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Kemppi X5 FastMig Series, Operating Manual

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Kemppi X5 FastMig Series Operating Manual Download Page 28

X5 FastMig

Operating manual - EN

2.3 Installing equipment on cart (optional)

The X5 FastMig has two transport unit options: a 4-wheel cart with gas bottle rack and a 2-wheel cart without gas bottle
rack. The X5 FastMig equipment can be installed on the cart with or without the cooling unit.

For more information on the connection interface and installing the power source on top of the cooling unit, refer to
"Installing cooling unit (optional)" on page 25.

The equipment installation principle and the bottom securing interface is the same with both carts. Only the top cart
connection bracket installation is different.

Tools needed:

1.

Install the cooling unit on the cart.

© Kemppi

28

1920960 / 2144

Summary of Contents for X5 FastMig Series

Page 1: ...X5 FastMig Operating manual EN X5 FastMig Kemppi 1 1920960 2144...

Page 2: ...tional 28 2 4 Installing wire feeder with fixed plate 31 2 5 Installing wire feeder with standard rotating plate 34 2 6 Installing wire feeder with lockable rotating plate 37 2 7 Installing cables 40...

Page 3: ...ing welding programs 92 3 4 Additional guidance to functions and features 94 3 4 1 Trigger logic functions 94 3 4 2 WiseFusion 94 3 4 3 WisePenetration 95 3 4 4 WiseSteel 95 3 4 5 WeldEye with DCM opt...

Page 4: ...00 500 X5 FastMig Manual 500 X5 FastMig Manual 500 X5 FastMig Synergic 500 X5 FastMig is designed to be used together with Kemppi s Flexlite GX MIG welding guns X5 FastMig can be used also for MMA wel...

Page 5: ...fort has been made to ensure that the information contained in this guide is accurate and com plete no liability can be accepted for any errors or omissions Kemppi reserves the right to change the spe...

Page 6: ...7 TFT LCD control panel Auto Includes automatic 1 MIG process that supports welding programs and Wise features Maximum wire spool diameter 300 mm X5 Wire Feeder 300 Auto Comes with 2 knob 5 7 TFT LCD...

Page 7: ...uperSnake GTX subfeeder refer to Kemppi Userdoc Optional accessories 4 wheel cart with gas bottle rack 2 wheel cart Remote control HR40 2 knob control Remote control HR43 1 knob control Accessory rack...

Page 8: ...switched off or during welding The LED blinks green when the MMA or Gouging power save mode is on the power save mode is automatically applied after 15 minutes of idling VRD is in use with MMA and Go...

Page 9: ...olant liquid is obstructed a thermal cutoff switches the welding system off Check and fix the error before using the welding system again Rear 1 Power switch 2 Control cable connector 3 Control cable...

Page 10: ...ly from the handle with slings e g for moving is allowed 1 Control panel For more information on the X5 Wire Feeder 200 Manual control panel refer to Manual control panel X5 FP 200R on page 13 2 Euro...

Page 11: ...ge 19 and Installing cables on page 40 Wire feeder fixing accessories X5 Wire Feeder 200 can be equipped with a steel pipe frame for additional protection and installation options When the steel pipe...

Page 12: ...re feed mechanism X5 Wire Feeder 200 wire feed mechanism 1 Drive rolls and drive roll mounting caps 2 Middle guide tube locking clip 3 Middle guide tube 4 Inlet guide tube 5 Pressure handles 6 Pressur...

Page 13: ...1 3 3 Manual control panel X5 FP 200R This section describes the controls and features of the X5 Wire Feeder 200 Manual control panel membrane panel 1 Left control knob 2 Right control knob 3 Trigger...

Page 14: ...e wire feeder top cover closed during welding to reduce the risk of injury or an electric shock Keep the top cover closed also at other times to keep the inside of the wire feeder clean The handle is...

Page 15: ...inch button Drive the filler wire forward with arc off 5 Gas test button Test the shielding gas flow and flush the gas line Inside wire feeder interconnection cable cabinet 1 Interconnection cable cab...

Page 16: ...locking mechanism for one wire feeder Rotating plate with locking mechanism for one wire feeder Double rotating plate with two locking mechanisms for two wire feeders Rotating plate with counter balan...

