HOMER tools MG-160 User manual

ALFA IN a.s. © www.alfain.eu HOMER MG-160 manual EN 07
WELDING MACHINE
HOMER MG-160
OPERATING MANUAL

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ALFA IN a.s. © www.alfain.eu
CONTENT
1. INTRO UCTION ..................................................................................... 3
2. SAFETY INSTRUCTIONS AN WARNINGS......................................... 4
3. CON ITIONS OF USE ........................................................................... 7
4. TECHNICAL ATA ................................................................................. 8
5. ACCESSORIES....................................................................................... 8
6. ESCRIPTION OF THE APPLIANCE .................................................. 10
7. GETTING STARTE ............................................................................. 12
8. WEL ING .............................................................................................. 15
9. ROUTINE MAINTENANCE & INSPECTION ........................................ 16
10. STATEMENT OF WARRANTY ............................................................. 17
11. ISPOSAL ............................................................................................. 18
12. WARRANTY LIST ................................................................................. 18

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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.
Welding machine HOMER MG-160 of our private brand HOMER tools is aimed
for MIG/MAG welding.
The machine can weld various types of joints (butt, single-sided, double-sided,
fillet, lap, etc.) using wire diameter from 0.6 to 0.8 mm, respectively. 1.0 mm
(flux cored wire) of different metals and alloys (carbon and alloy steels,
aluminium alloys, etc.). HOMER MG-160 is especially designed for bodywork
operations or maintenance work. Very good welding can be achieved under a
protective atmosphere of CO2. The machine welds very well by means of using
high-quality self-shielding wire (no gas cylinder and pressure reducer needed).
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. OPERATION AN MAINTENANCE OF WEL ING EQUIPMENT CAN BE
ANGEROUS AN HAZAR OUS 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. uring 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. o not expose the welding machine to direct sunlight or to heavy rain.
This equipment conforms to protection rating IP21S.
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 RA IATION 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.
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:

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Antimony
Chromium
Mercury
Nickel
Cobalt
Arsenic
Barium
Copper
Selenium
Beryllium
Lead
Silver
Cadmium Manganese Vanadium
20. Always read the Material Safety ata Sheets (MS S) that should be
supplied with the material you are using. These MS Ss 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:
29. o not work in a damp or humid environment.
30. o not use the machine if its cables are damaged in any way.
31. Make sure that the earthing system of the electric equipment is correctly
connected and operational.
32. The operator must be insulated from the metal components connected
to the return wire.
33. The earthing of the piece being worked could increase the risk of injury
to the operator.
34. EN 60974-1 Standard: Open-circuit voltage. uring 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.
35. 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.

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36. 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
C current: 113V
peak value
AC current: 68V
peak value and 48V
effective
2
Places without
increased risk of electric
shock
C current: 113V
peak value
AC current: 113V
peak value and 80V
effective
3
Torches held
mechanically with
increased protection for
the operator
C current: 141V
peak value
AC current: 141V
peak value and
100V effective
4 Plasma cutting C current: 500V
peak value
37. 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:
S
38. Before opening the machine switch off the machine and disconnect it
from the power socket.
39. Only personnel authorised by this company can carry out maintenance
on the machine.
WELDING 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

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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. uring installation, any electric work must only be carried out by trained
personnel.
3. evice complies with IEC 61000-3-12.
4. o not expose the plasma machine to direct sunlight or to rain or snow. This
equipment conforms to protection rating IP21S.
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, 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 machine must be protected against
a. Moisture and rain and snow
b. Mechanical damage
c. raft 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. uring operation,
the device may be the source of interference.

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ALFA IN a.s. © www.alfain.eu
Caution
We warn users, that they are responsible for possible interference from
4. TECHNICAL DATA
Method MIG/MAG
Mains voltage V/Hz 1 x 230/50
Welding current range A 45 - 160
Open-circuit voltage U20 V 32,0 - 55,5
Mains protection A 16 @
Max. effective current I1eff A 8,4
Welding current ( C=100%) I2 A 50
Welding current ( C=60%) I2 A 60
Welding current ( C=x%) I2 A 7 % = 160
Voltage steps 6
Protection IP 21 S
Standards EN 60 974-1, EN 60 974-10 cl.A
imensions (w x l x h) mm 265 x 490 x 360
Weight kg 28,2
Wire speed m/min 2,0 - 16,5
Spool diameter mm 200
Spool weight kg 5
. ACCESSORIES
DELIVERED WITH THE MACHINE
1. Welding torch 2,5 m, 150 A
2. Ground cable
3. Feeding roll 0,6 – 0,8 mm
4. Operating manual
ACCESSORIES TO ORDER
1. Pressure Reducer BASECONTROL Ar 2 manometers, ordering number:
6124
2. Pressure Reducer BASECONTROL CO2 2 manometers, ordering
number: 6125
3. Spare parts for torch
4. Wire cleaner
5. Welders Cart HOMER tools (Ordering No 5.0228)

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6. Welding helmets Barracuda S777C– Variours designes

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6. DESCRIPTION OF THE APPLIANCE
MAIN PARTS
Fig. 1 - Main parts

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Pos.
Description
1
LE
Overheating indicator
2
Voltage switch
3
EURO Connector for the welding torch
4 Ground cable
5
Wire speed potentiometer
6
Welding torch
7
Minus terminal
8
Plus terminal
9
Wire
f
eeder
10 Spool holder
11
Inlet
WIRE FEEDER
Fig. 2 – Wire feeder
Pos.
No.
Description
12
QTB106
Feeder inlet liner
13
QTB107
Fixing shaft
14
QTB108
Pressure arm
15
QTB109
Roll with plastic cup
15
6042
Roll 0,6
-
0,8 Homer MG
-
160
15
6043
Roll 0,6
-
0,8 Homer MG
-
160 T
16
QTB110
Torch inlet liner

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Fig. 3 – Parts of the torch QTB 180
Pos.
No.
Description
17
6067
Torch neck MG
-
150 with a valve
18 6066 Tip Adaptor for Torch MG-150 with a valve,
MG
-
160
19
PB1527
-
06
Girder
0.6 M6/6/25 MB PARKER
19
PB1527
-
08
Girder
0.8 M6/6/25 MB PARKER
20
145. 186
Nozzle M12 Bare
21 6068 Fixing nut for handle torch MG-150 with a
valve
22
6070
Trigger for MG
-
150 with a valve
23
QTB104
Handle
QTB 180
24 6068 Fixing nut for handle torch MG-150 with a
valve
7. GETTING STARTED
Getting started must be consistent with technical data and conditions of use.
Homer MG-160 is equipped with a roller with two grooves - 0.6 and 0.8 mm.
These grooves are intended for steel or aluminium solid wires of corresponding
diameter. For the flux cored self-protective wire diameter of 0.8 mm, 0.9 mm
or 1.0 mm is used the groove of 0.8 mm. For all types of wires is used the roller
with knurled groove (supplied).
1. Connect the earthing clamp 4 to the welding piece.
2. Plug the mains plug to 230 V mains.
3. Switch the machine on by the ON/OFF switch.
INSERTING THE WIRE
1. Open the side cover of the wire feeder space.
2. Put the wire spool on the spool holder 10.

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3. Put the inlet 11 onto the spool holder 10 followed by the spring and tighten
up the nut onto the holder 10.
4. Cut off the curved or damaged end of welding wire and lead it through the
feeder inlet liner 12, and the roll 1 into the torch inlet liner 16 (about 5 cm).
Make sure, that you use the suitable groove of the roll.
5. Make sure that the wire fits into the torch inlet liner 16!
6. Put the pressure arm 14 down to side and fix it by setting the fixing shaft 13
into vertical position.
7. Adjust the pressure of the fixing shaft 13 that way that it provides constant
movement of wire but it does not deform wire.
INSERTING THE WELDING WIRE INTO THE WELDING TORCH
1. Take off the torch gas cup.
2. Take off the torch tip.
3. Press the torch trigger, the wire will start feeding into the torch.
4. When the wire reaches the end of the torch, release the trigger, screw on
the tip and the nozzle.
CHANGING THE WIRE FEEDER ROLL
Every wire feeding roll in ALFA IN machines can be used for two different
diameters of welding wire – the rolls have two grooves.
1. Open the wire feeder by means of the fixing shaft 13.
2. Unscrew the plastic fixing cup 1 and take off the roll 1 .
3. In case there is suitable groove on the roll, turn it around and fix it back to
the feeder.

 
ABC
Fig. 4 - The influence of the roll groove on the wire (for this machine groves
0,6 and 0,8)
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.
A
Correct
B
Wrong
C
Wrong

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Fig. 5 – Gas fitting
Pos.
Description
F1
Gas
c
ylinder
F2
Cylinder
v
alve
F3
Gas heater connector
F4
Pressure
r
educer
F5
High
p
ressure
m
anometer
F6
Low
p
ressure
m
anometer
F7
Adjusting
s
crew
F8
Gas outlet
F9
Solenoid
v
alve
F10
Chain
The gas cylinder cannot be fixed to the HOMER MG-160. It can be fixed onto
the welders cart or other fixing appliance according to the user´s manual of
such appliance and in accordance with the safety rules.
1. Connect the pressure reduction valve on the gas cylinder.
2. Connect the gas hose to gas outlet F8 on the valve and the gas inlet on the
machine.
3. Open the F2 cylinder valve.
4. Set the voltage switch 2 to the position .
5. Adjust the amount of gas on the reduction gas valve (it is not a part of the
welding machine) by the F7 adjusting screw.

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8. WELDING
SETTING WELDING CURRENT AND VOLTAGE
When the wire had been installed and gas had been set it is possible to start
welding.
1. The appliance must be plugged into the mains, the ON/OFF switch on "I".
2. To select the voltage use voltage switch 2.
3. To select the current (that is linked to the wire speed) use the potentiometer
.
uty cycle mean percentage of time cycle of 10 minutes, after which the
machine can withstand weld at a given current, without switching off by means
of the thermal protection.
For orientating adjusting of the welding current and voltage you can use
empirical relation U2 = 14+0,05 I2. From that you can specify desired voltage.
According to this relation, one can determine the required voltage. When
setting the voltage has to considered the decline in load welding. The voltage
drop is approximately 4.5-5.0 V at 100 A.
Setting the welding current is performed so that the selected welding voltage
settles the desired welding current by increasing or decreasing wire feed speed
until the optimum welding arc is reached .
Please note that the actual settings for optimum arc may vary slightly
depending on the position of the weld material and voltage fluctuations.
To achieve a good quality of the welds and the optimum setting of the welding
current is necessary that the distance of the welding tip from the material is
about 10 times the diameter of the welding wire (Fig. 6)
Fig. 6 – istance of the welding tip from the material

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TABLE OF WIRE CONSUMPTION DURING WELDING
Wire
diameter
[mm]
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]
Wire
consumption
per 1 hour of
welding
[g/ho
ur
]
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
TABLE OF GAS CONSUMPTION DURING WELDING
Wire diameter [mm] Gas flow [l/min] Gas consumption per 1 hour
of welding [l/hour]
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
9. ROUTINE MAINTENANCE & INSPECTION
The only routine maintenance required for the machines is a thorough cleaning
and inspection, with the frequency depending on the usage and the operating
environment.
 WARNING 
isconnect the appliance from the mains supply voltage before disassembling.
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 

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1. o 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.
2. 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.
3. Troubleshooting and repairing of HOMER tools welding equipment should
only be carried out only by suitably qualified or competent person.
4. 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.
5. 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
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:
7. 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 epartment.
8. Equipment that has been used beyond the specifications established in the
operating manual.
9. Installation not in accordance with the installation/operating manual.
10. Any product that has been subjected to abuse, misuse, negligence or
accident.
11. 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.

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NOTE 
7. 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, eventually a warranty list on the last page of this
manual.
11. DISPOSAL
Only for EU countries. o not dispose of electric tools together with
household waste material.
In accordance with European Council irective 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.
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:
ay, month (written in words)
and year of sale:
Stamp and dealer signature: