Alfain PEGAS 250 MIG SYN User manual

ALFA IN a.s. © www.alfain.eu PEGAS 250-320 MIG SYN manual EN 05
WELDING MACHINES
PEGAS 250 MIG SYN
PEGAS 320 MIG SYN
INSTRUCTION MANUAL

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CONTENT
1. IN RODUC ION ......................................................................................... 3
2. SAFE Y PRECAU IONS ............................................................................ 4
3. OPERA ING CONDI IONS ........................................................................ 5
4. ECHNICAL DA A ...................................................................................... 6
5. ACCESSORIES ........................................................................................... 7
6. DESCRIP ION OF HE APPLIANCE ......................................................... 8
7. BASIC SE INGS ..................................................................................... 14
8. MIG/MAG WELDING SYNERGY ............................................................... 17
9. MIG/MAG WELDING MANUAL ................................................................. 18
10. MMA WELDING (COA ED ELEC RODE- ELE) ....................................... 19
11. ROU INE MAIN ENANCE & INSPEC ION .............................................. 19
12. DISPOSAL ................................................................................................. 23

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1. INTRODUCTION
Dear Consumers!
Company ALFA IN a.s. thanks you for buying our product and believe that you
will be satisfied with our machine.
Welding machine PEGAS 250/320 MIG SYN is IGB invertor. It is designed for
welding method MIG (Metal Inert gas) and MAG (Metal Active Gas). his is
welding in protective atmosphere. We are using inert (impassive) and active
gases during welding. hese methods are very productive and particularly
suitable for the connections of structural steels.
With welding machine PEGAS 250/320 MIG SYN it is possible to weld different
types of connections (blunt, single-sided, double-sided, fillet, lap etc.) using wire
diameter from 0,6 – 0,8 mm, or 1,0 – 1,2 mm of different metals and alloys
(carbon and alloy steels, aluminum alloys etc.).
S
he machine can be used for welding in areas with increased
danger of electric shock. Machines comply with the relevant requirements for CE
marking.
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 PRECAUTIONS
PERSONAL PROTECTION
1. For safety reasons, it is necessary to use welding gloves during welding.
hese gloves will protect you before intervention of electric current
(open circuit voltage). It protects you against thermal radiation and splashing
drops of hot metal too. Wear sturdy isolated shoes. Do not wear open shoes,
because drops of hot metal can cause burns.
2. Do not look into the welding arc without eye and face protection. Always use
good quality welding helmet with intact protective filter.
3. he persons appearing in the vicinity of the welding must be informed of the
danger and must be equipped with protective equipment.
4. During welding, especially in small spaces, it is necessary to ensure an
adequate supply of fresh air, because during welding, harmful fumes arise.
5. In tanks of gas, oil, fuel, etc., (even empty ones) do not make welding,
because there is a chance of explosion.
6. In areas with chance of explosion special provisions are applied.
7. Welding machines that are subjected to great exertion must comply with
specific security requirements. hese include the rail pressure of the vessel
etc. hese connections may only be carried out by competently trained
welders with the necessary permissions.
SAFETY REGULATIONS
1. Before starting work with welding machine it is necessary to get familiar with
the provisions of the ČSN 050601 and norm ČSN 050630.
2. With a bottle of CO2 or mixed gases should be handled according to the
regulations for working with pressure vessels contained in ČSN 07 83 05 and
norm ČSN 07 85 09.
3. he welder must use protective equipment.
4. Before working on the electrical part, removing the cover or cleaning it is
necessary to disconnect the device from the network.