Page 17: ...lls and pressure roll mounting pins 7 Pressure roll locking arms 8 Outlet guide tube For replacing the wire feed rolls refer to Installing and replacing feed rolls on page 59 For replacing the wire gu...

Page 18: ...trol panel on page 74 1 4 4 Auto control panel X5 FP 300 This section describes the controls and features of the X5 Wire Feeder 300 Auto control panel TFT LCD 1 Left control knob with push button func...

Page 19: ...able 4 Coolant hose outlet inlet color coded 5 Coolant hose outlet inlet color coded 6 Strain relief collar at the power source end 7 Strain relief block at the wire weeder end Without water cooling P...

Page 20: ...ol snap water gas DIX current X57030MW 70 mm2 30 m Water cooled 10 pin control snap water gas DIX current X57002MG 70 mm2 2 m Gas cooled 10 pin control snap water gas DIX current X57005MG 70 mm2 5 m G...

Page 21: ...erace for locking to the power source 6 Cooling liquid circulation button Keeping the button pressed activates the pump and circulates the cooling liquid throughout the system Once released the pump s...

Page 22: ...tower water cooler at the bottom power source in the middle and wire feeder at the top always install and secure the equipment onto a Kemppi cart compatible with X5 FastMig or secure the equipment to...

Page 23: ...cuit power of public low voltage system at the point of common coupling is higher than 5 8 MVA this equipment is compliant with IEC 61000 3 11 2017 and IEC 61000 3 12 2011 and can be connected to publ...

Page 24: ...phase plug according to the X5 FastMig power source and site requirements Refer also to Technical data on page 112 for power source specific technical information The mains cable includes the followi...

Page 25: ...nnector cover in the rear of the power source 2 Route the cooling unit s connection cables so that they remain accessible through the next steps 3 Lift the power source on top of the cooling unit so t...

Page 26: ...X5 FastMig Operating manual EN 4 Fix the units together with two screws M5x12 in the front and two screws M5x12 in the rear 5 Connect the cooling unit cables Kemppi 26 1920960 2144...

Page 27: ...X5 FastMig Operating manual EN Do not use force but make sure the connectors are properly connected 6 Replace the small connector cover Kemppi 27 1920960 2144...

Page 28: ...n the cart with or without the cooling unit For more information on the connection interface and installing the power source on top of the cooling unit refer to Installing cooling unit optional on pag...

Page 29: ...4 wheel cart Secure the equipment to the cart with the rear connection bracket rear fixing plate long Rear screws M8x16 top screws M6x30 5 2 wheel cart Secure the equipment to the cart with the two si...

Page 30: ...manual EN For more information on fixing plates and wire feeders refer to Installing wire feeder with fixed plate on the next page For lifting the equipment refer to Lifting X5 equipment on page 99 Ke...

Page 31: ...of the power source For stacked installation additional support is required Read the installation notes here Installation on page 22 Tools needed 1 Temporarily remove the power source top cover screws...

Page 32: ...king mechanism Depending on your X5 FastMig setup two different rear fixing plate options are available Both include an interface for the interconnection cable strain relief mechanism but the longer o...

Page 33: ...Operating manual EN 5 Ensure that also the front of the wire feeder is locked in position to the front fixing plate edge The rear locking is released by pulling the locking mechanism lever Kemppi 33 1...

Page 34: ...notes here Installation on page 22 and Other optional accessories on page 68 Tools needed 1 Temporarily remove the power source top cover screws 2 Place the wire feeder rotating plate on top of the po...

Page 35: ...xing plate using the power source top cover screws M6x30 Tip To gain access to the fixing holes in the lower plate turn the top plate 4 Slide the wire feeder from front to back until the bar in the ba...

Page 36: ...erating manual EN 5 Ensure that the front of the unit has also locked in position to the front edge of the rotating plate The rear locking is released by pulling the locking mechanism lever Kemppi 36...

Page 37: ...ked installation additional support is required Read the installation notes here Installation on page 22 and Other optional accessories on page 68 Tools needed 1 Temporarily remove the power source to...

Page 38: ...Tip To gain access to the fixing holes in the lower plate and to turn the rotating plate pull the release lever under the front edge of the wire feeder rotating plate and turn the top plate 4 Slide t...

Page 39: ...erating manual EN 5 Ensure that the front of the unit has also locked in position to the front edge of the rotating plate The rear locking is released by pulling the locking mechanism lever Kemppi 39...

Page 40: ...he welding current cable as much as you can by hand If the welding current cable connection is loose it may overheat 3 Push the shielding gas hose 1 to the shielding gas hose connector so that it lock...

Page 41: ...eeder 300 Place the cable s strain relief block to the slot on the wire feeder and secure it in place by closing and locking the strain relief latch Check the expanding locking knob tightness and tigh...

Page 42: ...door When connecting the cables to the wire feeder route the cables neatly so that the cable cabinet door closes properly The interconnection cable heats up during welding The wire feeder s cable cab...

Page 43: ...g gas hose 4 to the gas bottle 5 Connect the earth return cable to the minus connector 5 on the power source 6 If you have the optional cooling unit connect the cooling liquid hoses 6 The hoses are co...

Page 44: ...X5 FastMig Operating manual EN 1 2 Kemppi 44 1920960 2144...

Page 45: ...uid hoses to the wire feeder The hoses are color coded 3 Install and load the filler wire as described in Installing and changing wire X5 WF 300 on page 53 and Installing and changing wire X5 WF 200 o...

Page 46: ...X5 FastMig Operating manual EN 2 Attach the gun holder to the pistol grip handle holder with screws You can adjust the angle of the gun holder before tightening the screws Kemppi 46 1920960 2144...

Page 47: ...tings on page 75 Remote control HR43 HR40 1 Connect the remote control cable to the wire feeder s control cable connector 2 To adjust the remote control parameters refer to the control panel settings...

Page 48: ...r also to Installing and replacing feed rolls on page 59 To remove the wire spool 1 Open the wire feeder side hatch 2 Release the hub s lock and push the wire spool locking clips towards the center 3...

Page 49: ...e spool brake by turning the screw with Allen key in the center of the hub locking mechanism To install the filler wire 1 Release the filler wire end from the spool and cut off any deformed section so...

Page 50: ...r 3 Release the pressure arms to move the feed rolls apart 4 Guide the filler wire through the inlet tube a and middle wire guide tube b and into the outlet tube c which feeds the filler wire to the w...

Page 51: ...to the feed rolls Adjust the pressure of the feed rolls according to the table below Filler wire Feed roll profile Filler wire diameter mm Adjustment x100N Fe Ss solid V groove 0 8 1 0 1 5 2 0 1 2 2...

Page 52: ...button is located in the control panel Watch out for the wire when it reaches the contact tip and exits the gun 9 Before welding ensure that the welding parameters and settings on the control panel co...

Page 53: ...spool remove the remaining filler wire from the welding gun and wire feed mechanism before removing the wire spool Always ensure that the feed rolls are suitable for the filler wire diameter and mate...

Page 54: ...wire spool brake halves to the new wire spool by pushing them together inside the wire spool Secure them together by turning the tightening knob in the brake center Attach the spool brake hub to the...

Page 55: ...ler wire end from the spool and cut off any deformed section so that the end is straight Ensure that the filler wire does not spill from the spool when it is released 2 File the tip of the filler wire...

Page 56: ...outlet tube c which feeds the filler wire to the welding gun 5 Push the filler wire by hand into the gun so that the wire reaches the wire liner approx 20 cm 6 Close the pressure arms so that the fill...

Page 57: ...oove 0 8 1 0 1 5 2 0 1 2 2 0 2 5 Metal and flux cored V groove knurled 1 2 1 0 2 0 Self shielded gasless V groove knurled 1 6 2 0 3 0 Aluminum U groove 1 0 0 5 1 0 1 2 1 0 1 5 1 4 1 5 2 0 1 6 2 0 2 5...

Page 58: ...the welding parameters and settings on the control panel conform to your welding setup Refer to Using X5 Manual control panel on page 74 and Using X5 Auto control panel on page 80 for more information...

