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Summary of Contents for EWM Mira 301 KGE-M2.20
- Page 1 Operating instructions Welding machine Mira 301 KGE - M2.20 Mira 301 KGE - M2.40 099-005207-EW501 23.09.2011 Register now! For your benefit Jetzt Registrieren und Profitieren! www.ewm-group.com...
- Page 2 © EWM HIGHTEC WELDING GmbH · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer.
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Page 3: Table Of Contents
Contents Notes on the use of these operating instructions Contents 1 Contents..............................3 2 Safety instructions..........................6 Notes on the use of these operating instructions ................6 Explanation of icons........................7 General ............................8 Transport and installation ......................12 Ambient conditions........................13 2.5.1 In operation........................ - Page 4 10.1.1.2 Wire feed rollers for aluminium wires ............54 10.1.2 4-roll drive ........................55 10.1.2.1 Wire feed roller for steel wires...............55 10.1.2.2 Wire feed rollers for aluminium wires ............55 11 Appendix A............................56 11.1 JOB-List............................56 12 Appendix B............................57 12.1 Overview of EWM branches......................57 099-005207-EW501 23.09.2011...
- Page 5 Contents Notes on the use of these operating instructions 099-005207-EW501 23.09.2011...
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Page 6: Safety Instructions
Safety instructions Notes on the use of these operating instructions Safety instructions 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. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •... -
Page 7: Explanation Of Icons
Safety instructions Explanation of icons Explanation of icons Symbol Description Press Do not press Turn Switch Switch off machine Switch on machine ENTER (enter the menu) NAVIGATION (Navigating in the menu) EXIT (Exit the menu) Time display (example: wait 4s/press) Interruption in the menu display (other setting options possible) Tool not required/do not use Tool required/use... -
Page 8: General
Safety instructions General General DANGER Electromagnetic fields! The power source may cause electrical or electromagnetic fields to be produced which could affect the correct functioning of electronic equipment such as IT or CNC devices, telecommunication lines, power cables, signal lines and pacemakers. •... - Page 9 Safety instructions General WARNING 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! •...
- Page 10 Safety instructions General CAUTION Damage due to the use of non-genuine 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 11 Safety instructions General CAUTION EMC Machine Classification In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic compatibility classes (see technical data): Class A machines are not intended for use in residential areas where the power supply comes from the low-voltage public mains network.
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Page 12: Transport And Installation
Safety instructions Transport and installation Transport and installation WARNING Incorrect handling of shielding gas cylinders! Incorrect handling of shielding gas cylinders can result in serious and even fatal injury. • Observe the instructions from the gas manufacturer and in any relevant regulations concerning the use of compressed air! •... -
Page 13: Ambient Conditions
Safety instructions Ambient conditions Ambient conditions CAUTION Installation site! The machine must not be operated in the open air and must only be set up and operated on a suitable, stable and level base! • The operator must ensure that the ground is non-slip and level, and provide sufficient lighting for the place of work. -
Page 14: Intended Use
Intended use Applications Intended use WARNING Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! •... -
Page 15: 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 Machine control – operating elements chapter Wheels, guide castors Connection socket, workpiece lead Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger 099-005207-EW501 23.09.2011... -
Page 16: 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 17: Inside View
Machine description – quick overview Rear view 4.2.1 Inside view Figure 4-3 Item Symbol Description Inspection window for checking the wire and handle for opening the cover Wire delivery unit cover Wire feed unit Wire spool holder Flap support 099-005207-EW501 23.09.2011... -
Page 18: Machine Control - Operating Elements
Machine description – quick overview Machine control – Operating elements Machine control – Operating elements 4.3.1 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 Key button, Operating mode Non-latched Latched... - Page 19 Machine description – quick overview Machine control – Operating elements Item Symbol Description "Runtime parameters" button The parameters are set on the rotary transducer Gas post-flow time (0.0 s to 10.0 s) Wire burn-back (-50% to +50%) Spot time / pulse time (0.1 s to 5.0 s) Pulse pause (0.1 s to 2.0 s) Lower display Display of wire feed speed, welding current and runtime parameters.
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Page 20: M2.40 Welding Machine Control
Machine description – quick overview Machine control – Operating elements 4.3.2 M2.40 welding machine control Figure 4-5 Item Symbol Description Step switch, welding voltage Signal light, Functional error On when excess temperature detected Main switch, machine on/off Button, Welding task / operating point The parameters are set on the rotary transducer Wire speed display (m/min) Welding current display (A) - Page 21 Machine description – quick overview Machine control – Operating elements Item Symbol Description "Runtime parameters" button The parameters are set on the rotary transducer Gas post-flow time (0.0 s to 10.0 s) Wire burn-back (-50% to +50%) Spot time / pulse time (0.1 s to 5.0 s) Pulse pause (0.1 s to 2.0 s) Button, Test welding parameters Press the button and set the required welding voltage on the step switch at the same...
