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JESS WELDING E4-2800 PULS RMT Operating Manual

Inverter welding power source for mig/mag - processe
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Operating manual
Inverter Welding Power Source
for MIG/MAG - Processes
E4 – 2800/4200/5200 PULS RMT
M4 – 3000/4000/5500 RMT
Cooling Unit K4

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Summary of Contents for JESS WELDING E4-2800 PULS RMT

  • Page 1 Operating manual Inverter Welding Power Source for MIG/MAG - Processes E4 – 2800/4200/5200 PULS RMT M4 – 3000/4000/5500 RMT Cooling Unit K4...
  • Page 2 Recommendation: Please keep this operating instruction manual easily accessible for all welders and service staff. Read the brochure carefully and follow exactly the instructions given in order to prevent any malfunctions and operating errors. In the PDF version of this manual, hyperlinks for easy navigation through the document are included.

  • Page 3: Table Of Contents

    INTRODUCTION ......................3 Preface........................3 Product description ....................3 ESS Service network ....................3 SAFETY INSTRUCTIONS ....................4 General Information....................4 Transport ......................... 4 Installing and environmental conditions ..............4 Personal protection ....................4 Elektromagnetic Compatibility (EMC) ..............6 MAINTENANCE ......................8 TECHNICAL DATA ....................... 10 Technical Data Welding Power Source ..............10 Technical data cooling unit K4 ................12 Technical data undercarriage FW 4 ................12...
  • Page 4 Power Pulse ......................44 RMT- procedure .....................45 MMA - welding .......................46 PARAMETER LISTS ..................... 47 List of special characteristics – User template ............47 Job list - User template ...................48 10 PROBLEMS DURING OPERATION................50 10.1 General .......................50 10.2 List of error messages ..................51 10.3 List of Warnings ....................52 11 CIRCUIT DIAGRAMS AND LEGENDS .................

  • Page 5: Introduction

    INTRODUCTION Preface You have chosen a quality product of Jäckle & Ess System GmbH. Thank you for your trust! For more than 50 years, Jäckle & Ess units are characterized by a high quality standard and reliability. Long service life, even under the harshest conditions, is standard for all Jäckle & Ess products.

  • Page 6: Safety Instructions

    SAFETY INSTRUCTIONS 2.1 General Information The welding machine is constructed according to EN 60974-1. The unit may involve dangers, however, unless It is operated by qualified or at least trained personnel • It is used in accordance with the “intended purpose“ •...
  • Page 7 Smoke and gases Harmful metallic powder and smoke are released during welding. Ensure sufficient supply of fresh air and adequate ventilation. Never use oxygen for the ventilation of rooms. The following metals and alloys or workpieces that are coated with them require a suction device during welding: beryllium, lead, chrome, graphite, cadmium, mercury or zinc.

  • Page 8: Elektromagnetic Compatibility (Emc)

    Repairs and modifications may only be carried out by authorized, trained specialist • personnel. Welding units may only be used if all covers are present and correctly installed. • • Before moving the machine, pull out the mains plug. Do not operate with portable welding units while putting them around the shoulders with the carrying strap.
  • Page 9 Procedure to reduce emissions Mains supply: • Installation of additional mains filters, screening of mains supply lead. • Housing: All cover plates must be completely assembled. Welding cables: • Should be as short as possible and should run close together on or near to the floor.

  • Page 10: Maintenance

    MAINTENANCE Warning! Dangers of electricity! Before any work is carried out inside the power source, the machine must be switched off and the mains plug disconnected. After disconnecting the mains plug, wait at least three minutes, until the capacitors have discharged and reached safe values! Regular maintenance of the machine is essential for safe and trouble free operation.
  • Page 11 Periodic inspection according to EN 60974-4 This regulation does not lay down test intervals since this mainly depends on the degree of utilisation and the mechanical stress (such as use on construction sites). According to Test / activities Recommendation EN 60974-4 Depending of the degree Test interval of utilisation, at least...

  • Page 12: Technical Data

    TECHNICAL DATA Technical Data Welding Power Source Type: E4-2800 / M4-3000 Input: Line voltage 3/PE AC 400 V Nominal frequency 50 – 60 Hz Tolerance line input -20 % / + 25 % Primary current max / effective 16 / 11 A Input constant power 11 kVA Mains fuse protection, slow...
  • Page 13 Type: E4-4200 / M4-4000 E4–5200 / M4-5500 Input: Line voltage 3/PE AC 400 V 3/PE AC 400 V Nominal frequency 50 – 60 Hz 50 – 60 Hz Tolerance line input -20 % / + 25 % -20 % / + 25 % Primary current max / effective 25 / 16 A 38 / 31 A...

