Kemppi X8 MIG Operating Manual
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Kemppi X8 MIG Operating Manual

Kemppi X8 MIG Operating Manual

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X8 MIG Welder
OPERATING MANUAL

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  • Page 1 X8 MIG Welder OPERATING MANUAL...

  • Page 2: Table Of Contents

    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...
  • Page 3 2.8 Ordering codes..................................190 2.9 Disposal of unit.................................193...

  • Page 4: Read First

    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.
  • Page 5 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 Pulse MIG © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 6 X8 MIG WELDER 1.1 Symbols Symbol Description DProcess WiseRoot+ WiseThin+ WiseFusion WiseSteel WisePenetration+ ŕ Creep Start Hot Start Upslope Crater Fill with Downslope Crater Fill with Downlevel © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 7 X8 MIG WELDER 1.1 Symbols Symbol Description Ö Õ WP Switch Touch Sense Ignition Ɔ User manual © OPERATING MANUAL | EN KEMPPI | 2018-09-28...

  • Page 8: X8 Mig Welder

    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.

  • Page 9: Introduction To Weldeye For Welding Procedure And Qualification Management

    • 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) •...

  • Page 10: System Structure

    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.

  • Page 11: X8 Power Source

    X8 MIG WELDER 2.2 System structure 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 ©...
  • Page 12 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.
  • Page 13 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.
  • Page 14 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.

  • Page 15: X8 Wire Feeder

    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.
  • Page 16 X8 MIG WELDER 2.2 System structure Figure 2: The warning sticker inside the wire feeder 10. Wire spool 11. Wire spool locking cover 12. Feed rolls 13. Pressure handle 14. Wire guide 15. Inside control buttons © OPERATING MANUAL | EN...

  • Page 17: Control Panel

    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.
  • Page 18 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.
  • Page 19 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.

  • Page 20: X8 Mig Guns

    X8 MIG WELDER 2.2 System structure 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.
  • Page 21 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.

  • Page 22: Control Pad

    X8 MIG WELDER 2.2 System structure 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.
  • Page 23 X8 MIG WELDER 2.2 System structure 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.
  • Page 24 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. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...

  • Page 25: Installation

    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.

  • Page 26: Power Source Installation

    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.
  • Page 27 X8 MIG WELDER 2.3 Installation 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.
  • Page 28 X8 MIG WELDER 2.3 Installation 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.
  • Page 29 X8 MIG WELDER 2.3 Installation 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.
  • Page 30 X8 MIG WELDER 2.3 Installation 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.
  • Page 31 X8 MIG WELDER 2.3 Installation 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.
  • Page 32 X8 MIG WELDER 2.3 Installation Max. 20 Nm Place the gas cylinder on the cart. Fasten the straps in the cart around the gas cylinder. 2.3.2.3 Installing optional X8 Cooler If your setup does not include X8 Cooler, you can skip these instructions.
  • Page 33 X8 MIG WELDER 2.3 Installation 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.

  • Page 34: Wire Feeder Installation

    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.
  • Page 35 X8 MIG WELDER 2.3 Installation 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.
  • Page 36 X8 MIG WELDER 2.3 Installation 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.
  • Page 37 X8 MIG WELDER 2.3 Installation 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.
  • Page 38 X8 MIG WELDER 2.3 Installation Push the collars on the mounting pins of the feed rolls up to pull the mounting pins off. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 39 X8 MIG WELDER 2.3 Installation 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.
  • Page 40 X8 MIG WELDER 2.3 Installation Select the feed rolls according to the tables below. Wire feed rolls, plastic Filler wire Feed roll profile Filler wire Feed roll Drive roll code Pressure roll material diameter (mm) identification code Fe, Ss (Al, Mc,...
  • Page 41 X8 MIG WELDER 2.3 Installation Wire feed rolls, plastic W001049 W001050 W001051 W001052 W001053 W001054 W001055 W001056 Fc, Mc (Fe) V-groove, W001057 W001058 knurled W001059 W001060 1.4−1.6 W001061 W001062 W001063 W001064 W001065 W001066 Al (Fc, Mc, Ss, U-groove W001067 W001068...
  • Page 42 X8 MIG WELDER 2.3 Installation Wire feed rolls, plastic W001071 W001072 Wire feed rolls, metal Filler wire Feed roll profile Filler wire Feed roll Drive roll code Pressure roll material diameter (mm) identification code Fe, Ss (Al, Mc, V-groove 0.8−0.9...
  • Page 43 X8 MIG WELDER 2.3 Installation 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.
  • Page 44 X8 MIG WELDER 2.3 Installation 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.
  • Page 45 X8 MIG WELDER 2.3 Installation 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.
  • Page 46 X8 MIG WELDER 2.3 Installation Release the pressure arms to move the feed rolls apart. This opens a gap between the feed rolls. Release the filler wire end from the spool and cut off any deformed section so that the end is straight.
  • Page 47 X8 MIG WELDER 2.3 Installation Filler wire material Feed roll profile Filler wire diameter (mm) Adjustment (x100N) Fe/Ss solid V-groove 0.8−1.0 1.5−2.0 ≥ 1.2 2.0−2.5 Metal and flux cored V-groove, knurled ≥ 1.2 1.0−2.0 Self-shielded V-groove, knurled ≥ 1.6 2.0−3.0...
  • Page 48 You can also use this button to test that the gases flow through the system properly. Close the top cover. Wire spools X8 MIG Welder has three different wire spool hub options available for different wire spools: A. Standard spool B. Spool hub for the small wire spool Attach the extension pieces to the standard spool halves.
  • Page 49 X8 MIG WELDER 2.3 Installation 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.

