Kemppi SuperSnake GTX User manual

SuperSnake GTX
Operating manual - EN
SuperSnake GTX
Operating manual
© Kemppi 11921930 / 2144

SuperSnake GTX
Operating manual - EN
CONTENTS
1. General 3
1.1 Equipment description 4
2. Installation 8
2.1 Subfeeder installation 9
2.2 Feed roll pressure adjustment 13
2.3 Connecting subfeeder 15
2.4 Installing subfeeder into protective frame 18
2.5 Preparing filler wire 20
2.6 Loading filler wire into subfeeder 21
2.7 Shielding gas setting 22
2.8 Cooling unit preparation 23
3. Maintenance 24
3.1 Wire liner replacement 26
3.2 Disposal 31
4. Technical data 32
4.1 SuperSnake GTX technical data 32
4.2 Feed roll kit selection 33
4.3 Wire liner selection 34
4.4 Ordering 35
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SuperSnake GTX
Operating manual - EN
1. GENERAL
Kemppi SuperSnake GTX is a subfeeder device designed for professional use in MIG/MAG welding. When used together
with the protective frame, SuperSnake GTX is especially robust and durable in hard-to-reach welding conditions.
SuperSnake GTX compatible equipment:
•X5 FastMig with X5 Wire Feeder 300 Auto+ wire feeder
•Other X5 FastMig wire feeder equipment with dedicated subfeeder installation kit (contact your Kemppi dealer for
more information on compatibility).
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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SuperSnake GTX
Operating manual - EN
1.1 Equipment description
Kemppi SuperSnake GTX subfeeder is a combined solution for distance wire feeding and restricted access welding with
or without water cooling. It extends the reach of MIG/MAG welding guns up to 30 meters, providing simple distance
wire feeding for a variety of filler wires.
SuperSnake GTX subfeeder is delivered with Kemppi's steel spiral wire liner by default. DL Chili wire liner is available as
an option.
If the SuperSnake GTX subfeeder is not available in your X5 FastMig welding equipment's subfeeder settings, the
equipment firmware must be updated to the latest release version.
System
Subfeeder equipment:
1. SuperSnake GTX subfeeder
2. SuperSnake GTX protective frame
3. SuperSnake GTX interconnection cable
Other equipment:
4. MIG/MAG welding gun
5. Voltage sensing cable
Subfeeder face
1. Pressure arm locking and adjusting mechanism
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SuperSnake GTX
Operating manual - EN
2. Wire feed roll (drive roll)
3. Wire feed roll (pressure roll)
4. Wire outlet guide tube
5. Wire inlet guide tip
6. Subfeeder control panel
>> Displays for wire feed speed / welding current and for fine tuning
>> Error indicator (red), warning indicator (yellow)
7. Control knobs
>> A: Wire feed speed and/or welding current
>> B: Fine tuning (e.g. voltage, depending on welding process)
Automatic control knob activation: When the control knobs are not used, they are automatically deactivated to pre-
vent accidental changing of welding parameters. The control knob functions are activated again by turning either of
the control knobs a quarter of a turn. When active, the LED indicator between the control knobs turns green.
8. Wire inch and Gas test buttons
9. Welding ON/OFF indicator (lock)
>> Lock symbol is lit if the welding is turned off from the switch (10)
10. Welding ON/OFF switch
>> Prevents welding with the subfeeder if set to OFF.
The welding ON/OFF switch doesn't power down the subfeeder.
Subfeeder front connections
1. Welding cable Euro connector (for welding gun)
2. Control cable connector (e.g. for remote control)
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Operating manual - EN
Subfeeder rear connections
1. Welding cable Euro connector (for interconnection cable from wire feeder)
2. Control cable connector (for interconnection cable from wire feeder)
3. Subfeeder synchronization cable connector (for interconnection cable from wire feeder)
Interconnection cable
1. Welding cable (with Euro connector)
2. Control cable
3. Subfeeder synchronization cable
4. Voltage sensing cable
5. Coolant hoses
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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 making
repairs for example.
