Kemppi Flexlite GX 203G Operating Manual Download Page 7 | Manualshive

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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.

© Kemppi

8/49

1921390 / 2002

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Summary of Contents for Flexlite GX 203G

Page 1: ...Flexlite GX Operating manual EN Flexlite GX Kemppi 2 49 1921390 2002 ...

Page 2: ...odels 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 Te...

Page 3: ...G 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 40...

Page 4: ... 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 e...

Page 5: ...un 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 mul...

Page 6: ...ct 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 in...

Page 7: ...te 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 hig...

Page 8: ...r 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 t...

Page 9: ... 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 Kemppi 10 49 1921390 2002 ...

Page 10: ...he 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 ...

Page 11: ...re 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...

Page 12: ...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 g...

Page 13: ...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 ...

Page 14: ...iers 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 co...

Page 15: ...lti 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 Kemppi 16 49 1921390 2002 ...

Page 16: ...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 Kemppi 17 49 1921390 2002 ...

Page 17: ...ssary 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 Kemppi 18 49 1921390 2002 ...

Page 18: ...e 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 Kemppi 19 49 1921390 2002 ...

Page 19: ...ch 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 in...

Page 20: ...able 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 Kemppi 21 49 1921390 2002 ...

Page 21: ...ore than it is necessary to adjust the neck Typically the neck retaining nut is tightened so that the neck is still adjustable by hand but so that it does not accidentally shift position during welding Tighten or loosen the neck retaining nut with a spanner so that it is either possible to adjust the neck position by hand or tighten the nut so that it secures the neck into the desired welding posi...

Page 22: ...t interconnecting cable shielding gas hose earth return lead clamp and mains cable are in serviceable condition Ensure that the connectors are correctly fastened Loose connectors can impair welding per formance and damage connectors The exact function of the gun and trigger may vary depending on your welding machine settings e g 2T 4T or Mini log To start welding press the trigger switch Using gun...

Page 23: ...ment only Adjust the wire feed speed or change the memory channel by turning the roller switch on the gun handle Tip With the screw in front of the roller switch under the rubber cap it is possible to change the wheel s stepwise responsiveness Fully stepless adjustment is best suited for adjusting the welding current Kemppi 24 49 1921390 2002 ...

Page 24: ...nels The view shows the WPS name and the pass name If the WPS covers several passes use the arrow buttons 2 to move between the passes Adjusting welding parameters In the Settings view you can view and adjust e g wire feed speed Use the arrow buttons 2 to move between the parameters Use the roller switch 3 to adjust the parameter value You can save the changes in the channel by pressing and holdin...

Page 25: ...Flexlite GX Operating manual EN System error Welding is disabled Kemppi 26 49 1921390 2002 ...

Page 26: ...un gas connector for wear and damage Only the gas cooled gun has the O rings Clean dust from the liner with pressurized air every time you change the wire spool or every day during heavy use Check and remove any spatter build up from the nozzle When not using the gun keep it in the welding gun holder on the wire feeder For repairs contact your Kemppi dealer Periodic maintenance Only qualified serv...

Page 27: ...Flexlite GX Operating manual EN Maintenance test Test and calibration of operation and performance values when needed Find your closest service workshop at Kemppi website Kemppi 28 49 1921390 2002 ...

Page 28: ...heck that the filler wire has not run out Check that the filler wire is properly routed through the feed rolls to the wire liner Check that the pressure handle is properly closed Check that the feed roll pressure is adjusted correctly for the filler wire Blow compressed air through the wire liner to check that it is not blocked Welding gun The wire burns into the contact tip Make sure the size and...

Page 29: ...ity issues with the wire Weld quality Dirty and or poor weld quality Check that the shielding gas has not run out Check that the shielding gas flow is unobstructed Check that the gas type is correct for the application Check the polarity of the gun electrode Check that the welding procedure is correct for the application Varying welding performance Check that the wire feed mechanism is adjusted pr...

Page 30: ...electronic equipment and their implementation in accordance with national law electrical equipment that has reached the end of its life must be collected separately and taken to an appropriate environmentally responsible recycling facility The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection center as per the instructions of local authorities or a Kemppi ...

Page 31: ...00A water cooled on page 37 Technical data Flexlite GX 400A gas cooled on page 39 Technical data Flexlite GX 300A 400A 420A water cooled on page 41 Technical data Flexlite GX 500A 520A water cooled on page 43 Technical data Flexlite GX 600A water cooled on page 45 For component selection refer to Component selection on page 47 For ordering codes refer to Ordering codes on page 49 Kemppi 32 49 1921...

