Kemppi Flexlite GC User manual

Flexlite GC
Operating manual - EN
Flexlite GC
© Kemppi 11921860 / 2109

Flexlite GC
Operating manual - EN
CONTENTS
1. General 3
2. About equipment 4
3. Installation 6
3.1 Assembling gun 7
3.2 Connecting gun 8
3.3 Installing and replacing wire liner 9
3.4 Installing and removing grip handle (optional) 14
4. Operation 15
5. Maintenance 16
5.1 Troubleshooting 18
5.2 Disposal of machine 20
6. Technical data 21
6.1 Technical data: Flexlite GC 22
6.2 Component selection 23
7. Ordering codes 24
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Flexlite GC
Operating manual - EN
1. GENERAL
These instructions describe the use of Kemppi's Flexlite GC MIG welding guns. Flexlite GC welding guns are designed
for manual welding.
Flexlite GC models
With Euro connector: Fixed connection (with MinarcMig Evo):
GC253G GC223GMM
GC323G
In modelnames:G = Gas-cooled, MM = MinarcMig.
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 GC
Operating manual - EN
2. ABOUT EQUIPMENT
The Flexlite GC MIG welding gun equipment consists of:
1. Gas nozzle
2. Contact tip
3. Contact tip adapter / gas diffuser
4. Insulating ring
5. Gun neck
6. Trigger switch
7. Handle
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Flexlite GC
Operating manual - EN
8. Flexlite GC 253G and GC 323G: Gun connector (Euro)
9. Flexlite GC 223GMM: MinarcMig Evo gun connectors.
Flexlite GC 223GMM welding gun is delivered factory-installed with MinarcMig Evo welding equipment.
10. 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 GC
Operating manual - EN
3. INSTALLATION
Ensure that the welding equipment is not connected to the mains and 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
"Connecting gun" on page8
"Installing and replacing wire liner" on page9
"Installing and removing grip handle (optional)" on page14
Before installation and use
Make sure that you select appropriate welding gun contact tip and wire liner for the filler wire used. Refer also to
"Technical data: Flexlite GC" on page22 and "Component selection" on page23.
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 GC
Operating manual - EN
3.1 Assembling gun
For the correct components, refer to "Component selection" on page23.
Tools needed:
8mm / 12mm
1. Flexlite GC 253G and GC 223 GMM:Insert the isolation ring in place.
2. Attach the contact tip adapter and tighten it firmly in place. With Flexlite GC 253G and GC 223 GMM, use a span-
ner for tightening.
It is important to tighten the adapter properly to enable a tight connection of the contact tip to the gun.
3. Attach the contact tip and secure it with a spanner.
4. Attach the gas nozzle and hand-tighten it firmly in place.
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Flexlite GC
Operating manual - EN
3.2 Connecting gun
This section does not apply to Flexlite GC 223GMM welding gun. It comes factory-installed with MinarcMig Evo weld-
ing equipment.
Hand-tighten the gun connectors. Loose connectors may overheat, create contact disturbances, mechanical damage
and 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 the next page for instructions.
1. Connect the gun to your welding equipment.
2. Secure the connector in place by turning the collar clockwise.
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Flexlite GC
Operating manual - EN
3.3 Installing and replacing wire liner
This replacement instruction does not apply to Flexlite GC 223GMM welding gun. For replacing the wire liner in Flexl-
ite GC 223GMM welding gun, refer to MinarcMig Evo operating manual.
The Flexlite GC 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.
Both steel spiral wire liner and DL Chili wire liner can be used.
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 GC
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. (With GC 323G only contact tip adapter is required at this
stage.)
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7.
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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