Quick Response (QR) code
The serial number and other device-related identification information may also be saved in the form of a QR
code (or a barcode) on the device. Such code can be read by a smartphone camera or with a dedicated code
reader device providing fast access to the device-specific information.
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Operating manual - EN
2. INSTALLATION
Do not power on the equipment before the mechanical installation is complete.
Place the equipment on a stable and clean ground, the subfeeder control panel facing up. Protect the equipment
from rain and direct sunshine.
Before installation and use
Disconnect the welding machine from the mains before starting the subfeeder installation.
Always check before use that welding cables, shielding gas hose, earth return cable/clamp and mains cable are in ser-
viceable condition. Ensure that the connectors are correctly fastened. Loose connectors can impair welding per-
formance and damage connectors.
•The product is packed in specially designed transport cartons. However, always before use make sure the products
have not been damaged during transportation.
•Check also that you have received the components you ordered and that the operating manuals are available.
•Straighten the subfeeder cable by carrying the subfeeder close to the work place.
•Before loading the filler wire, ensure that there are no tight bends in the cable.
•Ensure that the correct wire liner is fitted and installed correctly for the intended welding application.
•Before welding, ensure that the installation as well as the filler wire, shielding gas, cooler and voltage sensing cable
preparations are completed.
Lifting subfeeder
SuperSnake GTX subfeeder can be lifted with a hoist and a 4-legged strap connected to the corners of the protective
frame. Without the protective frame, lifting the subfeeder with a hoist is not possible.
For lifting, temporarily coil the cables and tie them to the hoist hook (as applicable) so that the full weight of the cables
doesn't rest solely on the subfeeder connectors.
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Operating manual - EN
2.1 Subfeeder installation
Before connecting or loading the filler wire into the subfeeder, the wire feed rolls must be installed and the mechanism
must be set. Ensure that the feed rolls suit the filler wire size and type. Refer to "Feed roll kit selection" on page33 for
more information.
It is not recommended to use knurled feed rolls in the main wire feeder unit when using the SuperSnake GTX sub-
feeder. They may apply too much friction on the filler wire at the wire feeder end preventing the best possible out-
come with the SuperSnake GTX subfeeder.
The subfeeder is delivered with a standard wire line component kit and with steel spiral wire liner, if not specified oth-
erwise. Feed rolls are purchased separately. Ensure you have the correct components and feed rolls available and
installed.
Tools needed:
1. Open the feed mechanism door.
2. Release the pressure arm by lifting it up from the end.
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3. Remove the feed roll fixing pins (B) by pulling them up.
4. Install the wire inlet guide tip. Secure the component in place with a spanner.
5. Install the wire outlet guide by inserting it from the welding gun end of the subfeeder.
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6. Mount the drive roll in place, cogged roll section down, and secure the fixing pin/cap.
Make sure that the groove on the bottom of the roll aligns with the crossing pin on the drive shaft.
7. Mount the pressure roll in place, cogged roll section down, and secure the fixing pin/cap.
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8. Close the pressure arm.
For adjusting the feed roll pressure, refer to "Feed roll pressure adjustment" on the next page.
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Operating manual - EN
2.2 Feed roll pressure adjustment
Adjust the feed roll pressure with the adjustment roller mounted on the pressure arm. The load applied should be suf-
ficient to overcome a light braking force applied by hand to the filler wire as it exits the welding gun contact tip.
For smaller diameter and soft filler wires, less feed pressure is required. Refer to the table in the end of this chapter for
further guidance.
1. Release the pressure arm by lifting it up.
2. If not already in place, install the wire feed rolls as described in "Subfeeder installation" on page9.
3. Turn the roller adjuster on the pressure arm to adjust the feed roll pressure.
>> A graduated scale next to the adjustment roller indicates the pressure load in newtons (N).
>> For the correct pressure, refer to the table in the end of this section.
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4. Lock the adjustment by closing the pressure arm.
