Mira HM-2000 EVO User manual

Instruction Manual
English (EN)
Headmaster
Workstation

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Table of contents
Safety Regulations ............................................................................................................................3
Elementary safety-advices................................................................................................................4
Copyright ©........................................................................................................................................8
Non-liability........................................................................................................................................9
Warranty.............................................................................................................................................9
Declaration of conformity ...............................................................................................................10
Positioning.......................................................................................................................................11
Levelling...........................................................................................................................................11
Power network.................................................................................................................................11
9.1 220-240VAC / 50-60Hz......................................................................................................11
9.2 100-125VAC / 50-60Hz......................................................................................................11
Connections and type plate............................................................................................................12
Machine parts ..................................................................................................................................13
11.1 Front view.......................................................................................................................13
11.2 Rear view........................................................................................................................14
11.3 AV-2000 EVO .................................................................................................................15
11.4 Controls Multivac and Vario Drive...................................................................................16
Installation of the equipment..........................................................................................................17
12.1 Vario Drive......................................................................................................................17
12.2 Connecting the Vario Drive and Multivac........................................................................18
12.3 Electrical earthing ...........................................................................................................18
12.4 Control Box Vario Drive ..................................................................................................19
12.5 Fuse Control Box Vario Drive .........................................................................................19
12.6 Multivac...........................................................................................................................20
12.7 Fuse Multivac..................................................................................................................20
12.8 Multivac adaptor..............................................................................................................21
12.9 Tooling tray.....................................................................................................................21
12.10 Tool holder (optional)......................................................................................................21
12.11 Voltage transformer 100VAC 230VAC.......................................................................22
Cylinder head clamping device......................................................................................................23
13.1 Example for the clamping of a cylinder head ..................................................................26
Operation .........................................................................................................................................27
14.1 Vario Drive handling........................................................................................................27
14.2 Multivac handling............................................................................................................28
Troubleshooting..............................................................................................................................29
15.1 Start-up...........................................................................................................................29

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15.2 Preparations ...................................................................................................................29
15.3 Leak testing ....................................................................................................................29
Spare parts.......................................................................................................................................30
16.1 HM-2000 EVO.................................................................................................................31
16.2 AV-2000 EVO .................................................................................................................33
16.3 Pressure- and pivot spindle / Main spindle .....................................................................34
16.4 Hose retraction................................................................................................................35
16.5 Vario Drive......................................................................................................................36
16.6 Multivac...........................................................................................................................37
Schematic diagramm 230VAC ........................................................................................................38
Schematic diagramm 110VAC ........................................................................................................39
Maintenance.....................................................................................................................................40
Special accessories ........................................................................................................................42
20.1 Working lamp 230VAC....................................................................................................42
20.2 Additional carrying profiles..............................................................................................42
20.3 Tool holder......................................................................................................................42
Technical data..................................................................................................................................43

