Kemppi Flexlite TX User manual

Flexlite TX
Operating manual - EN
FLEXLITE TX
© Kemppi 2 1920910 / 2039

Flexlite TX
Operating manual - EN
CONTENTS
1. Flexlite TX 4
2. About equipment 5
3. Installation 7
3.1 Assembling torch 8
3.2 Installing torch remote 10
3.3 Installing start switch extension 12
3.4 Connecting torch 14
4. Operation 17
4.1 Consumable and gas flow selection 18
4.2 Electrode tip 19
5. Maintenance 21
5.1 Troubleshooting 23
5.2 Disposal of machine 25
6. Technical data 26
6.1 Technical data TX 133 27
6.2 Technical data TX 135 28
6.3 Technical data TX 163 29
6.4 Technical data TX 165 30
6.5 Technical data TX 223 and TX 253 31
6.6 Technical data TX 225 and TX 255 32
6.7 Technical data TX 303 and TX 353 33
6.8 Technical data TX 305 and TX 355 34
6.9 Technical data TX E 223, TX E 253 and TX E 353 35
7. Ordering codes 36
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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 4-
pin or 7-pin connectors. Flexlite TX range covers both water-cooled and gas-cooled models.
Flexlite TX torches are available in two different levels, K3 and K5, each designed to serve specific welding needs.
K3 level K5 level
TX 133 TX 135
TX 163 TX 165
TX 223 TX 225
TX 253 TX 255
TX 303 TX 305
TX 353 TX 355
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 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.
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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 connector (start and remote signals)
8. Welding cable connector (shielding gas and welding current)
9. Coolant outlet and inlet hose connectors (water-cooled models only)
K3 level torches differ from K5 level torches in connectors, for example. For information on K3 level torch connectors,
refer to "Connecting torch" on page14.
10. ON/OFF switch
11. Switch cover
12. Torch handle
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Flexlite TX
Operating manual - EN
* Some Flexlite TX torch models also include a back cap insulating ring, in addition to the gas nozzle insulating ring.
Separate K3 level torches with a DIX connector and a manual gas valve in the torch body are also available. Use these
torches with MMA power sources for scratch and TouchArc TIG ignition.
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" on the next page
"Installing torch remote" on page10
"Installing start switch extension" on page12
"Connecting torch" on page14
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.
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Flexlite TX
Operating manual - EN
3.1 Assembling torch
This chapter describes a typical Flexlite TX welding torch assembly. The details shown may vary depending on the
exact torch setup.
1. Install 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 welding
application. For more information, refer to the section "Electrode tip" on page19.
4. Push the electrode into the torch and through the collet and gas nozzle.
5. Install the electrode back cap. Tighten the back cap to lock 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.
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Flexlite TX
Operating manual - EN
3.2 Installing torch remote
You can install a torch remote on a K5 level torch only.
Many Flexlite TX welding torches are equipped as standard with ON/OFF start/stop switches. Optional remote control
devices can be fitted to these TX torch models, allowing both start/stop function and welding current adjustment.
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.
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Flexlite TX
Operating manual - EN
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:)
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.
© Kemppi 11 1920910 / 2039