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3. OPERATING CONDITIONS
1. Putting the machine into operation can be performed only by trained
personnel and only within the technical provisions. he manufacturer is not
liable for damages resulting from improper use or handling. For maintenance
and repair, use only original spare parts from ALFA IN.
2. Device complies with IEC 61000-3-12.
3. he welding machine is tested according to the degree of protection IP 23S,
which provides protection against the intrusion of solid bodies with a diameter
greater than 12 mm and protection against ingress of water, falling on the
machine in a vertical direction or max degree of 60°.
4. he machine must be positioned so that cooling air can enter and leave
through cooling vents with no problem. It is necessary to ensure that there
are no mechanical equipment, especially metal particles (e.g. during grinding)
drawn into the machine.
5. Handling handle is intended for movement, it is not designed to lifting the
machine.
6. In case of overheating of the machine welding is automatically stopped and
this condition is signalized by pilot light.
7. All interventions in the el. equipment as well as repair (removal of the plug,
fuse replacement) should be performed by an authorized person.
8. With competent mains voltage and input must match the plug.
9. Do not use the machine for other purposes, such as defrosting pipes, starter
source, etc.
10. It is necessary for welding machine to undergo a periodic inspection every
6/12 months by an authorized officer according to ČSN 331500 and ČSN
050630– see Maintenance and service tests.
11. he welding machine is designed especially for industrial areas. In case of
using it in other areas there may exist special measures (see EN 60974-10).
12. It is necessary to protect the machine against:
a) Moisture and rain
b) Mechanical damage
c) Draft and possibly ventilation of neighboring machines
d) Excessive overloading – exceeding tech. parameters
e) Rough treatment
f) Chemically aggressive environments
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
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.

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Caution
We warn users, that they are responsible for possible interference from
welding.
4. TECHNICAL DATA
echnical data
PEGAS 250
PEGAS 320
Method
MIG/MAG MMA MIG/MAG MMA
Mains voltage V/Hz 3 x 400/50-60 3 x 400/50-60
Fuse A 16 @ 16 @
Max. effective current I1eff A 12,9 13,1 12,9 12,8
he range of welding. current A 20-250 30-250 20-315 30-300
Open circuit voltage U20 V 54,4 63,1
Welding current (DZ=100%) I2 A 210 190 210 190
Welding current (DZ=60%) I2 A 250 230 250 230
Welding current (DZ=x%) I2 A 60%=250
50%=250
25%=315
20%=300
Protection IP 23S
Standards EN 60974-1; EN 60974-10 cl. A
Dimensions (w x d x h) mm 240 x 640 x 438
Weight kg 26,6
Wire feed speed m/min
1,0 - 15 1,0 - 15
Spool diameter mm 300 300
Spool Weight kg 15 15
Warming tests were made at ambient temperature 20÷25°C. he load factor for
ambient temperature of 40 ° C were determined by simulation.
S
he machine marked with this symbol can be used for welding in areas with
an increased risk of electric shock. he machine structure is designed so that,
in any case, even if the failure rectifier does not exceed the permitted peak value
of the open circuit voltage according to EN 60974-1, i.e., 113 V direct current or
68 V alternating.

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5. ACCESSORIES
INCLUDED IN DELIVERY
Des gnat on Descr pt on
5.0267-4 PEGAS 250 MIG SYN-4
5.0268-4 PEGAS 320 MIG SYN-4
ACCESSORIES ON REQUEST
Des gnat on Descr pt on
VM0321-3 Hose for gas connection PEGAS 3m
012.0252 Welding torch MB 24KD 4 m GRIP
VM0023 Welding cables PEGAS 2x 3m 35-50
NOTICE If you decide to use a different torch than the above, it is
necessary to choose one, according to your current range and load time of the
torch. ALFA IN a.s. is not liable for damage caused by overload welding torches.

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6. DESCRIPTION OF THE APPLIANCE
MAIN PARTS
Picture 1 – Main parts of the machine
A1 EURO connector of the torch
A2
Button gas
test
A3
Button Wire Feeding
A4
Instant JOB buttons
1
-
6
A5
Current encoder
A6
Control light Material thickness (mm)
A7
Control light Wire speed (m/min)
A8
Button for selecting the parameters to be displayed
A9
Control light Current (A)
A10
L
eft display
A11
R
ight display
A12
Control light of Voltage or Voltage Correction
A13
Button for selecting the parameters to
be displayed
A14
Control light of Wire Speed Correction
A15
Control light of Choke or Choke Correction

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A16
Encoder Voltage or Correction
A17 Control light two stroke – 2
A18
Control light
four stroke
–
4
A19
Button for selecting the parameters to
be displayed
A20 Quick connector (+)
A21
Quick connector
(
-
)
WIRE FEEDER
Picture 2 - Wire feeder
E1
Nut of pressure arm
E2
Pressure arm
E3 Inlet liner
E4
EURO connector
E5
Roll
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.
A Correct
B Wrong

