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Kemppi X8 MIG Welder Operating Manual

Kemppi X8 MIG Welder Operating Manual

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X8 MIG Welder
Operating manual - EN
X8 MIG Welder
1
© Kemppi
1902370 / 2324

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Summary of Contents for Kemppi X8 MIG Welder

  • Page 1 X8 MIG Welder Operating manual - EN X8 MIG Welder © Kemppi 1902370 / 2324...

  • Page 2: Table Of Contents

    2.5.3 Suspending Control Pad 2.6 Preparing and connecting welding gun 2.7 Lifting X8 MIG Welder 2.8 Purchasing and managing welding software 2.9 Optional accessories 3. Operation 3.1 X8 MIG Welder control devices 3.1.1 Control Pad Navigation © Kemppi 1902370 / 2324...
  • Page 3 Saving new welding programs Renaming channel 3.3.2 Using welding processes, programs and features Selecting welding program Standard MIG welding processes in X8 MIG Welder Wise processes Wise processes: before welding with WiseRoot+ or WiseThin+ Wise processes: using DProcess Wise processes: using WiseRoot+...
  • Page 4 X8 MIG Welder Operating manual - EN Cladding and brazing Trigger logic functions Start and stop functions 3.3.3 Using WeldEye services Digital WPS Digital WPS: introduction Digital WPS: activating WPS Digital WPS: selecting WPS pass in WPS view Digital WPS: selecting WPS or pass in channel view...
  • Page 5 X8 MIG Welder Operating manual - EN 5. Technical data 5.1 X8 Power Source 400 A / 400 A MV 5.2 X8 Power Source 500 A / 500 A MV 5.3 X8 Power Source 600 A / 600 A MV 5.4 X8 Cooler...

  • Page 6: General

    While every effort has been made to ensure that the information contained in this guide is accurate and com- plete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the spe- cification 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 7: System Introduction

    Operating manual - EN 1.1 System introduction X8 MIG Welder is a multi-process welding equipment intended for demanding professional use in general or heavy fab- rication. The welding system is suitable for various MIG/MAG processes (MIG, 1-MIG, Pulse, DPulse, WiseRoot+, WiseTh- in+ ) as well as MMA welding and gouging, cladding and brazing.

  • Page 8: Introduction To Weldeye

    The wheel set is included in the power source delivery The gas cylinder cart is optionally included in the power source delivery My Fleet web service Cloud-based service for viewing and managing various information about your X8 MIG Welder Provides manufacturer's validation certificate WeldEye (optional)
  • Page 9 X8 MIG Welder Operating manual - EN Includes document register functionalities and features for comprehensive welding project documentation and man- agement. For more information on the full system and other modules, see www.weldeye.com. © Kemppi 1902370 / 2324...

  • Page 10: System Structure

    Operating manual - EN 1.2 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 MIG Welder Operating manual - EN Front Indicator panel Transportation handle 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.
  • Page 12 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 13: X8 Wire Feeder

    X8 MIG Welder Operating manual - EN 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.
  • Page 14 X8 MIG Welder Operating manual - EN Main parts Top cover 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.
  • Page 15 X8 MIG Welder Operating manual - EN 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 Control panel The control panel on the front of the wire feeder enables easy control of the wire feeder's basic features. Although Con- trol 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 16 X8 MIG Welder Operating manual - EN >> Press and hold for 2 seconds to lock or release the display and buttons. Channel button >> The button lights up blue, when the view is activated. Settings button >> The button lights up orange, when the view is activated.

  • Page 17: Control Pad

    For information on the installation of the cables, see "Cables installation" on page 43. External component connectors Kemppi Gun Adapter >> Connects to the welding gun. The wire feeder is supplied with Kemppi Gun Adapter. Subfeeder >> Provides control to optional SuperSnake subfeeder or a motorized welding gun. Remote control >>...
  • Page 18 X8 MIG Welder Operating manual - EN Power button >> The button lights up orange, when you switch Control Pad on. Left control knob Right control knob Left and right button >> When the button lights up green, you can press the button to confirm an action.
  • Page 19 X8 MIG Welder Operating manual - EN 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. 15. Charger cable port >> A stopper shields the charger cable port.
  • Page 20 X8 MIG Welder Operating manual - EN 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.

