Kemppi X5 FastMig Operating Manual

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Operating manual (214 pages)

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X5 FastMig

Operating manual - EN

X5 FastMig

X5 FastMig Pulse

1920960 / 2440

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Summary of Contents for Kemppi X5 FastMig

Page 2: Table Of Contents
X5 FastMig Operating manual - EN CONTENTS 1. General 1.1 Equipment description 1.2 X5 Power Source 400 and 500 1.3 X5 Wire Feeder 200 1.3.1 Wire spool and hub (200) 1.3.2 Wire feed mechanism 1.3.3 Manual control panel 1.4 X5 Wire Feeder 300 1.4.1 Wire spools and hubs (300)
Page 3 X5 FastMig Operating manual - EN 2.16 How to get welding programs 3. Operation 3.1 Preparing welding system for use 3.1.1 Filling cooler and circulating coolant 3.1.2 Calibrating welding cable 3.1.3 Using voltage sensing cable 3.2 Using X5 Manual control panel 3.2.1 Manual control panel: Settings...
Page 4 X5 FastMig Operating manual - EN 3.4.19 Demo time 3.4.20 Settings lock 3.5 Using remote control HR40/HR43 3.6 Using remote control HR55 3.7 Lifting equipment 4. Maintenance 4.1 Daily maintenance 4.2 Periodic maintenance 4.3 Service workshops 4.4 Troubleshooting 4.5 Error codes 4.6 Installing and cleaning power source air filter...
Page 5: General
X5 FastMig is designed to be used together with Kemppi's Flexlite GX MIG welding guns. X5 FastMig can be used also for MMA welding, gouging and TIG welding. Note that TIG welding requires the use of ded- icated Flexlite TX TIG torches.
Page 6: Important Notes
X5 FastMig Auto equipment allows also automatic 1-MIG welding featuring additional welding processes as optional. X5 FastMig Pulse equipment allows also automatic 1-MIG and pulse welding featuring additional welding processes as optional. For more information on the individual X5 FastMig devices, refer to the "Equipment description" on the next page chapter. Important notes Read the instructions through carefully.
Page 7: Equipment Description
Operating manual - EN 1.1 Equipment description X5 FastMig has several power source and wire feeder options to choose from. The control panel is always fixed to the wire feeder. X5 FastMig supports welding cable calibration without an additional voltage sensing cable.
Page 8 X5 FastMig Operating manual - EN X5 wire feeders (AP/APC) • X5 Wire Feeder 300 APC >> Includes 2-knob 5.7" TFT/LCD control panel (APC control panel) >> Includes automatic 1-MIG process that supports welding programs as well as Wise/MAX features & processes >>...
Page 9: Welding Programs
Subfeeder support is available with all new X5 Wire Feeder 300 models. • SuperSnake GTX subfeeder. For more information on the SuperSnake GTX subfeeder, refer to Kemppi Userdoc. For more information on optional accessories, refer to "Optional accessories" on page 32 or contact your local Kemppi dealer. © Kemppi 1920960 / 2440...
Page 10 X5 FastMig Operating manual - EN EQUIPMENT IDENTIFICATION Serial number Serial number of the device is marked on the rating plate or in another distinctive location on the device. It is important to make correct reference to the serial number of the product when ordering spare parts or making repairs for example.
Page 11: X5 Power Source 400 And
X5 FastMig Operating manual - EN 1.2 X5 Power Source 400 and 500 This section describes the structure of X5 Power Source 400 and X5 Power Source 500 models. Front: Indicator panel * Transportation handle (not intended for mechanical lifting)
Page 12: Power Switch
X5 FastMig 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. If the circulation of the coolant liquid is obstructed, a thermal cutoff switches the welding system off. Check and fix the error before using the welding system again.
Page 13: X5 Wire Feeder
X5 FastMig Operating manual - EN 1.3 X5 Wire Feeder 200 This section describes the structure of the X5 Wire Feeder 200 Manual. Keep the wire feeder covers closed during welding to reduce the risk of injury or an electric shock. Keep the covers closed also at other times to keep the inside of the wire feeder clean.
Page 14: Wire Spool And Hub
X5 FastMig Operating manual - EN Inside wire feeder (interconnection cable cabinet) Interconnection cable cabinet hatch and locking latch >> The rear section of the hatch acts also as a strain relief for the cable Shielding gas hose connector Control cable connector...
Page 15: Wire Feed Mechanism
X5 FastMig Operating manual - EN Spool brake adjustment: 1.3.2 Wire feed mechanism X5 Wire Feeder 200 wire feed mechanism: Drive rolls and drive roll mounting caps Middle guide tube locking clip Middle guide tube Inlet guide tube Pressure handles Pressure rolls and pressure roll mounting pins ©...
Page 16: Manual Control Panel
X5 FastMig Operating manual - EN Pressure roll locking arms Outlet guide tube. For replacing the wire feed rolls, refer to "Installing and replacing feed rolls" on page 79. For replacing the wire guide tubes, refer to "Installing and replacing wire guide tubes" on page 82 1.3.3 Manual control panel...
Page 17: X5 Wire Feeder
X5 FastMig Operating manual - EN 1.4 X5 Wire Feeder 300 This section describes the structure of the X5 Wire Feeder 300 Manual and 300 AP/APC. Model-specific variations may occur. Control panel (and hinged control panel cover) >> For more information on the X5 Wire Feeder 300 AP/APC control panel, refer to "AP/APC control panel" on page 26.
Page 18 X5 FastMig Operating manual - EN Inside wire feeder (wire feeder cabinet) Wire spool >> For more information on the wire spools, refer to "Wire spools and hubs (300)" on the next page. Wire spool locking cover Wire feed roll mechanism Wire inch button >>...
Page 19: Wire Spools And Hubs
X5 FastMig Operating manual - EN X5 Wire Feeder 300 AP/APC: Voltage sensing cable connector for interconnection cable For installing and connecting the cables, refer to "X5 interconnection cable" on page 28 and "Installing cables" on page 55. If the built-in rotameter for gas is included, it is also located in the interconnection cable cabinet.
