Alfain PERUN 200 MIG MAN PFC User manual

ALFA IN a.s. © www.alfain.eu PERUN 200 MIG MAN PFC manual EN 02
WELDING MACHINE
PERUN 200 MIG MAN PFC
OPERATING MANUAL

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CONTENT
1. INTR DUCTI N ....................................................................................... 3
2. SAFETY PRECAUTI NS .......................................................................... 4
3. PERATING C NDITI NS ...................................................................... 5
4. TECHNICAL DATA .................................................................................... 6
5. EQUIPMENT ............................................................................................. 7
6. PERAT R C NTR LS .......................................................................... 9
7. GETTING STARTED MIG/MAG .............................................................. 14
8. GETTING STARTED TIG ........................................................................ 20
9. GETTING STARTED MMA ...................................................................... 22
10. R UTINE MAINTENANCE & INSPECTI N .......................................... 22
11. STATEMENT F WARRANTY .............................................................. 23
12. DISP SAL ............................................................................................. 23
13. WARRANTY LIST .................................................................................. 24

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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 perating 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.
The model of PERUN 200 MIG MAN PFC is the multi-function inverter power
generators welding by those methods
a) MIG/MAG in 2T, 4T, wires SG2 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) TIG Lift Arc
PERUN 200 MIG MAN PFC is equipped by system of Power Factor Correction
(PFC).
What are the advantage of PFC olution?
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. The 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 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 PRECAUTION
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. Make sure that the torch insulation and the earthing cable are in good
condition.
4. The persons appearing in the vicinity of the welding must be informed of
the danger and must be equipped with protective equipment.
5. During welding, especially in small spaces, it is necessary to ensure an
adequate supply of fresh air, because during welding, harmful fumes arise.
6. In tanks of gas, oil, fuel, etc., (even empty ones) do not make welding,
because there is a chance of explosion.
7. In areas with chance of explosion special provisions are applied.
8. 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 CSN 050601 and norm CSN 050630.
2. With a bottle of C 2 or mixed gases should be handled according to the
regulations for working with pressure vessels contained in CSN 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 CONDITIONS
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. Working ambient temperature between -10 and +40 °C.
5. Relative humidity below 90% at +20 °C.
6. Up to 3000 m altitude.
7. It is not permissible to connect multiple machines in parallel or in series.
8. 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. Cooling is controlled by electronic
temperature control.
9. It is necessary for welding machine to undergo a periodic inspection every
6/12 months by an authorized officer according to CSN 331500 and CSN
050630 – see Maintenance and service tests.
10. All interventions in the el. equipment as well as repair (removal of the
plug, fuse replacement) should be performed by an authorized person.
11. The welding machine is set by the manufacturer to 230V with a
tolerance range of 110 - 230 V ± 10%, which allows the device to operate
in a ~ 220V and ~ 110V network.
12. With competent mains voltage and input must match the plug.
Caution Exten ion cable mu t not have conductor with a maller
cro ection than 3x2,5 mm2. The machine can be operated on a ingle-
pha e electric generator 6 kVA (1x110V/50Hz) and more or 8 kVA
(1x230V/50Hz) and more, which ha en ured voltage tabilization ± 15%.
Generator with lower power can damage the machine.
13. 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
Method MIG/MAG MMA TIG MIG/MAG MMA TIG
Mains voltage V/Hz 1x110/50-60 1x230/50-60
Welding current
range
A 25 - 130 10 - 100 10 - 140 25 - 200 10 - 200 10 - 200
pen-circuit
voltage U
20
V 67,0 67,0
Mains
protection
A 20 @ 16 @
Max. effective
current I
1eff
A 22,0 17,5 18,0 14,5 16,0 12,0
Welding current
(DC=100%) I
2
A 85 80 90 130 120 140
Welding current
(DC=60%) I
2
A 110 100 110 150 140 160
Welding current
(DC=x%) I
2
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 230 x 640 x 420
Weight -
compact
kg 18,4
Wire speed m/min 1,5 - 4,5 --- --- 1,5 - 16,5 --- ---
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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5. EQUIPMENT
CONTENT OF DELIVERY
Item No. De cription
5.0292 PERUN 200 MIG MAN PFC
ACCESSORIES TO ORDER
Item No. De cription Picture
SGB25-3 Torch PARKER SGB 250 3m
(MIG/MAG)
SGB25-4 Torch PARKER SGB 250 4m
(MIG/MAG)
SGB25-5 Torch PARKER SGB 250 5m
(MIG/MAG)
T24ST Torch T2 4m 35-50 arc ST
T28ST Torch T2 8m 35-50 arc ST
5756 Set Connectors (9pin)
(for replacement TIG torch)
VM0151-1 Hose Gas 3m G1/4-G1/4
VM0253 Welding Cable Set 2x 3m
35-50 200A
Rolls – see chapter
VERVIEW F R LLS F R
WIRE FEED
S777C Welding Helmet Barracuda
S777C Black

