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Kemppi Flexlite GXe-C Operating Instructions Manual
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Kemppi Flexlite GXe-C Operating Instructions Manual

Kemppi Flexlite GXe-C Operating Instructions Manual

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Flexlite GXe-C
Operating manual - EN
Flexlite GXe-C
1
© Kemppi
1922560 / 2443

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Summary of Contents for Kemppi Flexlite GXe-C

  • Page 1 Flexlite GXe-C Operating manual - EN Flexlite GXe-C © Kemppi 1922560 / 2443...
  • Page 2 5. Maintenance 5.1 Troubleshooting 5.2 Disposal 6. Technical data 6.1 Technical data: Flexlite GXe-C 353G 0D (gas-cooled) 6.2 Technical data: Flexlite GXe-C 353G 22D (gas-cooled) 6.3 Technical data: Flexlite GXe-C 353G 35D (gas-cooled) 6.4 Technical data: Flexlite GXe-C 355G 0D (gas-cooled) 6.5 Technical data: Flexlite GXe-C 355G 22D (gas-cooled)
  • Page 3 These instructions describe the use of Kemppi's Flexlite GXe-C MIG welding torches designed for professional cobot welding (collaborative robot welding). The Flexlite GXe-C range covers both water-cooled (W) and gas-cooled (G) mod- els. The Flexlite GXe-C welding torches are available in model series 3 and 5 – both incorporating Euro welding con- nectors.
  • Page 4 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.
  • Page 5 Flexlite GXe-C Operating manual - EN 1.1 Welding safety Welding is always classified as hot work, and welding equipment typically contains high-voltage circuits. If you are not familiar with welding and welding principles, it is recommended that you acquire welding training or professional guid- ance before commencing welding.
  • Page 6 Flexlite GXe-C Operating manual - EN 2. ABOUT EQUIPMENT The exact visual details may be different between different Flexlite GXe-C models. Series 5 GXe-C: Gas nozzle Contact tip Contact tip adapter / gas diffuser Torch neck Wire inch forward button...
  • Page 7 Torch neck Start button Torch connector. Installation accessories The following installation accessories are available for installing the Flexlite GXe-C welding torch on a cobot: • Adapter flange: ISO 9409-1-50 M6 Adapter Flange (weight 0.12 kg) • Mounting bracket, size S: GXe-C Bracket Flex Mount S (weight 0.43 kg) •...
  • Page 8 Mechanization kit: GXe-C MT Kit The GXe-C MT Kit is used for connecting the Flexlite GXe-C welding torch to the MagTrac F 61 welding carriage. The GXe-C MT Kit is delivered with dedicated installation instructions. For information on the MagTrac F 61 welding carriage,...
  • Page 9 MagTrac F 61 welding carriage. Cable securing straps Cable securing straps are used to hold the Flexlite GXe-C welding torch cable in place on the cobot. Teaching tip Use the teaching tip instead of the contact tip to teach the welding path to the cobot without actually welding.
  • Page 10 Flexlite GXe-C Operating manual - EN 3. INSTALLATION Ensure that the welding equipment is not connected to the mains or that the welding torch is not connected to the welding machine until the installation is complete. Protect the equipment from rain and direct sunshine.
  • Page 11 Flexlite GXe-C Operating manual - EN 3.1 Assembling welding torch For the correct components, refer to "Component selection" on page 70. Tools needed: 8 mm Attach the contact tip adapter and hand-tighten it firmly in place. It is important to tighten the adapter properly to enable a tight connection of the contact tip to the welding torch.
  • Page 12 Operating manual - EN 3.2 Installing welding torch on cobot Install the Flexlite GXe-C welding torch on a cobot using the mounting bracket (GXe-C Bracket Flex Mount S/M) and the adapter flange (ISO 9409-1-50 M6 Adapter Flange). Do not exceed the torque values given. Over-tightening may damage the fixing accessories.
  • Page 13 Flexlite GXe-C Operating manual - EN Install the GXe-C welding torch into the welding torch holder. Tighten first the two fixing screws on the right and then the fixing screw on the left to 8 Nm torque. For instructions on adjusting the welding torch angle and position, refer to "Adjusting welding torch angle" on the next page and "Adjusting welding torch position"...
