Alfain PEGAS 320 AC/DC PULSE User manual

ALFA IN a.s. © www.alfain.eu PEGAS 320-400 AC-DC PULSE manual EN 01
WELDING MACHINES
PEGAS 320 AC/DC PULSE
PEGAS 400 AC/DC PULSE
OPERATING MANUAL

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CONTENT:
1. INTRODUCTION ...................................................................................... 3
2. SAFETY PRECAUTIONS ......................................................................... 4
3. OPERATING CONTROLS ........................................................................ 5
4. TECHNICAL DATA ................................................................................... 6
5. EQUIPMENT ............................................................................................ 8
6. OPERATOR CONTROLS....................................................................... 10
7. GETTING STARTED .............................................................................. 14
8. TWO STOKE AND FOUR STROKE IN TIG MODE ................................ 20
9. BASIC SETTINGS FOR TIG WELDING ................................................. 22
10. JOBS ...................................................................................................... 23
11. RESET ................................................................................................... 24
12. ROUTINE MAINTANCE & INSPECTION ............................................... 24
13. STATEMENT OF WARRANTY .............................................................. 24
14. DISPOSAL ............................................................................................. 25

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1. INTRODUCTION
Dear consumer,
Company ALFA IN a.s. thanks you for buying our product and believe that you
will be satisfied with our machine.
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 320 and 400 AC DC PULSE weld by those methods:
1. TIG (PULSE) DC (Lift arc or High Frequency ignition)
2. TIG (PULSE) AC (Lift arc or High Frequency ignition)
3. MMA DC coated electrodes
4. MMA AC coated electrodes
PEGAS 320 and 400 AC DC PULSE have these special functions for effective
use: Pre gas and Post gas of protective gas, Up slope and Down slope, Starting
current and Final current, HF ignition, 2T and 4T mode, Aluminum cleaning level,
Pulsed mode, AC balance and Up-down control from the torch.
For MMA method are these machines equipped with functions Hot Start, Arc
Force and Antistick.
Welding machine may be operated only by trained persons and only in the
technical provisions. Company ALFA IN a.s. accept no responsibility for damage
caused by improper use. Before commissioning please read carefully this
manual.
The machine complies with the appropriate CE mark.
For maintenance and repairs, use only original spare parts. There is of course a
complex of our services.
We reserve the law of adjustments and changes in case of printing errors,
change of technical paramaters, accessories etc. without previous notice. These
changes may not be reflected in the manuals for use in paper or electronic form.

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2. SAFETY PRECAUTIONS
PERSONAL PROTECTION
1. For safety reasons, it is necessary to use welding gloves during welding.
These 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. The 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. These include the rail pressure of the
vessel etc. These connections may only be carried out by competently
trained welders with the necessary permissions.
SAFETY REGUALTIONS
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.
3. The 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 CONTROLS
1. Putting the machine into operation can be performed only by trained
personnel and only within the technical provisions. The 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. The 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. The 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. 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.
6. All interventions in the el. equipment as well as repair (removal of the plug,
fuse replacement) should be performed by an authorized person.
7. With competent mains voltage and input must match the plug.
Cau ion Ex ension cables mus no have conduc ors wi h a smaller
cross sec ion han 4x2,5 mm2 (for machine PEGAS 320 AC/DC PULSE) and
4x4 mm2 (for machine PEGAS 400 AC/DC PULSE). The machine can be
opera ed on a hree-phase elec ric genera or 19 kVA – for PEGAS 320
AC/DC PULSE (for PEGAS 400 AC/DC PULSE 25 kVA) (3x400V/50Hz) and
more, which has ensured vol age s abiliza ion ± 10%. Genera ors wi h
lower power can damage he machine.
8. It is necessary to protect the machine against:
a. Moisture and rain
b. Chemically aggressive environments
c. Mechanical damage
d. Draft and possibly ventilation of neighboring machines
e. Excessive overloading – exceeding tech. parameters
f. Rough treatment

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ELECTROMAGNETIC COMPATIBILITY
The 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.
Caution
We warn users, that they are responsible for possible interference from
welding.
4. TECHNICAL DATA
PEGAS 320 AC/DC PULSE
Method MMA - AC MMA - DC TIG - AC TIG - DC
Mains voltage V Hz
3 x 400 50-60
Welding current range A 10 - 320 10 - 320 10 - 320 10 - 320
Open-circuit voltage U20 V --- 75,0 --- 75,0
Mains protection A 25 @
Max. effective current I1eff A 21,0 19,4 15,1 14,3
Welding current
(DC=100%) I
2
A 250 250
Welding current (DC=60%)
A 320 320
Welding current (DC=x%) I2
A 60%=320 60%=320
Protection IP23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm
240 x 600 x 440
Weight kg 25,2

