X8 wire cut system инструкция

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• Page 1
  X8 MIG Welder OPERATING MANUAL…

• Page 2: Table Of Contents

  2.7.2 Periodic maintenance of power source and wire feeder……….. 161 2.7.3 Service workshops……………………162 2.8 Technical data…………………………162 2.8.1 X8 Power Source 400 A………………….162 2.8.2 X8 Power Source 500 A / 500 A MV…………….. 164 2.8.3 X8 Cooler……………………….166 2.8.4 X8 Wire Feeder………………………167 2.8.5 X8 Control Pad……………………… 168 2.8.6 X8 MIG Gun 200-g……………………

• Page 3
  2.8.9 X8 MIG Gun 400-w……………………172 2.8.10 X8 MIG Gun 500-w…………………… 174 2.9 Ordering codes……………………….175 2.10 Disposal of unit……………………….178…

• Page 4: Read First

  X8 MIG WELDER 1.1 Disclaimer 1 Read first Kemppi takes special care in informing its customers about the safety of our products. We also mind the environment and aspire to disposing of our products according to specified European Directives. 1.1 Disclaimer While every effort has been made to ensure that the information contained in this guide is accurate and complete, no liability can be accepted for any errors or omissions.

• Page 5
  X8 MIG WELDER 1.3 Kemppi symbols Symbol Description EMC Class A This symbol indicates that the waste of electrical and electronic equipment must not be disposed as unsorted municipal waste and must be collected separately. Contact an authorized representative of the manufacturer for information concerning the decommissioning of your equipment.
• Page 6
  X8 MIG WELDER 1.3 Kemppi symbols Symbol Description Carbon arc gouging Pulse MIG WiseRoot WiseThin WiseFusion WiseSteel WisePenetration+ Creep Start © OPERATING MANUAL | EN KEMPPI 2017 | 1817…
• Page 7
  X8 MIG WELDER 1.3 Kemppi symbols Symbol Description Hot Start Upslope Crater Fill with Downslope Crater Fill with Downlevel Ö Õ User manual © OPERATING MANUAL | EN KEMPPI 2017 | 1817…

• Page 8: X8 Mig Welder

  2.1 Disclaimer 2 X8 MIG Welder These instructions describe the use of Kemppi’s X8 MIG Welder, the top-class welding system for demanding industrial use. The system consists of a power source, wire feeder, welding gun, Control Pad and various welding software components and connectivity to Kemppi cloud services.

• Page 9
  • The wheel set is included in the power source delivery • The gas cylinder cart is optionally included in the power source delivery 8. My Fleet web service • Cloud-based service for viewing and managing various information about your X8 MIG Welder • Provides manufacturer’s validation certificate 9.

• Page 10: Introduction To Weldeye For Welding Procedure And Qualification

  X8 MIG WELDER 2.3 System structure 2.2.1 Introduction to WeldEye for welding procedure and qualification management Welding procedure and qualification management WeldEye for Welding procedure and qualification management is a cloud-based tool for creating, managing and storing various welding-related documents and qualification certificates. WeldEye is an end-to-end solution for handling pWPS, WPQR and WPS documents as well as welder qualification certificates.

• Page 11: X8 Power Source

  X8 MIG WELDER 2.3 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 12
  X8 MIG WELDER 2.3 System structure Front 1. Indicator panel 2. Transportation handle 3. USB connector Connect a USB memory stick to upload the welding procedures (WPS) or Wise features to the power source or update firmware if a wireless connection is unavailable.
• Page 13
  X8 MIG WELDER 2.3 System structure Rear 1. Transportation handle 2. Welding current cable connectors (positive pole) 3. Earth return cable connectors (negative pole) 4. Measurement cable connectors Connectors for wire feeder 1 on the left, wire feeder 2 on the right side of the power source.
• Page 14
  4. Kemppi cloud connection The LED is blue when the wire feeder or power source is connected to Kemppi cloud services. The LED is blinking blue when the wire feeder or power source is connecting to Kemppi cloud services.

• Page 15: X8 Wire Feeder

  2. Coolant inlet hose 3. Coolant outlet hose 4. Welding current cable 5. Control cable 6. Measurement cable 7. Strain relief pin 2.3.2 X8 Wire Feeder This section describes the X8 Wire Feeder structure. © OPERATING MANUAL | EN KEMPPI 2017 | 1817…

• Page 16
  X8 MIG WELDER 2.3 System structure Main parts 1. Top cover Caution: Keep the wire feeder top cover closed during welding to reduce the risk of injury or an electric shock. Keep the top cover closed also at other times to keep the wire feeder insides clean.
• Page 17
  X8 MIG WELDER 2.3 System structure Figure 2: The warning sticker inside the wire feeder 10. Wire spool 11. Wire spool locking cover 12. Feed rolls 13. Pressure handle 14. Wire guide 15. Inside control buttons © OPERATING MANUAL | EN…

• Page 18: Control Panel

  X8 MIG WELDER 2.3 System structure Control panel The control panel on the front of the wire feeder enables easy control of the wire feeder’s basic features. Although Control Pad is the main control of the welding system, you can also use the wire feeder control panel or the welding gun remote control.

• Page 19
  X8 MIG WELDER 2.3 System structure 3. Settings button The button lights up orange, when the view is activated. 4. Left control knob 5. Right control knob 6. Left and right button For more information on the use and features of the control panel, see…
• Page 20
  External component connectors 1. Kemppi Gun Adapter Connects to the welding gun. Note: The wire feeder is supplied with Kemppi Gun Adapter. 2. Subfeeder Provides control to optional SuperSnake subfeeder or a motorized welding gun. © OPERATING MANUAL | EN…

• Page 21: X8 Mig Guns

  Delivers cold coolant to the welding gun. 6. Coolant inlet Receives heated coolant from the welding gun. 2.3.3 X8 MIG Guns This section describes the structure of X8 MIG guns. Gas-cooled gun 1. Gas nozzle 2. Contact tip 3. Contact tip adapter 4.

• Page 22
  2.3 System structure 6. Work light Press the trigger lightly to switch on the light. 7. Place for X8 Gun Remote Control The remote control will become available in a later release. 8. Trigger 9. Trigger on the pistol grip handle 10.

• Page 23: Control Pad

  2.3 System structure 7. Work light Press the trigger lightly to switch on the light. 8. Place for X8 Gun Remote Control The remote control will become available in a later release. 9. Trigger 10. Trigger on the pistol grip handle 11.

• Page 24
  X8 MIG WELDER 2.3 System structure 4. Left and right button When the button lights up green, you can press the button to confirm an action. 5. Display 6. View buttons 7. Channel button The button lights up blue, when the view is activated.
• Page 25
  X8 MIG WELDER 2.3 System structure When Control Pad is charging, green leds on the left side of the display indicate ongoing charging. The lowest led turns red when the charge level is low. © OPERATING MANUAL | EN KEMPPI 2017 | 1817…

• Page 26: Installation

  Combo cable port transfers both data and power. A stopper shields the combo cable port. 2.4 Installation Perform this installation procedure to prepare your X8 MIG Welder for use. Read the instructions carefully and follow them closely. 2.4.1 Before installation Make sure to acknowledge and follow the local and national requirements on installation and the use of high voltage units.

