2.1 System introduction............................................................................................................................................................. 8
2.1.1 Introduction to WeldEye for welding procedure and qualification management....................... 9
2.2 System structure..................................................................................................................................................................10
2.2.1 X8 Power Source.................................................................................................................................................11
2.2.4 Control Pad............................................................................................................................................................22
2.3.1 Before installation...............................................................................................................................................25
2.3.2 Power Source installation................................................................................................................................ 26
2.3.5 Control Pad installation....................................................................................................................................55
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
2.6.2 Periodic maintenance of power source and wire feeder..................................................................173
2.6.3 Service workshops........................................................................................................................................... 174
2.7.6 X8 Control Pad..................................................................................................................................................181
2.9 Disposal of unit.................................................................................................................................................................193
iii
X8 MIG WELDER1.1 Symbols
1 Read first
Kemppi takes special care in informing its customers about the safety of our products. We also mind the
environment and aspire to disposing of our products according to specified European Directives.
1.1 Symbols
Items in the manual that require particular attention, to minimize damage and personal harm, are indicated
with a three-level notification and warning system.
ConventionUsed for
Note:
Note text here.
Caution:
Caution text here.
Warning:
Warning text here.
Gives the user a piece of information of particular importance.
Describes a situation that may result in damage to the equipment or
system.
Describes a potentially dangerous situation that may result in personal
damage or fatal injury.
Kemppi symbols
Table 1: Kemppi symbols used in this documentation
SymbolDescription
CE mark
EMC Class A
This symbol indicates that the waste of electrical and electronic equipment
must not be disposed as unsorted municipal waste and must be collected
separately. Contact an authorized representative of the manufacturer for
information concerning the decommissioning of your equipment.
These instructions describe the use of Kemppi's X8 MIG Welder, the top-class welding system for demanding
industrial use. The system consists of a power source, wire feeder, welding gun, Control Pad and various
welding software components and connectivity to Kemppi cloud services. Read the instructions through
carefully.
Disclaimer
While every effort has been made to ensure that the information contained in this guide is accurate and
complete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the
specification 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 MIG Welder is a multi-process welding equipment intended for demanding professional use in general or
heavy fabrication. The welding system is suitable for various MIG/MAG processes (MIG, 1-MIG, Pulse, DPulse,
WiseRoot+, WiseThin+ ) as well as MMA welding and gouging, cladding and brazing.
1. X8 Power Source 400/500/600
• Includes all the software, welding programs and memory channels for the welding system
• Connects to one or two X8 Wire Feeders
2. X8 Wire Feeder
• Operates with several wire spool types (some of which require an adapter)
• Bundle of cables connecting the wire feeder to the power source
• Transfers the welding current, control signals, shielding gas and coolant from the power source to the
wire feeder
7. X8 Wheel Set (several options)
• The wheel set is included in the power source delivery
• The gas cylinder cart is optionally included in the power source delivery
8. My Fleet web service
• Cloud-based service for viewing and 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 welding-related
information
In addition:
• Several accessories (optional)
• Several welding software products (optional)
2.1.1 Introduction to WeldEye for welding procedure and qualification
management
Welding procedure and qualification management
WeldEye for Welding procedure and qualification management is a cloud-based tool for creating, managing
and storing various welding-related documents and qualification certificates. WeldEye is an end-to-end
solution for handling pWPS, WPQR and WPS documents as well as welder qualification certificates. The
software contains procedure and certificate templates to match all major welding standards. Together with its
integrated drawing tool, WeldEye is swift and easy to use.
The software enables you to keep track of qualification certificates and their expiration dates, and to easily
extend their validity. Revision history helps you track the changes made to the documents. With a flexible
search functionality, you can easily find the welding procedures, personnel, and certificates you need. You
WeldEye is your primary tool and storage space for keeping your welding-related documents in order.
There is even more to WeldEye than welding document management. WeldEye is a universal solution for
managing welding production. Fitting any size and type of organization that performs welding within the
requirements of international welding standards like ISO, ASME and AWS, WeldEye provides control in all
processes - including welding procedures, welder and inspector qualifications, documentation, reporting and
administration. Most importantly, you get 100% traceability for every weld you ever make.