Page 20: Wire Feed Mechanism
X5 FastMig Operating manual - EN 1.4.2 Wire feed mechanism X5 Wire Feeder 300 wire feed mechanism: Drive rolls and drive roll mounting caps Middle guide tube locking clip Middle guide tube Inlet guide tube Pressure handles Pressure rolls and pressure roll mounting pins Pressure roll locking arms Outlet guide tube.
Page 21: Ap/Apc Control Panel
X5 FastMig Operating manual - EN Left control knob Right control knob Trigger logic selection (2T/4T) Process selection (MIG/MMA/Gouging/TIG) Home button (default welding mode) Weld data button Settings button For using the control panel, refer to "Using X5 Manual control panel" on page 91.
Page 22: X5 Wire Feeder Hd300
X5 FastMig Operating manual - EN 1.5 X5 Wire Feeder HD300 This section describes the structure of the X5 Wire Feeder HD300. Model-specific variations may occur. X5 Wire Feeder HD300: Control panel (and hinged control panel cover) >> For more information on the X5 Wire Feeder 300 Manual control panel, refer to "Manual control panel" on page 26.
Page 23 X5 FastMig Operating manual - EN Inside wire feeder (wire feeder cabinet) Wire spool hub >> For more information on the wire spool, refer to "Installing and changing wire (X5 WF HD300)" on page 75. Wire feed roll mechanism Gas test button >>...
Page 24: Wire Spools (Hd300)
1.5.1 Wire spools (HD300) X5 Wire Feeder HD300 uses the standard wire spools (A) without additional adapters. Wire spools with a large center hole, e.g. a wire basket rim (B), require an additional spool adapter (available as Kemppi accessory): © Kemppi...
Page 25: Wire Feed Mechanism
X5 FastMig Operating manual - EN When installed, the pin next to the wire spool hub in the wire feeder must align and go into the hole in the spool or spool adapter. "Installing and changing wire (X5 WF HD300)" on page 75 1.5.2 Wire feed mechanism...
Page 26: Manual Control Panel
X5 FastMig Operating manual - EN Inlet guide tube Pressure handles Pressure rolls and pressure roll mounting pins Pressure roll locking arms Outlet guide tube. For replacing the wire feed rolls, refer to "Installing and replacing feed rolls" on page 79.
Page 27 X5 FastMig Operating manual - EN The AP/APC control panel of the X5 Wire Feeder 300 on the left and the AP/APC control panel of the X5 Wire Feeder HD300 on the right: Left control knob (with push button function)
Page 28: X5 Interconnection Cable
X5 FastMig Operating manual - EN 1.6 X5 interconnection cable The X5 FastMig interconnection cables come in multiple different lengths and configurations to suit your equipment setup. For installing the interconnection cable, refer to "Installing cables" on page 55. With water-cooling (PS = Power source end of the interconnection cable, WF = Wire feeder end of the interconnection cable.)
Page 29 X5 FastMig Operating manual - EN With voltage sensing cable and water-cooling (PS = Power source end of the interconnection cable, WF = Wire feeder end of the interconnection cable.) Shielding gas hose Control cable Welding current cable Coolant hose (outlet/inlet, color-coded)
Page 30 X5 FastMig Operating manual - EN Interconnection cable specifications Cable Cable type* Cable length Cooling Connector types X57002MW 70 mm Water-cooled 10-pin (control), snap (water/gas), DIX (current) 70 mm Water-cooled 10-pin (control), snap (water/gas), DIX (current) X57005MW 70 mm 10 m...
Page 31: X5 Cooling Unit (Optional)
X5 FastMig Operating manual - EN 1.7 X5 cooling unit (optional) Front: Cooler container cap Cooling liquid level indicator Front locking interface (for locking on the cart) Front locking interface (for locking to the power source) Rear locking interace (for locking to the power source) Cooling liquid circulation button >>...
Page 32: Optional Accessories
X5 FastMig Operating manual - EN 1.8 Optional accessories X5 PS X5 WF X5 WF X5 WF X5 WF X5 WF X5 CU 300 AP/APC 300 Manual 200 Manual HD300 HD300 M AP/APC 4-wheel cart with gas bottle rack ●...
Page 33 Wire feeder hanger for boom (for X5 WF 300) The wire feeder hanger for boom facilitates welding where it is difficult to bring the full X5 FastMig welding system. Do not hang the wire feeder from the handle. Use the wire feeder hanger for boom instead.
Page 34 X5 FastMig Operating manual - EN Wire feeder counterbalance arm (for X5 WF 300) The wire feeder counterbalance arm reduces the weight of the cable bundle over the working area. Double wire feeder rotating plate (for X5 WF 300) The double wire feeder rotating plate allows the use of two wire feeders on one power source.
Page 35 X5 FastMig Operating manual - EN Double interconnection cable adapter The double interconnection cable adapter allows to connect two wire feeders to one power source. Wire feeder cart (for X5 WF 300) The wire feeder cart allows more convenient wire feeder movement on site.
Page 36 Protection sliders can be used under the wire feeder to prevent damaging the wire feeder bottom. With X5 Wire Feeder HD300 protection sliders, an additional bracket provides also mechanical support for the welding cable connection. For more information on optional accessories, contact your local Kemppi dealer. © Kemppi...
Page 37 X5 FastMig Operating manual - EN For installing the optional accessories, refer to the installation instructions delivered with the equipment. © Kemppi 1920960 / 2440...
Page 38: Installation
When installing the full set of equipment stacked as a tower – water cooler at the bottom, power source in the middle and wire feeder at the top – always install and secure the equipment onto a Kemppi cart compatible with X5 FastMig or secure the equipment to other adequate support on site.
Page 39: Before Installation
X5 FastMig Operating manual - EN Before installation • Make sure to acknowledge and follow the local and national requirements regarding installation and use of high voltage units. • Check the contents of the packages and make sure the parts are not damaged.
Page 40: Installing Power Source Mains Plug
Do not connect the machine to the mains before the installation is complete. Install the 3-phase plug according to the X5 FastMig power source and site requirements. Refer also to "Technical data" on page 150 for power source specific technical information.
Page 41: Installing Cooling Unit (Optional)
X5 FastMig Operating manual - EN 2.2 Installing cooling unit (optional) The X5 cooling unit must be installed by authorized service personnel. Tools needed: Remove the small connector cover in the rear of the power source. Route the cooling unit's connection cables so that they remain accessible through the next steps.