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Page 22: Design And Function
Design and function General Design and function General 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 23: Transport And Installation
Design and function Transport and installation CAUTION Damage due to incorrect connection! Accessory components and the power source itself can be damaged by incorrect connection! • Only insert and lock accessory components into the relevant connection socket when the machine is switched off. •... -
Page 24: Mains Connection
Design and function Mains connection Mains connection DANGER Hazard caused by improper mains connection! An improper mains connection can cause injuries or damage property! • Only use machine with a plug socket that has a correctly fitted protective conductor. • If a mains plug must be fitted, this may only be carried out by an electrician in accordance with the relevant national provisions or regulations (any phase sequence for three-phase machines)! -
Page 25: Welding Torch And Workpiece Line Connection
Design and function Welding torch and workpiece line connection Welding torch and workpiece line connection Depending on the wire electrode diameter or type, either a spiral guide or plastic core with the correct inner diameter has to be inserted in the torch! Recommendation: •... - Page 26 Design and function Welding torch and workpiece line connection Figure 5-2 Item Symbol Description Central connection for welding torch (Euro) Integrated welding current, shielding gas and torch trigger Welding torch hose package Welding torch Connection socket, workpiece lead The welding current polarity (“+” or “-”) are based on the setting of the “Welding current polarity changeover switch".
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Page 27: Shielding Gas Supply
Design and function Shielding gas supply Shielding gas supply WARNING Risk of injury due to improper handling of shielding gas cylinders! Improper handling and insufficient securing of shielding gas cylinders can cause serious injuries! • Secure shielding gas cylinders using the standard fastening elements on the unit (chain/belt)! •... -
Page 28: Connecting The Shielding Gas Supply
Design and function Shielding gas supply 5.7.1 Connecting the shielding gas supply Figure 5-3 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 29: Gas Test Or "Rinse Tube Package
Design and function Shielding gas supply Figure 5-4 Item Symbol Description Pressure regulator Shielding gas cylinder Output side of the pressure regulator Cylinder valve • Tighten the pressure regulator screw connection on the gas bottle valve to be gas-tight. • Screw gas hose connection crown nut onto the output side of the pressure regulator. -
Page 30: Setting The Shielding Gas Quantity
Design and function Shielding gas supply 5.7.3 Setting the shielding gas quantity Welding process Recommended shielding gas quantity MAG welding Wire diameter x 11.5 = l/min MIG brazing Wire diameter x 11.5 = l/min MIG welding (aluminium) Wire diameter x 13.5 = l/min (100 % argon) Gas nozzle diameter in mm corresponds to l/min gas throughput Helium-rich gas mixtures require a higher gas volume! The table below can be used to correct the gas volume calculated where necessary:... -
Page 31: Inserting The Wire Electrode
Design and function Inserting the wire electrode Inserting the wire electrode 5.8.1 Inserting the wire spool NOTE Standard D300 wire spool holder can be used. Adapters (see accessories) are required when using standardised basket coils (DIN 8559). Figure 5-5 Item Symbol Description Carrier pin For fixing the wire spool... - Page 32 Design and function Inserting the wire electrode Figure 5-6 Item Symbol Description Clamping units Pressure units Drive rollers Driver plate Knurled screws • Unfasten pressure units and fold out (clamping units and pressure rollers will automatically flip upwards). • Unfasten and remove knurled screws •...
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Page 33: Inching The Wire Electrode
Design and function Inserting the wire electrode 5.8.3 Inching the wire electrode CAUTION Risk of injury due to welding wire escaping in an unpredictable manner! Welding wire can be conveyed at very high speeds and, if conveyed incorrectly, may escape in an uncontrolled manner and injure persons! •... -
Page 34: Spool Brake Setting
Design and function Inserting the wire electrode CAUTION Extensive wear due to incorrect contact pressure! Incorrect contact pressure will cause extensive wear of the wire feed rollers! • With the adjusting nuts of the pressure units set the contact pressure so that the wire electrode is conveyed but will still slip through if the wire spool jams. -
Page 35: Select Welding Task
Design and function Select welding task Select welding task 5.9.1 M2.20 welding machine control 5.9.1.1 Setting the operating point (welding output) This control works according to the twin-knob operation principle. To set the operating point, only the wire speed and the welding voltage need to be set according to the material and the electrode diameter. Operating Action Result... -
Page 36: Setting The Expert Parameters
Design and function Select welding task 5.9.1.3 Setting the expert parameters NOTE The parameter values set are preset in the JOB and can be modified if necessary. Operating Action Result element Select expert parameters. The key combination must be pressed within 3 seconds. Select expert parameters: Gas pre-flow time "GvS"... -