  • Page 14 Flexlite GXe-C Operating manual - EN 3.3 Adjusting welding torch angle Tools needed: 2.5 / 4 mm Loosen the welding torch holder's fixing screw. Remove the angle adjustment screw. © Kemppi 1922560 / 2443...
  • Page 15 Flexlite GXe-C Operating manual - EN Find the correct angle. For more information, refer to "Bracket angles" on the next page. Lock the angle by inserting the angle adjustment screw. Tighten to 0.5 Nm torque (or hand-tighten). © Kemppi 1922560 / 2443...
  • Page 16 Flexlite GXe-C Operating manual - EN Tighten the welding torch holder's fixing screw to 8 Nm torque. 3.3.1 Bracket angles This section describes the locking positions of the angle adjustment screws for the different bracket angles. The bracket angle is adjusted in 5° increments. Each increment has a dedicated screw locking position.
  • Page 17 Flexlite GXe-C Operating manual - EN GXe-C Bracket Flex Mount M © Kemppi 1922560 / 2443...
  • Page 18 Flexlite GXe-C Operating manual - EN 3.4 Adjusting welding torch position Tools needed: 5 mm Remove the two fixing screws from the mounting bracket. Slide the welding torch to the correct position. The welding torch position is adjustable in 5 mm increments. Make sure the alignment mark (*) aligns with the scale mark.
  • Page 19 Flexlite GXe-C Operating manual - EN Lock the position of the welding torch with the two fixing screws. Tighten to 8 Nm torque. © Kemppi 1922560 / 2443...
  • Page 20 Flexlite GXe-C welding torch with a neck angle of 35° Use the GXe-C Bracket Flex Mount S with the Flexlite GXe-C welding torch with a neck angle of 35° and adjust as follows (note the alignment mark *): © Kemppi...
  • Page 21 Weight without cable pack: 1.5 kg Flexlite GXe-C welding torch with a neck angle of 22° Use the GXe-C Bracket Flex Mount M with the Flexlite GXe-C welding torch with a neck angle of 22° and adjust as follows (note the alignment mark *): ©...
  • Page 22 Flexlite GXe-C Operating manual - EN Dimensions and center of mass position in optimal setup: Weight without cable pack: 1.6 kg © Kemppi 1922560 / 2443...
  • Page 23 3.6 Welding equipment firmware versions Ensure that your welding equipment has the required firmware version for cobot welding. Using the Flexlite GXe-C cobot welding torch with a welding device that does not have the appropriate firmware version will cause the device to malfunction.
  • Page 24 Flexlite GXe-C Operating manual - EN 3.7 Connecting welding torch to welding device Ensure that the firmware version required for cobot welding is installed on your welding device. Refer to "Welding equipment firmware versions" on the previous page. Hand-tighten the welding torch connectors. Loose connectors may overheat, create contact disturbances, mech- anical damage and water or gas leakage.
  • Page 25 Flexlite GXe-C Operating manual - EN Make sure to connect the coolant hoses to the correct hose connectors. If the connections cross, the welding torch may overheat. © Kemppi 1922560 / 2443...
  • Page 26 With most of the Flexlite GXe-C welding torch models both steel wire liner and DL Chili wire liner can be used. The filler wire must be removed before the wire liner replacement. Always read the instructions delivered with the replacement wire liner as well.
  • Page 27 Flexlite GXe-C Operating manual - EN 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. Feed the new wire liner into the cable hose until it stops at the torch neck end.
  • Page 28 Flexlite GXe-C Operating manual - EN Insert the sleeve nut next to the wire liner for measure. (Do not install the sleeve nut in its actual position at this stage.) Using carpet knife, cut the wire liner flush with the sleeve nut end.
  • Page 29 Flexlite GXe-C Operating manual - EN Place the sleeve nut on the wire liner and secure it in place by tightening it to 5 Nm torque. 3.8.2 Replacing steel wire liner Tools needed: Removing and inserting wire liner The visual details may vary slightly between different welding torch models. The method is the same for both gas- and water- cooled welding torches.