Page 42 X5 FastMig Operating manual - EN Fix the units together with two screws (M5x12) in the front and two screws (M5x12) in the rear. Connect the cooling unit cables. Do not use force, but make sure the connectors are properly connected.
Page 43: Installing Equipment On Cart (Optional)
2.3 Installing equipment on cart (optional) The X5 FastMig has two transport unit options: a 4-wheel cart with gas bottle rack and a 2-wheel cart without gas bottle rack. The X5 FastMig equipment can be installed on the cart with or without the cooling unit.
Page 44 X5 FastMig Operating manual - EN Install the cooling unit on the cart. Fix the cooling unit to the cart with two screws (M5x12) in the front and two screws (M5x12) in the rear. Install the power source on top of the cooling unit. Refer to "Installing cooling unit (optional)" on page 41 for install- ation details.
Page 45 X5 FastMig Operating manual - EN 4-wheel cart: Secure the equipment to the cart with the rear connection bracket (rear fixing plate, long). Rear screws: M8x16, top screws: M6x30. 2-wheel cart: Secure the equipment to the cart with the two side connection brackets. The 2-wheel cart's side connection brackets use the X5 power source's side plate top screw holes for securing. Replace the side plate top screws with the ones delivered with the 2-wheel cart side connection brackets.
Page 46: Installing Wire Feeder With Fixed Plate
X5 FastMig Operating manual - EN 2.4 Installing wire feeder with fixed plate This section describes the fixed installation of X5 Wire Feeder 300 (on top of the power source). For stacked installation, additional support is required. Read the installation notes here: "Installation" on page 38.
Page 47 (M6x40) provided with the locking mechanism. Depending on your X5 FastMig setup, two different rear fixing plate options are available. Both include an interface for the interconnection cable strain relief mechanism, but the longer one acts also as a cart connection bracket.
Page 48 X5 FastMig Operating manual - EN Ensure that also the front of the wire feeder is locked in position (to the front fixing plate edge). The rear locking is released by pulling the locking mechanism lever: © Kemppi 1920960 / 2440...
Page 49: Installing Wire Feeder With Standard Rotating Plate
If the rear fixing plate was not yet installed at this stage, install it together with the rotating plate. Depending on your X5 FastMig setup, two different rear fixing plate options are available. Both include an interface for the interconnection cable strain relief mechanism, but the longer one acts also as a cart connection bracket.
Page 50 X5 FastMig Operating manual - EN Secure the rotating plate in place (together with the rear fixing plate) using the power source top cover screws (M6x30). Tip: To gain access to the fixing holes in the lower plate, turn the top plate.
Page 51 X5 FastMig Operating manual - EN Ensure that the front of the unit has also locked in position (to the front edge of the rotating plate). The rear locking is released by pulling the locking mechanism lever: © Kemppi 1920960 / 2440...
Page 52: Installing Wire Feeder With Lockable Rotating Plate
If the rear fixing plate was not yet installed at this stage, install it together with the rotating plate. Depending on your X5 FastMig setup, two different rear fixing plate options are available. Both include an interface for the interconnection cable strain relief mechanism, but the longer one acts also as a cart connection bracket.
Page 53 X5 FastMig Operating manual - EN Secure the rotating plate in place (together with the rear fixing plate) using the power source top cover screws (M6x30). Tip: To gain access to the fixing holes in the lower plate, and to turn the rotating plate, pull the release lever under the front edge of the wire feeder rotating plate and turn the top plate: ©...
Page 54 X5 FastMig Operating manual - EN Slide the wire feeder from front to back until the bar in the back of the unit locks into the locking mechanism on the rotating plate. Ensure that the front of the unit has also locked in position (to the front edge of the rotating plate).
Page 55: Installing Cables
X5 FastMig Operating manual - EN 2.7 Installing cables Connect the interconnection cable first to the wire feeder and then to the power source. For the connector descriptions and their locations, refer to "X5 Wire Feeder 200" on page 13, "X5 Wire Feeder 300" on page 17 or "X5 Wire Feeder HD300"...
Page 56 X5 FastMig Operating manual - EN Secure cable strain relief. >> X5 Wire Feeder 200: Place the cable to the slot on the wire feeder and secure it in place by closing the hatch and lock- ing the latches. >> X5 Wire Feeder 300: Place the cable's strain relief block to the slot on the wire feeder and secure it in place by closing and locking the strain relief latch.
Page 57 X5 FastMig Operating manual - EN Check the expanding locking knob tightness and tighten if necessary: Tip: Additional X5 Wire Feeder 300 strain relief fixing (M6x16 screw), optional: X5 Wire Feeder 300: Close and lock the cable cabinet door. When connecting the cables to the wire feeder, route the cables neatly so that the cable cabinet door closes properly.
Page 58 X5 FastMig Operating manual - EN Connecting interconnection cable and earth return cable to power source Attach the cable's strain relief (1) to the rear fixing plate. Connect the welding current cable to the plus (+) connector (2) on the power source.
Page 59 X5 FastMig Operating manual - EN Pulse+ power source only: If you have the voltage sensing cable in use, connect it to the connector (7) on the rear of the power source. Most MIG/MAG applications and filler wires run the wire feed unit's welding current cable connected to the positive terminal of the power source.
Page 61: Connecting Welding Gun
Operating manual - EN 2.8 Connecting welding gun X5 FastMig is designed to be used with the Kemppi Flexlite GX welding guns. For the Flexlite GX operating instructions, refer to userdoc.kemppi.com. Always check that the wire liner, contact tip and gas nozzle are suitable for the job.
Page 62 X5 FastMig Operating manual - EN Attach the pistol grip handle holder with the cogged center hub and screws to the wire feeder. Attach the gun holder to the pistol grip handle holder with screws. You can adjust the angle of the gun holder before tightening the screws.
Page 63: Installing Remote Control
X5 FastMig Operating manual - EN 2.9 Installing remote control Remote controls are optional. To enable remote operation, connect the remote control device to the X5 FastMig welding equipment. Remote control HR43/HR40 Connect the remote control cable to the wire feeder's control cable connector.
Page 64: Installing And Changing Wire (X5 Wf 200)
X5 FastMig Operating manual - EN 2.10 Installing and changing wire (X5 WF 200) This section describes how to install the wire and spool on X5 Wire Feeder 200. Install the welding gun to the wire feeder before installing the wire spool.