WeldEye's modular structure is based on various useful functions that serve the needs of wide-ranging
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 qualifications
Includes the management and renewal processes of all personnel - welders and inspectors - qualification
certificates.
Quality management
Includes quality verification functionalities with digital WPS and qualification compliance control against
automatically collected digital welding data.
Welding management
Includes document register functionalities and features for comprehensive welding project
documentation and management.
For more information on the full system and other modules, see www.weldeye.com.
2.2 System structure
The parts of X8 MIG Welder are in close co-operation with each other. The information transfer is efficient
and quick, and the different functions, for example, the use of displays, follow the same principles.
Caution:
Do not modify the welding equipment in any way, except for the changes and adjustments covered
in the manufacturer’s instructions.
Connect a USB memory stick to upload the welding procedures (WPS) or Wise features to the power
source or update firmware if a wireless connection is unavailable.
4. Control Pad connector
Connect Control Pad to the power source with a cable to charge its battery or to use it in wired mode.
5. Front panel
6. Front panel latch
Pull to open the front panel and reveal the coolant container.
7. Coolant circulation button
Press to pump the coolant through the system.
Rear
1. Transportation handle
2. Welding current cable connectors (positive pole)
3. Earth return cable connectors (negative pole)
4. Measurement cable connectors
Connectors for wire feeder 1 on the left, wire feeder 2 on the right side of the power source.
5. Control cable connectors
Connectors for wire feeder 1 on the left, wire feeder 2 on the right side of the power source.
The LED is green when VRD is switched on and the no-load voltage is under 35 V.
The LED blinks red when VRD is switched on and the no-load voltage is above 35 V.
The LED is off when VRD is switched off or during welding.
Note:
VRD is in use with MMA and Gouging modes 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 cooled down.
4. Kemppi cloud connection
The LED is blue when the wire feeder or power source is connected to Kemppi cloud services.
The LED blinks blue when the wire feeder or power source is connecting to Kemppi cloud services.
5. Coolant level warning
The LED is yellow when the coolant level is too low.
If the coolant liquid overheats, a thermal cutoff switches the welding system off and does not
allow it to be used until the coolant liquid has cooled down.
7. Coolant circulation warning
The LED is green when the coolant circulation is working normally.
The LED is red when there is a problem in the coolant circulation.
The LED blinks green and red in turns when the circulation of the coolant liquid has been obstructed too
long.
Caution:
If the circulation of the coolant liquid is obstructed, a thermal cutoff switches the welding system
off. Check and fix the error before using the 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 pair the wire feeder or power source with Control Pad, press the button. If the power source is
connected to wire feeder(s), the wire feeder(s) pairs with Control Pad. If the power source is not
connected to a wire feeder, the power source pairs with Control Pad.
The LED is blue when the wire feeder or power source is wirelessly connected to Control Pad.
The LED blinks blue when the wire feeder or power source is pairing with Control Pad.
This section describes the structure of X8 Wire Feeder.
Main parts
1. Top cover
Caution:
Keep the 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 wire feeder insides clean.
2. Handle
Caution:
The handle is only intended for short distance manual carrying. Use Wire Feeder Hanger for
Boom for lifting or hanging the wire feeder.
The control panel on the front of the wire feeder enables easy control of the wire feeder's basic features.
Although Control Pad is the main control of the welding system, you can also use the wire feeder control
panel or the welding gun remote control.
The wire feeder control panel parts are:
1. Locking button
Press and hold for 2 seconds to lock or release the display and buttons.
2. Channel button
The button lights up blue, when the view is activated.
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.
Provided that the public low voltage short circuit power at the point of common coupling is higher
than or equal to 5.1 MVA, this equipment is compliant with IEC 61000-3-11 and IEC 61000-3-12 and
can be connected to public low voltage systems. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if necessary, that the
system impedance complies with the impedance restrictions.
