. From that you can specify desired voltage.
8.1 SETTING WELDING CURRENT AND VOLTAGE
When the wire had been installed and gas had been set it is possible to start
welding.
The appliance must be plugged into the mains, the ON/OFF switch on "I".
You will find the ON/OFF switch on the rear panel of the welder.
To select the voltage potentiometer 2.
To select the current (that is linked to the wire speed) use the voltage
potentiometer 3
To modify the arc characteristic use the chope potentiometer 12.
8.2 WELDING MODES
Machines works in four modes:

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•continuous two stroke (2T)
•continuous four stroke (4T)
To select the mode switch the 2T/4T switch into the appropriate position.
9. ROUTINE MAINTENANCE & INSPECTION
•The only routine maintenance required for the ALF range of machines is a
thorough cleaning and inspection, with the frequency depending on the
usage and the operating environment.
WARNING 
•Disconnect the ALF 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 ALF 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.
10. 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

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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.
11. 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.