Page 59: ...5 Wire Feeder 300 Model spe cific variations in the visual appearance and positioning may occur Replace the feed rolls when the material and diameter of the filler wire changes Proceed as follows 1 Op...

Page 60: ...e rolls mounting pins have central axles attached to them whereas the drive rolls central axles act as drive shafts attached directly to the wire feed mechanism motor 5 Remove the pressure rolls 6 Pul...

Page 61: ...urled 1 0 W001057 W001058 1 2 W001059 W001060 1 4 1 6 W001061 W001062 2 0 W001063 W001064 2 4 W001065 W001066 Al Fc Mc Ss Fe Cu U groove 1 0 W001067 W001068 1 2 W001069 W001070 1 4 W008974 W008975 1 6...

Page 62: ...the cut on the drive rolls bottom with the pin on the drive shaft 9 Reattach the mounting caps and mounting pins to lock the drive and pressure rolls into their places 10 Close the locking arms and l...

Page 63: ...he wire guide tubes 1 Release the pressure arms and remove the filler wire from the system 2 Pull out the inlet guide tube a and insert a new one in its place 3 Turn the locking clip aside to free the...

Page 64: ...P011442 1 4 SP007297 SP007277 SP016609 1 6 SP007298 SP007278 SP016610 2 0 SP007299 SP007279 SP016611 2 4 SP007300 SP007280 SP016612 Fe Mc Fc 0 6 SP007293 SP007273 SP016613 0 8 0 9 SP007536 SP007274 SP...

Page 65: ...e wire feeder before installing and testing the gas bottle Do not use the whole contents of the bottle Always use an approved and tested regulator and flow meter Contact your local Kemppi dealer for c...

Page 66: ...200 Manual the Gas test button is located in the control panel 7 Press the Gas test button again to adjust the gas flow Use either the built in rotameter or an external flow meter and regulator for me...

Page 67: ...ms and Wise features can also be added later on For more information on the available X5 FastMig welding program options and installing the welding programs as well as software updates contact your lo...

Page 68: ...lways use the broader front roller support plate delivered with the equipment This applies to the 4 wheel cart Read also the installation notes here Installation on page 22 Wire drum kit for X5 WF 300...

Page 69: ...WF 300 The wire feeder counterbalance arm reduces the weight of the cable bundle over the working area Double wire feeder rotating plate for X5 WF 300 The double wire feeder rotating plate allows the...

Page 70: ...F 300 The wire feeder cart allows more convenient wire feeder movement on site Accessory rack The accessory rack holds the small parts and tools needed for welding Install it on the side of the weldin...

Page 71: ...d when welding and the cables must be handled with caution if the cabinet door is opened right after welding Check that there is enough space for cooling air circulation in the machine vicinity If the...

Page 72: ...e cooler refer to Filling cooler and circulating coolant below To weld you must pump the coolant through the system by pressing the coolant circulation button in the front panel of the cooling unit Co...

Page 73: ...g the built in cable calibration function without additional measurement cable This calibration function is available only in MIG operation mode 1 Connect the earth return cable between the power sour...

Page 74: ...ment In Gouging mode Current adjustment 2 Right control knob In MIG mode Welding voltage adjustment In MIG mode push button Switch between welding voltage and dynamics adjustment In MMA mode Dynamics...

Page 75: ...between 2T and 4T trigger logic modes 4 Welding process operation mode selection Switches between MIG MMA and Gouging modes 5 Home button Switches to the default welding view mode 6 Weld data button S...

Page 76: ...the arc has extin guished This ensures that the hot weld does not come into contact with air after the arc is extinguished protecting the weld and also the electrode Used for all metals Especially sta...

Page 77: ...nnected this selection is not available Water cooler OFF Auto ON Default OFF Wire retract OFF ON This is an automatic wire retract feature Once the arc is extinguished the wire is retracted for additi...

Page 78: ...listed here are common system settings Parameter Parameter value Description Weld data Min Max 0 10 s step 1 0 OFF Default 5 s This defines how long the weld data sum mary is shown after each weld Di...

Page 79: ...mobile device Error log Shows error code date time and short description of the error Info Displays the serial numbers of the wire feeder and the power source connected Software version Displays the s...