  • Page 50: Cables Installation

    X8 MIG WELDER 2.3 Installation 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 .
  • Page 51 X8 MIG WELDER 2.3 Installation 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.
  • Page 52 X8 MIG WELDER 2.3 Installation Connect the cooling water hoses to the slot. Close and lock the cable cabinet door. Note: When connecting the cables to the wire feeder, route the cables neatly so that the cable cabinet door closes properly.
  • Page 53 X8 MIG WELDER 2.3 Installation Connect the welding current cable to the plus (+) side connector (1) on the power source. 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.
  • Page 54 X8 MIG WELDER 2.3 Installation Figure 3: Interconnection cabling for power source and wire feeder Table 3: Color codes Welding current cable Shielding gas hose Control cable Measurement cable Coolant input and output hoses © OPERATING MANUAL | EN KEMPPI | 2018-09-28...

  • Page 55: Control Pad Installation

    X8 MIG WELDER 2.3 Installation 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.
  • Page 56 X8 MIG WELDER 2.3 Installation 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.
  • Page 57 X8 MIG WELDER 2.3 Installation 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.
  • Page 58 X8 MIG WELDER 2.3 Installation 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.

  • Page 59: Welding Gun Installation

    2.3.6 Welding gun installation 2.3.6.1 Preparing and connecting welding gun X8 MIG Gun has been preassembled by the manufacturer: the wire liner, contact tip and gas nozzle are premounted. To start using the gun, proceed as follows: Check that the wire liner, contact tip and gas nozzle are suitable for the job. Change if needed. If your setup includes a gas-cooled gun, you can also change the neck.
  • Page 60 2.3 Installation 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.
  • Page 61 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)
  • Page 62 X8 MIG WELDER 2.3 Installation 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)
  • Page 63 X8 MIG WELDER 2.3 Installation 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.
  • Page 64 X8 MIG WELDER 2.3 Installation 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. ©...
  • Page 65 X8 MIG WELDER 2.3 Installation 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.
  • Page 66 X8 MIG WELDER 2.3 Installation 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.
  • Page 67 X8 MIG WELDER 2.3 Installation 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.
  • Page 68 X8 MIG WELDER 2.3 Installation 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.
  • Page 69 X8 MIG WELDER 2.3 Installation 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.
  • Page 70 X8 MIG WELDER 2.3 Installation Remove the guide nut from the tip of the sleeve. Remove the sleeve and pull out the liner together with the cone . © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 71 X8 MIG WELDER 2.3 Installation 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.
  • Page 72 X8 MIG WELDER 2.3 Installation 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. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 73 X8 MIG WELDER 2.3 Installation Cut the excessive liner leaving 1 - 2 mm. Use side cutting pliers for spiral liner and carpet knife for DL Chili liner. 1-2 mm Attach the guide nut at the tip of the sleeve.
  • Page 74 X8 MIG WELDER 2.3 Installation Changing gas nozzle (water-cooled gun) Screw the gas nozzle into its place. Changing contact tip (water-cooled gun) Remove the contact tip. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 75 X8 MIG WELDER 2.3 Installation 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.
  • Page 76 2.3 Installation 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).
  • Page 77 X8 MIG WELDER 2.3 Installation 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.

  • Page 78: Lifting X8 Mig Welder

    2.3 Installation 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.

  • Page 79: Purchasing And Managing Welding Software

    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.
  • Page 80 X8 MIG WELDER 2.3 Installation 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.
  • Page 81 X8 MIG WELDER 2.3 Installation Wire Feeder Counterbalance Arm The wire feeder counterbalance arm reduces the weight of the cable bundle over the working area. Proceed as follows: © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 82 X8 MIG WELDER 2.3 Installation 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.
  • Page 83 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.

  • Page 84: Operation

    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.
  • Page 85 X8 MIG WELDER 2.4 Operation 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.
  • Page 86 X8 MIG WELDER 2.4 Operation Figure 7: Control Pad display with the Adjust Figure 8: Control Pad display with the Select footer 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.
  • Page 87 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)
  • Page 88 X8 MIG WELDER 2.4 Operation 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.
  • Page 89 X8 MIG WELDER 2.4 Operation 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.
  • Page 90 X8 MIG WELDER 2.4 Operation 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.
  • Page 91 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.
  • Page 92 X8 MIG WELDER 2.4 Operation 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.
  • Page 93 X8 MIG WELDER 2.4 Operation 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.
  • Page 94 X8 MIG WELDER 2.4 Operation 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.
  • Page 95 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. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 96 X8 MIG WELDER 2.4 Operation 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.
  • Page 97 X8 MIG WELDER 2.4 Operation 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.
  • Page 98 X8 MIG WELDER 2.4 Operation 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.
  • Page 99 X8 MIG WELDER 2.4 Operation 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.
  • Page 100 X8 MIG WELDER 2.4 Operation • 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.

  • Page 101: Preparing Welding System For Use

    To switch on Control Pad, press and hold the power button for a few seconds. Preparing cooler Fill the coolant container inside the cooler with Kemppi coolant liquid. To weld, you must pump the coolant through the system. Press the coolant circulation button in the front panel of the power source. It activates the motor, which pumps the coolant to the hoses and to the welding gun.
  • Page 102 X8 MIG WELDER 2.4 Operation The indicator panel also includes indicator LEDs which are yellow if the coolant level is too low or the coolant temperature is too high. When the circulation is defectless, the indicator LED is green. Press the coolant circulation button after each time you change the welding gun.
  • Page 103 Ensure that the surface contact to the table is clean of metal oxide and paint and that the clamp is firmly secured. 2.4.2.1 Filling cooler Fill the cooler with 20-40 % coolant solution, for example, Kemppi cooling liquid. Proceed as follows: Pull the front panel latch and open the front panel of the power source.
  • Page 104 X8 MIG WELDER 2.4 Operation Screw the lid back on the cooler. Push to close the front panel of the power source. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 105 2.4.2.2 Calibrating arc voltage X8 MIG Welder measures the voltage of the welding arc and the voltage loss in the interconnection cable and welding gun. After calibration, the power source calculates the arc voltage, if the voltage sensing cable is not connected.
  • Page 106 2.4.2.3 Connecting to Kemppi cloud services To use the Kemppi cloud services, connect the welding machine to the Internet either through a WLAN or a wired connection. Form the connection by using the Cloud services view in the View menu. You can also see the status of the Cloud services there.
  • Page 107 X8 MIG WELDER 2.4 Operation Switch the WiFi on. Select the WLAN network. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 108 X8 MIG WELDER 2.4 Operation Fill in the password, if needed. Network details are shown in WiFi settings, when the WLAN connection is created. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 109 2.4 Operation Wired connection The Ethernet connection is automatically created when you connect the Ethernet cable to X8 MIG Welder. The Ethernet connection details are shown in Ethernet settings when the connection is created. Set DHCP to OFF to configure the Ethernet settings manually.

  • Page 110: How To Use Welding System

    2.4.3 How to use welding system Choosing the optimal welding program with the most suitable process and other parameters facilitates the use of X8 MIG Welder. Programs can be saved in memory channels for easy reach. Digital WPSs automatically adjust the welding machine settings.
  • Page 111 X8 MIG WELDER 2.4 Operation Selecting memory channel You can select a memory channel through Control Pad, wire feeder display or gun remote control. Proceed as follows: To select a memory channel through Control Pad or wire feeder display: a) Press the Channel button.
  • Page 112 X8 MIG WELDER 2.4 Operation d) Scroll to the channel where to save the new settings. e) Press the green button. The name of the memory channel changes to the name of the welding program. © OPERATING MANUAL | EN...
  • Page 113 X8 MIG WELDER 2.4 Operation Creating new memory channel settings When you create a welding program to a memory channel, always select an existing program as a basis for the modifications. Proceed as follows: Go to Channels and select a memory channel where to start modifications.
  • Page 114 X8 MIG WELDER 2.4 Operation Select the target channel and press the green button. When you save the welding parameters, the channel name changes to the program name. Modify the parameters. Save the modified parameters. See Saving modified memory channel settings on page 111.
  • Page 115 X8 MIG WELDER 2.4 Operation Renaming channel Proceed as follows: Go to the Channel view. Press the green button to open Actions. Select Rename and press the green button. Control Pad shows you a keypad. © OPERATING MANUAL | EN...
  • Page 116 X8 MIG WELDER 2.4 Operation Turn the knob to go to the eraser and press Erase character on the right knob to delete the former name. Turn the right knob and press the green button on it to select letters.
  • Page 117 Saving new welding programs on page 114. The welding programs in X8 MIG Welder suit the most common wire types, wire diameters, shielding gases and different base materials. Programs can be purchased at Kemppi DataStore. Kemppi also offers Synergic ©...
  • Page 118 2.4 Operation Customized Welding programs which are designed and created according to customer-specific welding applications. For more information, contact your local Kemppi dealer. Selecting a welding program through Channel view The easiest way to select a welding program is to browse through the memory channels in the Channel view and select the memory channel that has the appropriate program saved in it.
  • Page 119 2.4 Operation The MMA and GOUGING modes just have one pre-installed welding program each. Standard MIG welding processes in X8 MIG Welder The processes described in this chapter are available when the MIG mode is selected. For more information on selecting the MIG mode, see Selecting a welding program.
  • Page 120 X8 MIG WELDER 2.4 Operation Figure 29: MIG Welding view When using MIG, you can adjust the following welding parameters through Settings > Parameters: • Wire Feed Speed • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed •...
  • Page 121 X8 MIG WELDER 2.4 Operation Figure 30: 1-MIG Welding view When using 1-MIG, you can adjust the following welding parameters through Settings > Parameters: • Wire Feed Speed • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed •...
  • Page 122 X8 MIG WELDER 2.4 Operation appearance of the weld. Pulse is suitable for all position welding. It is excellent for welding aluminium and stainless steel, especially when the material thickness is small. Pulse supports WisePenetration+ and WiseFusion features, as well as various optimized welding programs.
  • Page 123 X8 MIG WELDER 2.4 Operation DPulse is a pulse welding process with two separate power levels. The welding power varies between these two levels, and the parameters of each level are controlled independently. In the Welding view, toggle between level 1 and level 2 by pressing the left Control Pad button. The inactive power level is shown with a gray line on the wire feed speed diagram.
  • Page 124 DPulse supports the WiseFusion feature and various optimized welding programs. Wise processes Kemppi’s Wise products are welding processes and features designed to ease the user's work and increase the productivity by controlling the welding arc. For more information, visit www.kemppi.com.
  • Page 125 • Dynamics: -10...+10. Adjusts the short circuit behavior. On the minus side, the arc is softer (less spatter). On the plus side, the arc is harder (the arc is more stable). During welding, X8 MIG Welder uses both welding parameter sets in the manner that you have chosen in the frequency and time percentage settings.
  • Page 126 X8 MIG WELDER 2.4 Operation Using WiseRoot+ WiseRoot+ is a synergic MIG/MAG process optimized for open-gap root pass welding. The process is based on precise measurement of voltage between the welding gun nozzle and the workpiece. The measurement data serves as input for the current control. The process is suitable for root pass welding in all positions, and provides a smooth and spatter-free arc.
  • Page 127 • StartLevel: -30...+30. Finetunes the arc length for arc ignition. • StopPower: -30...+30. Adjusts the power level for arc stop. Wise features Kemppi Wise features improve the quality of welds. For more information on Wise products, visit www.kemppi.com. Introduction to WiseFusion The WiseFusion welding function enables adaptive arc length control, which keeps the arc optimally short and focused.
  • Page 128 X8 MIG WELDER 2.4 Operation To take WiseFusion into use, select Settings > Wise features > WiseFusion. To adjust the welding power / wire feed speed, in the Control Pad's Welding view, turn the left knob. To fine tune heat output, in the Control Pad's Welding view, turn the right knob.
  • Page 129 X8 MIG WELDER 2.4 Operation To take WiseSteel into use, select Settings > Wise features > WiseSteel. To adjust the welding power/wire feed speed while welding, in the Control Pad's Welding view, turn the left knob. To fine tune heat output while welding, in the Control Pad's Welding view, turn the right knob.
  • Page 130 2. Select the MMA welding program. An all-around MMA welding program pre-installed. Note: X8 MIG Welder features a voltage reduction device (VRD). When the welding machine is on but the welding arc is not ignited, the welding machine is on open circuit voltage (50 V). If the VRD is in use, it keeps the open circuit voltage on a lower, pre-set level (20 V/12 V).
  • Page 131 To use gouging, in Control Pad, select Settings > Mode > Gouging. Note: X8 MIG Welder features an integrated voltage reduction device (VRD). When the welding machine is on but the welding arc is not ignited, the welding machine is on open circuit voltage (50 V). When the VRD is in use, it keeps the open circuit voltage on a pre-set level (20V /12 V).
  • Page 132 Cladding (surfacing) means depositing a layer of filler material on the workpiece to achieve certain properties or dimensions. To use X8 MIG Welder for cladding, in Settings, select the mode (MMA/MIG), and in the filter list, for Type, select Cladding to see the suitable welding programs.
  • Page 133 X8 MIG WELDER 2.4 Operation To use X8 MIG Welder for brazing, in Settings, select the mode (MMA/MIG), and in the filter list, for Type, select Brazing to see the suitable welding programs. Trigger logic functions You can select the trigger logic through Control Pad in Settings > Trigger logic.
  • Page 134 X8 MIG WELDER 2.4 Operation Start and stop functions Touch Sense Ignition Touch Sense Ignition delivers minimum spatter and stabilizes the arc immediately after ignition. To set Touch Sense Ignition ON or OFF with Control Pad, go to Settings > Start and stop logic > Touch Sense Ignition.
  • Page 135 X8 MIG WELDER 2.4 Operation Figure 45: 4T/WP Switch Hot start 1. Trigger is pressed. 2. Trigger is released. 3. Trigger is pressed. 4. Trigger is released. To adjust Hot start, with Control Pad, go to Settings > Start and stop logic > Hot start. When you select ON, the options for adjusting Time and Level appear on the screen.
  • Page 136 X8 MIG WELDER 2.4 Operation Figure 47: 4T/WP Switch Crater Fill 1. Trigger is pressed. 2. Trigger is released. 3. Trigger is pressed. 4. Trigger is released. To adjust the Creater Fill parameters, with Control Pad, go to Settings > Start and stop logic > Crater fill.
  • Page 137 The WeldEye cloud service consists of several independent modules. When Quality Control or Welding Production Analysis has been activated, you can use Control Pad and X8 MIG Welder to collect the welding data for the WeldEye service. For more information on Weldeye, see www.weldeye.com.
  • Page 138 X8 MIG WELDER 2.4 Operation machines connected to WeldEye. If no Internet connection is available, it is possible transfer the dWPSs on a USB stick. The user can then view, activate and select the dWPSs with Control Pad. It is also possible to select dWPSs through the wire feeder display or the welding gun remote control.
  • Page 139 X8 MIG WELDER 2.4 Operation To see the list of available WPSs, press the green button. The WPS list opens. Figure 50: Advanced mode Figure 51: Basic mode Move the focus to the WPS that you want to activate. Depending on the mode of Control Pad, select one of the following options: a) If the Control Pad is in the Advanced mode, press the green button to open the Actions menu.
  • Page 140 X8 MIG WELDER 2.4 Operation b) If the Control Pad is in the Basic mode, press the green button to activate the WPS. Control Pad opens the WPS view. Here you can see all the WPS details that the welder needs to know for the job, including the pictures and details of the filler and the gas.
  • Page 141 X8 MIG WELDER 2.4 Operation If the WPS includes several passes, select the pass in Active pass. See Selecting WPS pass in WPS view on page 141. Press a view button to leave the WPS view. Note: You can also change WPS or the pass in Channel view. See...
  • Page 142 X8 MIG WELDER 2.4 Operation If there is no active WPS, Control Pad shows the WPS list. Select the WPS. Move focus to Active pass. The information under Active pass is pass-specific and varies according to the pass. Press the green button to open the menu.
  • Page 143 X8 MIG WELDER 2.4 Operation To change the pass selection, scroll to a pass in a list. Press the green button to select the pass and to return to the WPS View. Note: You can also select the WPS or pass in the Channel view. See...
  • Page 144 X8 MIG WELDER 2.4 Operation Scroll through the list of WPSs and passes to move the focus to the pass you want to take into use. The pass immediately activates. Caution: After changing WPS or pass, check the pass details to make sure you are using the correct filler wire and gas.
  • Page 145 The parameter for which the warning is shown depends on the process in use. For more information on the parameters related to various processes, see Standard MIG welding processes in X8 MIG Welder on page 119 and Wise processes on page 124.