  • Page 21: Installation

    This chapter describes the control pad installation. "Preparing and connecting welding gun" on page 51 Assemble the welding gun and connect it to the wire feeder with Kemppi Gun Adapter. "Lifting X8 MIG Welder" on page 53 "Purchasing and managing welding software" on page 54 Kemppi offers a wide selection of welding software to ensure high-quality welds.

  • Page 22: Before Installation

    X8 MIG Welder Operating manual - EN 2.1 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.

  • Page 23: Power Source Installation

    X8 MIG Welder Operating manual - EN 2.2 Power source installation For power source cable connections, see "Installing interconnection cable" on page 43 and "Installing or replacing mains cable" on page 30. For operating the power source, see "Preparing welding system for use" on page 73.
  • Page 24 X8 MIG Welder Operating manual - EN 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.
  • Page 25 X8 MIG Welder Operating manual - EN 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. 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.

  • Page 26: Installing Optional Gas Cylinder Cart

    X8 MIG Welder Operating manual - EN When the wheels are attached, lift the power source off the pallet. If your setup includes X8 Gas Cylinder Cart, proceed to "Installing optional gas cylinder cart" below. 2.2.2 Installing optional gas cylinder cart To transport a larger gas cylinder with the power source, install X8 Gas Cylinder Cart.
  • Page 27 X8 MIG Welder Operating manual - EN 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. Attach the wheel set of the gas cylinder cart to the axle with a bolt (1) and washers (2, 3, 4) from both sides.
  • Page 28 X8 MIG Welder Operating manual - EN Place the upper part of the gas cylinder cart on the wheel set, and push it down until the claw fastens over the trans- portation 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 29: Installing Optional X8 Cooler

    X8 MIG Welder Operating manual - EN Place the gas cylinder on the cart. Fasten the straps in the cart around the gas cylinder. 2.2.3 Installing optional X8 Cooler If your setup does not include X8 Cooler, you can skip these instructions.

  • Page 30: Installing Or Replacing Mains Cable

    X8 MIG Welder Operating manual - EN Proceed as follows: Detach the two screws in the front panel of the power source. Pull the front panel outwards from the lower edge. Remove the lower left cover from the rear of the power source.

  • Page 31: Wire Feeder Installation

    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. "Installing wire feeder" below 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 32 X8 MIG Welder Operating manual - EN 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).

  • Page 33: Installing Welding Gun Holder

    X8 MIG Welder Operating manual - EN With the control panel facing the same way as the power source front panel, place the wire feeder in the cor- responding 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 34 X8 MIG Welder Operating manual - EN Open the top cover and lift the pressure handle. Push the collars on the mounting pins of the feed rolls up to pull the mounting pins off. 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.
  • Page 35 X8 MIG Welder Operating manual - EN Fe, Ss (Al, Mc, Fc) V-groove W001045 W001046 0.8−0.9 W001047 W001048 W000675 W000676 W000960 W000961 W001049 W001050 W001051 W001052 W001053 W001054 W001055 W001056 Fc, Mc (Fe) V-groove, W001057 W001058 knurled W001059 W001060 1.4−1.6...

  • Page 36: Replacing Wire Guides

    X8 MIG Welder Operating manual - EN Place the feed rolls back to their places. Align the cut on a drive roll's bottom with the pin on the drive 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.
  • Page 37 X8 MIG Welder Operating manual - EN If you change the filler wire to a different diameter or material, change the feed rolls accordingly. Proceed as follows: Remove the wire spool: Open the top cover latch. Lift the top cover up.
  • Page 38 X8 MIG Welder Operating manual - EN Attach the wire spool brake halves to the new wire spool by pushing them together inside the wire spool. Tighten if necessary. 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 39 X8 MIG Welder Operating manual - EN File the tip of the filler wire smooth. 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 the filler wire to the welding gun.
  • Page 40 X8 MIG Welder Operating manual - EN Press Wire inch to drive the filler wire to the welding gun's contact tip. To speed up the wire feed speed, turn the left control knob on the control panel. The control panel shows how much the filler wire has run.