Table 2: Cable type and fuse rating requirements
High voltage version (380-460V)Multi-voltage version (220-230/380-460V)Unit amperage
Cable typeFuse ratingCable typeFuse rating
400 A6 mm
500 A6 mm
600 A6 mm
2
2
2
25 A--
32 A16 mm
35 A16 mm
2
2
63 A
63 A
2.3.2 Power Source installation
For power source cable connections, see Installing interconnection cable and Installing or replacing mains
cable. For operating the power source, see Preparing welding system for use.
2.3.2.1 Installing wheels
To have turning wheels in the front and the back, install the front wheel assembly to the front of the unit.
To have fixed wheels in the front, install the rear wheel assembly to the front of the unit. See also Installing
optional gas cylinder cart.
Proceed as follows:
Install the rear wheels:
Remove the packaging from the sides but leave the power source resting on the pallet.
If your setup includes X8 Gas Cylinder Cart, proceed to Installing optional gas cylinder cart.
2.3.2.2 Installing optional gas cylinder cart
To transport a larger gas cylinder with the power source, install X8 Gas Cylinder Cart. For detailed
instructions, see X8 Gas Cylinder Cart Mounting Instructions. If your setup does not include the gas cylinder
cart, proceed to Installing optional X8 Cooler.
Remove the packaging from the sides but leave the power source resting on the pallet.
1.
Attach a wheel set to the front of the unit.
2.
• To have turning wheels in the front and the back, install the front wheel assembly to the front of the
unit.
For more information, see Installing wheels on page 26.
• To have fixed wheels in the front, install the rear wheel assembly to the front of the unit.
For more information, see Installing wheels on page 26.
Attach the gas cylinder cart to the rear of the unit:
Push the axle through the opening in the bottom of the rear side of the unit.
Place the upper part of the gas cylinder cart on the wheel set, and push it down until the claw fastens
6.
over the transportation handle.
Attach the upper part of the gas cylinder cart to the wheel set with two bolts (1) and washers (2, 3) from
7.
both sides.
Attach the bottom of the gas cylinder cart to the wheel set with six bolts (1) and washers (2, 3).
8.
The gas cylinder cart bottom has two alternative settings (the lower setting described in the figure). The
higher setting gives a better ground clearance, but you must lift the gas cylinder higher.
Pull the front panel outwards from the lower edge.
2.
Remove the lower left cover from the rear of the power source.
3.
Push the cooler inside the power source from the opening in the front.
4.
Note:
Do not use force, but make sure the connectors on the cooler and the power source are
properly connected.
Fill the coolant container with applicable coolant solution. For more information, see Filling cooler on
5.
page 103.
Attach the two screws in the front panel of the power source.
6.
2.3.2.4 Installing or replacing mains cable
The power source is supplied with a 5-meter mains cable without a plug installed.
Warning:
The mains cable must be installed by an authorized electrician.
For high voltage versions, install the 6 mm2 cable. For multi-voltage versions, install the 16 mm2 cable.
The mains cable includes the following wires:
1. Brown: L1
2. Black: L2
3. Grey: L3
4. Yellow-green: Protective earth
2.3.3 Wire Feeder installation
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 panel on page 96.
Caution:
Welding quality and efficiency are greatly dependent on the consumable parts used on the wire
line. These include the wire guide tubes, feed rolls, wire liners, gas nozzles and contact tips. Always
ensure that you are using the correct consumable parts suitable for the filler wire size and material.
For more information, visit Kemppi consumable kit selection site at kitselect.kemppi.com.
2.3.3.1 Installing wire feeder
The installation of the Wire Feeder Rotating Plate and Double Wire Feeder Rotating Plate is identical, as is
installing one or two wire feeders.
Install the wire feeder on the power source with a Wire Feeder Rotating Plate. To install two wire feeders, use
a Double Wire Feeder Rotating Plate.
Note: To set up the system for double wire feeder configuration, you need certain assembly parts.
For more information, see Double wire feeder assembly parts.
The mounting pins are different: The drive rolls' mounting pins have a circular mark on the
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 each other.
Pull the drive rolls upwards (1) and the pressure rolls out of their slots (2).
The wire feed mechanism includes two wire guide tubes. Replace them when the filler wire diameter grows
or the material changes.
1. Inlet tube
Pull out the inlet tube and insert a new one. There is no additional locking.