Excessive pressure flattens the filler wire and may damage coated or cored filler wires. Excessive pressure also unne-
cessarily wears the feed rolls and increases gearbox load.
The use of knurled feed rolls in the main wire feeder unit when the SuperSnake GTX subfeeder is in use is not recom-
mended.
When the SuperSnake GTX subfeeder is selected in the X5 FastMig welding equipment settings, the wire inch feature
will feed the wire automatically to the system when the Wire inch button on the wire feeder is pressed.
Filler wire
types Feed roll profile Filler wire diameter, ø mm
Interconnection cable*, length
m
Adjustment
(x100N)
Fe, Ss V-groove 1.0...1.4 10...20 2.0
1.0...1.4 25 2.5
Fe V-groove,
knurled
1.6 10...25 1.5
Fc, Mc V-groove,
knurled
1.2...1.6 10...25 1.5
Al U-groove 1.2...1.6 10...20 2.0
1.2...1.6 25 2.5
* SuperSnake GTX interconnection cable.
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2.3 Connecting subfeeder
The welding cable with Euro connector transfers welding power, shielding gas and filler wire. The separate control cable
connection is used for additional welding controls (e.g. remote control).
All of the subfeeder cables should be connected before installing the subfeeder into the protective frame. Refer to
"Installing subfeeder into protective frame" on page18.
If voltage sensing cable and/or water cooling is used, the subfeeder must be turned upside down for correct cable
routing and connections.
1. Connect the subfeeder interconnection cable (welding cable, control cable and synchronization cable) to the sub-
feeder. Secure the cables by hand tightening the collars.
2. Connect the welding gun to the subfeeder. Secure the welding cable by hand tightening the collar.
To ensure reliable welding performance, please ensure the gun is suitable for the intended welding application and is
in good working order, correctly fitted with suitable wire liner components and contact tip as well as with the water
cooling hoses.
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3. If water cooling is used, connect and route the cooling hoses under the brackets on the subfeeder bottom. Cooling
hoses are color-coded.
4. If voltage sensing cable is used, connect and route the cable under the brackets on the subfeeder.
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5. If the protective frame is used, refer to "Installing subfeeder into protective frame" on the next page.
6. Connect the subfeeder interconnection cable to your welding equipment. Refer to your welding equipment's oper-
ating instructions for more details (X5 FastMig: here).
7. On your wire feeder's user interface, select SuperSnake GTX subfeeder and the subfeeder interconnection cable
length. Refer to your welding equipment's operating instructions for more details (X5 FastMig: here).
If the SuperSnake GTX is not available in the settings, and you're using compatible welding equipment, your welding
equipment's firmware must be updated to the latest release version.
When you continue welding without the subfeeder, change the subfeeder setting accordingly.
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2.4 Installing subfeeder into protective frame
The protective frame provides support and protection for the subfeeder itself as well as for the cables connected.
All of the subfeeder cables should be connected before installing the subfeeder into the protective frame.
1. Place the protective frame on a flat surface upside down and open the bottom hatch.
>> To release the locking mechanism, pull the latches on one side towards the center and lift that side up.
2. Lift the fully connected subfeeder upside down into the protective frame. Ensure that:
>> The Euro connector housings in both ends of the subfeeder sits firmly on the pads in the protective frame.
>> The groove in the interconnection cable collar aligns with the support bracket in the end of the protective
frame.
3. Close the hatch so that the locking mechanism latches lock properly in place. Ensure that:
>> The cables are routed properly and don't get caught between the frame and the hatch.
>> The supports incorporated in both ends of the hatch provide additional support for the main cables.
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4. Turn the subfeeder assembly back the right way around (subfeeder face up).
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2.5 Preparing filler wire
Install the wire spool into the wire feeder according to the wire feeder operating instructions. Note also the following:
Sharp edges on the filler wire tip may damage the wire liner.
Cut off any deformed section and with a fine file or abrasive cloth, remove any sharp edges from the filler wire end,
before loading into the subfeeder.
Ensure that the end of the filler wire is straight and without any bends or edges.
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