  • Page 41: Wire Spools

    X8 MIG Welder Operating manual - EN Close the top cover. Wire spools X8 MIG Welder has three different wire spool hub options available for different wire spools: • Standard spool (A) • Spool hub for the small wire spool (B) >>...
  • Page 42 X8 MIG Welder Operating manual - EN If the wire feeder is on the power source, insert the strain relief pin to the holder from above. Insert the supplied locking pin through the hole in the strain relief pin. 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.

  • Page 43: Cables Installation

    X8 MIG Welder Operating manual - EN 2.4 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. "Installing interconnection cable" below "Cabling diagram"...
  • Page 44 X8 MIG Welder Operating manual - EN 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.

  • Page 45: Cabling Diagram

    X8 MIG Welder Operating manual - EN Connect the interconnection cable to the power source: 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.
  • Page 46 X8 MIG Welder Operating manual - EN Figure: Interconnection cabling for power source and wire feeder: Color codes: Welding current cable Shielding gas hose Control cable Measurement cable Coolant input and output hoses Earth return cable © Kemppi 1902370 / 2324...

  • Page 47: Control Pad Installation

    X8 MIG Welder Operating manual - EN 2.5 Control Pad installation This chapter describes the Control Pad installation. For information on operating Control Pad, see "Control Pad" on page 60. "Wireless connection" below Control Pad connects wirelessly to X8 Wire Feeder. If there are two wire feeders in the system, choose which one to con- nect to.
  • Page 48 X8 MIG Welder Operating manual - EN >> 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.

  • Page 49: Wired Connection

    X8 MIG Welder Operating manual - EN >> Move focus to a wire feeder or a power source. >> Press the green button. 2.5.2 Wired connection Control Pad makes a wired connection with X8 Power Source and X8 Wire Feeder. Connect Control Pad to a wired con- nection, when wireless connection is unavailable.

  • Page 50: Suspending Control Pad

    X8 MIG Welder Operating manual - EN >> Plug the combo cable to the combo cable port on the bottom of Control Pad. Use mainly the external charger to charge Control Pad. 2.5.3 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.

  • Page 51: Preparing And Connecting Welding Gun

    The welding gun has been preassembled by the manufacturer: the wire liner, contact tip and gas nozzle are pre- mounted. For instructions on installing and changing Flexlite GX MIG welding gun parts, refer to userdoc.kemppi.com. To start using the gun, proceed as follows: Check that the wire liner, contact tip and gas nozzle are suitable for the job.
  • Page 52 X8 MIG Welder Operating manual - EN 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. Trim the excess filler wire at a slight angle to improve ignition.

  • Page 53: Lifting X8 Mig Welder

    Operating manual - EN 2.7 Lifting X8 MIG Welder If you need to lift X8 MIG Welder, pay special attention to the safety measures. Follow the local regulations. Do not lift the welder with the gas cylinder. Proceed as follows: Loop two lifting straps through the handle at the front and two straps through the handle at the back of the power source.

  • Page 54: Purchasing And Managing Welding Software

    2.8 Purchasing and managing welding software Kemppi offers a wide selection of welding software to ensure high-quality welds. 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 55: Optional Accessories

    To use the wire drum kit, drill a hole at the back of X8 Wire Feeder's transparent cover. 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.
  • Page 56 X8 MIG Welder Operating manual - EN Proceed as follows: © Kemppi 1902370 / 2324...
  • Page 57 X8 MIG Welder Operating manual - EN Lock the rotating plate to its position. Adjust the length of the arm. Tighten the screws to lock to position. Turn to adjust the tension of the counterbalance spring. Turn to adjust the damping of the up and down movement.
  • Page 58 X8 MIG Welder Operating manual - EN © Kemppi 1902370 / 2324...

