X8 MIG Welder OPERATING MANUAL
ii Contents 1 Read first.................................................................................................................... 4 1.1 Symbols..................................................................................................................................................................................... 4 2 X8 MIG Welder.......................................................................................................... 8 2.1 System introduction........................
iii 2.8 Ordering codes..................................................................................................................................................................190 2.9 Disposal of unit.................................................................................................................................................................
X8 MIG WELDER 1.1 Symbols 1 Read first Kemppi takes special care in informing its customers about the safety of our products. We also mind the environment and aspire to disposing of our products according to specified European Directives. 1.1 Symbols Items in the manual that require particular attention, to minimize damage and personal harm, are indicated with a three-level notification and warning system. Convention Note: Used for Gives the user a piece of information of particular importance.
X8 MIG WELDER Symbol 1.
X8 MIG WELDER Symbol 1.
X8 MIG WELDER Symbol Ö Õ W Ɔ O OPERATING MANUAL | EN 1.
X8 MIG WELDER 2.1 System introduction 2 X8 MIG Welder These instructions describe the use of Kemppi's X8 MIG Welder, the top-class welding system for demanding industrial use. The system consists of a power source, wire feeder, welding gun, Control Pad and various welding software components and connectivity to Kemppi cloud services. Read the instructions through carefully.
X8 MIG WELDER 2.1 System introduction • Contains a control panel for basic adjustment of welding parameters, memory channels and settings 3. X8 MIG Gun 200/300/400-g, 420/520/600-w, X8 MIG Gun WS 420-w • • • • Connects to the wire feeder with Kemppi Gun Adapter Gas-cooled models feature a rotating, changeable neck Remote control for selecting memory channels and adjusting settings (optional) Ergonomic pistol grip handle 4.
X8 MIG WELDER 2.2 System structure can print out documents or, for example, a list of welders with a certain qualification certificate. Attachments can be added to any document. Discover WeldEye – universal welding management software WeldEye is your primary tool and storage space for keeping your welding-related documents in order. There is even more to WeldEye than welding document management. WeldEye is a universal solution for managing welding production.
X8 MIG WELDER 2.2 System structure Figure 1: A chart of the connections between the different parts of X8 MIG Welder 2.2.1 X8 Power Source This section describes the structure of X8 Power Source. Front 2 1 3 4 6 7 5 1. Indicator panel 2.
X8 MIG WELDER 2.2 System structure 3. USB connector Connect a USB memory stick to upload the welding procedures (WPS) or Wise features to the power source or update firmware if a wireless connection is unavailable. 4. Control Pad connector Connect Control Pad to the power source with a cable to charge its battery or to use it in wired mode. 5. Front panel 6. Front panel latch Pull to open the front panel and reveal the coolant container. 7.
X8 MIG WELDER 2.2 System structure 12. Strain relief holder Indicator panel 1. Power indicator The LED is green when the unit is on. 2. Voltage Reduction Device (VRD) indicator The LED is green when VRD is switched on and the no-load voltage is under 35 V. The LED blinks red when VRD is switched on and the no-load voltage is above 35 V. The LED is off when VRD is switched off or during welding. Note: VRD is in use with MMA and Gouging modes only. 3.
X8 MIG WELDER 2.2 System structure If the coolant liquid overheats, a thermal cutoff switches the welding system off and does not allow it to be used until the coolant liquid has cooled down. 7. Coolant circulation warning The LED is green when the coolant circulation is working normally. The LED is red when there is a problem in the coolant circulation. The LED blinks green and red in turns when the circulation of the coolant liquid has been obstructed too long.
X8 MIG WELDER 2.2 System structure 6. Measurement cable 7. Strain relief pin 2.2.2 X8 Wire Feeder This section describes the structure of X8 Wire Feeder. Main parts 1. Top cover Caution: Keep the wire feeder top cover closed during welding to reduce the risk of injury or an electric shock. Keep the top cover closed also at other times to keep the wire feeder insides clean. 2. Handle Caution: The handle is only intended for short distance manual carrying.
X8 MIG WELDER 2.2 System structure 11 10 13 15 12 14 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.
X8 MIG WELDER 2.2 System structure Control panel The control panel on the front of the wire feeder enables easy control of the wire feeder's basic features. Although Control Pad is the main control of the welding system, you can also use the wire feeder control panel or the welding gun remote control. 2 4 3 1 6 5 The wire feeder control panel parts are: 1. Locking button Press and hold for 2 seconds to lock or release the display and buttons. 2.
X8 MIG WELDER 2.2 System structure 3. Settings button The button lights up orange, when the view is activated. 4. Left control knob 5. Right control knob 6. Left and right button For more information on the use and features of the control panel, see Wire feeder views on page 96. Control buttons on the inside The wire feeder has control buttons inside the wire cabinet. 1. Wire retract button Drive the filler wire backward with arc off. 2.
X8 MIG WELDER 2.2 System structure 1. Welding current Supplies current from the power source to the wire feeder. 2. Shielding gas Supplies shielding gas to the welding gun. 3. Measurement Supplies the welding parameters measured during welding. 4. Control Supplies data and operating voltage to the wire feeder. 5. Coolant outlet and inlet Circulates coolant to and from the welding gun. For information on the installation of the cables, see Cables installation on page 50. External component connectors 1.
X8 MIG WELDER 2.2 System structure 2.2.3 X8 MIG Guns Gas-cooled gun 8 10 4 3 5 6 7 9 2 1 11 12 13 1. Gas nozzle 2. Insulating bush 3. Contact tip 4. Contact tip adapter 5. Neck 6. Neck tightener 7. Work light Press the trigger lightly to switch on the light. 8. Handle cover plate Covers the handle if the remote control is not used. 9. Trigger 10. X8 Gun Remote Control The remote control is an optional accessory. 11.
X8 MIG WELDER 2.2 System structure 12. Pistol grip handle Quick to attach and detach. 13. Kemppi Gun Connector Water-cooled gun 1. Gas nozzle 2. Insulating bush 3. Contact tip 4. Contact tip adapter 5. Neck 6. Work light Press the trigger lightly to switch on the light. 7. Handle cover plate Covers the handle if the remote control is not used. 8. Trigger 9. X8 Gun Remote Control The remote control is an optional accessory. 10. Trigger on the pistol grip handle 11.
X8 MIG WELDER 2.2 System structure 2.2.4 Control Pad This section describes the structure of Control Pad. 6 4 7 8 2 9 5 4 3 1 1. Power button The button lights up orange, when you switch Control Pad on. 2. Left control knob 3. Right control knob 4. Left and right button When the button lights up green, you can press the button to confirm an action. 5. Display 6. View buttons 7. Channel button The button lights up blue, when the view is activated. 8.
X8 MIG WELDER 2.2 System structure 13 12 11 10 14 10. NFC reader 11. Barcode reader 12. ON/OFF button for NFC and barcode readers The button also acts as a shortcut button for reading a barcode in any Control Pad view. 13. Loop for the carrying strap 14. Hook When you connect or disconnect the charger, Control Pad shows you the charge level.
X8 MIG WELDER 2.2 System structure When Control Pad is charging, green leds on the left side of the display indicate ongoing charging. The lowest led turns red when the charge level is low.
X8 MIG WELDER 2.3 Installation 15 18 16 17 15. Charger cable port A stopper shields the charger cable port. 16. Micro USB port A cover shields the micro USB port and the USB cable port. 17. USB cable port 18. Combo cable port Combo cable port transfers both data and power. A stopper shields the combo cable port. 2.3 Installation Perform this installation procedure to prepare your X8 MIG Welder for use. Read the instructions carefully and follow them closely. 2.3.
X8 MIG WELDER 2.3 Installation Warning: Provided that the public low voltage short circuit power at the point of common coupling is higher than or equal to 5.1 MVA, this equipment is compliant with IEC 61000-3-11 and IEC 61000-3-12 and can be connected to public low voltage systems. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the system impedance complies with the impedance restrictions.
X8 MIG WELDER 2.3 Installation 2. Push the rear axle through the opening in the bottom of the rear side of the unit and set the axle in the middle. 3. Slide the two wheel spacers (1) onto the axle. 4. Slide the two wheels (2) onto the axle. 5. Slide the two washers (3) onto the axle. 6. Slide the two retaining rings (4) on the axle, until they lock into the groove on the axle. 1 2 3 4 Install the front wheels: 7.