• Page 27: Power Source Installation

  X8 MIG WELDER 2.4 Installation The mains cable must be installed by an authorized electrician. Warning: Provided that the public low voltage short circuit power at the point of common coupling is higher than or equal to 5.1 MVA, this equipment is compliant with IEC 61000-3-11 and IEC 61000-3-12 and can be connected to public low voltage systems.

• Page 28
  X8 MIG WELDER 2.4 Installation b) Push the rear axle through the opening in the bottom of the rear side of the unit and set the axle in the middle. c) Slide the two wheel spacers (1) onto the axle.
• Page 29
  X8 MIG WELDER 2.4 Installation Install the front wheels. a) Push the front axle through the opening in the bottom of the front side of the unit and set the axle in the middle. b) 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 30
  2.4.2.2 Installing optional gas cylinder cart To transport a larger gas cylinder with the power source, install X8 Gas Cylinder Cart. For detailed instructions, see X8 Gas Cylinder Cart Mounting Instructions. If your setup does not include the gas cylinder cart, proceed to Installing optional X8 Cooler.
• Page 31
  X8 MIG WELDER 2.4 Installation Attach a wheel set to the front of the unit. • To have turning wheels in the front and the back, install the front wheel assembly to the front of the unit. For more information, see Installing wheels on page 27.
• Page 32
  X8 MIG WELDER 2.4 Installation c) Insert cover plugs to the open ends of the wheel set. d) Place the upper part of the gas cylinder cart on the wheel set, and push it down until the claw fastens over the transportation handle.
• Page 33
  2.4.2.3 Installing optional X8 Cooler If your setup does not include X8 Cooler, you can skip these instructions. Caution: X8 Cooler must be installed by authorized service personnel. Do not open the covers of X8 Power Source. © OPERATING MANUAL | EN…
• Page 34
  X8 MIG WELDER 2.4 Installation 1. Front panel 2. Front panel latch 3. Coolant circulation button 4. Cooler 5. Coolant container 6. Connectors for the liquid cooling unit Proceed as follows: Detach the two screws in the front panel of the power source.

• Page 35: Wire Feeder Installation

  X8 MIG WELDER 2.4 Installation Pull the front panel outwards from the lower edge. Remove the lower left cover from the rear of the power source. Push the cooler inside the power source from the opening in the front. Note: Do not use force, but make sure the connectors on the cooler and the power source are properly connected.

• Page 36
  X8 MIG WELDER 2.4 Installation 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 37
  X8 MIG WELDER 2.4 Installation 5 Nm With the control panel facing the same way as the power source front panel, place the wire feeder in the corresponding grooves on the wire feeder rotating plate. Slide the wire feeder from front to back until the bar in the back of the unit locks to the orange claw at the back of the wire feeder rotating plate.
• Page 38
  X8 MIG WELDER 2.4 Installation Proceed as follows: Install the welding gun holder mount to the wire feeder with 2 screws going to the corresponding holes on the wire feeder upper cover hinge. Attach the welding gun holder to the mount with 2 screws.
• Page 39
  X8 MIG WELDER 2.4 Installation Push the collars on the mounting pins of the feed rolls up to pull the mounting pins off. © OPERATING MANUAL | EN KEMPPI 2017 | 1817…
• Page 40
  X8 MIG WELDER 2.4 Installation Note: The mounting pins are different: The drive rolls’ mounting pins have a circular mark on the top, while the pressure rolls’ mounting pins have no marks. The pressure rolls’ mounting pins have central axles attached to them, so the drive and pressure rolls’ mounting pins cannot be confused with each other.
• Page 41
  X8 MIG WELDER 2.4 Installation Select the feed rolls according to the tables below. Wire feed rolls, plastic Filler wire Feed roll Filler wire Feed roll Drive roll Pressure roll material profile diameter identification code code (mm) Fe, Ss (Al,…
• Page 42
  X8 MIG WELDER 2.4 Installation Wire feed rolls, plastic W000960 W000961 W001049 W001050 W001051 W001052 W001053 W001054 W001055 W001056 Fc, Mc (Fe) V-groove, W001057 W001058 knurled W001059 W001060 1.4−1.6 W001061 W001062 W001063 W001064 W001065 W001066 © OPERATING MANUAL | EN…
• Page 43
  X8 MIG WELDER 2.4 Installation Wire feed rolls, plastic Al (Fc, Mc, U-groove W001067 W001068 Ss, Fe) W001069 W001070 W001071 W001072 Wire feed rolls, metal Filler wire Feed roll Filler wire Feed roll Drive roll Pressure roll material profile diameter…
• Page 44
  X8 MIG WELDER 2.4 Installation Reattach the mounting pins to lock the drive and pressure rolls to their places. Align one of the cuts on the bottom of the pressure rolls’ mounting pin with the stud on the mount. Lower the pressure handle on the feed rolls and close the top cover.
• Page 45
  X8 MIG WELDER 2.4 Installation 1. Inlet tube Pull out the inlet tube and insert a new one. There is no additional locking. 2. Middle tube A metal piece locks the middle wire guide tube in its place. Turn the piece aside to free the middle wire guide tube for replacement.
• Page 46
  X8 MIG WELDER 2.4 Installation Note: The sharp cut tip of the filler wire may cause damage to the wire liner, if not filed. d) Press Wire retract to pull back the remaining filler wire from the welding gun (4).
• Page 47
  X8 MIG WELDER 2.4 Installation Ensure that the wire spool is facing the right direction, the filler wire running from the top of the spool to the feed rolls. d) Lift the pressure handle off of the feed rolls (4).
• Page 48
  X8 MIG WELDER 2.4 Installation 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 Filler wire Adjustment material…
• Page 49
  Close the top cover. Wire spools X8 MIG Welder has three different wire spool hub options available for different wire spools: A. Standard spool B. Spool hub for the small wire spool Attach the extension pieces to the standard spool halves with a screw.
• Page 50
  X8 MIG WELDER 2.4 Installation All parts are delivered with the wire feeder. Pull the spool halves to detach them. There is also a screw in the center of the hub that you can use. 2.4.3.6 Attaching interconnection cable to strain relief To ease the installation of the interconnection cable and to prevent any unnecessary strain on the cable connectors, attach both ends of the interconnection cable bundle to a strain relief.

• Page 51: Cables Installation

  X8 MIG WELDER 2.4 Installation Insert the supplied locking pin through the hole in the strain relief pin. Route the cable bundle from the back of the power source and attach the strain relief in the other end of the cable to the left-hand side of the wire feeder. For more information, see .