Page 32: ...A 250 A 60 Ar 18 CO 200 A 100 Ar 18 CO 35 CO 60 CO 100 CO Gas flow l min in load capacity test 13 13 13 Filler wire diameter in load capacity test 1 0 1 0 1 0 Stick out length in load capacity test 15 15 15 Filler wire diameters mm Fe 0 8 1 2 0 8 1 2 0 6 1 2 Fe MC FC 0 9 1 2 0 9 1 2 0 9 1 2 Ss 0 8 1 2 0 8 1 2 0 8 1 2 Ss MC FC 0 9 1 2 0 9 1 2 0 9 1 2 Al 0 8 1 2 0 8 1 2 0 8 1 2 Operating temperature...

Page 33: ...ee figure below 45 50 40 Standards IEC60974 7 IEC60974 7 IEC60974 7 Gun length m 3 5 5 3 5 5 3 5 5 Measured using the longest gun length available Neck dimensions G models Neck dimensions W models Neck dimensions MN models Kemppi 34 49 1921390 2002 ...

Page 34: ... 2 Load capacity 35 Ar 18 CO 300 A 350 A 300 A 60 Ar 18 CO 300 A 100 Ar 18 CO 35 CO 60 CO 100 CO Gas flow l min in load capacity test 15 15 15 15 Filler wire diameter in load capacity test 1 2 1 2 1 2 1 2 Stick out length in load capacity test 18 18 18 18 Filler wire diameters mm Fe 0 8 1 2 0 8 1 2 0 8 1 2 Fe MC FC 0 9 1 2 0 9 1 2 0 9 1 2 Ss 0 8 1 2 0 8 1 2 1 0 0 8 1 2 Ss MC FC 0 9 1 2 0 9 1 2 0 9...

Page 35: ... below 100 97 100 97 Neck angle ɑ see figure below 50 50 50 50 Standards IEC60974 7 IEC60974 7 IEC60974 7 IEC60974 7 Gun length m 3 5 5 3 5 5 6 8 3 5 5 Measured using the longest gun length available Neck dimensions G models Neck dimensions W models Neck dimensions MN models Kemppi 36 49 1921390 2002 ...

Page 36: ... 0 8 1 6 1 0 1 6 Load capacity 35 Ar 18 CO 60 Ar 18 CO 100 Ar 18 CO 300 A 250 A 35 CO 60 CO 100 CO Gas flow l min in load capacity test 15 15 Filler wire diameter in load capacity test 1 2 1 2 Stick out length in load capacity test 18 18 Filler wire diameters mm Fe 0 8 1 6 Fe MC FC 0 9 1 6 Ss 0 8 1 6 1 0 1 2 Ss MC FC 0 9 1 6 Al 0 8 1 6 1 2 1 6 Operating temperature range 20 C 40 C 20 C 40 C Storag...

Page 37: ...ck angle ɑ see figure below 45 45 Standards IEC60974 7 IEC60974 7 Gun length m 3 5 5 6 Measured using the longest gun length available Neck dimensions G models Neck dimensions W models Neck dimensions MN models Kemppi 38 49 1921390 2002 ...

Page 38: ...city 35 Ar 18 CO 400 A 60 Ar 18 CO 400 A 100 Ar 18 CO 35 CO 60 CO 100 CO Gas flow l min in load capacity test 20 20 Filler wire diameter in load capacity test 1 6 1 6 Stick out length in load capacity test 22 22 Filler wire diameters mm Fe 0 8 1 6 0 8 1 6 Fe MC FC 0 9 1 6 0 9 1 6 Ss 0 8 1 6 0 8 1 6 Ss MC FC 0 9 1 6 0 9 1 6 Al 0 8 1 6 0 8 1 6 Operating temperature range 20 C 40 C 20 C 40 C Storage ...

Page 39: ... angle ɑ see figure below 50 50 Standards IEC60974 7 IEC60974 7 Gun length m 3 5 5 3 5 5 Measured using the longest gun length available Neck dimensions G models Neck dimensions W models Neck dimensions MN models Kemppi 40 49 1921390 2002 ...

Page 40: ...Wire diameters mm 0 8 1 6 1 0 1 6 0 8 1 6 1 2 1 6 Load capacity 35 Ar 18 CO 60 Ar 18 CO 100 Ar 18 CO 400 A 300 A 420 A 300 A 35 CO 60 CO 100 CO Gas flow l min in load capacity test 20 20 20 20 Filler wire diameter in load capacity test 1 6 1 6 1 6 1 6 Stick out length in load capacity test 22 22 22 22 Filler wire diameters mm Fe 0 8 1 6 0 8 1 6 Fe MC FC 0 9 1 6 0 9 1 6 Ss 0 8 1 6 1 0 1 2 0 8 1 6 1...