X8 MIG WELDER 2.3 Installation 8. 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. 9. Attach the front wheel assembly to the end of the axle with a bolt (1) and washer (2) from both sides. Max. 20 Nm 1 2 10. When the wheels are attached, lift the power source off the pallet.
X8 MIG WELDER 2.3 Installation Note: If your setup includes X8 Gas Cylinder Cart, proceed to Installing optional gas cylinder cart. 2.3.2.2 Installing optional gas cylinder cart To transport a larger gas cylinder with the power source, install X8 Gas Cylinder Cart. For detailed instructions, see X8 Gas Cylinder Cart Mounting Instructions. If your setup does not include the gas cylinder cart, proceed to Installing optional X8 Cooler. 1.
X8 MIG WELDER 4. 2.3 Installation Attach the wheel set of the gas cylinder cart to the axle with a bolt (1) and washers (2, 3, 4) from both sides. 1 5. 2 3 4 Insert cover plugs to the open ends of the wheel set.
X8 MIG WELDER 6. 2.3 Installation Place the upper part of the gas cylinder cart on the wheel set, and push it down until the claw fastens over the transportation handle. 3 2 1 7. Attach the upper part of the gas cylinder cart to the wheel set with two bolts (1) and washers (2, 3) from both sides. 8. Attach the bottom of the gas cylinder cart to the wheel set with six bolts (1) and washers (2, 3). The gas cylinder cart bottom has two alternative settings (the lower setting described in the figure).
X8 MIG WELDER 2.3 Installation Max. 20 Nm 3 9. 2 1 Place the gas cylinder on the cart. 10. Fasten the straps in the cart around the gas cylinder. 2.3.2.3 Installing optional X8 Cooler If your setup does not include X8 Cooler, you can skip these instructions. Caution: X8 Cooler must be installed by authorized service personnel. Do not open the covers of X8 Power Source.
X8 MIG WELDER 2.3 Installation 2 3 1 4 5 6 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: 1. Detach the two screws in the front panel of the power source.
X8 MIG WELDER 2.3 Installation 2. Pull the front panel outwards from the lower edge. 3. Remove the lower left cover from the rear of the power source. 4. 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. 5. Fill the coolant container with applicable coolant solution. For more information, see Filling cooler on page 103. 6.
X8 MIG WELDER 2.3 Installation 1. Place the wire feeder rotating plate or double rotating plate on top of the power source, with the orange claw at the rear of the unit. 2. 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. 3. Attach the bottom of the wire feeder rotating plate to the power source with four screws (1) and washers (2).
X8 MIG WELDER 2.3 Installation 5 Nm 1 2 4. 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. 5. Slide the wire feeder from front to back until the bar in the back of the unit locks to the orange claw at the back of the wire feeder rotating plate. 2.3.3.2 Installing welding gun holder Install the welding gun holder to either side of the wire feeder.
X8 MIG WELDER 2.3 Installation 2 1 Proceed as follows: 1. 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. 2. Attach the welding gun holder to the mount with 2 screws. 2.3.3.3 Replacing feed rolls Replace the feed rolls when the material and diameter of the filler wire changes. Proceed as follows: 1. Open the top cover and lift the pressure handle.
X8 MIG WELDER 2. 2.3 Installation Push the collars on the mounting pins of the feed rolls up to pull the mounting pins off.
X8 MIG WELDER 2.3 Installation Note: The mounting pins are different: The drive rolls' mounting pins have a circular mark on the top, while the pressure rolls' mounting pins have no marks. The pressure rolls' mounting pins have central axles attached to them, so the drive and pressure rolls' mounting pins cannot be confused with each other. 3. Pull the drive rolls upwards (1) and the pressure rolls out of their slots (2).
X8 MIG WELDER 2.3 Installation 1 2 4. Select the feed rolls according to the tables below. Wire feed rolls, plastic Filler wire material Feed roll profile Filler wire diameter (mm) Fe, Ss (Al, Mc, Fc) V-groove OPERATING MANUAL | EN Drive roll code Pressure roll code 0.6 W001045 W001046 0.8−0.9 W001047 W001048 1.0 W000675 W000676 1.
X8 MIG WELDER 2.3 Installation Wire feed rolls, plastic Fc, Mc (Fe) Al (Fc, Mc, Ss, Fe) OPERATING MANUAL | EN V-groove, knurled U-groove 1.4 W001049 W001050 1.6 W001051 W001052 2.0 W001053 W001054 2.4 W001055 W001056 1.0 W001057 W001058 1.2 W001059 W001060 1.4−1.6 W001061 W001062 2.0 W001063 W001064 2.4 W001065 W001066 1.0 W001067 W001068 1.
X8 MIG WELDER 2.3 Installation Wire feed rolls, plastic 1.6 W001071 W001072 Wire feed rolls, metal Filler wire material Feed roll profile Filler wire diameter (mm) Feed roll identification Drive roll code Pressure roll code Fe, Ss (Al, Mc, Fc) V-groove See the text on the roll W006074 W006075 W006076 W006077 1.2 W004754 W004753 1.4 W006078 W006079 1.0 W006080 W006081 1.2 W006082 W006083 1.4−1.6 W006084 W006085 2.0 W006086 W006087 1.0 W006088 W006089 1.
X8 MIG WELDER 2.3 Installation 2.3.3.4 Replacing wire guides The wire feed mechanism includes two wire guide tubes. Replace them when the filler wire diameter grows or the material changes. 2 1 1. Inlet tube Pull out the inlet tube and insert a new one. There is no additional locking. 2. Middle tube A metal piece locks the middle wire guide tube in its place. Turn the piece aside to free the middle wire guide tube for replacement. Turn it back to lock down the new middle wire guide tube. 2.3.3.
X8 MIG WELDER 2.3 Installation 1. Open the top cover latch. 2. Lift the top cover up. 3. Cut and file the tip of the filler wire. Note: The sharp cut tip of the filler wire may cause damage to the wire liner, if not filed. 4. Press Wire retract to pull back the remaining filler wire from the welding gun. 5. Push the wire spool locking cover aside. 6. Lift the wire spool from the wire feeder. 7. Loosen and pull the wire spool brake halves apart.
X8 MIG WELDER 8. 2.3 Installation Attach the wire spool brake halves to the new wire spool by pushing them together inside the wire spool. Tighten if necessary. Note: The spool brake is equipped with an optional wire tensioning feature, which keeps the wire feed steady in short repeated welds and with heavy wire spools. To enable wire tensioning, attach the spool brake hub to the wire spool so that the tightening knob is on the right, seen from the front. 9. Lower the wire spool to its socket.
X8 MIG WELDER 2.3 Installation 11. Release the pressure arms to move the feed rolls apart. This opens a gap between the feed rolls. 12. Release the filler wire end from the spool and cut off any deformed section so that the end is straight. Note: Ensure that the filler wire does not spill from the spool when it is released. 13. File the tip of the filler wire smooth. Caution: Sharp edges on the filler wire tip may damage the wire liner. 14.
X8 MIG WELDER 2.3 Installation Filler wire material Feed roll profile Filler wire diameter (mm) Adjustment (x100N) Fe/Ss solid V-groove 0.8−1.0 1.5−2.0 ≥ 1.2 2.0−2.5 Metal and flux cored V-groove, knurled ≥ 1.2 1.0−2.0 Self-shielded V-groove, knurled ≥ 1.6 2.0−3.0 Aluminium U-groove 1.0 0.5 1.0 1.2 1.0−1.5 1.4 1.5−2.0 ≥ 1.6 2.0−2.5 Caution: Excessive pressure flattens the filler wire and may damage coated or cored filler wires.
X8 MIG WELDER 2.3 Installation Finalize the installation: 19. Select the shielding gas and attach the gas cylinder to the wire feeder. 20. Press Gas test to flush the former shielding gas from the system. Note: You can also use this button to test that the gases flow through the system properly. 21. 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.
X8 MIG WELDER 2.3 Installation 2.3.3.6 Attaching interconnection cable to strain relief To ease the installation of the interconnection cable and to prevent any unnecessary strain on the cable connectors, attach both ends of the interconnection cable bundle to a strain relief. Proceed as follows: 1. Attach the strain relief holder to the transportation handle at the rear of the power source. Fasten the strain relief holder with a bolt from below. 2.
