Kemppi FLEXLiTE TX Series User manual

Flexlite TX
Operating manual - EN
FLEXLiTE TX
© Kemppi 1/24 1920910 / 1921

Flexlite TX
Operating manual - EN
CONTENTS
1. Flexlite TX 3
2. About equipment 4
3. Installation 6
3.1 Assembling torch 6
3.2 Installing torch remote 7
3.3 Connecting torch 10
4. Operation 13
4.1 Consumable and gas flow selection 13
4.2 Electrode tip 14
5. Maintenance 16
5.1 Troubleshooting 17
5.2 Disposal of machine 18
6. Technical data 19
6.1 Technical data TX 135 19
6.2 Technical data TX 165 20
6.3 Technical data TX 225 and TX 255 20
6.4 Technical data TX 305 and TX 355 21
7. Ordering codes 23
© Kemppi 2/24 1920910 / 1921

Flexlite TX
Operating manual - EN
1. FLEXLITE TX
These instructions describe the use of Kemppi's Flexlite TX TIG welding torches. Flexlite TX torches are designed for
manual welding in demanding industrial use and they are compatible with Kemppi TIG welding equipment with 7-
pin connectors. Flexlite TX range covers both, water-cooled and gas-cooled models.
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 TX
Operating manual - EN
2. ABOUT EQUIPMENT
The Flexlite TX TIG welding torches are packed with features designed to support professional welding. The equip-
ment consists of:
1. Gas nozzle
2. Collet body
3. Collet
4. Insulating ring*
5. Torch body
6. Electrode back cap
7. Control cable connection (start and remote signals)
8. Welding cable connection (shielding gas and welding current)
9. Coolant outlet and inlet hose connectors (water-cooled models only)
10. ON/OFF switch
11. Switch cover
12. Torch handle
* Some Flexlite TX torch models also include a back cap insulating ring, in addition to the gas nozzle insulating ring.
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Flexlite TX
Operating manual - EN
Dedicated lens models of the collet body and the gas nozzle exist for laminar flow welding. Bigger lens consumables
require an additional insulating ring.
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 TX
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 at this stage.
Protect the equipment from rain and direct sunshine.
"Assembling torch" below
"Installing torch remote" on the next page
"Connecting torch" on page10
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.
Do not connect welding equipment to the mains before the installation is complete.
3.1 Assembling torch
1. Depending on your specific welding torch setup, assemble the torch starting with the insulating ring and collet
body.
Some Flexlite TX torch models also include a back cap insulating ring, in addition to the gas nozzle insulating ring.
2. Install the gas nozzle and the collet.
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Flexlite TX
Operating manual - EN
3. Prior to installing the tungsten electrode, grind the electrode tip to the appropriate dimensions for your weld-
ing application. For more information, refer to the section "Electrode tip" on page14.
4. Push the electrode into the torch and through the collet and gas nozzle.
5. Install the electrode back cap. Tightening the back cap also locks the electrode in place.
Do not use excessive force. Overtightening may damage the torch components.
By loosening the electrode back cap, the electrode can be installed also by pushing it into the torch from the other
side.
3.2 Installing torch remote
Many Flexlite TX welding torches are equipped as standard with ON/OFF start/stop switches. Optional remote con-
trol devices can be fitted to these TX torch models, allowing both start/stop function and welding current adjust-
ment.
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Flexlite TX
Operating manual - EN
Ensure that the welding equipment is not connected to the mains or that the welding torch is not connected to the
welding machine at this stage.
1. Open the switch cover by releasing the screws in the rear section of the cover and remove the cover.
2. Take the existing circuit board out of its slot in the handle and unplug the connector.
3. Connect the torch remote control circuit board to the connector and place it in its slot in the handle. (Rocker
switch model shown on the left and roller switch model on the right:)
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Flexlite TX
Operating manual - EN
4. Install the new switch cover by placing the front end of the cover in first and then pushing the rear end of the
cover down. (Rocker switch model shown on the left and roller switch model on the right:)
5. Secure the switch cover in place with the two screws in the rear section of the cover.
Start switch extension (For use with the standard ON/OFF switch only):
1. Open the switch cover by releasing the screws in the rear section of the cover and remove the cover.
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Flexlite TX
Operating manual - EN
2. Replace the standard start switch button on the cover with the extended start switch button.
3. Install the cover with the start switch extension in place.
4. Secure the switch cover in place with the two screws in the rear section of the cover.
The switch extension cannot be used with the S neck TX torch models.
