Alfain SVAROG 420 HD User manual

ALFA IN a.s. ©www.alfain.eu SVAROG 420 520 HD návod EN 06
WELDING MACHINE
SVAROG 420/520 HD
SVAROG 420/520 HD PULSE
SVAROG 420/520 HD DOUBLE PULSE
OPERATING MANUAL

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ALFA IN a.s. © www.alfain.eu
CONTENT
PERSONAL PROTECTION ..........................................................................5
SAFETY REGULATIONS..............................................................................6
MACHINE PROTECTION .............................................................................6
ELECTROMAGNETIC COMPATIBILITY.......................................................8
PART OF DELIVERY....................................................................................9
ACCESSORIES TO ORDER.........................................................................9
TORCHS TO ORDER...................................................................................9
MAIN PARTS OF THE MACHINE...............................................................10
COOLING UNIT (only for water-cooled versions)........................................12
WATER TORCH COOLING SYSTEM.........................................................12
BLEEDING THE TORCH COOLING SYSTEM............................................13
DESCRIPTION OF CONTROL PANEL.......................................................13
MENU STRUCTURE...................................................................................15
MENU 1 (SECONDARY PARAMETERS MENU)........................................15
TOKEN........................................................................................................17
JOB STORAGE...........................................................................................19
LOADING JOB (JOB LOA)..........................................................................19
QUICK SELECT JOB –MEMORY..............................................................19
ELECTRODE HOLDER AND GROUND CABLE CONNECTION................20
TORCH CONNECTION ..............................................................................21
GROUND CABLE CONNECTION...............................................................21

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ALFA IN a.s. © www.alfain.eu
GAS SUPPLY ATTACHMENT....................................................................21
CONNECTING CABLE CONNECTION.......................................................23
TORCH CONNECTION ..............................................................................23
GROUND CABLE CONNECTION...............................................................23
EARTH TERMINAL CONNECTION............................................................23
NETWORK CONNECTION.........................................................................23
WIRE COIL INSTALLATION.......................................................................23
GUIDING THE WIRE INTO FEED...............................................................24
OVERVIEW OF WIRE FEED PULLEYS .....................................................25
....................................................................................................................26
GAS SUPPLY ATTACHMENT....................................................................26
MACHINE ADJUSTMENT –ALUMINUM WELDING ..................................26
WIRE CONSUMPTION TABLE DURING MIG / MAG WELDING................30
GAS CONSUMPTION TABLE DURING MIG / MAG WELDING..................30
TABLE OF CONSUMPTION DURING TIG WELDING................................30
ELECTRODE CONSUMPTION TABLE DURING WELDING......................31

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ALFA IN a.s. © www.alfain.eu
OPERATIONAL SAFETY CONTROL OF THE RESOURCE ACCORDING
TO EN 60 974-1..........................................................................................32
ERROR MESSAGES..................................................................................32
STATEMENT OF WARRANTY ...................................................................33
WARRANTY AND POST-WARRANTY REPAIRS.......................................33
INFORMATION FOR USERS FOR DISPOSAL OF ELECTRICAL AND
ELECTRONIC EQUIPMENT IN THE CZECH REPUBLIC:..........................34
INTRODUCTION
Dear consumer,
Company ALFA IN a.s. thanks you for buying our product and believe that you
will be satisfied with our machine.
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.
The SVAROG 420/520 HD synergic welding machine is a new generation of
multifunctional synergic welding machines of the ALFA IN brand.
The machine is designed for welding method MIG/MAG, MMA, TIG and the AIR
method. The SVAROG HD series is very variable and in addition to perfect
welding properties, is characterized by the following specifics:
1. Very high load 500 A at 60% (420 A at 100%) most other machines have
significantly lower power.
2. Ecological –efficiency higher than 89%. This means that at least 89% of the
energy from grid is converted into arc energy.
3. Remote control as standard –Thankstothe strongmagnet, youcan reliably
place it at a distance of up to 12m (the length of the extension cable is 6m).
You can easily place the panel on any ferromagnetic material, the side of the
welder or directly on the welded structure.

