Kemppi X8 MIG Operating Manual

X8 MIG Welder

OPERATING MANUAL

Contents

1 Read first.................................................................................................................... 4

1.1 Symbols..................................................................................................................................................................................... 4

2 X8 MIG Welder.......................................................................................................... 8

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

2.2.2 X8 Wire Feeder....................................................................................................................................................15

2.2.3 X8 MIG Guns........................................................................................................................................................ 20

2.2.4 Control Pad............................................................................................................................................................22

2.3 Installation..............................................................................................................................................................................25

2.3.1 Before installation...............................................................................................................................................25

2.3.2 Power Source installation................................................................................................................................ 26

2.3.3 Wire Feeder installation...................................................................................................................................34

2.3.4 Cables installation...............................................................................................................................................50

2.3.5 Control Pad installation....................................................................................................................................55

2.3.6 Welding gun installation..................................................................................................................................59

2.3.7 Lifting X8 MIG Welder......................................................................................................................................78

2.3.8 Purchasing and managing welding software.......................................................................................... 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

2.5.1 Error codes..........................................................................................................................................................170

2.6 Maintenance....................................................................................................................................................................... 170

2.6.1 Daily maintenance............................................................................................................................................171

2.6.2 Periodic maintenance of power source and wire feeder..................................................................173

2.6.3 Service workshops........................................................................................................................................... 174

2.7 Technical data.................................................................................................................................................................... 174

2.7.1 X8 Power Source 400 A / 400AMV....................................................................................................... 174

2.7.2 X8 Power Source 500 A / 500AMV....................................................................................................... 176

2.7.3 X8 Power Source 600 A / 600AMV....................................................................................................... 178

2.7.4 X8 Cooler.............................................................................................................................................................180

2.7.5 X8 Wire Feeder..................................................................................................................................................180

2.7.6 X8 Control Pad..................................................................................................................................................181

2.7.7 X8 MIG Gun 200-g.......................................................................................................................................... 182

2.7.8 X8 MIG Gun 300-g.......................................................................................................................................... 183

2.7.9 X8 MIG Gun 400-g.......................................................................................................................................... 184

2.7.10 X8 MIG Gun 420-w....................................................................................................................................... 185

2.7.11 X8 MIG Gun 520-w....................................................................................................................................... 186

2.7.12 X8 MIG Gun 600-w....................................................................................................................................... 187

2.7.13 X8 MIG Gun WS 420-w...............................................................................................................................189

2.8 Ordering codes..................................................................................................................................................................190

2.9 Disposal of unit.................................................................................................................................................................193

iii

X8 MIG WELDER 1.1 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.

Convention Used 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

Symbol Description

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.

Coolant input

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X8 MIG WELDER 1.1 Symbols

Symbol Description

Coolant output

Gas input

Gas output

High voltage

Protective earth

1-MIG

DPulse MIG

Carbon arc gouging

MIG

MMA

Pulse MIG

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X8 MIG WELDER 1.1 Symbols

Symbol Description

DProcess

WiseRoot+

WiseThin+

WiseFusion

WiseSteel

WisePenetration+

Creep Start

Hot Start

Upslope

Crater Fill with Downslope

Crater Fill with Downlevel

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X8 MIG WELDER 1.1 Symbols

Symbol Description

WP Switch

Touch Sense Ignition

User manual

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X8 MIG WELDER 2.1 System introduction

2 X8 MIG Welder

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)

• Connects to an external wire drum

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• Contains a control panel for basic adjustment of welding parameters, memory channels and settings

3. X8 MIG Gun 200/300/400-g, 420/520/600-w, X8 MIG Gun WS 420-w

• Connects to the wire feeder with Kemppi Gun Adapter

• Gas-cooled models feature a rotating, changeable neck

• Remote control for selecting memory channels and adjusting settings (optional)

• Ergonomic pistol grip handle

4. X8 Cooler (optional)

• Optionally included in the power source delivery

• Can also be purchased separately

• Essential for welding with a current over 400 A

5. Control Pad

• Wireless remote interface for operating X8 MIG Welder

6. Interconnection Cable 70/95-w/-g (several options)

• 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

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X8 MIG WELDER 2.2 System structure

can print out documents or, for example, a list of welders with a certain qualification certificate. Attachments can be added to any document.

Discover WeldEye – universal welding management software

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.

