Kemppi Flexlite GX Series User manual

Flexlite GX
Operating manual - EN
Flexlite GX
© Kemppi 11921390 / 2310

Flexlite GX
Operating manual - EN
CONTENTS
1. General 3
2. About equipment 5
3. Installation 7
3.1 Assembling gun 8
3.2 Installing gun remote 9
3.3 Connecting gun 11
3.4 Installing and replacing wire liner 12
3.4.1 Replacing DL Chili wire liner 12
3.4.2 Replacing steel wire liner 16
3.4.3 Replacing wire liner for multi-neck 21
3.5 Trigger switch replacement 24
3.5.1 Trigger switch setting (GX series 5) – W015263 until 9/2020 25
3.5.2 Trigger switch setting (GX series 5) – W015263 since 10/2020 26
3.5.3 Trigger switch setting (GX series 5) – W022322 28
3.6 Installing and removing grip handle (optional) 30
3.7 Adjusting and tightening neck (gas-cooled models) 31
4. Operation 32
4.1 Using gun remote GXR10 (series 5) 33
4.2 Using gun remote GXR80B (series 8) 34
5. Maintenance 36
5.1 Troubleshooting 38
5.2 Disposal 40
6. Technical data 41
6.1 Technical data: Flexlite GX 200A/250A (gas-cooled) 42
6.2 Technical data: Flexlite GX 300A/350A (gas-cooled) 44
6.3 Technical data: Flexlite GX 250A/300A (water-cooled) 46
6.4 Technical data: Flexlite GX 400A (gas-cooled) 48
6.5 Technical data: Flexlite GX 300A/400A/420A (water-cooled) 50
6.6 Technical data: Flexlite GX 500A/520A (water-cooled) 52
6.7 Technical data: Flexlite GX 600A (water-cooled) 54
6.8 Technical data: Flexlite GX HD 300A (gas-cooled) 56
6.9 Technical data: Flexlite GX HD 400A (gas-cooled) 58
6.10 Component selection 60
7. Ordering codes 62
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Flexlite GX
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's Flexlite GX MIG welding guns. Flexlite GX welding guns are designed for
professional manual welding. Flexlite GX range covers both water-cooled and gas-cooled models for MIG welding. Flexl-
ite GX welding guns are available in three different series – 3, 5 and 8 – each designed to serve specific welding needs.
Flexlite GX models
Series 3*: Series 5**: Series 8***:
GX 203G GX 205G GX 208GMN
GX 253G GX 255G GX 308GMN
GX 303G/W GX 305G/W GX 408GMN
GX 303GHD GX 305GHD GX 428W
GX 403G/W GX 305GMN GX 428WS
GX 403GHD GX305GS GX 528W
GX 503W GX305WS GX 608W
GX 405G/W
GX 405GHD
GX 405WS
GX 505W
GX 605W
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Flexlite GX
Operating manual - EN
* Series 3 welding gun models are compatible with the majority of welding equipment.
** Series 5 welding gun models are designed for Kemppi Fastmig equipment with limited support to other models.
*** Series 8 welding gun models are compatible with Kemppi X8 MIG Welder.
In model names:G = gas-cooled, W = water-cooled, MN = multi-neck, S = long cable, HD = heavy-duty.
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.
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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Flexlite GX
Operating manual - EN
2. ABOUT EQUIPMENT
The Flexlite GX MIG welding gun equipment consists of:
The exact visual details may be different between different Flexlite GX models.
1. Gas nozzle
2. Contact tip
3. Contact tip adapter / gas diffuser
4. Gun neck
5. Handle
6. Trigger switch
7. Cover plate
>> This covers the handle if a welding gun remote is not used (Flexlite GX series 5 and series 8 models). For more
information on the gun remotes, refer to "Installing gun remote" on page9.
>> Not available with Flexlite GX series 3 models.
8. Gun connector
9. Coolant inlet and outlet hose connectors
>> With water-cooled welding guns only.
10. Neck tightening collar
>> With multi-neck welding guns only.
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Flexlite GX
Operating manual - EN
11. Additional grip handle
EQUIPMENT IDENTIFICATION
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 GX
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
welding machine until the installation is complete.
