Homer MG-15 Instruction 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, doublesided, 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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