Full Text Searchable PDF User Manual
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PEGAS 162-202 E PFC Manual EN 02
WELDING INVERTER
PEGAS 162 E PFC
PEGAS 202 E PFC
OPERATING MANUAL
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CONTENT:
1.
INTRODUCTION ....................................................................................... 3
2.
SAFETY INSTRUCTIONS AND WARNINGS ............................................ 4
3.
TECHNICAL DATA .................................................................................... 6
4.
EQUIPMENT ............................................................................................. 7
5.
OPERATOR CONTROLS .......................................................................... 8
6.
GETTING STARTED ................................................................................. 9
7.
ROUTINE MAINTENANCE & INSPECTION ............................................ 10
8.
STATEMENT OF WARRANTY ................................................................ 11
9.
DISPOSAL ............................................................................................... 11
10.
DECLARATION OF CONFORMITY ........................................................ 12
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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 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 162 E PFC/PEGAS 202 E PFC welds by those methods
a)
E – (MMA) coated electrodes up to 4,0 mm
b)
TIG lift arc.
PEGAS 162 E PFC/PEGAS 202 E PFC is equipped by system of Power Factor
Correction (PFC) – which enables operating on AC power supply of 95V – 270V.
What are the advantages of PFC solution?
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 INSTRUCTIONS AND WARNINGS
1. Once the packing has been opened, make sure that the machine is not
damaged. If in any doubt, call the service centre.
2. This equipment must only be used by qualified personnel.
3. During installation, any electric work must only be carried out by trained
personnel.
4. The machine must be used in a dry place with good ventilation.
5. 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.
6. It is prohibited to connect more than one INVERTER generator in series or
in parallel.
7. When installing the machine, follow the local regulations on safety.
8. The position of the machine must allow easy access by the operator to the
controls and connectors.
9. When the welding machine is operating, all its covers and doors must be
closed and well fixed.
10.
Do not expose the welding machine to direct sunlight or to heavy
rain. This equipment conforms to protection rating IP23S.
11.
During welding, the welding cables must be located near or at ground
level. They should be as short as possible.
12.
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 welding.
13.
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 electrical 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.
14.
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.
15.
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.
16.
The operator must ensure all flammable materials are removed from
the work area to avoid any risk of fire.
17.
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.
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18.
The operator must be aware of all the special regulations which he
needs to conform to when welding in enclosed spaces with a high risk of
explosion.
19.
To prevent electric shock, we strongly suggest the following rules:
20.
Do not work in a damp or humid environment.
21.
Do not use the welding machine if its cables are damaged in any
way.
22.
Make sure that the earthing system of the electric equipment is
correctly connected and operational.
23.
The operator must be insulated from the metal components
connected to the return wire.
24.
The earthing of the piece being worked could increase the risk of
injury to the operator.
25.
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 welding clamps. In our
generator this voltage is 58V.
26.
The maximum open-circuit voltage of the welding machines is
established by national and international standards (EN 60974-1)
depending on the type of weld 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.
27.
In high electrical risk areas (in confined spaces) it is only allowed to
use machines with – sign S.
28.
Before opening the machine switch off the machine and disconnect
it from the power socket.
29.
Only personnel authorised by this company can carry out
maintenance on the machine.
NOTE:
Device complies with IEC 61000-3-12.
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.
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3. TECHNICAL DATA
PEGAS 162 E PFC
Method
MMA
TIG
MMA
TIG
Mains voltage
V/Hz
1x110/50-60
1x230/50-60
Welding current range
A
10 - 100
10 - 100
10 - 160
10 - 160
Open-circuit voltage U
20
V
68
68
Mains protection
A
16 @
16 @
Max. effective current
I
1eff
A
15,4
10,8
13,4
10,1
Welding current
(DC=100%) I
2
A
70
75
100
110
Welding current
(DC=60%) I
2
A
80
90
130
140
Welding current
(DC=x%) I
2
A
35%=100
50%=100
35%=160
40%=160
Protection
IP23S
Standards
EN 60974-1; EN 60974-10 cl. A
Dimensions (w x l x h)
mm
135 x 390 x 230
Weight
kg
9,2
PEGAS 202 E PFC
Method
MMA
TIG
MMA
TIG
Mains voltage
V/Hz
1x110/50-60
1x230/50-60
Welding current range
A
10 - 120
10 - 120
10 - 200
10 - 200
Open-circuit voltage U
20
V
68
68
Mains protection
A
16 @ (25@)
16 @ (25 @)
Max. effective current
I
1eff
A
16,0 (25,6) 16,0 (23,2) 16,0 (20,2) 14,2 (14,2)
Welding current
(DC=100%) I
2
A
70 (95)
75 (105)
100 (135)
160 (160)
Welding current
(DC=60%) I
2
A
80 (120)
90 (120)
130 (160)
185 (185)
Welding current
(DC=x%) I
2
A
25%=120
(60%=120)
40%=120
(90%=120)
25%=200
(40%=200)
50%=200
(50%=200)
Protection
IP23S
Standards
EN 60974-1; EN 60974-10 cl. A
Dimensions (w x l x h)
mm
135 x 390 x 230
Weight
kg
9,2
The machine is equipped with a 16 A plug for connection to a single phase
supply 1 x 230 V, the corresponding data for this 16 A plug (Duty Cycle = DC)
are in the table above without brackets.