Protect the equipment from rain and direct sunshine.
"Assembling gun" on the next page
"Installing gun remote" on page9
"Connecting gun" on page11
"Replacing steel wire liner" on page16
"Replacing wire liner for multi-neck" on page21
"Installing and removing grip handle (optional)" on page30
"Adjusting and tightening neck (gas-cooled models)" on page31
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 GX
Operating manual - EN
3.1 Assembling gun
For the correct components, refer to "Component selection" on page60.
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.
With multi-neck gun models only:
4. Attach the assembled neck to the gun body. Secure with the neck tightening collar.
Hand-tighten the neck tightening collar only. Over-tightening and/or using a tool can damage the gun components.
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Flexlite GX
Operating manual - EN
3.2 Installing gun remote
The Flexlite GX series 5 welding gun remote (GXR10) can be used with Kemppi Fastmig equipment only.
The Flexlite GX series 8 welding gun and digital gun remote (GXR80B) can be used with Kemppi X8 MIG Welder only.
Ensure that the welding equipment is not connected to the mains or that the welding gun is not connected at this
stage.
Tools needed:
TX20
1. Remove the cover by releasing the screws on the sides and then moving the cover slightly forward and up.
2. Remove the existing circuit board chip from the connectors inside the gun.
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Operating manual - EN
3. Set the new gun remote control cover against the gun body slightly off to the front and slide it backward so that
the connectors (*) align and connect.
4. Secure the remote control cover in place with the screws from the sides.
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Operating manual - EN
3.3 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 "Replacing steel wire
liner" on page16 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
3.4 Installing and replacing wire liner
The Flexlite GX MIG welding gun cable packs are delivered with the wire liner preinstalled, except the S-models (long
cable packages). Refer to this section when the wire liner needs to be replaced or when taking a Flexlite GX S-model in
use.
The wire liner is a consumable part, which needs to be changed if worn and when the filler wire material changes.
For replacing the steel wire liner, refer to "Replacing steel wire liner" on page16.
For replacing the DL Chili wire liner, refer to "Replacing DL Chili wire liner" below.
For the multi-neck wire liner replacement, refer to "Replacing wire liner for multi-neck" on page21 in conjunction with
the main wire liner replacement instructions.
If you change the filler wire to a different diameter or material, change also the feed rolls in the wire feed system
accordingly.
With most of the Flexlite GX welding gun models both steel wire liner and DL Chili wire liner can be used. However,
with Flexlite GX S-models, it is recommended to use only DL Chili wire liners.
The filler wire must be removed before the wire liner replacement.
This replacement instruction applies to wire liners with a joint end cap and sleeve nut assembly (A). For replacing a wire
liner using a separate end cap and sleeve nut assembly (B), refer to the instructions here (pdf). Always read the instruc-
tions delivered with the replacement wire liner as well.
3.4.1 Replacing DL Chili wire liner
Tools needed:
Removing and inserting wire liner
This same method applies to both Euro connector (GX series 3 and 5) and Kemppi connector (GX series 8) welding guns, but
the visual details may vary. The method is the same also for both gas- and water-cooled welding guns.
1. Straighten the welding gun cable pack.
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Operating manual - EN
2. At the wire feeder end of the cable, remove the wire liner's sleeve nut and retainer cone.
The GX series 8 welding gun has a long sleeve nut and the series 8 GMN, WS and 608W models include also an addi-
tional sealing ring (*). Remove that also.
3. 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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Operating manual - EN
4. Feed the new wire liner into the cable hose until it stops at the gun neck end.
The standard DL Chili wire liner includes a short metal spiral section at its front end. This metal spiral end goes in
first. The DL Chili wire liner for a multi-neck welding gun does not include the metal spiral section.
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5 and "Assembling gun" on page8. In case of a
multi-neck welding gun, the wire liner does not go into the neck. With a multi-neck welding gun, the neck is to be
removed (refer to "Replacing wire liner for multi-neck" on page21).
For finalizing the wire liner installation, refer to (depending on your welding gun model):
"Installing sleeve assembly and cutting wire liner (Euro connector:series 3 and series 5 welding guns)" below or
"Installing sleeve assembly and cutting wire liner (Kemppi connector:series 8 welding guns)" on the next page.
Installing sleeve assembly and cutting wire liner (Euro connector:series 3 and series 5 welding
guns)
The method is the same for both gas- and water-cooled welding guns.
1. Insert the sleeve nut next to the wire liner for measure.
2. Using carpet knife, cut the wire liner flush with groove in the sleeve nut end.
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Operating manual - EN
3. Insert the retainer cone onto the wire liner and push in place.
4. Place the sleeve nut on the wire liner and secure it in place. Tighten to 12 Nm torque.
Installing sleeve assembly and cutting wire liner (Kemppi connector:series 8 welding guns)
The method is the same for both gas- and water-cooled welding guns, except for the additional sealing ring with the below-
mentioned models.
1. Temporarily remove the end cap from the long sleeve nut.
2. Insert the retainer cone and sleeve nut (without end cap) on the wire liner and secure them in place. Tighten to 12
Nm torque.
All series 8 Flexlite GX models (Kemppi connector) include a longer wire liner sleeve. The series 8 GMN, WS and 608W
models include also an additional sealing ring (*):
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Operating manual - EN
3. Cut the wire liner flush with the sleeve nut end. Use a carpet knife for cutting.
4. Install the end cap. Tighten to 1 Nm torque.
3.4.2 Replacing steel wire liner
Tools needed:
Removing and inserting wire liner
This same method applies to both Euro connector (GX series 3 and 5) and Kemppi connector (GX series 8) welding guns, but
the visual details may vary. The method is the same also for both gas- and water-cooled welding guns.
1. Straighten the welding gun cable pack.
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Flexlite GX
Operating manual - EN
2. At the wire feeder end of the cable, remove the wire liner's sleeve nut and retainer cone.
The GX series 8 welding gun has a long sleeve nut and the series 8 GMN, WS and 608W models include also an addi-
tional sealing ring (*). Remove that also.
3. 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 GX
Operating manual - EN
4. Feed the new wire liner into the cable hose until it stops at the gun neck end.
The standard steel wire liner includes a stripped steel spiral section(*) at its front end. This section goes in first. The
steel wire liner for a multi-neck welding gun does not include a stripped section.
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5 and "Assembling gun" on page8. In case of a
multi-neck welding gun, the wire liner does not go into the neck. With a multi-neck welding gun, the neck is to be
removed (refer to "Replacing wire liner for multi-neck" on page21).
For finalizing the wire liner installation, refer to (depending on your welding gun model):
"Installing sleeve assembly and cutting wire liner (Euro connector:series 3 and 5 welding guns)" below or
"Installing sleeve assembly and cutting wire liner (Kemppi connector: series 8 welding guns)" on the next page.
Installing sleeve assembly and cutting wire liner (Euro connector:series 3 and 5 welding guns)
The method is the same for both gas- and water-cooled welding guns.
1. Insert the sleeve nut next to the wire liner for measure.
2. Using side cutting pliers, cut the wire liner flush with groove in the sleeve nut end.
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Operating manual - EN
3. File the end of the liner.
Don't leave any rough, inward edges that could potentially damage the filler wire.
4. Insert the retainer cone onto the wire liner and push it in place.
5. Place the sleeve nut on the wire liner and secure it in place. Tighten to 12 Nm torque.
Installing sleeve assembly and cutting wire liner (Kemppi connector: series 8 welding guns)
The method is the same for both gas- and water-cooled welding guns, except for the additional sealing ring with the below-
mentioned models.
1. Temporarily remove the end cap from the long sleeve nut.
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Flexlite GX
Operating manual - EN
2. Insert the retainer cone and sleeve nut (without the end cap) on the wire liner and secure them in place. Tighten to
12 Nm torque.
Series 8 Flexlite GX models (Kemppi connector) include a longer wire liner sleeve. The series 8 GMN, WS and 608W
models include also an additional sealing ring (*):
3. Cut the wire liner leaving 1-2 mm of excess liner measured from the sleeve nut end. Use side cutting pliers for cut-
ting.
4. File the end of the liner.
Don't leave any rough, inward edges that could potentially damage the filler wire.
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