• Page 52
  X8 MIG WELDER 2.4 Installation Connect the interconnection cable to the wire feeder a) Lift the cable cabinet latch to reveal the connectors. b) Connect the welding current cable to the wire feeder. Push the cable as far as it goes and turn the connector clockwise to tighten the cable to its place.
• Page 53
  X8 MIG WELDER 2.4 Installation i) Connect the cooling water hoses to the slot. j) Close and lock the cable cabinet door. Note: When connecting the cables to the wire feeder, route the cables neatly so that the cable cabinet door closes properly.
• Page 54
  X8 MIG WELDER 2.4 Installation f) If the water cooler is present, use the blue connector (6) for the hose that comes from the cooler. g) If you need shielding gas, connect the shielding gas hose to the gas cylinder.

• Page 55: Control Pad Installation

  94. 2.4.5.1 Wireless connection Control Pad connects wirelessly to X8 Wire Feeder. If there are two wire feeders in the system, choose which one to connect to. Control Pad can be connected to X8 Power Source in applications where no wire feeder is needed, such as stick welding or gouging.

• Page 56
  X8 MIG WELDER 2.4 Installation Proceed as follows: To connect Control Pad wirelessly to a wire feeder or power source: a) Press the wireless pairing button on the power source indicator panel. The led on the power source begins to blink when it is searching for Control Pad.
• Page 57
  X8 MIG WELDER 2.4 Installation Figure 4: Connecting to wire feeder Figure 5: Connecting to power source b) Move focus to select the connection and press the green button. Note: The connection list shows the serial numbers of the available wire feeders and a power source.
• Page 58
  Move focus to a wire feeder or a power source. c) Press the green button. 2.4.5.2 Wired connection Control Pad makes a wired connection with X8 Power Source and X8 Wire Feeder. Connect Control Pad to a wired connection, when wireless connection is unavailable. Proceed as follows: To make a wired connection between Control Pad and the power source: a) Plug the combo cable to the Control Pad connector of the power source.
• Page 59
  X8 MIG WELDER 2.4 Installation To make a wired connection between Control Pad and the wire feeder: a) Plug the combo cable to the remote control connector of the wire feeder. The connector is marked with a Control Pad icon.

• Page 60: Welding Gun Installation

  Connect the welding gun to the wire feeder, prepare it for use, and change consumable parts. 2.4.6.1 Preparing and connecting welding gun The X8 MIG Gun has been preassembled by the manufacturer: the wire liner, contact tip and gas nozzle are premounted. To start using the gun, proceed as follows: Check that the wire liner, contact tip, gas nozzle are suitable for the job.

• Page 61
  2.4 Installation Note: X8 MIG Guns connect to X8 Wire Feeder with a special Kemppi Gun Adapter that enables, among other things, accurate measurement of the actual arc voltage and the usage of the remote control (available in a later release). Therefore, X8 MIG Guns are only compatible with X8 Wire Feeder.
• Page 62
  X8 MIG WELDER 2.4 Installation Trim the excess filler wire at a slight angle to improve ignition. Check the gas flow rate. The welding gun is now ready for use. When not using the gun, you can keep it in the gun holder on the side of the wire feeder.
• Page 63
  X8 MIG WELDER 2.4 Installation X8300403500 X8300405000 X8300503500 X8300505000 Contact tip X8 MIG Gun X8 MIG Gun X8 MIG Gun X8 MIG Gun 400-W 3.5m 400-W 5.0m 500-W 3.5m 500-W 5.0m W006826 Standard Standard 1.0/D10 M8 / W006518 Standard Standard 1.2/D10 M8 /…
• Page 64
  W012611 Standard Standard X8 liner RED 3.5m W012612 Standard Standard X8 liner RED 5.0m W012613 X8 liner YE 3.5m W012614 X8 liner YE 5.0m W012622 X8 liner 3.5m Ø1,5/5,9 DL-Chili W012623 X8 liner 5.0m Ø1,5/5,9 DL-Chili W012624 X8 liner 3.5m Ø2,0/5,9 DL-Chili…
• Page 65
  X8 MIG WELDER 2.4 Installation Wire liner X8300403500 X8300405000 X8300503500 X8300505000 X8 MIG Gun X8 MIG Gun X8 MIG Gun X8 MIG Gun 400-W 3.5m 400-W 5.0m 500-W 3.5m 500-W 5.0m W012626 X8 liner 3.5m Ø2,5/5,9 DL-Chili W012627 X8 liner 5.0m Ø2,5/5,9 DL-Chili…
• Page 66
  X8 MIG WELDER 2.4 Installation Liner guide X8300403500 X8300405000 X8300503500 X8300505000 tube X8 MIG Gun X8 MIG Gun X8 MIG Gun X8 MIG Gun 400-W 3.5m 400-W 5.0m 500-W 3.5m 500-W 5.0m W011887 Guide tube out 0.8-0.9 WH Metal W011888 Guide tube out 1.0 RD Metal…
• Page 67
  X8 MIG WELDER 2.4 Installation Contact tipX8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m G 5.0m G 3.5m…
• Page 68
  X8 MIG WELDER 2.4 Installation Gas nozzle X8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m G 5.0m G 3.5m…
• Page 69
  X8 MIG WELDER 2.4 Installation Wire liner X8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m G 5.0m G 3.5m…
• Page 70
  X8 MIG WELDER 2.4 Installation Wire liners for gas-cooled guns Wire liner X8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m…
• Page 71
  X8 MIG WELDER 2.4 Installation Wire liner X8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m G 5.0m G 3.5m…
• Page 72
  X8 MIG WELDER 2.4 Installation Wire liner X8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m G 5.0m G 3.5m…
• Page 73
  X8 MIG WELDER 2.4 Installation Wire liner X8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m G 5.0m G 3.5m…
• Page 74
  X8 MIG WELDER 2.4 Installation Liner X8301203500 X8301205000 X8301303500 X8301305000 X8301403500 X8301405000 guide tube X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG X8 MIG Gun 200- Gun 200- Gun 300- Gun 300- Gun 400- Gun 400- G 3.5m G 5.0m…
• Page 75
  X8 MIG WELDER 2.4 Installation Changing liner (gas-cooled gun) Lay the welding gun cable straight on a flat surface. Loosen the neck tightener by rotating it half a turn, and remove the neck. Remove the guide nut from the tip of the sleeve.
• Page 76
  X8 MIG WELDER 2.4 Installation Load the new liner through the welding gun connector as far as you can push it. Check that you have pushed the liner far enough: the liner must be visible at the tip of the gun.
• Page 77
  X8 MIG WELDER 2.4 Installation Assemble the cone (1), seal (2) and sleeve (3) (supplied with the new liner) over the liner protruding from the welding gun connector. Tighten the sleeve as tight as possible with a spanner. Cut the excessive liner (spiral liner with side cutting pliers, DL Chili liner with a carpet knife) leaving 1 — 2 mm.
• Page 78
  X8 MIG WELDER 2.4 Installation 1-2 mm Attach the guide nut at the tip of the sleeve. Re-assemble the neck and tighten the neck tightener to secure. Changing neck (gas-cooled gun) You can change the neck easily, without tools. Turn the neck tightener half a turn counter-clockwise to loosen it, and pull the neck out.
• Page 79
  X8 MIG WELDER 2.4 Installation Push in the new neck and turn the neck tightener half a turn clockwise to secure it. Make sure you push the neck deep enough: When the neck is correctly inserted, the groove on the neck is completely hidden under the neck tightener.
• Page 80
  X8 MIG WELDER 2.4 Installation Changing contact tip (gas-cooled gun) Remove the contact tip. Replace the contact tip adapter / gas diffuser, if needed. Screw in and hand-tighten the new adapter as tight as possible (no tool is needed). Make sure there is no gap between the contact tip adapter and the black plastic bushing.
• Page 81
  X8 MIG WELDER 2.4 Installation Screw in a new contact tip and tighten it with an appropriate tool. Some thread grooves on the contact tip remain visible when the contact tip is properly connected to the gun. Changing wire liner (water-cooled gun) Caution: Use the correct wire liner.
• Page 82
  X8 MIG WELDER 2.4 Installation Remove the guide nut from the tip of the sleeve. Remove the sleeve and pull out the liner together with the cone (1) and the seal (2). © OPERATING MANUAL | EN KEMPPI 2017 | 1817…
• Page 83
  X8 MIG WELDER 2.4 Installation Load the new liner through the welding gun connector until enough liner protrudes from the neck. Adjust the length according to the contact tip adapter. Note: Make sure the liner is properly inside the contact tip adapter before you cut the liner at the connector end.
• Page 84
  X8 MIG WELDER 2.4 Installation Assemble the cone (1), seal (2) and sleeve (3) (supplied with the liner) over the liner protruding from the welding gun connector. Tighten the sleeve with a spanner to secure. © OPERATING MANUAL | EN…
• Page 85
  X8 MIG WELDER 2.4 Installation Cut the excessive liner (spiral liner with side cutting pliers, DL Chili liner with a carpet knife) leaving 1 — 2 mm. 1-2 mm Attach the guide nut at the tip of the sleeve. ©…
• Page 86
  X8 MIG WELDER 2.4 Installation Changing gas nozzle (water-cooled gun) To remove the old gas nozzle, turn the nozzle slightly anti-clockwise and pull. Push the new nozzle in until it clicks firmly into place. © OPERATING MANUAL | EN KEMPPI 2017 | 1817…
• Page 87
  X8 MIG WELDER 2.4 Installation Changing contact tip (water-cooled gun) Remove the gas nozzle and the contact tip. Replace the contact tip adapter (1) and gas diffuser (2), if needed. Screw in and tighten the new adapter with a tool.
• Page 88
  Screw in a new contact tip and tighten it properly with a tool. 2.4.6.3 Installing pistol grip handle The pistol grip handle is suitable for all X8 MIG Guns. The handle improves the ergonomics of many welding positions. To attact the pistol grip handle, align the grooves and pull the handle forward to attach the front side (1), and then push the handle back to snap-lock it into its place (2).

