Related Manuals for EWM Mira 301 M2.20 FKG
Summary of Contents for EWM Mira 301 M2.20 FKG
- Page 1 Operating instructions Welding machine Mira 301 M2.20 FKG Mira 301 M2.40 FKG 099-005207-EW501 18.05.2017...
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Page 2: General Instructions
+49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com. Liability relating to the operation of this equipment is restricted solely to the function of the equipment. -
Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents ..............................3 2 For your safety ............................5 Notes on the use of these operating instructions ................5 Explanation of icons ........................6 Safety instructions .......................... 6 Transport and installation ......................9 3 Intended use ............................ - Page 4 10.1 Wire feed rollers ........................... 48 10.1.1 Wire feed rollers for steel wire ..................48 10.1.2 Wire feed rollers for aluminium wire ................48 11 Appendix A ............................49 11.1 JOB-List............................49 12 Appendix B ............................50 12.1 Overview of EWM branches......................50 099-005207-EW501 18.05.2017...
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Page 5: For Your Safety
For your safety Notes on the use of these operating instructions For your safety Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. •... -
Page 6: Explanation Of Icons
For your safety Explanation of icons Explanation of icons Symbol Description Symbol Description Indicates technical aspects which the Activate and release/tap/tip user must observe. Switch off machine Release Switch on machine Press and keep pressed Switch Wrong Turn Numerical value – adjustable Correct Menu entry Signal light lights up in green... - Page 7 For your safety Safety instructions WARNING Hazard when interconnecting multiple power sources! If a number of power sources are to be connected in parallel or in series, only a technical specialist may interconnect the sources as per standard IEC 60974-9:2010: Installation and use and German Accident Prevention Regulation BVG D1 (formerly VBG 15) or country-specific regulations.
- Page 8 For your safety Safety instructions CAUTION Smoke and gases! Smoke and gases can lead to breathing difficulties and poisoning. In addition, solvent vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to the ultraviolet radiation of the arc! • Ensure that there is sufficient fresh air! •...
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Page 9: Transport And Installation
For your safety Transport and installation CAUTION According to IEC 60974-10, welding machines are divided into two classes of electromagnetic compatibility (the EMC class can be found in the Technical data) > see 8 chapter: Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network. - Page 10 For your safety Transport and installation CAUTION Risk of accidents due to incorrectly installed leads! Incorrectly installed leads (mains, control and welding leads or intermediate hose packages ) can present a tripping hazard. • Lay the supply lines flat on the floor (avoid loops). •...
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Page 11: Intended Use
In case of unauthorised changes, improper repairs, non-compliance with specified deadlines for "Arc Welding Equipment – Inspection and Testing during Operation", and/or prohibited modifications which have not been explicitly authorised by EWM, this declaration shall be voided. An original document of the specific declaration of conformity is included with every product. -
Page 12: Machine Description - Quick Overview
Machine description – quick overview Front view Machine description – quick overview Front view Figure 4-1 Item Symbol Description Carrying handle Machine control > see 4.4 chapter Wheels, guide castors Connection socket, workpiece lead Welding torch connection (Euro torch connector) Welding current, shielding gas and torch trigger integrated 099-005207-EW501 18.05.2017... -
Page 13: Rear View
Machine description – quick overview Rear view Rear view Figure 4-2 Item Symbol Description Securing elements for shielding gas cylinder (strap/chain) Key button, Automatic cutout Wire feed motor supply voltage fuse (press to reset a triggered fuse) Connecting nipple G¼, shielding gas connection Bracket for shielding gas cylinder Wheels, fixed castors Mains connection cable >... -
Page 14: Inside View
Machine description – quick overview Inside view Inside view Figure 4-3 Item Symbol Description Inspection window for checking the wire and handle for opening the cover Protective cap Cover for the wire feed mechanism and other operating elements. Depending on the machine series, you can find additional stickers with information on the operation and maintenance of the machine on the inside of the cap. -
Page 15: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 4.4.1 M2.20 welding machine control Figure 4-4 Item Symbol Description Step switch, welding voltage Signal light, Functional error On when excess temperature detected Main switch, machine on/off Operating mode push-button >... -
Page 16: M2.40 Welding Machine Control
Machine description – quick overview Machine control – Operating elements Item Symbol Description Push-button, wire inching Potential- and gas-free inching of the wire electrode through the hose package to the welding torch > see 5.1.8.4 chapter. Upper, display Displays welding voltage or person who designated the runtime parameters Signal light, HOLD Lit: Display shows the last parameters used for welding. - Page 17 Machine description – quick overview Machine control – Operating elements Item Symbol Description Operating mode push-button > see 5.3 chapter -------- Non-latched ------- Latched ------ Spot welding ----- Interval/Interval (latched) Operating / Connection element not used in this system! Wire feed speed/welding parameter rotary knob Infinite adjustment of the wire feed speed/welding parameters and corresponding values Sequence parameter push-button...