X8 MIG WELDER 2.3 Installation 3. Insert the supplied locking pin through the hole in the strain relief pin. 4. Route the cable bundle from the back of the power source and attach the strain relief in the other end of the cable to the left-hand side of the wire feeder. For more information, see . 2.3.4 Cables installation For a detailed description of the power source and wire feeder cabling, see Installing interconnection cable. For a full overview of the cabling, see Cabling diagram. 2.3.4.
X8 MIG WELDER 2.3 Installation Connect the interconnection cable to the wire feeder: 1. Lift the cable cabinet latch to reveal the connectors. 2. Connect the welding current cable to the wire feeder. Push the cable as far as it goes and turn the connector clockwise to tighten the cable to its place. Caution: Tighten the welding current cable as much as you can by hand. If the welding current cable connection is loose, it may overheat. 3.
X8 MIG WELDER 9. 2.3 Installation Connect the cooling water hoses to the slot. 10. 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.
X8 MIG WELDER 2.3 Installation 11. Connect the welding current cable to the plus (+) side connector (1) on the power source. The interconnection cable crosses from the wire feeder to the power source connector diagonally. Note: If two wire feeders are connected to a power source, connect the interconnection cable upright: from the wire feeder on the left to the connector (1) on the left. 12. Connect the earth return cable to the minus (-) side connector (2). 13.
X8 MIG WELDER 2.
X8 MIG WELDER 2.3 Installation Earth return cable 2.3.5 Control Pad installation This chapter describes the control pad installation. For information on operating Control Pad, see Control Pad on page 84. 2.3.5.1 Wireless connection Control Pad connects wirelessly to X8 Wire Feeder. If there are two wire feeders in the system, choose which one to connect to. Control Pad can be connected to X8 Power Source in applications where no wire feeder is needed, such as stick welding or gouging.
X8 MIG WELDER 2.3 Installation The led on the power source begins to blink when it is searching for Control Pad. The serial numbers of the nearby available wire feeders or power sources appear on Control Pad's display. Note: When there are wire feeders connected to the welding system, pressing the wireless pairing button allows you to connect Control Pad to a wire feeder. When there are no wire feeders connected to the system, Control Pad allows you to connect to a power source.
X8 MIG WELDER 2.3 Installation The connection list shows the serial numbers of the available wire feeders and a power source. Check the serial number on the device rating plate. A connection forms between the wire feeder or power source and Control Pad. The led on the power source lights up permanently. Note: Once you have created the connection, Control Pad tries to reconnect if you take it out of the connection distance. Select Disconnect on Control Pad to disconnect the connection. 2.
X8 MIG WELDER 2.3 Installation b) Plug the combo cable to the combo cable port on the bottom of Control Pad. 2. To make a wired connection between Control Pad and the wire feeder: a) Plug the combo cable to the remote control connector of the wire feeder. The connector is marked with a Control Pad icon. b) Plug the combo cable to the combo cable port on the bottom of Control Pad. Note: Use mainly the external charger to charge Control Pad. 2.3.5.
X8 MIG WELDER 2.3 Installation 2.3.6 Welding gun installation 2.3.6.1 Preparing and connecting welding gun X8 MIG Gun has been preassembled by the manufacturer: the wire liner, contact tip and gas nozzle are premounted. To start using the gun, proceed as follows: 1. Check that the wire liner, contact tip and gas nozzle are suitable for the job. Change if needed. If your setup includes a gas-cooled gun, you can also change the neck. 2. Attach the pistol grip handle, if suitable for the job. 3.
X8 MIG WELDER 2.3 Installation Note: X8 MIG Guns connect to X8 Wire Feeder with Kemppi Gun Adapter that enables, among other things, accurate measurement of the actual arc voltage and the usage of the remote control. Therefore, X8 MIG Guns are only compatible with X8 Wire Feeder. 5. If your setup includes a water-cooled gun, connect the cooling hoses to the wire feeder. The coolant inlet hose is marked with blue and the coolant outlet hose with red color. 6.
X8 MIG WELDER 2.3 Installation 8. Trim the excess filler wire at a slight angle to improve ignition. 9. Check the gas flow rate. The welding gun is now ready for use. When not using the gun, keep it in the welding gun holder on the wire feeder. 2.3.6.2 Replacing consumable parts of welding gun Select a suitable contact tip, gas nozzle, neck and wire liner according to the job. See also how to change the feed rolls of the wire feeder accordingly: Replacing feed rolls on page 37.
X8 MIG WELDER 2.3 Installation X8 MIG Gun 400-g (3.5 m) X8301403500 X8 MIG Gun 400-g (5.0 m) X8301405000 Contact tip W012134 Contact tip adapter W011483 Gas nozzle W011472 Wire guide tube SP011869 X8 MIG Gun 400-g (3.5 m) X8301403500 Wire liner W012361 X8 MIG Gun 400-g (5.0 m) X8301405000 Wire liner W012362 Water-cooled guns X8 MIG Gun 420-w (3.5 m) X8300423500 X8 MIG Gun 420-w (5.
X8 MIG WELDER 2.3 Installation Changing wire liner (gas-cooled gun) Caution: Use the correct wire liner. The tip of the filler wire may damage an incorrect liner. 1. Lay the welding gun cable straight on a flat surface. 2. Loosen the neck tightener by rotating it half a turn, and remove the neck. 3. Remove the guide nut from the tip of the sleeve. 4. Remove the sleeve and pull out the liner. Make sure the cone and the seal slide out with the liner.
X8 MIG WELDER 2.3 Installation 1 5. 2 Load the new liner through the welding gun connector as far as it goes. Check that you have pushed the liner far enough: the liner must be visible at the tip of the gun.
X8 MIG WELDER 6. 2.3 Installation Assemble the cone (1), seal (2) and sleeve (3) (supplied with the new liner) over the liner protruding from the welding gun connector. Tighten the sleeve as tight as possible with a spanner. 1 7. 2 3 Cut the excessive liner leaving 1 - 2 mm. Use side cutting pliers for spiral liner and carpet knife for DL Chili liner.
X8 MIG WELDER 2.3 Installation 1-2 mm 8. Attach the guide nut at the tip of the sleeve. 9. Re-assemble the neck and tighten the neck tightener to secure. Changing neck (gas-cooled gun) You can change the neck without tools. 1. Turn the neck tightener half a turn counter-clockwise to loosen it, and pull the neck out.
X8 MIG WELDER 2. 2.3 Installation Push in the new neck and turn the neck tightener half a turn clockwise to secure it. Make sure you push the neck deep enough: When the neck is correctly inserted, the groove on the neck is completely hidden under the neck tightener. Note: You can rotate the neck into different positions without loosening the neck tightener. Changing gas nozzle (gas-cooled gun) Screw the gas nozzle into its place.
X8 MIG WELDER 2.3 Installation Changing contact tip (gas-cooled gun) 1. Remove the contact tip. 2. Replace the contact tip adapter / gas diffuser, if needed. Screw in and hand-tighten the new adapter as tight as possible (no tool is needed). Make sure there is no gap between the contact tip adapter and the black plastic bushing. Note: It is important to tighten the adapter properly to enable a tight connection of the contact tip to the gun.
X8 MIG WELDER 3. 2.3 Installation Screw in a new contact tip and tighten it with an appropriate tool. Some thread grooves on the contact tip remain visible when the contact tip is properly connected to the gun. Changing wire liner (water-cooled gun) Caution: Use the correct wire liner. The tip of the filler wire may damage an incorrect liner. 1. Lay the welding gun cable straight on a flat surface.
X8 MIG WELDER 2.3 Installation 2. Remove the guide nut from the tip of the sleeve. 3. Remove the sleeve and pull out the liner together with the cone .
X8 MIG WELDER 4. 2.3 Installation Load the new liner through the welding gun connector as far as it goes The liner should be just visible, a couple of millimeters from the tip of the gun. Note: Make sure the liner is properly inside the contact tip adapter before you cut the liner at the connector end.