Page 80: ...The automatic 1 MIG process is available along with the Kemppi welding programs and Wise features optional For more information on welding programs and Wise features refer to How to get welding progr...

Page 81: ...ol knob 2 Confirm view change by pressing the control knob 2 Views 7 A Home view B Channels view C Welding parameters view D Weld history view E Device settings view F Info view After each weld a weld...

Page 82: ...panel Memory channels The memory channel view can be accessed either via the panel s view selection or by pressing the physical memory channel shortcut button above the display refer to Using X5 Auto...

Page 83: ...anel Applying welding programs on page 92 Create all Create new channels based on all of the unused welding programs available in MIG mode only Delete all Delete all channels The skewed channel number...

Page 84: ...culation by pressing the control knob button 3 3 4 Auto control panel Welding parameters The Welding parameters view includes a start and stop curve for adjusting the most essential parameters for a w...

Page 85: ...nels on page 82 for more information Welding parameters and feature descriptions MIG and 1 MIG welding parameters The parameters listed here are available for adjustment with the MIG and 1 MIG process...

Page 86: ...r to the 1 MIG parameter table Crater fill time 0 0 10 0 s step 0 1 Default 1 0 s Crater fill wire feed speed 0 5 25 0 m min step 0 05 or 0 1 Default 5 m min Crater fill voltage 450A 10 45 V 500A 10 5...

Page 87: ...at the end of the welding job so that the crater can be filled using a lower power level With 1 MIG process Crater fill start level duration and end level are preset by the user Crater fill start leve...

Page 88: ...her the arc Hot start level MMA 30 30 Default 0 Welding function that uses higher or lower wire feed speed and welding cur rent at the start of the weld After the Hot start period the current changes...

Page 89: ...data view After each weld a weld summary is displayed briefly To change the weld data view duration or how the weld data aver ages are calculated with or without slope phases refer to Auto control pa...

Page 90: ...channels 10 TIG channels 10 MMA channels and 10 gouging channels The memory channel and system settings are saved automatically for the logged in user Settings Parameter Parameter value Description Us...

Page 91: ...l safety The user can change the wire retract delay and length settings Note Wire retract function is disabled if a subfeeder is connected Retract delay 2 10 s step 1 Default 5 s Retract length 1 10 c...

Page 92: ...the welding program that is in accordance with your welding setup e g welding wire and gas properties The use of additional welding programs and Wise features is possible with the X5 FastMig Synergic...

Page 93: ...Select the memory channel slot for saving and confirm Once ready you can continue to the Welding parameters view to adjust the welding settings for the new channel create a new channel or go back to...

Page 94: ...ith X5 Wire Feeder 300 Auto and 300 Auto you can select the trigger logic in the Welding parameters view 2T In 2T pressing the trigger ignites the arc Releasing the trigger switches the arc off 4T In...

Page 95: ...nto use go to the control panel s Welding parameters view and apply the WisePen etration feature To adjust the welding current while welding in the control panel s Home view turn the left control knob...

Page 96: ...ints and speeds up the work The pulsing is not noticeable to the welder The shape and control of the current are close to the conventional spray arc welding For more information on Wise products visit...

Page 97: ...udes quality verification functionalities with digital WPS and qualification compliance control against auto matically collected digital welding data Welding management Includes document register func...

Page 98: ...control panel s two control knobs In the manual MIG mode the adjustments on the remote control as well as the minimum and maximum values for the adjusted parameters can be set in the control panel se...

Page 99: ...quipment is installed securely on a dedicated transport unit DO NOT attempt to lift the equipment with a hoist from the handle If a gas bottle is installed on cart DO NOT attempt to lift the cart with...

Page 100: ...X5 FastMig Operating manual EN 2 wheel cart 1 Ensure that the welding equipment is properly secured to the cart 2 Connect the hoist hook to the lifting handle on the cart Kemppi 100 1920960 2144...

Page 101: ...nd planning routine maintenance consider the operating frequency of the welding system and the working environment Correct operating of the welding machine and regular maintenance helps you avoid unne...

Page 102: ...em Check that all covers and components are intact Check all the cables and connectors Do not use them if they are damaged and contact service for replacements Check the wire feeder s feed rolls and t...

Page 103: ...unit at least every six months Clean oxidized parts and tighten loose connectors Where applicable use the correct tension torque when fastening loose parts Clean the outside parts of the unit from du...

Page 104: ...dure are Cleanup of the machine Maintenance of the welding tools Checkup of the connectors and switches Checkup of all electric connections Checkup of the power source mains cable and plug Repair of d...

Page 105: ...cool down Check that none of the cables is loose The wire feeder may have overheated Wait for it to cool down and see that the welding current cable is properly attached The power source may have ove...

Page 106: ...ow compressed air through the wire liner to check that it is not blocked Check that the wire liner is correct for the selected wire size and type Check the welding gun contact tip s size type and wear...

Page 107: ...r source If problem persists contact Kemppi service 12 Welding cable failure Plus and minus cables are connected together Check the connections of welding cable and earth return cable 13 IGBT overcurr...

Page 108: ...Faulty sensor or wiring in wire feeder Restart the welding system If problem persists con tact Kemppi service 50 Welding pro gram error Required welding program is not installed Contact Kemppi servic...

Page 109: ...directly onto the power source air intake Using the optional air filter decreases the rated power levels of the power source as follows output 40 C 60 45 and 100 100 20A This is due to the slightly r...

Page 110: ...g Operating manual EN Cleansing 1 Remove the air filter from the power source by releasing the clips on the edge of the air filter casing 2 Blow the air filter clean with compressed air Kemppi 110 192...

Page 111: ...nic equipment and their implementation in accordance with national law electrical equipment that has reached the end of its life must be collected separately and taken to an appropriate environmentall...

Page 112: ...refer to X5 power sources on the next page For X5 wire feeder technical data refer to X5 wire feeders on page 117 For X5 cooling unit technical data refer to X5 cooling unit on page 120 Additional in...

Page 113: ...oad voltage U0 52 67 V Open circuit voltage Uav 52 67 V Fuse Slow 25 A Output at 40 C 60 400 A 100 350 A Welding current and voltage range MIG 15 A 12 V 400 A 42 V MMA 15 A 10 V 400 A 42 V TIG 15 A 1...

Page 114: ...astMig Operating manual EN Voltage supply for cooling unit 380 460 V 24 V Recommended minimum generator power Sgen 25 kVA Wired communication type CAN bus Standards IEC 60974 1 10 Kemppi 114 1920960 2...

Page 115: ...voltage Uav 59 75 V Fuse Slow 32 A Output at 40 C 60 500 A 100 430 A Welding current and voltage range MIG 15 A 10 V 500 A 47 V MMA 15 A 10 V 500 A 47 V TIG 15 A 1 V 500 A 47 V Maximum welding voltag...

Page 116: ...X5 FastMig Operating manual EN Recommended minimum generator power Sgen 35 kVA Wired communication type CAN bus Standards IEC 60974 1 10 Kemppi 116 1920960 2144...

Page 117: ...feed speed 0 5 25 m min Maximum wire spool weight 5 kg Maximum wire spool diameter 200 mm Maximum shielding gas pressure 0 5 MPa Operating temperature range 20 40 C Storage temperature range 40 60 C E...

Page 118: ...kage external dimensions L x W x H 730 x 300 x 520 mm Weight 10 9 kg Wireless communication type Auto Auto wire feeder only 2 4 GHz Bluetooth Bluetooth version Auto Auto wire feeder only 4 0 BT40DM Tr...

Page 119: ...OLED Rating 12 V DC 100 mA Host device power output to control panel shall not exceed 15W X5 Wire Feeder 300 Auto control panel X5 Wire Feeder 300 Auto control panel Feature Value Model X5 Feeder Pane...

Page 120: ...r 1 l min 1 1 kW Recommended coolant MGP 4456 Kemppi mixture Maximum coolant pressure 0 4 MPa Tank volume 4 l Operating temperature range With recommended coolant 10 40 C Storage temperature range 40...

Page 121: ...X5 FastMig Operating manual EN 5 4 X5 ordering info For X5 FastMig ordering information and optional accessories refer to Kemppi com Kemppi 121 1920960 2144...

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