  • Page 14: Technical Data Cooling Unit K4

    Technical data cooling unit K4 Cooling unit Line voltage 3/PE AC 400 V Nominal frequency 50 Hz Mains fuse protection 16 A Max. cooling capacity 800 W Max. pressure 4,0 bar Type of protection IP 23 Type of cooling Dimensions L x W x H 700 x 350 x 240 mm Weight 24 kg...

  • Page 15: Machine Description

    MACHINE DESCRIPTION Front view Fig. 5-1 Pos. Description Torch cooling Central connector for the welding torch CAN-connector for remote control / welding torch Control panel welding power source 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 13...

  • Page 16: Rear View

    Rear view Pos. Description Fig. 5-2 Power ON / OFF Key gas test Shield gas connection G ¼“ Bracket for gas cylinder with straps to secure Workpiece connection minus pole Plus pole connection Fill opening for coolant Button for water pump test / filling Power supply Page 14 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500...

  • Page 17: Wire Feed Unit

    Wire feed unit Pos. Description Mandrel for wire coil with brake and safety catch Clamping lever for contact pressure of wire feed rollers Pushbutton for wire inching Fig. 5-3 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 15...

  • Page 18: Connection For Push-Pull Welding Torch And For Potentiometer-Control (Option)

    Connection for Push-Pull welding torch and for potentiometer-control (Option) Pos. Description Connector socket Fig. 5-4 Connection via flange socket with the following assignment: Negative connection (left stop) for both potentiometers Bridge to „C“ for detection „potentiometers available“ + 24V, supplied internally. Do not apply voltage! Torch key to +24V = „C“, optional Poti 1 = ‚Energy’, center tap.

  • Page 19: Operating Elements For Machine Control

    OPERATING ELEMENTS FOR MACHINE CONTROL 6.1 Operating concept Jäckle & Ess MIG/MAG Inverter welding power sources can be operated with different operating concepts: Operation via welding unit (front panel FLKC (UNO) • Operation by remote control with all functions / sub-functions •...

  • Page 20: Control Panel Version Uno - Overview

    Control panel version UNO – Overview Compact control unit – also available as a remote control Fig. 6-1 Section Description Selection of welding procedure Selection of characteristic curves for pulsed arc, RMT and short arc Display for special characteristics / system failure messages Control panel „Comfort“...

  • Page 21: Control Panel - Details

    Control panel – details 6.3.1 Selection of welding process Section selection welding process TIG welding (optional) MMA welding (electrode) Pulsed welding Synergic – normal welding (one-knob operation) Normal welding (voltage + wire feed speed) Select button for welding method By a short pressure on the key the Status-LED jumps one step up. Non-existing methods are skipped.
  • Page 22 Section - Selection of filler material and inert gas Selection of filler material and inert gas are summarized to reasonable welding standard combinations. - Detail Descr. Range of material Spec. Characteristics for MSG-brazing, RMT, HC MAG Special characteristics for specific applications When selecting Spec, additional parameters are indicated on the display in section...
  • Page 23 Section Display for special characteristics / System failure messages Text display for special characteristics When selecting Spec in section (selection of filler material) Text display the display is active. Special characteristics can be selected with the keys . Fig. 6-6 Display for System failure messages Existing system errors are indicated on the display.
  • Page 24 6.3.3 Selection of advanced parameters, Job administration Section Frontpanel „UNO“ for selection of advanced parameters and for Job administration Selection of special characteristics press short : job selection press long : store job Text display Scroll up Job list Scroll down Job list Press long : Activation of editing mode...
  • Page 25 Description of advanced parameters: Fig. 6-9 LED Function Unit Pre-gas time Preflow of welding gas before start of welding in order to avoid shortage of shielding gas at welding start and to facilitate safe ignition. Wire creep-in speed % of factory setting Reduced speed of the wire electrode until the initial contact with the workpiece, in order to facilitate ignition.
  • Page 26 Job administration Parameters and settings for frequently used welding tasks can be stored in a Job. The following parameters and settings are stored in a Job: Welding process • • Characteristics Operating mode • Advanced parameters • Current values of energy –...
  • Page 27 Select a Job Briefly press the key (U) ➔ Display is active. • Use the keys (U) and (D) to select a Job. Only stored Jobs are displayed. • The selected Job is immediately active, the welding process can be started. •...
  • Page 28 6.3.4 Selection of operating modes 2-cycle / 4-cycle Section - Operating modes Descr. Function Special 4-cycle 4-cycle 2-cycle LED is lit 2-cycle - spot Fig. 6-11 LED flashes A „cycle“ is one of the following actions: • Press torch trigger •...
  • Page 29 4 – cycle For welding longer seams. The torch trigger can be released during welding. The sequence of cycles is specified by pre-set times in the welding process control. ➔ Time controlled processes cycle Press torch trigger 1. Shield gas flows fort he pre-set time (5) - (a) Arc ignites with pre-set creep-in speed (5) -(b)
  • Page 30 2-cycle spot (2-cycle LED flashes) Welding with an adjustable time interval t cycle Press and hold the torch trigger 1. Shield gas flows for the pre-set time (5) - (a) 2. Arc ignites with pre-set creep-in speed (5) - (b) 3.
  • Page 31 Special 4 – cycle For welding longer seams. The torch trigger can be released during welding. The sequence of cycles is defined by the welder. You can switch between the pre-set values of energy E1, E2, E3 by briefly tapping the torch trigger. ➔...
  • Page 32 6.3.5 Adjustment of wire feed speed / energy Section Adjustment of wire feed speed / energy Display for: • Welding current [A] Plate thickness [mm] • • Wire feed speed [mmin] Current „Hold-value “ • Rotary pushbutton for pre-set values: Rotational function: Selection of wire feed speed / energy •...
  • Page 33 6.3.6 Adjustment of voltage / arc length correction Section Adjustment of voltage / arc length correction Display for: Voltage value [V] Arc length correction [%] • • Choke adjustment [%] Pulse dynamics [%] 2cycle - spot • Time [sec] „Hold-value“ voltage •...