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Safety Regulations
Observe local regulations when making any electrical installations. We suggest the installation of an external main switch with an
integrated fuse near the machine. For this electric installation, contact your local electrician / expert!
We would like to draw your attention to some dangers which may occur. You should therefore read the following instructions carefully
and proceed accordingly.
It is prohibited to run the workbench in moist, dusty or explosive environment! There is a danger of a short circuit!
The workbench must not be operated with an opened boardsheet!
Clamping device rotating 300 degrees only!
The isolation of the flexible drive shaft and all visible cables have to be checked regularly.
Overpasting or bridging of the handle switch is dangerous!
Safety Goggles have to be worn while using the unit!
With long hair, either a head covering must be worn or the hair must be bound up!
The rotating spindle on the vario drive unit poses a risk of injury.
The clamping device must be cautiously clamped and released on both sides. Theres a risk of squeezing by incorrect working!
Avoid suck in of dirt or liquids!
Inspect the suction line and filter for soiling and defects regularly!
When polluted, clean the suction line and replace the filter!
Switch off the vacuum pump when it is not in use!
Power must be disconnected prior to any electrical work or repair operations!
Repair operations may only be performed by the local Mira representative or by the manufacturer!
Use only genuine MIRA spare parts that are listed in the respective operating instructions!
Avoid all contact with the electrical circuits of the machine! => Risk of electrocution!
Modifications of the electronic components may have serious consequences!
Earthing of the workstation
To minimize shock hazard, the drive must be connected to an electrical ground. Earthing equipment must be connected to the
protective earthing conductor of the power supply!
Do not use in explosive environment!
Operation of this machine in the presence of inflammable gases, fumes ordustmay cause an ignition of this environment and has to be
prevented.
CAUTION!
1. It is not permitted to operate the machine in dusty surroundings as there is a risk of fire resulting from the overheating of small
particles.
2. To avoid shock hazards do not expose this machine to moisture, rain or dew as this may cause an electrical short between mains and
controls.
3. Installation, adjustment and service of this device must be made by qualified personal only. Works or repairs on electrical parts
of the device is very dangerous because of the high voltages the circuit is working with. These high voltages are capable of causing
death and are present even after disconnecting mains. Before starting servicing and repairs it is essential to disconnect any mains.
4. It is not permitted to work on the outputs if the power supply is switched on, even if the connected motor is not activated or the
drive is interlocked.
5. Operation of this machine without a mechanical switch and a fuse in the supplying wiring is not permitted.
6. Do not attempt internal service or adjustment unless another person, capable of disconnecting mains and rendering first aid, is
present.
7. This machine should never be used as a safety device or for realizing an emergency function. A malfunction of the connected motor
even with switched on mains cannot be prevented.
8. Do not touch the electrical parts of the devices. During operation the electrical parts are carrying dangerous voltages and might
lead to death. In addition, the machine can be damaged if the electrical circuit is touched, as a result of static discharge effects.
9. To prevent additional hazards, do not make modifications or installation of substitute parts. Before any modification, installation
of substitute parts or additions are made, ask for the authorization of the manufacturer (Minelli Corporation).

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Elementary safety-advices
Advices in the instruction manual
•The knowledge of the Basic safety advices and safety regulation are basic conditions for the
design to security using of this machine in cooperation with the “Safety Regulations” on page 3.
•The instruction manual contains the core of the importants advices, to use this machine in a safe
condition.
•The instruction manual, especially the safety advices, must be considered by all users, who work
on this machine.
•Beyond that it must be paid attention to the locally valid regulations and the compliance of the
accident control.
Responsibility of the operator
Operation on this machine and its controls is only allowed, if the employees
•will be introduced to the basic advices for working safety and accident control. They must also be
instructed to the machine applications as well.
•have read and understood the safety advices and warning indications in the instruction manual
The operator should regularly control the safety -conscious work of the employees.
Responsibility of the employees
The employees, who work on the machine, have to oblige to the following principles:
•that they pay attention to the basic safety advices of work safety and accident control.
•that they have read and understood the safety advices and warning notices in the instruction
manual.
Risk in using the machine
The machine HM2000-EVO has been developed according to state of the art technology and was
constructed by the accepted safety-related regulations. However, it is possible by using the machine,
that there could appear some risks for employees / third party, especially if the machine is misused
and operated not accordingly to the MIRA instruction manual. Only utilise the machine:
•for designated use.
•in safety-related good condition.
Breakdowns must be corrected immediately!
Designated utilisation
The MIRA HM-2000 EVO machines are exclusively designed for clamping and machining cylinder-
heads from combustion engines (Diesel and Gasoline). Another- or beyond going utilisation is not
intended and permitted. The Minelli Corporation will not be rendered liable for damages which evolve
from improper machine-use. The following references belong to a conventional use as well:
•to pay attention to every advice from the instruction manual.
•to observe the maintenance rate and service work schedules.
•to work and operate according to locally valid regulations and the compliance of the accident
control.
•to use only genuine MIRATOOL spare parts for maintenance and repair servicing.

