Kemppi SuperSnake GTX04HD User manual

SuperSnake GTX04HD
Operating manual - EN
SuperSnake GTX04HD
Operating manual
© Kemppi 11922220 / 2340

SuperSnake GTX04HD
Operating manual - EN
CONTENTS
1. General 3
1.1 Equipment description 4
2. Installation 7
2.1 Subfeeder installation 8
2.2 Feed roll pressure adjustment 12
2.3 Connecting subfeeder 13
2.4 Preparing filler wire 17
2.5 Loading filler wire into subfeeder 18
2.6 Shielding gas setting 19
2.7 Cooling unit preparation 20
3. Maintenance 21
3.1 Wire liner replacement 23
3.2 Disposal 28
4. Technical data 29
4.1 SuperSnake GTX04HD technical data 29
4.2 Feed roll kit selection 30
4.3 Wire liner selection 31
4.4 Ordering 32
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SuperSnake GTX04HD
Operating manual - EN
1. GENERAL
Kemppi SuperSnake GTX04HD is a robust and durable subfeeder device designed for professional use in MIG/MAG weld-
ing in hard-to-reach welding conditions. SuperSnake GTX04HD has a steel casing and a rigid steel pipe frame integrated
into the subfeeder device.
SuperSnake GTX04HD compatible equipment:
•X5 FastMig with X5 Wire Feeder 300/HD300 wire feeders
•Other X5 FastMig wire feeder equipment with dedicated subfeeder installation kit
•Master M 353, 355 and 358 welding 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 GTX04HD
Operating manual - EN
1.1 Equipment description
Kemppi SuperSnake GTX04HD 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 dis-
tance wire feeding for a variety of filler wires.
SuperSnake GTX04HD subfeeder is delivered with Kemppi's steel spiral wire liner by default. DL Chili wire liner is avail-
able as an option.
If the SuperSnake GTX04HD subfeeder is not available in your X5 FastMig or Master M (353, 355, 358) welding equip-
ment's subfeeder settings, the equipment firmware must be updated to the latest release version.
System
Subfeeder equipment:
1. SuperSnake GTX04HD subfeeder
2. SuperSnake GTX04HD protective frame (integrated)
3. SuperSnake GTX04HD interconnection cable
Other equipment:
4. MIG/MAG welding gun
5. Voltage sensing cable
Subfeeder control panel
1. Subfeeder control panel
>> Displays for wire feed speed / welding current and for fine tuning
>> Error indicator (red), warning indicator (yellow)
2. Control knobs
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SuperSnake GTX04HD
Operating manual - EN
>> Wire feed speed and/or welding current
>> 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.
3. Gas test and Wire inch buttons
4. Welding ON/OFF indicator (lock)
>> Lock symbol is lit if the welding is turned off from the welding ON/OFF switch
The welding ON/OFF switch doesn't power down the subfeeder.
Subfeeder wire feed mechanism
1. Pressure arm locking and adjusting mechanisms
2. Wire feed rolls (drive rolls) and wire feed roll caps
3. Wire feed rolls (pressure rolls) and wire feed roll pins
4. Wire outlet guide tube
5. Wire inlet guide tip
6. Middle wire guide tube
Subfeeder back (wire feeder end)
1. Welding ON/OFF switch
>> Prevents welding with the subfeeder if set to OFF.
2. Welding cable Euro connector (for interconnection cable from wire feeder)
3. Control cable connector (for interconnection cable from wire feeder)
4. Subfeeder synchronization cable connector (for interconnection cable from wire feeder)
5. Interconnection cable strain relief mechanism
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SuperSnake GTX04HD
Operating manual - EN
Subfeeder front (welding gun end)
1. Welding cable Euro connector (for welding gun)
2. Control cable connector (e.g. for remote control)
3. 3-pin +48V connector, pin sequence: A) GND, B) +48V (max. 10W), C) CAN bus
4. Welding cable strain relief mechanism
Interconnection cable
1. Welding cable (with Euro connector)
2. Control cable
3. Subfeeder synchronization cable
4. Voltage sensing cable
5. Coolant hoses
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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SuperSnake GTX04HD
Operating manual - EN
2. INSTALLATION
Do not power on the equipment before the mechanical installation is complete.
Do not lift the SuperSnake GTX04HD subfeeder with a hoist.
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.
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SuperSnake GTX04HD
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30 for
more information.
It is not recommended to use knurled feed rolls in the main wire feeder unit when using the SuperSnake GTX04HD
subfeeder. They may apply too much friction on the filler wire at the wire feeder end preventing the best possible out-
come with the SuperSnake GTX04HD 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 and release the pressure arms by pulling them.
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SuperSnake GTX04HD
Operating manual - EN
2. Remove the feed roll fixing pins/caps (A, B) by pulling them out.
3. Install the wire guides:
>> Install the wire inlet guide (A). Secure the component in place with a spanner.
>> Install the wire outlet guide tube (B) by inserting it from the welding gun end of the subfeeder.
The steel spiral wire inlet guide liner is factory-installed in the Euro connector behind the wire inlet guide (A). The
wire inlet guide liner needs to be replaced if using DL Chili wire liner (e.g. when welding aluminum).