  • Page 34: Potentiometer Control (Option)

    Potentiometer control (Option) There are many applications where power setting of the welding unit and / or correction is set by potentiometer. These potentiometers specify an absolute value which is valid over the entire system and can only be changed from that single point. This application is not compatible with the current operating philosophy of the E2 / E4 range, where we work with encoders and thus have the opportunity to intervene from different locations on the settings of the machine.

  • Page 35: Commissioning

    COMMISSIONING General Instructions Caution! Electrical hazards! Carefully read the Safety Instructions prior to first commissioning. All welding leads and cables may only be connected when the power source is switched off! Utilisation for intended purposes only The welding machine is intended to be used exclusively for MIG/MAG – welding, MIG - brazing, TIG-welding and MMA.

  • Page 36: Cooling Of The Machine - Cooling Set K4

    Cooling of the machine – Cooling set K4 The cooling unit is factory-filled with approx. 2 l of coolant EFS 15. Top up the water container with coolant via the fill opening on the rear of the device (Pos. 11, Fig. 5-2).

  • Page 37: Equipment For Mig/Mag Welding And Mig Brazing

    Equipment for MIG/MAG welding and MIG brazing 7.6.1 Connection of the welding torch Prepare the welding torch according to the desired scope of application, insert it into the central torch connector (Pos. 2, Fig. 5-1) and tighten it. Connect the welding torch hoses of watercooled welding torches to the plug-in connectors (Pos.
  • Page 38 7.6.4 Insert / replace wire spool Mount the wire spool onto the spool holder (Pos. 14, Fig. 5-3). The driving pin should • seat firmly in the spool bore. Secure the wire spool with the safety cap (pressing together the flat surfaces) •...
  • Page 39 7.6.5 Changing the wire feed rollers Clamping lever for contact pressure Pressure rollers Fig. 7-2 Fig. 7-3 Knurled screws for cover plate Wire feed rollers Open clamping lever for contact pressure (Pos. 15, Fig. 5-3) • • Loosen the knurled screws of the cover plate •...
  • Page 40 Remedy with wire feed problems: • Use appropriate wire feed rollers Ensure for correct adjustment of contact pressure of the wire feed rollers • Check welding torch hoses for damage • • Check welding torch core for appropriate diameter • Check welding torch core for contamination / or if it can only be moved too hard Check spool brake...

  • Page 41: Welding Procedures

    WELDING PROCEDURES Possible processes E4-2800 Pulsed welding + Synergic welding + Normal welding The following welding processes are practicable with the welding power source: • Metal Inert Gas (MIG) Pulsed Synergic • Metal Active Gas (MAG) Pulsed Synergic Metal Inert Gas brazing (MIG brazing) Pulsed Synergic •...
  • Page 42 Conventional MIG/MAG-process (short arc, transitional arc, spray arc) Depending on the power in use, there will be different kinds of material transition with conventional MIG/MAG welding, which are classified by their arc length. The short arc is generated in the lower power range. It is characterized by a relatively low energy input. Short arc is especially suitable for welding thin sheet and for root-pass welding.

