Kemppi X5 FastMig Series User manual

X5 FastMig
Operating manual - EN
X5 FastMig
© Kemppi 11920960 / 2144

X5 FastMig
Operating manual - EN
CONTENTS
1. General 4
1.1 Equipment description 6
1.2 X5 Power Source 400 and 500 8
1.3 X5 Wire Feeder 200 10
1.3.1 Wire spool and hub (200) 11
1.3.2 Wire feed mechanism 12
1.3.3 Manual control panel (X5 FP 200R) 13
1.4 X5 Wire Feeder 300 14
1.4.1 Wire spools and hubs (300) 16
1.4.2 Wire feed mechanism 17
1.4.3 Manual control panel (X5 FP 300R) 17
1.4.4 Auto control panel (X5 FP 300) 18
1.5 X5 interconnection cable 19
1.6 X5 cooling unit (optional) 21
2. Installation 22
2.1 Installing power source mains plug 24
2.2 Installing cooling unit (optional) 25
2.3 Installing equipment on cart (optional) 28
2.4 Installing wire feeder with fixed plate 31
2.5 Installing wire feeder with standard rotating plate 34
2.6 Installing wire feeder with lockable rotating plate 37
2.7 Installing cables 40
2.8 Connecting welding gun 45
2.8.1 Installing welding gun holder 45
2.9 Installing remote control 47
2.10 Installing and changing wire (X5 WF 200) 48
2.11 Installing and changing wire (X5 WF 300) 53
2.12 Installing and replacing feed rolls 59
2.13 Installing and replacing wire guide tubes 63
2.14 Installing gas bottle and testing gas flow 65
2.15 How to get welding programs 67
2.16 Other optional accessories 68
3. Operation 71
3.1 Preparing welding system for use 72
3.1.1 Filling cooler and circulating coolant 72
3.1.2 Calibrating welding cable 73
3.2 Using X5 Manual control panel 74
© Kemppi 21920960 / 2144

X5 FastMig
Operating manual - EN
3.2.1 Manual control panel: Settings 75
3.3 Using X5 Auto control panel 80
3.3.1 Auto control panel: Home view 81
3.3.2 Auto control panel: Memory channels 82
3.3.3 Auto control panel: Weld history 83
3.3.4 Auto control panel: Welding parameters 84
3.3.5 Auto control panel: Info view 88
3.3.6 Auto control panel: Weld data view 89
3.3.7 Auto control panel: System settings 90
3.3.8 Auto control panel: Applying welding programs 92
3.4 Additional guidance to functions and features 94
3.4.1 Trigger logic functions 94
3.4.2 WiseFusion 94
3.4.3 WisePenetration+ 95
3.4.4 WiseSteel 95
3.4.5 WeldEye with DCM (optional) 96
3.5 Using remote control 98
3.6 Lifting X5 equipment 99
4. Maintenance 101
4.1 Daily maintenance 102
4.2 Periodic maintenance 103
4.3 Service workshops 104
4.4 Troubleshooting 105
4.5 Error codes 107
4.6 Installing and cleaning power source air filter (optional) 109
4.7 Disposal 111
5. Technical data 112
5.1 X5 power sources 113
5.2 X5 wire feeders 117
5.3 X5 cooling unit 120
5.4 X5 ordering info 121
© Kemppi 31920960 / 2144

X5 FastMig
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's X5 FastMig equipment. The equipment consists of multi-purpose weld-
ing power sources, wire feeders and cooling unit (optional) designed for demanding professional use in MIG/MAG weld-
ing.
The equipment is intended for manual MIG/MAG welding as well as automatic 1-MIG welding with X5 FastMig Synergic.
The 1-MIG function is accompanied by welding programs, work packs and also the WiseSteel, WiseFusion and WisePen-
etration+ features as optional.
X5 FastMig systems:
Wire Feeder
200 Manual 300 Manual 300 Auto / 300 Auto+
Power Source
400 X5 FastMig Manual 400 X5 FastMig Manual 400 X5 FastMig Synergic 400
500 X5 FastMig Manual 500 X5 FastMig Manual 500 X5 FastMig Synergic 500
X5 FastMig is designed to be used together with Kemppi's Flexlite GX MIG welding guns.
X5 FastMig can be used also for MMA welding, gouging and, with X5 Wire Feeder 300 Auto and 300 Auto+, for TIG weld-
ing*.
* TIG welding requires the use of dedicated Flexlite TX TIG torches.
Important notes
Read the instructions through carefully. For your own safety, and that of your working environment, pay particular atten-
tion to the safety instructions delivered with the equipment.
Items in the manual that require particular attention in order to minimize damage and harm are indicated with the
below symbols. Read these sections carefully and follow their instructions.
Note: Gives the user a useful piece of information.
Caution: Describes a situation that may result in damage to the equipment or system.
© Kemppi 41920960 / 2144

