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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
ALFA IN a.s. © www.alfain.eu ALF 251-261-280-320-400 BASIC-
MINOR2-MAJOR-SYNERGY AXE MANUAL EN 06
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CONTENT:
1. INTRODUCTION .......................................................................................... 3
2. SAFETY INSTRUCTIONS AND WARNINGS ..................................................... 4
3. CONDITIONS OF USE................................................................................... 7
4. TECHNICAL DATA ....................................................................................... 8
5. ACCESSORIES ............................................................................................ 10
6. DESCRIPTION OF THE APPLIANCE ............................................................... 11
7. GETTING STARTED ..................................................................................... 18
8. WELDING .................................................................................................. 23
9. ROUTINE MAINTENANCE & INSPECTION .................................................... 29
10. STATEMENT OF WARRANTY ...................................................................... 29
11. DISPOSAL .................................................................................................. 30
12. WARRANTY LIST ........................................................................................ 31
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CONTROL MODEL
BASIC
MINOR
2 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
speed
2 stoke / 4 stroke
YES
YES
YES
YES
time
Spot and Interval welding
YES
YES
YES
YES
Adjustable Burn Back Time
NO
YES
YES
YES
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.
Machines ALF with KTC version aXe differ from the original version of the
machine by another kind of BASIC electronics - description of changes can be
found below the table of the technical data.
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.
Electronic feedback of the wire
Adjustable Post and Pre Gas
ALFA IN a.s. ©
NO YES YES YES
NO YES YES YES
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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.
2. SAFETY INSTRUCTIONS AND WARNINGS
1. OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN
BE DANGEROUS AND HAZARDOUS TO YOURHEALTH.
2. 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.
3. Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
4. This equipment must only be used by qualified personnel.
5. During installation, any electric work must only be carried out by trained
personnel.
6. The machine must be used in a dry place with good ventilation.
7. 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.
8. It is prohibited to connect more than one generator in series or in parallel.
9. When installing the machine, follow the local regulations on safety.
10. The position of the machine must allow easy access by the
operator to the controls and connectors.
11. When the welding machine is operating, all its covers and doors
must be closed and well fixed.
12. Do not expose the welding machine to direct sunlight or to heavy
rain. This equipment conforms to protection rating IP23S.
13. 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.
14. 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.
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Antimony
Chromium
Mercury
Nickel
Cobalt
Arsenic
Barium
Copper
Selenium
Cadmium
Manganese
Vanadium
15. 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.
16. Keep all fumes and gases from the breathing area.
17. Keep your head out of the fume plume.
18. Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.
19. The kinds of fumes and gases from the plasma arc depend on the
kind of 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:
Beryllium Lead Silver
20. 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.
21. 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.
22. 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.
23. To protect your hearing from loud noise, wear protective ear plugs
and/or ear muffs. Protect others in the workplace.
24. Noise levels should be measured to be sure the decibels (sound)
do not exceed safe levels.
25. The operator must ensure all flammable materials are removed
from the work area to avoid any risk of fire.
26. 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.
27. 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.
28. To prevent electric shock, we strongly suggest the following rules:
a) Do not work in a damp or humid environment.
b) Do not use the machine if its cables are damaged in any way.
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Case
Working conditions
Open
-circuit voltage
effective
effective
the operator
peak value
S
c) Make sure that the earthing system of the electric equipment is
correctly connected and operational.
d) The operator must be insulated from the metal components
connected to the return wire.
e) The earthing of the piece being worked could increase the risk of
injury to the operator.
29. EN 60974-1 Standard: Open-circuit voltage. During the operation
of the machine, the highest voltage, with which it is possible to come into
contact, is the open-circuit voltage between the clamps.
30. 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.
31. 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:
1
2
3 Torches held
4
32. In case 1, the dc machines with rectifier must be built in such a way
33. Before opening the machine switch off the machine and disconnect
34. Only personnel authorised by this company can carry out
Places with increased
risk of electric shock
Places without increased
risk of electric shock
mechanically with
increased protection for
Plasma cutting
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:
it from the power socket.
maintenance on the machine.
DC current: 113V
peak value
DC current: 113V
peak value
DC current: 141V
peak value
DC current: 500V
AC current: 68V
peak value and 48V
AC current: 113V
peak value and 80V
AC current: 141V
peak value and
100V effective
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PROTECTIVE UTTILITIES
1. Welding helmet with filter shade at least 10
2. Welding gloves
3. Welding apron and cloth
4. Welding boots
RISK OVERVIEW
1. Risk of electric shock.
2. Ultraviolet light and light radiation
3. Risk of inhaling gas fumes and dust particles
4. Burns
5. Noise
NOTE
1. It is forbidden to operate a machine with damaged insulation of the
welding torch or supply cable.
