Kemppi X8 MIG Operating Manual Download

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X8 MIG WELDER

2.3 Installation

2.3.6 Welding gun installation

2.3.6.1 Preparing and connecting welding gun

X8 MIG Gun has been preassembled by the manufacturer: the wire liner, contact tip and gas nozzle are

premounted. To start using the gun, proceed as follows:

Check that the wire liner, contact tip and gas nozzle are suitable for the job. Change if needed. If your

setup includes a gas-cooled gun, you can also change the neck.

Attach the pistol grip handle, if suitable for the job.

Attach X8 Gun Remote Control, if suitable for the job (optional accessory).

Connect the welding gun to the wire feeder: Push the welding gun connector into the wire feeder gun

adapter, and hand-tighten the collar.

OPERATING MANUAL | EN

KEMPPI | 2018-09-28

Summary of Contents for X8 MIG

Page 1: ...X8 MIG Welder OPERATING MANUAL...

Page 2: ...tware 79 2 3 9 Optional accessories 79 2 4 Operation 84 2 4 1 X8 MIG Welder control devices 84 2 4 2 Preparing welding system for use 101 2 4 3 How to use welding system 110 2 5 Troubleshooting 166 2...

Page 3: ...iii 2 8 Ordering codes 190 2 9 Disposal of unit 193...

Page 4: ...f particular importance Caution Caution text here Describes a situation that may result in damage to the equipment or system Warning Warning text here Describes a potentially dangerous situation that...

Page 5: ...IG WELDER 1 1 Symbols Symbol Description Coolant output Gas input Gas output High voltage Protective earth 1 MIG DPulse MIG 8 Carbon arc gouging MIG 5 MMA Pulse MIG OPERATING MANUAL EN 5 KEMPPI 2018 0...

Page 6: ...ols Symbol Description DProcess WiseRoot WiseThin WiseFusion E WiseSteel WisePenetration P Creep Start S Hot Start R Upslope T Crater Fill with Downslope U Crater Fill with Downlevel OPERATING MANUAL...

Page 7: ...X8 MIG WELDER 1 1 Symbols Symbol Description 2T 4T W WP Switch Touch Sense Ignition O User manual OPERATING MANUAL EN 7 KEMPPI 2018 09 28...

Page 8: ...ification of the product described at any time without prior notice Do not copy record reproduce or transmit the contents of this guide without prior permission from Kemppi 2 1 System introduction X8...

Page 9: ...nd managing various information about your X8 MIG Welder Provides manufacturer s validation certificate 9 WeldEye optional Cloud based service for creating and managing digital WPS documents and other...

Page 10: ...ging industries and welding related tasks Welding procedures Includes the digital library and management of pWPS WPQR and WPS templates according to the most important welding standards Personnel and...

Page 11: ...art of the connections between the different parts of X8 MIG Welder 2 2 1 X8 Power Source This section describes the structure of X8 Power Source Front 5 7 1 6 4 2 3 1 Indicator panel 2 Transportation...

Page 12: ...ant circulation button Press to pump the coolant through the system Rear 6 2 3 3 2 4 4 8 5 5 9 7 10 1 11 12 1 Transportation handle 2 Welding current cable connectors positive pole 3 Earth return cabl...

Page 13: ...odes only 3 Overheat indicator The LED is yellow when the unit is overheating Caution If the power source overheats a thermal cutoff switches the unit off and does not allow it to be used until it has...

Page 14: ...e welding system again If the error was caused in an unsuccessful filling of the cooler refill the cooler In other cases the error disappears automatically in 30 seconds 8 Wireless pairing button To p...

Page 15: ...e risk of injury or an electric shock Keep the top cover closed also at other times to keep the wire feeder insides clean 2 Handle Caution The handle is only intended for short distance manual carryin...

Page 16: ...ture 15 12 13 14 10 11 Figure 2 The warning sticker inside the wire feeder 10 Wire spool 11 Wire spool locking cover 12 Feed rolls 13 Pressure handle 14 Wire guide 15 Inside control buttons OPERATING...

Page 17: ...e main control of the welding system you can also use the wire feeder control panel or the welding gun remote control 5 6 2 1 4 3 5 6 2 1 4 3 The wire feeder control panel parts are 1 Locking button P...

Page 18: ...trol panel see Wire feeder views on page 96 Control buttons on the inside The wire feeder has control buttons inside the wire cabinet 1 Wire retract button Drive the filler wire backward with arc off...

Page 19: ...es see Cables installation on page 50 External component connectors 1 Kemppi Gun Adapter Connects to the welding gun Note The wire feeder is supplied with Kemppi Gun Adapter 2 Subfeeder Provides contr...

Page 20: ...ip 4 Contact tip adapter 5 Neck 6 Neck tightener 7 Work light Press the trigger lightly to switch on the light 8 Handle cover plate Covers the handle if the remote control is not used 9 Trigger 10 X8...

Page 21: ...k light Press the trigger lightly to switch on the light 7 Handle cover plate Covers the handle if the remote control is not used 8 Trigger 9 X8 Gun Remote Control The remote control is an optional ac...

