Kemppi X5 FastMig Series User manual

X5 FastMig
Operating manual - EN
X5 FastMig
© Kemppi 2 1920960 / 2039

X5 FastMig
Operating manual - EN
CONTENTS
1. General 5
1.1 Equipment description 7
1.2 X5 Power source 9
1.3 X5 Wire feeder 11
1.3.1 X5 Wire spools and hubs 13
1.3.2 X5 Wire feed mechanism 13
1.4 X5 Manual control panel (X5 FP 300R) 14
1.5 X5 Auto control panel (X5 FP 300) 15
1.6 X5 Interconnection cable 16
1.7 X5 Cooling unit (optional) 18
2. Installation 19
2.1 Installing power source mains plug 21
2.2 Installing cooling unit (optional) 22
2.3 Installing equipment on cart (optional) 25
2.4 Installing wire feeder with fixed plate 28
2.5 Installing wire feeder with rotating plate 31
2.6 Installing cables 34
2.7 Connecting welding gun 38
2.7.1 Installing welding gun holder 38
2.8 Installing remote control 40
2.9 Installing and changing wire 41
2.10 Installing and replacing feed rolls 47
2.11 Installing and replacing wire guide tubes 51
2.12 Installing gas bottle and testing gas flow 53
2.13 How to get welding programs 55
2.14 Other optional accessories 56
3. Operation 60
3.1 Preparing welding system for use 61
3.1.1 Filling cooler and circulating coolant 62
3.1.2 Calibrating welding cable 62
3.2 Using X5 Manual control panel 63
3.2.1 Manual control panel: Settings 64
3.3 Using X5 Auto control panel 68
3.3.1 Auto control panel: Home view 69
3.3.2 Auto control panel: Memory channels 70
3.3.3 Auto control panel: Weld history 71
3.3.4 Auto control panel: Welding parameters 72
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X5 FastMig
Operating manual - EN
3.3.5 Auto control panel: Info view 76
3.3.6 Auto control panel: Weld data view 77
3.3.7 Auto control panel: System settings 78
3.3.8 Auto control panel: Applying welding programs 79
3.4 Additional guidance to functions and features 82
3.4.1 Trigger logic functions 82
3.4.2 WiseFusion 82
3.4.3 WisePenetration+ 83
3.4.4 WiseSteel 83
3.4.5 WeldEye with DCM (optional) 84
3.5 Using remote control 86
3.6 Lifting X5 equipment 87
4. Maintenance 89
4.1 Daily maintenance 90
4.2 Periodic maintenance 91
4.3 Service workshops 92
4.4 Troubleshooting 93
4.5 Error codes 95
4.6 Installing and cleaning power source air filter (optional) 97
4.7 Disposal 99
5. Technical data 100
5.1 X5 Power sources 101
5.2 X5 Wire feeders 105
5.3 X5 Cooling unit 107
5.4 X5 Ordering info 108
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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
welding power sources, wire feeders and cooling unit (optional) designed for demanding professional use in
MIG/MAG welding.
The equipment is intended for manual MIG/MAG welding as well as automatic 1-MIG welding with X5 FastMig Syn-
ergic. The 1-MIG function is accompanied by welding programs, work packs and also the WiseSteel, WiseFusion and
WisePenetration+ features as optional.
X5 FastMig systems:
Wire feeder
300 Manual 300 Auto
Power source
400 X5 FastMig Manual 400 X5 FastMig Synergic 400
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, for TIG welding*.
* 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
attention 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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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" on page9.
X5 wire feeders:
•X5 Wire Feeder 300 Manual
>> Comes with 2-knob membrane control panel
•X5 Wire Feeder 300 Auto
>> Comes with 2-knob 5.7" TFT/LCD control panel
>> Includes automatic 1-MIG process that supports welding programs and Wise features
For the wire feeder part descriptions, refer to "X5 Wire feeder" on page11, "X5 Wire spools and hubs" on page13 and
"X5 Wire feed mechanism" on page13.
For the control panel descriptions, refer to "X5 Manual control panel (X5 FP 300R)" on page14 and "X5 Auto control
panel (X5 FP 300)" on page15.
X5 cooling units:
•X5 Cooler, 1 kW.
For the cooling unit part descriptions, refer to "X5 Cooling unit (optional)" on page18.
MIG welding guns:
•Flexlite GX welding guns.
For more information on the Flexlite GX welding guns, refer to Kemppi Userdoc.
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.
Optional accessories:
•4-wheel cart with gas bottle rack
•2-wheel cart
•Wire feeder cart
•Wire feeder rotating plate, single and double
•Wire feeder hanger for boom, single and double
•Wire feeder counterbalance arm
•Wire feeder cabinet heater
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•Gun holder
•Remote control
•Accessory rack
•Wire drum kit.