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Warranty and liability
Warranty matters are described in MIRA‘s terms of sales and return policy conditions and are a
integral part of any sales contract between MIRA an the customer. Warranty- and liability by people
and material assets are void, if they had one or more of the following causations:
➢Non-designated use of the machine
➢Incorrect mounting, launching, using and servicing of the machine
➢Operation of the machine with damaged safety-devices or incorrect and missing mounting of the
safety- and protective gears
➢Non-observance of the advices in the instruction manual with regard to the transport, storage,
assembling, launching, operating and servicing of the machine
➢Independent constructive manipulations of the machine
➢Independent manipulation of the HM-2000 EVO (for example: removing of safety labels, controls,
safety- and protection shields)
➢Manipulation and removing of the original MIRA type plate
➢Bad monitoring of machine parts which are wearout and in dire need of maintenance
➢Improper servicing, repairs and maintenance work
➢Emergencies by external-material influence and “force-majeure” situations
Symbol- and advice description
The following descriptions and icons will be used for risks and dangerous situations:
Warning notice –Generally danger: Indicates a potentially dangerous situation, which can
induce low to severe injuries up to death, if they will be ignored.
Warning notice –Danger of electrocution: Indicates a dangerous situation, which can induce
electrical shocks, severe burns up to electrocution, if they will be ignored.
Warning notice –Crushing hazard: Indicates a potentially dangerous situation, which can
induce low to severe constant injuries, if they will be ignored.
Info-notice: Indicates Informations and/or additions, which are importantfor the appropriate use
of the machine and its functionality.
Application-notice: Indicates accessories and further application-features of the machine.
Organisational provisions
•The operator must prepare the required safety-equipment / gears.
•All safety-devices must be checked in regular intervalls.
Protection-apparates
•Before launching the machine, all protection-devices must be installed and tested correctly.
•Protection-devices may only be removed
- after shutdown and
- coverage against re-launching of the machine
•By mounting additional machine parts, the dismounted protection gears must be installed in a
correct and designated manner. The operator has to make sure all protective shields and gears
are installed again in the correct order and fully functionally.

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Informative safety provisions
•The instruction manual must be kept by the machine at all times.
•Additional to the instruction manual, there must be paid attention to the general and local
regulations of the accident- and pollution control.
•All safety- and warning symbols on the machine have to be kept in good condition.
Training of the users
•Only introduced and trained employees are permitted to work on the machine.
•The user competence must be clearly appointed for the mounting, launching, handling, servicing
and repairing of the machine.
•Beginners / trainees may only work on the machine under the attendance of an experienced
employee or operator.
Machine- and apparate electrics
•Do NOT consider any alterations and manipulations on the motor control unit or the control box
of the Vario Drive. Manipulation on the machine / device wiring are strictly prohibited.
•Only introduced and trained employees are permitted to operate the Vario Drive.
CAUTION => Pay attention to rotative machine parts and tools!
Safety provisions in the standard mode
•All protection-devices must be absolute functioning, if the machine is in operation.
•Before switching-on the machine, there must bepaid attention that nobody is exposed to therisks
by starting the machine.
•The machine should be checked for external damages and safety-device functioning
(EMERGENCY-Push button) on every working shift.
Risks of electricity and electrocution
•The work on electrical power supplies must be done by an expert (Certified Electrician)
•The electrical equipment of the machine must be checked in constant intevalls. (crippled cords
and damaged cable strands, defective Controls etc.)
•The boardsheet has to be closed at all times, especially during operation!
•Repairs and servicing on hot wires / cables is strictly prohibited => contact MIRATOOL Service
•By permanent Non-use of the machine - remove the power cord from the main socket.
Especially danger areas
•If the clamping-device is not tightened enough or fully loosened, there is a risk of rotating. This
can be dangerous for squeezing of fingers, hands and arms. If necessary, lock and/or unlock the
clamping device with the help from a second party.
•Make sure that the machine will be secured against accidental switch-on!
•General risk of clamping and squeezing by setting and clamping the cylinder-heads. Tighten
securely the clamping plate and the clamping device against loosening.
•The vario drive and the respective valve seat refacing units contain rotating machine parts, who
are a demanding risk for (long) hair, hands and fingers. Wear suitable safety equipment (e.g.
hairnet etc.).
Leaking of hazardous dust and vapours
•During the refacing of the valve seats, metal dust, particles and vapours from the cutting oil can
occur. They can irritate and injure the lungs and the eyes. Wear suitable safety equipment (e.g.
protection goggles, mask etc.). Ensure enough ventilation on the workstation. Special safety
precaution, for example: eyeflushing device.

