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
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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. 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.
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Flexlite GX
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 "Installing and repla-
cing wire liner" on the next page 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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Flexlite GX
Operating manual - EN
3.4 Installing and replacing wire liner
New 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 the multi-neck wire liner replacement, refer to "Installing and replacing wire liner for multi-neck" on page16 in
conjunction with this section.
If you change the filler wire to a different diameter or material, change also the feed rolls accordingly.
With most of the Flexlite GX welding gun models both steel spiral wire liner and DL Chili wire liner can be used.
However, note the following:
- Separate DL Chili wire liner options exist for water-cooled and gas-cooled Flexlite GX welding guns.
- Only DL Chili wire liners are available for the Flexlite GX S-models.
The filler wire must be removed before the wire liner replacement.
Tools needed:
1. Straighten the welding gun cable pack.
2. At the wire feeder end of the cable, remove the wire liner's short guide tip, sleeve and cone.
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Flexlite GX
Operating manual - EN
>> With K8 level Flexlite GX models, see also the note at the end of this section.
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.
4. Feed the new wire liner into the cable hose until it stops at the gun neck end.
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6 and "Assembling gun" on page9. 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 "Installing and replacing wire liner for multi-neck" on page16).
5. Insert the cone and the liner sleeve without the short guide tip on the wire liner. Secure them by tightening the
liner sleeve.
Tip: The wire liner needs to be cut exactly at the edge of the liner sleeve. To get the best possible result,
mark and cut the wire liner already before securing the liner sleeve.
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Flexlite GX
Operating manual - EN
>> With the K8 level Flexlite GX models, see also the note in the end of this section.
6. Cut the wire liner at the edge of the liner sleeve so that it is flush with the liner sleeve end.
Cut the excess of the steel liner with side cutting pliers and the excess of the Chili liner with a carpet knife. Don't leave
any rough, inward edges that could potentially damage the filler wire.
If any additional excess wire is left, it may interfere with the next installation step.
7. Insert the short guide tip to the end of the liner sleeve and secure it in place.
All K8 level Flexlite GX models include a longer wire liner sleeve and the K8 level gas-cooled models also an additional
sealing ring (*):
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Flexlite GX
Operating manual - EN
3.5 Installing and replacing wire liner for multi-neck
With Flexlite GX multi-neck welding guns the wire liner needs to be replaced separately for the neck. For more
information on wire liner replacement in general, refer to "Installing and replacing wire liner" on page13.
1. Remove the neck.
2. Release the neck liner fastener and remove the old neck wire liner.
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Flexlite GX
Operating manual - EN
3. Insert the new neck wire liner into the neck and secure with the fastener.
4. Attach the assembled neck to the gun body. Secure with the neck tightening collar.
Hand-tighten only. Over-tightening and/or using a tool can damage the gun components.
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Flexlite GX
Operating manual - EN
3.6 Trigger switch replacement
In normal use, the trigger switch replacement is not a frequent task. However, removing the trigger switch tem-
porarily may be necessary, for example, when using a K5 level Flexlite GX welding gun with other than Kemppi Fast-
mig equipment.
Tools needed:
TX20
1. Remove the screws holding the trigger switch in place.
2. Slide the trigger switch slightly forward (towards the gun welding end) and pull it out.
Do not use excessive force, the trigger switch is still attached with a wiring connection underneath.
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Flexlite GX
Operating manual - EN
3. Disconnect the wiring connector from the trigger switch.
4. To reinstate the trigger switch or to install a replacement trigger switch, repeat the previous steps in reverse.
Use caution when connecting the wiring connector. Wrong alignment and/or too much force may damage the con-
nector pins.
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Flexlite GX
Operating manual - EN
3.7 Trigger switch setting (K5 level)
K5 level Flexlite GX welding guns are designed and set up for Kemppi Fastmig equipment. The trigger switch setting
described here, provides only limited support for other than Kemppi Fastmig welding equipment. Use this option with
caution.
Tools needed:
TX6
1. Detach the trigger switch. Refer to "Trigger switch replacement" on page18 for more detailed instructions.
2. Release the small screw holding the trigger switch circuit board and remove the circuit board.
3. Using the tip of a small screwdriver, set the two dip switches on the circuit board to ON.
4. Reassemble and reinstate the trigger switch. Refer to "Trigger switch replacement" on page18 for more detailed
instructions.
By default, the K5 level Flexlite GX welding gun models are set up for Kemppi Fastmig support.
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Flexlite GX
Operating manual - EN
3.8 Installing and removing grip handle (optional)
The additional grip handle is available for all Flexlite GX MIG welding guns.
1. Keeping the bottom of the grip handle pointing forward, fit the inside grooves of the grip handle over the
screws on the gun.
2. Pull the handle backward to lock it in position.
To remove the grip handle, press the unlock button in the grip handle rear:
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