  • Page 30 Flexlite GXe-C Operating manual - EN 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. Feed the new wire liner into the cable hose until it stops at the torch neck end.
  • Page 31 Flexlite GXe-C Operating manual - EN Insert the sleeve nut next to the wire liner for measure. (Do not install the sleeve nut in its actual position at this stage.) Using side cutting pliers, cut the wire liner flush with sleeve nut end.
  • Page 32 Flexlite GXe-C Operating manual - EN Insert the retainer cone onto the wire liner and push it in place. Ensure that the wire liner goes all the way into the tip of the retainer cone. Place the sleeve nut on the wire liner and secure it in place by tightening it to 5 Nm torque.
  • Page 33 Ensure that the connectors are correctly fastened. Loose connectors can impair welding per- formance and damage connectors. When the Flexlite GXe-C welding torch is connected to the MagTrac F 61 welding carriage, the function buttons on the welding torch are inactive (this applies to both series 3 and series 5 models).
  • Page 34 Flexlite GXe-C Operating manual - EN To test the shielding gas flow, press the gas test button. Series 3 GXe-C: To start welding, press the start button. © Kemppi 1922560 / 2443...
  • Page 35 • Check regularly that all the components are tightly fastened. • Check that the current transfer surface on the Kemppi torch adapter is clean and unscratched, and the connector pins are straight and undamaged. • Check the protective hose on the cable for damage.
  • Page 36 The torch neck overheats • Make sure you are using original Kemppi consumable and spare parts. Incorrect spare part materials may cause the overheating of the neck. © Kemppi 1922560 / 2443...
  • Page 37 Flexlite GXe-C Operating manual - EN The welding torch connector overheats • Make sure the connector is properly connected to the wire feeder. • Make sure the current transfer surface and the connector pins of the torch connector are clean and undamaged.
  • Page 38 The owner of the equip- ment is obliged to deliver a decommissioned unit to a regional collection center, as per the instructions of local author- ities or a Kemppi representative. By applying these European Directives you improve the environment and human health.
  • Page 39 Flexlite GXe-C Operating manual - EN 6. TECHNICAL DATA "Technical data: Flexlite GXe-C 353G 0D (gas-cooled)" on the next page "Technical data: Flexlite GXe-C 353G 22D (gas-cooled)" on page 42 "Technical data: Flexlite GXe-C 353G 35D (gas-cooled)" on page 44 "Technical data: Flexlite GXe-C 355G 0D (gas-cooled)" on page 46 "Technical data: Flexlite GXe-C 355G 22D (gas-cooled)"...
  • Page 40 Flexlite GXe-C Operating manual - EN 6.1 Technical data: Flexlite GXe-C 353G 0D (gas-cooled) GXe-C 353G 0D Feature Value Welding connection type Euro Type of cooling Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 41 Flexlite GXe-C Operating manual - EN Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 350 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm Load capacity test, stick out length...
  • Page 42 Flexlite GXe-C Operating manual - EN 6.2 Technical data: Flexlite GXe-C 353G 22D (gas-cooled) GXe-C 353G 22D Feature Value Welding connection type Euro Type of cooling Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 43 Flexlite GXe-C Operating manual - EN Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 350 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm Load capacity test, stick out length...
  • Page 44 Flexlite GXe-C Operating manual - EN 6.3 Technical data: Flexlite GXe-C 353G 35D (gas-cooled) GXe-C 353G 35D Feature Value Welding connection type Euro Type of cooling Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 45 Flexlite GXe-C Operating manual - EN Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 350 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm Load capacity test, stick out length...
  • Page 46 Flexlite GXe-C Operating manual - EN 6.4 Technical data: Flexlite GXe-C 355G 0D (gas-cooled) GXe-C 355G 0D Feature Value Welding connection type Euro Type of cooling Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 47 Flexlite GXe-C Operating manual - EN Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 350 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm Load capacity test, stick out length...
  • Page 48 Flexlite GXe-C Operating manual - EN 6.5 Technical data: Flexlite GXe-C 355G 22D (gas-cooled) GXe-C 355G 22D Feature Value Welding connection type Euro Type of cooling Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 49 Flexlite GXe-C Operating manual - EN Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 350 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm Load capacity test, stick out length...