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In order to fully use the technical capabilities of the machine, the machine must
be connected to the industrial single phase networks with a blue plug 32 A with
the maximum permissible fuse of 25 A. The corresponding data for such a 32 A
plug are stated in the table above in brackets.
Replacement of the plug may only be performed by ALFA IN as authorized
service personnel.
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.
4. EQUIPMENT
ACCESSORIES TO ORDER
Item No.
Description
VM0253
Welding Cable Set 2x 3m 35-50 160A
5.0178
Box black 50x58,5x18 cm
6124
Pressure Reducer BASECONTROL Ar 2 manometers
6125
Pressure Reducer BASECONTROL CO2 2 manometers
706.1037
Torch SRT 17 4m V 35-50
S7S
Welding helmet S7S
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5. OPERATOR CONTROLS
Fig . 1 Main parts
Pos.
Description
1
LED TIG
2
LED MMA
3
Display – set current
4
Method switch MMA (electrode)/TIG
5
LED ON
6
LED over heating
7
Current potentiometer
8
Quick connector -
9
Quick connector +
10
ON/OFF switch
11
Mains socket with a pulg
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6. GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
Insert the mains plug into a suitable 1x230 V (or 1 x 110 V) mains socket. The
supply fuses or circuit breaker should correspond to the technical data in section
4. Switch the machine on by the ON/OFF switch
10
. LED
5
will illuminate.
GETTING STARTED MMA – COATED ELECTRODE
1. Connect the electrode holder and the work lead to terminals
8
and
9
according the instructions on the electrode package
.
NOTE Prevent
touching the electrode any metal material for in this mode the
terminals 8 and 9 are under current.
2. By means of the switch
4
select MMA
.
3. To select the current use potentiometer
7.
4. Insert the coated electrode into the electrode holder.
GETTING STARTED TIG LIFT ARC
1. Fit the TIG Torch to the minus terminal
8
and fasten it by turning the
connector to the right.
2. Connect the work lead to positive terminal
9
and fasten it by turning the
connector to the right.
3. Connect the work clamp to the work piece or at the welding table.
4. By means of the switch
4
select TIG
.
How
to
connect the gas cylinder
1. Ensure that the gas cylinder is secured to a building pillar, wall bracket or
otherwise securely fixed in an upright position.
2. Open the gas valve once to blow out possible dirt particles.
3. Connect the gas regulator to the gas cylinder valve.
4. Connect the gas hose of the TIG torch to the gas regulator.
5. Open the gas cylinder valve, open the valve on the TIG torch and adjust
the gas flow on the gas regulator. The flow rate will be shown at the flow
meter. This should be done according the table below.
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Basic settings for TIG welding – stainless steel, DC current
Material
thickness
mm
Tungsten
electrode
diameter
mm
Filler material
diameter mm
Welding
current
A
Argon flow
l/min
Gas
nozzle mm
1
1
1,5
40-60
3
10
1,5
1,5
1,5
50-90
4
10
2
2
2
80-100
4
12
3
2-3
2-3
90-140
5
12
4-5
3-4
3-4
110-180
5
12
7. ROUTINE MAINTENANCE & INSPECTION
1. The only routine maintenance required for the PEGAS range of machines
is a thorough cleaning and inspection, with the frequency depending on
the usage and the operating environment.
2.
WARNING
Disconnect the PEGAS 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.
4.
CAUTION
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 PEGAS 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.
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8. STATEMENT OF WARRANTY
1. 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.
2. 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.
3. 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.
4. If warranty is being sought, please contact your ALFA IN product
supplier for the warranty repair procedure.
5. ALFA IN warranty will not apply to:
1. 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.
2. Equipment that has been used beyond the specifications
established in the operating manual.
3. Installation not in accordance with the installation/operating
manual.
4. Any product that has been subjected to abuse, misuse,
negligence or accident.
5. Failure to clean and maintain (including lack of lubrication,
maintenance and protection), the machine as set forth in the
operating, installation or service manual.
6. Within this operating manual are details regarding the maintenance
necessary to ensure trouble free operation.
7.
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.
8. As a warranty list serves proof of purchase (invoice) on which is the
serial number of the machine.
9. 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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10.
DECLARATION OF CONFORMITY