3.3 Connecting torch
Hand tighten the torch connectors. Loose connectors may overheat, create contact disturbances, mechanical damage
and water or gas leakage.
For connecting the torch (and applicable extension parts), refer also to your welding equipment’s instructions.
© Kemppi 10/24 1920910 / 1921

Flexlite TX
Operating manual - EN
Gas-cooled TIG torch:
1. Connect the welding cable and the control cable to the power source. Secure by turning the connectors clock-
wise.
Water-cooled TIG torch:
1. Connect the welding cable and the control cable to the power source. Secure by turning the connectors clock-
wise.
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Flexlite TX
Operating manual - EN
2. Connect the coolant inlet and outlet hoses to the cooling unit. Note that the connectors are color-coded.
Make sure to connect the coolant hoses to the correct hose connectors. If the connections cross, the torch and torch
body may overheat.
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Flexlite TX
Operating manual - EN
4. OPERATION
Before using the equipment, ensure that all the necessary installation actions have been completed according to
your equipment setup and instructions.
Welding is forbidden in places where there is an immediate fire or explosion hazard!
Welding fumes may cause injury. Take care to ensure sufficient ventilation during welding and wear respiratory pro-
tection!
Always check before use that 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.
Many Flexlite TX torches are equipped with an ON/OFF switch. The exact operation and function of the switch may
vary depending on your welding machine settings (e.g. 2T, 4T or Minilog).
1. Ensure that the earth return cable is connected to the welding machine and piece to be welded.
2. To start welding, press the ON/OFF switch (1) on the welding torch handle.
3. With the roller and rocker switch versions only: Adjust the welding current by rolling the roller switch (2/3) or by
pulling/pushing the rocker switch (2/3).
4.1 Consumable and gas flow selection
The tables in this chapter provide some basic guidance only and must not be considered as a definitive source of elec-
trode and gas flow rate information.
The welding current setting defines the electrode size and the shielding gas flow rate. The most typical shielding
gas for TIG welding is argon.
The following tables provide some basic guidance for the electrode size and shielding gas flow rate selection.
Welding current DC- (AC) Electrode Gas nozzle Gas flow rate
A ø mm Number ø mm l/min
5...80 (5...50) 1.0 4/5 6.5/8.0 5...6
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Flexlite TX
Operating manual - EN
70...150 (30...100) 1.6 4/5/6 6.5/8.0/9.5 6...7
130...250 (80...150) 2.4 6/7 9.5/11.0 7...8
220...350 (120...210) 3.2 7/8/10 11.0/12.5/16.0 8...10
330...500 (180...280) 4.0 10/11/12 16.0/17.5/19.0 10...12
Electrode Welding current Base material
Type Symbol color Fe Ss Al Ti
WC20 grey AC, DC- x x x
WZ8 white AC, DC- x
Wgreen AC, DC- x
4.2 Electrode tip
DC welding
For DC TIG welding, grind the tip of the tungsten electrode lengthways, into cone shape. The sharpened electrode
tip provides a steady and concentrated arc into the weld piece. The sharpening angle and length has an effect on
the arc width and penetration depth.
Sharpening principle:
Where I = 1…5 x d.
The sharpening length best suited for your purposes depends on the most used welding current level:
a. Low currents
b. Mid currents
c. High currents
When sharpening the electrode, always grind along the electrode.
© Kemppi 14/24 1920910 / 1921

Flexlite TX
Operating manual - EN
AC welding
In AC TIG welding the electrode tip temperature can exceed the melting point of the electrode. Therefore the elec-
trode diameter selected and its suitability for welding current applied, can be evaluated based on the formation of
the electrode tip.
a. Too low welding current or too big electrode size. The arc is not steady and directed on the weld piece.
b. Suitable current.
c. The welding current is too high for the electrode diameter selected.