Page 22: ...2 Left control knob 3 Right control knob 4 Left and right button When the button lights up green you can press the button to confirm an action 5 Display 6 View buttons 7 Channel button The button ligh...

Page 23: ...OFF button for NFC and barcode readers The button also acts as a shortcut button for reading a barcode in any Control Pad view 13 Loop for the carrying strap 14 Hook When you connect or disconnect the...

Page 24: ...2 2 System structure When Control Pad is charging green leds on the left side of the display indicate ongoing charging The lowest led turns red when the charge level is low OPERATING MANUAL EN 24 KEMP...

Page 25: ...ructions carefully and follow them closely 2 3 1 Before installation Make sure to acknowledge and follow the local and national requirements on installation and the use of high voltage units Before in...

Page 26: ...80 460V Unit amperage Cable type Fuse rating Cable type Fuse rating 400 A 6 mm 2 25 A 500 A 6 mm 2 32 A 16 mm 2 63 A 600 A 6 mm 2 35 A 16 mm 2 63 A 2 3 2 Power Source installation For power source cab...

Page 27: ...1 onto the axle 4 Slide the two wheels 2 onto the axle 5 Slide the two washers 3 onto the axle 6 Slide the two retaining rings 4 on the axle until they lock into the groove on the axle 1 2 3 4 Install...

Page 28: ...mbly and align the holes in the wheel assembly with the ends of the axle 9 Attach the front wheel assembly to the end of the axle with a bolt 1 and washer 2 from both sides 2 1 Max 20 Nm 10 When the w...

Page 29: ...Cooler 1 Remove the packaging from the sides but leave the power source resting on the pallet 2 Attach a wheel set to the front of the unit To have turning wheels in the front and the back install th...

Page 30: ...tallation 4 Attach the wheel set of the gas cylinder cart to the axle with a bolt 1 and washers 2 3 4 from both sides 4 3 2 1 5 Insert cover plugs to the open ends of the wheel set OPERATING MANUAL EN...

Page 31: ...cylinder cart to the wheel set with two bolts 1 and washers 2 3 from both sides 8 Attach the bottom of the gas cylinder cart to the wheel set with six bolts 1 and washers 2 3 The gas cylinder cart bot...

Page 32: ...aps in the cart around the gas cylinder 2 3 2 3 Installing optional X8 Cooler If your setup does not include X8 Cooler you can skip these instructions Caution X8 Cooler must be installed by authorized...

Page 33: ...t panel 2 Front panel latch 3 Coolant circulation button 4 Cooler 5 Coolant container 6 Connectors for the liquid cooling unit Proceed as follows 1 Detach the two screws in the front panel of the powe...

Page 34: ...ation This chapter describes the wire feeder installation For wire feeder cable connections see Installing interconnection cable For information on operating the wire feeder see Wire feeder control pa...

Page 35: ...th the orange claw at the rear of the unit 2 Pull the release lever at the front of the wire feeder rotating plate and turn the top sideways to allow access to the bottom half 3 Attach the bottom of t...

Page 36: ...responding grooves on the wire feeder rotating plate 5 Slide the wire feeder from front to back until the bar in the back of the unit locks to the orange claw at the back of the wire feeder rotating p...

Page 37: ...the corresponding holes on the wire feeder upper cover hinge 2 Attach the welding gun holder to the mount with 2 screws 2 3 3 3 Replacing feed rolls Replace the feed rolls when the material and diamet...

Page 38: ...X8 MIG WELDER 2 3 Installation 2 Push the collars on the mounting pins of the feed rolls up to pull the mounting pins off OPERATING MANUAL EN 38 KEMPPI 2018 09 28...

Page 39: ...top while the pressure rolls mounting pins have no marks The pressure rolls mounting pins have central axles attached to them so the drive and pressure rolls mounting pins cannot be confused with eac...

Page 40: ...e feed rolls plastic Filler wire material Feed roll profile Filler wire diameter mm Feed roll identification Drive roll code Pressure roll code 0 6 W001045 W001046 0 8 0 9 W001047 W001048 1 0 W000675...

Page 41: ...1 W001052 2 0 W001053 W001054 2 4 W001055 W001056 1 0 W001057 W001058 1 2 W001059 W001060 1 4 1 6 W001061 W001062 2 0 W001063 W001064 Fc Mc Fe V groove knurled 2 4 W001065 W001066 1 0 W001067 W001068...

Page 42: ...W006084 W006085 Fc Mc Fe V groove knurled 2 0 W006086 W006087 1 0 W006088 W006089 1 2 W006090 W006091 Al Fc Mc Ss Fe U groove 1 6 See the text on the roll W006092 W006093 5 Place the feed rolls back t...

Page 43: ...ube A metal piece locks the middle wire guide tube in its place Turn the piece aside to free the middle wire guide tube for replacement Turn it back to lock down the new middle wire guide tube 2 3 3 5...

Page 44: ...the filler wire may cause damage to the wire liner if not filed 4 Press Wire retract to pull back the remaining filler wire from the welding gun 5 Push the wire spool locking cover aside 6 Lift the w...

Page 45: ...n short repeated welds and with heavy wire spools To enable wire tensioning attach the spool brake hub to the wire spool so that the tightening knob is on the right seen from the front 9 Lower the wir...

Page 46: ...wire guide tube B to the outlet which feeds the filler wire to the welding gun Push the filler wire by hand inside the gun so that the wire reaches the wire liner about 20 cm 15 Close the pressure arm...

Page 47: ...4 1 6 0 5 1 0 1 0 1 5 1 5 2 0 2 0 2 5 Caution Excessive pressure flattens the filler wire and may damage coated or cored filler wires Excessive pressure also unnecessarily wears the feed rolls and in...

Page 48: ...ow through the system properly 21 Close the top cover Wire spools X8 MIG Welder has three different wire spool hub options available for different wire spools A Standard spool B Spool hub for the smal...

Page 49: ...strain relief holder to the transportation handle at the rear of the power source Fasten the strain relief holder with a bolt from below 2 Take the power source end of the interconnection cable and in...

Page 50: ...hand side of the wire feeder For more information see 2 3 4 Cables installation For a detailed description of the power source and wire feeder cabling see Installing interconnection cable For a full...

Page 51: ...nt cable connection is loose it may overheat 3 Push the shielding gas hose towards the shielding gas hose connector base until it locks down 4 Attach the strain relief to the slot on the wire feeder 5...

Page 52: ...the slot 10 Close and lock the cable cabinet door Note When connecting the cables to the wire feeder route the cables neatly so that the cable cabinet door closes properly Connect the interconnection...

Page 53: ...e control cable to the control cable connector 3 on the same side as the measurement cable 15 If the water cooler is present use the red connector 5 for the hose that goes to the cooler 16 If the wate...

Page 54: ...Figure 3 Interconnection cabling for power source and wire feeder Table 3 Color codes Welding current cable Shielding gas hose Control cable Measurement cable Coolant input and output hoses OPERATING...

Page 55: ...e to connect to Control Pad can be connected to X8 Power Source in applications where no wire feeder is needed such as stick welding or gouging To set up a wired connection between Control Pad and the...

Page 56: ...ere are wire feeders connected to the welding system pressing the wireless pairing button allows you to connect Control Pad to a wire feeder When there are no wire feeders connected to the system Cont...

Page 57: ...f the wire feeder is far from the power source a Go to Settings Wireless devices Connect The wire feeder connects automatically to Control Pad 3 If the buttons of the power source and wire feeder are...

Page 58: ...eder The connector is marked with a Control Pad icon b Plug the combo cable to the combo cable port on the bottom of Control Pad Note Use mainly the external charger to charge Control Pad 2 3 5 3 Susp...

Page 59: ...that the wire liner contact tip and gas nozzle are suitable for the job Change if needed If your setup includes a gas cooled gun you can also change the neck 2 Attach the pistol grip handle if suitab...

Page 60: ...IG Guns are only compatible with X8 Wire Feeder 5 If your setup includes a water cooled gun connect the cooling hoses to the wire feeder The coolant inlet hose is marked with blue and the coolant outl...

Page 61: ...set of consumable parts The tables below list the consumable parts that are delivered with the welding gun To find other compatible parts for various materials use Kemppi s Consumable Kit Selector at...

Page 62: ...00 X8 MIG Gun 420 w 5 0 m X8300425000 Contact tip W012132 Contact tip adapter W011483 Gas nozzle W011478 Liner guide tube SP011868 X8 MIG Gun 420 w 3 5 m X8300423500 Wire liner W013628 X8 MIG Gun 420...

Page 63: ...an incorrect liner 1 Lay the welding gun cable straight on a flat surface 2 Loosen the neck tightener by rotating it half a turn and remove the neck 3 Remove the guide nut from the tip of the sleeve 4...

Page 64: ...allation 1 2 5 Load the new liner through the welding gun connector as far as it goes Check that you have pushed the liner far enough the liner must be visible at the tip of the gun OPERATING MANUAL E...

Page 65: ...e new liner over the liner protruding from the welding gun connector Tighten the sleeve as tight as possible with a spanner 1 2 3 7 Cut the excessive liner leaving 1 2 mm Use side cutting pliers for s...

Page 66: ...the sleeve 9 Re assemble the neck and tighten the neck tightener to secure Changing neck gas cooled gun You can change the neck without tools 1 Turn the neck tightener half a turn counter clockwise t...

Page 67: ...ush the neck deep enough When the neck is correctly inserted the groove on the neck is completely hidden under the neck tightener Note You can rotate the neck into different positions without loosenin...

Page 68: ...ser if needed Screw in and hand tighten the new adapter as tight as possible no tool is needed Make sure there is no gap between the contact tip adapter and the black plastic bushing Note It is import...

Page 69: ...ves on the contact tip remain visible when the contact tip is properly connected to the gun Changing wire liner water cooled gun Caution Use the correct wire liner The tip of the filler wire may damag...

Page 70: ...X8 MIG WELDER 2 3 Installation 2 Remove the guide nut from the tip of the sleeve 3 Remove the sleeve and pull out the liner together with the cone OPERATING MANUAL EN 70 KEMPPI 2018 09 28...

Page 71: ...g gun connector as far as it goes The liner should be just visible a couple of millimeters from the tip of the gun Note Make sure the liner is properly inside the contact tip adapter before you cut th...

Page 72: ...Installation 5 Assemble the cone 1 and sleeve 2 supplied with the liner over the liner protruding from the welding gun connector Tighten the sleeve with a spanner to secure 1 2 OPERATING MANUAL EN 72...

Page 73: ...allation 6 Cut the excessive liner leaving 1 2 mm Use side cutting pliers for spiral liner and carpet knife for DL Chili liner 1 2 mm 7 Attach the guide nut at the tip of the sleeve OPERATING MANUAL E...

Page 74: ...IG WELDER 2 3 Installation Changing gas nozzle water cooled gun Screw the gas nozzle into its place Changing contact tip water cooled gun 1 Remove the contact tip OPERATING MANUAL EN 74 KEMPPI 2018 09...

Page 75: ...ble no tool is needed Note It is important to tighten the adapter properly to enable a tight connection of the contact tip to the gun 3 Screw in a new contact tip and tighten it properly with a tool S...

Page 76: ...o attact the pistol grip handle align the grooves and pull the handle forward to attach the front side 1 and then push the handle back to snap lock it into its place 2 To detach the pistol grip handle...

Page 77: ...it forwards and lifting it up TORX 20 3 Remove the interface card that covers the connectors Note Store the interface card in case you want to remove the remote control later If you remove the remote...

Page 78: ...ews 2 3 7 Lifting X8 MIG Welder If you need to lift X8 MIG Welder pay special attention to the safety measures Follow the local regulations Warning Do not lift the welder with the gas cylinder Proceed...

Page 79: ...urchasing and managing welding software You can purchase Kemppi welding software licenses to X8 MIG Welder Installed licenses can be viewed with Control Pad For more information visit www kemppi com 2...

Page 80: ...facilitates welding where it is difficult to bring the full X8 MIG Welder welding system The hanger allows more fluent transitions in constricted spaces Caution Do not hang the wire feeder from the h...

Page 81: ...LDER 2 3 Installation Wire Feeder Counterbalance Arm The wire feeder counterbalance arm reduces the weight of the cable bundle over the working area Proceed as follows OPERATING MANUAL EN 81 KEMPPI 20...

Page 82: ...ce spring 4 Turn to adjust the damping of the up and down movement Wire Feeder Cabinet Heater The wire feeder cabinet heater prevents moisture from condensing inside the wire feeder cabinet so that th...

Page 83: ...sportation or storage Note This is an alternative accessory for the gas cylinder cart Both cannot be installed at the same time X8 Accessory Tray The accessory rack holds the small parts and tools nee...

Page 84: ...ol Pad Control Pad is a window to X8 MIG Welder Control Pad shows you all the settings and licenses installed in the welding system You can adjust the welding parameters and their values remotely with...

Page 85: ...o open an item If you need to perform a reversing action such as Cancel or Default press the green button to accept Header and footer Control Pad s header displays the serial number of the welding mac...

Page 86: ...he change comes into effect after pressing the green button the footer command is OK Control Pad views There are three main views on Control Pad display Channel memory channels Welding and Settings To...

Page 87: ...e first row shows the memory channel s name The second row shows the welding program s name which consists of the filler wire material and diameter and the shielding gas If you have modified the weldi...

Page 88: ...ine tune the secondary welding parameter with the right control knob The adjustable secondary parameter varies according to the welding process and function The welding power graph shows with grey ras...

Page 89: ...m Figure 15 The minimum and maximum stoppers The value range of the welding power and voltage graphs specified by the Welding Procedure Specification WPS are displayed with a green arc between the sto...

Page 90: ...age to a level outside the WPS range the parameter graph turns red and a warning symbol appears on the display Note If you have installed WeldEye it saves the data as unsuitable use even if the weldin...

Page 91: ...process in a welding program Settings features an additional menu DPulse For more information see Standard MIG welding processes in X8 MIG Welder on page 119 DProcess menu If the welding program incl...

Page 92: ...selection Select the sub feeder you are using and its length or the motorized gun 3 WF Motor warning level Select a limit for the welding current The system warns you if the value exceeds the limit 4...

Page 93: ...ding programs in Control Pad Select the mode in Settings Mode Then select one of the welding programs in Welding program The MMA and GOUGING modes have one welding program each and you can adjust thei...

Page 94: ...n the memory channels The memory channel displays the same information of the welding parameters as the Welding view To take a channel into use move the focus to it Each user has their own memory chan...

Page 95: ...ormation on the last welds 3 WPS For more information on WPSs see Using digital WPSs on page 137 4 Licenses Displays the licenses installed into the welding system 5 Error log Displays the error occur...

Page 96: ...hese buttons to change the view on the wire feeder s display Press the button again to return to the Welding view Use the knobs under the display to move focus in the display and to adjust the values...

Page 97: ...the Channel button on the left to see the Channel view A menu of the memory channels appears on the left side of the display To take a channel into use move focus to it with the right control knob A t...

Page 98: ...Hot start Switch the HotStart feature ON or OFF Crater fill Switch the crater fill feature ON or OFF Weld data Shows you the information on the latest weld Press the green button on the right knob to...

Page 99: ...remote control 1 Channel button 2 Arrow buttons 3 Adjustment roll The remote control has two views Channel view and Settings view Use the Channel button to move between the views Figure 23 Moving betw...

Page 100: ...adjust wire feed speed fine tuning and dynamics Use the arrow buttons to move between the parameters Use the adjustment roll to adjust the parameter value Figure 25 Parameters in the Settings view You...

Page 101: ...left unused for a longer period detach the mains plug to disconnect it from the mains Switching on Control Pad To switch on Control Pad press and hold the power button for a few seconds Preparing coo...

Page 102: ...circulation button after each time you change the welding gun For instructions on filling the cooler see Filling cooler Connecting earth return cable Warning Keep the welding piece bonded or connecte...

Page 103: ...d 2 4 2 1 Filling cooler Fill the cooler with 20 40 coolant solution for example Kemppi cooling liquid Proceed as follows 1 Pull the front panel latch and open the front panel of the power source 2 Un...

Page 104: ...X8 MIG WELDER 2 4 Operation 4 Screw the lid back on the cooler 5 Push to close the front panel of the power source OPERATING MANUAL EN 104 KEMPPI 2018 09 28...

Page 105: ...gun After calibration the power source calculates the arc voltage if the voltage sensing cable is not connected Figure 28 Calibration of the welding cables Proceed as follows 1 Ensure that the measure...

Page 106: ...peat steps 1 4 every time you change the length of the interconnection or earth return cable 2 4 2 3 Connecting to Kemppi cloud services To use the Kemppi cloud services connect the welding machine to...

Page 107: ...X8 MIG WELDER 2 4 Operation 2 Switch the WiFi on 3 Select the WLAN network OPERATING MANUAL EN 107 KEMPPI 2018 09 28...

Page 108: ...X8 MIG WELDER 2 4 Operation 4 Fill in the password if needed 5 Network details are shown in WiFi settings when the WLAN connection is created OPERATING MANUAL EN 108 KEMPPI 2018 09 28...

Page 109: ...e Ethernet cable to X8 MIG Welder The Ethernet connection details are shown in Ethernet settings when the connection is created Set DHCP to OFF to configure the Ethernet settings manually Cloud servic...

Page 110: ...s automatically adjust the welding machine settings 2 4 3 1 Using memory channels When you start using the X8 MIG Welder select the memory channel where the correct welding program with pre selected p...

Page 111: ...mote control on page 99 Saving modified memory channel settings Proceed as follows 1 To save modified settings in Control Pad or on the wire feeder display over the current settings of a memory channe...

Page 112: ...R 2 4 Operation d Scroll to the channel where to save the new settings e Press the green button The name of the memory channel changes to the name of the welding program OPERATING MANUAL EN 112 KEMPPI...

Page 113: ...ory channel always select an existing program as a basis for the modifications Proceed as follows 1 Go to Channels and select a memory channel where to start modifications 2 Press the green button to...

Page 114: ...ry channel for each of them before use Proceed as follows 1 Install the new welding programs as instructed The welding programs automatically transfer into the memory of the welding system Note You ca...

Page 115: ...tion Renaming channel Proceed as follows 1 Go to the Channel view 2 Press the green button to open Actions 3 Select Rename and press the green button Control Pad shows you a keypad OPERATING MANUAL EN...

Page 116: ...ion 4 Turn the knob to go to the eraser and press Erase character on the right knob to delete the former name 5 Turn the right knob and press the green button on it to select letters OPERATING MANUAL...

Page 117: ...elding programs are saved in the memory of the power source Welding programs and memory channels are managed through Control Pad For more information on saving welding programs see Saving new welding...

Page 118: ...see Using memory channels on page 110 Selecting a welding program through Settings view You can find the optimal welding program for the job at hand by using the search filters First select the weldin...

Page 119: ...y channel with a welding program that uses that process For more information see Channel view on page 94 The list of adjustable welding parameters in Settings Parameters varies according to the select...

Page 120: ...rc is more stable StartPower 30 30 Adjusts the power level for arc ignition 1 MIG 1 MIG is a synergic MIG MAG welding process when you adjust the wire feed speed the power source adjusts the voltage a...

Page 121: ...ter less spatter On the plus side the arc is harder the arc is more stable StartPower 30 30 Adjusts the power level for arc ignition StartLevel 30 30 Fine tunes the arc length for arc ignition StopPow...