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
 
ABC
Picture 3 - he influence of the roll groove on the welding wire
OVERVIEW OF ROLLS FOR WIRE FEED
ab
2 rolls 4 rolls
a = 22 mm
a = 10 mm
b = 30 mm
b = 30 mm
Groove type
Wire diameter
Item No
Steel
0,6
-
0,8
2187
5434
0,8
-
1,0
2188
5435
1,0
-
1,2
2189
5436
Aluminum
0,8
-
1,0
2270
5437
1,0-1,2 2269 5438
Flux core
0,8
-
1,0
2318
5439
1,0
-
1,2
2319
5440
1,2-1,4 2320 5441
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 right, pressure roll E2 will be opened upward
2. Unscrew the plastic locking element E5 and remove the roll
C Wrong

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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.
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 aluminum 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.
Picture 4 – Customization of the feed for the aluminium wire
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
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. If a spool (size of 15 or 18 kg) is used, put on each side of the spool
adapter D3. he hole in the back of the adapter must fit into the pin on the
wire spool holder!
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.

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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.
Picture 5 - Spool holder
ADJUSTING PRESSURE FORCE OF FEED ROLLS
Important thing for reliable operation of the feeding mechanism is the size of
pressure force of feed rolls.
he amount of force depends on the type of welding wire, for aluminum or tube
wire, we choose a smaller pressure force
If the pressure force is too small, slippage may occur and thus irregular wire
feeding speed.
If the pressure force is too high, it will lead to increased mechanical wear of
bearings and it can damage the machine. Before putting into operation, clean
the rolls from preservative oil.
INSERTING THE WIRE TO THE TORCH AND CONNECTION OF EARTH
CABLE
1. Connect the earthling clamps to the welder or to the welding table.
Notice When inserting the wire do not point with torch to the eyes!
2. Screw the central end of the torch B2 to connector B1 on the machine
while the machine is turned off
3. Remove the gas nozzle from the torch
4. Unscrew the current nozzle
5. Connect the machine to power supply
6. urn the main switch on the back panel to ON
7. Press button (pic. 1) A3. he welding wire is fed into the torch. After coming
off from the torch tube, screw the current nozzle and gas nozzle on
8. Before welding, spray the area in a gas hose and current nozzle with a
separation spray, to prevent damage.
D1
Spool Holder
D2
Nut Spool Holder
D3
Adapter

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Picture 6 - Connection of torch
B1
EURO connector, in pic. 1 position A1
B2
EURO connector male
B3 orch
C1
Earth
ling
cable,
in pic
. 1
position
A21
C2
Earth
ling
clamps
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.
Not ce 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. Fit the gas hose to the outlet on the back panel of the machine
2. Press button (pic. 1) A2 on the main panel. If you hold the button for less
than 3 s, after releasing the button, the gas valve will turn off. If you hold
the button for more than 3 s, it will turn off the gas valve after about 20 s,
or after pressing any 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.

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Picture 7 – Gas flow setting
F1
Gas b
ottle
F2
Cylinder
Valve
F4
Pressure Reducer
F5
High Pressure Manometer
F6
Low Pressure Manometer
F7
Adjusting Screw
F9
Gas outlet
7. BASIC SETTINGS
SETTING THE METHOD OF WELDING
1. Long pressing the button A5 opens the menu.
2. By turning the button A5 choose the method ELE (covered electrode
MMA); MAN (MIG/MAG manual) or SYN (MIG/MAG synergistic). Confirm
your choice by pressing the button A5.
QUICK SETTING THE JOB - MEMORY
Works for three welding methods.
1. Long press one of the buttons A4 (1,2,3,4,5,6) to save set parameters to
memory.
2. Short press one of the buttons A4 (1,2,3,4,5,6) to load parameters from
memory.
WELDING MODE 2T – TWO STROKE
Works for both welding methods MIG/MAG.
Press the button A19 to switch between the modes 2T / 4T . he
two stroke mode is signalized by LED A17.
1.
act
–
press and hold the button
the machine will start welding
2. act – release the torch button the machine will stop

