Kemppi Flexlite GF User manual

Flexlite GF
Operating manual - EN
Flexlite GF
© Kemppi 11921590 / 2109

Flexlite GF
Operating manual - EN
CONTENTS
1. General 3
2. About equipment 4
3. Installation 5
3.1 Assembling gun 6
3.2 Connecting gun 7
3.3 Installing and replacing wire liner 9
3.4 Installing and removing grip handle (optional) 14
3.5 Replacing and adjusting vacuum nozzle 15
3.6 Replacing vacuum hose cover 16
4. Operation 17
4.1 Measuring and decreasing fume extraction air flow 18
4.2 Optimizing fume extraction efficiency 19
5. Maintenance 21
5.1 Troubleshooting 22
5.2 Disposal of machine 24
6. Technical data 25
6.1 Technical data: Flexlite GF 300 A (gas-cooled) 26
6.2 Technical data: Flexlite GF 300 A (water-cooled) 28
6.3 Technical data: Flexlite GF 400 A (gas-cooled) 30
6.4 Technical data: Flexlite GF 400 A (water-cooled) 32
6.5 Technical data: Flexlite GF 400 A Carsat (water-cooled) 34
7. Ordering codes 36
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Flexlite GF
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's Flexlite GF MIG fume extraction welding guns. Flexlite GF welding
guns capture welding fumes at the arc, cleaning the welder’s breathing zone. Flexlite GF range covers both water-
cooled and gas-cooled models for MIG welding.
Fume extraction guns are used in conjunction with a fume extraction unit. The Flexlite GF welding guns are com-
patible with fume extraction units of most major manufacturers. For more information, refer to the fume extraction
unit manufacturer's documentation.
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.
Warning: Describes a potentially dangerous situation. If not avoided, it will result in personal damage or fatal injury.
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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Flexlite GF
Operating manual - EN
2. ABOUT EQUIPMENT
The Flexlite GF MIG welding gun equipment consists of:
The exact visual details may be different between different Flexlite GF models.
1. Vacuum nozzle
2. Gas nozzle
3. Contact tip
4. Contact tip adapter / gas diffuser
5. Gun neck
6. Trigger switch
7. Handle
8. Gun connector
9. Coolant inlet and outlet hose connectors
>> With water-cooled welding guns only.
EQUIPMENT IDENTIFICATION
Serial number
Serial number of the device is marked on the rating plate or in another distinctive location on the device. It is
important to make correct reference to the serial number of the product when ordering spare parts or mak-
ing repairs for example.
Quick Response (QR) code
Device-related information or a web link to such information may be found in the form of a QR code on the
device. The code can be read, for example, with a mobile device camera and a QR code application.
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Flexlite GF
Operating manual - EN
3. INSTALLATION
Ensure that the welding equipment is not connected to the mains or that the welding gun is not connected to the weld-
ing machine until the installation is complete.
Protect the equipment from rain and direct sunshine.
"Assembling gun" on the next page
"Connecting gun" on page7
"Installing and replacing wire liner" on page9
"Installing and removing grip handle (optional)" on page14
"Replacing and adjusting vacuum nozzle" on page15
"Replacing vacuum hose cover" on page16
Before installation and use
Ensure compliance with your local and national safety requirements regarding the installation and use of high
voltage units.
Check the contents of the packages and make sure the parts are not damaged.
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Flexlite GF
Operating manual - EN
3.1 Assembling gun
For component selection, refer to the product catalogue at Kemppi.com.
Tools needed:
8mm
1. Attach the contact tip adapter and hand-tighten it firmly in place. It is important to tighten the adapter properly
to enable a tight connection of the contact tip to the gun.
2. Attach the contact tip and secure it with the 8 mm spanner.
3. Attach the gas nozzle and hand-tighten it firmly in place.
4. Attach the vacuum nozzle so that the locking pin snaps into one of the three holes. The holes are at different
points for adjusting the vacuum nozzle lengthwise.
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Operating manual - EN
3.2 Connecting gun
Hand-tighten the gun connectors. Loose connectors may overheat, create contact disturbances, mechanical damage
and water or gas leakage.
For connecting the gun (and applicable extension parts), refer also to your welding equipment’s instructions.
If not already preinstalled, the wire liner must be installed before connecting the gun. Refer to "Installing and replacing
wire liner" on page9 for instructions.
1. Connect the gun to your welding equipment. Secure the connector in place by turning the collar clockwise.
2. Water-cooled models only: Connect the coolant inlet and outlet hoses to your welding equipment. Note that the
connectors are color-coded.
Make sure to connect the coolant hoses to the correct hose connectors. If the connections cross, the welding gun may
overheat.
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Operating manual - EN
3. Connect the gun's vacuum hose to the hose connected to the fume extraction unit. If necessary, secure the con-
nection with tape.
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Flexlite GF
Operating manual - EN
3.3 Installing and replacing wire liner
The Flexlite GF MIG welding gun cable packs are delivered with the wire liner preinstalled. Refer to this section when
the wire liner needs to be replaced.
The wire liner is a consumable part, which needs to be changed if worn and when the filler wire material changes.
If you change the filler wire to a different diameter or material, change also the feed rolls accordingly.
With most of the Flexlite GF welding gun models both steel spiral wire liner and DL Chili wire liner can be used.
However, note the following:
- Separate DL Chili wire liner options exist for water-cooled and gas-cooled Flexlite GF welding guns.
The filler wire must be removed before the wire liner replacement.
Tools needed:
Removing and inserting wire liner
1. Straighten the welding gun cable.
2. At the wire feeder end of the cable, remove the wire liner's end cap, sleeve nut and retainer cone.
3. If you are replacing an existing wire liner with a new one, remove the old wire liner from the cable hose.
If you still plan to use the same wire liner later, make sure not to damage the wire liner at this stage.
