mig/mag welding machines homer mg-15 instruction
Contents
1. HOMER tools MIG MAG WELDING MACHINES HOMER MG 15 INSTRUCTION MANUAL Content t INIRODUCHON Pr 2 2 SAFETY INSTRUCTIONS AND WARNINGS eere mmm 2 COMPUT IONS 6 E911 rm 6 ACCESSORIES a D DESCRIPTION OP tenants coins 9 VEEECILANR CRUS IND se en da eu ot 10 o 13 9 ROUTINE MAINTENANCE amp 1 14 10 SIATEMENT OF WARRANTY seasscmanas tte 15 MONS OSG 15 12 DECLARATION OF CONFORMITY 16 ALFA IN a s 2013 www alfain eu HOMER MG 150 MANUAL EN 1 doc page 2 of 16 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 th2. carried out by trained personnel e he machine must be used in a dry place with good ventilation ALFA IN a s O www alfain eu page 3 of 16 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 235 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 f
3. ER 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 e Do not work in a damp or humid environment e 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 e he 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 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
4. al 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 235 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 moisture and rain and snow mechanical damage draft and any ventilation of neighbouring machine excessive overloading crossing technical parameters rough handling 4 TECHNICAL DATA ALF 181 ALFA IN a s O www alfain eu page of 16 Mains voltage V Hz 1 x 230 50 Ormcmiwtgeum Su a 0 Welding current DC 100 I2 U2 Welding current DC x I2 U2 10 140 21 0 Voltage steps Insulation class E Protection PS Standards 009741 Spool diameter mm 200 5 5 ACCESSORIES 5 1 DELIVERED WITH THE MACHINE Welding torch Ground cab
5. e F2 cylinder valve ALFA IN a s O www alfain eu page 13 of 16 4 Press the torch trigger o 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 4 on 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 Welding current MAX 2 120A MAX 1 9 MIN 2 MIN 1 BA 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 opt
6. ectro 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 atleast 10 Welding gloves Welding apron and cloth Welding boots 2 3 RISK OVERVIEW e Risk of electric shock e Ultraviolet light and light radiation e Risk of inhaling gas fumes and dust particles ALFA IN a s O www alfain eu 6 16 Burns Noise NOTES b c d e 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 profession
7. imum 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 ALFA IN a s www alfain eu page 14 of 16 Fig 5 distance of the welding tip from the material 9 ROUTINE MAINTENANCE amp 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 wy WARNING wy 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 South NW 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 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 car
8. is 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 e OPERATION AND MAINTENANCE OF WELDING EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOURHEALTH e 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 e Once the packing has been opened make sure that the machine is not damaged If in any doubt call the service centre e his equipment must only be used by qualified personnel e During installation any electric work must only be
9. le Brush Feeding roll 0 6 0 8 mm Welding shield 5 2 ACCESSORIES TO ORDER e Wire cleaner ALFA IN a s O www alfain eu page 8 of 16 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 ALFA IN a s www alfain eu page 9 of 16 6 DESCRIPTION OF THE APPLIANCE 6 1 MAIN PARTS 1 23 45 6 7 8 9 10 1112 13 14 15 6 Fig 1 Main parts ALFA IN a s www alfain eu page 10 of 16 Wire speed potentiometer Voltage switch MIN MAX Voltage switch 1 2 LED over heating indicator ON OFF Switch LED Over heating Indicator Welding torch Ground cable Mains cable Gas connector 10 Fitted on welding wire spool not part of delivery 11 Spool Holder 12 Inlet 13 14 Plus terminal 15 Minus terminal black 6 2 WIRE FEEDER 16 1718 19 20 Fig 2 Wire feeder escription eeder inlet liner ixing shaft ressure arm oll Plastic cup orch 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 Con
10. nect the earthing clamp 7 to the welding piece 2 Plug the mains plug to 230 V mains ALFA IN a s O www alfain eu gt page 11 of 16 Switch the machine on by the ON OFF switch 4 7 1 INSERTING THE WIRE Open the side cover of the wire feeder space Put the wire spool 10 on the wire spool holder 11 Put the Inlet 12 onto the holder 11 followed by the spring and tighten up the nut onto the holder 11 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 Make sure that the wire fits into the Torch inlet liner 20 Put the pressure arm 18 down and fix it by setting the Fixing shaft 17 into vertical position 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 Take off the torch gas cup off the torch tip Press the torch trigger the wire will start feeding into the torch 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 Open the wire feeder by means of the Fixing shaft 17 U
11. nscrew the plastic fixing cup 19 and take off the roll 19 In case there is suitable groove on the roll turn it around and fix it back to the feeder Fig 3 The influence of the roll groove on the wire for this machine groves 0 6 and 0 8 ALFA IN a s O www alfain eu page 12 of 16 A Correct 0 0 B Wrong gt S C Wrong gt s amp 0 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 F4 F5 F6 7 F8 i F7 F1 F10 Fig 4 Gas fitting Gas Cylinder F2 Cylinder Valve F3 Gas heater connector F4 Pressure Reducer F5 High Pressure Manometer F6 Low Pressure Manometer F7 Adjusting Serew 11 O F8 Gas outlet Z O F9 Solenoid Valve FiO Chan 2 v iJ JJ s 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 9 on the rear panel of the machine 3 Open th
12. nsent obtained from ALFA IN Service Department e Equipment that has been used beyond the specifications established in the operating manual e Installation not in accordance with the installation operating manual e 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 6 Within this operating manual are details regarding the maintenance necessary to ensure trouble free operation 7 wore Y 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 ALFA IN a s O www alfain eu page 16 of 16 service life must be collected separately and returned to an environmentally compatible recycling facility 12 DECLARATION OF CONFORMIT Y ES PROHL SEN O SHODE DECLARATION OF CONFORMITY My firma ALFA IN a s We Nova Ves 74 675 21 Okrisky ICO 25535366 OR vedeny Krajskym soudem v Brn oddil B vlo ka 2702 prohla
13. ried out only by suitably qualified or competent person 4 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 ALFA IN a s O www alfain eu page 15 of 16 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 f warranty is being sought please contact your ALFA IN product supplier for the warranty repair procedure 5 ALFA IN warranty will not apply to e Equipment that has been modified by any other party other than ALFA IN s own service personnel or with prior written co
14. sujeme na svou vylucnou odpovednost ze vyrobek hereby declare under our sole responsibility that the machine type HOMER MG 150 je v souladu se sm rnici is in compliance with the directives 2002 85 EC 2004 108 EC 2006 85 EC a spl uje po adavky harmonizovanych norem and that the following standards apply 60974 01 EM 60974 10 Pas be S M V In Nova Ves _ Ing Vlasta Sl mov Datum dated 3 8 2012 mistopredsedkyne Sredstavenstva ALFA IN a s Vicechairman of the board of directors ALFA IM a s 120803 V 8 ALFA IN a s www alfain eu
15. to the various cases shown in the following table Working conditions Open circuit voltage 1 Places with increased DC current 113V AC current 68V risk of electric shock peak value peak value and 48V effective 2 Places without increased DC current 113V AC current 113V risk of electric shock peak value peak value and 80V effective Torches held DC current 141V AC current 141V ALFA IN a s O www alfain eu mechanically with peak value and 100V effective the operator Ls jw cutting DC current 500V peak value increased protection for page 5 of 16 peak value e case 1 the dc machines with rectifier must be built in 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 e Before opening the machine switch off the machine and disconnect it from the power socket e 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 T Vs videos telephones burglar alarms etc Computers robots el
16. umes 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 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 ALFA IN a s O www alfain eu 4 16 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 NEV
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