Page 122: ...age and other parameters accordingly for example base current pulse current and frequency In addition you can adjust the following parameters through Settings Parameters Wire Feed Speed min adjusts th...

Page 123: ...hen using DPulse you can adjust the following parameters through Settings Parameters Wire Feed Speed adjusts the wire feed speed for level 1 min adjusts the minimum set value for wire feed speed max a...

Page 124: ...and various optimized welding programs Wise processes Kemppi s Wise products are welding processes and features designed to ease the user s work and increase the productivity by controlling the weldin...

Page 125: ...sed on suitable materials Wire Feed Speed 2 Define the wire feed speed for set 2 min Define the minimum set value for wire feed speed max Define the maximum set value for wire feed speed Fine tuning 2...

Page 126: ...m set value for wire feed speed max adjusts the maximum set value for wire feed speed Fine tuning adjusts the heat of the arc Dynamics 10 10 Adjusts the short circuit behavior On the minus side the ar...

Page 127: ...harder the arc is more stable StartPower 30 30 Adjusts the power level for arc ignition StartLevel 30 30 Finetunes the arc length for arc ignition StopPower 30 30 Adjusts the power level for arc stop...

Page 128: ...e of the current is similar to the traditional short arc welding When a short arc is used in vertical up welding where weaving motion is applied WiseSteel ensures good quality through adapting to the...

Page 129: ...ard MIG MAG welding changes in stick out length cause welding current to fluctuate WisePenetration maintains constant welding current by controlling the wire feed speed according to the stick out leng...

Page 130: ...der features a voltage reduction device VRD When the welding machine is on but the welding arc is not ignited the welding machine is on open circuit voltage 50 V If the VRD is in use it keeps the open...

Page 131: ...st iron nickel copper magnesium and aluminium The equipment used in carbon arc gouging comprises the power source a carbon holder and its cables and the gouging carbon Also a sufficient compressed air...

Page 132: ...ng Cladding surfacing means depositing a layer of filler material on the workpiece to achieve certain properties or dimensions To use X8 MIG Welder for cladding in Settings select the mode MMA MIG and...

Page 133: ...g the trigger again 3 switch the arc off Releasing the trigger 4 ends the Postgas Figure 42 4T trigger logic WP Switch The WP Switch trigger logic is similar to the 4T logic but it includes a secondar...

Page 134: ...djusting Time and Level appear on the screen Hot start S When you use the Hot start function welding starts with parameter values that are different from the values used for the rest of the welding jo...

Page 135: ...ll function gradually decreases the welding power wire feed speed at the end of the welding job so that the crater can be filled using a lower power level When the 2T trigger logic is in use releasing...

Page 136: ...l does not come into contact with air This is essential with materials that require a good gas shield like stainless steels aluminium and titanium When the 2T trigger logic is in use the Pregas lasts...

Page 137: ...te To use the WeldEye services connect the welding machine to the Internet through a WLAN or a wired connection For more information see Connecting to Kemppi cloud services on page 106 Using digital W...

Page 138: ...al adjustments are not necessary However fine tuning of the parameters is still possible The user can see the detailed information about the dWPS as well as the related joint design and welding sequen...

Page 139: ...dvanced mode Figure 51 Basic mode 3 Move the focus to the WPS that you want to activate 4 Depending on the mode of Control Pad select one of the following options a If the Control Pad is in the Advanc...

Page 140: ...c mode press the green button to activate the WPS Control Pad opens the WPS view Here you can see all the WPS details that the welder needs to know for the job including the pictures and details of th...

Page 141: ...page 141 5 Press a view button to leave the WPS view Note You can also change WPS or the pass in Channel view See Selecting WPS or pass in Channel view on page 143 Selecting WPS pass in WPS view Proc...

Page 142: ...e WPS Control Pad shows the WPS list Select the WPS 2 Move focus to Active pass The information under Active pass is pass specific and varies according to the pass 3 Press the green button to open the...

Page 143: ...return to the WPS View Note You can also select the WPS or pass in the Channel view See Selecting WPS or pass in Channel view on page 143 Selecting WPS or pass in Channel view Proceed as follows 1 Go...

Page 144: ...ediately activates Caution After changing WPS or pass check the pass details to make sure you are using the correct filler wire and gas 3 To see all the details of the selected WPS press the Menu butt...

Page 145: ...ine tuning and dynamics If you adjust a parameter whose correct value is essential for the process the current voltage or wire feed speed beyond the range defined in the WPS the system displays a warn...

Page 146: ...All the welding machines of the company can be connected to WeldEye You can see a list of all the connected machines If My Fleet is also in use the services share the same list of machines For more i...

Page 147: ...DER 2 4 Operation 2 Press the green button 3 Select a WPS from the list 4 Press the green button to open the command menu 5 Select Delete WPS and press the green button OPERATING MANUAL EN 147 KEMPPI...

Page 148: ...n filter by material thickness and joint type Proceed as follows 1 Go to the View menu WPS 2 Scroll up to move the focus to the filter header 3 Press the green button to open the filter wizard 4 Turn...