Page 65 X5 FastMig Operating manual - EN Secure the wire spool in place by turning to lock knob in closed position. If needed, adjust the spool brake by turning the screw (with Allen key) in the center of the hub locking mechanism.
Page 66 X5 FastMig Operating manual - EN File the tip of the filler wire smooth. Sharp edges on the filler wire tip may damage the wire liner. Release the pressure arms to move the feed rolls apart. Guide the filler wire through the inlet tube (a) and middle wire guide tube (b) and into the outlet tube (c), which feeds the filler wire to the welding gun.
Page 67 X5 FastMig Operating manual - EN Close the pressure arms so that the filler wire is locked between the feed rolls. Ensure that the filler wire sits in the feed roll grooves. Adjust the pressure of the feed rolls with the pressure adjustment wheels. The pressure is the same for both feed roll pairs.
Page 68 X5 FastMig Operating manual - EN Press the wire inch button to drive the filler wire into the welding gun. Stop when the wire reaches the welding gun's contact tip. >> In X5 Wire Feeder 200 the wire inch button is located in the control panel.
Page 69: Installing And Changing Wire (X5 Wf 300)
X5 FastMig Operating manual - EN 2.11 Installing and changing wire (X5 WF 300) This section describes how to install the wire and spool on X5 Wire Feeder 300. Install the welding gun to the wire feeder before installing the wire spool.
Page 70 X5 FastMig Operating manual - EN To remove the spool brake hub, release the spool brake tightening knob in the brake center and pull the brake halves apart. To install a new wire spool: Open the wire feeder top cover and the wire spool locking cover.
Page 71 X5 FastMig Operating manual - EN Secure the wire spool in place by closing the wire spool locking cover. To install the filler wire: Release the filler wire end from the spool and cut off any deformed section so that the end is straight.
Page 72 X5 FastMig Operating manual - EN Guide the filler wire through the inlet tube (a) and middle wire guide tube (b) and into the outlet tube (c), which feeds the filler wire to the welding gun. Push the filler wire by hand into the gun so that the wire reaches the wire liner (approx. 20 cm).
Page 73 X5 FastMig Operating manual - EN Adjust the pressure of the feed rolls with the pressure adjustment wheels. The pressure is the same for both feed roll pairs. The graduated scales on the pressure handle indicate the pressure applied to the feed rolls. Adjust the pressure of the feed rolls according to the table below.
Page 74 X5 FastMig Operating manual - EN Before welding, ensure that the welding parameters and settings on the control panel conform to your welding setup. >> Refer to "Using X5 Manual control panel" on page 91 and "Using X5 AP/APC control panel" on page 98 for more information.
Page 75: Installing And Changing Wire (X5 Wf Hd300)
X5 FastMig Operating manual - EN 2.12 Installing and changing wire (X5 WF HD300) This section describes how to install the wire and spool on X5 Wire Feeder HD300. Install the welding gun to the wire feeder before installing the wire spool.
Page 76 X5 FastMig Operating manual - EN If needed, adjust the spool brake by turning the spool brake tightening knob in the center of the spool hub. To install the filler wire: Release the filler wire end from the spool and cut off any deformed section so that the end is straight.
Page 77 X5 FastMig Operating manual - EN Guide the filler wire through the inlet tube (a) and middle wire guide tube (b) and into the outlet tube (c), which feeds the filler wire to the welding gun. Push the filler wire by hand into the gun so that the wire reaches the wire liner (approx. 20 cm).
Page 78 X5 FastMig Operating manual - EN The graduated scales on the pressure handle indicate the pressure applied to the feed rolls. Adjust the pressure of the feed rolls according to the table below. Filler wire Feed roll profile Filler wire diameter (mm)
Page 79: Installing And Replacing Feed Rolls
X5 FastMig Operating manual - EN 2.13 Installing and replacing feed rolls The installation method described here is the same with both X5 Wire Feeder 200 and X5 Wire Feeder 300. Model-spe- cific variations in the visual appearance and positioning may occur.
Page 80 X5 FastMig Operating manual - EN Pull the pressure roll mounting pins off. The pressure rolls' mounting pins have central axles attached to them, whereas the drive rolls' central axles act as drive shafts attached directly to the wire feed mechanism/motor.
Page 81 X5 FastMig Operating manual - EN Follow the previous steps in reverse to install the wire feed rolls. Align the cut on the drive rolls' bottom with the pin on the drive shaft. Reattach the mounting caps and mounting pins to lock the drive and pressure rolls into their places.
Page 82: Installing And Replacing Wire Guide Tubes
X5 FastMig Operating manual - EN 2.14 Installing and replacing wire guide tubes The wire feed mechanism includes three wire guide tubes. Replace them when the filler wire diameter grows or the material changes. When replacing the outlet guide tube, the welding gun must be detached.
Page 83 X5 FastMig Operating manual - EN Replace the outlet guide tube (c) by pushing the old outlet tube out from either direction. © Kemppi 1920960 / 2440...
Page 84: Installing Gas Bottle And Testing Gas Flow
- Do not use the whole contents of the bottle. - Always use an approved and tested regulator and flow meter. Contact your local Kemppi dealer for choosing the gas and the equipment. Without gas bottle cart: Place the gas bottle in a suitable, secure location.
Page 85 X5 FastMig Operating manual - EN >> With X5 Wire Feeder 300 the Gas test button is located in the wire feed cabinet: >> With X5 Wire Feeder 300 HD the Gas test button is located in the wire feed cabinet: Press the Gas test button again to adjust the gas flow.
Page 86 X5 FastMig Operating manual - EN Argon + 18-25% CO2 10...25 l/min 10...25 l/min * Depending on the gas nozzle size. ** Depending on the gas nozzle size and welding current. Adjusting gas guard (optional) The sensitivity level of the optional (with X5 Wire Feeder HD300 only) gas guard can be adjusted as follows.
Page 87: How To Get Welding Programs
2.16 How to get welding programs The use of welding programs and Wise and MAX features and processes is possible with the X5 FastMig Auto and Pulse system configurations (see "General" on page 5). WiseRoot+, WiseThin+ and MAX Position processes require a pulse welding system (with the Wise processes specifically a Pulse+ power source is required).