  • Page 59: Operation

    X8 MIG Welder Operating manual - EN 3. OPERATION Follow these operating instructions carefully to have full advantage of your X8 MIG Welder and to minimize the risk of malfunctions. "X8 MIG Welder control devices" on the next page Welding with X8 MIG Welder can be controlled through three different control panels, which offer slightly different fea- tures for adjusting the welding parameters.

  • Page 60: X8 Mig Welder Control Devices

    The actual features vary according to the functions and usability of the control panel. "Control Pad" below Control Pad is a window to X8 MIG Welder: Control Pad shows you all the settings and licenses installed in the welding system.
  • Page 61 X8 MIG Welder Operating manual - EN Use the knobs under the display to move in the display and to adjust the values. When there is a green light in the cen- ter of the knob, the knob also functions as a push button.

  • Page 62: Control Pad Views

    X8 MIG Welder Operating manual - EN Figure: Control Pad display with the Adjust footer / 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.

  • Page 63: Control Pad Views: Welding

    X8 MIG Welder Operating manual - EN Control Pad views: Welding 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: Memory channel, its number and the welding program >>...
  • Page 64 X8 MIG Welder Operating manual - EN The welding power graph shows with grey raster pattern the area, where the selected values result in globular transfer. Figure: 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.
  • Page 65 X8 MIG Welder Operating manual - EN Figure: 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.

  • Page 66: Control Pad Views: Settings

    For more information on welding programs, see "Welding programs in Control Pad" on page 68. 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 88. © Kemppi 1902370 / 2324...
  • Page 67 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 88. Wise feature menu Wise feature displays the Wise features available for use with the welding program.

  • Page 68: Welding Programs In Control Pad

    X8 MIG Welder Operating manual - EN Panel settings Panel settings display Control Pad's mechanical settings: 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.

  • Page 69: Control Pad Views: Channel

    X8 MIG Welder Operating manual - EN Type >> Select welding/brazing or cladding. Process Polarity >> Not available for all materials. >> Which polarity is in use. If the polarity is positive (+), connect the + side to the wire feeder.

  • Page 70: Wire Feeder Control Panel

    System >> Displays information on the welding system. Cloud services >> Connect to Kemppi cloud services. 3.1.2 Wire feeder control panel The control panel of the wire feeder has a one-knob navigation and push buttons for selecting parameters or values.

  • Page 71: Wire Feeder Views

    X8 MIG Welder Operating manual - EN 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.

  • Page 72: Wire Feeder Settings View

    X8 MIG Welder Operating manual - EN 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.

  • Page 73: Preparing Welding System For Use

    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 74 "Calibrating arc voltage" on page 77 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 75: Filling Cooler

    X8 MIG Welder Operating manual - EN 3.2.1 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 76 X8 MIG Welder Operating manual - EN Fill the cooler with coolant solution. Do not fill over the line. Screw the lid back on the cooler. Push to close the front panel of the power source. © Kemppi 1902370 / 2324...

  • Page 77: Calibrating Arc Voltage

    3.2.2 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 78 X8 MIG Welder Operating manual - EN WLAN connection Proceed as follows: Go to the View menu > Cloud services > WiFi settings. Switch the WiFi on. Select the WLAN network. © Kemppi 1902370 / 2324...
  • Page 79 Network details are shown in WiFi settings, when the WLAN connection is created. 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.
  • Page 80 X8 MIG Welder Operating manual - EN Cloud services status The different icons for cloud services are in the table below. Table 1. Cloud services icons: Connection to the service No connection to the service No user rights to the service ©...

