OPERATING MANUAL 1920840 1843 EN X3 A7 MIG Welder
CONTENTS Read first.. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 4.2 Controlling the welding system.............................................................. 12 1.1 1.2 General. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 About X3 MIG Welder product series. . . . . . . ...................
READ FIRST 1.2 About X3 MIG Welder product series 1.1 General Congratulations on choosing the X3 MIG Welder series power source. Used correctly, Kemppi products can significantly increase the productivity of your welding, and provide years of economical service. This operating manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specifications of the device can be found at the end of the manual.
X3 MIG WELDER STRUCTURE 2.2 X3 Power Source 2.1 System introduction 1 7 10 8 2 9 3 • X3 Power Source • X3 Wire Feeder 300: The wire feeder can be installed as stand-alone, or it can be mounted on top of the power source with an optional X3 Wire Feeder Mounting Plate. • X3 Wheel Set / X3 Four Wheel Set (optional). The power source can be equipped with large rear wheels and/or a set of turning front wheels. • P20 undercarriage (optional) • Power supply for external gas heater 4 5 6 FRONT 1. 2. 3.
2.3 X3 Wire Feeder 1 3 4 2 1. 2. 3. 4. 5. Control panel Welding gun connection Shielding gas connection Control cable connection Welding current cable connection 5 INSTALLATION 3.1 Before use 3.2 Positioning of the machine Always make sure before use that the products have not been damaged during transportation. Place the machine on a sturdy, level surface that is dry and does not allow dust or other impurities to enter the machines cooling air flow.
3.4 Connecting cables All regular electrical devices without special circuits generate harmonic currents into distribution network. High rates of harmonic current may cause losses and disturbance to some equipment. X3 Power Source 400 / 400 AU This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 4.7 MVA at the interface point between the user’s supply and the public supply network.
3.4.2 Wire feeder connection 3.4.3 Earth return cable connection To connect the wire feeder to the power source, complete the following steps: Attach the earth return cable to the minus (–) connector. Hand tighten the connector with a clockwise push and twist action to lock. Attach the other end of the earth return cable to the workpiece before welding. 3 1 1. 2. 3.
3.5 Optional accessories 3.5.2 Undercarriage The X3 Power Source can be fitted with wheels for easy movement of the unit. To enable easy movement of the unit, the power source can be mounted on the P20 undercarriage. Installation instructions are delivered with the undercarriage package. x4 There are two different wheel sets available, one with big rear wheels only and another with big rear wheels and turning front wheels. Installation instructions are delivered with the wheel set package.
4. OPERATION 4.1.1 Mounting and locking the wire spool LOCKED 4.1.2 Adjusting the spool brake 4.1.3 Adjusting the pressure arms Brake force is adjusted through the hole behind the locking clip. Remove the locking clip by hand, and adjust the tension and pressure to the friction pads mounted inside with a screw driver. See diagram and location A. Adjust the drive pressure to the filler wire with the thumb screws mounted over the pressure arms. Notice the graduated scales indicating load.
4.1.4 Feeding the filler wire 4.1.5 Wire feed mechanism DuraTorque 400 Wire guide tubes ø mm Ss, Al, (Fe, Mc, Fc) plastic Fe, Mc, Fc metal 1. 2. 3. 4. Connect the welding gun and tighten the collar. Straighten about 20 cm of filler wire and ensure the tip has no sharp edges. File if necessary, as a sharp wire edge may damage the wire gun liner – particularly softer plastic liners. Present the filler wire tip to the back of the wire feed rolls and press the wire inch switch on the wire feed panel.
Wire feed rolls, metal ø mm Fe, Ss, (Al, Mc, Fc) V-groove Fc, Mc, (Fe) V-groove, knurled colour lower upper 0.6 W001045 W001046 0.8 – 0.9 W001047 W001048 1.0 W000675 W000676 1.2 W000960 W000961 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 W001063 W001064 W001065 W001066 1.0 W001067 W001068 1.2 W001069 W001070 1.6 W001071 W001072 2.0 2.