When using Kemppi AC TIG equipment for specific applications, it is also possible to prepare and maintain a small
point on the electrode tip (d). This improves the directional control of the welding arc and weld pool size.
Tip: You can also prepare the basic tip formation for AC welding with the following technique:
1. Adjust the welding current a little higher than required.
2. Burn the arc over a waste piece of material, keeping the torch electrode in a vertical position.
3. Extinguish the arc immediately when the electrode tip has formed rounded spherical surface, no larger
than the diameter of the electrode, holding the same torch position as the electrode cools during the
post gas cycle.
4. Reduce the current setting to a level suitable for the work target and start welding.
Electrode tip length
The optimal protrusion (l) of the electrode tip measured from the gas nozzle tip depends on the electrode diameter,
welding current level and weld joint type.
Tip: Cleaning the electrode with steel wool can improve ignition and overall welding properties, by remov-
ing surface oxides.
© Kemppi 15/24 1920910 / 1921

Flexlite TX
Operating manual - EN
5. MAINTENANCE
When planning routine maintenance, consider the operating frequency of the welding equipment and the working
environment.
Correct operation of the welding equipment and regular maintenance helps you avoid unnecessary downtime and
equipment failure. Mainly due to the high temperatures, the TIG torch head and parts require regular checks and
maintenance. Periodically, check the cables set for damage and ensure connections are tightened correctly.
Daily maintenance
Disconnect the power source from the mains power supply before handling electrical cables.
Torch head maintenance
•All insulations are undamaged and intact.
•Gas nozzle is intact and suitable for work.
•Shielding gas flows freely and steadily.
•Electrode is intact and suitable for work.
•Fastening parts of the electrode are intact and the electrode is fastened tightly in place.
•Check all the cables and connectors. Do not use them if they are damaged.
Maintenance of torch cable
•Torch cable insulations and connectors are intact.
•There are no sharp bends in the torch cable.
•Components are tightly fastened.
•Check that the current transfer surface on the torch current connector is clean and undamaged.
•Check the protective hose on the cable for damage.
For repairs, contact your Kemppi dealer.
Periodic maintenance
Only qualified service personnel are allowed to carry out periodic maintenance.
Check the electric connectors of the unit at least every six months. Clean oxidized parts and tighten loose con-
nectors.
Use the correct tension torque when fastening loose parts.
Do not use pressure washing devices.
Service workshops
Kemppi Service Workshops complete the welding system maintenance according to the Kemppi service agreement.
The main aspects in the service workshop maintenance procedure are:
•Cleanup of the machine
•Maintenance of the welding tools
•Checkup of the connectors and switches
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Flexlite TX
Operating manual - EN
•Checkup of all electric connections
•Checkup of the power source mains cable and plug
•Repair of defective parts and replacement of defective components
•Maintenance test
•Test and calibration of operation and performance values when needed.
Find your closest service workshop at Kemppi website.
5.1 Troubleshooting
The problems and the possible causes listed are not definitive, but suggest some typical situations that may turn up
during normal use of the welding system. For further information and assistance, contact your nearest Kemppi service
workshop.
General:
The welding system does not power up
•Check that the mains cable is plugged in properly.
•Check that the mains switch of the power source is at the ON position.
•Check that the mains power distribution is on.
•Check the mains fuse and/or the circuit breaker.
•Check that the earth return cable is connected.
The welding system stops working
•The torch may have overheated. Wait for it to cool down.
•Check that none of the cables is loose.
•The power source may have overheated. Wait for it to cool down and see that the cooling fans work properly
and the air flow is unobstructed.
Welding torch:
The torch overheats
•Make sure the torch body is properly connected.
•Make sure that the welding parameters are within the range of the welding torch. If different torch com-
ponents have separate limits for the maximum current; the lower one of these is the maximum current that can
be used.
•Make sure the coolant circulation is working normally (see the coolant circulation warning LED on the power
source).
•Measure the coolant circulation speed: detach the coolant output hose from the cooler unit when the power
source is on, and let the coolant run into a measurement cup. The circulation must be at least 0.5 l/min.
•Make sure you are using original Kemppi consumable and spare parts. Incorrect spare part materials may also
cause overheating.