Page 88: Operation
X5 FastMig Operating manual - EN 3. OPERATION Before using the equipment, ensure that all the necessary installation actions have been completed according to your equipment setup and instructions. Only connect the welding machine to an earthed electric network. Welding is forbidden in places where there is an immediate fire or explosion hazard! The interconnection cable heats up during welding.
Page 89: Preparing Welding System For Use
Preparing cooler Fill the coolant container inside the cooler with Kemppi cooling liquid. For instructions on filling the cooler, refer to "Filling cooler and circulating coolant" on the next page. To weld, you must pump the coolant through the system by pressing the coolant circulation button in the front panel of the cooling unit.
Page 90: Filling Cooler And Circulating Coolant
Complete the coolant circulation operation after each time you change the welding gun. 3.1.2 Calibrating welding cable With X5 FastMig, the welding cable resistance can be measured using the built-in cable calibration function without additional measurement cable. This calibration function is available only in MIG operation mode.
Page 91: Using Voltage Sensing Cable
Available with Pulse+ power sources. While the continuous use of the separate voltage sensing cable is not necessary with X5 FastMig, the voltage sensing cable is required with the advanced WiseRoot+ and WiseThin+ processes. These processes are based on the accurate measurement of arc voltage.
Page 92 X5 FastMig Operating manual - EN X5 Wire Feeder 300 Manual control panel (X5 FP 300R) Left control knob >> In MIG mode: Wire feed speed >> In MMA mode: Welding current adjustment >> In Gouging mode: Current adjustment Right control knob >>...
Page 93: Manual Control Panel: Settings
X5 FastMig Operating manual - EN X5 Wire Feeder 200 Manual control panel (X5 FP 200R) Left control knob >> In MIG mode: Wire feed speed >> In MMA mode: Welding current adjustment >> In Gouging mode: Current adjustment Right control knob >>...
Page 94 X5 FastMig Operating manual - EN Press the Settings menu button. Switch between the menu items by turning the control knob. Select a menu item for adjustment by pressing the control knob button. Adjust the parameter value (or other settings value) by turning the control knob.
Page 95 X5 FastMig Operating manual - EN WF end step ON/OFF Wire feed end step feature prevents the Default = OFF filler wire from sticking to the contact tip when the welding ends. Dynamics Min/Max = -10.0 ... +10.0, step 0.2...
Page 96 X5 FastMig Operating manual - EN Subfeeder Subfeeder model / OFF If a compatible subfeeder is connected, (with X5 Wire Feeder 300 only) Default = OFF select the subfeeder from the list. Compatible subfeeders: SuperSnake GTX /GT02S(10m, 15m, 20m, 25m), Binzel PP401D, Binzel PP36D.
Page 97 This resets the time counter. Language Available languages Help >>> Panel display shows QR code for quick access to Kemppi Userdoc on a mobile device. Error log * >>> Shows error code, date & time and short description of the error.
Page 98: Using X5 Ap/Apc Control Panel
X5 FastMig also for TIG (DC) and MMA welding and gouging. The automatic 1-MIG process is available along with the Kemppi welding programs as well as Wise and MAX features and processes (optional). For more information, refer to "How to get welding programs" on page 87.
Page 99: Ap/Apc Control Panel: Home View
X5 FastMig Operating manual - EN >> Long press of the button returns to Home view, or if already in Home view, to the last used view. Welding parameters button >> Shortcut to the welding parameters view View selection >> Change view by turning the control knob (2) >>...
Page 100: Ap/Apc Control Panel: Weld Assist
X5 FastMig Operating manual - EN Welding voltage >> With 1-MIG process voltage fine tuning is displayed >> With Wise/MAX process a corresponding Wise/MAX parameter adjustment is displayed. Configurable function for the right control knob button >> To define a shortcut, keep the right control knob button pressed for 3 seconds and select the shortcut function from the list of available options.
Page 101 X5 FastMig Operating manual - EN To start, go to the Weld Assist view and select 'Next' with the control knob button. Select: >> The welding joint type: butt joint / corner joint / edge joint / lap joint / T-joint / tube joint / tube+plate joint.
Page 102: Ap/Apc Control Panel: Channels
X5 FastMig Operating manual - EN Save the Weld Assist’s recommendation for welding settings by selecting 'Save'. Select the memory channel slot for saving. Once saved, the memory channel can be taken into use by selecting Use in Weld Assist, or later in the Memory channels view.
Page 103: Apc Control Panel: Wps View
(WLAN). Refer to "Wireless connection (WLAN)" on page 126 for instructions. Trial registration The X5 FastMig with X5 Wire Feeder 300 APC comes preinstalled with a trial license for the WeldEye Welding Procedures module. The trial license can be activated by following these steps: ©...
Page 104 Using dWPS The WPS view shows the digital WPSs with one or more weld passes assigned to the welder or welding station in the Kemppi WeldEye cloud service. To take a dWPS in use: Select the desired dWPS for viewing and for selecting a weld pass by turning the right control knob and pressing the right control knob button.
Page 105 X5 FastMig Operating manual - EN Select a weld pass on the dWPS by turning the right control knob and enter the actions menu by pressing the right control knob button. >> The linked memory channel set as default is emphasized (in brighter blue) for each weld pass.
Page 106: Ap/Apc Control Panel: Welding Parameters
X5 FastMig Operating manual - EN The active WPS can be deactivated by selecting 'Stop using' in the WPS's weld pass actions menu. More feature descriptions here: >> "Digital Welding Procedure Specification (dWPS)" on page 127 >> "WeldEye ArcVision" on page 128 3.3.5 AP/APC control panel: Welding parameters...
Page 107 X5 FastMig Operating manual - EN Adjusting welding parameters Turn the right control knob to highlight the desired welding parameter. Press the right control knob to select the welding parameter for adjustment. Turn the right control knob to adjust welding parameter value.
Page 108 X5 FastMig Operating manual - EN Creep start 10...90 %, Auto, step 1 The Creep start function defines the wire feed speed before the welding arc ignites, that is, before the filler wire comes in contact with the workpiece. When the arc ignites, the wire feed speed is automatically switched to the normal user-set speed.
Page 109 X5 FastMig Operating manual - EN Wire feed end step (WF end step) OFF/ON Wire feed end step feature prevents the Default = OFF filler wire from sticking to the contact tip when the welding ends. Post gas 0.0 ... 9.9 s, Auto, step 0.1 Welding function that continues the 0.0 = OFF...