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Flexlite GF
Operating manual - EN
4. Feed the new wire liner into the cable hose until it stops at the gun neck end.
Ensure that the contact tip adapter and contact tip are in place at this stage. Otherwise, depending on the welding
gun model, the wire liner will go through without stopping.
To ensure that the wire liner is in the correct position, temporarily remove the welding gun contact tip. For more
information on the contact tip, refer to "About equipment" on page4 and "Assembling gun" on page6.
Steel spiral: Cutting wire liner and installing sleeve assembly
1. Cut off the fixed sleeve nut at the end of the wire liner.
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Operating manual - EN
2. Insert the sleeve nut (delivered with the wire liner) without end cap and retainer cone on the wire liner and
tighten it temporarily in place for measure.
3. Cut the wire liner flush with the sleeve nut end.
Cut the excess of the steel spiral liner with side cutting pliers.
4. Remove the sleeve nut.
5. Steel spiral wire liner only: File the end of the liner.
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Operating manual - EN
Don't leave any rough edges that could potentially damage the filler wire.
6. Insert first the retainer cone and then the sleeve and end cap on the wire liner. Tighten the sleeve and end cap
in place.
DL Chili: Cutting wire liner and installing sleeve assembly
1. Insert the sleeve nut (delivered with the wire liner) with the retainer cone on the wire liner and tighten it in
place.
2. Cut the wire liner flush with the sleeve nut end.
Cut the excess of the Chili liner with a carpet knife.
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Operating manual - EN
3. Insert first the retainer cone and then the sleeve and end cap on the wire liner. Tighten the sleeve and end cap
in place.
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Operating manual - EN
3.4 Installing and removing grip handle (optional)
The additional grip handle is available for all Flexlite GF MIG welding guns.
1. Keeping the bottom of the grip handle pointing forward, fit the inside grooves of the grip handle over the
screws on the gun.
2. Pull the handle backward to lock it in position.
To remove the grip handle, press the unlock button in the grip handle rear:
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Operating manual - EN
3.5 Replacing and adjusting vacuum nozzle
The vacuum nozzle is a consumable part, which needs to be changed if worn.
1. Remove the old vacuum nozzle by pressing the locking pin and pulling out the vacuum nozzle.
2. Attach the new vacuum nozzle so that the locking pin snaps into one of the three holes. The three holes are at
different points for adjusting the vacuum nozzle lengthwise.
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Flexlite GF
Operating manual - EN
3.6 Replacing vacuum hose cover
The Flexlite GF welding gun's vacuum hose comes with a leather cover, attached with cable ties. Refer to this section
when the vacuum hose leather cover needs to be replaced.
The vacuum hose leather cover is a consumable part, which needs to be changed if worn.
1. Remove the old leather cover.
2. Wrap the new leather cover around the vacuum hose.
3. Close the hook-and-loop fastener.
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Operating manual - EN
4. OPERATION
Before using the equipment, ensure that all the necessary installation actions have been completed according to
your equipment setup and instructions.
Welding is forbidden in places where there is an immediate fire or explosion hazard!
Welding fumes may cause injury. Take care to ensure sufficient ventilation during welding and wear respiratory pro-
tection!
Always check before use that interconnecting cable, shielding gas hose, earth return lead/clamp and mains cable are in
serviceable condition. Ensure that the connectors are correctly fastened. Loose connectors can impair welding per-
formance and damage connectors.
The exact function of the gun and trigger may vary depending on your welding machine settings (e.g. 2T, 4T or Mini-
log).
Before you start welding, measure and adjust the fume extraction airflow. Refer to "Measuring and decreasing fume
extraction air flow" on the next page.
With fume extraction on, hot fumes pass through the gun handle and affect the handle's temperature.
To start welding, press the trigger switch.
For component selection, refer to the product catalogue at Kemppi.com.
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Flexlite GF
Operating manual - EN
4.1 Measuring and decreasing fume extraction air flow
Fume extraction guns need to provide the appropriate amount of shielding gas to protect the weld from defects
without compromising the fume capture efficiency of the gun. If the fume extraction air flow is too strong, it cap-
tures shielding gas. If the fume extraction air flow is too weak, it doesn't capture welding fumes effectively enough.
Before welding, measure the fume extraction air flow with a fume extraction air flow meter (sold separately).
Measuring fume extraction air flow
1. Insert the vacuum nozzle of the welding gun into the fume extraction air flow meter.
2. Turn the fume extraction on.
>> The pointer rises to indicate the used fume extraction air flow rate.
For adjusting the fume extraction air flow at the fume extraction unit, refer to the operating manuals of the fume
extraction unit manufacturer.
Decreasing fume extraction air flow
To decrease the fume extraction air flow, use the air flow bypass valve at the gun handle.
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Operating manual - EN
4.2 Optimizing fume extraction efficiency
The following factors help maximizing the fume extraction efficiency of a Flexlite GF welding gun.
Welding positions and joint types
The most effective position for fume extraction is the flat position (on the left) because the fumes naturally rise
upward.
The following figures display how joint types affect fume capture efficiency. The best optimization is shown on the
left.
Wire material and gun angle
When welding with solid wires, weld with a 0 ... 15° pushing gun angle.
When welding with flux-cored wires, weld with a 0 ... 15° pulling gun angle.
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Operating manual - EN
Removal of residual fumes
At the end of welding, hold the fume extraction gun in place for 10 ... 15 seconds. This allows the gun to remove
residual fumes as the weld is cooling.
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