Page 41: ... see figure below 100 100 104 104 Neck angle ɑ see figure below 48 48 50 50 Standards IEC60974 7 IEC60974 7 IEC60974 7 IEC60974 7 Gun length m 3 5 5 6 8 3 5 5 8 Measured using the longest gun length available Neck dimensions G models Neck dimensions W models Neck dimensions MN models Kemppi 42 49 1921390 2002 ...

Page 42: ... 8 1 6 Load capacity 35 Ar 18 CO 60 Ar 18 CO 100 Ar 18 CO 500 A 520 A 35 CO 60 CO 100 CO Gas flow l min in load capacity test 20 20 Filler wire diameter in load capacity test 1 6 1 6 Stick out length in load capacity test 22 22 Filler wire diameters mm Fe 0 8 1 6 0 8 1 6 Fe MC FC 0 9 1 6 0 9 1 6 Ss 0 8 1 6 0 8 1 6 Ss MC FC 0 9 1 6 0 9 1 6 Al 0 8 1 6 0 8 1 6 Operating temperature range 20 C 40 C 20...

Page 43: ... angle ɑ see figure below 48 50 Standards IEC60974 7 IEC60974 7 Gun length m 3 5 5 3 5 5 Measured using the longest gun length available Neck dimensions G models Neck dimensions W models Neck dimensions MN models Kemppi 44 49 1921390 2002 ...

Page 44: ...4 Load capacity 35 Ar 18 CO 600 A 40 600 A 40 60 Ar 18 CO 100 Ar 18 CO 35 CO 60 CO 100 CO Gas flow l min in load capacity test 25 25 Filler wire diameter in load capacity test 1 6 1 6 Stick out length in load capacity test 25 25 Filler wire diameters mm Fe 1 2 2 4 1 2 2 4 Fe MC FC 1 2 2 4 1 2 2 4 Ss 1 2 1 6 1 2 1 6 Ss MC FC 1 2 1 6 1 2 1 6 Al 1 2 2 4 1 2 2 4 Operating temperature range 20 C 40 C 2...

Page 45: ...Neck angle ɑ see figure below 30 30 Standards IEC60974 7 IEC60974 7 Gun length m 5 5 Measured using the longest gun length available Neck dimensions G models Neck dimensions W models Neck dimensions MN models Kemppi 46 49 1921390 2002 ...

Page 46: ...15 threaded GX 305G GX 403G L60 OD28 D15 threaded 1 2C1 M10 GX 405G GX 303W L57 OD22 D14 threaded 1 0C1 M10 GX 305W GX 403W L57 OD15 D25 threaded GX 405W GX 503W L60 OD28 D15 threaded 1 2C1 M10 GX 505W GX 605W L64 OD30 D17 threaded GX 305GMN L57 OD25 D15 threaded 1 0C1 M10 GX 305GS L57 OD25 D15 threaded 1 2C1 M10 GX 305WS L57 OD22 D14 threaded GX 405WS L57 OD25 D15 threaded GX 428W L61 OD25 D16 th...

Page 47: ...30 D17 threaded GX 428WS L61 OD25 D16 threaded GX 528W N250 L64 OD28 D17 threaded GX 408GMN L60 OD28 D15 threaded The letters in the gas nozzle specification stand for L length OD outer diameter at the widest point D diameter inner diameter of the gas nozzle tip Kemppi 48 49 1921390 2002 ...

Page 48: ...GX305GMN5 Flexlite GX 305GS GX305GS6 GX305GS8 Flexlite GX 305WS GX305WS6 Flexlite GX 403G GX403G35 GX403G5 Flexlite GX 403W GX403W35 GX403W5 Flexlite GX 405G GX405G35 GX405G5 Flexlite GX 405W GX405W35 GX405W5 Flexlite GX 405WS GX405WS6 GX405WS8 Flexlite GX 503W GX503W35 GX503W5 Flexlite GX 505W GX505W35 GX505W5 Flexlite GX 605W GX605W5 Flexlite GX 208GMN GX208GMN35 GX208GMN5 Flexlite GX 308GMN GX3...

Page 49: ...Flexlite GX Operating manual EN Flexlite GX remotes optional Product Ordering code GXR10 gun remote K5 level GXR10 GXR80 gun remote K8 level GXR80 Kemppi 50 49 1921390 2002 ...

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