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PEGAS 400 AC/DC PULSE
Method MMA - AC MMA - DC TIG - AC TIG - DC
Mains voltage V Hz
3 x 400 50-60
Welding current range A 10 - 400 10 - 400 10 - 400 10 - 400
Open-circuit voltage U20 V --- 75,0 --- 75,0
Mains protection A 32 @
Max. effective current I1eff A 26,4 26,3 20,0 19,4
Welding current
(DC=100%) I
2
A 320 320
Welding current (DC=60%)
A 400 400
Welding current (DC=x%) I2
A 60%=400 60%=400
Protection IP23S
Standards EN 60974-1, EN 60974-10 cl. A
Dimensions (w x l x h) mm
240 x 600 x 440
Weight kg 26,7
COOLING UNIT
Cooling power (Q=1l min) kW 0,92
Total liquid content l 5,0
Max. pressure Bar 3,5
Max. flow l min 8
Input voltage U1 [V Hz] V Hz 230 1~50
Input current I1 [A] A 1,3
Protection IP 23 S
Weight kg 22,8
Dimensions (w x l x h) mm 240 x 660 x 310
Standards EN 60974-2
Cau ion Due to the size of installed power can be for connecting device to
public distribution network necessary the agreement from distribution
establishment.

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5. EQUIPMENT
CONTENT OF DELIVERY
I em No. Descrip ion Pic ure
5.0526 PEGAS 320 AC DC PULSE
5.0525 PEGAS 400 AC DC PULSE
5847 Set Connectors ST 12 PIN
ACCESSORIES TO ORDER
I em No. Descrip ion Pic ure
VM0321-2 Hose Gas 3m Pegas quick connector
G1 4
VM0025 Earthing cable 3 m 500 A 70 mm2
VM0185 Cable with E holder 3 m 400 A 35-70
18SCSL4ST Torch PARKER SGT 18SC
4m 35-50 ST
18SCSL8ST Torch PARKER SGT 18SC
8m 35-50 ST
18SCSL4STUD
Torch PARKER SGT 18SC
4m 35-50 ST UD
18SCSL8STUD
Torch PARKER SGT 18SC
8m 35-50 ST UD

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6008 Pressure Reducer FIXICONTROL Ar
2 manometers GCE
5.0174ST Foot Pedal Remote CTRL 3 m
PEGAS incl. Connector ST
S7SUN9B Welding Helmet S9B Shooting Blue
Shark
5.0529 CS Cooling Unit PEGAS 320 a 400
AC DC
6009 Cooling Liquid ACL-15 5L

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6. OPERATOR CONTROLS
MAIN PARTS
Fig. 1 – Main parts
Pos. Descrip ion
A1 TIG connector of gas connection
A2 Quick connector (-)
A3 TIG connector of remote control
A4 Quick connector (+)
A5 Connector of cooling unit connection
A6 Connector of gas connection
A7 Mains cable
A8 Main switch

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COOLING UNIT
Fig. 2 – Cooling unit
Pos. Descrip ion
B1 Quick connector (blue)
B2 Quick connector (red)
B3 Tank for cooling liquid
B4 Connector for connecting the cooling unit to the machine
B5 Quick connector (blue)
B6 Quick connector (red)
1. Like cooling liquid use ACL 15 or Binzel BTC 15. Avoid pollution of the
cooling liquid with mechanical dirt, grease, possibly with other, especially
flammable substances.
2. If the error message “E11 - Lack of liquid“ illuminates during operation,
turn off the main switch A8 and check or refill the cooling liquid. After
turning on the machine, perform the test of the cooling unit. If the error
repeats, it is necessary to find out the cause of the error.
3. Note: If is connected the gascooled torch, it is necessary to connect quick
connectors with connecting hose of liquid circuit! If this condition is not met,
it can cause the pump damage.