• Page 89: Lifting X8 Mig Welder

  To detach the pistol grip handle, press the lock button at the back of the handle. 2.4.7 Lifting X8 MIG Welder If you need to lift X8 MIG Welder, pay special attention to the safety measures. Follow the local regulations.

• Page 90: Purchasing And Managing Welding Software

  X8 MIG Welder has several accessories to facilitate its use and improve welding quality. Wire Drum Kit To use the wire drum kit, drill a hole at the back of X8 Wire Feeder’s transparent cover. © OPERATING MANUAL | EN…

• Page 91
  X8 MIG WELDER 2.4 Installation Wire Feeder Hanger for Boom The wire feeder hanger for boom facilitates welding where it is difficult to bring the full X8 MIG Welder welding system. The hanger allows more fluent transitions in constricted spaces. Caution: Do not hang the wire feeder from the handle.
• Page 92
  X8 MIG WELDER 2.4 Installation Wire Feeder Counterbalance Arm The wire feeder counterbalance arm reduces the weight of the cable bundle over the working area. Wire Feeder Cabinet Heater © OPERATING MANUAL | EN KEMPPI 2017 | 1817…

• Page 93: Operation

  The double wire feeder rotating plate allows the use of two wire feeders on one power source. 2.5 Operation Follow these operating instructions carefully to have full advantage of your X8 MIG Welder and to minimize the risk of malfunctions.

• Page 94
  2.5 Operation 2.5.1.1 Control Pad Control Pad is a window to X8 MIG Welder: Control Pad shows you all the settings and licenses installed in the welding system. You can adjust the welding parameters and their values remotely with the one-knob navigation, and connect Control Pad to any X8 MIG Welder nearby.
• Page 95
  X8 MIG WELDER 2.5 Operation There is an instruction on the footer above the knob, when the knob has a specific function. A green circle in the footer prompts the push of the button on the control knob. The adjustable parameter or value in focus is highlighted with orange.
• Page 96
  X8 MIG WELDER 2.5 Operation Figure 10: The Welding view button Figure 11: The Settings view button Welding view In the Welding view, you can: • See an overview of the settings of the selected welding program • Adjust the main parameters (welding power and fine tuning)
• Page 97
  X8 MIG WELDER 2.5 Operation If you have modified the welding settings, the channel number tilts to the right. To save changes, press and hold the Channel button until the number returns to its normal position. 2. Operation mode of the welding gun (trigger logic) 3.
• Page 98
  X8 MIG WELDER 2.5 Operation Figure 12: Raster pattern in the wire feed arc In DPulse and WP Switch, you can adjust two value sets: the first level and the second power level. Press the left green button to toggle between them. Adjust the values with the control knobs. The other power level is shown with gray line on the wire feed speed diagram.
• Page 99
  X8 MIG WELDER 2.5 Operation Figure 15: The minimum and maximum stoppers The value range of the welding power and voltage graphs specified by the Welding Procedure Specification (WPS) are displayed with a green arc between the stoppers. The stoppers are by default at the top and bottom of the specified WPS area, but you can adjust them to your preferences: to narrow the area or to weld outside the specified area.
• Page 100
  X8 MIG WELDER 2.5 Operation Note: If you have installed WeldEye, it saves the data as unsuitable use, even if the welding job requires such values. Figure 17: Values outside the range specified by WPS Settings view Settings displays all the welding parameters and other settings of the selected program. The contents under the titles are collapsed by default.
• Page 101
  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 MIG X8 Welder on page 138. Wise feature menu Wise feature displays the Wise features available for use with the welding program.
• Page 102
  X8 MIG WELDER 2.5 Operation • Voltage • Fine tuning • Dynamics • Pulse current percent • Start power • Start level • Stop power For more information, see the description of the processes. System settings The options under System settings are: 1.
• Page 103
  X8 MIG WELDER 2.5 Operation Figure 19: The Welding program menu in Settings You can use the filters under Welding program to filter the welding programs on the selection list. You can also select the needed welding program without using the filters.
• Page 104
  X8 MIG WELDER 2.5 Operation Welding parameters are stored in the memory channels. The memory channel displays the same information of the welding parameters as the Welding view. To take a channel into use, move the focus to it. Each user has their own memory channels.
• Page 105
  X8 MIG WELDER 2.5 Operation Figure 21: The list of the additional views The View menu displays the following views: 1. Welding Press to return to the Welding view. 2. Weld data Displays information on the last welds. 3. WPS…
• Page 106
  7. System Displays information on the welding system. 8. Cloud services Connect to Kemppi cloud services. 2.5.1.2 Wire feeder control panel The control panel of the wire feeder has a one-knob navigation and push buttons for selecting parameters or values. You can, for example, adjust the welding parameters and save settings on memory channels.
• Page 107
  X8 MIG WELDER 2.5 Operation 1. Memory channel 2. Welding power The unit of the parameter varies according to the welding process. 3. Voltage Note: Not all processes have this parameter. 4. Fine tuning The unit of the parameter varies according to the welding process.