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Page 18: Design And Function
Design and function Transport and installation Design and function WARNING Risk of injury from electric shock! Contact with live parts, e.g. welding current sockets, is potentially fatal! • Follow safety instructions on the opening pages of the operating instructions. • Commissioning may only be carried out by persons who have the relevant expertise of working with arc welding machines! •... -
Page 19: Workpiece Lead, General
Design and function Transport and installation 5.1.3 Workpiece lead, general CAUTION Risk of burning due to incorrect welding current connection! If the welding current plugs (machine connections) are not locked or if the workpiece connection is contaminated (paint, corrosion), these connections and leads can heat up and cause burns when touched! •... -
Page 20: Stray Welding Currents
Design and function Transport and installation Always keep leads as short as possible! Lay any excess cable lengths in meanders. Figure 5-3 5.1.4.1 Stray welding currents WARNING Risk of injury due to stray welding currents! Stray welding currents can destroy protective earth conductors, damage machines and electronic devices and cause overheating of components, leading to fire. -
Page 21: Mains Connection
Design and function Transport and installation 5.1.5 Mains connection DANGER Hazards caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only operate machine using a socket that has correctly fitted protective earth. • The mains voltage indicated on the rating plate must match the supply voltage. -
Page 22: Pressure Regulator Connection
Design and function Transport and installation An unhindered shielding gas supply from the shielding gas cylinder to the welding torch is a fundamental requirement for optimum welding results. In addition, a blocked shielding gas supply may result in the welding torch being destroyed. •... -
Page 23: Shielding Gas Hose Connection
Design and function Transport and installation 5.1.6.2 Shielding gas hose connection Figure 5-7 Item Symbol Description Securing elements for shielding gas cylinder (strap/chain) Bracket for shielding gas cylinder Connecting nipple G¼, shielding gas connection • Place the shielding gas cylinder into the relevant cylinder bracket. •... -
Page 24: Shielding Gas Volume Settings
Design and function Transport and installation 5.1.6.3 Shielding gas volume settings If the shielding gas setting is too low or too high, this can introduce air to the weld pool and may cause pores to form. Adjust the shielding gas quantity to suit the welding task! •... -
Page 25: Welding Torch And Workpiece Line Connection
Design and function Transport and installation 5.1.7 Welding torch and workpiece line connection On delivery, the Euro torch connector is fitted with a capillary tube for welding torches with a steel liner. Conversion is necessary if a welding torch with a liner is used! •... -
Page 26: Wire Feed
Design and function Transport and installation Item Symbol Description Workpiece lead Workpiece • Insert the central plug for the welding torch into the central connector and screw together with crown nut. • Insert cable plug on the workpiece lead into the connection socket for workpiece lead and lock by turning to the right. -
Page 27: Changing The Wire Feed Rollers
Design and function Transport and installation Figure 5-10 Item Symbol Description Carrier pin For fixing the wire spool Knurled nut For fixing the wire spool • Loosen knurled nut from spool holder. • Fix welding wire reel onto the spool holder so that the carrier pin locks into the spool bore. •... -
Page 28: Inching The Wire Electrode
Design and function Transport and installation • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards). • Unfasten and remove knurled screws • Remove the drive rollers together with the driver plates. • Slide new drive roller onto driver plate. •... -
Page 29: Spool Brake Setting
Design and function Welding task selection Item Symbol Description Wire feed nipple Capillary tube or plastic liner with support tube, depending on torch equipment • Extend and lay out the torch hose package. • Unfasten and tilt the feed roll tensioner. The clamping units will automatically turn upwards. •... -
Page 30: Setting The Operating Mode And Runtime Parameters
Design and function Welding task selection 5.2.1.2 Setting the operating mode and runtime parameters The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select operating mode: ----------Non-latched --------Latched --------Spots -------Interval Select welding parameter: -------Set gas post-flow time "GnS"... -
Page 31: M2.40 Welding Machine Control
Design and function Welding task selection 5.2.2 M2.40 welding machine control 5.2.2.1 Select JOB number (welding task) This microprocessor-controlled control works according to the one-dial operation principle. Only the gas type, material type and wire electrode diameter should be set as the JOB number on the control, as well as welding output via the step switch. -
Page 32: Setting The Operating Point (Welding Output)
Design and function Welding task selection 5.2.2.2 Setting the operating point (welding output) The operating point setting in JOB "0" (manual) is carried out as described in the chapter of the same name for control M2.4x. The following settings are therefore only intended for work in JOBs 1-24. -
Page 33: Welding Parameter Ignition Time "Tzn" Diagram
Design and function Operating modes (functional sequences) 5.2.2.5 Welding parameter ignition time "tZn" diagram The arc striking is positively affected by the adjustable ignition time. After the arc striking, the wire feeder continues operating in wire creep speed for the set ignition time. This behaviour occurs whenever the pause time between the welding operations is at least 1.5 seconds. -
Page 34: Operating Modes (Functional Sequences)
Design and function Operating modes (functional sequences) Operating modes (functional sequences) There are optimum pre-sets for welding parameters such as gas pre-flow and burn back, etc. for numerous applications (although these can also be changed if required). 5.3.1 Explanation of signs and functions Symbol Meaning Press torch trigger... - Page 35 Design and function Operating modes (functional sequences) Non-latched mode Figure 5-18 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •...