X8 MIG WELDER 5. 2.3 Installation Assemble the cone (1) and sleeve (2) (supplied with the liner) over the liner protruding from the welding gun connector. Tighten the sleeve with a spanner to secure.
X8 MIG WELDER 6. 2.3 Installation Cut the excessive liner leaving 1 - 2 mm. Use side cutting pliers for spiral liner and carpet knife for DL Chili liner. 1-2 mm 7. Attach the guide nut at the tip of the sleeve.
X8 MIG WELDER 2.3 Installation Changing gas nozzle (water-cooled gun) Screw the gas nozzle into its place. Changing contact tip (water-cooled gun) 1. Remove the contact tip.
X8 MIG WELDER 2. 2.3 Installation Replace the contact tip adapter/gas diffuser , if needed. Screw in and hand-tighten the new adapter as tight as possible (no tool is needed). Note: It is important to tighten the adapter properly to enable a tight connection of the contact tip to the gun. 3. Screw in a new contact tip and tighten it properly with a tool. Some thread grooves on the contact tip remain visible when the contact tip is properly connected to the gun.
X8 MIG WELDER 2.3 Installation 2.3.6.3 Installing pistol grip handle The pistol grip handle is suitable for all X8 MIG Guns. The handle improves the ergonomics of many welding positions. To attact the pistol grip handle, align the grooves and pull the handle forward to attach the front side (1), and then push the handle back to snap-lock it into its place (2). To detach the pistol grip handle, press the lock button at the back of the handle. 2.3.6.
X8 MIG WELDER 2.3 Installation For operation instructions, see Gun remote control on page 99. 1. Unscrew the two screws that attach the cover to the gun. 2. Remove the protective cover from the gun by pushing it forwards and lifting it up. TORX 20 3. Remove the interface card that covers the connectors. Note: Store the interface card in case you want to remove the remote control later. If you remove the remote control, re-mount the interface and the cover on the gun. 4.
X8 MIG WELDER 5. 2.3 Installation Screw in the two screws. 2.3.7 Lifting X8 MIG Welder If you need to lift X8 MIG Welder, pay special attention to the safety measures. Follow the local regulations. Warning: Do not lift the welder with the gas cylinder.
X8 MIG WELDER 1. 2.3 Installation Loop two lifting straps through the handle at the front and two straps through the handle at the back of the power source. Caution: Place the straps as close to the power source as possible. 2. Lift steadily straight up. 2.3.8 Purchasing and managing welding software You can purchase Kemppi welding software licenses to X8 MIG Welder. Installed licenses can be viewed with Control Pad. For more information, visit www.kemppi.com. 2.3.
X8 MIG WELDER 2.3 Installation Wire Feeder Hanger for Boom The wire feeder hanger for boom facilitates welding where it is difficult to bring the full X8 MIG Welder welding system. The hanger allows more fluent transitions in constricted spaces. Caution: Do not hang the wire feeder from the handle. Use the wire feeder hanger for boom instead.
X8 MIG WELDER 2.3 Installation Wire Feeder Counterbalance Arm The wire feeder counterbalance arm reduces the weight of the cable bundle over the working area.
X8 MIG WELDER 1. 2. 3. 4. 2.3 Installation Lock the rotating plate to its position. Adjust the length of the arm. Tighten the screws to lock to position. Turn to adjust the tension of the counterbalance spring. Turn to adjust the damping of the up and down movement. Wire Feeder Cabinet Heater The wire feeder cabinet heater prevents moisture from condensing inside the wire feeder cabinet so that the wire spool stays dry.
X8 MIG WELDER 2.3 Installation X8 Cable Rack The cable rack holds the interconnection cable during transportation or storage. Note: This is an alternative accessory for the gas cylinder cart. Both cannot be installed at the same time. X8 Accessory Tray The accessory rack holds the small parts and tools needed for welding. Install it on the side of the welding machine.
X8 MIG WELDER 2.4 Operation 2.4 Operation Follow these operating instructions carefully to have full advantage of your X8 MIG Welder and to minimize the risk of malfunctions. 2.4.1 X8 MIG Welder control devices Welding with X8 MIG Welder can be controlled through three different control panels, which offer slightly different features for adjusting the welding parameters. The actual features vary according to the functions and usability of the control panel. 2.4.1.
X8 MIG WELDER 2.4 Operation Figure 6: The View menu In the Welding view, adjust the welding power with the left knob and the fine tuning with the right knob. In most welding processes, this secondary parameter is voltage. In all other views, move up and down in the menus with the right knob. Press the green button in the center of the knob to open an item. If you need to perform a reversing action, such as Cancel or Default, press the green button to accept.
X8 MIG WELDER Figure 7: Control Pad display with the Adjust footer 2.4 Operation Figure 8: Control Pad display with the Select footer If the selection of the toggle button comes into effect right away, the footer command is Close. If the change comes into effect after pressing the green button, the footer command is OK. Control Pad views There are three main views on Control Pad display: Channel (memory channels), Welding, and Settings. Toggle between the views with the view buttons.
X8 MIG WELDER 2.4 Operation Figure 11: The Settings button Welding view In the Welding view, you can: • See an overview of the settings of the selected welding program • Adjust the main parameters (welding power and fine tuning) Depending on the selected welding process, function and program, some or all of the following information is shown: 1. Memory channel, its number and the welding program The first row shows the memory channel's name.
X8 MIG WELDER 2.4 Operation 4. Upslope The selected start and stop logics. 5. Estimated welding current 6. Estimated plate material thickness 7. Wire feed speed 8. Serial number of the power source, wire feeder's number (1 or 2) and user name 9. Welding process 10. Hot start The selected start and stop logics. 11. Crater fill The selected start and stop logics. 12. Voltage 13. Voltage/Fine tuning Adjust the welding power with the left control knob.
X8 MIG WELDER 2.4 Operation Figure 13: Toggling DPulse (1) Figure 14: Toggling DPulse (2) You can specify the minimum and maximum values of the wire feed speed. They are displayed as white stoppers beside the wire feed speed diagram. 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.
X8 MIG WELDER 2.4 Operation Figure 16: The minimum and maximum stoppers for WPS If you adjust the wire feed speed or voltage to a level outside the WPS range, the parameter graph turns red and a warning symbol appears on the display. Note: If you have installed WeldEye, it saves the data as unsuitable use, even if the welding job requires such values.
X8 MIG WELDER 2.4 Operation Settings view Settings displays all the welding parameters and other settings of the selected program. The contents under the titles are collapsed by default. Press the green button to expand the columns. There are two modes, Basic and Advanced. This section describes the Settings view in the Advanced mode. Figure 18: The Settings view menu in the Advanced mode For more information on welding programs, see Welding programs in Control Pad on page 93.
X8 MIG WELDER 2.4 Operation Start and stop logic menu Start and stop logic displays several options. For more information, see Start and stop functions on page 134. Parameters The parameters available vary according to the welding process used: • Wire feed speed • • • • • • • In addition to wire feed speed, you can adjust the minimum and maximum values of wire feed speed here.
X8 MIG WELDER 2.4 Operation 1. PIN lock Lock Control Pad with a 4-digit PIN code. When PIN lock is on, PIN code is required every time when Control Pad is turned on. PIN lock does not prevent welding. 2. Change PIN code Change the 4-digit PIN code. 3. Language Choose the language out of 13 options. 4. Basic/Advanced mode (User interface mode) 5. Brightness Brightness of the display in percents. 6. Power usage The settings available are Minimum, Economic and Normal.
X8 MIG WELDER 2.4 Operation 1. Material Select the material of the welding piece. 2. Wire material 3. Wire diameter 4. Shielding gas 5. Type Select welding/brazing or cladding. 6. Process 7. Polarity Not available for all materials. Which polarity is in use. If the polarity is positive (+), connect the + side to the wire feeder. 8. Welding program After filtering, this column displays the suitable welding programs. Channel view Welding parameters are stored in the memory channels.
X8 MIG WELDER 2.4 Operation View menu In the Welding view, press the Menu button again to see the list of the available additional views. Figure 21: The list of the additional views The View menu displays the following views: 1. Welding Press to return to the Welding view. 2. Weld data Displays information on the last welds. 3. WPS For more information on WPSs, see Using digital WPSs on page 137. 4. Licenses Displays the licenses installed into the welding system. 5.