• Page 108: Preparing Welding System For Use

  X8 MIG WELDER 2.5 Operation Press the Settings button to access the wire feeder settings. When the settings view is open, the Settings button lights up orange. Modify the parameters with the right knob. Press the green button in the center of the knob to select and turn the right knob to adjust a parameter.

• Page 109
  To switch on Control Pad, press and hold the power button for a few seconds. Preparing cooler Fill the coolant container inside the cooler with Kemppi coolant liquid. To weld, you must pump the coolant through the system. Press the coolant circulation button in the front panel of the power source.
• Page 110
  X8 MIG WELDER 2.5 Operation Press the coolant circulation button after each time you change the welding gun. For instructions on filling the cooler, see Filling cooler. Connecting earth return cable Warning: Keep the welding piece bonded or connected to earth to reduce the risk of injury to users or damage to electrical equipment.
• Page 111
  X8 MIG WELDER 2.5 Operation 2.5.2.1 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. Unscrew the lid on top of the cooler.
• Page 112
  X8 MIG WELDER 2.5 Operation Screw the lid back on the cooler. Push to close the front panel of the power source. © OPERATING MANUAL | EN KEMPPI 2017 | 1817…
• Page 113
  2.5 Operation 2.5.2.2 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 114
  2.5.2.3 Connecting to Kemppi cloud services To use the Kemppi cloud services, connect the welding machine to the Internet either through a WLAN or a wired connection. Form the connection by using the Cloud services view in the View menu.
• Page 115
  X8 MIG WELDER 2.5 Operation There is also Ethernet settings available at the View menu > Cloud services. Switch the WiFi on. © OPERATING MANUAL | EN KEMPPI 2017 | 1817…
• Page 116
  X8 MIG WELDER 2.5 Operation Select the WLAN network. Fill in the password, if needed. © OPERATING MANUAL | EN KEMPPI 2017 | 1817…

• Page 117: How To Use Welding System

  2.5.3 How to use welding system Choosing the optimal welding program with the most suitable process and other parameters facilitates the use of X8 MIG Welder. Programs can be saved in memory channels for easy reach. Digital WPSs automatically adjust the welding machine settings.