Page 37: Welding Parameter Ignition Time "Tzn" Diagram
Design and function Select welding task 5.9.1.5 Welding parameter ignition time "tZn" diagram NOTE In the ignition time, the wire feed continues to run at creep speed after the arc is ignited; the ignition behaviour is improved with the optimum setting. The process described below is always used if there is a pause between welding processes of not less than 1.5 seconds. -
Page 38: M2.40 Welding Machine Control
Design and function Select welding task 5.9.2 M2.40 welding machine control 5.9.2.1 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 39: Setting The Operating Point (Welding Output)
Design and function Select welding task 5.9.2.2 Setting the operating point (welding output) NOTE 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 40: Setting The Operating Mode And Runtime Parameters
Design and function Select welding task 5.9.2.4 Setting the operating mode and runtime parameters NOTE 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 41: Explanation Of Symbols
Design and function Select welding task 5.9.2.6 Explanation of symbols Symbol Meaning "GnS" - Gas post-flows "drb" - Wire burn-back "t1" - Spot time "t2" - Interval time "GvS" - Gas pre-flows "On" - Wire creep "tZn" - Ignition time "tyP"... -
Page 42: Mig/Mag Functional Sequences / Operating Modes
Design and function MIG/MAG functional sequences / operating modes 5.10 MIG/MAG functional sequences / operating modes NOTE 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). 5.10.1 Explanation of signs and functions Symbol Meaning... -
Page 43: Non-Latched Operation
Design and function MIG/MAG functional sequences / operating modes 5.10.2 Non-latched operation Figure 5-13 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 44: Latched Operation
Design and function MIG/MAG functional sequences / operating modes 5.10.3 Latched operation Figure 5-14 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. •... -
Page 45: Spot Welding
Design and function MIG/MAG functional sequences / operating modes 5.10.4 Spot welding Figure 5-15 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 46: Interval
Design and function MIG/MAG functional sequences / operating modes 5.10.5 Interval Figure 5-16 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 47: Maintenance, Care And Disposal
Maintenance, care and disposal General Maintenance, care and disposal DANGER Risk of injury from electric shock! Cleaning machines that are not disconnected from the mains can lead to serious injuries! • Disconnect the machine completely from the mains. • Remove the mains plug! •... -
Page 48: Maintenance Work
Information about giving back used equipment or about collections can be obtained from the respective municipal administration office. • EWM participates in an approved waste disposal and recycling system and is registered in the Used Electrical Equipment Register (EAR) under number WEEE DE 57686922. •... -
Page 49: Rectifying Faults
Rectifying faults Customer checklist 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 50: Check The Machine Type Setting
Rectifying faults Check the machine type setting Check the machine type setting NOTE Only with the M2.xx machine control. After switching on, the machine type that has been set is displayed for a short time, denoted as "tyP". If the machine type displayed does not match the machine, you have to correct this setting. -
Page 51: Resetting The Control (Reset All)
Rectifying faults Resetting the control (Reset all) Resetting the control (Reset all) NOTE M2.xx control The first action should always be to check and if necessary correct the machine type setting. All user settings will be overwritten with factory settings and must therefore be checked afterwards, or set up again! After resetting the machine control to the factory settings, it is essential that the machine type used is checked and reset if necessary. -
Page 52: Technical Data
Technical data Mira 301 Technical data Mira 301 NOTE Performance specifications and guarantee only in connection with original spare and replacement parts! Switching steps Welding current setting range 30 A–300 A Welding voltage 15,5V - 29V Duty cycle at 25 °C 300 A 100% 170 A... -
Page 53: Accessories
Accessories General accessories Accessories NOTE 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. ADAP DZA/EZA Adapter for welding torches with Dinse connector to 094-016765-00000 Euro central connector, on the machine AK300 Adapter for K300 basket coil... -
Page 54: Replaceable Parts
Replaceable parts Wire feed rollers Replaceable parts CAUTION Damage due to the use of non-genuine 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 55: 4-Roll Drive
Replaceable parts Wire feed rollers 10.1.2 4-roll drive 10.1.2.1 Wire feed roller for steel wires Type Designation Item no. FE 2DR4R 0,6+0,8 Drive rollers, 37 mm, steel 092-000839-00000 FE 2DR4R 0,8+1,0 Drive rollers, 37 mm, steel 092-000840-00000 FE 2DR4R 0,9+1,2 Drive rollers, 37 mm, steel 092-000841-00000 FE 2DR4R 1,0+1,2... -
Page 56: Job-List
Appendix A JOB-List Appendix A 11.1 JOB-List 094-010488-00500 Wire Material Job-Nr. CO 100 SG2/3 G3/4 Si1 Ar82/18 CrNi Ar98/2 AlMg Ar100 AlSi Ar100 Al99 Ar100 Manuell / no program 099-005207-EW501 23.09.2011... -
Page 57: Overview Of Ewm Branches
Appendix B Overview of EWM branches Appendix B 12.1 Overview of EWM branches 099-005207-EW501 23.09.2011...
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