Page 110 X5 FastMig Operating manual - EN Wise feature None, WiseFusion, WisePenetration, When selected, a list of available Wise fea- WiseSteel tures is opened for selection. For more information on these features, refer to "Additional guidance to functions and features" on page 120.
Page 111 X5 FastMig Operating manual - EN DPulse level 2: Wire feed speed 0.50 ... 25 m/min, step 0.05 or 0.1 Second double pulse level wire feed speed. The DPulse level 2 wire feed speed changes automatically when the DPulse level 1 wire feed speed setting is adjusted.
Page 112: Ap/Apc Control Panel: Weld History
X5 FastMig Operating manual - EN Current limit min Min/Max = 10 ... machine size A, step 1 Minimum and maximum limits for the Default = 10 A current adjustment. Current limit max Min/Max = 10 ... machine size A, step 1...
Page 113: Ap/Apc Control Panel: Info View
X5 FastMig Operating manual - EN settings" on page 114. Heat input calculation in weld history view The heat input of a weld can be calculated by entering the weld length into the weld's history entry. Select 'Set length' by pressing the right control knob button.
Page 114: Ap/Apc Control Panel: Device Settings
X5 FastMig Operating manual - EN 3.3.8 AP/APC control panel: Device settings Changing settings Turn the right control knob to highlight the desired settings parameter. Press the right control knob to select the settings parameter for adjustment. Turn the right control knob to select the settings value.
Page 115 X5 FastMig Operating manual - EN Demo time OFF/ON The demo time feature allows you to try out optional welding features and func- tions without a license for a limited time. The total available demo time is 3 hours. The demo time passes only when weld- ing using a welding feature you don't have a license for.
Page 116 The screensaver image is shown on dis- Screensaver Default = 5 min play after the set time period. By default, the Kemppi logo is shown. To change the screensaver image, refer to "USB update" on page 130. OFF/1...120 min, step 1...
Page 117: Ap/Apc Control Panel: Applying Welding Programs
(optional), MAX Cool (optional), WiseRoot+ (optional) and WiseThin+ (optional). The use of additional welding programs and Wise and MAX features is possible with the X5 FastMig Auto equipment in MIG operation mode. Pulse power source is required for the MAX Position (optional) process and Pulse+ power source for the WiseRoot+ (optional) and WiseThin+ (optional) processes.
Page 118 X5 FastMig Operating manual - EN Once ready, go to the Welding program selection at the bottom to view the suitable welding programs. Select a welding program. >> The selected welding program is now shown in the filter view. To save, scroll down to Save to and select it.
Page 119: Ap/Apc Control Panel: Weld Data View
X5 FastMig Operating manual - EN 3.3.10 AP/APC control panel: Weld data view After each weld, a weld summary is displayed briefly. To change the weld data view duration or how the weld data aver- ages are calculated (with or without slope phases) refer to "AP/APC control panel: Device settings" on page 114.
Page 120: Additional Guidance To Functions And Features
This section describes the advanced X5 FastMig functions and features and how to use them. Many of the features described here are optional and available with the X5 FastMig Auto and Pulse system con- figurations only (see "General" on page 5). Refer to the feature-specific descriptions for more information on each fea- ture and function.
Page 121: 1-Mig
X5 FastMig Operating manual - EN To take Powerlog into use, go to the control panel's Welding parameters view and select Powerlog as the trigger logic. Once selected, choose whether 2 or 3 power levels are used. Still in the Welding parameters view, set up the power levels for this function.
Page 122: Wisepenetration Feature
>> To adjust the welding power/wire feed speed, in the control panel's Home view, turn the left control knob. >> To fine-tune the heat output while welding, in the control panel's Home view, turn the right control knob. For more information on Wise products, visit www.kemppi.com. 3.4.4 WisePenetration feature X5 WF AP/APC In standard MIG/MAG welding, changes in stick-out length cause welding current to fluctuate.
Page 123: Pulse Welding
DPulse is a double-pulse MIG/MAG welding process with two separate power levels. The welding power varies between these two levels. With X5 FastMig, the parameters of each level are controlled independently. >> To take DPulse welding process into use, go to Memory channels view and select an available DPulse channel.
Page 124: Wiseroot+ Process
X5 FastMig Operating manual - EN 3.4.7 WiseRoot+ process X5 PS Pulse+ X5 WF AP/APC The additional voltage sensing cable is required. The WiseRoot+ welding process improves the quality of root pass welds. WiseRoot+ is based on accurate measurement of arc voltage.
Page 125: Max Position Process
X5 FastMig Operating manual - EN 3.4.10 MAX Position process X5 PS Pulse/Pulse+ X5 WF AP/APC MAX Position is a synergic MIG/MAG welding process optimized for vertical fillet welds (position: PF). MAX Position auto- matically switches between two separate power levels. The two power levels can use the same welding process or two different welding processes.
Page 126: Wireless Connection (Wlan)
X5 FastMig Operating manual - EN 3.4.12 Wireless connection (WLAN) X5 WF APC To connect the welding equipment to your local wireless network: On the control panel, go to the WLAN view. Turn the WLAN feature on by turning and pressing the right control knob.
Page 127: Network Time Protocol (Ntp)
Digital Welding Procedure Specification (dWPS) is a WPS in digital format that can be set to observe the welding para- meters of the supported X5 FastMig equipment. The WPS view shows the digital WPSs with one or more weld passes assigned to the welder or welding station in the Kemppi WeldEye cloud service.
Page 128: Weldeye Arcvision
To take the WeldEye ArcVision feature in use, the equipment must be connected to the internet via the built-in wireless connection (WLAN). Refer to "Wireless connection (WLAN)" on page 126 for instructions. The X5 FastMig with X5 Wire Feeder 300 APC comes preinstalled with a trial license for ArcVision. The trial license can be activated by following these steps: On the X5 Wire Feeder 300 APC control panel, go to the WPS view.
Page 129: Usb Backup And Restore
This feature allows the current welding parameters, memory channels and other settings to be backed up on a USB memory stick. These can be restored later on the same welding equipment or other compatible X5 FastMig equipment. Turn the welding equipment on.
