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JESS WELDING E4-4200 PULS RMT User Manual

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76 pages
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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

Table of Contents

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JESS WELDING E4-4200 PULS RMT Specifications

General IconGeneral
BrandJESS WELDING
ModelE4-4200 PULS RMT
CategoryWelding System
LanguageEnglish

Summary

Introduction to Welding Power Sources

Manual Preface and Purpose

Brief introduction to the manual and its purpose.

Product Overview

Overview of the MIG/MAG pulse inverter welding power source features.

Service and Support Network

Information on the company's after-sales service and support availability.

Safety Instructions and Precautions

General Safety Information

General safety rules and operational guidelines for the welding machine.

Safe Handling During Transport

Instructions and precautions for safely transporting the welding unit.

Installation and Environmental Guidelines

Guidelines for proper installation and environmental considerations for operation.

Personal Protective Equipment

Essential personal protective equipment and measures during welding operations.

Electromagnetic Compatibility (EMC)

Information regarding the device's compliance with EMC directives and potential interference.

Machine Maintenance Procedures

Wearing Parts Maintenance

Procedures for regular maintenance of components subject to wear and tear.

Daily Operational Checks

Daily inspection routines to ensure the machine's operational readiness and safety.

Electrical Safety Testing

Guidelines for periodic inspections and testing of electrical safety standards.

Periodic Inspection Standards

Technical Specifications

Welding Power Source Data

Detailed technical specifications for the welding power source unit.

Cooling Unit K4 Specifications

Technical specifications for the K4 cooling unit.

Undercarriage FW 4 Specifications

Technical specifications for the FW 4 undercarriage.

Machine Components and Description

Front Panel View

Identification and description of components visible on the front panel.

Rear Panel View

Identification and description of components visible on the rear panel.

Wire Feed Unit Details

Description and components of the wire feed unit for welding wire.

Torch and Control Connections

Details on connecting welding torches and optional remote controls.

Machine Control Elements Overview

Operating Concepts

Overview of the different operating methods for the welding unit.

UNO Control Panel Layout

Detailed overview of the UNO control panel layout and functions.

Control Panel Detailed Functions

Detailed breakdown of control panel functions and selections.

Filler Material and Gas Selection

Information on selecting filler materials and inert gases for standard welding combinations.

Characteristic and Failure Message Display

How the display shows special characteristics or system failure messages.

System Failure LED Indicators

Explanation of system failure indicators using LEDs and their meanings.

Advanced Parameters and Job Administration

Guide to selecting advanced parameters and managing welding jobs.

Job Management Functions

Detailed functions for managing, editing, copying, and deleting welding jobs.

Operating Modes: 2-cycle / 4-cycle

Instructions for selecting and using 2-cycle, 4-cycle, and special operating modes.

Wire Feed Speed and Energy Adjustment

How to adjust wire feed speed and energy parameters using the control panel.

Voltage and Arc Length Correction

How to adjust voltage and arc length correction parameters via the control panel.

Optional Potentiometer Control

Information on using optional potentiometer controls for power setting and correction.

Commissioning and Setup Procedures

Initial Commissioning Instructions

Important safety and initial setup instructions before commissioning the device.

Intended Use Clarification

Clarification of the machine's intended use and limitations.

Installation Requirements

Requirements for secure installation, accessibility, and environmental protection.

Mains Power Connection

Instructions for connecting the welding machine to the mains power supply.

Cooling Unit K4 Setup

Procedures for filling and maintaining the K4 cooling unit with coolant.

Equipment Setup for Welding

Steps for connecting torches, workpiece, and gas supply for welding.

Wire Spool Insertion and Replacement

Procedures for mounting and replacing the welding wire spool.

Wire Feed Roller Replacement

Guidance on selecting and changing wire feed rollers based on wire material and diameter.

Welding Procedures and Methods

Supported Welding Processes

List of welding processes supported by the machine, including MIG, MAG, MMA, etc.

Description of Welding Methods

Explanations of different welding methods like conventional MIG/MAG, pulsed, brazing, and MMA.

MIG/MAG Normal Welding and Brazing

Step-by-step guide for performing normal MIG/MAG welding and brazing.

Synergic MIG/MAG Welding

Instructions for using the synergic mode for easier welding parameter selection.

Pulsed Welding and Brazing

Guide for performing pulsed welding and brazing operations with the E4-2800/4200/5200 models.

Power Pulse Process

Explanation of the Power Pulse process, alternating between two energy levels for enhanced welding.

RMT Welding Procedure

Description of the RMT method for increased weld penetration in Synergic MIG/MAG welding.

MMA Welding Guide

Instructions for performing Manual Metal Arc (MMA) welding with the machine.

Parameter Lists and Job Management

Special Characteristics User Template

A template for listing and saving special welding characteristics and parameters.

Job List User Template

A template for listing and managing saved welding jobs and their parameters.

Troubleshooting and Error Handling

General Troubleshooting Advice

General troubleshooting advice and distinction between errors and warnings.

System Failure LED Indicators

Explanation of system failure indicators shown by LEDs on the control panel.

Accessing Error Memory

Procedure to access and scroll through the error memory displayed on the unit.

List of Error Messages

Comprehensive list of error codes, their status reports, descriptions, and remedies.

List of Warning Messages

List of warning messages, their descriptions, and recommended actions to resolve them.

Circuit Diagrams and Legends

Main Power Source Circuit Diagram

Electrical circuit diagrams for the main welding power source units.

Power Source Circuit Diagram Legend (Part 1)

Legend and description of components used in the main power source circuit diagrams.

Cooling Set K4 Circuit Diagram

Electrical circuit diagram for the K4 water cooling unit.

Cooling Set K4 Circuit Diagram Legend

Legend and description of components used in the cooling unit K4 circuit diagram.

Spare Parts List

Remote Control RC Multi Operation

RC Multi Technical Data

Technical specifications for the RC Multi remote control unit.

RC Multi Front View Description

Identification of connectors and controls on the front view of the RC Multi.

RC Multi Control Panel Overview

Overview of the RC Multi control panel, buttons, and their functions.

RC Multi Energy Value Adjustment

How to adjust and display energy values using the RC Multi control.

RC Multi Correction Value Adjustment

How to adjust voltage, arc length correction, and choke settings with the RC Multi.

RC Multi Job Functions

Functions for selecting, managing, and exiting welding jobs using the RC Multi.

RC Multi Power Pulse Functions

Explanation of Power Pulse functions and parameter adjustments via the RC Multi.

RC Multi HC MAG Functions

Explanation of HC MAG functions and parameter adjustments via the RC Multi.

RC Multi HC MAG Value Adjustment

How to select HC MAG values for heat and penetration control using the RC Multi.

Abbreviations

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