• Page 118
  2.5 Operation 2.5.3.1 Using memory channels When you start using the X8 MIG Welder, select the memory channel where the correct welding program with pre-selected process and parameter values is stored and adjust the parameters. For general information on memory channels, see Channel view on page 103.
• Page 119
  X8 MIG WELDER 2.5 Operation To save modified settings in Control Pad on a different memory channel: a) Press Channel. b) Open Actions. c) Select Save to and press the green button. d) Scroll to the channel where to save the new settings.
• Page 120
  X8 MIG WELDER 2.5 Operation Creating new memory channel settings When you create a welding program to a memory channel, always select an existing program as a basis for the modifications. Proceed as follows: Go to Channels and select a memory channel where to start modifications.
• Page 121
  X8 MIG WELDER 2.5 Operation Select the target channel and press the green button. When you save the welding parameters, the channel name changes to the program name. Modify the parameters. Save the modified parameters. See Saving modified memory channel settings on page 118.
• Page 122
  X8 MIG WELDER 2.5 Operation Renaming channel Proceed as follows: Go to the Channel view. Press the green button to open Actions. Select Rename and press the green button. Control Pad shows you a keypad. © OPERATING MANUAL | EN…
• Page 123
  X8 MIG WELDER 2.5 Operation Turn the knob to go to the eraser and press Erase character on the right knob to delete the former name. Turn the right knob and press the green button on it to select letters.
• Page 124
  When you select a digital WPS, the welding machine settings are automatically adjusted accordingly. Note: This feature is only available if the welding machine is registered in Kemppi’s WeldEye cloud service. For more information, see Introduction to WeldEye for welding procedure and qualification management on page 10.
• Page 125
  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 126
  X8 MIG WELDER 2.5 Operation To see the list of available WPSs, press the green button. The WPS list opens. Figure 26: Advanced mode Figure 27: Basic mode Move the focus to the WPS that you want to activate. Depending on the mode of Control Pad, select one of the following options: a) If the Control Pad is in the Advanced mode, press the green button to open the Actions menu.
• Page 127
  X8 MIG WELDER 2.5 Operation b) If the Control Pad is in the Basic mode, press the green button to activate the WPS. Control Pad opens the WPS view. Here you can see all the WPS details that the welder needs to know for the job, including the pictures and details of the filler and the gas.
• Page 128
  X8 MIG WELDER 2.5 Operation If the WPS includes several passes, select the pass in Active pass. See Selecting WPS pass in WPS view on page 128. Press a view button to leave the WPS view. Note: You can also change WPS or the pass in Channel view. See…
• Page 129
  X8 MIG WELDER 2.5 Operation If there is no active WPS, Control Pad shows the WPS list. Select the WPS. Move focus to Active pass. The information under Active pass is pass-specific and varies according to the pass. Press the green button to open the menu.
• Page 130
  X8 MIG WELDER 2.5 Operation To change the pass selection, scroll to a pass in a list. Press the green button to select the pass and to return to the WPS View. Note: You can also select the WPS or pass in the Channel view. See…
• Page 131
  X8 MIG WELDER 2.5 Operation Scroll through the list of WPSs and passes to move the focus to the pass you want to take into use. The pass immediately activates. Caution: After changing WPS or pass, check the pass details to make sure you are using the correct filler wire and gas.
• Page 132
  Welding machines are connected to WeldEye in the WeldEye settings. You will need the serial number and security code on the X8 Power Source rating plate. You can find more detailed instructions in the WeldEye Help. Once the welding machine has been connected to WeldEye, within an hour, WPSs are automatically transferred to the welding machine.
• Page 133
  Save the WPS on a USB stick. Insert the USB stick in the USB port of the X8 Power Source. All the WPSs on the USB stick are saved in the welding machine and are available in the WPS lists, after you have confirmed the copying through Control Pad.
• Page 134
  X8 MIG WELDER 2.5 Operation Select Delete WPS and press the green button. 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.
• Page 135
  X8 MIG WELDER 2.5 Operation Press the green button to open the filter wizard. Turn the knob to move focus. Press the green button to select the material of the welding piece. Turn the knob to move focus and press the green button to select the thickness of the wire.
• Page 136
  X8 MIG WELDER 2.5 Operation When you have selected all values, the wizard returns you to the WPS list and displays the WPSs available with the filters you have selected. The settings show ISO/ANSI and metric/imperial terms concurrently. 2.5.3.3 Using welding processes, programs and features Selecting a welding program A welding program combines the optimal welding settings for a given welding job.
• Page 137
  Saving new welding programs on page 121. 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 programs which are designed and created according to customer-specific welding applications.
• Page 138
  2.5 Operation The MMA and GOUGING modes just have one pre-installed welding program each. Standard MIG welding processes in MIG X8 Welder The processes described in this chapter are available when the MIG mode is selected. For more information on selecting the MIG mode, see Selecting a welding program on page 136.
• Page 139
  X8 MIG WELDER 2.5 Operation When using MIG, you can adjust the following welding parameters through Settings > Parameters: • Wire Feed Speed • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed •…
• Page 140
  X8 MIG WELDER 2.5 Operation Figure 29: 1-MIG Welding view When using 1-MIG, you can adjust the following welding parameters through Settings > Parameters: • Wire Feed Speed • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed •…
• Page 141
  X8 MIG WELDER 2.5 Operation It is excellent for welding aluminium and stainless steel, especially when the material thickness is small. Pulse supports WisePenetration+ and WiseFusion features, as well as various optimized welding programs. To adjust the welding power / wire feed speed while welding, in the Control Pad’s Welding view, turn the left knob.
• Page 142
  X8 MIG WELDER 2.5 Operation Welding view, toggle between level 1 and level 2 by pressing the left Control Pad button. The inactive power level is shown with a gray line on the wire feed speed diagram. Figure 31: DPulse Welding view To adjust the welding power / wire feed speed while welding, in the Control Pad’s Welding view, turn the left knob.
• Page 143
  DPulse supports the WiseFusion feature and various optimized welding programs. Wise processes Kemppi’s Wise products are welding processes and features designed to ease the user’s work and increase the productivity by controlling the welding arc. For more information, visit www.kemppi.com.
• Page 144
  X8 MIG WELDER 2.5 Operation Figure 32: Voltage sensing cable Using WiseRoot+ WiseRoot+ is a synergic MIG/MAG process optimized for open-gap root pass welding. The process is based on precise measurement of voltage between the welding gun nozzle and the workpiece.
• Page 145
  X8 MIG WELDER 2.5 Operation When using WiseRoot+, depending on the welding program, you can adjust the following parameters through Settings > Parameters: • Wire Feed Speed • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed •…
• Page 146
  • StartLevel: -30…+30. Finetunes the arc length for arc ignition. • StopPower: -30…+30. Adjusts the power level for arc stop. Wise features Kemppi Wise features improve the quality of welds. For more information on Wise products, visit www.kemppi.com. Introduction to WiseFusion The WiseFusion welding function enables adaptive arc length control, which keeps the arc optimally short and focused.
• Page 147
  X8 MIG WELDER 2.5 Operation Introduction to WiseSteel The WiseSteel function is based on modifying the conventional MIG/MAG arcs to enable higher quality of welds. WiseSteel improves the arc control, reduces spatter and helps create an optimally-formed weld pool. When using WiseSteel, different adjustment methods are applied at different power ranges (different arcs).
• Page 148
  X8 MIG WELDER 2.5 Operation Figure 36: WiseSteel Welding view Note: The wire feed speed / current indicator shows the arc range: 1. Short arc 2. Globular arc 3. Spray arc The adjustment method is different for each range. Introduction to WisePenetration+ In standard MIG/MAG welding, changes in stick-out length cause welding current to fluctuate.
• Page 149
  2. Select the MMA welding program. An all-around MMA welding program pre-installed. Note: X8 MIG Welder features a voltage reduction device (VRD). When the welding machine is on but the welding arc is not ignited, the welding machine is on open circuit voltage (50 V).
• Page 150
  To use gouging, in Control Pad, select Settings > Mode > Gouging. Note: X8 MIG Welder features an integrated voltage reduction device (VRD). When the welding machine is on but the welding arc is not ignited, the welding machine is on open circuit voltage (50 V).
• Page 151
  Cladding (surfacing) means depositing a layer of filler material on the workpiece to achieve certain properties or dimensions. To use X8 MIG Welder for cladding, in Settings, select the mode (MMA/MIG), and in the filter list, for Type, select Cladding to see the suitable welding programs.
• Page 152
  X8 MIG WELDER 2.5 Operation To use X8 MIG Welder for brazing, in Settings, select the mode (MMA/MIG), and in the filter list, for Type, select Brazing to see the suitable welding programs. Trigger logic functions You can select the trigger logic through Control Pad in Settings > Trigger logic.
• Page 153
  X8 MIG WELDER 2.5 Operation Start and stop functions Upslope The UpSlope function gradually increases the welding power / wire feed speed up to the desired level. The user sets the function ON/OFF and sets the initial value for the Upslope power / wire feed speed.
• Page 154
  X8 MIG WELDER 2.5 Operation 1. Trigger is pressed. 2. Trigger is released. 3. Trigger is pressed. 4. Trigger is released. To adjust Hot start, with Control Pad, go to Settings > Start and stop logic > Hot start. When you select ON, the options for adjusting Time and Level appear on the screen.
• Page 155
  X8 MIG WELDER 2.5 Operation • Stop level: the level on which the Crater Fill is finished. When the 4T Timer is in use, pressing the trigger (in the case of WP Switch, > 0.5 s) launches the Crater Fill sequence, and the sequence lasts at least for the period of time defined for the 4T Timer, even if the trigger is released before that time has passed.

• Page 156: Troubleshooting

  • Check that the pressure handle is properly closed. • 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 157
  The gun neck overheats • Make sure you are using original Kemppi consumable and spare parts. Incorrect spare part materials may cause the overheating of the neck.
• Page 158
  X8 MIG WELDER 2.6 Troubleshooting Problem Recommended actions The wire burns into the contact tip • Make sure the size and type of the current tip and wire liner are suitable for the filler wire. • Make sure the wire liner is clean.

• Page 159: Error Codes

  X8 MIG WELDER 2.7 Maintenance Problem Recommended actions 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.

• Page 160
  Maintenance of guns • Check regularly that all the components are tightly fastened. • Check that the current transfer surface on the Kemppi gun adapter is clean and unscratched, and the connector pins are straight and undamaged. • Check the protective hose on the cable for damage.