Page 130: Usb Update
There can be only one ZIP file on the USB memory stick inserted into the welding system at once. This can be either a dedicated firmware pack for this welding system or a welding program and license pack (matching the power source serial number). For more information on the available software and compatibility, contact your local Kemppi rep- resentative.
Page 131 X5 FastMig Operating manual - EN Firmware and welding software Ensure you have the correct firmware/software ZIP package saved on your computer for the welding equipment in question. Connect the USB memory stick to the computer. Prepare the USB memory stick by copying the firmware/software ZIP file into the root folder of the memory stick.
Page 132: Cycle Timer
X5 FastMig Operating manual - EN On your computer web browser, go to https://kemp.cc/screensaver. Following the on-screen instructions, upload, edit and download the new screen saver image onto a USB memory stick. Connect the USB memory stick to the X5 control panel following the same principle than with the software updates (previous chapter) and the on-screen instructions.
Page 133: Settings Lock
X5 FastMig Operating manual - EN >> Requires X5 Wire Feeder AP/APC. For more information, refer to "WisePenetration feature" on page 122. • WiseRoot+ >> Requires X5 Wire Feeder AP/APC and X5 Power Source 400/500 Pulse+. For more information, refer to "WiseRoot+ pro- cess"...
Page 134: Using Remote Control Hr40/Hr43
For the HR40 remote control, welding equipment firmware version 1.30 or newer is required. Check the currently installed version in the AP/APC control panel's Info view (select 'Device info') or in the Manual control panel's advanced settings (select 'Info'). For more information on firmware updates, contact your local Kemppi dealer. © Kemppi...
Page 135: Using Remote Control Hr55
X5 FastMig equipment. In a double wire feeder setup, the remote-controlled wire feeder can be selected directly from the remote without mov- ing the cable.
Page 136 X5 FastMig Operating manual - EN Remote control views and operation Change between the views by pressing the left/right arrow buttons. • Memory channel view (MIG/MAG only): The memory channel is changed by pressing the +/- buttons. Long press of a +/- button scrolls the parameter values faster.
Page 137: Lifting Equipment
3.7 Lifting equipment If you need to lift X5 FastMig equipment, pay special attention to the safety measures. Also follow the local regulations. The X5 FastMig equipment can be lifted with a mechanical hoist as a whole only when the equipment is installed securely on a dedicated transport unit.
Page 138 X5 FastMig Operating manual - EN 2 wheel cart: Ensure that the welding equipment is properly secured to the cart. Connect the hoist hook to the lifting handle on the cart. © Kemppi 1920960 / 2440...
Page 139: Maintenance
X5 FastMig 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 140: Daily Maintenance
Check the wire feeder's feed rolls and the pressure handle. Clean and lubricate with a small quantity of light machine oil if needed. For repairs, contact Kemppi at www.kemppi.com or your dealer. Welding gun maintenance For Flexlite GX MIG gun instructions, refer to userdoc.kemppi.com. © Kemppi 1920960 / 2440...
Page 141: Periodic Maintenance
X5 FastMig Operating manual - EN 4.2 Periodic maintenance 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 142: Service Workshops
X5 FastMig 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 • Maintenance of the welding tools •...
Page 143: Troubleshooting
X5 FastMig Operating manual - EN 4.4 Troubleshooting The problems listed and the possible causes are not definitive, but suggest some typical situations that may turn up during normal use of the welding system. Welding system: Problem Recommended actions The welding system does not power up Check that the mains cable is plugged in properly.
Page 144 X5 FastMig Operating manual - EN Dirty and/or poor quality weld Check that the shielding gas has not run out. Check that the shielding gas flow is unobstructed. Check that the gas type is correct for the application. Check the polarity of the gun/electrode.
Page 145: Error Codes
Too long welding session with high power. Do not shut down, let the fans cool the machine. If overheated fans are not running, contact Kemppi service Internal 24V Power source contains an inoperative 24V Restart the power source. If problem persists, contact voltage is too power supply unit .
Page 146 Wire feeder lost connection to the robot Check the robot control device and interconnection device lost control device. cables. If problem persists, contact Kemppi service. Subfeeder not Use of subfeeder is not allowed with selec- Remove the subfeeder or change the welding pro- allowed ted welding process.
Page 147: Installing And Cleaning Power Source Air Filter
X5 FastMig Operating manual - EN 4.6 Installing and cleaning power source air filter An optional power source air filter can be purchased separately. The air filter comes with a fixed casing designed to be mounted directly onto the power source air intake.
Page 148 X5 FastMig Operating manual - EN Cleansing Remove the air filter from the power source by releasing the clips on the edge of the air filter casing. Blow the air filter clean with compressed air. © Kemppi 1920960 / 2440...
Page 149: Disposal
The owner of the equip- ment is obliged to deliver a decommissioned unit to a regional collection center, 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 150: Technical Data
X5 FastMig Operating manual - EN 5. TECHNICAL DATA Technical data: • For X5 power source technical data, refer to "X5 power sources" on the next page. • For X5 wire feeder technical data, refer to "X5 wire feeders" on page 161.
Page 151: X5 Power Sources
X5 FastMig Operating manual - EN 5.1 X5 power sources X5 Power Source 400 X5 Power Source 400 Feature Value Mains connection voltage 380...460 V ±10 % Mains connection phases 3~50/60 Hz Mains connection cable type H07RN-F Mains connection cable size 4 mm²...
Page 152 X5 FastMig Operating manual - EN X5 Power Source 400 MV X5 Power Source 400 MV WP Feature Value Mains connection voltage 380...460 V ±10 % Mains connection voltage MV low range 220...230 V ±10 % Mains connection phases 3~50/60 Hz...
Page 153 X5 FastMig Operating manual - EN Degree of protection IP23 External dimensions L x W x H 750 x 263 x 456 mm Weight without accessories 43.5 kg Standards IEC 60974-1, -10 © Kemppi 1920960 / 2440...
Page 154 X5 FastMig Operating manual - EN X5 Power Source 400 Pulse X5 Power Source 400 Pulse Feature Value Mains connection voltage 380...460 V ±10 % Mains connection phases 3~50/60 Hz Mains connection cable type H07RN-F Mains connection cable size 4 mm²...