X5 FastMig
Operating manual - EN
Warning: Describes a potentially dangerous situation. If not avoided, it will result in personal damage or fatal injury.
Kemppi symbols: Userdoc.
DISCLAIMER
While every effort has been made to ensure that the information contained in this guide is accurate and com-
plete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the spe-
cification of the product described at any time without prior notice. Do not copy, record, reproduce or transmit
the contents of this guide without prior permission from Kemppi.
© Kemppi 51920960 / 2144

X5 FastMig
Operating manual - EN
1.1 Equipment description
X5 FastMig has several power source and wire feeder options to choose from. The control panel is always fixed to the
wire feeder.
X5 FastMig supports welding cable calibration without an additional measuring cable.
X5 power sources:
•X5 Power Source 400 (400 A)
•X5 Power Source 500 (500 A)
•X5 Power Source 400 (WP) (400 A, work pack version)
•X5 Power Source 500 (WP) (500 A, work pack version).
For the power source part descriptions, refer to "X5 Power Source 400 and 500" on page8.
X5 wire feeders:
•X5 Wire Feeder 200 Manual
>> Comes with 2-knob membrane control panel (Manual)
>> Maximum wire spool diameter 200 mm
>> Not stackable with X5 power source (except with the additional steel pipe frame)
>> Optional model version with built-in rotameter for gas available
•X5 Wire Feeder 300 Manual
>> Comes with 2-knob membrane control panel (Manual)
>> Maximum wire spool diameter 300 mm
•X5 Wire Feeder 300 Auto
>> Comes with 2-knob 5.7" TFT/LCD control panel (Auto)
>> Includes automatic 1-MIG process that supports welding programs and Wise features
>> Maximum wire spool diameter 300 mm
•X5 Wire Feeder 300 Auto+
>> Comes with 2-knob 5.7" TFT/LCD control panel (Auto)
>> Includes automatic 1-MIG process that supports welding programs and Wise features
>> Maximum wire spool diameter 300 mm
>> Includes subfeeder support
>> Includes built-in rotameter for gas
For the X5 Wire Feeder 200 part descriptions, refer to "X5 Wire Feeder 200" on page10, "Wire spool and hub (200)" on
page11 and "Wire feed mechanism" on page17.
For the X5 Wire Feeder 300 part descriptions, refer to "X5 Wire Feeder 300" on page14, "Wire spools and hubs (300)" on
page16 and "Wire feed mechanism" on page17.
For the control panel descriptions, refer to "Manual control panel (X5 FP 200R)" on page13, "Manual control panel (X5 FP
300R)" on page17 and "Auto control panel (X5 FP 300)" on page18.
X5 cooling units:
•X5 Cooler, 1 kW.
For the cooling unit part descriptions, refer to "X5 cooling unit (optional)" on page21.
MIG welding guns:
•Flexlite GX welding guns.
For more information on the Flexlite GX welding guns, refer to Kemppi Userdoc.
© Kemppi 61920960 / 2144