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OPERATING PANEL
Fig. 3 – Operating panel
Pos. Descrip ion
V1 Button of welding method selection (MMA TIG)
V2 LED JOB
V3 LED A, values on the display V4 are in A
V4 Left display
V5 LED Hz, values on the display V4 are in Hz
V6 LED s, values on the display V4 are in s
V7 LED %, values on the display V4 are in %
V8 Right display
V9 LED of turning on the machine
V10 LED of cooling unit error
V11 LED ALARM
V12 Button of cooling selection – air water
V13 LED of gascooled torch
V14 LED of watercooled torch
V15 LED 2T (2 stroke)
V16 LED 4T (4 stroke
V17 LED HOT START for MMA

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V18 LED of welding current setting for MMA
V19 LED ARC FORCE for MMA
V20 Button of selection 2T 4T
V21 TIG parameters curve
V22 Encoder
V23 Button of welding current mode selection (AC DC)
V24 LED DC wave
V25 LED AC triangle wave
V26 LED AC sine wave
V27 LED AC advanced square wave
V28 LED MMA
V29 LED TIG LIFT
V30 LED TIG HF
Fig. 4 – Parameters curve
Pos. Descrip ion
K1 LED pre gas 0,1 – 2,0 s
K2 LED pulsed mode is ON
K3 LED AC balance -5 – +5
K4 LED pulsed mode is OFF
K5 LED pulse width 5 – 95 %
Only available when the pulsed mode is selected.
K6 LED AC frequency 50 – 250 Hz
K7 LED pulse frequency 0,5 – 999 Hz
Only available when the pulsed mode is selected.
K8 LED post gas 0 – 10 s
K9 LED final current 10 – 320A 400A
Only available in 4T.

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K10 LED down slope 0 – 10 s
K11 LED base current 10 – 320A 400A
K12 LED main welding current 10 – 320A 400A
K13 LED up slope 0 – 10 s
K14 LED starting current 10 – 320A 400A
7. GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
GETTING STARTED MMA – COATED ELECTRODE
Fig. 5 – Getting started MMA
1. Insert the mains plug into a suitable 3x400 V mains socket, 50-60 Hz. The
supply fuses or circuit breaker should correspond to the technical data
stated in this manual.
2. Connect the welding cables to the quick connectors (+) A4 and (-) A2
according the instruction on the electrodes packing.
3. Switch the machine on by the main switch A8.
4. By means of the button V1 select MMA method, LED V28 will shine.
5. By means of the button V23 select the welding current mode (AC or DC)
6. By means of the encoder V22 set the welding current. The values will be
showed on the display V4.
7. Press and then rotate the encoder V22 to adjusting the level of 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.

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8. Then switch to the MMA mode by means of the encoder V22, LED V18
must shine and LEDs V7 and V11 may not illuminate.
9. Connect the earthing clamp to the weldment.
10. Insert into the electrode holder the appropriate electrode and you can start
welding.
NOTE Prevent touching the electrode any metal material for in this mode
the quick connectors A4 and A2 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.
GETTING STARTED TIG
TIG MODE WITH WATERCOOLED TORCH
Fig. 6 – Getting started TIG with watercooled torch

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1. Insert the mains plug into a suitable 3x400 V mains socket, 50-60 Hz.
2. Connect the watercooled torch to the front panel of the welding machine
and to the front panel of the cooling unit, see fig. above.
3. Connect the earting clamp to the quick connector (+) A4.
4. Connect the cooling unit to the welding machine (if it is not already
connected) according to fig. above.
5. Connect the gas hose to the gas cylinder connector on the gas bottle and
to the connector A6 on the rear panel.
6. Switch the machine on by the main switch A8.
7. By means of the button V1 select method TIG LIFT or TIG HF, LED V29
or V30 will shine.
8. Switch the cooling unit on by the switch on the rear panel of the cooling
unit.
9. By means of the button V12 select the water cooling of the torch. LED V14
will shine.
10. By means of the torch button activate the gas test and set the required flow
of the protective gas.
11. By means of the button V20 select TIG 2T or 4T. The appropriate LED
V15, T16 will shine.
12. By means of the button V23 select the welding current mode (AC or DC).
Method must have the appropriate tungsten electrode and grinding
method. The appropriate LEDs V24, V25, V26, V27 will shine.
13. By means of the encoder V22 set the required welding current.
14. The others parameters (TIG parameters curve) is possible modify by
means of the encoder V22. The appropriate LED will shine. The required
parameter is automatically saved, when you go over to the next parameter
or after 3 s of the encoder inactivity. For more information see COOLING
UNIT
Fig. 2 – Cooling unit
Pos. Descrip ion
B1 Quick connector (blue)
B2 Quick connector (red)
B3 Tank for cooling liquid
B4 Connector for connecting the cooling unit to the machine
B5 Quick connector (blue)
B6 Quick connector (red)
4. Like cooling liquid use ACL 15 or Binzel BTC 15. Avoid pollution of the
cooling liquid with mechanical dirt, grease, possibly with other, especially
flammable substances.
5. If the error message “E11 - Lack of liquid“ illuminates during operation,