X8 MIG WELDER 2.4 Operation 2.4.1.2 Wire feeder control panel The control panel of the wire feeder has a one-knob navigation and push buttons for selecting parameters or values. You can, for example, adjust the welding parameters and save settings on memory channels. Wire feeder navigation The three main views on the wire feeder display are the same as in Control Pad: Channel, Welding, and Settings. Note: You can press the Power button to lock the wire feeder and avoid starting welding accidentally.
X8 MIG WELDER 2.4 Operation 1. Memory channel 2. Welding power The unit of the parameter varies according to the welding process. 3. Voltage Note: Not all processes have this parameter. 4. Fine tuning The unit of the parameter varies according to the welding process. 5. Applied settings displayed in symbols For more information on symbols, see Kemppi symbols. Adjust the welding power with the left control knob. Note: The welding parameter shown is Wire feed speed, Current or Plate Thickness.
X8 MIG WELDER 2.4 Operation WP Switch ON/OFF Switch the WP Switch feature ON or OFF. Dynamics Adjust the dynamics setting for MIG, 1-MIG, Pulse, DPulse and WiseThin+. DPulse and WP Switch also have a Dynamics2 setting for adjusting the second level dynamics. Touch sense ignition Switch the optimized ignition feature ON or OFF. Hot start Switch the HotStart feature ON or OFF. Crater fill Switch the crater fill feature ON or OFF. Weld data Shows you the information on the latest weld.
X8 MIG WELDER 2.4 Operation 2.4.1.3 Gun remote control With the remote control, you can select memory channels and WPSs, and adjust wire feed speed, fine tuning and dynamics. 2 1 2 3 Figure 22: Control buttons of the remote control 1. Channel button 2. Arrow buttons 3. Adjustment roll The remote control has two views: Channel view and Settings view. Use the Channel button to move between the views.
X8 MIG WELDER 2.4 Operation • Memory channels. The view shows the number of the memory channel, the name of the welding program, and the process symbol. • WPS channels. The view shows the WPS name and the pass name. If the WPS covers several passes, use the arrow buttons to move between the passes. Figure 24: Channel view: memory channel and WPS channel Adjusting welding parameters In the Settings view, you can view and adjust wire feed speed, fine tuning and dynamics.
X8 MIG WELDER 2.4 Operation 4. Use the arrow buttons to go the the parameter you want to adjust. 5. Use the adjustment roll to change the parameter value. Note: The remote control is disabled if MMA or Gouging mode is selected. Note: For information on warning and error icons, see Error codes on page 170. 2.4.2 Preparing welding system for use Switching on the welding system To switch on the power source and wire feeder, turn the power source main switch to ON (I) position.
X8 MIG WELDER 2.4 Operation The indicator panel also includes indicator LEDs which are yellow if the coolant level is too low or the coolant temperature is too high. When the circulation is defectless, the indicator LED is green. Press the coolant circulation button after each time you change the welding gun. For instructions on filling the cooler, see Filling cooler.
X8 MIG WELDER 2.4 Operation Ensure that the surface contact to the table is clean of metal oxide and paint and that the clamp is firmly secured. 2.4.2.1 Filling cooler Fill the cooler with 20-40 % coolant solution, for example, Kemppi cooling liquid. Proceed as follows: 1. Pull the front panel latch and open the front panel of the power source. 2. Unscrew the lid on top of the cooler. 3. Fill the cooler with coolant solution. Do not fill over the line.
X8 MIG WELDER 2.4 Operation 4. Screw the lid back on the cooler. 5. Push to close the front panel of the power source.
X8 MIG WELDER 2.4 Operation 2.4.2.2 Calibrating arc voltage X8 MIG Welder measures the voltage of the welding arc and the voltage loss in the interconnection cable and welding gun. After calibration, the power source calculates the arc voltage, if the voltage sensing cable is not connected. Figure 28: Calibration of the welding cables Proceed as follows: 1. Ensure that the measurement cable connects the wire feeder and the power source. 2.
X8 MIG WELDER 2.4 Operation 3. Adjust the welding parameters. 4. Weld for at least 4 welds of 5 seconds. With several welds, the measurement result is more accurate. The welder calibrates to the length of the interconnection cable. The values are saved, so you only need to calibrate once after installing the welder package. 5. After the calibration, you can view arc voltage on Control Pad and the wire feeder control panel during and after welding.
X8 MIG WELDER 2. Switch the WiFi on. 3. Select the WLAN network. OPERATING MANUAL | EN 2.
X8 MIG WELDER 2.4 Operation 4. Fill in the password, if needed. 5. Network details are shown in WiFi settings, when the WLAN connection is created.
X8 MIG WELDER 2.4 Operation Wired connection The Ethernet connection is automatically created when you connect the Ethernet cable to X8 MIG Welder. The Ethernet connection details are shown in Ethernet settings when the connection is created. Set DHCP to OFF to configure the Ethernet settings manually. Cloud services status The different icons for cloud services are in the table below.
X8 MIG WELDER 2.4 Operation Table 5: Cloud services icons Connection to the service No connection to the service No user rights to the service 2.4.3 How to use welding system Choosing the optimal welding program with the most suitable process and other parameters facilitates the use of X8 MIG Welder. Programs can be saved in memory channels for easy reach. Digital WPSs automatically adjust the welding machine settings. 2.4.3.
X8 MIG WELDER 2.4 Operation Selecting memory channel You can select a memory channel through Control Pad, wire feeder display or gun remote control. Proceed as follows: 1. To select a memory channel through Control Pad or wire feeder display: a) Press the Channel button. b) Scroll with the right knob to a memory channel. The selection activates immediately. 2. To select a memory channel through the gun remote control, see Gun remote control on page 99.
X8 MIG WELDER 2.4 Operation d) Scroll to the channel where to save the new settings. e) Press the green button. The name of the memory channel changes to the name of the welding program.
X8 MIG WELDER 2.4 Operation Creating new memory channel settings When you create a welding program to a memory channel, always select an existing program as a basis for the modifications. Proceed as follows: 1. Go to Channels and select a memory channel where to start modifications. 2. Press the green button to open the Actions menu. 3. Select Save to and press the green button.
X8 MIG WELDER 4. 2.4 Operation Select the target channel and press the green button. When you save the welding parameters, the channel name changes to the program name. 5. Modify the parameters. 6. Save the modified parameters. See Saving modified memory channel settings on page 111. Saving new welding programs When you install new welding programs, you need to create a memory channel for each of them before use. Proceed as follows: 1. Install the new welding programs as instructed.
X8 MIG WELDER 2.4 Operation Renaming channel Proceed as follows: 1. Go to the Channel view. 2. Press the green button to open Actions. 3. Select Rename and press the green button. Control Pad shows you a keypad.
X8 MIG WELDER 2.4 Operation 4. Turn the knob to go to the eraser and press Erase character on the right knob to delete the former name. 5. Turn the right knob and press the green button on it to select letters.
X8 MIG WELDER 6. 2.4 Operation Move focus to OK and press the green button to return to the Channel view. 2.4.3.2 Using welding processes, programs and features Selecting a welding program A welding program combines the optimal welding settings for a given welding job. Welding programs are saved in the memory of the power source. Welding programs and memory channels are managed through Control Pad. For more information on saving welding programs, see Saving new welding programs on page 114.
X8 MIG WELDER 2.4 Operation Customized Welding programs which are designed and created according to customer-specific welding applications. For more information, contact your local Kemppi dealer. Selecting a welding program through Channel view The easiest way to select a welding program is to browse through the memory channels in the Channel view and select the memory channel that has the appropriate program saved in it. For more information, see Using memory channels on page 110.
X8 MIG WELDER 2.4 Operation The MMA and GOUGING modes just have one pre-installed welding program each. Standard MIG welding processes in X8 MIG Welder The processes described in this chapter are available when the MIG mode is selected. For more information on selecting the MIG mode, see Selecting a welding program. The easiest way to take a certain process into use is to select a memory channel with a welding program that uses that process. For more information, see Channel view on page 94.
X8 MIG WELDER 2.4 Operation Figure 29: MIG Welding view When using MIG, you can adjust the following welding parameters through Settings > Parameters: • Wire Feed Speed • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed • Voltage: adjusts the voltage (arc length). • Dynamics: -10...+10. Adjusts the short circuit behavior. On the minus side, the arc is softer (less spatter). On the plus side, the arc is harder (the arc is more stable).