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Service and repairs, troubleshooting
•Arrange the prescribed setting-, servicing- and maintenance work to the appointed deadlines.
•Informing the responsible employees of the machine about imminent servicing and repairs.
•All of the machine pre- or after switched machine parts and operating mediums, e.g. pressurised
air, must be ensured against accidentally re-launching.
•By all servicing-, checking- and repairing works, the machine must be switched off from the main
supply and the main switch must be locked against unexpected re-launching
- Lock and strip of the key from the main switch, if it is possible.
- Add a shield or an information-sign on to the machine,
that the machine may not can be switched on.
•Great assemblies must be carefully mounted and ensured on lifting gears. Only use inspected
lifting gears according to the local regulations!
•Check loosened screw fittings for straight fixation.
•After finishing the service work, the saftey devices of the machine must be checked and verified
Constructive modifications on the machine
•Without written authorisation by the manufacturer Minelli Corp. (MIRA), theres no right to add
components and/or making some modifications to the machine. This is also valid for welding on
supporting assemblies.
•All constructive modifications require a written confirmation from the Minelli Corp. (MIRA)
•Machine parts in poor condition have to be replaced by original MIRA spare sparts only!
•Only use original genuine MIRA spare and wearing parts.
- By spare parts of an unknown third party and/or other supplier, there is no guarantee, that those
parts are constructed for the required operational demands and safety factors.
Cleaning of the machine and disposal of wastes
•Used stuff and materials must be disposed correctly, especially:
- working on lubrication systems- and devices
- waste from cleaning with dissolvers and cleaners
•The machine must be cleaned in constant intevalls, with a dryflannel and the least of machine- or
industry cleaner. => See maintenance rate!
•Further cleaning per grade of using and grade of pollution of the machine.
•The packaging material of the HM-2000 EVO, after delivering, must be disposed correctly in the
respective waste containers and/or according to the local waste- and environmental legislations!
Noise emission of the machine
•The noise pressure level, going out from this machine, by maximum spindle rotation of the Vario
Drive, amounts to 70dB(A). The constant noise level amounts to approx. 40dB(A) (quietly
environment).
•Based on the local environment, there is a possibility of a higher noise pressure level. This can
cause noise deafness. In this case, the employees must be wearing protection devices (e.g.
hearing protection, Oro-pax etc.).
Safety advices for transportation
•By transportation, secure all moving parts from the machine against loosening.
•The machine must be protected against damages from transportation. If necessary, the machine
has to be packed in completely.
•By transportation, the machine must be always secured with inspected tension belts and other
tensioning mean, to avoid injuries and damages on employees and machine.
•To leveling up the machine with lifting equipment, the respective safety regulations must be
observed. There is a risk of an accident by non-observance! MINELLI Corp will not be rendered
liable for damages which evolve from improper machine levelling and handling.

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Copyright ©
The exclusive copyright of this instruction manual remains in the hands of the MINELLI Corporation (MIRA).
This instruction manual is appointed to the operator and the corresponding employees.
Minelli Corporation
MIRA Division
Mattenstrasse 3
8330 Pfäffikon ZH
Switzerland
For the provided technical documentation see the authorised person in chapter „Declaration of conformity“
on page 10.

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Non-liability
The HM-2000 EVO workstation mayonly be operated according tothe instruction manual. Themanufacturer
refuses to accept any liability for accidents and damages caused by incorrect operation and non-designated
use. He also refuses any liability for alienated use of the machine.
Warranty
In case of manufacturing or material defects Minelli Corporation will replace the defective part or parts at no
charge within 12 months after the date of final purchase. No further claims can be covered under the
warranty. Defective parts must be returned along with proof of purchase. Warranty does not cover any
subsequent damage caused by these defective parts. Warranty does not cover non-designated handling, the
use of incorrect electronic parts or deliberate damage, nor does it cover shipping and packing costs.