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X8 MIG WELDER 2.2 System structure

42 3

Figure 1: A chart 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

1. Indicator panel

2. Transportation handle

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X8 MIG WELDER 2.2 System structure

3. USB connector

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.

6. Ethernet connector

7. Power switch

8. Coolant outlet hose connector

9. Coolant inlet hose connector

10. Rear panel

11. Mains cable

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12. Strain relief holder

Indicator panel

1. Power indicator

The LED is green when the unit is on.

2. Voltage Reduction Device (VRD) indicator

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.

6. Coolant temperature warning

The LED is yellow when the cooler is overheating.

Caution:

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X8 MIG WELDER 2.2 System structure

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.

Interconnection cable

1. Shielding gas hose

2. Coolant inlet hose

3. Coolant outlet hose

4. Welding current cable

5. Control cable

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X8 MIG WELDER 2.2 System structure

6. Measurement cable

7. Strain relief pin

2.2.2 X8 Wire Feeder

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.

3. Top cover latch

4. Cable cabinet door

5. Cable cabinet latch

6. Control panel

7. Strain relief

8. Strain relief latch

9. Gun holder mount

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1011

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

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X8 MIG WELDER 2.2 System structure

Control panel

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.

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X8 MIG WELDER 2.2 System structure

3. Settings button

The button lights up orange, when the view is activated.

4. Left control knob

5. Right control knob

6. Left and right button

For more information on the use and features of the control 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.

2. Gas test button

Test the shielding gas flow, or flush out the remainder of the previous gas.

3. Wire inch button

Drive the filler wire forward with arc off.

Interconnection cable connectors

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X8 MIG WELDER 2.2 System structure

1. Welding current

Supplies current from the power source to the wire feeder.

2. Shielding gas

Supplies shielding gas to the welding gun.

3. Measurement

Supplies the welding parameters measured during welding.

4. Control

Supplies data and operating voltage to the wire feeder.

5. Coolant outlet and inlet

Circulates coolant to and from the welding gun.

For information on the installation of the cables, 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 control to optional SuperSnake subfeeder or a motorized welding gun.

3. Remote control

Connects to remote control devices (Control Pad). Supplies power and data connection with 12 V voltage.

4. Voltage sensing

Connects to the welding piece and measures arc voltage in real time.

5. Coolant outlet

Delivers cold coolant to the welding gun.

6. Coolant inlet

Receives heated coolant from the welding gun.

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108

65 7 9

11212

2.2.3 X8 MIG Guns

Gas-cooled gun

1. Gas nozzle

2. Insulating bush

3. Contact tip

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 Gun Remote Control

The remote control is an optional accessory.

11. Trigger on the pistol grip handle

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X8 MIG WELDER 2.2 System structure

12. Pistol grip handle

Quick to attach and detach.

13. Kemppi Gun Connector

Water-cooled gun

1. Gas nozzle

2. Insulating bush

3. Contact tip

4. Contact tip adapter

5. Neck

6. Work 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 accessory.

10. Trigger on the pistol grip handle

11. Pistol grip handle

Quick to attach and detach.

12. Kemppi Gun Connector

13. Coolant inlet hose

14. Coolant outlet hose

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2.2.4 Control Pad

This section describes the structure of Control Pad.

1. Power button

The button lights up orange, when you switch Control Pad on.

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 lights up blue, when the view is activated.

8. Menu button

The button lights up white, when the view is activated.

9. Settings button

The button lights up orange, when the view is activated.

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10. NFC reader

11. Barcode reader

12. ON/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 charger, Control Pad shows you the charge level.

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X8 MIG WELDER 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.

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X8 MIG WELDER 2.3 Installation

15. Charger cable port

A stopper shields the charger cable port.

16. Micro USB port

A cover shields the micro USB port and the USB cable port.

17. USB cable port

18. Combo cable port

Combo cable port transfers both data and power. A stopper shields the combo cable port.

2.3 Installation

Perform this installation procedure to prepare your X8 MIG Welder for use.

Read the instructions 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 installation, check the contents of the packages and make sure the parts are not damaged.

Before you remove the power source completely from its packaging, install the wheel set.

Before you install the power source on the site, see the following requirements regarding the mains cable type and fuse rating.

Warning:

The mains cable must be installed by an authorized electrician.

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X8 MIG WELDER 2.3 Installation

Warning:

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 type Fuse rating Cable type Fuse rating

400 A 6 mm

500 A 6 mm

600 A 6 mm

25 A - -

32 A 16 mm

35 A 16 mm

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.