X8 MIG WELDER 2.4 Operation Figure 30: 1-MIG Welding view When using 1-MIG, you can adjust the following welding parameters through Settings > Parameters: • Wire Feed Speed • • • • • • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed Fine tuning: adjusts the voltage (arc length). Dynamics: -10...+10. Adjusts the short circuit behavior. On the minus side, the arc is softer (less spatter).
X8 MIG WELDER 2.4 Operation appearance of the weld. Pulse is suitable for all position welding. It is excellent for welding aluminium and stainless steel, especially when the material thickness is small. Pulse supports WisePenetration+ and WiseFusion features, as well as various optimized welding programs. To adjust the welding power / wire feed speed while welding, in the Control Pad's Welding view, turn the left knob.
X8 MIG WELDER 2.4 Operation DPulse is a pulse welding process with two separate power levels. The welding power varies between these two levels, and the parameters of each level are controlled independently. In the Welding view, toggle between level 1 and level 2 by pressing the left Control Pad button. The inactive power level is shown with a gray line on the wire feed speed diagram.
X8 MIG WELDER 2.4 Operation • DPulse frequency: the frequency on which the power fluctuates between the levels. • DPulse time percentage: the relative time of the power level on the wire feed speed level 1. • Wire Feed Speed 2: adjusts the wire feed speed for level 2. • min: adjusts the minimum set value for wire feed speed • max: adjusts the maximum set value for wire feed speed • Fine tuning #2: fine tunes voltage for level 2 DPulse supports the WiseFusion feature and various optimized welding programs.
X8 MIG WELDER 2.4 Operation Figure 33: Voltage sensing cable Using DProcess DProcess is a welding process that lets you combine two completely different sets of welding parameters that may even include different welding processes. This way you can optimize the welding arc for the desired application, such as vertical up welding. To use DProcess, you need to define an alternative set of welding parameters (set 2), which will then be combined with the currently selected values (set 1).
X8 MIG WELDER 2.4 Operation Using WiseRoot+ WiseRoot+ is a synergic MIG/MAG process optimized for open-gap root pass welding. The process is based on precise measurement of voltage between the welding gun nozzle and the workpiece. The measurement data serves as input for the current control. The process is suitable for root pass welding in all positions, and provides a smooth and spatter-free arc. To adjust the welding power / wire feed speed, in the Control Pad's Welding view, turn the left knob.
X8 MIG WELDER 2.4 Operation To fine tune the voltage while welding, in the Control Pad's Welding view, turn the right knob. Figure 35: WiseThin+ Welding view When using WiseThin+, depending on the welding program, 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 Fine tuning: adjusts the voltage (arc length). Dynamics: -10...+10.
X8 MIG WELDER 2.4 Operation To take WiseFusion into use, select Settings > Wise features > WiseFusion. To adjust the welding power / wire feed speed, in the Control Pad's Welding view, turn the left knob. To fine tune heat output, in the Control Pad's Welding view, turn the right knob. Figure 36: WiseFusion Welding view Introduction to WiseSteel The WiseSteel function is based on modifying the conventional MIG/MAG arcs to enable higher quality of welds.
X8 MIG WELDER 2.4 Operation To take WiseSteel into use, select Settings > Wise features > WiseSteel. To adjust the welding power/wire feed speed while welding, in the Control Pad's Welding view, turn the left knob. To fine tune heat output while welding, in the Control Pad's Welding view, turn the right knob. Figure 37: 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.
X8 MIG WELDER 2.4 Operation To fine tune heat output, in the Control Pad's Welding view, turn the right knob. Figure 38: WisePenetration+ Welding view MMA welding 5 To use X8 MIG Welder in MMA mode, in Control Pad: 1. Select Settings > Mode > MMA. 2. Select the MMA welding program. An all-around MMA welding program pre-installed. Note: X8 MIG Welder features a voltage reduction device (VRD).
X8 MIG WELDER 2.4 Operation Figure 39: MMA Welding View You can adjust the following parameters through Settings > Parameters: • Welding current • Dynamics: adjusts the short circuit behaviour. On the minus side, the arc is softer (less spatter). On the plus side, the arc is harder (the arc is more stable). • StartPower: Adjusts the power level for arc ignition. You can use this parameter to give extra power or less power for the arc ignition.
X8 MIG WELDER 2.4 Operation Figure 40: Gouging Welding view You can adjust the following parameters through Settings > Parameters: • Gouging welding program: gouging program selection • Current: adjusts the gouging current • Dynamics: adjusts the short circuit behaviour. On the minus side, the arc is softer. On the plus side, the arc is harder (the arc is more stable).
X8 MIG WELDER 2.4 Operation To use X8 MIG Welder for brazing, in Settings, select the mode (MMA/MIG), and in the filter list, for Type, select Brazing to see the suitable welding programs. Trigger logic functions You can select the trigger logic through Control Pad in Settings > Trigger logic. • 2T: Pressing the trigger (1) ignites the arc. Releasing the trigger (2) switches the arc off.
X8 MIG WELDER 2.4 Operation Start and stop functions Touch Sense Ignition Touch Sense Ignition delivers minimum spatter and stabilizes the arc immediately after ignition. To set Touch Sense Ignition ON or OFF with Control Pad, go to Settings > Start and stop logic > Touch Sense Ignition. 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.
X8 MIG WELDER 2.4 Operation Figure 45: 4T/WP Switch Hot start 1. 2. 3. 4. Trigger is pressed. Trigger is released. Trigger is pressed. 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. The default setting for Hot start is OFF. Crater fill When welding with high power, a crater is usually formed at the end of the weld.
X8 MIG WELDER 2.4 Operation Figure 47: 4T/WP Switch Crater Fill 1. 2. 3. 4. Trigger is pressed. Trigger is released. Trigger is pressed. Trigger is released. To adjust the Creater Fill parameters, with Control Pad, go to Settings > Start and stop logic > Crater fill. When you select ON, the options for adjusting Time, Start Level and End level appear on the screen. • Time: For 2T, this defines the period of time that the Crater Fill sequence takes.
X8 MIG WELDER 2.4 Operation Creep start P 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. The Creep start function is always on. To adjust the Creep start level, in Control Pad, go to Settings > Start and stop logic > Creep start level. The adjustment range is 10%...90%.
X8 MIG WELDER 2.4 Operation machines connected to WeldEye. If no Internet connection is available, it is possible transfer the dWPSs on a USB stick. The user can then view, activate and select the dWPSs with Control Pad. It is also possible to select dWPSs through the wire feeder display or the welding gun remote control. When a dWPS is selected, the welding system settings are automatically adjusted accordingly.
X8 MIG WELDER 2. 2.4 Operation To see the list of available WPSs, press the green button. The WPS list opens. Figure 50: Advanced mode Figure 51: Basic mode 3. Move the focus to the WPS that you want to activate. 4. 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. Select Activate WPS.
X8 MIG WELDER 2.4 Operation b) If the Control Pad is in the Basic mode, press the green button to activate the WPS. Control Pad opens the WPS view. Here you can see all the WPS details that the welder needs to know for the job, including the pictures and details of the filler and the gas.
X8 MIG WELDER 2.4 Operation If the WPS includes several passes, select the pass in Active pass. See Selecting WPS pass in WPS view on page 141. 5. Press a view button to leave the WPS view. Note: You can also change WPS or the pass in Channel view. See Selecting WPS or pass in Channel view on page 143. Selecting WPS pass in WPS view Proceed as follows: 1. Go to the View menu > WPS. Control Pad shows the active WPS in the WPS view.
X8 MIG WELDER 2.4 Operation If there is no active WPS, Control Pad shows the WPS list. Select the WPS. 2. Move focus to Active pass. The information under Active pass is pass-specific and varies according to the pass. 3. Press the green button to open the menu.
X8 MIG WELDER 2.4 Operation 4. To change the pass selection, scroll to a pass in a list. 5. 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 Selecting WPS or pass in Channel view on page 143. Selecting WPS or pass in Channel view Proceed as follows: 1. Go to Channel view. Channel displays the memory channel or WPS and the pass you are currently using.