  • Page 81: How To Use Welding System

    The WeldEye cloud service consists of several independent modules. When Quality Control or Welding Production Ana- lysis 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 82 X8 MIG Welder Operating manual - EN To save modified settings in Control Pad over the current settings of a memory channel: >> Press Channel. >> Open Actions. >> Select Save changes and press the green button. To save modified settings in Control Pad on a different memory channel: >>...

  • Page 83: Creating New Memory Channel Settings

    X8 MIG Welder Operating manual - EN >> Press the green button. The name of the memory channel changes to the name of the welding program. 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 modi- fications.

  • Page 84: Saving New Welding Programs

    X8 MIG Welder Operating manual - EN Go to Channels and select a memory channel where to start modifications. Press the green button to open the Actions menu. Select Save to and press the green button. Select the target channel and press the green button.

  • Page 85: Renaming Channel

    X8 MIG Welder Operating manual - EN Select the Channel view. Select a memory channel. Press the green button to open the Actions menu. Select Create all and press the green button. >> Control Pad creates a memory channel to each new welding program.
  • Page 86 X8 MIG Welder Operating manual - EN 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 87: Using Welding Processes, Programs And Features

    "Saving new welding programs" on page 84. 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 Customized Welding pro- grams which are designed and created according to customer-specific welding applications.

  • Page 88: Standard Mig Welding Processes In X8 Mig Welder

    It is possible that there is just one program matching your filter selection. 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 welding program"...
  • Page 89 X8 MIG Welder Operating manual - EN Figure: 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 >>...
  • Page 90 X8 MIG Welder Operating manual - EN • Wire Feed Speed >> min: adjusts the minimum set value for wire feed speed >> max: adjusts the maximum set value for wire feed speed • Fine tuning: adjusts the voltage (arc length).
  • Page 91 X8 MIG Welder Operating manual - EN DPulse 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.

  • Page 92: Wise Processes

    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 pro- ductivity by controlling the welding arc. For more information, visit www.kemppi.com.

  • Page 93: Wise Processes: Using Dprocess

    >> 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 94: Wise Processes: Using Wisethin

    X8 MIG Welder Operating manual - EN the current control. The process is suitable for root pass welding in all positions, and provides a smooth and spatter-free arc. To adjust the welding power / wire feed speed, in the Control Pad's Welding view, turn the left knob.

  • Page 95: Wise Features

    • 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. "Wise features: introduction to WiseFusion" below "Wise features: using WiseFusion" below "Wise features: introduction to WiseSteel" on the next page "Wise features: using WiseSteel"...

  • Page 96: Wise Features: Introduction To Wisesteel

    X8 MIG Welder Operating manual - EN The WiseFusion welding function enables adaptive arc length control, which keeps the arc optimally short and focused. WiseFusion increases the welding speed and penetration and decreases heat input. WiseFusion can be used throughout the power range (short arc, globular arc, spray arc and pulsed arc).

  • Page 97: Wise Features: Introduction To Wisepenetration

    X8 MIG Welder Operating manual - EN When using WiseSteel, different adjustment methods are applied at different power ranges (different arcs). Within the short arc range, WiseSteel is based on adaptive short arc control; that is, the process adjusts the short circuit ratio. This creates an easily-adjustable arc and less spatter.

  • Page 98: Mma Welding

    Select the MMA welding program. An all-around MMA welding program pre-installed. 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 99: Gouging

    To use gouging, in Control Pad, select Settings > Mode > Gouging. X8 MIG Welder features an integrated voltage reduction device (VRD). When the welding machine is on but the weld- ing 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 100: Cladding And Brazing

    X8 MIG Welder has a variety of optimized welding programs for cladding. Brazing In brazing, only the filler material is melted while the base material stays solid. With X8 MIG Welder, you can use a variety of welding programs and filler materials for brazing.