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S7SUN9B Welding Helmet S9B
Shooting Blue Shark
4488
Wire 0.8 Coreshield 15 A
D200 Self Shielding 4,5kg
spool
SGL2 Small Gas Lens Body Starter
Kit 1.6mm
-
1/16"
SGL4 Small Gas Lens Body Starter
Kit 2.4mm
-
3/32"
SGL5 Small Gas Lens Body Starter
Kit 3.2mm
-
1/8"
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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6. OPERATOR CONTROLS
Fig. 1. PERUN 200 MIG MAN PFC
Po . De cription
A1 Control panel
A2 Quick connector (+) of welding cables

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A3 Central MIG/MAG torch connector
A4 TIG torch control connector
A5 Gas connector for TIG torch
A6 Quick connector (-) of welding cables or TIG torch connector
A7 Handle
A8 Mains cable
A9 Secondary control panel (see details below)
A10 Terminals of change polarity MIG/MAG torch
A11 Wire feeder
CONTROL PANEL
Fig. 2. Control panel
Po . De cription
V1 LED. If it lights the method MIG/MAG has been selected by the
button V19.
V2 LED. If it lights the method MMA has been selected by the
button V19.

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V3 LED. If it lights the method TIG has been selected by the button
V19.
V4 Button for selecting the 2T or 4T mode.
V5 LED. If it lights the mode 2T has been selected by the button
V4.
V6 LED. If it lights the mode 4T has been selected by the button
V4.
V7
Potentiometer:
 Wire speed feed for MIG/MAG
 Current for MMA and TIG
V8
Potentiometer:
 Voltage for MIG/MAG MAN
 ARC F RCE for MMA
 Down Slope for TIG
V9 Choke potentiometer
V10 LED. If it lights the thermo-switch is disconnected. In such a
case leave the machine on to cool down.
V11 LED. If it lights the machine is switched on by the main switch.
V12 LED. If it lights the display V15 shows the time of down slope in
s.
V13 LED. If it lights the display V15 shows the value of ARC
F RCE.
V14 LED. If it lights the display V15 shows the voltage in V.
V15 Right display
V16 LED. If it lights the display V18 shows the wire feed speed in
m/min.
V17 LED. If it lights the display V18 shows welding current in A.
V18 Left display
V19 Button for selecting the welding method.

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Fig. 3. Secondary control panel – panel in the space of the wire feeder
Po . De cription
32 Switch Remote. N – on the remote control
FF – of the remote control
33 Switch Spool Gun. In the N position one can weld with the
Spool Gun
34 Potentiometer for the Burnback time setting
35 Potentiometer for the initial wire speed setting
36 Potentiometer for the Pre Gas time setting
37 Potentiometer for the Post Gas time setting
38 Gas setting button
39 Wire feeding button

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WIRE FEEDER
Fig. 4. Wire feeder
Po . De cription
E1 Nut of pressure arm
E2 Pressure arm
E3 Inlet liner
E4 EUR connector
E5 Roll
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
Aluminum
0,8-1,0 2270
Flux core
0,8
-
1,0
2318
1,0
-
1,2
2319