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56.
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1.2 X5 Power source
This section describes the structure of X5 power sources.
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 auto-
matically 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.
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X5 FastMig
Operating manual - EN
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.
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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1.3 X5 Wire feeder
This section describes the structure of the X5 Wire Feeder 300 Manual 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 "X5 Auto control panel (X5 FP
300)" on page15.
>> For more information on the X5 Wire Feeder 300 Manual control panel, refer to "X5 Manual control panel (X5
FP 300R)" on page14.
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)
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Inside wire feeder (wire feeder cabinet)
1. Wire spool
>> For more information on the wire spools, refer to "X5 Wire spools and hubs" 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, or flush out the gas.
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
For installing and connecting the cables, refer to "X5 Interconnection cable" on page16 and "Installing cables" on
page34.
Wire feeder fixing accessories
X5 Wire Feeder 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
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•Rotating plate with counter-balance arm for one wire feeder.
1.3.1 X5 Wire spools and hubs
X5 FastMig 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.
1.3.2 X5 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.
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For replacing the wire feed rolls, refer to "Installing and replacing feed rolls" on page47.
For replacing the wire guide tubes, refer to "Installing and replacing wire guide tubes" on page51
1.4 X5 Manual control panel (X5 FP 300R)
This section describes the controls and features of the X5 Wire Feeder 300 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
For using the control panel, refer to "Using X5 Manual control panel" on page63.
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1.5 X5 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68.
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1.6 X5 Interconnection cable
The X5 FastMig interconnection cables come in multiple different lengths and configurations to suit your equipment
setup.
For installing the interconnection cable, refer to "Installing cables" on page34.
With water-cooling
(PS = Powersource 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 = Powersource 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.
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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
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1.7 X5 Cooling unit (optional)
Front:
1. Cooler container cap
2. Cooling liquid level indicator
3. Front locking interface (for locking on the cart)
4. Front locking interface (for locking to the power source)
5. Rear locking interace (for locking to the power source)
6. Cooling liquid circulation button
>> Keeping the button pressed activates the pump and circulates the cooling liquid throughout the system.
Once released, the pump stops.
Rear:
7. Coolant inlet/outlet connector (color-coded)
8. Coolant inlet/outlet connector (color-coded)
9. Rear locking interface (for locking on the cart)
10. Cooling unit to power source connectors
11. Additional strain relief mount.
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2. INSTALLATION
Do not connect the equipment to the mains before the installation is complete.
Do not modify the welding equipment in any way, except for the changes and adjustments covered in the man-
ufacturer’s instructions.
Do not attempt to move or hang the equipment mechanically (e.g. with a hoist) from the handle on the power source
unit or on the wire feeder unit. The handles are for manual moving only.
When installing the full set of equipment stacked as a tower – water cooler at the bottom, power source in the middle
and wire feeder at the top – always install and secure the equipment onto a Kemppi cart compatible with X5 FastMig
or secure the equipment to other adequate support on site.
When installing the full set of equipment stacked as a tower and using the double wire feeder rotating plate or coun-
terbalance arm, always use the broader front roller support plate delivered with the equipment. This applies to the 4
wheel cart.
Place the machine on a horizontal, stable and clean ground. Protect the machine from rain and direct sunshine. Check
that there is enough space for cooling air circulation in the machine vicinity.
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Before installation
•Make sure to acknowledge and follow the local and national requirements regarding installation and use of
high voltage units.
•Check the contents of the packages and make sure the parts are not damaged.
•Before you install the power source on site, see the requirements for the mains cable type and fuse rating.
Distribution network
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the pub-
lic low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those loc-
ations, due to conducted as well as radiated radio-frequency disturbances.
X5 power source 400A: Provided that the short circuit power of public low voltage system at the point of common
coupling is higher than 5.8 MVA, this equipment is compliant with IEC 61000-3-11:2017 and IEC 61000-3-12:2011
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.
X5 power source 500A: Provided that the short circuit power of public low voltage system at the point of common
coupling is higher than 6.4 MVA, this equipment is compliant with IEC 61000-3-11:2017 and IEC 61000-3-12:2011
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.
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2.1 Installing power source mains plug
Only an authorized electrician is allowed to install the mains cable and plug.
Do not connect the machine to the mains before the installation is complete.
Install the 3-phase plug according to the X5 FastMig power source and site requirements. Refer also to "Technical
data" on page100 for power source specific technical information.
The mains cable includes the following wires:
1. Brown: L1
2. Black: L2
3. Grey: L3
4. Yellow-green: Protective earth
Cable type and fuse rating requirements:
Unit amperage High voltage version (380-460V)
Cable type Fuse rating
400 A 4 mm225 A
500 A 6 mm232 A
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