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ALFA IN a.s. © www.alfain.eu
4. Possibility to choose control panel with classic panel buttons or sub-foil
solution of buttons. Classic buttons give many welders a sense of security
when operating the welder.
5. Easy lock –the control panel can be locked by holding the button,
unintentional change of settings is therefore unlikely.
6. Direct storage of 5 JOBs by holding the button and recalling JOBs by a short
direct button. We reserved our own button for each of the JOBs out of 5.
7. Innovative industrial Torch ARC M6W with remote control as standard.
Thanks to it, the Torch maintenance time is up to ⅔.
8. ARC gun torch as alternative for high-performance welding.
9. Torch calibration –The accuracy of the synergy depends on the resistance
of the welding circuit. Different lengths of torch, connection, ground cable or
ground location affect the accuracy of the synergic curve. The Torch
calibration function allows you to eliminate these effects.
10. Pulse mode can remove up to 70% of finishing work.
11. Coolant filter in the basic equipment of the machine.
12. Coolant ACL-10 –does not harm the enviroment, is not toxic.
13. Modularity of chassis for gas cylinders –for one, two or no cylinder.
14. Variable feed position on the current generator (Separate).
15. Czech prices of spare parts and service work.
16. Practical and smart cable Torch holders.
With this machine it is possible to weld various types of joints (blunt, single-sided,
double-sided, corner, overlapped, etc.). Using wires with a diameter of 0.8 to 1.2
and up to 1.6 mm, from various metal materials and alloys (carbon and alloy
steel, aluminum alloys, etc.). They are designed not only for heavy industrial
operations, but also for industries demanding accuracy and speed.
We reserve the right to make modifications and changes in case of printing
errors, changes in technical parameteres, accessories, etc. Without prior notice.
These changes may not be reflected in the paper or electronic operating
instructions.
SAFETY PRECAUTIONS
PERSONAL PROTECTION
1. For safety reasons, protective gloves must be worn during welding. These

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gloves protect you from electric shock (circuit voltage at no load). It also
protects you from heat radiation and splashing drops of hot metal.
2. Wear stury insulated shoes. Open shoes are not suitable as drops of hot
metal can cause burns.
3. Do not look into the welding arc without face and eye protection. Always
use a high-quality welding helmet with an intact protective filter.
4. Notice
Persons with implanted pacemakers must not work with the machine or
move in their immediate vicinity! There is a risk of the stimulator
malfunctioning!
5. Persons in the vicinity of the welding site must also be informed of the
danger and provided with protective equipment.
6. When welding especially in small spaces, it is necessary to ensure a
sufficient supply of fresh air, as welding produces harmful emissions.
7. Do not perform welding work on gas, oil, fuel, etc. Tanks (even empty
ones) as there is a risk of explosion.
8. Special regulations apply in potentially explosive atmospheres.
9. Stop welding immediately if the power cord is damaged. Do not touch this
cable. Unplug it.
10.In areas with an increased risk of electric shock. Only machines marked
with the symbol can be used
S
.
11.Welded joints that are subject to high stress must meet special safety
requirements. These are mainly rails, pressure vessels, etc. These joints
may only be made by qualified trained welders with the necessary
authorization.
SAFETY REGULATIONS
1. Before use, the operator is obliged to inform himself about the legislation
in the country of use that deals with safety for welding, metal welding and
arc welding.
2. The CO2 bottle of mixed gases must be handled in accordance with the
regulations for working with pressure vessels.
3. The welder must use protective equipment.
4. When handling the machine with a lifting device, hook the machine on all
crane eyes. Other mounting is not permitted!
5. Disconnect the device from the mains before carrying out any work on the
electrical systém, removing the cover or cleaning it.
MACHINE PROTECTION
This machine is electronically protected againts overload. Do not turn off the
main power switch while the machine loaded.
ACL-10 coolant is designed for ambient temperatures up to -10˚C.
NoticePersons with implanted pacemakers must not operate the