  • Page 43: Mig/Mag - Normal Welding And Brazing

    MIG/MAG - normal welding and brazing Two-knob operation Wire feed speed and voltage must be adjusted separately. 1. Commissioning of the device (see Chapter 2. Starting the device with the power switch (Pos. 5, Fig. 5-2) Section Selection of welding process Select „Norm“...

  • Page 44: Mig/Mag Synergic - Normal Welding And Brazing

    MIG/MAG Synergic – Normal welding and brazing One-knob operation A voltage value is associated to the wire feed speed via a so-called synergy table. 1. Commissioning of the device (see chapter 2. Starting the device with the power switch (Pos. 5, Abb. 5.2) Section Selection of welding process Select „Syn“...

  • Page 45: Pulsed Welding And Brazing (Only E4-2800/4200/5200)

    Pulsed welding and brazing (only E4-2800/4200/5200) One-knob operation The pulse welding values are associated to the wire feed speed via a so-called synergy table. 1. Commissioning of the device (see chapter 2. Starting the device with the power switch (Pos.5, Fig. 5.2) Section Selection of welding process Select „Pulsed“...

  • Page 46: Power Pulse

    Power Pulse The Power Pulse process switches alternately between two energy levels. Power Pulse can be selected both in MIG/MAG – Synergic normal welding –pulsed welding. 1. Adjustment of the device in accordance with chapter 2. Selection of Power Pulse section function In factory setting, the device now switches between two energy levels...

  • Page 47: Rmt- Procedure

    RMT- procedure The RMT method is used to increase weld penetration in welding mode MIG/MAG Synergic – normal welding. Adjustment of the device in accordance with chapter 1. Selection of RMT Enabling the special characteristics: see section Select “Spez”. Display section lights.

  • Page 48: Mma - Welding

    MMA - welding 1. Commissioning of the device (see chapter The plus pole connecter is located on the backside of the power source (Pos.10, Fig. 5-2) Connection of electrode holder and workpiece lead in accordance with the required polarity on the connectors Pluspole: Pos.10, Fig.5-2 Minus pole:...

  • Page 49: Parameter Lists

    PARAMETER LISTS List of special characteristics – User template Material Wire Ø Inert gas Procedure Remarks [mm] 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 47...

  • Page 50: Job List - User Template

    Job list - User template Job – No. Date Remarks Page 48 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 04/2014...
  • Page 51 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 49...

  • Page 52: Problems During Operation

    PROBLEMS DURING OPERATION 10.1 General All equipmet is subject to strict final inspections. However, should there be any problem, the device has to be checked according to the following instructions. In case the problem can not be solved, please contact your authorized dealer. A distinction is made between errors and warnings: Errors If errors occur, the welding process is stopped immediately.

  • Page 53: List Of Error Messages

    10.2 List of error messages Error codes on the display (section Number Status report Description Remedy Error 1 ESS-CAN not ok Fault in general CAN Notify service Error 2 DSP-CAN not ok Fault in inverter - CAN Notify service Error 3 Overtemperature Overtemperature of inverter After cooling;...

  • Page 54: List Of Warnings

    10.3 List of Warnings Warnings on the text display (section Number Display Description Remedy Check cooling system, Warning 1 Overtemperature Overtemperatur warning longer weld break Regulation of welding current Reduce the welding current Warning 2 Overcurrent protection active (reduced pulses) Reset message:press the torch button (arc on) Check coolant level,...

  • Page 55: Circuit Diagrams And Legends

    CIRCUIT DIAGRAMS AND LEGENDS 11.1 Circuit diagram E4–2800/4200/5200, M4-3000/4000/5500 Circuit diagram E4 – 2800/4200/5200, M4-3000/4000/5500 – part 1 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 53...
  • Page 56 Circuit diagram E4 – 2800/4200/5200, M4-3000/4000/5500 – part 2 Page 54 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 04/2014...
  • Page 57 Circuit diagram E4 – 2800/4200/5200, M4-3000/4000/5500 – part 3 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 55...
  • Page 58 Circuit diagram E4 – 2800/4200/5200, M4-3000/4000/5500 – part 4 Page 56 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 04/2014...
  • Page 59 Circuit diagram E4 – 2800/4200/5200, M4-3000/4000/5500 – part 5 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 57...
  • Page 60 Circuit diagram E4 – 2800/4200/5200 M4-3000/4000/5500 – part 6 Page 58 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 04/2014...
  • Page 61 Circuit diagram E4 – 2800/4200/5200, M4-3000/4000/5500 – part 7 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 59...