• Page 161: Periodic Maintenance Of Power Source And Wire Feeder

  Maintenance of Control Pad Control Pad is water resistant and can be wiped clean with a moist cloth. Do not use detergents. For repairs, contact Kemppi at www.kemppi.com or your dealer. 2.7.2 Periodic maintenance of power source and wire feeder Caution: Only qualified service personnel is allowed to carry out periodic maintenance.

• Page 162: Service Workshops

  Update the wire feeder to the latest firmware version and load new welding software. 2.7.3 Service workshops Kemppi Service Workshops complete the welding system maintenance according to the Kemppi service agreement. The main aspects in the service workshop maintenance procedure are: •…

• Page 163
  X8 MIG WELDER 2.8 Technical data Feature Description Value Rated power 40 % ED 60 % ED 19 kVA 100 % ED 14 kVA Supply current (maximum)  @ 220-230 V 1max  @ 380-460 V 28 — 25 A 1max Supply current (effective)  @ 220-230 V 1eff  @ 380-460 V 22-19 A 1eff Idle power without cooler and wire feeder 45 — 52 W…

• Page 164: X8 Power Source 500 A / 500 A Mv

  2.4 GHz Bluetooth and WLAN • 2400-2483.5 MHz 20 dBm Wired communication type Ethernet & USB Standards IEC 60974-1, -10 2.8.2 X8 Power Source 500 A / 500 A MV Feature Description Value 500 A 500 A MV Mains connection cable H07RN-F 6 mm²…

• Page 165
  X8 MIG WELDER 2.8 Technical data Feature Description Value 500 A 500 A MV Supply current (effective) 52 — 51 A 1eff @ 220-230 V 29 — 26 A 29 — 26 A 1eff @ 380-460 V Idle power without cooler and wire 45 — 52 W 40 — 52 W feeder (MIG) 51 — 58 W 48 — 58 W Idle power with cooler, without wire…

• Page 166: X8 Cooler

  X8 MIG WELDER 2.8 Technical data Feature Description Value 500 A 500 A MV Minimum short-circuit power S 5.1 MVA 5.1 MVA supply network Degree of protection IP23S IP23S External dimensions LxWxH 921x348x795 mm 921x348x795 mm Weight without accessories 95 kg 95 kg Voltage supply for auxiliary devices U…

• Page 167: X8 Wire Feeder

  EMC class Degree of protection ** IP23S Weight without accessories 15.5 kg Standards IEC 60974-2, -10 * With recommended coolant ** When mounted 2.8.4 X8 Wire Feeder Feature Description Value Operating voltage 48 V DC Supply current at max load 6 A 1max Idle power 6 W…

• Page 168: X8 Control Pad

  640 x 220 x 400 mm Weight without accessories 11.2 kg Wireless communication type 2.4 GHz Bluetooth • Transmitter frequency and • 2402-2480 MHz 19 dBm power Standards IEC 60974-5, 10 2.8.5 X8 Control Pad Feature Description Value Operating voltage 12 V Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C…

• Page 169: X8 Mig Gun 200-G

  Feature Description Value Standards • IEC 60950-1 • EN 62368-1 • EN 300 328 v2.1.1 • EN 300 330 v2.1.1 • EN 301 489-1 v2.1.1 • EN 301 489-3 v2.1.0 • EN 301 489-17 v3.1.1 2.8.6 X8 MIG Gun 200-g Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling Type of connection Kemppi Wire diameters 0.8/0.9/1.0 mm…

• Page 170: X8 Mig Gun 300-G

  Neck angle ɑ (see figure 50° below) Standards IEC 60974-7 *Gun length 5 m Figure 50: Neck dimensions and bending angle 2.8.7 X8 MIG Gun 300-g Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling…

• Page 171: X8 Mig Gun 400-G

  Neck angle ɑ (see figure 50° below) Standards IEC 60974-7 *Gun length 5 m Figure 51: Neck dimensions and bending angle 2.8.8 X8 MIG Gun 400-g Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling…

• Page 172: X8 Mig Gun 400-W

  Neck angle ɑ (see figure 50° below) Standards IEC 60974-7 *Gun length 5 m Figure 52: Neck dimensions and bending angle 2.8.9 X8 MIG Gun 400-w Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling Liquid ©…

• Page 173
  X8 MIG WELDER 2.8 Technical data Feature Description Value Coolant flow rate 1 l/min Coolant pressure (max) 5 bar Type of connection Kemppi Wire diameters 0.8/0.9/1.0/1.2/1.6 mm Load capacity @ 60 % (MIXED GAS) @ 100 % (MIXED 400 A GAS) @ 60 % (CO @ 100 % (CO Filler wires 0.8/0.9/1.0/1.2/1.6 mm Fe-MC/FC 0.9/1.0/1.2/1.6 mm…

• Page 174: X8 Mig Gun 500-W

  X8 MIG WELDER 2.8 Technical data Figure 53: Neck dimensions and bending angle 2.8.10 X8 MIG Gun 500-w Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling Liquid Coolant flow rate 1 l/min Coolant pressure (max) 5 bar…

• Page 175: Ordering Codes

  X8550000 X8 Power Source 500 with Cooler * X8100501000 X8 Power Source 500 with Cooler and X8100501010 Software Pack 1 * X8 Power Source 500 MV with Cooler * X8100501100 X8 Cooler X8600000000 X8 Wheel Set X8701010000 * X8 Power Source includes Control Pad…

• Page 176
  X8 MIG WELDER 2.9 Ordering codes Part Ordering code X8 Wire Feeder with Cabinet Heater X8200000001 Wire Feeder Rotating Plate X8702010000 Double Wire Feeder Rotating Plate X8702020000 Wire Feeder Hanger for Boom X8702040000 Wire Drum Kit 5 m W012757 Wire Drum Kit 10 m…
• Page 177
  70 mm 30 m X8800703000 95 mm 30 m X8800953000 Table 11: Control Pad Control Pad Ordering code Control Pad X8400110001 Table 12: Accessories Accessory Ordering code X8 Gas Cylinder Cart X8701020000 © OPERATING MANUAL | EN KEMPPI 2017 | 1817…