•Make sure the connectors are clean, undamaged and properly fastened.
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 torch/electrode.
•Check that the welding procedure is correct for the application.
Varying welding performance
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Flexlite TX
Operating manual - EN
•Check the welding electrode size, type and wear.
•Check that the welding torch is not overheating.
•Check that the earth return clamp is properly attached to a clean surface of the workpiece.
Arc is not ignited
•Cable is loose or there is a bad connection.
•The torch electrode is highly oxidized. Sharpen again lengthwise. Check that the post gas time is long enough.
Check ignition by using pre gas.
•There are impurities in shielding gas (moisture, air).
•Protective hose or another insulation of torch is broken and ignition spark is “escaping”.
•Torch is wet.
•Too big or blunt electrode is used at low currents.
Gas shielding is bad (weld pool “boils”, electrode gets oxidized)
•There are impurities in shielding gas (moisture, air).
•There are impurities in base material (rust, base coat, grease).
•Impurities stuck on gas nozzle or on collet body.
•Net of gas lens is damaged.
•There is too much draft at welding place.
5.2 Disposal of machine
Do not dispose of any electrical equipment with normal waste!
In observance of WEEE Directive 2012/19/EU on waste of electrical and electronic equipment and European Directive
2011/65/EU on the restriction of the use of certain hazardous substances in electrical and 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 representative. By applying these European Directives you improve the environment
and human health.
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Flexlite TX
Operating manual - EN
6. TECHNICAL DATA
"Technical data TX 135" below
"Technical data TX 165" on the next page
"Technical data TX 225 and TX 255" on the next page
"Technical data TX 305 and TX 355" on page21
6.1 Technical data TX 135
Flexlite TX 135GF
Feature Value
Type of cooling Gas
Coolant flow rate (l/min) l/min -
Coolant pressure (min) MPa -
Coolant pressure (max) -
Arc striking voltage kV 10
Rating of electrical components (remote, nominal) V 10
mA 10
Type of connection Current-gas R1/4
Control 7-pin
Coolant -
Electrode diameters mm 1.0…2.4
Load capacity @ 40 % (Argon) A 130
Load capacity @ 100 % (Argon) A -
Operating temperature range (°C) °C -10…+40 °C
Storage temperature range °C -40…+60 °C
Minimum cooling power at 1.0 l/min kW -
Remote control Optional
Neck type Bendable
This equipment complies with standard IEC 60974-7.
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Flexlite TX
Operating manual - EN
6.2 Technical data TX 165
Flexlite TX 165GF, TX 165GS, TX 165G
Feature Value
TX 165GF: TX 165GS: TX 165G:
Type of cooling Gas Gas Gas
Coolant flow rate (l/min) l/min ---
Coolant pressure (min) MPa ---
Coolant pressure (max) ---
Arc striking voltage kV 10 10 10
Rating of electrical components (remote, nominal) V 10 10 10
mA 10 10 10
Type of connection Gas/current R1/4 R1/4 R1/4
Control 7-pin 7-pin 7-pin
Coolant ---
Electrode diameters mm 1.0…4.0 1.0…2.4 1.0…4.0
Load capacity @ 40 % (Argon) A 160 160 160
Load capacity @ 100 % (Argon) A ---
Operating temperature range (°C) °C -10…+40 °C -10…+40 °C -10…+40 °C
Storage temperature range °C -40…+60 °C -40…+60 °C -40…+60 °C
Minimum cooling power at 1.0 l/min kW ---
Remote control Optional Optional Optional
Neck type Bendable Rotating 70° angle
This equipment complies with standard IEC 60974-7.
6.3 Technical data TX 225 and TX 255
Flexlite TX 225G, TX 225GS, TX 255WS
Feature Value
TX 225G: TX 225GS: TX 255WS:
Type of cooling Gas Gas Liquid
Coolant flow rate (l/min) l/min --1
Coolant pressure (min) MPa --1
Coolant pressure (max) --5
Arc striking voltage kV 10 10 10
Rating of electrical components (remote, nominal) V 10 10 10
mA 10 10 10
© Kemppi 20/24 1920910 / 1921