2. Middle tube
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 Changing wire spool
Note:
Install the welding gun to the wire feeder before installing the wire spool.
Caution:
If you change the filler wire to a different diameter or material, change the feed rolls accordingly.
Attach the wire spool brake halves to the new wire spool by pushing them together inside the wire
8.
spool. Tighten if necessary.
Note:
The spool brake is equipped with an optional wire tensioning feature, which keeps the wire feed
steady in 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.
Lower the wire spool to its socket.
9.
Note:
Ensure that the wire spool is facing the right direction, the filler wire running from the top of the
spool to the feed rolls.
Filler wire materialFeed roll profileFiller wire diameter (mm) Adjustment (x100N)
Fe/Ss solidV-groove0.8−1.0
≥ 1.2
1.5−2.0
2.0−2.5
Metal and flux coredV-groove, knurled≥ 1.21.0−2.0
Self-shieldedV-groove, knurled≥ 1.62.0−3.0
AluminiumU-groove1.0
1.2
1.4
≥ 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 increases gearbox load.
Press Wire inch to drive the filler wire to the welding gun's contact tip. To speed up the wire feed speed,
18.
turn the left control knob on the control panel.
Note:
The control panel shows how much the filler wire has run.
2.3.3.6 Attaching interconnection cable to strain relief
To ease the installation of the interconnection cable and to prevent any unnecessary strain on the cable
connectors, attach both ends of the interconnection cable bundle to a strain relief.
Proceed as follows:
Attach the strain relief holder to the transportation handle at the rear of the power source. Fasten the
1.
strain relief holder with a bolt from below.
Take the power source end of the interconnection cable and insert the strain relief pin to the strain relief
2.
holder.
Note:
If the wire feeder is detached from the power source, insert the strain relief pin to the holder
from below.
Note:
If the wire feeder is on the power source, insert the strain relief pin to the holder from above.
Insert the supplied locking pin through the hole in the strain relief pin.
3.
Route the cable bundle from the back of the power source and attach the strain relief in the other end of
4.
the cable to the left-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 overview of the cabling, see Cabling diagram.
2.3.4.1 Installing interconnection cable
Install the interconnection cable first to the the wire feeder and then to the power source.
Connect the welding current cable to the plus (+) side connector (1) on the power source.
11.
The interconnection cable crosses from the wire feeder to the power source connector diagonally.
Note:
If two wire feeders are connected to a power source, connect the interconnection cable upright:
from the wire feeder on the left to the connector (1) on the left.
Connect the earth return cable to the minus (-) side connector (2).
12.
Connect the measurement cable to the measurement cable connector (4).
13.
Connect the control cable to the control cable connector (3) on the same side as the measurement
14.
cable.
If the water cooler is present, use the red connector (5) for the hose that goes to the cooler.
15.
If the water cooler is present, use the blue connector (6) for the hose that comes from the cooler.
16.
If you need shielding gas, connect the shielding gas hose to the gas cylinder.
17.
The power source can be connected to two wire feeders at the same time.
Caution:
Ensure that you have connected and tightened all the cables properly.
2.3.4.2 Cabling diagram
Connect the interconnection cables to power source and wire feeder. The figure below shows the cables with
colors to facilitate the identification.
This chapter describes the control pad installation.
For information on operating Control Pad, see Control Pad on page 84.
2.3.5.1 Wireless connection
Control Pad connects wirelessly to X8 Wire Feeder. If there are two wire feeders in the system, choose which
one 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 power source or the wire feeder, see Wired
connection on page 57.
If Control Pad is not connected, you see this info message on the display.
Proceed as follows:
To connect Control Pad wirelessly to a wire feeder or power source:
1.
a) Press the wireless pairing button on the power source indicator panel.
The led on the power source begins to blink when it is searching for Control Pad.
The serial numbers of the nearby available wire feeders or power sources appear on Control Pad's
display.
Note:
When there 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, Control Pad allows you to connect to a power source.
Figure 4: Connecting to wire feederFigure 5: Connecting to power source
b) Move focus to select the connection and press the green button.
The connection list shows the serial numbers of the available wire feeders and a power
source. Check the serial number on the device rating plate.