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turn off the main switch A8 and check or refill the cooling liquid. After
turning on the machine, perform the test of the cooling unit. If the error
repeats, it is necessary to find out the cause of the error.
6. Note: If is connected the gascooled torch, it is necessary to connect quick
connectors with connecting hose of liquid circuit! If this condition is not met,
it can cause the pump damage.
15. OPERATING PANEL.
16. You can start welding.
TIG MODE WITH GASCOOLED TORCH
Fig. 7 – Getting started TIG with gascooled torch
1. Insert the mains plug into a suitable 3x400 V mains socket, 50-60 Hz.
2. Connect the gascooled torch to the front panel, see fig. above.
3. Connect the earting clamp to the quick connector (+) A4.
4. Connect the gas hose to the gas cylinder connector on the gas bottle and
to the connector A6 on the rear panel.
5. Switch the machine on by the main switch A8.
6. By means of the button V1 select method TIG LIFT or TIG HF, LED V29
or V30 will shine.
7. By means of the button V12 select the gas cooling of the torch. LED V13
will shine.
8. By means of the torch button activate the gas test and set the required flow

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of the protective gas.
9. By means of the button V20 select TIG 2T or 4T. The appropriate LED
V15, V16 will shine.
10. By means of the button V23 select the welding current mode (AC or DC).
Method must have the appropriate tungsten electrode and grinding
method. The appropriate LEDs V24, V25, V26, V27 will shine.
11. By means of the encoder V22 set the required welding current.
12. The others parameters (TIG parameters curve) is possible modify by
means of the encoder V22. The appropriate LED will shine. The required
parameter is automatically saved, when you go over to the next parameter
or after 3 s of the encoder inactivity. For more information see COOLING
UNIT
Fig. 2 – Cooling unit
Pos. Descrip ion
B1 Quick connector (blue)
B2 Quick connector (red)
B3 Tank for cooling liquid
B4 Connector for connecting the cooling unit to the machine
B5 Quick connector (blue)
B6 Quick connector (red)
7. Like cooling liquid use ACL 15 or Binzel BTC 15. Avoid pollution of the
cooling liquid with mechanical dirt, grease, possibly with other, especially
flammable substances.
8. If the error message “E11 - Lack of liquid“ illuminates during operation,
turn off the main switch A8 and check or refill the cooling liquid. After
turning on the machine, perform the test of the cooling unit. If the error
repeats, it is necessary to find out the cause of the error.
9. Note: If is connected the gascooled torch, it is necessary to connect quick
connectors with connecting hose of liquid circuit! If this condition is not met,
it can cause the pump damage.
13. OPERATING PANEL.
14. You can start welding.
Caution Make sure, that in gascooled torch welding method is the cooling
unit turned off. At turning of the cooling unit on and at choise of the gascooled
torch can happened the pump damage.
BALANCE FUNCTION IN AC MODE
Function allows to set the ratio between the cleaning effect (plus part of the
wave) and the penetration (minus part of the wave).

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Shape of the current
curve
BALANCE Value 15% Value 50%
Cleaning effect Smallest Biggest
Penetration Deep Shallow
Level of wear of the
tungsten electrode Smaller Bigger
REMOTE CONTROL
PEGAS 320-400 AC DC PULSE can work in both of TIG modes with three types
of remote control.
1. TIG torch with UP-DOWN buttons for selecting size of welding current.
2. Additional remote control of welding current size.
3. Foot pedal.
Remote controls are connected with connector A3.
Func ion of he foo pedal
Fig. 8 – Foot pedal remote control
Pos. Descrip ion
P1 Stepping surface

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P3 Connector of the remote control (connect to matching connector
A3 on the front panel)
1. When you connect the connector P3 to matching connector A3 on the front
panel, the function setting the current from the torch will be automatically
blocked.
2. By means of the encoder V22 set maximal required value of the current.
3. Set the machine to the mode 2T.
4. By pressing the stepping surface P1 down, you start the welding process.
The value of the welding current depends on the level of pressing the
stepping surface. To reach the maximal current, set by the encoder V22,
requires to gently pressing to the lowest position of the stepping surface
P1. The set current will be displayed on the current display V4 see fig. n.
3.
5. The welding process ends after releasing the stepping surface P1.
8. TWO STOKE AND FOUR STROKE IN TIG MODE
TWO STROKE – 2T
Gas
Pregas Postgas
Down slope
Current
Welding current