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Declaration of conformity

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HM-2000 EVO
The HM-2000 EVO contains the newly constructed clamping system AV-2000 EVO and represents the all
new generation of MIRA headmaster workstations. The state of the art developed Vario Drive and Multivac
units are modularly integrated in the headmaster workstation and can be easily retrofitted into the system
afterwards.
Positioning
To establish the HM-2000 EVO, it is necessary to
provide a clean and bright working base with a
power supply. About 1,7 x 1,3m should be
provided as a platform as well as at least 2,0m
ceiling height. The floor loading for the HM-2000
EVO amounts to 320kg (706lbs).
Levelling
The HM-2000 EVO has to be established
absolutely steadfast and firmly to guarantee an
appropriate and solid handling. Thus, the four
mounting feet can be levelled individually with an
open-end wrench (size 24) by rotating cw or ccw
to the required level. The levelling range amounts
to 70mm in overall.
There can be used a spirit level, laid alongside to
the clamping plate, for an exact and even levelling
of the workstation. The four mounting feet can be
secured with the lock nut as soon as the levelling
is completed.
Power network
9.1 220-240VAC / 50-60Hz
This is the standardised power network for
operation in the following countries: Switzerland,
EU, UK, Africa, Russia, Australia, Asia and
parts of Latin America.
=> The Vario Drive andMultivac can beconnected
directly to the pre-installed multiple socket and
therefore to the local 230VAC power network.
9.2 100-125VAC / 50-60Hz
For operation in the following countries: USA, Japan,
Central America und parts of Latin America, the use of
an external voltage transformer is required. The voltage
transformer provides the required 220-240VAC / 50-60Hz
electricity from the local 100-125VAC power network.
=> The voltage transformer will be connected to the
multiple socket. On the output of the voltage transformer,
the Vario Drive and Multivac can be directly operated with
230VAC. The voltage transformer will be delivered as an
additional device. See also chapter 12.11.
Fig. 1 - Levelling of the HM-2000 EVO

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Fig. 2 - Type plate HM-2000 EVO
Connections and type plate
The pre-installed multiple socket is located on the rear side of the HM-2000 EVO. The VGX-21 valve seat
refacing unit can be connected alongside with the Vario Drive and Multivac unit to the multiple socket. For
operation in a 110VAC power network, an external voltage transformer will be connected to the multiple
socket. This ensures that the Vario Drive and Multivac are operated with the required 230VAC power
network. Up to 8 devices can be connected to the multiple socket. The type plate is located on the rear side
of the HM-2000 EVO on the right corner. => Manipulation and removing of the type plate are not allowed.
The original specifications on the type plate (serial-no., fabrication-no. and technical specifics) must be in
readable condition if service repairs and warranty is required.
Available variations:
*8xSwiss type, 230V 50Hz
*with 10A thermal fuse
8xSchuko, 230V 50Hz
8xUSA Nema 5-15, 110V 60Hz
Cable bushing
for Vario Drive
and Multivac
Type plate with
technical
specifics and
serial-no.,
fabrication-no.
of the HM-2000
EVO

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Machine parts
11.1 Front view
Vario Drive unit
Tool holder
(optional)
Tooling tray
Clamping
system
AV-2000 EVO
Hose retraction
for vacuum
testing unit
Revolving
handle
AV-2000 EVO
Clamping lever
AV-2000 EVO
Mounting foot
with levelling
Shelf
Clamping lever
AV-2000 EVO
Drawer
(retractable)
Front-panel
Vario Drive
controls
Multivac unit
Board sheet
with service
access
Tooling plug for
Vario Drive
EMERGENCY
STOP
Vario Drive

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11.2 Rear view
Vario Drive
assembly
Mounting angle
for Vario Drive
assembly
Including rubber
stops (4x)
Multiple socket
Type plate
HM-2000 EVO
Cable bushing
for Vario Drive
and Multivac

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11.3 AV-2000 EVO
Main spindle for
elevation of the
clamping plate
Pressure- and
inclining spindle
Lateral guides
Linear roll
bearing
Ball bearing
trapezoidal
spindle
Trapezspindel
Clamping plate
Supporting
guides
Adjusting collar
Carrying
profiles,
moveable
Adjustable stop
Star grip for
securing the
clamping plate

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Fig. 5 - Vario Drive controls
Fig. 4 - Vario Drive hand grip with switch-key button
Fig. 3 - Multivac controls
11.4 Controls Multivac and Vario Drive
EMERGENCY
STOP
Vario Drive
ON-OFF
Vario Drive
Switch key
button
Rotation speed
control (RPM)
Vacuum
indication
Vacuum setting
ON-OFF
Vacuum pump
Flexible shaft
Hand grip
Vario Drive
Driving pin to
VGX-21 device

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Installation of the equipment
The installation of the equipment can be divided into mounting of the Vario Drive and Multivac. The VGX-
21 unit is not fixly integrated in the HM-2000 EVO and therefore must be connected as an external device
to the multiple socket of the workstation.
The multiple socket provides, including Multivac and Vario Drive connection, up to 6 connections for external
devices and additional equipment.
Pay attention! The use of an external voltage transformer is required if the installed Vario
Drive and Multivac are operated in a 110VAC power network!
12.1 Vario Drive
The Vario Drive assembly will be mounted on the rear side
of the HM-2000 EVO. The assembly will be provided in a
separate transport packagin (inside of the HM-2000 EVO
handling case). The separate Vario Drive assembly
packaging includes the following:
1x Drive assembly with motor and frequency transformer
1x Mounting angle with fastening material
4x Rubber stops
4x Inhex screw
4x Nordlock lock washer
ATTENTION!
It is necessary to carry out this setup work
with 2 persons. Risk of an accident and severe
material damage by incorrect handling!
The Vario Drive assembly will be delivered pre-installed with the mounting angle and four rubber stops. The
pre-installed assembly can be mounted corresponding to the figure above. It can be secured with the 4
inhex screws / 4 Nordlock lock washer from the inside of the rear sheet panel.
Fig. 6 - Installation of the Vario Drive assembly

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12.2 Connecting the Vario Drive and Multivac
No.1 => Power cable with C13 coupling to Vario Drive assembly
No.2 => Potentiometer cable female to Vario Drive assembly
No.3 => Multivac power cable 230VAC
No.4 => Vario Drive control box power cable 230VAC
No.5 => Cable bushing
The two connection leads for the Vario
Drive assembly are pre-installed above the
multiple socket and can be connected
directly. The potentiometer cable (M12
socket) can be connected to the central
supply line (M12 plug) of the Vario Drive
assembly. The power cable (C13 coupling)
can be connected to the lowermost supply
line (C14 coupling) of the Vario Drive
assembly.
ATTENTION!
The Vario Drive and Multivac units must be
connected in a de-energised mode. Isolate
the workstation from the power network and
secure it against unintended re-powering!
12.3 Electrical earthing
The earthing assembly is pre-installed on the frequency
transformer of the Vario Drive assembly. After mounting the
Vario Drive assembly, the earthing must be secured against
the rear sheet panel of the HM-2000 EVO.
=> installation by the customer.
The earthing can be mounted corresponding to
the figure beside. It can be attached on the rear
sheet panel of the HM-2000 EVO with the
provided mounting material. Secure the earthing
from the inside of the rear sheet panel with a hex
nut and a lock washer.
Fig. 9 - Earthing of the Vario Drive assembly
Fig. 8 - Connection of the Vario Drive assembly
No.2 - Connection
potentiometer cable
with screw coupling
male
Cable for handgrip
(internal wiring)
No.1 - Connection
power cable with
C14 coupling
Fig. 7 - Fixly provided multiple socket with power cables
2
1
3
4
5

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Fig. 10 - Vario Drive control box
12.4 Control Box Vario Drive
The associated control box for operating the Vario Drive unit
is firmly mounted inside the front panel of the HM-2000 EVO
and ready for use. The power supply for the Vario Drive will
be provided through the pre-installed multiple socket of the
HM-2000 EVO workstation. Otherwise, through the external
voltage transformer if operating in a 110VAC power network.
ATTENTION!
The pre-wired control box should not be
removed from the front panel and therefore
should not be opened. The front panel, board
sheet and the wiring should not be removed
unless there is the need of replacing a fuse!
12.5 Fuse Control Box Vario Drive
The Vario Drive control box is secured with two 6,3A fuses on the power supply side. In case of replacing
the fuses, please follow the steps below:
ATTENTION!
The Vario Drive and Multivac units must be connected in a de-energised mode! Isolate the
workstation from the power network and secure it against unintended re-powering!
1. Remove the 6 pan head screws as
well as the board sheet carefully.
2. Remove the outer pan head screws
and pull out the front panel with the
Vario Drive control box.
3. Remove the power cable on the left
side completely.
4. Draw-out the fuse bin and replace
the respective fuses. (max. 2pcs).
Order-No: 1ESI6300
(Range of use 110-230VAC 50-60Hz)
Afterwards, the Vario Drive control box
can be installed again and the board
sheet can be fixed with the respective
pan head screws. Connect the HM-2000
EVO workstation to the power network
and launch it for operational use.
3
4
2
1
Power cable to
multiple socket
Fig. 11 - Power supply and fuse location of the Vario Drive control box
Table of contents