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SuperSnake GTX04HD
Operating manual - EN
4. Install the middle guide tube. Lock it in place by turning the locking clip.
5. Mount the drive rolls (A) in place, cogged roll section down, and install the fixing caps (B).
Make sure that the groove on the bottom of the roll aligns with the crossing pin on the drive shaft.
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SuperSnake GTX04HD
Operating manual - EN
6. Slide the pressure rolls (C) in place, cogged roll section down, and install the fixing pins (D).
7. Close the pressure arms.
For adjusting the feed roll pressure, refer to "Feed roll pressure adjustment" on the next page.
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SuperSnake GTX04HD
Operating manual - EN
2.2 Feed roll pressure adjustment
Adjust the feed roll pressure with the adjustment rollers mounted on the pressure arms. 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. If not already in place, install the wire feed rolls as described in "Subfeeder installation" on page8.
2. Adjust the pressure of the feed rolls with the pressure adjustment rollers. The pressure is the same for both feed roll
pairs.
>> 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.
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 GTX04HD subfeeder is in use is not
recommended.
When the SuperSnake GTX04HD 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 Feed roll profile Filler wire diameter (mm) Adjustment (x100N)
Fe/Ss solid V-groove 0.8-1.0 1.5−2.0
≥ 1.2 2.0−2.5
Metal and flux cored (MC, FC) V-groove, knurled ≥ 1.2 1.0−2.0
Self-shielded (gasless) V-groove, knurled ≥ 1.6 2.0−3.0
Al U-groove 1.0 0.5−1.0
1.2 1.0−1.5
1.4 1.5−2.0
≥ 1.6 2.0−2.5
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SuperSnake GTX04HD
Operating manual - EN
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).
1. Open the cable strain relief mechanisms.
2. Connect the subfeeder interconnection cable (welding cable, control cable and synchronization cable) to the sub-
feeder.
>> Secure the cables by hand tightening the collars.
>> Close the interconnection cable strain relief mechanism (*).
3. If water cooling is used:
>> Remove the screws and securing clip from the frame bracket.
>> Route the cooling hoses under the bracket on the subfeeder side.
>> Attach the securing clip to the cooling hoses.
>> Secure to the frame with the clip and screws provided.
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SuperSnake GTX04HD
Operating manual - EN
4. Connect the welding gun to the subfeeder.
>> Secure the welding cable by hand tightening the collar.
>> Close the welding cable strain relief mechanism (*).
The welding cable strain relief mechanism distance can be adjusted according to the welding gun used.
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.
5. If water cooling is used:
>> Route the welding gun cooling hoses under the brackets on the subfeeder side.
>> Connect the cooling hose snap connectors. Cooling hoses are color-coded.
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SuperSnake GTX04HD
Operating manual - EN
6. If voltage sensing cable is used:
>> Connect the voltage sensing cable to the connector coming from the interconnection cable.
7. Connect the subfeeder interconnection cable to your welding equipment. Refer to your welding equipment's oper-
ating instructions for more details (X5 FastMig: here).
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SuperSnake GTX04HD
Operating manual - EN
8. On your wire feeder's user interface, select SuperSnake GTX04HD subfeeder and the subfeeder interconnection
cable length. Refer to your welding equipment's operating instructions for more details (X5 FastMig: here).
If the SuperSnake GTX04HD is not available in the settings, and you're using compatible welding equipment, your weld-
ing equipment's firmware must be updated to the latest release version.
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SuperSnake GTX04HD
Operating manual - EN
2.4 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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SuperSnake GTX04HD
Operating manual - EN
2.5 Loading filler wire into subfeeder
1. Straighten the subfeeder cable.
2. Ensure that the wire feed mechanism pressure arms are closed and correctly adjusted in both, the wire feeder and
the subfeeder.
3. Press the Wire inch button on the wire feeder or directly on the subfeeder.
The system will automatically load the filler wire to the subfeeder until the wire hits the feed rolls or when the set sub-
feeder cable length plus 0.5 meters has been fed from the wire feeder. If you want to stop the automatic filler wire
feed, press the Wire inch button again.
Flush the system with shielding gas before welding by pressing the Gas test button on the wire feeder or directly on
the subfeeder.
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SuperSnake GTX04HD
Operating manual - EN
2.6 Shielding gas setting
The shielding gas flow rate from the welding gun is set according to the application, weld joint, gas type and gas nozzle
shape and size. The flow rate should be measured at the welding gun nozzle via a rotameter before welding. Normally
the measure is between 10...20 liters per minute for various welding applications.
If you have not welded for a while, flush the system with shielding gas before welding by pressing the Gas test button
on the wire feeder or directly on the subfeeder.
Handle shielding gas bottle with care. Assess the risks associated with handling and using compressed gas. Always
use a cylinder transport carriage and secure the cylinder safely.
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SuperSnake GTX04HD
Operating manual - EN
2.7 Cooling unit preparation
The use of a subfeeder increases the cooling liquid consumption. Before welding, ensure that there is enough cooling
liquid in the cooler and that also the subfeeder system is filled with coolant. Add cooling liquid, as necessary, and cir-
culate the coolant throughout the system.
Run the coolant through the system by operating your welding equipment. Refer to your welding equipment's oper-
ating instructions for more details (X5 FastMig: here, Master M353, 355:here, Master M 358:here).
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