X8 MIG WELDER 2. 2.4 Operation Scroll through the list of WPSs and passes to move the focus to the pass you want to take into use. The pass immediately activates. Caution: After changing WPS or pass, check the pass details to make sure you are using the correct filler wire and gas. 3. To see all the details of the selected WPS, press the Menu button twice and select WPS. To fine tune WPS parameters in the Welding view, press the Menu button once.
X8 MIG WELDER 2.4 Operation Selecting WPS or WPS pass through wire feeder display You can select a WPS or change the WPS pass through the wire feeder display. Note: The first time you use a WPS, you must activate it with Control Pad. After the activation, you can also use the wire feeder display or the gun remote control to select the WPS. Selecting WPS through gun remote control You can select a WPS using the welding gun remote control.
X8 MIG WELDER 2.4 Operation Note: The WPSs must be approved in WeldEye before they can be transferred to the welding machine. 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.
X8 MIG WELDER 2.4 Operation 2. Press the green button. 3. Select a WPS from the list. 4. Press the green button to open the command menu. 5. Select Delete WPS and press the green button.
X8 MIG WELDER 2.4 Operation Filtering WPSs If more than 5 WPSs are available, you can filter the WPSs to narrow down the list. You can filter by material, thickness and joint type. Proceed as follows: 1. Go to the View menu > WPS. 2. Scroll up to move the focus to the filter header. 3. Press the green button to open the filter wizard. 4. Turn the knob to move focus. Press the green button to select the material of the welding piece.
X8 MIG WELDER 2.4 Operation 5. Turn the knob to move focus and press the green button to select the thickness of the wire. 6. Turn the knob to move focus and press the green button to select the weld type.
X8 MIG WELDER 7. 2.4 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. Using welding data collection X8 MIG Welder can be used for automated monitoring of quality and productivity of arc welding. The device records welding parameter data and transmits it to the WeldEye cloud service through a wired or wireless network.
X8 MIG WELDER 2.4 Operation Enabling welding data collection This functionality is available only if your company has acquired WeldEye for Welding Quality Management or WeldEye for Welding Production Analysis. You must connect X8 MIG Welder to Internet and to the WeldEye cloud service to use the functionality on this device. For more information, see WeldEye operating manual. When welding data collection is enabled, press the green button on Control Pad's right control knob to access the Task view.
X8 MIG WELDER 2.4 Operation This identification data resides in the WeldEye cloud service, from where the device takes the data and matches it with the identifiers that the welder has entered either manually or using barcodes. The identification database is synchronized from WeldEye to the device every 15 minutes when the welding system is online. A local database is stored in the power source's internal memory to ensure reliable WeldEye functionality also in poor connectivity situations.
X8 MIG WELDER 2.4 Operation • Activate code reader to read the barcode or QR code on your ID card OR • Enter barcode to enter the barcode manually 4. Read the barcode or QR code on your ID card or enter the barcode manually. For more information, see Control Pad.
X8 MIG WELDER 5. 2.4 Operation Identify the WPS to be used. Select the WPS in the Task view or read the barcode on the printed document. The first pass of the WPS is selected automatically. For more information, see Selecting WPS pass in WPS view. 6. Identify the weld. Read the weld's barcode from a printed work order or select the information on the display. Information about the weld appears on Control Pad's display. During welding, the recorded welding data is linked to the weld in WeldEye.
X8 MIG WELDER 7. 2.4 Operation Record the filler material batch number to provide traceability. Read the barcode from the filler wire package. If there is no barcode available, select Enter barcode in the Task view. Use the virtual keyboard to enter the barcode number by hand. When you read or enter the barcode for the first time, Control Pad does not recognize it. Select Filler batch to indicate that the barcode refers to the filler batch number. 8.
X8 MIG WELDER 2.4 Operation Note: This function is available only if the weld has been identified. The availability is controlled in the WeldEye cloud service settings. If heat input tracking is enabled, enter the length of the weld, which is used for heat input calculation. For more information, see Tracking heat input. 10. When you finish using the welding machine, log out of the system. Power off the machine or scroll to Welder, press the green button, and select Log out.
X8 MIG WELDER 2.4 Operation In the WeldEye cloud service settings, you can filter the items that Control Pad shows to be identified. For example, you can have the WPS and the filler batch number shown, but not the filler material or shielding gas. This does not prevent you from scanning also other identifiers with the barcode reader. Alarms in WeldEye services Before welding, Control Pad shows alarms for insufficient welder qualifications, wrong filler material, and wrong shielding gas.
X8 MIG WELDER 2.4 Operation White: The measured value is within the WPS limits or the WPS is not identified. Yellow: The measured value is near the WPS limits. (Warning) Red: The measured value is outside the WPS limits. (Alert) There is a short reaction time, usually a few seconds, before the color changes. This makes the display easier to read and enables monitoring of the overall welding quality. For more information, see WeldEye help on Real-time WPS monitoring.
X8 MIG WELDER 2.4 Operation Tracking heat input You can set the device to track the heat input of each weld and provide the welder with heat input values. To get the heat input value, select Complete Pass. Identify the weld and perform at least one welding run. After this, the Complete Pass selection appears in Control Pad's Task view. In heat input calculation the system uses travel speed, welding current, voltage, and welding process information.
X8 MIG WELDER 2.4 Operation After you mark the pass complete, Control Pad shows the average heat input and travel speed values and indicates whether they are within the WPS limits. You can use this feedback to adjust the parameters or welding technique. The device also sends the data to the WeldEye cloud service for documentation. Control Pad displays the number of completed passes with a round green checkmark next to it. Enable heat input tracking in the WeldEye cloud service.
X8 MIG WELDER 2.4 Operation Create work orders in the WeldEye cloud service, and once released, they become automatically available to welding machines within 15 minutes. You can restrict the visibility of the work orders to individual persons or welding machines. For more information about the automated collection of welding data, see Using welding data collection. Using work orders Digital work orders provide a simple way to achieve traceability in WeldEye and to reduce the amount of printed paper.
X8 MIG WELDER 3. 2.4 Operation Activate the work order or a weld. If the work order contains a list of welds, scroll to the desired weld and press the green button on the right control knob to select it. If the work order does not contain welds, scroll to Activate work order and press the green button on the right control knob to select it.
X8 MIG WELDER 4. 2.4 Operation If the active work order or weld has predefined WPSs in WeldEye, Control Pad promps you to select one of them. The work order is now selected and visible in the Task view. You can start welding. Completing work order When you have completed the work defined by the work order, mark it as completed. When you do that, Control Pad stores the end time in the WeldEye cloud service and the status of the work order changes to Completed.
X8 MIG WELDER 2.4 Operation 1. In Control Pad's Task view, select the work order and press the green button on the right control knob. 2. Select Complete work order. Control Pad marks the work order completed with a green checkmark icon. 3. You can deselect the work order. For more information, see Changing work order. Once completed, the work order is automatically removed from the work order list in Control Pad within 15 minutes or as soon as X8 MIG Welder is connected to Internet.
X8 MIG WELDER 3. 2.4 Operation A list of work orders appears. To select another work order, select it from the list. To deselect the current work order, scroll up to the list and select No work order. Recommended WPSs Work orders and welds can include recommended Welding Procedure Specifications (WPSs). They help welder to choose the correct WPS for the job, which reduces the risk of errors.
X8 MIG WELDER 2.5 Troubleshooting Time tracking Digital work orders can be used to track lead times at work order level. X8 MIG Welder automatically records the exact time when the work order is started, stopped, and completed. With this information, WeldEye calculates for each work order the lead time (total time from start to finish) and the active working time (lead time exclusive of pauses and breaks). These times are available for reporting in the WeldEye cloud service. 2.
X8 MIG WELDER 2.5 Troubleshooting Problem Recommended actions The welding system stops working • Gas-cooled gun may have overheated. Wait for it to cool down. • Check that none of the cables is loose. • The wire feeder may have overheated. Wait for it to cool down and see that the welding current cable is properly attached. • The power source may have overheated. Wait for it to cool down and see that the cooling fans work properly and the air flow is unobstructed.