X5 FastMig
Operating manual - EN
Welding programs:
Welding programs and Wise features are available with the automatic, 1-MIG-enabled wire feeders.
•Welding program work pack (factory-installed or on-demand / at the time of purchase)
•Additional 1-MIG welding programs (on-demand / at the time of purchase)
•Additional Wise features: WiseSteel, WiseFusion and WisePenetration+ (on-demand / at the time of purchase).
For more information on selecting welding programs, contact your local Kemppi dealer.
Subfeeders:
Subfeeder support is available with X5 Wire Feeder 300 Auto+. To other X5 Wire Feeder 300 models, the subfeeder
support can be added with a separate installation kit.
•SuperSnake GTX subfeeder.
For more information on the SuperSnake GTX subfeeder, refer to Kemppi Userdoc.
Optional accessories:
•4-wheel cart with gas bottle rack
•2-wheel cart
•Remote control HR40 (2-knob control)
•Remote control HR43 (1-knob control)
•Accessory rack
•Wire feeder cabinet heater
•Wire feeder cart (for X5 Wire Feeder 300)*
•Wire feeder rotating plate, single and double (for X5 Wire Feeder 300)*
•Wire feeder hanger for boom, single and double (for X5 Wire Feeder 300)*
•Wire feeder counterbalance arm (for X5 Wire Feeder 300)*
•Gun holder (for X5 Wire Feeder 300)
•Wire drum kit (for X5 Wire Feeder 300)
•Additional steel pipe frame (for X5 Wire Feeder 200).
* Can be used with X5 Wire Feeder 200 together with the additional steel pipe frame.
For more information on optional accessories, contact your local Kemppi dealer.
For installing the optional accessories, refer to the corresponding equipment installation chapters and "Other optional
accessories" on page68.
© Kemppi 71920960 / 2144

X5 FastMig
Operating manual - EN
1.2 X5 Power Source 400 and 500
This section describes the structure of X5 Power Source 400 and X5 Power Source 500.
Front:
1. Indicator panel *
2. Transportation handle (not intended for mechanical lifting)
3. Front locking interface (locking on top of the cooling unit or on the cart)
* Indicator panel
1. VRD (Voltage Reduction Device) 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.
>> The LED blinks green when the MMA or Gouging power save mode is on (the power save mode is automatically
applied after 15 minutes of idling).
VRD is in use with MMA and Gouging modes only.
2. High temperature indicator (overheating)
>> The LED is yellow when the unit is overheating.
If the power source overheats, a thermal cutoff switches the unit off and does not allow it to be used until it has
cooled down.
3. Power on/off indicator
>> The LED is green when the unit is on.
4. Coolant temperature warning
>> The LED is yellow when the cooler is overheating.
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.
© Kemppi 81920960 / 2144

X5 FastMig
Operating manual - EN
5. Coolant circulation warning
>> The LED is green when the coolant circulation is working normally.
>> The LED is red when there is a problem in the coolant circulation.
If the circulation of the coolant liquid is obstructed, a thermal cutoff switches the welding system off. Check and fix
the error before using the welding system again.
Rear:
1. Power switch
2. Control cable connector
3. Control cable connector
4. Mains cable
5. Welding current cable connector, plus (+) connector
6. Earth return cable connector, minus (-) connector
7. Rear locking interface
>> For locking on top of the cooling unit or on the cart.
© Kemppi 91920960 / 2144

X5 FastMig
Operating manual - EN
1.3 X5 Wire Feeder 200
This section describes the structure of the X5 Wire Feeder 200 Manual.
Keep the wire feeder covers closed during welding to reduce the risk of injury or an electric shock. Keep the covers
closed also at other times to keep the inside of the wire feeder clean.
The handle is intended for short distance manual carrying. Suspending the equipment temporarily from the handle
with slings (e.g. for moving) is allowed.
1. Control panel
>> For more information on the X5 Wire Feeder 200 Manual control panel, refer to "Manual control panel (X5 FP
200R)" on page13.
2. Euro connector for welding cable connection
3. Coolant inlet and outlet connectors (color-coded)
4. Control cable connector
5. Wire feed cabinet side
6. Interconnection cable cabinet side
Inside wire feeder (wire feed cabinet)
1. Wire feed roll mechanism
2. Wire spool hub
>> For more information on the wire spools, refer to "Wire spool and hub (200)" on the next page.
3. Wire feeder cabinet door latch
© Kemppi 10 1920960 / 2144

X5 FastMig
Operating manual - EN
Inside wire feeder (interconnection cable cabinet)
1. Interconnection cable cabinet hatch and locking latch
>> The rear section of the hatch acts also as a strain relief for the cable
2. Shielding gas hose connector
3. Control cable connector
4. Welding current cable connector
5. Coolant hose mounting slot
For installing and connecting the cables, refer to "X5 interconnection cable" on page19 and "Installing cables" on
page40.
Wire feeder fixing accessories
X5 Wire Feeder 200 can be equipped with a steel pipe frame for additional protection and installation options. When the
steel pipe frame is used, X5 Wire Feeder 200 can also be installed on top of the X5 power sources using the same
optional fixing accessory sets than with the X5 Wire Feeder 300.
1.3.1 Wire spool and hub (200)
The wire spool can be released and removed by opening the lock and pushing the locking clips towards the center. The
locking clips are locked by turning the lock knob between the locking levers:
© Kemppi 11 1920960 / 2144