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WELDING MODE 4T – FOUR STROKE
Works for both welding methods MIG/MAG.
Press the button A19 to switch between the modes 2T / 4T . he
two stroke mode is signalized by LED A18.
1.
act
–
press and hold the button
the machine will start welding
2.
act
–
release the torch button
the machine will continue
3.
act
-
press the torch button
the machine will stop
4.
tact
-
release the torch button
SECONDARY PARAMETERS MENU
From start the welding machine is set to factory settings (default). For most of
the work it is not appropriate to change the secondary parameters. Secondary
parameters for manual and synergistic methods are identical.
1. Simultaneously pressing A19 and A5 encoder enters the menu for
secondary parameters.
2. A5 encoder selects a parameter (ISP, PRG, PoG, brn), A19 encoder sets
the desired value.
3. Press the encoder A5 to confirm the change.
4. Press any button to exit the menu without saving changes.
Symbol
Mean ng
Range (Default)
ISP
(Initial speed)
Approaching speed
10
-
100 % (30 %).
PrG
(Pre gas time)
Pre gas
0
-
20 s (0,1 sec).
PoG
(Post gas time)
Post gas
0
-
20 s (0,5 sec).
brn
(
Burn back
)
Burn
back
0
-
75 ms (35 ms)
CAL (Calibration menu)
Calibration menu x.xx (version sw PCB
engine)
he last menu item is CAL – it is used to enter the calibration menu, which is
intended only for authorized service.

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REMOTE CONTROL
Picture 8 – Remote control from the torch
Designation
Description
H1
Display of remote control
H2
Display
H3
orch button M for choosing the function
MAN: Wire speed, Voltage/Choke, JOB (See How to
switch on the remote control of JOBs on below)
SYN:
Power
,
Correction
/
Choke
, JOB
H4
orch button LOCK lock/unlock the buttons UP/DOWN
and M
he UP/DOWN and M buttons get automatically locked
when the torch trigger is pressed.
H5 When the LED is on it indicates UP/DOWN and M button
are functioning.
H6 orch button UP
H7
orch button
DOWN
HOW TO SWITCH ON THE REMOTE CONTROL OF JOBS
1. Press buttons V13 and V19 at the same time for more than 3 s. he
displays V10 and V11 will show JOB ON. ( o switch off this function, press
shortly V13 and V19 at the same time.
2. By means of the button H3 set the function JOB change.
3. By means of buttons H6 (UP) and H7 (DOWN) switch among the saved
JOBs.
Symbols on the torch display H1
Symbol Description
A synergic program is running on the welding machine

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Amperage setting (SYN)
Wire speed setting
No symbol Material thickness setting (SYN)
Voltage setting (MAN)
Correction (SYN)
Symbols on the torch display H2
J.xx JOBs (xx – JOB No)
I.xx Choke level (SYN/MAN).
(Only with firmware 2015 and newer)
ELE Machine is in MMA (Electrode) mode
RESET
1. Pressing A8 + A19 at the same time more than 3 s makes RESE – default
parameters will be restored.
2. It will delete saved JOBs!
8. MIG/MAG WELDING SYNERGY
1. Choose SYN method (see SETTING THE METHOD OF WELDING)
2. Left display A10 shows SYN, right display A11 shows the number of
synergistic curve.
3. Selects synergic curve (program number) using encoder A16 according to
the table, which is located inside. o confirm the program number press
the encoder A5.
Picture 9 – able of synergic curves
4. Use A8 button to select the values you want to set the machine with, the
corresponding light will illuminate.