  • Page 62: Legend To Circuit Diagram E4-2800/4200/5200, M4-3000/4000/5500 - Part 1

    11.2 Legend to circuit diagram E4–2800/4200/5200, M4-3000/4000/5500 - part 1 Page 60 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 04/2014...
  • Page 63 Legend E4 – 2800/4200/5200, M4-3000/4000/5500 – part 2 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 61...

  • Page 64: Circuit Diagram Cooling Set K4

    11.3 Circuit diagram cooling set K4 Page 62 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 04/2014...

  • Page 65: Legend To Circuit Diagram Cooling Set K4

    11.4 Legend to circuit diagram cooling set K4 04/2014 Operating Manual E4-2800/4200/5200 / M4-3000/4000/5500 Page 63...

  • Page 66: Spare Parts List E4 - 2800/4200/5200, M4-3000/4000/5500, Cooling Set K4

    SPARE PARTS LIST E4 – 2800/4200/5200, M4-3000/4000/5500, COOLING SET K4 Spare parts may be obtained on request from our after-sales service or from our authorized dealers. Description Art.-No. Sticker E4-2800 231562 Sticker E4-4200 231570 Sticker E4-5200 231571 Sticker M4-3000 231580 Sticker M4-4000 231581 Sticker M4-5500...
  • Page 67 Description Art.-No. Patch cable S/STP-PiMF Cat.6, gn, 1 m 330693 Toroidal control transformer 861402 Coil mandrel with safety catch 890706 Pushbutton 5000.0101, grey 930551 Seivel castor (steel plate) 760402 Solid rubber wheel – J with Star lock caps ST-KA 20 590018 + 660370 Tank lid 290055...

  • Page 68: Remote Control Rc Multi

    Remote Control RC Multi 13.1 Technical data remote control RC Multi Type: RC Multi Operating voltage 24 V DC Dimensions L x W x H 225 x 142 x 74 mm Weight 1,5 kg According to EN 60 974-1 13.2 Description front view Remote control RC Multi Pos.

  • Page 69: Remote Control Rc Multi - Overview

    13.3 Remote control RC Multi - overview Control panel RC Multi Section Description With procedure Norm / Synergic / Pulse: Adhustment of wire feed speed & energy With selection of PowerPuls function in addition: Adjustment of arc length correction energy 1 & time t1 With selection of special characteristic HC MAG in addition:...

  • Page 70: Energy Value

    13.4 Energy value Display for: Welding current [A] • • Plate thickness [mm] • Wire feed speed [mmin] Welding current „Hold-value “ • Rotary pushbutton for pre-set values: Rotational function: • Selection of wire feed speed / energy Push function for changing display (press for 3 sec) •...

  • Page 71: Correction Value

    13.5 Correction value Display for: • Voltage value [V] Arc length correction [%] • Choke adjustment [%] Pulse dynamics [%] Time 2-cycle - spot [sec] • Hold-value“ voltage • Rotary pushbutton for default values Turning functions: • Selection voltage value / arc length correction •...

  • Page 72: Job - Functions

    13.6 Job - functions Scroll up Job list Scroll down Job list Select a Job • Briefly press the key (U) ➔ Display is active. • Use the keys (U) and (D) to select a Job. Only stored Jobs are displayed. The selected Job is immediately active, the welding process can be started.

  • Page 73: Hc Mag Functions

    13.8 HC MAG functions 13.8.1 Adjustment of poling Change poling by pressing the key „HC“: DC+ Plus pole on welding torch , minus pole on the workpiece Continuous light DC- Minus pole on the welding torch, plus pole on the workpiece Flashing HC MAG procedure (AC) The change to poling DC- and AC is only possible if:...
  • Page 74 13.8.3 Adjustment of HC MAG – value type of poling DC+ and DC- has been selected, the following functions are active on the rotary pushbutton (V): By turning the rotary pushbutton (V), a voltage value [V] / arc length correction [%] can be selected.

  • Page 75: Abbreviations

    ABBREVIATIONS < Less than page > Greater than als Second Ampere Inert gas Figure Silicon Aluminium Spray arc Argon Wrench size in mm Description Synergic normal welding Torch trigger Table ÜLB Data Bus Transition arc UNO Operating concept: Carbon dioxide One control panel Cr-Ni Chrome nickel...

This manual is also suitable for:

E4-4200 puls rmtE4-5200 puls rmtM4-3000 rmtM4-4000 rmtM4-5500 rmt

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