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1 2 3 4

Push the rear axle through the opening in the bottom of the rear side of the unit and set the axle in the

middle.

Slide the two wheel spacers (1) onto the axle.

Slide the two wheels (2) onto the axle.

Slide the two washers (3) onto the axle.

Slide the two retaining rings (4) on the axle, until they lock into the groove on the axle.

Install the front wheels:

Push the front axle through the opening in the bottom of the front side of the unit and set the axle in

the middle.

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Max. 20 Nm

Place the transportation handle over the ridge in the wheel assembly and align the holes in the wheel

assembly with the ends of the axle.

Attach the front wheel assembly to the end of the axle with a bolt (1) and washer (2) from both sides.

When the wheels are attached, lift the power source off the pallet.

10.

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Note:

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.

Attach a wheel set to the front of the unit.

• 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.

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4321

Attach the wheel set of the gas cylinder cart to the axle with a bolt (1) and washers (2, 3, 4) from both

sides.

Insert cover plugs to the open ends of the wheel set.

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3 2 1

Place the upper part of the gas cylinder cart on the wheel set, and push it down until the claw fastens

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

both sides.

Attach the bottom of the gas cylinder cart to the wheel set with six bolts (1) and washers (2, 3).

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.

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3 2 1

Max. 20 Nm

Place the gas cylinder on the cart.

Fasten the straps in the cart around the gas cylinder.

10.

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 service personnel. Do not open the covers of X8 Power Source.

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64 5

1. Front panel

2. Front panel latch

3. Coolant circulation button

4. Cooler

5. Coolant container

6. Connectors for the liquid cooling unit

Proceed as follows:

Detach the two screws in the front panel of the power source.

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Pull the front panel outwards from the lower edge.

Remove the lower left cover from the rear of the power source.

Push the cooler inside the power source from the opening in the front.

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

page 103.

Attach the two screws in the front panel of the power source.

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.

Proceed as follows:

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Place the wire feeder rotating plate or double rotating plate on top of the power source, with the orange

claw at the rear of the unit.

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.

Attach the bottom of the wire feeder rotating plate to the power source with four screws (1) and

washers (2).

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5 Nm

With the control panel facing the same way as the power source front panel, place the wire feeder in the

corresponding grooves on the wire feeder rotating plate.

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 plate.

2.3.3.2 Installing welding gun holder

Install the welding gun holder to either side of the wire feeder.

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121

Proceed as follows:

Install the welding gun holder mount to the wire feeder with 2 screws going to the corresponding holes

on the wire feeder upper cover hinge.

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 diameter of the filler wire changes.

Proceed as follows:

Open the top cover and lift the pressure handle.

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Push the collars on the mounting pins of the feed rolls up to pull the mounting pins off.

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Note:

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).

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Select the feed rolls according to the tables below.

Wire feed rolls, plastic

Filler wire material

Fe, Ss (Al, Mc,

Feed roll profile Filler wire

diameter (mm)

V-groove

0.6 W001045 W001046

Fc)

0.8−0.9 W001047 W001048

1.0 W000675 W000676

1.2 W000960 W000961

Feed roll identification

Drive roll code Pressure roll

code

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Wire feed rolls, plastic

1.4 W001049 W001050

1.6 W001051 W001052

2.0 W001053 W001054

2.4 W001055 W001056

Fc, Mc (Fe) V-groove,

knurled

1.0 W001057 W001058

1.2 W001059 W001060

1.4−1.6 W001061 W001062

2.0 W001063 W001064

2.4 W001065 W001066

U-groove

1.0 W001067 W001068Al (Fc, Mc, Ss,

Fe)

1.2 W001069 W001070

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Wire feed rolls, plastic

1.6 W001071 W001072

Wire feed rolls, metal

Filler wire material

Fe, Ss (Al, Mc, Fc)

Feed roll profile Filler wire

diameter (mm)

V-groove

0.8−0.9 W006074 W006075

1.0 W006076 W006077

Feed roll identification

See the text on the roll

Drive roll code Pressure roll

code

1.2 W004754 W004753

1.4 W006078 W006079

Fc, Mc (Fe) V-groove,

knurled

1.0 W006080 W006081

1.2 W006082 W006083

1.4−1.6 W006084 W006085

2.0 W006086 W006087

Al (Fc, Mc, Ss,

U-groove

Fe)

Place the feed rolls back to their places. Align the cut on a drive roll's bottom with the pin on the drive

1.0 W006088 W006089

1.2 W006090 W006091

1.6

W006092 W006093

shaft.

