Kemppi Flexlite GX Series User manual

Flexlite GX
Operating manual - EN
Flexlite GX
© Kemppi 2/49 1921390 / 2002

Flexlite GX
Operating manual - EN
CONTENTS
1. General 4
2. About equipment 6
3. Installation 8
3.1 Assembling gun 9
3.2 Installing gun remote 10
3.3 Connecting gun 12
3.4 Installing and replacing wire liner 13
3.5 Installing and replacing wire liner for multi-neck 16
3.6 Trigger switch replacement 18
3.7 Trigger switch setting (K5 level) 20
3.8 Installing and removing grip handle (optional) 21
3.9 Adjusting and tightening neck (gas-cooled models) 22
4. Operation 23
4.1 Using gun remote (K5 level) 24
4.2 Using gun remote (K8 level) 25
5. Maintenance 27
5.1 Troubleshooting 29
5.2 Disposal of machine 31
6. Technical data 32
6.1 Technical data: Flexlite GX 200A/250A (gas-cooled) 33
6.2 Technical data: Flexlite GX 300A/350A (gas-cooled) 35
6.3 Technical data: Flexlite GX 250A/300A (water-cooled) 37
6.4 Technical data: Flexlite GX 400A (gas-cooled) 39
6.5 Technical data: Flexlite GX 300A/400A/420A (water-cooled) 41
6.6 Technical data: Flexlite GX 500A/520A (water-cooled) 43
6.7 Technical data: Flexlite GX 600A (water-cooled) 45
6.8 Component selection 47
7. Ordering codes 49
© Kemppi 3/49 1921390 / 2002

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. Flexlite GX welding guns are available in three different levels – K3, K5 and K8 – each designed to
serve specific welding needs. For more information on Kemppi levels, refer to www.kemppi.com.
Flexlite GX models
K3 level*: K5 level**: K8 level***:
GX 203G GX 205G GX 208GMN
GX 253G GX 255G GX 308GMN
GX 303G/W GX 305G/W GX 408GMN
GX 403G/W GX 305GMN GX 428W
GX 503W GX305GS GX 428WS
GX305WS GX 528W
GX 405G/W GX 608W
GX 405WS
GX 505W
GX 605W
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Flexlite GX
Operating manual - EN
* K3 level welding gun models are compatible with the majority of welding equipment.
** K5 level welding gun models are designed for Kemppi Fastmig equipment with limited support to other models.
*** K8 level welding gun models are compatible with Kemppi X8 MIG Welder.
In modelnames:G = Gas-cooled, W = Water-cooled, MN = Multi-neck, S = Long cable.
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
complete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the
specification 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 K5 and K8 level models). For more
information on the gun remotes, refer to "Installing gun remote" on page10.
>> Not available with Flexlite GX K3 level 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
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
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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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10
"Connecting gun" on page12
"Installing and replacing wire liner" on page13
"Installing and replacing wire liner for multi-neck" on page16
"Installing and removing grip handle (optional)" on page21
"Adjusting and tightening neck (gas-cooled models)" on page22
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47.
Tools needed:
8mm
1. Attach the contact tip adapter and hand-tighten it firmly in place. It is important to tighten the adapter prop-
erly 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 K5 level welding gun remote can be used with Kemppi Fastmig equipment only.
The Flexlite GX K8 level welding gun and digital gun remote 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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Flexlite GX
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.
© Kemppi 11/49 1921390 / 2002