X8 MIG WELDER 2.5 Troubleshooting Problem Recommended actions The gun overheats • Make sure the gun's neck is correctly connected to the handle: push the neck deep enough and check that the neck tightener is properly tightened. • Make sure that the contact tip adapter is properly handtightened and the contact tip properly attached to it. • Make sure that the welding parameters are within the range of the welding gun and the neck.
X8 MIG WELDER 2.5 Troubleshooting Problem Recommended actions The gun overheats • Make sure the coolant circulation is working normally (see the coolant circulation warning LED in the power source). • Measure the coolant circulation speed: detach the coolant output hose from the wire feeder while the power source is on, and let the coolant run into a measurement cup. The circulation must be at least 0.5 l/min. • Make sure that the welding parameters are within the range of the welding gun and the neck.
X8 MIG WELDER 2.6 Maintenance Problem Recommended actions High spatter volume • • • • Check the welding parameter values and welding procedure. Check the gas type and flow. Check the polarity of the gun/electrode. Check that the filler wire is correct for the current application. 2.5.1 Error codes Control Pad In error situations, Control Pad displays the number and title of the error, a description of the possible cause (Reasons) and the Actions to fix the error.
X8 MIG WELDER 2.6 Maintenance 2.6.1 Daily maintenance Caution: Disconnect the power source from the mains before handling electrical cables. Maintenance of power source and wire feeder Follow these maintenance procedures to maintain the proper functioning of the welding system: • Check that all covers and components are intact. • Check all the cables and connectors. Do not use them if they are damaged and contact service for replacements. • Check the wire feeder's feed rolls and the pressure handle.
X8 MIG WELDER 2.6 Maintenance Figure 54: Water-cooled gun • Check and remove any spatter build-up from the nozzle.
X8 MIG WELDER 2.6 Maintenance Figure 56: Water-cooled gun • When not using the gun, keep it in the welding gun holder on the wire feeder. Maintenance of Control Pad Control Pad is water resistant and can be wiped clean with a moist cloth. Do not use detergents. For repairs, contact Kemppi at www.kemppi.com or your dealer. 2.6.2 Periodic maintenance of power source and wire feeder Caution: Only qualified service personnel is allowed to carry out periodic maintenance.
X8 MIG WELDER 2.7 Technical data Update the wire feeder to the latest firmware version and load new welding software. 2.6.3 Service workshops Kemppi Service Workshops complete the welding system maintenance according to the Kemppi service agreement.
X8 MIG WELDER Feature 2.
X8 MIG WELDER Feature 2.7 Technical data Description Wireless communication type • Transmitter frequency and power Value 400 A 400 A MV 2.4 GHz WiFi & Bluetooth 2.4 GHz WiFi & Bluetooth 2.4 GHz Bluetooth and 2.4 GHz Bluetooth and WLAN WLAN • 2400-2483.5 MHz 20 dBm • 2400-2483.5 MHz 20 dBm Wired communication type Ethernet & USB Ethernet & USB Standards IEC 60974-1, -10 IEC 60974-1, -10 2.7.
X8 MIG WELDER Feature 2.
X8 MIG WELDER Feature 2.7 Technical data Description Standards Value 500 A 500 A MV IEC 60974-1, -10 IEC 60974-1, -10 2.7.
X8 MIG WELDER Feature Output Welding current and voltage range Welding current and voltage range 2.
X8 MIG WELDER Feature 2.7 Technical data Description Standards Value 600 A 600 A MV IEC 60974-1, -10 IEC 60974-1, -10 2.7.4 X8 Cooler Feature Description Value Operating voltage, U1 3~50/60 Hz 220 - 230 V ±10 % 380 - 460 V ±10 % Supply current (maximum) I1max 1.0 A Supply current (effective) I1eff 0.6 A Rated cooling power at 1 l/min 1.4 kW Rated cooling power at 1.6 l/min 1.9 kW Recommended coolant MPG 4456 (Kemppi mixture) Coolant pressure (max) 0.
X8 MIG WELDER Feature 2.7 Technical data Description Value Gun connection Kemppi Wire feed mechanism 4-roll, twin-motor Diameter of feed rolls 32 mm Filler wires Fe 0.6 - 2.4 mm Ss 0.6 - 2.4 mm MC/FC 0.8 - 2.4 mm Al 0.8 - 2.4 mm Wire feed speed 0.5 - 25 m/min Wire spool weight (max) 20 kg Wire spool diameter (max) 300 mm Shielding gas pressure (max) pmax 0.
X8 MIG WELDER Feature 2.7 Technical data Description Value Typical battery charging time 5h Power supply output voltage 12 V Power supply output current 2.5 A Wireless communication type 2.4 GHz Bluetooth • Transmitter frequencies and powers • 2400-2483.5 MHz 14 dBm • 13.56 MHz -1.3 dBμA/m Typical wireless communication range 15 m Wired communication type USB Display type TFT LCD Display size 5.7" Standards • • • • • • • IEC 60950-1 EN 62368-1 EN 300 328 v2.1.1 EN 300 330 v2.1.
X8 MIG WELDER 2.7 Technical data Feature Description Value Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C Pistol grip handle Yes Changeable neck Yes Rotating neck Yes Neck dimensions Neck angle Length x (see figure below) 101 mm Height y (see figure below) 86 mm ɑ (see figure below) 50° Standards IEC 60974-7 Figure 57: Neck dimensions and angle 2.7.
X8 MIG WELDER 2.7 Technical data Feature Description Value Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C Pistol grip handle Yes Changeable neck Yes Rotating neck Yes Neck dimensions Neck angle Length x (see figure below) 117 mm Height y (see figure below) 97 mm ɑ (see figure below) 50° Standards IEC 60974-7 Figure 58: Neck dimensions and angle 2.7.
X8 MIG WELDER 2.7 Technical data Feature Description Value Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C Pistol grip handle Yes Changeable neck Yes Rotating neck Yes Neck dimensions Neck angle Length x (see figure below) 132 mm Height y (see figure below) 110 mm ɑ (see figure below) 50° Standards IEC 60974-7 Figure 59: Neck dimensions and angle 2.7.
X8 MIG WELDER 2.7 Technical data Feature Description Value Ss-MC/FC 0.9 - 1.6 mm Al 0.8 - 1.6 mm Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C Minimum cooling power at 1.6 l/min * 1.9 kW Minimum flow rate 1.
X8 MIG WELDER 2.7 Technical data Feature Filler wires Description Value @ 100 % (MIXED GAS) 520 A @ 60 % (CO2) - @ 100 % (CO2) - Fe 0.8 - 1.6 mm Fe-MC/FC 0.9 - 1.6 mm Ss 0.8 - 1.6 mm Ss-MC/FC 0.9 - 1.6 mm Al 0.8 - 1.6 mm Operating temperature range -20…+40 °C Storage temperature range -40…+60 °C Minimum cooling power at 1.6 l/min * 1.9 kW Minimum flow rate 1.
X8 MIG WELDER Feature 2.7 Technical data Description Value Type of cooling Liquid Coolant flow rate 1 l/min Coolant pressure (max) 5 bar Type of connection Kemppi Wire diameters 1.2 - 2.4 mm Load capacity Filler wires @ 60 % (MIXED GAS) - @ 100 % (MIXED GAS) 600 A @ 60 % (CO2) - @ 100 % (CO2) - Fe 1.2 - 2.4 mm Fe-MC/FC 1.2 - 2.4 mm Ss 1.2 - 1.6 mm Ss-MC/FC 1.2 - 1.6 mm Al 1.2 - 2.
X8 MIG WELDER 2.7 Technical data 2.7.13 X8 MIG Gun WS 420-w Feature Description Value Welding process MIG/MAG Method of guidance Manual Type of cooling Liquid Coolant flow rate 1 l/min Coolant pressure (max) 5 bar Type of connection Kemppi Wire diameters 1.2 - 1.6 mm Load capacity @ 60 % (MIXED GAS) - Filler wires @ 100 % (MIXED GAS) 300 A @ 60 % (CO2) - @ 100 % (CO2) - Ss 1.2 - 1.6 mm Al 1.2 - 1.
X8 MIG WELDER 2.8 Ordering codes Figure 63: Neck dimensions and angle 2.
X8 MIG WELDER 2.
X8 MIG WELDER 2.
X8 MIG WELDER 2.
X8 MIG WELDER 2.9 Disposal of unit recycling facility. 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.