  • Page 146 My Fleet, see About My Fleet. Transferring dWPSs without a connection to Kemppi Cloud Services In WeldEye, open a WPS. Click the welding machine icon on the toolbar. A dialog opens. Click Download dWPS. You get the WPS in a file format.
  • Page 147 X8 MIG WELDER 2.4 Operation Press the green button. Select a WPS from the list. Press the green button to open the command menu. Select Delete WPS and press the green button. © OPERATING MANUAL | EN KEMPPI | 2018-09-28...
  • Page 148 X8 MIG WELDER 2.4 Operation Filtering WPSs If more than 5 WPSs are available, you can filter the WPSs to narrow down the list. You can filter by material, thickness and joint type. Proceed as follows: Go to the View menu > WPS.
  • Page 149 X8 MIG WELDER 2.4 Operation Turn the knob to move focus and press the green button to select the thickness of the wire. Turn the knob to move focus and press the green button to select the weld type. ©...
  • Page 150 The settings show ISO/ANSI and metric/imperial terms concurrently. Using welding data collection X8 MIG Welder can be used for automated monitoring of quality and productivity of arc welding. The device records welding parameter data and transmits it to the WeldEye cloud service through a wired or wireless network.
  • Page 151 Settings view of the WeldEye cloud service. Identifier database X8 MIG Welder can provide 100 % traceability for every weld. For this, enter various identifiers in the system before welding, for example, the welder's identity, WPS, and the number of the weld.
  • Page 152 X8 MIG WELDER 2.4 Operation This identification data resides in the WeldEye cloud service, from where the device takes the data and matches it with the identifiers that the welder has entered either manually or using barcodes. The identification database is synchronized from WeldEye to the device every 15 minutes when the welding system is online.
  • Page 153 X8 MIG WELDER 2.4 Operation • Activate code reader to read the barcode or QR code on your ID card • Enter barcode to enter the barcode manually Read the barcode or QR code on your ID card or enter the barcode manually.
  • Page 154 X8 MIG WELDER 2.4 Operation Identify the WPS to be used. Select the WPS in the Task view or read the barcode on the printed document. The first pass of the WPS is selected automatically. For more information, see Selecting WPS pass in WPS view.
  • Page 155 X8 MIG WELDER 2.4 Operation Record the filler material batch number to provide traceability. Read the barcode from the filler wire package. If there is no barcode available, select Enter barcode in the Task view. Use the virtual keyboard to enter the barcode number by hand.
  • Page 156 X8 MIG WELDER 2.4 Operation Note: This function is available only if the weld has been identified. The availability is controlled in the WeldEye cloud service settings. If heat input tracking is enabled, enter the length of the weld, which is used for heat input calculation.
  • Page 157 X8 MIG WELDER 2.4 Operation In the WeldEye cloud service settings, you can filter the items that Control Pad shows to be identified. For example, you can have the WPS and the filler batch number shown, but not the filler material or shielding gas.
  • Page 158 X8 MIG WELDER 2.4 Operation White: The measured value is within the WPS limits or the WPS is not identified. Yellow: The measured value is near the WPS limits. (Warning) Red: The measured value is outside the WPS limits. (Alert) There is a short reaction time, usually a few seconds, before the color changes.
  • Page 159 X8 MIG WELDER 2.4 Operation Tracking heat input You can set the device to track the heat input of each weld and provide the welder with heat input values. To get the heat input value, select Complete Pass. Identify the weld and perform at least one welding run.
  • Page 160 X8 MIG WELDER 2.4 Operation After you mark the pass complete, Control Pad shows the average heat input and travel speed values and indicates whether they are within the WPS limits. You can use this feedback to adjust the parameters or welding technique.
  • Page 161 X8 MIG WELDER 2.4 Operation Create work orders in the WeldEye cloud service, and once released, they become automatically available to welding machines within 15 minutes. You can restrict the visibility of the work orders to individual persons or welding machines.
  • Page 162 X8 MIG WELDER 2.4 Operation Activate the work order or a weld. If the work order contains a list of welds, scroll to the desired weld and press the green button on the right control knob to select it. If the work order does not contain welds, scroll to Activate work order and press the green button on the right control knob to select it.
  • Page 163 X8 MIG WELDER 2.4 Operation If the active work order or weld has predefined WPSs in WeldEye, Control Pad promps you to select one of them. The work order is now selected and visible in the Task view. You can start welding.
  • Page 164 Once completed, the work order is automatically removed from the work order list in Control Pad within 15 minutes or as soon as X8 MIG Welder is connected to Internet. Changing work order If you deselect the active work order or change it to another work order, the welding data is no longer associated with it and the time tracking stops.
  • Page 165 X8 MIG WELDER 2.4 Operation A list of work orders appears. To select another work order, select it from the list. To deselect the current work order, scroll up to the list and select No work order. Recommended WPSs Work orders and welds can include recommended Welding Procedure Specifications (WPSs). They help welder to choose the correct WPS for the job, which reduces the risk of errors.