Page 155 X5 FastMig Operating manual - EN X5 Power Source 400 Pulse+ X5 Power Source 400 Pulse+ Feature Value Mains connection voltage 380...460 V ±10 % Mains connection phases 3~50/60 Hz Mains connection cable type H07RN-F Mains connection cable size 4 mm²...
Page 156 X5 FastMig Operating manual - EN X5 Power Source 400 MV Pulse+ X5 Power Source 400 MV Pulse+ Feature Value Mains connection voltage 380...460 V ±10 % Mains connection voltage MV low range 220...230 V ±10 % Mains connection phases...
Page 157 X5 FastMig Operating manual - EN EMC class Degree of protection IP23S External dimensions L x W x H 750 x 263 x 456 mm Weight without accessories 43.5 kg Standards IEC 60974-1, -10 © Kemppi 1920960 / 2440...
Page 158 X5 FastMig Operating manual - EN X5 Power Source 500 X5 Power Source 500 Feature Value Mains connection voltage 380...460 V ±10 % Mains connection phases 3~50/60 Hz Mains connection cable type H07RN-F Mains connection cable size 6 mm² Rated maximum input power [ S...
Page 159 X5 FastMig Operating manual - EN X5 Power Source 500 Pulse X5 Power Source 500 Pulse Feature Value Mains connection voltage 380...460 V ±10 % Mains connection phases 3~50/60 Hz Mains connection cable type H07RN-F Mains connection cable size 6 mm²...
Page 160 X5 FastMig Operating manual - EN X5 Power Source 500 Pulse+ X5 Power Source 500 Pulse+ Feature Value Mains connection voltage 380...460 V ±10 % Mains connection phases 3~50/60 Hz Mains connection cable type H07RN-F Mains connection cable size 6 mm²...
Page 161: X5 Wire Feeders
X5 FastMig Operating manual - EN 5.2 X5 wire feeders X5 Wire Feeder 200 Manual X5 Wire Feeder 200 Manual Feature Value Supply voltage 48 V Supply current at maximum load 6.3 A Idle power Idle power with cabinet heater...
Page 162 X5 FastMig Operating manual - EN Feature Value Supply voltage 48 V Supply current at maximum load 6.3 A Idle power Idle power with cabinet heater 30 W Welding current 60% 500 A Welding current 100% 430 A Welding connection type...
Page 163 X5 FastMig Operating manual - EN Idle power with cabinet heater 30 W Welding current 60% 500 A Welding current 100% 430 A Welding connection type Euro Wire feed mechanism 4-roll, Single-motor Diameter of feed rolls 32 mm Filler wire diameter, Fe 0.8...2 mm...
Page 164 X5 FastMig Operating manual - EN Diameter of feed rolls 32 mm Filler wire diameter, Fe 0.8...2 mm Filler wire diameter, Ss 0.8...2 mm Filler wire diameter, MC/FC 0.8...2.4 mm Filler wire diameter, Al 0.8...2.4 mm Wire feed speed 0.5...25 m/min...
Page 165 X5 FastMig Operating manual - EN Welding connection type Euro Wire feed mechanism 4-roll, Single-motor Diameter of feed rolls 32 mm Filler wire diameter, Fe 0.8...2 mm Filler wire diameter, Ss 0.8...2 mm Filler wire diameter, MC/FC 0.8...2.4 mm Filler wire diameter, Al 0.8...2.4 mm...
Page 166 X5 FastMig Operating manual - EN Diameter of feed rolls 32 mm Filler wire diameter, Fe 0.8...2 mm Filler wire diameter, Ss 0.8...2 mm Filler wire diameter, MC/FC 0.8...2.4 mm Filler wire diameter, Al 0.8...2.4 mm Wire feed speed 0.5...25 m/min...
Page 167 X5 FastMig Operating manual - EN Idle power with cabinet heater 11 W Welding current 60% 500 A Welding current 100% 430 A Welding connection type Euro Wire feed mechanism 4-roll, Single-motor Diameter of feed rolls 32 mm Filler wire diameter, Fe 0.8...2 mm...
Page 168: X5 Cooling Units
X5 FastMig Operating manual - EN 5.3 X5 cooling units X5 Cooler X5 Cooler Feature Value Supply voltage 380...460 V ±10 % Maximum supply current [ I 0.7 A 1max Cooling power at 1 l/min 1.1 kW Maximum coolant pressure...
Page 169: X5 Ordering Info
X5 FastMig Operating manual - EN 5.4 X5 ordering info For X5 FastMig ordering information and optional accessories, refer to Kemppi.com. © Kemppi 1920960 / 2440...
Page 170: Wire Feeder Consumables
The wire feeder consumables can be ordered in Configurator.kemppi.com. In the tables, standard refers to plastic feed rolls and heavy-duty refers to metal feed rolls. The materials mentioned first refer to primary suitability and the materials mentioned inside brackets refer to secondary suitability.
Page 171: Feed Rolls
X5 FastMig Operating manual - EN SP007293 SP007273 SP016608 Al, Ss (Fe, MC, FC) 0.8−0.9 SP007294 SP007274 SP011440 SP007295 SP007275 SP011441 SP007296 SP007276 SP011442 SP007297 SP007277 SP016609 SP007298 SP007278 SP016610 SP007299 SP007279 SP016611 SP007300 SP007280 SP016612 (SP007293) (SP007273) SP016613 Fe, MC, FC 0.8−0.9...
Page 172 X5 FastMig Operating manual - EN MC/FC (Fe) V-groove, knurled W001057 W001058 W001059 W001060 1.4−1.6 W001061 W001062 W001063 W001064 W001065 W001066 Al (MC/FC, Ss, Fe, U-groove W001067 W001068 W001069 W001070 W008974 W008975 W001071 W001072 The table below lists the heavy-duty feed rolls available.
Page 173: Welding Program Work Packs
Welding program work packs include a set of standard welding programs to allow welding with e.g. automatic 1-MIG and pulse processes. For more information on the available X5 FastMig welding program options and installing the weld- ing programs or software updates, contact your local Kemppi dealer or go to Kemppi.com.
Page 174 X5 FastMig Operating manual - EN 1-MIG FC-CrNiMo Ar+18%CO2 Standard Pulse work pack: The Pulse work pack includes also all 1-MIG work pack welding programs. Welding program Process Wire material Wire diameter Shielding gas Description Pulse AlMg5 Standard Pulse AlMg5...

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