Page 149: ...ation 5 Turn the knob to move focus and press the green button to select the thickness of the wire 6 Turn the knob to move focus and press the green button to select the weld type OPERATING MANUAL EN...

Page 150: ...8 MIG Welder can be used for automated monitoring of quality and productivity of arc welding The device records welding parameter data and transmits it to the WeldEye cloud service through a wired or...

Page 151: ...Eye after the welding run ends WeldEye never shows values for ongoing welding because the data is transmitted only after the welding ends If the device is not connected to Internet the data is buffere...

Page 152: ...identifiers added to the WeldEye database Time keeping To provide accurate information about the welding activities the device uses an internal real time clock It records the exact time when welding...

Page 153: ...to read the barcode or QR code on your ID card OR Enter barcode to enter the barcode manually 4 Read the barcode or QR code on your ID card or enter the barcode manually For more information see Contr...

Page 154: ...elected automatically For more information see Selecting WPS pass in WPS view 6 Identify the weld Read the weld s barcode from a printed work order or select the information on the display Information...

Page 155: ...the virtual keyboard to enter the barcode number by hand When you read or enter the barcode for the first time Control Pad does not recognize it Select Filler batch to indicate that the barcode refers...

Page 156: ...enter the length of the weld which is used for heat input calculation For more information see Tracking heat input 10 When you finish using the welding machine log out of the system Power off the mach...

Page 157: ...Eye If a welder s certificate lacks the necessary qualifications required by the WPS the system raises an alert If the welder restrains from welding the system drops the alert However if the welder st...

Page 158: ...ctivities to track non welding time or events causing pauses in the production Activities are divided into expected pauses for example lunch breaks and unexpected pauses for example waiting for a mate...

Page 159: ...l Pad Identify the WPS and the weld The device considers all subsequent welding to be part of a pass and takes it into account in heat input calculation 2 When you have finished welding select Complet...

Page 160: ...ion Control Pad displays the number of completed passes with a round green checkmark next to it Enable heat input tracking in the WeldEye cloud service Digital work order Note This function is availab...

Page 161: ...lists on paper as they are delivered digitally to each welding station where each welder can see the necessary information Rather than reading barcodes the welders select the weld they are about to p...

Page 162: ...s a list of welds scroll to the desired weld and press the green button on the right control knob to select it If the work order does not contain welds scroll to Activate work order and press the gree...

Page 163: ...lding Completing work order When you have completed the work defined by the work order mark it as completed When you do that Control Pad stores the end time in the WeldEye cloud service and the status...

Page 164: ...ompleted the work order is automatically removed from the work order list in Control Pad within 15 minutes or as soon as X8 MIG Welder is connected to Internet Changing work order If you deselect the...

Page 165: ...ers and welds can include recommended Welding Procedure Specifications WPSs They help welder to choose the correct WPS for the job which reduces the risk of errors When you use Control Pad to select a...

Page 166: ...bleshooting Note The problems listed and the possible causes are not definitive but suggest some typical situations that may turn up during normal use of the welding system Table 6 Welding system Prob...

Page 167: ...ler wire is properly routed through the feed rolls to the wire liner Check that the pressure handle is properly closed Check that the feed roll pressure is adjusted correctly for the filler wire Check...

Page 168: ...e gun connector are clean and undamaged The gun vibrates too much during welding Check the tightness of the contact tip adapter and contact tip Check the motor current Check the wire liner Check the f...

Page 169: ...eck the wire liner Check the filler wire It must be straight and start coiling when it comes out from the contact tip If not check the tightness of the feeding rolls Gun remote control displays a warn...

Page 170: ...or warning symbol Check the Control Pad or Wire feeder control panel to see more information Symbol in gun remote control display Meaning System warning The warning concerns an error in the system for...

Page 171: ...and the pressure handle Clean and lubricate with a small quantity of light machine oil if needed Maintenance of guns Check regularly that all the components are tightly fastened Check that the current...

Page 172: ...X8 MIG WELDER 2 6 Maintenance Figure 54 Water cooled gun Check and remove any spatter build up from the nozzle Figure 55 Gas cooled gun OPERATING MANUAL EN 172 KEMPPI 2018 09 28...

Page 173: ...carry out electrical work Caution Before removing the cover plate disconnect the power source from the mains and wait for about 2 minutes before discharging the capacitor Check the electric connectors...

Page 174: ...calibration of operation and performance values when needed Find your closest service workshop at Kemppi website 2 7 Technical data This section contains the technical details of the welding system 2...

Page 175: ...MIG 380 V 20 A 14 V 400 A 50 V 20 A 14 V 400 A 50 V Welding current and voltage range MMA 220 V 15 A 20 V 400 A 58 V MMA 380 V 15 A 20 V 400 A 58 V 15 A 20 V 400 A 58 V Welding voltage max 58 V 58 V P...