  • Page 166: Troubleshooting

    Digital work orders can be used to track lead times at work order level. X8 MIG Welder automatically records the exact time when the work order is started, stopped, and completed. With this information, WeldEye calculates for each work order the lead time (total time from start to finish) and the active working time (lead time exclusive of pauses and breaks).
  • Page 167 • Check that the feed roll pressure is adjusted correctly for the filler wire. • Check that the Kemppi Gun Adapter is properly connected to the wire feeder. • Blow compressed air through the wire liner to check that it is not blocked.
  • Page 168 The gun neck overheats • Make sure you are using original Kemppi consumable and spare parts. Incorrect spare part materials may cause the overheating of the neck.
  • Page 169 X8 MIG WELDER 2.5 Troubleshooting Problem Recommended actions The gun overheats • Make sure the coolant circulation is working normally (see the coolant circulation warning LED in the power source). • Measure the coolant circulation speed: detach the coolant output hose from the wire feeder while the power source is on, and let the coolant run into a measurement cup.

  • Page 170: Error Codes

    X8 MIG WELDER 2.6 Maintenance Problem Recommended actions High spatter volume • Check the welding parameter values and welding procedure. • Check the gas type and flow. • Check the polarity of the gun/electrode. • Check that the filler wire is correct for the current application.

  • Page 171: Daily Maintenance

    Maintenance of guns • Check regularly that all the components are tightly fastened. • Check that the current transfer surface on the Kemppi gun adapter is clean and unscratched, and the connector pins are straight and undamaged. • Check the protective hose on the cable for damage.
  • Page 172 X8 MIG WELDER 2.6 Maintenance Figure 54: Water-cooled gun • Check and remove any spatter build-up from the nozzle. Figure 55: Gas-cooled gun © OPERATING MANUAL | EN KEMPPI | 2018-09-28...

  • Page 173: Periodic Maintenance Of Power Source And Wire Feeder

    Maintenance of Control Pad Control Pad is water resistant and can be wiped clean with a moist cloth. Do not use detergents. For repairs, contact Kemppi at www.kemppi.com or your dealer. 2.6.2 Periodic maintenance of power source and wire feeder Caution: Only qualified service personnel is allowed to carry out periodic maintenance.

  • Page 174: Service Workshops

    Update the wire feeder to the latest firmware version and load new welding software. 2.6.3 Service workshops Kemppi Service Workshops complete the welding system maintenance according to the Kemppi service agreement. The main aspects in the service workshop maintenance procedure are: •...
  • Page 175 X8 MIG WELDER 2.7 Technical data Feature Description Value 400 A 400 A MV Open circuit voltage (MMA) 50 V 50 V Open circuit power (MMA) (without 44 - 53 W 44 - 53 W cooler and wire feeder, fans OFF) Open circuit power (MMA) (without 107 - 111 W 99 - 111 W...

  • Page 176: X8 Power Source 500 A / 500 A Mv

    X8 MIG WELDER 2.7 Technical data Feature Description Value 400 A 400 A MV 2.4 GHz WiFi & 2.4 GHz WiFi & Wireless communication type Bluetooth Bluetooth • Transmitter frequency and power 2.4 GHz Bluetooth and 2.4 GHz Bluetooth and WLAN WLAN • 2400-2483.5 MHz • 2400-2483.5 MHz 20 dBm...
  • Page 177 X8 MIG WELDER 2.7 Technical data Feature Description Value 500 A 500 A MV No-load voltage (MIG & MMA) 76 - 92V DC 76 - 92V DC 0 peak No-load voltage (MMA) 72 - 86 V DC 72 - 86 V DC r peak Fuse 220 - 230 V 63 A 380 - 460 V 32 A 32 A Output 40 % ED 60 % ED 500 A 500 A 100 % ED...

  • Page 178: X8 Power Source 600 A / 600 A Mv

    X8 MIG WELDER 2.7 Technical data Feature Description Value 500 A 500 A MV Standards IEC 60974-1, -10 IEC 60974-1, -10 2.7.3 X8 Power Source 600 A / 600 A MV Feature Description Value 600 A 600 A MV Mains connection cable H07RN-F 6 mm²...
  • Page 179 X8 MIG WELDER 2.7 Technical data Feature Description Value 600 A 600 A MV 380 - 460 V 35 A 35 A Output 40 % ED 600 A 600 A 60 % ED 530 A 530 A 100 % ED 440 A 440 A Welding current and voltage range MIG @ 220 V 20 A/14 V - 600 A/46 V MIG @ 380 V 20 A/14 V - 600 A/55 V20 A/14 V - 600 A/55 V Welding current and voltage range MMA @ 220 V...

  • Page 180: X8 Cooler

    X8 MIG WELDER 2.7 Technical data Feature Description Value 600 A 600 A MV Standards IEC 60974-1, -10 IEC 60974-1, -10 2.7.4 X8 Cooler Feature Description Value Operating voltage, U 3~50/60 Hz 220 - 230 V ±10 % 380 - 460 V ±10 % Supply current (maximum) 1.0 A 1max Supply current (effective) 0.6 A...