2. Never operate the machine taken down or damaged covers.
3. It is forbidden to operate the machine in wet environments and
outdoors in rain or snow.
4. Ensure proper grounding clamping pliers, which also reduces the risk
of electric shock.
5. Use prescribed protective utilities, keep them dry.
6. 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.
7. Never aim the torch against the eyes, body or other person.
3. CONDITIONS OF USE
1. This equipment must only be used by qualified personnel.
2. During installation, any electric work must only be carried out by trained
personnel.
3. Device complies with IEC 61000-3-12.
4. Do not expose the plasma machine to direct sunlight or to rain or snow.
This equipment conforms to protection rating IP23S.
5. Working ambient temperature between -10 and +40 °C.
6. Relative humidity below 90% at +20 °C.
7. Up to 3000 m altitude.
8. Place the machine the way that the cooling air can enter the vents
without restriction to. It is necessary to ensure that no impurities,
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especially metal particles, are not drawn into the machine.
9. 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).
10. The stability of the machine is guaranteed up to 10° inclination
under the following conditions:
a. The machine must be secured against rolling away
b. The wire feed unit must not be mounted on the generator
c. The gas bottle with a maximum height of 0.9 m may be placed and
properly anchored on the platform
11. 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
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
ALF 251 ALF 261
Mains voltage V/Hz 3x400/50 3x400/50
Mains protection A 16 @ 16 @
Max. effective current I
A 10,4 8,9
1eff
Welding current range A 25 - 250 25 - 260
Open-circuit voltage U20 V 17,9 - 45,2 17,9 - 45,2
Welding current (DC=100%) I2 A 170 170
Welding current (DC=60%) I2 A 200 200
Welding current (DC=x%) I2 A x=30% 250 x=25% 260
Voltage steps 10 10
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Protection IP 23S
Standards EN 60974-1; EN 60974-10 cl. A
Dimensions (w x l x h) compact mm 500x868x806
Dimensions (w x l x h) generator
Weight compact kg 76 76
Weight generator kg x x
Wire speed m/min 1 - 19 1 - 19
Wire speed (for KTC version) m/min 1,5 - 16 1,5 - 16
Spool diameter mm 300 300
Spool weight kg 18 18
mm x x
ALF 280 ALF 320 ALF 400
Mains voltage V/Hz
Mains protection A 16 @ 16 @ 20 @
Max. effective current I
Welding current range A 40 - 290 40 - 340 50 - 400
Open-circuit voltage U20 V 18,3 - 40,1 18,2 - 44,9 19,4 - 49,8
Welding current (DC=100%) I2 A 170 200 240
A 8,4 10,8 13,7
1eff
3x400/50 3x400/50 3x400/50
Welding current (DC=60%) I2 A 210 230 290
Welding current (DC=x%) I2 A 30%=290 25%=340 25% = 400
Voltage steps 10 12 2 x 10
Protection IP 23S
Standards EN 60974-1; EN 60974-10 cl. A
Dimensions (w x l x h) compact mm 500x868x806
Dimensions (w x l x h) generator mm 500x868x889
Weight compact kg 88 99 109
Weight generator kg 83 94 103
Wire speed m/min
Wire speed (for KTC version) m/min
Spool diameter mm 300 300 300
Spool weight kg 18 18 18
1 - 19 1 - 19 1 - 19
1,5 - 19 / /
Wire Feed Unit PS4 GAS aXe
Wire speed m/min
Input voltage U1 V/Hz 24/1~50
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Torch type
Cooling
Welder
MB 24KD
Gas
ALF
251-280
aXe
MB 36KD
Gas
ALF 320
aXe
MB 36KD
Gas
ALF 400
aXe
Input current I1 A 4
Welding current I2 (DZ=100%) A 320
Welding current I2 (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
Machines ALF with KTC version aXe differ from the original version of the
machine in parameter values of pregas time and postgas time:
Pregas time 0,1 s
Postgas time 0,5 s
5. ACCESSORIES
DELIVERED WITH THE MACHINE
1. Earthing cable 3m with a clamp
2. Feed roll 0,8 - 1,0mm
3. Gas hoses
ACCESSORIES TO ORDER
1. Wire cleaner
2. CO2 Gas pre heating cable
3. Reduction valve KU 5, K 2
4. Gay cylinder
5. Torch consumables
6. Earthing cable 4 - 5 m
7. Feed rolls 0,6-0,8 1,0-1,2 1,4-1,6 for carbon steels, aluminium, flux
core wires
8. Torches with UP-DOWN remote control
9. Welding torches (see the table below)
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6. DESCRIPTION OF THE APPLIANCE
MAIN PARTS
Fig. 1 - Main parts of ALF compact aXe
Fig. 2 - Main parts of ALF compact aXe
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Fig. 3 – Main parts of ALF Separate aXe
Fig. 4 - Main parts of ALF Separate aXe
A1 ON / OFF Switch
A2 Switch coarse
A3 Switch smooth
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V2 ON / OFF Switch
A4 Quick connector A5 Quick connector - -
A6 PCB control panel
A7 EURO connector
A8 Wire Feeder
A9 Spool Holder
A10 Solenoid Valve
A11 Mains Cable
A12 Feeder Holder Feeder
A13 Feeder Holder Generator
A14 Quick Connector
A15 Connector female
A16 Connector male
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A17 Quick Connector male
A18 Clamp for the cable Bundle
A19 Clamp for the cable Bundle
A20 Cable Bundle Inlet Feeder
A21 Cable Bundle
A22 Cable Bundle Generator
A23 LED ON Indicator
A24 Gas heater connector
CONTROL PANEL - OVERVIEW
Fig. 5 - ALF 400 aXe control panel
V1 PCB - encoder
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V3 Switch coarse
V4 Switch smooth
Pos.
Symbol
Description
default RESET (together with button
X2)
default
RESET (together with button
X1)
mode
DIGITAL CONTROL PANEL MINOR2-MAJOR-SYNERGY
Fig. 6 – MINOR2-MAJOR-SYNERGY digital control panel
Button
X1
Wire insertion
Button
X2
Gas test
Button
X3
Switches between 2S or 4S,
Press more than 3s will initiate spot or interval
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button X5)
button X3)
SYNERGY).
- Int -
Time of int
erval [s]
HOLD function of A+V (last measured parameters)
cool
down by means of the fans.
Switches and choke settings (Just SYNERGY)
(
just
SYNERGY).
Enters secondary parameters (together with
X4
X5
X6
X7
X8
Green LED 2 Stroke
Button
In MANUAL disabled
In SYNERGY switches among A, wire speed or
material thickness
Enters secondary parameters (together with
Green LED – lights if on the display X8 are displayed
Amperes (required setting), (just SYNERGY).
Green LED - lights if on the display X8 is displayed
Wire Speed in m/min (required setting), (just
Left Display X8, shows:
Amperage (real or required)
Wire speed
Material thickness
Program No
Secondary parameters:
- ISP – initial speed (soft start) [%]
- PrG – Pre gas time [s]
- PoG – Post gas time [s]
- brn – Burn back time [s]
- SPo – Time of tack welding [s]
X9
X10
X11
X12
X13
X14
X15
X16
LED - Cooling circuit error
LED - Lights after finishing welding and signals the
LED - Thermal overheating. Leave the machine on to
Right Display
Voltage (real)
Values of the secondary parameters
Position of the coarse switch (just SYNERGY)
Position of the smooth switch (just SYNERGY)
Position of the choke (just SYNERGY)
LED – The mode of selecting the program is active
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material thickness, (just SYNERGY).
been selected
Sets secondary parameters
X17
Green LED – lights if on the display X8 is displayed
X18
LED - 4 Stroke
LED
When flashes, the interval welding mode has
X19
When illuminated, the spot welding mode has
Encoder
Sets wire speed (all models) , Amperage or
X20
Selects program No (just SYNERGY)
BASIC CONTROL PANEL
been selected
material thickness (just SYNERGY)
Fig. 7 – BASIC control panel
V2 On/Off Switch
V3 Switch Coarse
V4 Switch Fine
V5 Wire speed
V6 Spot time
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Pos. Description
E2 Pressure arm
E3 Liner
- Feeder
E4 EURO connector
E5 Roll
, Plastic cup
V7 Interval time
V8 LED ON
V9 LED thermal protection
V10 Switch 2T/4T (optional)
V11 Wire insertion
V12 Gas test
V13 A meter (optional)
V14 V meter (optional)
WIRE FEEDER
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Fig 8 – Wire feeder 4 rolls, 2 rolls
E1 Fixing shaft
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PS 2(W)
PS 4(W)
2-rolls
4-
rolls
a = 22 mm
a = 22 mm
b = 30 mm
b = 30 mm
Grove type
Wire diameter
Item No
0,6-0,8 2187
0,8-1,0 2188
1,0-1,2 2189
1,4-1,6 2176
1,2-1,6 2511
2,0-2,4 2512
0,8-1,0 2270
1,0-1,2 2269
1,4-1,6 2315
1,2-1,6 2316
1,6-2,0 2513
0,8-1,0 2318
1,0-1,2 2319
1,2-1,6 2321
1,6-2,0 2514
2,0-2,4 2515
C1 Quick Connector Male
C2 Earthing Clamp
a
Steel
Aluminium
Flux core
b
1,2-1,4 2320
7. GETTING STARTED
Fig 9 – Earthing cable connecting
C3 Quick Connector -
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C4 Quick Connector
- -
D1 Spool Holder
D3 Adapter
1. Connect the quick connector C1 into C3 or C4 (according the welding
current).
