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
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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
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