X5 FastMig
Operating manual - EN
Spool brake adjustment:
1.3.2 Wire feed mechanism
X5 Wire Feeder 200 wire feed mechanism:
1. Drive rolls and drive roll mounting caps
2. Middle guide tube locking clip
3. Middle guide tube
4. Inlet guide tube
5. Pressure handles
6. Pressure rolls and pressure roll mounting pins
© Kemppi 12 1920960 / 2144

X5 FastMig
Operating manual - EN
7. Pressure roll locking arms
8. Outlet guide tube.
For replacing the wire feed rolls, refer to "Installing and replacing feed rolls" on page59.
For replacing the wire guide tubes, refer to "Installing and replacing wire guide tubes" on page63
1.3.3 Manual control panel (X5 FP 200R)
This section describes the controls and features of the X5 Wire Feeder 200 Manual control panel (membrane panel).
1. Left control knob
2. Right control knob
3. Trigger logic selection (2T/4T)
4. Process selection (MIG/MMA/Gouging)
5. Home button (default welding mode)
6. Weld data button
7. Settings button
8. Gas test button
9. Wire inch button
For using the control panel, refer to "Using X5 Manual control panel" on page74.
© Kemppi 13 1920960 / 2144

X5 FastMig
Operating manual - EN
1.4 X5 Wire Feeder 300
This section describes the structure of the X5 Wire Feeder 300 Manual, 300 Auto and 300 Auto+.
Model-specific variations may occur.
1. Control panel (and hinged control panel cover)
>> For more information on the X5 Wire Feeder 300 Auto control panel, refer to "Auto control panel (X5 FP 300)"
on page18.
>> For more information on the X5 Wire Feeder 300 Manual control panel, refer to "Manual control panel (X5 FP
300R)" on page17.
2. Top cover
>> Wire feeder cabinet door
>> Handle
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 inside of the wire feeder clean.
The handle is intended for short distance manual carrying. Suspending the equipment temporarily from the handle
with slings (e.g. for moving) is allowed.
3. Top cover latch
4. Euro connector for welding cable connection
5. Control cable connector
6. Coolant inlet and outlet connectors (color-coded)
7. X5 Wire Feeder 300 Auto+ : Subfeeder synchronization connector
8. X5 Wire Feeder 300 Auto+ : Voltage sensing cable connector
Refer to "Auto control panel: System settings" on page90 for the full list of supported subfeeders.
© Kemppi 14 1920960 / 2144

X5 FastMig
Operating manual - EN
Inside wire feeder (wire feeder cabinet)
1. Wire spool
>> For more information on the wire spools, refer to "Wire spools and hubs (300)" on the next page.
2. Wire spool locking cover
3. Wire feed roll mechanism
4. Wire inch button
>> Drive the filler wire forward (with arc off).
5. Gas test button
>> Test the shielding gas flow and flush the gas line.
Inside wire feeder (interconnection cable cabinet)
1. Interconnection cable cabinet door and latch
2. Shielding gas hose connector
3. Control cable connector
4. Welding current cable connector
5. Coolant hose mounting slot
6. Interconnection cable strain relief
With X5 Wire Feeder 300 Auto+ also:
© Kemppi 15 1920960 / 2144

X5 FastMig
Operating manual - EN
7. X5 Wire Feeder 300 Auto+ : Rotameter for gas
8. X5 Wire Feeder 300 Auto+ : Voltage sensing cable connector for interconnection cable
For installing and connecting the cables, refer to "X5 interconnection cable" on page19 and "Installing cables" on
page40.
Wire feeder fixing accessories
X5 Wire Feeder 300 can be installed on top of the X5 Power Source with the following optional fixing accessory sets:
•Fixed fixing plates and locking mechanism for one wire feeder
•Rotating plate with locking mechanism for one wire feeder
•Double rotating plate with two locking mechanisms for two wire feeders
•Rotating plate with counter-balance arm for one wire feeder.
1.4.1 Wire spools and hubs (300)
X5 Wire Feeder 300 has three different wire spool hub options available for different wire spools:
•Standard spool (A)
•Spool hub for the small wire spool (B)
>> Attach the extension pieces to the standard spool halves.
•Spool hub for the wire spool with a large center hole (C)
All parts are delivered with the wire feeder.
Loosen and pull the spool hub halves apart to detach them.
© Kemppi 16 1920960 / 2144