• Page 178: Disposal Of Unit

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

• Page 1
  WIRE CUT- EDM Operation Manual SOFTWARE VERSION：W5F F0800 MANUAL VER：B Copyright Reserved CHING HUNG MACHINERY & ELECTRIC INDUSTRIAL CO., LTD.  886-4-23500333 Please Read This Manual Thoroughly Before Operation…
• Page 2
  1. Wire EDM operators should have received relative training from our local agency, or directly from CHMER headquarter. CHMER wire EDM can only applied to the machining of several kinds metal work-piece, such as steel, aluminum, tungsten steel, copper and graphite.
• Page 3
  INDEX 0-1 Company Profile————————————————— 0-2 Safe Instruction————————————————— Chapter 1. System Introduction 1-1 System Composition——————————————— 1-2 Panel & Keyboard———————————————— 1-3 Machine Body & Filtration Unit——————————- 1-16 1-4 System Boot Up and Shut Off———————————- 1-21 Chapter 2. W5F Software Function 2-0 Map of W5F Software 2-1 DISP Mode——————————————————— 2-2 FILE Mode——————————————————— 2-10…
• Page 4
  CHMER Wire-Cut EDM Operation Manual W5F 0-1 Company Profile CHMER BRIEF EVENTS: ◆CHMER EDM company was founded（with registered capital 1.1975 NT$200.000.-）to market the first“Transistor”EDM machine in Taiwan. ◆The first hydraulic control EDM machine came out. 2.1976 ◆EDM machine with the functions of free adjustment of pulse on & off 3.1977…
• Page 5
  CHMER Wire-Cut EDM Operation Manual W5F ◆In October, the patent for improvement structure of the worktable guide 15.1991 bridge type of EDM（NEW MODEL NO.68192） ◆Obtaining the patent for improved structure of the Prototype of EDM tank ascending & descending（NEW MODEL NO.74419）.
• Page 6
  Company” award. ◆In January, “CW-32CF/S”wire-cut EDM models obtained of “IT’S 28.2004 VERY WELL MADE IN TAIWAN” award. ◆In March, CHMER obtained ISO 14000 Quality system certified, who is the 1 among EDM manufacture in Taiwan. ◆In March, Introduce the 1 linear motor high precision wire-cut EDM in Taiwan.
• Page 7
  CHMER Wire-Cut EDM Operation Manual W5F COMPANY ORGAIZATION Taichung Headquarters： 1.CHING HUNG MACHINERY & ELECTRIC INDUSTRIAL CO.,LTD No.3, Jing-Ke 1st Road, Nantun District, Taichung City 408, Taiwan TEL:+886 4-23509188 FAX:+886 4-23509199 2.Taipei Branch office HUNG YU TRADING CO.,LTD. NO.13,Dec4.Chung Hsing Ed , San Chung City, Taiwan, R.O.C TEL：02-2988-8668 FAX：02-2985-0850…
• Page 8
  CHMER Wire-Cut EDM Operation Manual W5F 0-2 Safety Instruction 0-2-1Machine stop When the emergency occurs, operator can stop machine by following two ways： Emergency Stop & Main Power switch. No Fuse Breaker Emergency Stop Main Power Emergency Stop：When pressed, except of computer power, motors, pumps would be shut off.
• Page 9
  CHMER Wire-Cut EDM Operation Manual W5F 0-2-3 Operation precautions 1. If find or smell or hear any abnormal conditions, please press emergency stop button immediately then start to locate the problem. 2. There will have fatal high voltage high current passing through on duration.
• Page 10
  CHMER Wire-Cut EDM Operation Manual W5F 19. Avoiding water splash on floor at any time, that has potential dangers people fall down or get electric shock. 20. The light from the work-lamp could generate high heat on the items illuminated. Please be aware and keep fusible material such as plastic cables away from being irradiated by work-lamp.
• Page 11
  CHMER Wire-Cut EDM Operation Manual W5F 3. Is Cutting technology well setup? 4. For no-man operation, please make sure machine can achieve： a. Smooth and reliable cutting condition? b. Constant and stable flush pressure? c. Dielectric level (for submerge type) remains constant？…
• Page 12
  Chapter 1 System Introduction ■ 1.1 System Composition ■ 1.2 Panel & Keyboard ■ 1.3 Machine Body & Filtration Unit 1-16 ■ 1.4 System Boot Up and Shut Off 1-21…
• Page 13
  CHMER Wire-Cut EDM Operation Manual W5F 1-1 System Composition Filtration Unit Machine Body Power Cabinet Filtration Unit Wire Cut machine is consisted of three major parts：Power Cabinet, Machine Tool, and Filtration Unit. 1. Power Cabinet Contains majority of fuses, TFT LCD Display, Power Line, Computer and Sparking Circuit.
• Page 14
  CHMER Wire-Cut EDM Operation Manual W5F 1-2 Power Cabinet, Console Panel and Remote Control 1-2-1 Power Cabinet & Console Panel Console Panel Power Cabinet…
• Page 15
  CHMER Wire-Cut EDM Operation Manual W5F 1. Analog Voltage Meter Display the variation of EDM voltage to control machining speed. 2. Monitor 15”(standard) TFT LCD monitor. 3. Control panel a. Text key: for normal information and number input. b. Hot key: control the EDM conditions. (e.g. EDM power supply, dielectric, wire feed rate and tension) c.
• Page 16
  CHMER Wire-Cut EDM Operation Manual W5F 1-2-2 Introduction of text keys 1. A~Z Input key of English alphabet 2. 0~9 Number input 3. Page up, Page down For page exchange (NC program or column) 4. Home, End When executing program edit or data input, move the cursor to the left or right of the line.
• Page 17
  CHMER Wire-Cut EDM Operation Manual W5F 1-2-3 Introduction of quick function key Operator could apply below quick command： 1. Use ＋/－ button to change the value of each item of sparking data. 2. Type S ??? (ex: S045) in Data Bar is to backup current sparking data to S-code No.
• Page 18
  CHMER Wire-Cut EDM Operation Manual W5F 1-2-4 Introduction of operation key If this button is pressed, four kinds of table moving speed are selectable including H (high speed), M (middle speed), ML (speed between middle and low) and L (low speed). Under this mode, if the axis-moving key is pressed, the table will move by setting speed.
• Page 19
  CHMER Wire-Cut EDM Operation Manual W5F Note: 1. Additionally increases the JOG speed to be 2 steps. Setting method: Press H or M key twice in 1 second. Flash indicator means that setting is finished. 2. The value of STEP JOG feed-rate override may adjust in the mode Help-2>「System Double Value Parameter」, PA#42~PA#47 (We…
• Page 20
  CHMER Wire-Cut EDM Operation Manual W5F B.PT This key is for break point quick return. When it is pressed, the worktable will return to wire break point quickly. If the indicator is lit, it represents that the present position is the break point.

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• Supplier: Dongguan,Guangyi,Wire,Cutting,Materials,Co.,Ltd.

Product Overview

Description

Delivery way: TNT, EMS, UPS, FED, DHL, Air transport, Sea Transport are available.We will choose the fastest, cheapest and safest shipment way for your 0.18mm edm wire cutting machine.

Advantages & Disadvantages:

• Express delivery: 4-6days, wide coverage area (volume & weight restricted)

• Sea transport: cheap, volume unlimited (long sailing time, influenced by climate)

• Air transport: 4-6days, simple packing (expensive, volume restricted)

Any question, please do not hesitate to contact us!

Sales: Helen Chen

China Tel: +86 076983327422  Phone Number: +86 15907699969

China Fax: +86 (0)917 3258889

Skype: Helen.chen301

Thanks for your visit to our website. Welcome to your inquiry and look forward to working with you in the near future!

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