4.2 Controlling the welding system 4.2.1 Setup panel 4.2.3 LCD display Use the Setup panel on the X3 Power Source to change the settings of your welding system. Gas test button 2 Gas select button 3 Press to select between 2T and 4T gun trigger modes. 4 Crater fill button 5 Wire feed speed adjustment knob 6 Voltage adjustment knob Press to test the shielding gas flow. Press to select either CO₂ or mixed shielding gas (MAG).
4.2.5 Settings menu parameters Parameter Values CrE Creep start 1 = On / 0 = Off PrE Pre gas 1 = On / 0 = Off Pre gas Pre gas 1 = On / 0 = Off Pos Post gas 1 = On / 0 = Off Ign Hard ignition Makes the arc ignition stronger by increasing welding voltage at the start of the weld. 1 = On / 0 = Off HSt Hot stop 1 = On / 0 = Off Enhances the end of the weld in certain applications by delaying the arc extinction and raising the welding voltage at the end of welding.
Use the Control panel on the X3 Wire Feeder to adjust the welding parameters. Press the shielding gas selection button to set the shielding gas type to either CO₂ or mixed gas according to the gas you are using. The purpose of Crater fill is to facilitate controlled finishing of welding and to reduce the welding faults caused by the final crater. The Crater fill parameters can be specified in the Setup panel. Select CO₂ if you are using carbon dioxide. Select Ar + CO₂ (MAG) if you are using mixed gas.
4T mode • Pess the trigger – welding starts after preset Pre gas time. • Release the trigger – values drop to preset Crater fill level and welding ends after preset time. Post gas flows for preset time. 4T mode and Crater fill function MIG welding with 4T mode of the gun trigger. • Trigger pressed down – flow of shielding gas starts. • Trigger released – welding starts. • Trigger pressed down – welding ends and shielding gas flow continues. • Trigger released – flow of shielding gas ends.
4.6 Calibrating wire feed speed To calibrate the wire feed speed 1. At the power source control panel, press the Crater fill button for 3 seconds. 2. Cut the filler wire at the contact tip. 3. Press Wire Inch button at the wire feeder. Wire feed starts and continues for 12 seconds. To skip the calibration, do one of the following: • Exit the calibration mode by pressing Crater fill button for 3 seconds. • Exit the calibration mode by leaving the machine idle for 5 minutes.
TROUBLESHOOTING 6. Problem Cause The machine stops working. Overheating indicator is lit, and Err 4 is displayed. The machine has overheated. • Ensure that cooling air has unrestricted flow. • The machine’s duty cycle has been exceeded. If no other damage is caused, the fan starts working and the machine recovers within a couple of minutes. If the problem persists, please contact Kemppi service representative. Machine stops working. Err 2 or Err 3 is displayed.
TECHNICAL DATA X3 Power Source 400 / 400 AU 500 / 500 AU Mains connection voltage 3~, 50/60 Hz 380 – 440 V (–10 %…+10 %) 380 – 440 V (–10 %…+10 %) Mains connection cable H07RN-F 4 G4 4 G4 Rated power at max. current 60 % ED 17.6 kVA 24.5 kVA 100 % ED 12.
X3 Wire Feeder 300 U1 24 V Gun connection Euro Wire feed mechanism Filler wires 4-roll Fe 0.6 – 1.6 mm MC/FC 0.8 – 2.0 mm Wire feed speed 0 – 25 m/min Wire spool weight (max) 20 kg Wire spool diameter (max) 300 mm Operating temperature range –20...+40 °C Storage temperature range –40...
Fe 0.8 mm, CO₂ 4 8.0 11.5 14.0 16.0 18.0 V 14.5 17 18 21 24 A 45 60 80 110 140 160 170 190 N : < ; mm 1 1.5 2 3 4 m/min 2.8 4.0 5.0 8.0 11.5 14.0 16.0 18.0 V 14.5 16.5 17.5 20 A 50 70 90 120 150 160 180 200 N : < ; mm 1.2 1.5 2 3 4 6 8 m/min 2.2 3.0 4.3 6.0 7.3 9.7 12.0 15.0 18.0 V 16.5 18.0 19.5 22.2 24.0 27.3 31.0 35.0 38.0 A 60 85 120 150 170 200 230 260 285 N : < ; mm 1.2 1.5 2 3 4 6 8 m/min 2.2 3.0 4.3 6.0 7.3 9.7 12.0 14.5 18.
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