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5. Machine output (current, wire feed speed, material thickness) is set by the
encoder A5.
6. If necessary, power and its characteristics can by fine-tuned by encoder
A16.
7. he value of the voltage or the choke correction are shown on the display
A11 only during the configuration.
8. From the factory, the machine is set to use voltage correction. ( o change
the meaning of the correction from Voltage to Wire speed, press and hold
the button A13). (When you change the welding power by turning the
encoder A5 it will reset the correction, in other words the machine uses
parameters from the factory stored synergic curves. he machine supports
the possibility of maintaining a user-defined correction when changing the
welding power. Switching to such arrangements must be made by the
manufacturer or an authorized service center.)
9. Button A13 to switches between correction of voltage and correction of the
choke. Confirm the change with encored A16.
9. MIG/MAG WELDING MANUAL
1. Choose MAN method (see SETTING THE METHOD OF WELDING)
2. he left display A10 shows MAN.
3. he left display A10 shows the wire feed speed, the right display A11
shows voltage or choke.
4. Wire feed speed is set by the encoder A5.
5. Voltage or choke is adjusted via the encoder A16.
6. Voltage or choke can be displayed and set by long-pressing A13.
7. During welding, the display A10 shows measured values of welding
current and the display A11 shows measured values of voltage.
8. After welding, on the displays will remain measured values (HOLD) for 6
sec. WELDING VOL AGE
It is set using voltage potentiometer pic. 1, A16
WELDING CURRENT – GENERAL INFORMATION
Size of the welding current depends on the wire feed speed and voltage.
Characteristic of the curve ("hardness / softness") can be controlled by
correction of the choke.
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 4.5-5.0 V at
100 A.

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Set the welding current by setting the welding voltage first and then configure
the wire feed speed to the point, where the burning of the arc is ideal.
Please note that the actual settings for ideal arc may vary slightly depending on
the position of the weld material and voltage fluctuations.
o achieve a good quality of the welds and the optimum setting of the welding
current it is necessary to ensure that the distance of the power nozzle from the
material was about 10 times the diameter of the welding wire (pic. 10)
Picture 10 – Distance from nozzle to material
10. MMA WELDING (COATED ELECTRODE- ELE)
1. Choose ELE method (see SETTING THE METHOD OF WELDING)
2. he left display A10 shows the value of welding current, the right display
A11 shows ELE.
3. he welding current is set by the encoder A5.
4. During welding, the display shows measured values of welding current.
5. After welding, on the display will remain measured value (HOLD) for 6 sec.
6. If the MIG/MAG remote torch stays connected, on its display will be shown
ELE. he remote function will not work. Careful, the welding voltage will
be on the torch.
11. ROUTINE MAINTENANCE & INSPECTION
1. he only routine maintenance required for the PEGAS range of machines
is a thorough cleaning and inspection, with the frequency depending on
the usage and the operating environment.
 WARNING 
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.
CAU ION 
Do not blow air into the welder during cleaning. Blowing air into the welder

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can cause metal particles to interfere with sensitive electronic components
and cause damage to the welder.
3. o clean the welder, disconnect it from the mains supply voltage then open
the enclosure and use a vacuum cleaner to remove any accumulated dirt
and dust. he welder should also be wiped clean. If necessary, solvents
that are recommended for cleaning electrical apparatus may be used.
4. roubleshooting and repairing of ALF 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. he person carrying out the servicing needs and repairs must know what
to look at, what to look for and what to do.
OPERATIONAL SAFETY INSPECTION OF THE MACHINE ACCORDING TO
ČSN EN 60 974-4
Prescribed operations of tests, procedures, and required documentation are
listed in EN 60974-4. SERVIS
ERROR MESSAGES
he left display A10 shows Err, the right display A11 shows number of the error.
Err 1 Overheating of the machine. DO NO POWER OFF HE MACHINE!
TROUBLE SHOOTING
S
ymptom
R
eason
Solut on
he torch is too
hot
Nozzle is not fixed. ighten the nozzle
Button on the
torch does not
respond
Connection of EURO
connector
is not fixed
.
ighten the EURO
connector
he power line in the
torch is damaged.
Check and replace if
necessary
.
Irregular wire feed
or wire is caked to
the nozzle.
he wire on the spool is
too tightly wound.
Check and replace the
spool
if necessary.
he ball is fused to the
nozzle.
Cut out the ball and piece
of the wire at the
beginning.
Irregular or no
wire feed.
Poor pressure in the
wire feed rolls
Adjust the pressure
according to this
instruction manual
.
he torch is damaged. Check and replace if
necessary.