Reattach the mounting pins to lock the drive and pressure rolls to their places. Align one of the cuts on

the bottom of the pressure rolls' mounting pin with the stud on the mount.

Lower the pressure handle on the feed rolls and close the top cover.

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2.3.3.4 Replacing wire guides

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.

Proceed as follows:

Remove the wire spool:

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Open the top cover latch.

Lift the top cover up.

Cut and file the tip of the filler wire.

Note:

The sharp cut tip of the filler wire may cause damage to the wire liner, if not filed.

Press Wire retract to pull back the remaining filler wire from the welding gun.

Push the wire spool locking cover aside.

Lift the wire spool from the wire feeder.

Loosen and pull the wire spool brake halves apart.

Install a new wire spool:

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Attach the wire spool brake halves to the new wire spool by pushing them together inside the wire

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.

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.

Lift the pressure handle off of the feed rolls.

10.

Install the filler wire:

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Release the pressure arms to move the feed rolls apart. This opens a gap between the feed rolls.

11.

Release the filler wire end from the spool and cut off any deformed section so that the end is straight.

12.

Note:

Ensure that the filler wire does not spill from the spool when it is released.

File the tip of the filler wire smooth.

13.

Caution:

Sharp edges on the filler wire tip may damage the wire liner.

Guide the filler wire through the inlet tube (A) and middle wire guide tube (B) to the outlet, which feeds

14.

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).

Close the pressure arms so that the filler wire is locked between the feed rolls. Ensure that the filler wire

15.

sits in the feed roll grooves.

Lower the pressure handle on the feed rolls.

16.

Adjust the pressure of the feed rolls with the pressure adjustment wheels. The pressure is the same for

17.

both feed roll pairs. The graduated scales on the pressure handle indicate the pressure applied to the feed rolls. Adjust the

pressure of the feed rolls according to the table below.

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Filler wire material Feed roll profile Filler wire diameter (mm) Adjustment (x100N)

Fe/Ss solid V-groove 0.8−1.0

≥ 1.2

1.5−2.0

2.0−2.5

Metal and flux cored V-groove, knurled ≥ 1.2 1.0−2.0

Self-shielded V-groove, knurled ≥ 1.6 2.0−3.0

Aluminium U-groove 1.0

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.

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Finalize the installation:

Select the shielding gas and attach the gas cylinder to the wire feeder.

19.

Press Gas test to flush the former shielding gas from the system.

20.

Note:

You can also use this button to test that the gases flow through the system properly.

Close the top cover.

21.

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 small wire spool

Attach the extension pieces to the standard spool halves.

C. Spool hub for the wire spool with a large center hole

All parts are delivered with the wire feeder.

Loosen and pull the spool halves to detach them.

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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

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

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.

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Insert the supplied locking pin through the hole in the strain relief pin.

Route the cable bundle from the back of the power source and attach the strain relief in the other end of

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.

Proceed as follows:

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Connect the interconnection cable to the wire feeder:

Lift the cable cabinet latch to reveal the connectors.

Connect the welding current cable to the wire feeder. Push the cable as far as it goes and turn the

connector clockwise to tighten the cable to its place.

Caution:

Tighten the welding current cable as much as you can by hand. If the welding current cable connection is loose, it may overheat.

Push the shielding gas hose towards the shielding gas hose connector base until it locks down.

Attach the strain relief to the slot on the wire feeder.

Lock the strain relief latch to secure the strain relief.

Connect the control cable to the connector. Rotate the collar clockwise to lock it in place.

Connect the measurement cable to the connector. Rotate the collar clockwise to lock it in place.

If you have the optional cooler, pull the cover over the cooling water hoses' slot to remove it.

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Connect the cooling water hoses to the slot.

Close and lock the cable cabinet door.

10.

Note:

When connecting the cables to the wire feeder, route the cables neatly so that the cable cabinet door closes properly.

Connect the interconnection cable to the power source:

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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.

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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

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Earth return cable

2.3.5 Control Pad installation

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:

a) Press the wireless pairing button on the power source indicator panel.

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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 feeder Figure 5: Connecting to power source

b) Move focus to select the connection and press the green button.

Note:

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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

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:

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:

a) Plug the combo cable to the Control Pad connector of the power source.