X5 FastMig
Operating manual - EN
1.4.2 Wire feed mechanism
X5 Wire Feeder 300 wire feed mechanism:
1. Drive rolls and drive roll mounting caps
2. Middle guide tube locking clip
3. Middle guide tube
4. Inlet guide tube
5. Pressure handles
6. Pressure rolls and pressure roll mounting pins
7. Pressure roll locking arms
8. Outlet guide tube.
For replacing the wire feed rolls, refer to "Installing and replacing feed rolls" on page59.
For replacing the wire guide tubes, refer to "Installing and replacing wire guide tubes" on page63
1.4.3 Manual control panel (X5 FP 300R)
This section describes the controls and features of the X5 Wire Feeder 300 Manual control panel (membrane panel).
© Kemppi 17 1920960 / 2144

X5 FastMig
Operating manual - EN
1. Left control knob
2. Right control knob
3. Trigger logic selection (2T/4T)
4. Process selection (MIG/MMA/Gouging)
5. Home button (default welding mode)
6. Weld data button
7. Settings button
For using the control panel, refer to "Using X5 Manual control panel" on page74.
1.4.4 Auto control panel (X5 FP 300)
This section describes the controls and features of the X5 Wire Feeder 300 Auto control panel (TFT/LCD).
1. Left control knob (with push button function)
2. Right control knob (with push button function)
3. Memory channel selection (shortcut button)
4. View selection (shortcut button)
5. Welding parameters view (shortcut button).
For using the control panel, refer to "Using X5 Auto control panel" on page80.
© Kemppi 18 1920960 / 2144

X5 FastMig
Operating manual - EN
1.5 X5 interconnection cable
The X5 FastMig interconnection cables come in multiple different lengths and configurations to suit your equipment
setup.
For installing the interconnection cable, refer to "Installing cables" on page40.
With water-cooling
(PS = Power source end of the interconnection cable, WF = Wire feeder end of the interconnection cable.)
1. Shielding gas hose
2. Control cable
3. Welding current cable
4. Coolant hose (outlet/inlet, color-coded)
5. Coolant hose (outlet/inlet, color-coded)
6. Strain relief collar (at the power source end)
7. Strain relief block (at the wire weeder end).
Without water-cooling
(PS = Power source end of the interconnection cable, WF = Wire feeder end of the interconnection cable.)
1. Shielding gas hose
2. Control cable
3. Welding current cable
4. Strain relief collar (at the power source end)
5. Strain relief block (at the wire weeder end).
Adapter cable for double wire feeder installation
The adapter cable for a double wire feeder installation divides one interconnection cable for two wire feeders.
© Kemppi 19 1920960 / 2144

X5 FastMig
Operating manual - EN
Interconnection cable specifications
Cable Cable type* Cable length Cooling Connector types
X57002MW 70 mm22 m Water-cooled 10-pin (control), snap (water/gas), DIX (current)
X57005MW 70 mm25 m Water-cooled 10-pin (control), snap (water/gas), DIX (current)
X57010MW 70 mm210 m Water-cooled 10-pin (control), snap (water/gas), DIX (current)
X57020MW 70 mm220 m Water-cooled 10-pin (control), snap (water/gas), DIX (current)
X57030MW 70 mm230 m Water-cooled 10-pin (control), snap (water/gas), DIX (current)
X57002MG 70 mm22 m Gas-cooled 10-pin (control), snap (water/gas), DIX (current)
X57005MG 70 mm25 m Gas-cooled 10-pin (control), snap (water/gas), DIX (current)
X57010MG 70 mm210 m Gas-cooled 10-pin (control), snap (water/gas), DIX (current)
X57020MG 70 mm220 m Gas-cooled 10-pin (control), snap (water/gas), DIX (current)
X57030MG 70 mm230 m Gas-cooled 10-pin (control), snap (water/gas), DIX (current)
X59502MW 95 mm22 m Water-cooled 10-pin (control), snap (water/gas), DIX (current)
* Welding current cable
© Kemppi 20 1920960 / 2144