A connection forms between the wire feeder or power source and Control Pad. The led on the power
source lights up permanently.
Note:
Once you have created the connection, Control Pad tries to reconnect if you take it out of the
connection distance. Select Disconnect on Control Pad to disconnect the connection.
You can also connect Control Pad to the wire feeder through the wire feeder control panel if the wire
2.
feeder is far from the power source.
a) Go to Settings > Wireless devices > Connect.
The wire feeder connects automatically to Control Pad.
If the buttons of the power source and wire feeder are unreachable:
3.
a) Go to Settings > WirelessDevicesAvailable in Control Pad.
b) Move focus to a wire feeder or a power source.
c) Press the green button.
2.3.5.2 Wired connection
Control Pad makes a wired connection with X8 Power Source and X8 Wire Feeder. Connect Control Pad to a
wired connection, when wireless connection is unavailable.
Proceed as follows:
To make a wired connection between Control Pad and the power source:
1.
a) Plug the combo cable to the Control Pad connector of the power source.
b) Plug the combo cable to the combo cable port on the bottom of Control Pad.
To make a wired connection between Control Pad and the wire feeder:
2.
a) Plug the combo cable to the remote control connector of the wire feeder.
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 Suspending Control Pad
Control Pad has a hook, which you can use to suspend it on the welding machine or other suitable place.
Control Pad also has a loop in each corner, which you can use for the carrying strap.
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
1.
setup includes a gas-cooled gun, you can also change the neck.
Attach the pistol grip handle, if suitable for the job.
2.
Attach X8 Gun Remote Control, if suitable for the job (optional accessory).
3.
Connect the welding gun to the wire feeder: Push the welding gun connector into the wire feeder gun
X8 MIG Guns connect to X8 Wire Feeder with Kemppi Gun Adapter that enables, among other
things, accurate measurement of the actual arc voltage and the usage of the remote control.
Therefore, X8 MIG Guns are only compatible with X8 Wire Feeder.
If your setup includes a water-cooled gun, connect the cooling hoses to the wire feeder. The coolant
5.
inlet hose is marked with blue and the coolant outlet hose with red color.
Dress the sharp filler wire tip before loading to improve wire loading and to lengthen consumables'
6.
lifetime.
Press the Wire inch button to load the filler wire.
Trim the excess filler wire at a slight angle to improve ignition.
8.
Check the gas flow rate.
9.
The welding gun is now ready for use. When not using the gun, keep it in the welding gun holder on the wire
feeder.
2.3.6.2 Replacing consumable parts of welding gun
Select a suitable contact tip, gas nozzle, neck and wire liner according to the job. See also how to change the
feed rolls of the wire feeder accordingly: Replacing feed rolls on page 37.
Standard delivery 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 kitselect.kemppi.com.
The pistol grip handle is suitable for all X8 MIG Guns. The handle improves the ergonomics of many welding
positions.
To 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, press the lock button at the back of the handle.
2.3.6.4 Installing remote control
X8 Gun Remote Control is an optional accessory for X8 MIG Gun.
For operation instructions, see Gun remote control on page 99.
Unscrew the two screws that attach the cover to the gun.
1.
Remove the protective cover from the gun by pushing it forwards and lifting it up.
2.
Remove the interface card that covers the connectors.
3.
Note:
Store the interface card in case you want to remove the remote control later. If you remove the
remote control, re-mount the interface and the cover on the gun.
Attach the remote control by pushing it down and backwards into its place so that the connectors align.
The wire feeder hanger for boom 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 handle. Use the wire feeder hanger for boom instead.
Follow these operating instructions carefully to have full advantage of your X8 MIG Welder and to minimize
the risk of malfunctions.
2.4.1 X8 MIG Welder control devices
Welding with X8 MIG Welder can be controlled through three different control panels, which offer slightly
different features for adjusting the welding parameters.
The actual features vary according to the functions and usability of the control panel.
2.4.1.1 Control 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 the one-knob navigation, and connect
Control Pad to any X8 MIG Welder nearby.
Navigation
Above the display, Control Pad has three view buttons. Press these buttons to change the view on Control
Pad's display. Press the Menu button twice to open the View menu.
Use the knobs under the display to move in the display and to adjust the values. When there is a green light
in the center of the knob, the knob also functions as a push button.
In the Welding view, adjust the welding power with the left knob and the fine tuning with the right knob. In
most welding processes, this secondary parameter is voltage.
In all other views, move up and down in the menus with the right knob. Press the green button in the center
of the knob to 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 machine, the selected wire feeder, and the
name of the user:
There is an instruction on the footer above the knob, when the knob has a specific function. A green circle in
the footer prompts the push of the button on the control knob. The adjustable parameter or value in focus is
highlighted with orange.
Figure 7: Control Pad display with the Adjust
footer
Figure 8: Control Pad display with the Select footer
If the selection of the toggle button comes into effect right away, the footer command is Close. If the 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.
Toggle between the views with the view buttons. The View menu inside Welding opens, when you press the
8. Serial number of the power source, wire feeder's number (1 or 2) and user name
9. Welding process
10. Hot start
The selected start and stop logics.
11. Crater fill
The selected start and stop logics.
12. Voltage
13. Voltage/Fine tuning
Adjust the welding power with the left control knob.
Fine 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 raster pattern the area, where the selected values result in
globular transfer.
Figure 12: Raster pattern in the wire feed arc
In DPulse, WP Switch and DProcess, you can adjust two value sets: the first level and the second power level.
Press the left green button to toggle between them. Adjust the values with the control knobs. The other
power level is shown with gray line on the wire feed speed diagram.
You can specify the minimum and maximum values of the wire feed speed. They are displayed as white
stoppers beside the wire feed speed diagram.
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 stoppers. The stoppers are by default at the top and
bottom of the specified WPS area, but you can adjust them to your preferences: to narrow the area or to
weld outside the specified area.
Figure 16: The minimum and maximum stoppers for WPS
If you adjust the wire feed speed or voltage 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 welding job requires
such values.
Figure 17: Values outside the range specified by WPS
Settings displays all the welding parameters and other settings of the selected program. The contents under
the titles are collapsed by default. Press the green button to expand the columns. There are two modes, Basic
and Advanced. This section describes the Settings view in the Advanced mode.
Figure 18: The Settings view menu in the Advanced mode
For more information on welding programs, see Welding programs in Control Pad on page 93.
DPulse menu
With the DPulse 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 includes the DProcess process, the DProcess menu appears in the Settings view.
For more information, see Standard MIG welding processes in X8 MIG Welder on page 119.
Wise feature menu
Wise feature displays the Wise features available for use with the welding program.
For more information, see Wise features on page 127.
Trigger logic menu
Trigger logic displays the trigger logic options: 2T, 4T and WP Switch.
For more information, see Trigger logic functions on page 133.
Start and stop logic displays several options. For more information, see Start and stop functions on page
134.
Parameters
The parameters available vary according to the welding process used:
• Wire feed speed
In addition to wire feed speed, you can adjust the minimum and maximum values of wire feed speed here.
• Voltage
• Fine tuning
• Dynamics
• Pulse current percent
• Start power
• Start level
• Stop power
For more information, see the description of the processes.
System settings
The options under System settings are:
1. Water cooling
Set water cooling ON, OFF or on AUTO.
In ON mode, the water cooling is continuous. In OFF mode, the water cooling is fully stopped. In AUTO
mode, the water cooling is on when needed.
2. Sub feeder 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. Voltage display mode
Select the welding voltage: terminal or arc voltage.
5. Safe wire inch
Set the Safe wire inch ON or OFF. If the Safe wire inch is ON, the wire feeder feeds maximum 5 cm of the
wire, if the arc does not ignite until then. If the Safe wire inch is OFF, the wire feeder feeds maximum 5 m
of the wire. This is to prevent the wire from hitting the welder.
6. Voltage reduction device (VRD)
Switch VRD ON or OFF if you are using MMA or gouging process. VRD reduces the maximum unloaded
open circuit voltage across the output terminals of the welding machine to a safe voltage.
7. Factory reset
Restore the settings back to factory default settings.