  • Page 181: X8 Control Pad

    X8 MIG WELDER 2.7 Technical data Feature Description Value Gun connection Kemppi Wire feed mechanism 4-roll, twin-motor Diameter of feed rolls 32 mm Filler wires 0.6 - 2.4 mm 0.6 - 2.4 mm MC/FC 0.8 - 2.4 mm 0.8 - 2.4 mm Wire feed speed 0.5 - 25 m/min Wire spool weight (max) 20 kg Wire spool diameter (max) 300 mm...

  • Page 182: X8 Mig Gun 200-G

    Display size 5.7" Standards • IEC 60950-1 • EN 62368-1 • EN 300 328 v2.1.1 • EN 300 330 v2.1.1 • EN 301 489-1 v2.1.1 • EN 301 489-3 v2.1.0 • EN 301 489-17 v3.1.1 2.7.7 X8 MIG Gun 200-g Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling Type of connection Kemppi Wire diameters 0.8 - 1.2 mm...

  • Page 183: X8 Mig Gun 300-G

    Height y (see figure 86 mm below) Neck angle ɑ (see figure below) 50° Standards IEC 60974-7 Figure 57: Neck dimensions and angle 2.7.8 X8 MIG Gun 300-g Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling...

  • Page 184: X8 Mig Gun 400-G

    Height y (see figure 97 mm below) Neck angle ɑ (see figure below) 50° Standards IEC 60974-7 Figure 58: Neck dimensions and angle 2.7.9 X8 MIG Gun 400-g Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling...

  • Page 185: X8 Mig Gun 420-W

    Height y (see figure 110 mm below) Neck angle ɑ (see figure below) 50° Standards IEC 60974-7 Figure 59: Neck dimensions and angle 2.7.10 X8 MIG Gun 420-w Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling...

  • Page 186: X8 Mig Gun 520-W

    104 mm below) Neck angle ɑ (see figure below) 50° Standards IEC 60974-7 *Gun length 5 m Figure 60: Neck dimensions and angle 2.7.11 X8 MIG Gun 520-w Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling...

  • Page 187: X8 Mig Gun 600-W

    111 mm below) Neck angle ɑ (see figure below) 50° Standards IEC 60974-7 *Gun length 5 m Figure 61: Neck dimensions and angle 2.7.12 X8 MIG Gun 600-w Feature Description Value Welding process MIG/MAG Method of guidance Manual © OPERATING MANUAL | EN...
  • Page 188 X8 MIG WELDER 2.7 Technical data Feature Description Value Type of cooling Liquid Coolant flow rate 1 l/min Coolant pressure (max) 5 bar Type of connection Kemppi Wire diameters 1.2 - 2.4 mm Load capacity @ 60 % (MIXED GAS) @ 100 % (MIXED GAS) 600 A @ 60 % (CO @ 100 % (CO...

  • Page 189: X8 Mig Gun Ws 420-W

    X8 MIG WELDER 2.7 Technical data 2.7.13 X8 MIG Gun WS 420-w Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling Liquid Coolant flow rate 1 l/min Coolant pressure (max) 5 bar Type of connection Kemppi Wire diameters 1.2 - 1.6 mm...

  • Page 190: Ordering Codes

    X8 MIG WELDER 2.8 Ordering codes Figure 63: Neck dimensions and angle 2.8 Ordering codes Table 11: X8 Power Source Part Ordering code X8 Power Source without software X8 Power Source 400 X8100400000 X8 Power Source 400 + X8 Cooler...
  • Page 191 = 245 mm, y = 111 mm X8300523501 X8 MIG Gun 520-w (5.0 m) x = 245 mm, y = 111 mm X8300525001 X8 MIG Gun WS 420-w (8.0 m) x = 132 mm, y = 104 mm X8300428000 X8 Mounting Ring Tool SP012703 ©...
  • Page 192 X8 MIG WELDER 2.8 Ordering codes Figure 64: Neck dimensions and angle Table 15: Interconnection cables, gas-cooled Interconnection cable cross Cable length Ordering code section 95 mm 2 m X8801950200 70 mm 5 m X8801700500 95 mm 5 m X8801950500 70 mm 10 m X8801701000 95 mm 10 m X8801951000 70 mm...
  • Page 193 WiseRoot+ X8500003 WiseSteel X8500001 WiseThin+ X8500004 For the ordering codes of consumable kits for the guns and wire feeder, see kitselect.kemppi.com. For the ordering codes of welding program packs, see Kemppi DataStore. 2.9 Disposal of unit Note: Do not dispose of any electrical equipment with normal waste! At the end of the useful working life of the unit and its accessories, make sure that you follow national and local regulations regarding the disposal of the unit.
  • Page 194 The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre, as per the instructions of local authorities or a Kemppi representative. By applying these European Directives you improve the environment and human health.

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