The connector is marked with a Control Pad icon.

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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:

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.

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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.

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Note:

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

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'

lifetime.

Press the Wire inch button to load the filler wire.

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Trim the excess filler wire at a slight angle to improve ignition.

Check the gas flow rate.

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.

Gas-cooled guns

X8 MIG Gun 200-g (3.5m) X8301203500

X8 MIG Gun 200-g (5.0m) X8301205000

X8 MIG Gun 300-g (3.5m) X8301303500

X8 MIG Gun 300-g (5.0m) X8301305000

Contact tip W012132

Contact tip adapter W011483

Gas nozzle W011478

Wire guide tube SP011868

X8 MIG Gun 200-g (3.5m) X8301203500

X8 MIG Gun 300-g (3.5m) X8301305000

Wire liner W012361

X8 MIG Gun 200-g (5.0m) X8301205000

X8 MIG Gun 300-g (5.0m) X8301305000

Wire liner W012362

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X8 MIG Gun 400-g (3.5m) X8301403500

X8 MIG Gun 400-g (5.0m) X8301405000

Contact tip W012134

Contact tip adapter W011483

Gas nozzle W011472

Wire guide tube SP011869

X8 MIG Gun 400-g (3.5m) X8301403500

Wire liner W012361

X8 MIG Gun 400-g (5.0m) X8301405000

Wire liner W012362

Water-cooled guns

X8 MIG Gun 420-w (3.5m) X8300423500

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-w 5.0m X8300425000

Wire liner W013632

X8 MIG Gun 520-w (3.5m) X8300523500

X8 MIG Gun 520-w (5.0m) X8300525000

Contact tip W012134

Contact tip adapter W011483

Gas nozzle W011472

Liner guide tube SP011869

X8 MIG Gun 520-w (3.5m) X8300523500

Wire liner W013628

X8 MIG Gun 520-w (5.0m) X8300525000

Wire liner W013632

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Changing wire liner (gas-cooled gun)

Caution:

Use the correct wire liner. The tip of the filler wire may damage an incorrect liner.

Lay the welding gun cable straight on a flat surface.

Loosen the neck tightener by rotating it half a turn, and remove the neck.

Remove the guide nut from the tip of the sleeve.

Remove the sleeve and pull out the liner. Make sure the cone and the seal slide out with the liner.

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1 2

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.

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1 2 3

Assemble the cone (1), seal (2) and sleeve (3) (supplied with the new liner) over the liner protruding from

the welding gun connector. Tighten the sleeve as tight as possible with a spanner.

Cut the excessive liner leaving 1 - 2 mm. Use side cutting pliers for spiral liner and carpet knife for DL

Chili liner.

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1-2 mm

Attach the guide nut at the tip of the sleeve.

Re-assemble the neck and tighten the neck tightener to secure.

Changing neck (gas-cooled gun)

You can change the neck without tools.

Turn the neck tightener half a turn counter-clockwise to loosen it, and pull the neck out.

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Push in the new neck and turn the neck tightener half a turn clockwise to secure it. Make sure you push

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 loosening the neck tightener.

Changing gas nozzle (gas-cooled gun)

Screw the gas nozzle into its place.

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Changing contact tip (gas-cooled gun)

Remove the contact tip.

Replace the contact tip adapter / gas diffuser, 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 important to tighten the adapter properly to enable a tight connection of the contact tip to the gun.

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Screw in a new contact tip and tighten it with an appropriate tool. Some thread grooves 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 damage an incorrect liner.

Lay the welding gun cable straight on a flat surface.

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Remove the guide nut from the tip of the sleeve.

Remove the sleeve and pull out the liner together with the cone .

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Load the new liner through the welding 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 the liner at the connector end.

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1 2

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.

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1-2 mm

Cut the excessive liner leaving 1 - 2 mm. Use side cutting pliers for spiral liner and carpet knife for DL

Chili liner.

Attach the guide nut at the tip of the sleeve.

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Changing gas nozzle (water-cooled gun)

Screw the gas nozzle into its place.

Changing contact tip (water-cooled gun)

Remove the contact tip.

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Replace the contact tip adapter/gas diffuser , if needed. Screw in and hand-tighten the new adapter as

tight as possible (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.

Screw in a new contact tip and tighten it properly with a tool. Some thread grooves on the contact tip

remain visible when the contact tip is properly connected to the gun.