  • Page 50 Flexlite GXe-C Operating manual - EN 6.6 Technical data: Flexlite GXe-C 355G 35D (gas-cooled) GXe-C 355G 35D Feature Value Welding connection type Euro Type of cooling Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 51 Flexlite GXe-C Operating manual - EN Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 350 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm Load capacity test, stick out length...
  • Page 52 Flexlite GXe-C Operating manual - EN 6.7 Technical data: Flexlite GXe-C 503W 0D (water-cooled) GXe-C 503W 0D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 53 Flexlite GXe-C Operating manual - EN GXe-C 503W 0D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 500 A Load capacity test, filler wire material 1.6 mm...
  • Page 54 Flexlite GXe-C Operating manual - EN Neck dimensions, G-models: x = length © Kemppi 1922560 / 2443...
  • Page 55 Flexlite GXe-C Operating manual - EN 6.8 Technical data: Flexlite GXe-C 503W 22D (water-cooled) GXe-C 503W 22D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 56 Flexlite GXe-C Operating manual - EN Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 500 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm...
  • Page 57 Flexlite GXe-C Operating manual - EN Neck dimensions, G-models: y = height, x = length, ɑ = angle © Kemppi 1922560 / 2443...
  • Page 58 Flexlite GXe-C Operating manual - EN 6.9 Technical data: Flexlite GXe-C 503W 35D (water-cooled) GXe-C 503W 35D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 59 Flexlite GXe-C Operating manual - EN Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 500 A Load capacity test, filler wire material Load capacity test, filler wire diameter 1.6 mm...
  • Page 60 Flexlite GXe-C Operating manual - EN Neck dimensions, G-models: y = height, x = length, ɑ = angle © Kemppi 1922560 / 2443...
  • Page 61 Flexlite GXe-C Operating manual - EN 6.10 Technical data: Flexlite GXe-C 505W 0D (water-cooled) GXe-C 505W 0D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 62 Flexlite GXe-C Operating manual - EN GXe-C 505W 0D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 500 A Load capacity test, filler wire material 1.6 mm...
  • Page 63 Flexlite GXe-C Operating manual - EN Neck dimensions, G-models: x = length © Kemppi 1922560 / 2443...
  • Page 64 Flexlite GXe-C Operating manual - EN 6.11 Technical data: Flexlite GXe-C 505W 22D (water-cooled) GXe-C 505W 22D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 65 Flexlite GXe-C Operating manual - EN GXe-C 505W 22D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 500 A Load capacity test, filler wire material 1.6 mm...
  • Page 66 Flexlite GXe-C Operating manual - EN Neck dimensions, G-models: y = height, x = length, ɑ = angle © Kemppi 1922560 / 2443...
  • Page 67 Flexlite GXe-C Operating manual - EN 6.12 Technical data: Flexlite GXe-C 505W 35D (water-cooled) GXe-C 505W 35D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2...
  • Page 68 Flexlite GXe-C Operating manual - EN GXe-C 505W 35D Feature Value Welding connection type Euro Type of cooling Liquid Contact tip M10X1 Method of guidance Mechanical Load capacity 100% / Ar + 18% CO2 500 A Load capacity test, filler wire material 1.6 mm...
  • Page 69 Flexlite GXe-C Operating manual - EN Neck dimensions, G-models: y = height, x = length, ɑ = angle © Kemppi 1922560 / 2443...
  • Page 70 Flexlite GXe-C Operating manual - EN 6.13 Component selection The following table lists the Flexlite GXe-C gas nozzles and contact tips in the factory setup. Model Gas nozzle Contact tip GXe-C 353G 25/15 L59 HD 1.2C1 L+, M10 GXe-C 355G 25/15 L59 HD 1.2C1 L+, M10...
  • Page 71 Flexlite GXe-C Operating manual - EN 7. ORDERING INFORMATION For Flexlite GXe-C ordering information and optional accessories, refer to Kemppi.com. © Kemppi 1922560 / 2443...

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