2. Connect the earthing clamp C2 to the welding piece
3. In case your appliance is a model with separate wire feeder connect the
feeder with the generator by means of cable bundle A21.
4. Plug the mains plug to 3x400 V mains.
5. Switch the machine on by the ON/OFF switch A1
6. There will appear type of the machine and software version on the
displays for ca 3 s time – not on BASIC.
7. Then the machine will enter the manual program (P0) and on the left
display will be the wire speed in m/min (or the last parameters of previous
settings). On the right display will appear symbol --- (in manual P0
program) or the recommended settings (in programs P1 – P9) - not on
BASIC
INSERTING THE WIRE
D2 Nut Spool Holder
Fig. 10 – Spool holder
1. Open the side cover of the wire feeder space
2. Put the wire spool on the wire spool holder D1 using the adapter D3 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 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.
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B1 EURO connector
B2 EURO connector male
B3 Torch
INSERTING THE WELDING WIRE INTO THE WELDING TORCH
Fig. 11 – Welding torch connecting
1. Connect the torch B3 to the EURO connector B1 on the
2. It is recommended to use torches form 2 up to 5 m long.
3. Take off the torch gas cup
4. Take off the torch tip
5. Press the button inlet wire X1 for digital, V11 for BASIC
6. When the wire reaches the end of the torch, release the button X1/V11,
screw on the tip and open nozzle.
CHANGING THE WIRE FEEDER ROLL
1. Every wire feeding roll in ALFA IN machines can be used for two different
diameters of welding wire – the rolls have two grooves.
2. When the machine is equipped with two roll wire feeder move the lever
E1 to the right (2 roll feeder)/ forward (4 roll feeder). The pressure arm
shall pop up.
3. Unscrew the plastic fixing cup E5 and take off the roll
4. In case there is suitable groove on the roll, turn it around and fix it back
to the feeder.
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B
C
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G1 EURO connector
G2 Rolls
G3 Liner terminal for 4,0mm, 4,7mm outer
diameter
G4 O –
ring 3,5x1,5mm
G5 Nut
G6 Teflon Liner
G7 Sustain pipe for teflon and plastic liner
A Correct
C Wrong
Fig. 12- The influence of the roll groove on the wire
B Wrong
ADJUSTING THE MACHINE FOR WELDING OF ALUMINIUM
For feeding the AL wire it is necessary to use roll with the “U” profile of the
groove. To prevent problems with feeding use wires with diameter 1,0 or
more mm of AlMg3 or AlMg5. The torch must be equipped with Teflon liner
and special tip. As shielding atmosphere use Argon.
Fig 13 – Set for welding aluminium
GAS FLOW SETTING
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.
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F1 Gas Cylinder
F3 Gas heater connector
F4 Pressure Reducer
F5 High Pressure
Manometer
F6 Low Pressure Manometer
F7 Adjusting Screw
F9 Solenoid Valve
F10
Chain
Fig. 14 – Gas fitting
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F2 Cylinder Valve
F8 Gas outlet
1. Place the gas cylinder on the platform and fix it properly by the fixing
chain. We recommend using bolts and nuts to fix it more safely.
2. Connect the pressure reduction valve on the gas cylinder.
3. Connect the gas hose to gas outlet F8 on the valve and the gas inlet F9
on the machine
4. In case you use gas CO2 it may be needed to use suitable gas heater
(only above 6 l/min). Connect the heater to the F3 heater connector
(optional). Use type corresponding to voltage and current given on the
shield.
5. Open the F2 cylinder valve
6. Press the button Gas test X2 for digital, V12 for BASIC
7. Adjust the amount of gas on the reduction gas valve (it is not a part of
the welding machine) by the F7 adjusting screw
8. Release the button X2 for digital, V12 for BASIC
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8. WELDING
For orientating adjusting of the welding current and voltage you can use
empirical relation U2 = 14+0,05 2. From that you can specify desired voltage.
SETTING WELDING CURRENT AND VOLTAGE
When the wire had been installed and gas had been set it is possible to start
welding.
The appliance must be plugged into the mains, the ON/OFF switch V2 on "I".
To select the voltage use step switches V3, V4 - ALF 400, ALF 280 and 320
only V3
To select the current (that is linked to the wire speed) use the encoder V1.
WELDING MODES
Machines works in four modes:
1. Continuous two stroke (2T)
2. Continuous four stroke (4T)
3. Spot welding
4. Interval welding
TWO STROKE DIGITAL
Press the button X3 (2T/4T) and select the LED X4 . Welding
procedure starts by pressing the button in the torch handle. It is necessary to
keep the button pressed all the time during welding. The welding stops by
releasing the torch button.
TWO STROKE BASIC
Potentiometers V6 and V7 must be in 0 position.
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FOUR STROKE DIGITAL
Press the button X3 (2T/4T ) and select the LED X18 . The four stroke
mode is being used mostly for long welds, when there is no need to hold the
torch button pressed. The welding procedure start by pressing the torch button;
after releasing the torch button the welding continues. The welding stops after
the second pressing and releasing the torch button then.
FOUR STROKE BASIC
Set the potentiometers V7 into any position 1 – 10. Potentiometer V6 must be
in 0 position.
SPOT AND INTERVAL WELDING DIGITAL
Keep pressing the button X3 (2T/4T) for at least 3s
If led LED 16 continuously lights the spot mode has been selected. If led
16 flashes the interval mode has been selected.
You can have spot or interval welding both in 2 stroke and in 4 stroke mode
(by means of short pressing the button X 3 - LEDs X4 and X18
indicate the mode. Those modes are available in 2T or 4T mode.
To get out of those modes, keep pressing the button 3 for more than 3 s.
SPOT AND INTERVAL WELDING BASIC
SPOT and INTERWAL welding in BASIC are just in 2T.
SPOT WELDING – The potentiometer V7 must be in 0 position. By means of
potentiometer V6 select the time of a spot.
INTERVAL WELDING - By means of potentiometer V6 select the time of a spot
and by means of potentiometer V7 select the time of an interval (the period
during which the machines do not weld)
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Initial wire speed (soft start)
ISP
Pre gas time
PrG
Post gas time
PoG
Burn back time
brn
Time of spots (tack or interval welding)
SPo
Time of intervals (interval welding)
Int
The spot welding mode is being used for welding short welds of the same
length. The pressing the torch button activates the time circuit that starts and
end the welding procedure.
SECONDARY PARAMETERS
If necessary it is possible to change the secondary parameters:
Press buttons X3 and X5 at the same time for at least.
On left display will appear ISP. On the right display will appear value of the
chosen parameter.
By means of the Encoder you can change the parameter.
Use the button X3 to select the next parameter. When you press the button
X3, the value of the previous parameter had been stored.
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SYNERGY MODE (ONLY FOR THE SYNERGY MODELS)
Synergy machines can advise the welder the optimum settings. Please keep
in mind that those machines are not equipped with incremental sensors and
therefore the advised settings are always approximate (+/- 1÷3 steps on the
fine voltage step).
It depends also on welding position, kind of welding wire, gas and mains
voltage.
The optimal setting has been determined for welding position PA.
The welder select the parameter that he knows by means the button X5 and
the encoder X20 (Current in A, wire speed in m/min or material thickness).
Then the welder can the recommended settings see on the right display (see
Fig. 17).
SELECTING PROGRAM
1. press button X3 for 3 s
2. LED X16 will illuminate. On left display X8 No of the last program
will appear.
3. Selects the desired program (see the table below) by means of Encoder
X20 and confirm by pressing button X3. (If within 10 s is not selected
program and confirmed by button X3 LED X16 would turn off and
program has not been selected).
Fig. 15 – Table of programs ALF320, ALF400
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Fig. 16 – Table of programs ALF280
SYSTEM OF ADVICES ON DISPLAY X12 (JUST SYNERGY)
1. First left figure – coarse voltage A - B (JUST ALF 400).
2. Second left figure - fine voltage 1 - 9, the tenth position of the switch is
signed as „0“; ALF 320 shows numbers 1-12.
3. Third left figure – choke position.
Fig. 17 – Synergy advice
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diameter
[g/hour]
TABLE OF WIRE CONSUMPTION DURING WELDING
Wire
[mm]
Steel wire
0,6 2 - 5 5 2,3 11,5 690
0,8 3 - 6 6 4 24 1440
1,0 3 - 12 12 6 72 4320
1,2 4 -18 18 9 162 9720
Stainless steel wire
0,6 2 - 5 5 2,3 11,5 690
0,8 3 - 6 6 4 24 1440
1,0 3 - 12 12 6 72 4320
1,2 4 -18 18 9 162 9720
Aluminum wire
0,6 2 - 5 5 0,8 4 240
0,8 3 - 6 6 1,3 7,8 468
1,0 3 - 12 12 2 24 1440
1,2 4 -18 18 3 54 3240
Range of
wire feed
speed
[m/min]
Maximal
wire feed
speed
[m/min]
Weight of
1 m wire
[g]
Wire consumption
per 1 minute of
welding
[g/min]
consumption
per 1 hour of
Wire
welding
TABLE OF GAS CONSUMPTION DURING WELDING
Wire diameter [mm] Gas flow [l/min]
0,6 6 6 * 60 = 360
0,8 8 8 * 60 = 480
1,0 10 10 * 60 = 600
1,2 12 12 * 60 = 720
1,6 16 16 * 60 = 960
2,0 20 20 * 60 = 1200
Gas consumption per 1 hour
of welding [l/hour]
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9. ROUTINE MAINTENANCE & INSPECTION
1. The only routine maintenance required for the ALF range of machines is
a thorough cleaning and inspection, with the frequency depending on the
usage and the operating environment.
WARNING
2. Disconnect the ALF from the mains supply voltage before disassembling.
3. Special maintenance is not necessary for the control unit parts in the
Welder. If these parts are damaged for any reason, replacement is
recommended.
CAUTION
4. Do not blow air into the welder during cleaning. Blowing air into the
welder can cause metal particles to interfere with sensitive electronic
components and cause damage to the welder.
5. To 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. The welder should also be wiped clean. If
necessary, solvents that are recommended for cleaning electrical
apparatus may be used.
6. Troubleshooting and repairing of ALF welding equipment should only be
carried out only by suitably qualified or competent person.
7. 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.
8. The person carrying out the servicing needs and repairs must know what
to look at, what to look for and what to do.
10. STATEMENT OF WARRANTY
In accordance with the warranty periods stated below, ALFA IN guarantees
the proposed product to be free from defects in material or workmanship
when operated in accordance with the written instructions as defined in this
operating manual.
ALFA IN welding products are manufactured for use by commercial and
industrial users and trained personnel with experience in the use and
maintenance of electrical welding and cutting equipment.
ALFA IN will repair or replace, at its discretion, any warranted parts or
components that fail due to defects in material or workmanship within the
warranty period. The warranty period begins on the date of sale to the end
user.
If warranty is being sought, please contact your ALFA IN product supplier
for the warranty repair procedure.
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ALFA IN warranty will not apply to:
a. Equipment that has been modified by any other party other than
ALFA IN’s own service personnel or with prior written consent
obtained from ALFA IN Service Department.
b. Equipment that has been used beyond the specifications established
in the operating manual.
c. Installation not in accordance with the installation/operating manual.
d. Any product that has been subjected to abuse, misuse, negligence
or accident.
e. Failure to clean and maintain (including lack of lubrication,
maintenance and protection), the machine as set forth in the
operating, installation or service manual.
Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.
NOTE
Warranty repairs must be performed by either an ALFA IN Service Centre,
an ALFA IN distributor or an Authorised Service Agent approved by the
company ALFA IN.
As a warranty list serves proof of purchase (invoice) on which is the serial
number of the machine, eventually a warranty list on the last page of this
manual.
11. DISPOSAL
Only for EU countries. Do not dispose of electric tools together with
household waste material.
In accordance with European Council Directive 2002/96/EC on
electrical and electronic equipment waste and its implementation in
accordance with national law, electric tools that have reached the end of their
service life must be collected separately and returned to an environmentally
compatible recycling facility.
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12. WARRANTY LIST
As a warranty list serves proof of purchase (invoice) on which is the serial
number of the machine, eventually a warranty list below, which is filled in by
an authorized dealer.
Serial number:
Day, month (written in words)
and year of sale:
Stamp and dealer signature:
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