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2.3.6.3 Installing pistol grip handle

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.

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TORX 20

For operation instructions, see Gun remote control on page 99.

Unscrew the two screws that attach the cover to the gun.

Remove the protective cover from the gun by pushing it forwards and lifting it up.

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 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.

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Screw in the two screws.

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 as follows:

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Loop two lifting straps through the handle at the front and two straps through the handle at the back of

the power source.

Caution:

Place the straps as close to the power source as possible.

Lift steadily straight up.

2.3.8 Purchasing 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.

2.3.9 Optional accessories

X8 MIG Welder has several accessories to facilitate its use and improve welding quality.

Wire Drum Kit

To use the wire drum kit, drill a hole at the back of X8 Wire Feeder's transparent cover.

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Wire Feeder Hanger for Boom

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.

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Wire Feeder Counterbalance Arm

The wire feeder counterbalance arm reduces the weight of the cable bundle over the working area.

Proceed as follows:

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1. Lock the rotating plate to its position.

2. Adjust the length of the arm. Tighten the screws to lock to position.

3. Turn to adjust the tension of the counterbalance 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 the wire spool stays dry.

Double Wire Feeder Rotating Plate

The double wire feeder rotating plate allows the use of two wire feeders on one power source.

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X8 MIG WELDER 2.3 Installation

X8 Cable Rack

The cable rack holds the interconnection cable during transportation 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 needed for welding. Install it on the side of the welding machine.

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2.4 Operation

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.

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Figure 6: The View menu

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.

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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

Menu button again in the Welding view.

Figure 9: The Channel button

Figure 10: The Menu button

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X8 MIG WELDER 2.4 Operation

Figure 11: The Settings button

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)

Depending on the selected welding process, function and program, some or all of the following information is shown:

1. Memory channel, its number and the welding program

The 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 welding settings, the channel number tilts to the right. To save changes, press

and hold the Channel button until the number returns to its normal position.

2. Operation mode of the welding gun (trigger logic)

2T, 4T or WP Switch. For more information, see Trigger logic functions on page 133.

3. Touch sense ignition

Option for smooth ignition with less spatter.

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4. Upslope

The selected start and stop logics.

5. Estimated welding current

6. Estimated plate material thickness

7. Wire feed speed

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.

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Figure 13: Toggling DPulse (1) Figure 14: Toggling DPulse (2)

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.

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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

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X8 MIG WELDER 2.4 Operation

Settings view

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.

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Start and stop logic menu

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:

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1. PIN lock

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.

Welding program menu

The filters under Welding program are:

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1. Material

Select the material of the welding piece.

2. Wire material

3. Wire diameter

4. Shielding gas

5. Type

Select welding/brazing or cladding.

6. Process

7. Polarity

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.

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View menu

In the Welding view, press the Menu button again to see the list of the available additional views.

Figure 21: The list of the additional views

The View menu displays the following views:

1. Welding

Press to return to the Welding view.

2. Weld data

Displays information 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 occurred previously and its point of time. Select the error and press the green button to view the details.

6. Date & time

Set the date, time and the time zone.

7. System

Displays information on the welding system.

8. Cloud services

Connect to Kemppi cloud services.

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2.4.1.2 Wire feeder control panel

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)

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1. Memory channel

2. Welding power

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

Trigger Change the welding gun trigger mode (2T/4T).

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WP Switch ON/OFF Switch the WP Switch feature ON or OFF.

Dynamics Adjust the dynamics setting for MIG, 1-MIG, Pulse,

DPulse and WiseThin+.

DPulse and WP Switch also have a Dynamics2 setting for adjusting the second level dynamics.

Touch sense ignition Switch the optimized ignition feature ON or OFF.

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 view more information.

Device information Shows you the serial number and software versions

of the welding system.

Press the green button on the right knob to view more information.

Wireless devices Press the Connect button on the right to set a

wireless connection to Control Pad.

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2 1

2.4.1.3 Gun remote control

With the remote control, you can select memory channels and WPSs, and adjust wire feed speed, fine tuning and dynamics.

Figure 22: Control buttons of the 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 between Channel view and Settings view

Selecting a memory channel or WPS

In the Channel view, use the arrow buttons to move between the channels. There are two kinds of channels:

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• 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.

Browse the channels with the arrow buttons until you find the channel you want to use.

Press the Channel button to open the Settings view.

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Kemppi X8 MIG Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual