Homer MG-15 User manual
ALFA IN a.s. © 2013 www.alfain.eu HOMER MG-150 MANUAL EN 1.doc
MIG/MAG WELDING MACHINES
HOMER MG-15
INSTRUCTION MANUAL
Content:
1.INTRODUCTION..................................................................................................2
2.SAFETYINSTRUCTIONSANDWARNINGS............................................................2
3.CONDITIONSOFUSE...........................................................................................6
4.TECHNICALDATA................................................................................................6
5.ACCESSORIES......................................................................................................7
6.DESCRIPTIONOFTHEAPPLIANCE.......................................................................9
7.GETTINGSTARTED............................................................................................10
8.WELDING..........................................................................................................13
9.ROUTINEMAINTENANCE&INSPECTION..........................................................14
10.STATEMENTOFWARRANTY.............................................................................15
11.DISPOSAL..........................................................................................................15
12.DECLARATIONOFCONFORMITY......................................................................16
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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.
Welding machine HOMER MG-150 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-150 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).
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.
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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
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
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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
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 DC current: 141V AC current: 141V
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mechanically with
increased protection for
the operator
peak value 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:
S
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.).
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
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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.
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 181
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Mains voltage V/Hz 1 x 230/50
Mains protection A 16 slow
Max. input power I1 A 24,2
Max. effective current I1eff A 7,7
Welding current range A/V 40/16,0 - 140/21,0
Open-circuit voltage U20 V 32,3 - 53,3
Welding current (DC=100%) I2 /U2 A/V 50/16,5
Welding current (DC=60%) I2 /U2 A/V 60/17,0
Welding current (DC=x%) I2 /U2 A/V 10% = 140/21,0
Voltage steps 4
Insulation class F
Protection
IP 21 S
Standards
EN 60974-1
Dimensions (w x l x h) mm 260 x 450 x 390
Weight kg 27,0
Wire speed m/min 1,5 - 17,5
Spool diameter mm 200
Spool weight kg 5
5. ACCESSORIES
5.1 DELIVERED WITH THE MACHINE
Welding torch
Ground cable
Brush
Feeding roll 0,6 – 0,8 mm
Welding shield
5.2 ACCESSORIES TO ORDER
Wire cleaner
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CO2 Gas pre heating cable
Reduction valve KU 5, K 2
Gay cylinder
Torch consumables
Feed rolls 0,6-0,8 mm, for carbon steels, aluminium, flux core wires
Welding helmets S777s– Variours designes
Welders Cart HOMER tools (Ordering No 5.0228)
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6. DESCRIPTION OF THE APPLIANCE
6.1 MAIN PARTS
Fig. 1 - Main parts
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1 Wire speed potentiometer
2 Voltage switch MIN/MAX
3 Voltage switch 1/2 LED over heating indicator
4 ON / OFF Switch
5 LED Over heating Indicator
6 Welding torch
7 Ground cable
8 Mains cable
9 Gas connector
10 Fitted on welding wire spool (not part of delivery)
11 Spool Holder
12 Inlet
13 Wire Feeder
14 Plus terminal (red)
15 Minus terminal (black)
6.2 WIRE FEEDER
Fig 2 – Wire feeder
Pos. Description
16 Feeder inlet liner
17 Fixing shaft
18 Pressure arm
19 Roll, Plastic cup
20 Torch inlet liner
7. GETTING STARTED
Homer MG-150 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 7to the welding piece
2. Plug the mains plug to 230 V mains.
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3. Switch the machine on by the ON/OFF switch 4.
7.1 INSERTING THE WIRE
1. Open the side cover of the wire feeder space.
2. Put the wire spool 10 on the wire spool holder 11.
3. Put the Inlet 12 onto the holder 11 followed by the spring and tighten up
the nut onto the holder 11.
4. Cut off the curved or damaged end of welding wire and lead it through the
Feeder inlet liner 16, and the roll 19 into the Torch inlet liner 20 (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 20!
6. Put the pressure arm 18 down and fix it by setting the Fixing shaft 17 into
vertical position.
7. Adjust the pressure of the Fixing shaft 17 that way that it provides
constant movement of wire but it does not deform wire.
7.2 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.
7.3 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 17
2. Unscrew the plastic fixing cup 19 and take off the roll 19
3. In case there is suitable groove on the roll, turn it around and fix it back to
the feeder.
ABC
Fig. 3- The influence of the roll groove on the wire (for this machine groves
0,6 and 0,8)
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7.4 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.
Fig. 4 – Gas fitting
F1 Gas Cylinder
F2 Cylinder Valve
F3 Gas heater connector
F4 Pressure Reducer
F5 High Pressure Manometer
F6 Low Pressure Manometer
F7 Adjusting Screw
F8 Gas outlet
F9 Solenoid Valve
F10 Chain
The gas cylinder cannot be fixed to the HOMER MG-150. 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 9on
the rear panel of the machine
3. Open the F2 cylinder valve
A Correct
B Wrong
C Wrong
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4. Press the torch trigger
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
6. Release the torch trigger
8. WELDING
8.1 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 4on
"I".
2. To select the voltage use step switch 2 and 3.
3. To select the current (that is linked to the wire speed) use the
potentiometer 1.
Positions of the switch Duty cycle Welding current
MAX-2 10% 120 A
MAX-1 95 A
MIN-2 60% 51 A
MIN-1 35 A
Duty 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 2. 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. 5)
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Fig. 5 – distance of the welding tip from the material
9. ROUTINE MAINTENANCE & INSPECTION
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
Disconnect 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
1. 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.
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.
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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:
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.
Equipment that has been used beyond the specifications established
in the operating manual.
Installation not in accordance with the installation/operating manual.
Any product that has been subjected to abuse, misuse, negligence or
accident.
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.
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.
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
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service life must be collected separately and returned to an environmentally
compatible recycling facility.
12. DECLARATION OF CONFORMITY
Table of contents