  • Page 101: Start And Stop Functions

    X8 MIG Welder Operating manual - EN • 4T: Pressing the trigger (1) starts the Pregas, and releasing the trigger (2) ignites the arc. Pressing the trigger again (3) switch the arc off. Releasing the trigger (4) ends the Postgas.
  • Page 102 X8 MIG Welder Operating manual - EN defined period of time. The functionality can be used, for example, when welding thick materials, where using extra power (heat) at the start helps ensure the high quality of the weld. When the 2T trigger logic is in use, Hot start lasts for the predefined period of time.
  • Page 103 X8 MIG Welder Operating manual - EN When the 4T or WP Switch is in use, pressing the trigger during the welding (in the case of WP Switch, pressing > 0.5 s) launches the Crater fill sequence. The system stays on the Crater fill finishing level until the trigger is released. Releasing the trigger immediately finishes the Crater fill sequence.

  • Page 104: Using Weldeye Services

    The WeldEye cloud service consists of several independent modules. When Quality Control or Welding Production Ana- lysis 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 105: Digital Wps: Introduction

    A separate WPS is developed for each material alloy and each welding type. Kemppi's WeldEye cloud service provides tools for creating and editing WPSs. When the welding system is connected to WeldEye, dWPSs are automatically transferred to the power source memory of all welding machines connected to WeldEye.

  • Page 106: Digital Wps: Activating Wps

    X8 MIG Welder Operating manual - EN Figure: dWPS process For more information on WeldEye, see "Introduction to WeldEye" on page 8. Digital WPS: activating WPS Proceed as follows: Go to the View menu (in the Welding view, press the Menu button) and select WPS.
  • Page 107 X8 MIG Welder Operating manual - EN Move the focus to the WPS that you want to activate. Depending on the mode of Control Pad, select one of the following options: >> If the Control Pad is in the Advanced mode, press the green button to open the Actions menu. Select Activate WPS.

  • Page 108: Digital Wps: Selecting Wps Pass In Wps View

    X8 MIG Welder Operating manual - EN If the WPS includes several passes, select the pass in Active pass. See "Digital WPS: selecting WPS pass in WPS view" below. Press a view button to leave the WPS view. You can also change WPS or the pass in Channel view. See "Digital WPS: selecting WPS or pass in channel view" on the next page.

  • Page 109: Digital Wps: Selecting Wps Or Pass In Channel View

    X8 MIG Welder Operating manual - EN Press the green button to open the menu. 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.

  • Page 110: Digital Wps: Selecting Wps Or Wps Pass Through Wire Feeder Display

    X8 MIG Welder Operating manual - EN 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. After changing WPS or pass, check the pass details to make sure you are using the correct filler wire and gas.

  • Page 111: Digital Wps: Transferring Dwps To Welding Machine

    WPS, the system displays a warning on Control Pad and on the wire feeder display. 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 88 and "Wise processes" on page 92.
  • Page 112 X8 MIG Welder Operating manual - EN Go to the View menu > WPS. 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.

  • Page 113: Digital Wps: Filtering Wpss

    X8 MIG Welder Operating manual - EN Digital WPS: 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 >...
  • Page 114 X8 MIG Welder Operating manual - EN 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 115: Welding Data Collection

    This functionality is available only if your company has acquired WeldEye for Welding Quality Management or WeldEye for Welding Production Analysis. You must connect X8 MIG Welder to Internet and to the WeldEye cloud service to use the functionality on this device. For more information, see WeldEye operating manual.

  • Page 116: Welding Data Collection: Fluctuation And Averaging

    Settings view of the WeldEye cloud service. Welding data collection: identifier database X8 MIG Welder can provide 100 % traceability for every weld. For this, enter various identifiers in the system before weld- ing, for example, the welder's identity, WPS, and the number of the weld.
  • Page 117 X8 MIG Welder Operating manual - EN Before welding Press the green button to select Task. Switch the barcode reader ON at the front of Control Pad, if you want to use it to read a barcode. You can also enter the barcode manually.
  • Page 118 X8 MIG Welder Operating manual - EN Read the barcode or QR code on your ID card or enter the barcode manually. For more information, see Control Pad. 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 selec- ted automatically.
  • Page 119 X8 MIG Welder Operating manual - EN 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 120: Welding Data Collection: Alarms In Weldeye Services

    X8 MIG Welder Operating manual - EN When you finish using the welding machine, log out of the system. >> Power off the machine or scroll to Welder, press the green button, and select Log out. Log out of the system to avoid the next welding data getting registered under your name.