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machines or move in close proximity to them! There is a risk of impaired
pacemaker function!
OPERATINGS CONDITIONS
1. SVAROG 420/520 Pulse H20 welding machine is designed for welding
aluminium steels and their alloys, for commercial and industrial use.
2. Use only the specified transport equipment to transport the welder. Do not
use a forklift or simple crates to move.
3. The welding machine can be manipulated with the help of crane eyes,
which are part of the chassis. The machine can only be handled if it is
attached to all crane eyes. The SVAROG transport with crane eyes is
prohibited if a gas cylinder is placed on the platform.
4. The device may only be put into operation by trained personnel and only
within the technical regulations. The manufacturer is not liable for damage
caused by improrer use and operation. Only use original spare parts from
ALFA IN for maintenance and repairs.
5. The device complies with IEC 61000-3-12.
6. The welding machine is tested according to the snadard for degree of
protection IP 23S, which provides protection against intusion of solids with
a diameter greater than 12 mm and protection against intrusion of water
falling in a vertical to oblique direction to a slope of 60˚.
7. Operating ambient temperature between -10 to +40 °C.
8. Relative humidity below 90% at +20 °C.
9. Up to 3000 m above sea level.
10.The machine must be located so that the cooling air can enter and exit
through the cooling vents without restriction. Care must be taken to ensure
that no mechanical particles, especially metal particles, are sucked into the
machine (eg during grinding).
11.The handling handle is intended for travel only, it is not designed for lifting
machines.
12.All interventions in the el. equipment as well as repairs (disassembly of the
mains plug, replacement of fuses) may only be carried out by an
authorized person.
13.For the welding machine, it is necessary to perform a periodic inspeciton
once every 6/12 months by an authorized employee –see paragraph
Maintenance and service tests.
14.From the point of view of interference suppression, the welding machine is
designed primarily for industrial premises. If other premises are used,
specieal measures may be required (see EN 60974-10).
15.The machine must be protected against:
a. Moisture and rain
b. Mechanical damage
c. Drafts and possible ventilation of neighboring machines
d. Excessive overloading –exceeding tech. parameters
e. Rough treatment

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ALFA IN a.s. © www.alfain.eu
ELECTROMAGNETIC COMPATIBILITY
In terms of interference suppression, the welding equipment is designed
primarily for industrial premises. It meets the requirements of EN 60974-10 class
A and is not intended for use in residential areas where electricity is supplied by
a public low-voltage power supply network. There may be possible problems
with ensuring electromagnetic compatibility in these areas, caused by line
propagation interference as well as radiated interference.
The device may be a source of interference during operation.
Notice
Due to the size of the installed capacity, the approval of the distribution plants
must be required to connect the equipment to the public distribution network.
We warn the user that he is responsible for any interference from welding.
TECHNICAL DATA
SVAROG 520 PULSE H2O
Method
MIG/MAG
MMA
TIG
Mains voltage
V/Hz
3x400/50-60
Welding current
range
A
20 - 500
10 - 500
10 - 500
Open-circuit voltage
U20
V
94,0
103,0
100,0
Mains protection
A
32 @
Max. effective
current I1eff
A
32,0
31,4
27,0
Welding current
(DC=100%) I2
A
420
400
420
Welding current
(DC=60%) I2
A
500
450
500
Welding current
(DC=x%) I2
A
60% = 500
55% = 500
60% = 500
Protection
IP 23S
Standards
EN IEC 60974-1, EN 60974-10 cl. A
Dimensions (w x l x
h) generator
mm
650 x 1140 x 1090
Compact weight
kg
100
Wire speed
m/min
1,0 - 20,0
---
---
Spool diameter
mm
300
---
---
Spool weight
kg
18
---
---
Weight - feeder
kg
16
---
---
Cooling power
(Q=1l/min)
kW
0,74
---
0,74
Total liquid content
l
5,0
---
5,0

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Max. pressure
Bar
3,5
---
3,5
Max. flow
l/min
9
---
9
Max. input power
I1max
A
41,2
42,3
34,6
Open-circuit voltage
reduced U2R
V
16,0
Insulation class
F
Max. input power
S1max
kVA
28,6
29,1
24,4
Efficiency
%
88
Input power in idle
mode P10
W
25
MACHINE ACCESSORIES
PART OF DELIVERY
1. Operating manual
2. Grounding cable 3 m 500 A 70 mm2
3. Pulley (s) for wire diameters 1,0 - 1,2 mm
4. 2x Reduciton for wire spool
ACCESSORIES TO ORDER
See Catalog
TORCHS TO ORDER
1. Torch ARC M6W 3m DIGIMIG
2. Torch ARC M6W 4m DIGIMIG
3. Torch ARC M6W 5m DIGIMIG
4. Torch ARC M6W 3m DIGIMIG PISTOL
5. Torch ARC M6W 4m DIGIMIG PISTOL
6. Torch ARC M6W 5m DIGIMIG PISTOL
7. Torch ARC M6OSW 3m DIGIMIG
8. Torch ARC M6OSW 4m DIGIMIG
Assembly and maintenance instructions M6WP/M6OSWP:
NoticeIf you decide to use a torch other than the one above, you must

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select according to the current range used and the torch load time. ALFA IN a.s.
is not responsible for damage to welding torches due to overload.
DESCRIPTION OF THE MACHINE AND FUNCTIONS
MAIN PARTS OF THE MACHINE
Pos.
Name
A1
ON/OFF switch
A2
Remote control connector (generator)