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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. These
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. nly 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. 5. The influence of the roll groove on the welding wire
INSERTING THE WIRE
1. pen 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 EUR 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. The adjusting screw is located under the
plastic screw E1.
6. The 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. 6. Spool holder
A Correct
B Wrong
C Wrong
Po . De cription
D1 Spool Holder
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. 7. Connection of the main MIG/MAG components
1. Connect the torch B6 to connector A3 on the machine while the machine is
turned off.
2. Connect the ground cable B4 to the quick connector of welding cables (-) A6.
3. Connect the ground clamps B5 to the welder B7 or to the welding table.
Notice When inserting the wire do not point with torch to the eyes!
4. Remove the gas nozzle from the torch.
5. Unscrew the current nozzle.
6. Connect the machine to power supply.
7. Turn the main switch on the back panel to N.
8. Press the button V19 to select the mode MIG/MAG . LED V1 lights up.
9. Press the button V4 to select 2T or 4T. The corresponding LED V5 or V6

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lights up.
10. Press the button 39 in the space of the wire feeder. The welding wire is fed
into the torch. After coming off from the torch tube, screw the current nozzle
and gas nozzle on.
11. Before welding, spray the area in a gas hose and current nozzle with a
separation spray, to prevent damage.
ADJUSTMENT OF GAS FLOW
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.
Notice Gas bottle must be well secured against fall. This 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 on the rear panel of the machine.
2. Press the button 38 in the space of the wire feeder.
3. Turn the adjusting screw F7 at the bottom side pressure reducing valve, until
the meter F6 shows the required flow, then release the button. The 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. 8. Gas flow setting
Po . De cription
F1 Gas bottle
F2 Cylinder Valve
F4 Pressure Reducer
F5 High Pressure Manometer
F6 Low Pressure Manometer
F7 Adjusting Screw
F8 Gas outlet

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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. The voltage drop is
approximately 4,8 V at 100 A.
2. By means of the potentiometer V8 select voltage.
3. Then by means of the potentiometer V7 select the appropriate wire speed.
4. By means of the potentiometer V9 tune the arc by changing the levels of
the choke.
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
Table of approximate parameter settings
ADJUSTING THE MACHINE FOR ANOTHER WIRE DIAMETER
In all machines ALFA IN MIG / MAG are used rolls with two grooves. These
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. pen the nut E1 to the right, 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. The 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. The middle terminal K3 is connected to the central euro connector of the
MIG/MAG torch. We supply the welder with K3 connected by means the
bridge K2 to (+) K1.
4. In case of welding with flux core wire with (-) polarity, connect K3 by means
the bridge K2 with K4 (+) terminal. Use Phillips screwdriver.
5. Make sure you fasten the terminals properly.
6. Connect the ground cable B4 to the (+) quick connector A2.

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Fig. 9. Terminals for changing the polarity of the MIG/MAG torch
Po . De cription
K1 Upper terminal (+)
K2 Bridge
K3 Middle terminal
K4 Lower terminal (-)
 CAUTION 
In case that you want to weld with a flux core wire, it is necessary to remove the
gas nozzle from the torch before you start welding. During the welding process,
you must not touch the weldment with the contact tip. There would be a risk of
wire baking.

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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 VERVIEW R LLS WIRE FEED. To 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.
Fig. 10. Customization of the feed for the aluminium wire
Po . De cription
G1 EUR connector
G2 Rolls
G3 Liner terminal for 4,0mm, 4,7mm outer diameter
G4 -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.
TORCH CONNECTION SCHEMA
5737 CONNECTOR ST 12 PIN MALE
PIN
NO. MMA FOOT PEDAL
SPOOL
GUN TIG TORCH MIG TORCH
1 / /
(-)
SP L
GUN
/ (-)
SP L GUN
2 / / / / (+)
SP L GUN
3 / / / / (+)
P TENTI METER
4 / /
(+)
SP L
GUN
/ P TENTI METER
CENTER TAP
5 / / / (+)
P TENTI METER
(-)
P TENTI METER
6 / / /
(-)
P TENTI METER
/
7 / / /
SIGNAL
P TENTI METER
TIG
/
8 / / / START/ST P START/ST P
9 / / / START/ST P
(GND)
START/ST P
(GND)
10 / / / / /
11 / / / / /
12 / / / / SPARE LINE