  • Page 121: Welding Data Collection: Entering Information About Non-Welding Activity

    X8 MIG Welder Operating manual - EN Figure: The welder is not qualified for welding with the selected WPS Control Pad shows the welding current and voltage during welding and indicates whether the values are within the lim- its of the WPS. This information may be useful for the bystanders observing the welding. The values are shown in white, yellow or red.

  • Page 122: Welding Data Collection: Tracking Heat Input

    X8 MIG Welder Operating manual - EN In the Task view, scroll to Activity and press the green button. Select the activity from the menu. >> The activity becomes visible in Control Pad's Task view. The selected activity remains active until the device detects welding or you select another activity.

  • Page 123: Digital Work Order

    X8 MIG Welder Operating manual - EN 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. The device also sends the data to the WeldEye cloud service for documentation.

  • Page 124: Digital Work Order: Using

    X8 MIG Welder Operating manual - EN "Digital work order: recommended WPSs" on page 127 "Digital work order: time tracking" on page 127 Digital work order: using Digital work orders provide a simple way to achieve traceability in WeldEye and to reduce the amount of printed paper.
  • Page 125 X8 MIG Welder Operating manual - EN 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 con- trol knob to select it.

  • Page 126: Digital Work Order: Completing

    For more information, see "Digital work order: changing" below. 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. Digital work order: changing 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 127: Digital Work Order: Recommended Wpss

    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 128: Maintenance

    X8 MIG Welder Operating manual - EN 4. MAINTENANCE When considering and planning routine maintenance, consider the operating frequency of the welding system and the working environment. Correct operating of the welding machine and regular maintenance helps you avoid unnecessary downtime and equip- ment failure.

  • Page 129: Daily Maintenance

    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. Welding gun maintenance For information on Flexlite GX MIG welding gun maintenance, refer to userdoc.kemppi.com. © Kemppi 1902370 / 2324...

  • Page 130: Periodic Maintenance Of Power Source And Wire Feeder

    X8 MIG Welder Operating manual - EN 4.2 Periodic maintenance of power source and wire feeder Only qualified service personnel is allowed to carry out periodic maintenance. Only an authorized electrician is allowed to carry out electrical work. Before removing the cover plate, disconnect the power source from the mains and wait for about 2 minutes before discharging the capacitor.

  • Page 131: Service Workshops

    X8 MIG Welder Operating manual - EN 4.3 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: • Cleanup of the machine •...

  • Page 132: Troubleshooting

    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 133 X8 MIG Welder Operating manual - EN Varying welding performance Check that the wire feed mechanism is adjusted properly. Blow compressed air through the wire liner to check that it is not blocked. Check that the wire liner is correct for the selected wire size and type.

  • Page 134: Error Codes

    X8 MIG Welder Operating manual - EN 4.5 Error codes Control Pad In error situations, Control Pad displays the number and title of the error, a description of the possible cause (Reasons) and the Actions to fix the error. Go to View > Error log to see the error history.

  • Page 135: Disposal Of Unit

    The owner of the equip- ment is obliged to deliver a decommissioned unit to a regional collection centre, as per the instructions of local author- ities or a Kemppi representative. By applying these European Directives you improve the environment and human health.

  • Page 136: Technical Data

    "X8 Power Source 600 A / 600 A MV" on page 141 "X8 Cooler" on page 143 "X8 Wire Feeder" on page 144 "X8 Control Pad" on page 145 For technical details of Flexlite GX MIG welding guns, refer to userdoc.kemppi.com. © Kemppi 1902370 / 2324...

  • Page 137: X8 Power Source 400 A / 400 A Mv

    X8 MIG Welder Operating manual - EN 5.1 X8 Power Source 400 A / 400 A MV Value Feature Description 400 A 400 A MV Mains connection cable H07RN-F 6 mm² 16 mm² Mains connection voltage 3~ 50/60 Hz 220 - 230 V ±10 % 380 - 460 V ±10 % 380 - 460 V ±10 % Rated power 40 % ED...
  • Page 138 X8 MIG Welder Operating manual - EN Weight without accessories 95 kg 95 kg Voltage supply for auxiliary devices 48 V/500 W 48 V/500 W Voltage supply for cooling unit 220 - 230 V ±10 % 380 - 460 V ±10 % 380 - 460 V ±10 % Recommended generator power (min) 25 kVA 25 kVA Wireless communication type 2.4 GHz WiFi & Bluetooth 2.4 GHz WiFi &...

  • Page 139: X8 Power Source 500 A / 500 A Mv

    X8 MIG Welder Operating manual - EN 5.2 X8 Power Source 500 A / 500 A MV Value Feature Description 500 A 500 A MV Mains connection cable H07RN-F 6 mm² 16 mm² Mains connection voltage 3~ 50/60 Hz 220 - 230 V ±10 % Mains connection voltage 3~ 50/60 Hz 380 - 460 V ±10 %...
  • Page 140 X8 MIG Welder Operating manual - EN Weight without accessories 95 kg 95 kg Voltage supply for auxiliary devices 48 V/500 W 48 V/500 W Voltage supply for cooling unit 220 - 230 V ±10 % 380 - 460 V ±10 % 380 - 460 V ±10 % Recommended generator power (min) 35 kVA 35 kVA Wireless communication type 2.4 GHz WiFi & Bluetooth 2.4 GHz WiFi &...

  • Page 141: X8 Power Source 600 A / 600 A Mv

    X8 MIG Welder Operating manual - EN 5.3 X8 Power Source 600 A / 600 A MV Value Feature Description 600 A 600 A MV Mains connection cable H07RN-F 6 mm² 16 mm² Mains connection voltage 3~ 50/60 Hz 220 - 230 V ±10 % Mains connection voltage 3~ 50/60 Hz 380 - 460 V ±10 %...
  • Page 142 X8 MIG Welder Operating manual - EN Weight without accessories 95 kg 95 kg Voltage supply for auxiliary devices 48 V/500 W 48 V/500 W Voltage supply for cooling unit 220 - 230 V ±10 % 380 - 460 V ±10 % 380 - 460 V ±10 % Recommended generator power (min) 40 kVA 40 kVA Wireless communication type 2.4 GHz WiFi & Bluetooth 2.4 GHz WiFi &...

  • Page 143: X8 Cooler

    X8 MIG Welder Operating manual - EN 5.4 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 1eff Rated cooling power at 1 l/min 1.4 kW Rated cooling power at 1.6 l/min 1.9 kW...

  • Page 144: X8 Wire Feeder

    X8 MIG Welder Operating manual - EN 5.5 X8 Wire Feeder Feature Description Value Operating voltage 48 V DC Supply current at max load 6 A 1max Idle power 6 W Idle power with cabinet heater 30 W Welding current, I 40 % ED 600 A 60 % ED 530 A 100 % ED...

  • Page 145: X8 Control Pad

    X8 MIG Welder Operating manual - EN 5.6 X8 Control Pad Feature Description Value Operating voltage 12 V Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C Degree of protection IP54 External dimensions LxWxH 200 x 130 x 33 mm Weight without accessories 0.89 kg Typical battery operation time 15 - 24 h...

  • Page 146: Ordering Codes

    X8 MIG Welder Operating manual - EN 6. ORDERING CODES For ordering codes, see X8 MIG Welder. © Kemppi 1902370 / 2324...

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