- Page 36 Design and function Operating modes (functional sequences) Latched mode Figure 5-19 Step 1 • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites when the wire electrode makes contact with the workpiece; welding current flows. •...
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Page 37: Spot Welding
Design and function Operating modes (functional sequences) 5.3.2 Spot welding Figure 5-20 1. Start • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire feed motor runs at "creep speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •... -
Page 38: Interval
Design and function Operating modes (functional sequences) 5.3.3 Interval Figure 5-21 1. Start • Press and hold torch trigger. • Shielding gas is expelled (gas pre-flows). • Wire-feed motor runs at "creep-start speed". • Arc ignites after the wire electrode makes contact with the workpiece; welding current flows. •... -
Page 39: Interval (Latched)
Design and function Operating modes (functional sequences) 5.3.4 Interval (latched) To activate the Latched interval operating mode, parameter Int in the Expert menu has to be changed to 4t > see 5.4 chapter. Figure 5-22 cycle • Press the torch trigger and hold down •... -
Page 40: Setting The Expert Parameters
Design and function Setting the expert parameters Setting the expert parameters The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Expert parameter selection. The combination of buttons has to be pressed within 3 seconds. Select Expert parameter: Gas pre-flow time (0 to 10 sec) Wire creep speed 1.5 to 20 m/min. -
Page 41: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal General DANGER Risk of injury due to electrical voltage after switching off! Working on an open machine can lead to fatal injuries! Capacitors are loaded with electrical voltage during operation. Voltage remains present for up to four minutes after the mains plug is removed. -
Page 42: Maintenance Work, Intervals
A periodic test according to IEC 60974-4 "Periodic inspection and test" has to be carried out. In addition to the regulations on testing given here, the relevant local laws and regulations must also be observed. For more information refer to the "Warranty registration" brochure supplied and our information regarding warranty, maintenance and testing at www.ewm-group.com! 099-005207-EW501 18.05.2017... -
Page 43: Disposing Of Equipment
In addition to this, returns are also possible throughout Europe via EWM sales partners. Meeting the requirements of RoHS We, EWM AG in Mündersbach, Germany, hereby confirm that all products which we supply to you and that are subject to the RoHS directive comply with RoHS requirements (also see applicable EC directives on the Declaration of Conformity on your machine). -
Page 44: Rectifying Faults
Rectifying faults Checklist for rectifying faults Rectifying faults All products are subject to rigorous production checks and final checks. If, despite this, something fails to work at any time, please check the product using the following flowchart. If none of the fault rectification procedures described leads to the correct functioning of the product, please inform your authorised dealer. -
Page 45: Setting The Machine Type
Rectifying faults Resetting the control (Reset all) 7.2.1 Setting the machine type Operating Action Result element Switch off the welding machine Keep both push-buttons pressed Switch on the welding machine; the display shows “Anl”. With “Anl” on the display, set the machine type: 0 ---------- Saturn 251 FKG 1 ---------- Saturn 301 FKG 2 ---------- Saturn 351 FKG... -
Page 46: Technical Data
Technical data Mira 301 Technical data Performance specifications and guarantee only in connection with original spare and replacement parts! Mira 301 Switching steps 30 A–300 A Setting range for welding current Welding voltage 15.5 V–29 V Duty cycle at 25 °C 300 A 170 A 100%... -
Page 47: Accessories
Accessories General accessories Accessories Performance-dependent accessories like torches, workpiece leads, electrode holders or intermediate hose packages are available from your authorised dealer. General accessories Type Designation Item no. ADAPTER EZA --> DINSE-ZA Adapter for welding torches with Dinse connector to 094-016765-00000 Euro central connector, on the machine AK300... -
Page 48: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode holders, remote controls, spare parts and replacement parts, etc.) from our range of products! •... -
Page 49: Job-List
Appendix A JOB-List Appendix A 11.1 JOB-List Figure 11-1 099-005207-EW501 18.05.2017... -
Page 50: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005207-EW501 18.05.2017...
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