Alfain ALF 251 aXe User manual

ALFA IN a.s. © www.alfain.eu Version 1

MIG/MAG WELDING MACHINES

ALF 251 aXe

ALF 261 aXe

ALF 280 aXe

ALF 320 aXe

ALF 400 aXe

MINOR2 - MAJOR – SYNERGY

BASIC

INSTRUCTION MANUAL

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ALFA IN a.s. © www.alfain.eu

Content:

INTRODUCTION...................................................................................3

SAFETY INSTRUCTIONS AND WARNINGS........................................4

CONDITIONS OF USE..........................................................................8

TECHNICAL DATA................................................................................8

ACCESSORIES...................................................................................10

DESCRIPTION OF THE APPLIANCE .................................................11

GETTING STARTED...........................................................................18

WELDING............................................................................................22

ROUTINE MAINTENANCE & INSPECTION........................................27

10.

STATEMENT OF WARRANTY............................................................28

11.

DISPOSAL...........................................................................................28

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ALFA IN a.s. © www.alfain.eu

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.

ALF 251/261/280/320/400 aXe 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.

The users interface is as simple as possible; however, there are secondary

parameters that can be set from the main front panel if suitable. All of them

are available in compact models, ALF 280, 320 and 400 can be ordered also

as sets consisting of the generator, interconnection cable bundle and

separate wire feeding unit. We will refer to the MINOR2-MAJOR and

SYNERGY controls as DIGITAL.

CONTROL MODEL BASIC MINOR2 MAJOR

SYNERGY

A + V meter optional NO YES YES

Wire initial speed (Soft Start) NO NO YES YES

Advice of the parameter settings

NO NO NO YES

Electronic feedback of the wire

speed NO YES YES YES

2 stoke / 4 stroke YES YES YES YES

Adjustable Post and Pre Gas

time NO YES YES YES

Spot and Interval welding YES YES YES YES

Adjustable Burn Back Time NO YES YES YES

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ALFA IN a.s. © www.alfain.eu

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.

•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

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ALFA IN a.s. © www.alfain.eu

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

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

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ALFA IN a.s. © www.alfain.eu

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

increased protection for

the operator

DC current: 141V

peak value AC current: 141V

peak value and

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:

•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.).

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ALFA IN a.s. © www.alfain.eu

•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

•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.

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ALFA IN a.s. © www.alfain.eu

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

4. TECHNICAL DATA

ALF 251 ALF 261

Mains voltage V/Hz

3x400/50 3x400/50

Mains protection A 16 16 T

Max. input power I1 A 17,0 17,9

Max. effective current

I1eff A 10,4 8,9

Welding current

range A/V 25/15,3 -

250/26,5 25/15,3 -

260/27,0

Open-circuit voltage

U20 V 17,9 - 45,2 17,9 - 45,2

Welding current

(DC=100%) I2 /U2 A/V 170/22,5 170/22,5

Welding current

(DC=60%) I2 /U2 A/V 200/24 200/24,0

Welding current

(DC=x%) I2 /U2 A/V x=30%

250/26,5 x=25%

260/27,0

Voltage steps 10 10

Insulation class F F

Protection IP 23S IP 23S

Standards EN 60 974-1 EN 60 974-1

Dimensions (w x l x h)

compact mm 500x868x806

500x868x806

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ALFA IN a.s. © www.alfain.eu

Dimensions (w x l x h)

generator mm x x

Weight compact kg 76 76

Weight generator kg x x

Wire speed m/min

1 - 19 1 - 19

Spool diameter mm 300 300

Spool weight kg 18 18

ALF 280 ALF 320 ALF 400

Mains voltage V/Hz

3x400/50 3x400/50 3x400/50

Mains protection A 16 T 16 T 20 T

Max. input power I1 A 16,7 21,5 27,3

Max. effective current

I1eff A 8,4 10,8 13,7

Welding current

range A/V 40/16,0 -

290/28,5 40/16,0 -

340/31,0 50/16,5 -

400/34,0

Open-circuit voltage

U20 V 18,3 - 40,1 18,2 - 44,9 19,4 - 49,8

Welding current

(DC=100%) I2 /U2 A/V 170/22,5 200/24,0 240/26,0

Welding current

(DC=60%) I2 /U2 A/V 210/24,5 230/25,5 290/28,5

Welding current

(DC=x%) I2 /U2 A/V 30%=290/28,

5 25%=340/31,

0 25% =

400/34,0

Voltage steps 10 12 2 x 10

Insulation class F F F

Protection IP 23S IP 23S IP 23S

Standards EN 60 974-1 EN 60 974-1 EN 60 974-1

Dimensions (w x l x h)

compact mm 500x868x806

500x868x806

Dimensions (w x l x h)

generator mm 500x868x889

500x868x889

Weight compact kg 88 99 109

Weight generator kg 83 94 103

Wire speed m/min

1 - 19 1 - 19 1 - 19

Spool diameter mm 300 300 300

Spool weight kg 18 18 18

Wire Feed Unit PS4 GAS aXe

Wire speed m/min

1 - 19

Input voltage U

V/Hz 24/1~50

Input current I

A 4

Welding current I

(DZ=100%) A 320

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ALFA IN a.s. © www.alfain.eu

Welding current I

(DZ=60%) A 400

Spool diameter mm 300

Spool weight kg 18

Protection IP 21S

Dimensions (w x l x

h) mm 264x704x507

Unit weight (without

wire and torch) Kg 21

Standards EN 60974-5

5. ACCESSORIES

5.1 DELIVERED WITH THE MACHINE

•Earthing cable 3m with a clamp

•Feed roll 0,8 - 1,0mm

•Gas hoses

5.2 ACCESSORIES TO ORDER

•Wire cleaner

•CO2 Gas pre heating cable

•Reduction valve KU 5, K 2

•Gay cylinder

•Torch consumables

•Earthing cable 4 - 5 m

•Feed rolls 0,6-0,8 1,0-1,2 1,4-1,6 for carbon steels, aluminium, flux

core wires

•Torches with UP-DOWN remote control

•Welding torches (see the table below)

Torch type Cooling Welder

MB 24KD Gas ALF 251-280 aXe

MB 36KD Gas ALF 320 aXe

MB 36KD Gas ALF 400 aXe

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