Page 176: ...ns connection voltage 3 50 60 Hz 380 460 V 10 380 460 V 10 Rated power 40 ED 60 ED 26 kVA 26 kVA 100 ED 18 kVA 18 kVA Supply current maximum I1max 220 230 V 67 66 A I1max 380 460 V 38 33 A 38 33 A Sup...

Page 177: ...nt 89 91 89 91 Operating temperature range 20 40 C 20 40 C Storage temperature range 40 60 C 40 60 C EMC class A A Minimum short circuit power SSC of supply network SSC 5 1 MVA 5 1 MVA Degree of prote...

Page 178: ...42 A 50 42 A Supply current effective I1eff 220 230 V 57 53 A I1eff 380 460 V 33 27 A 33 27 A Idle power without cooler and wire feeder MIG Pi 45 52 W 40 52 W Idle power with cooler without wire feede...

Page 179: ...ture range 20 40 C 20 40 C Storage temperature range 40 60 C 40 60 C EMC class A A Minimum short circuit power SSC of supply network SSC 5 1 MVA 5 1 MVA Degree of protection IP23S IP23S External dimen...

Page 180: ...Recommended coolant MPG 4456 Kemppi mixture Coolant pressure max 0 4 MPa Tank volume 4 l Operating temperature range 10 40 C Storage temperature range 40 60 C EMC class A Degree of protection IP23S We...

Page 181: ...ion IP23S External dimensions LxWxH 640 x 220 x 400 mm Weight without accessories 11 2 kg Wireless communication type Transmitter frequency and power 2 4 GHz Bluetooth 2402 2480 MHz 19 dBm Standards I...

Page 182: ...type USB Display type TFT LCD Display size 5 7 Standards IEC 60950 1 EN 62368 1 EN 300 328 v2 1 1 EN 300 330 v2 1 1 EN 301 489 1 v2 1 1 EN 301 489 3 v2 1 0 EN 301 489 17 v3 1 1 2 7 7 X8 MIG Gun 200 g...

Page 183: ...86 mm Neck angle see figure below 50 Standards IEC 60974 7 Figure 57 Neck dimensions and angle 2 7 8 X8 MIG Gun 300 g Feature Description Value Welding process MIG MAG Method of guidance Manual Type o...

Page 184: ...97 mm Neck angle see figure below 50 Standards IEC 60974 7 Figure 58 Neck dimensions and angle 2 7 9 X8 MIG Gun 400 g Feature Description Value Welding process MIG MAG Method of guidance Manual Type o...

Page 185: ...angle see figure below 50 Standards IEC 60974 7 Figure 59 Neck dimensions and angle 2 7 10 X8 MIG Gun 420 w Feature Description Value Welding process MIG MAG Method of guidance Manual Type of cooling...

Page 186: ...No Length x see figure below 132 232 mm Neck dimensions Height y see figure below 104 mm Neck angle see figure below 50 Standards IEC 60974 7 Gun length 5 m Figure 60 Neck dimensions and angle 2 7 11...

Page 187: ...inimum cooling power at 1 6 l min 1 9 kW Minimum flow rate 1 6 l min Pistol grip handle Yes Changeable neck No Rotating neck No Length x see figure below 145 245 mm Neck dimensions Height y see figure...

Page 188: ...2 4 mm Fe MC FC 1 2 2 4 mm Ss 1 2 1 6 mm Ss MC FC 1 2 1 6 mm Filler wires Al 1 2 2 4 mm Operating temperature range 20 40 C Storage temperature range 40 60 C Minimum cooling power at 1 6 l min IEC 609...

Page 189: ...0 MIXED GAS 300 A 60 CO2 Load capacity 100 CO2 Ss 1 2 1 6 mm Filler wires Al 1 2 1 6 mm Operating temperature range 20 40 C Storage temperature range 40 60 C Minimum cooling power at 1 6 l min 1 9 kW...

Page 190: ...er Source X8560000 X8 Power Source 600 with Cooler X8100601000 X8 Power Source 600 with Cooler and Software Pack 1 X8100601010 X8 Cooler X8600000000 X8 Wheel Set X8701010000 X8 Power Source with Weldi...

Page 191: ...117 mm y 97 mm X8301303500 X8 MIG Gun 300 g 5 0 m x 117 mm y 97 mm X8301305000 X8 MIG Gun 400 g 3 5 m x 132 mm y 110 mm X8301403500 X8 MIG Gun 400 g 5 0 m x 132 mm y 110 mm X8301405000 X8 MIG Gun 420...

Page 192: ...0 95 mm 2 20 m X8801952000 70 mm 2 30 m X8801703000 95 mm 2 30 m X8801953000 Table 16 Interconnection cables water cooled Interconnection cable cross section Cable length Ordering code 95 mm 2 2 m X88...

Page 193: ...odes of welding program packs see Kemppi DataStore 2 9 Disposal of unit Note Do not dispose of any electrical equipment with normal waste At the end of the useful working life of the unit and its acce...

Page 194: ...ent is obliged to deliver a decommissioned unit to a regional collection centre as per the instructions of local authorities or a Kemppi representative By applying these European Directives you improv...

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