Panel settings
Panel settings display Control Pad's mechanical settings:
Lock Control Pad with a 4-digit PIN code. When PIN lock is on, PIN code is required every time when
Control Pad is turned on. PIN lock does not prevent welding.
2. Change PIN code
Change the 4-digit PIN code.
3. Language
Choose the language out of 13 options.
4. Basic/Advanced mode
(User interface mode)
5. Brightness
Brightness of the display in percents.
6. Power usage
The settings available are Minimum, Economic and Normal.
Welding 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 their settings in
Parameters.
Figure 19: The Welding program menu in Settings
You can use the filters under Welding program to filter the welding programs on the selection list. You can
also select the needed welding program without using the filters.
The parameters available in Settings vary according to the selected welding process and the Basic/Advanced
mode.
Not available for all materials.
Which polarity is in use. If the polarity is positive (+), connect the + side to the wire feeder.
8. Welding program
After filtering, this column displays the suitable welding programs.
Channel view
Welding parameters are stored in 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 channels.
Figure 20: The Channel view
To adjust the welding parameters of the channel in focus, press the Menu or Settings button. When you
adjust a parameter, the number of the memory channel tilts to the right to indicate a difference from the
saved settings.
A WPS defines a range of values for welding parameters. If a WPS is used to create a memory channel, the
parameters are set in the middle of the range.
The control panel of the wire feeder has a one-knob navigation and push buttons for selecting parameters or
values. You can, for example, adjust the welding parameters and save settings on memory channels.
Wire feeder navigation
The three main views on the wire feeder display are the same as in Control Pad: Channel, Welding, and
Settings.
Note:
You can press the Power button to lock the wire feeder and avoid starting welding accidentally.
The wire feeder has a memory channels button on the left and the Settings button on the right side of the
display. Press these 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. When there is a green
light in the center of the knob, the knob also functions as a push button.
In the Welding view, adjust the welding power with the left knob and the fine tuning with the right knob. In
most welding processes, this secondary parameter is voltage.
In all other views, move up and down in the menus with the right knob. Press the green button in the center
of the knob to open an item.
Wire feeder views
Welding view
In the Welding view, you can:
• See an overview of the settings of the selected welding program
• Adjust the main parameters (welding power and fine tuning)
The unit of the parameter varies according to the welding process.
3. Voltage
Note:
Not all processes have this parameter.
4. Fine tuning
The unit of the parameter varies according to the welding process.
5. Applied settings displayed in symbols
For more information on symbols, see Kemppi symbols.
Adjust the welding power with the left control knob.
Note:
The welding parameter shown is Wire feed speed, Current or Plate Thickness.
Fine tune the secondary welding parameter with the right control knob. The adjustable secondary parameter
varies according to the welding process and function.
Memory Channels view
Welding parameters are stored in the memory channels. The memory channel displays the same information
of the welding parameters as the Welding view. Each user has their own memory channels.
Press 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 tilted
number of the memory channel indicates that the parameters of the original memory channel have been
modified.
To save a modified channel, press and hold the Channel button or press Save on the green button of the
right knob.
Settings view
For more information on wire feeder's settings, see Wire feeder settings view on page 97.
Wire feeder settings view
You can adjust the selected memory channel or the settings of the wire feeder through the Settings view.
Press the Settings button to access the wire feeder settings. When the settings view is open, the Settings
button lights up orange.
Modify the parameters with the right knob. Press the green button in the center of the knob to select and
turn the right knob to adjust a parameter.
Table 4: Wire feeder settings
TriggerChange the welding gun trigger mode (2T/4T).
• Memory channels. The view shows the number of the memory channel, the name of the welding program,
and the process symbol.
• WPS channels. The view shows the WPS name and the pass name. If the WPS covers several passes, use
the arrow buttons to move between the passes.
Figure 24: Channel view: memory channel and WPS channel
Adjusting welding parameters
In the Settings view, you can view and 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 can save the changes in the channel by pressing and holding the channel button for more than 3
seconds.
Example
To select a channel and adjust its settings, proceed as follows:
Press the Channel button to open the Channel view.
1.
Browse the channels with the arrow buttons until you find the channel you want to use.
2.
Press the Channel button to open the Settings view.