ESAB TXH 121 User manual

Brand: ESAB

Model: TXH 121

Category: Welding System

Type: User manual

This manual is also suitable for

TXH™

Instruction manual

0463 349 001 GB 20150126

TXH 121, TXH 151, TXH 201,

TXH 251, TXH 401

TABLE OF CONTENTS

0463 349 001 © ESAB AB 2015

1 SAFETY ................................................................................................................ 4

2 INTRODUCTION................................................................................................... 6

2.1 Overview ............................................................................................................... 6

3 TECHNICAL DATA ............................................................................................... 7

4 OPERATION ......................................................................................................... 9

4.1 General.................................................................................................................. 9

4.2 Connections .........................................................................................................9

4.3 Choice of electrode.............................................................................................. 9

4.4 Grinding .............................................................................................................. 10

4.5 Bending of the flexible torch.............................................................................10

5 MAINTENANCE.................................................................................................. 11

5.1 Daily..................................................................................................................... 11

6 FAULT-TRACING................................................................................................ 12

7 ORDERING SPARE PARTS ............................................................................... 13

FLOW CHARACTERISTIC ........................................................................................14

ORDERING NUMBERS.............................................................................................15

WEAR PARTS............................................................................................................18

ACCESSORIES .........................................................................................................25

Rights reserved to alter specifications without notice.

1 SAFETY

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who

works on or near the equipment observes all the relevant safety precautions. Safety

precautions must meet the requirements that apply to this type of equipment. The following

recommendations should be observed in addition to the standard regulations that apply to

the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the

equipment. Incorrect operation of the equipment may lead to hazardous situations which can

result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

○ its operation

○ location of emergency stops

○ its function

○ relevant safety precautions

○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:

○ no unauthorised person is stationed within the working area of the equipment when it

is started up

○ no-one is unprotected when the arc is struck or work is started with the equipment

3. The workplace must:

○ be suitable for the purpose

○ be free from drafts

4. Personal safety equipment:

○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could

become trapped or cause burns

5. General precautions:

○ Make sure the return cable is connected securely

○ Work on high voltage equipment may only be carried out by a qualified electrician

○ Appropriate fire extinquishing equipment must be clearly marked and close at hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

CAUTION!

Read and understand the instruction manual before

installing or operating.

1 SAFETY

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WARNING!

Arc welding and cutting can be injurious to yourself and others. Take precautions

when welding and cutting. Ask for your employer's safety practices which should

be based on manufacturers' hazard data.

ELECTRIC SHOCK - Can kill

• Install and earth the unit in accordance with applicable standards

• Do not touch live electrical parts or electrodes with bare skin, wet gloves or

wet clothing

• Insulate yourself from earth and the workpiece

• Ensure your working stance is safe

FUMES AND GASES - Can be dangerous to health

• Keep your head out of the fumes

• Use ventilation, extraction at the arc, or both, to take fumes and gases away

from your breathing zone and the general area

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens and

wear protective clothing

• Protect bystanders with suitable screens or curtains

FIRE HAZARD

• Sparks (spatter) can cause fire. Make sure therefore that there are no

inflammable materials nearby

NOISE - Excessive noise can damage hearing

• Protect your ears. Use earmuffs or other hearing protection.

• Warn bystanders of the risk

MALFUNCTION - Call for expert assistance in the event of malfunction.

Read and understand the instruction manual before installing or operating.

PROTECT YOURSELF AND OTHERS!

ESAB can provide you with all necessary welding protection and accessories.

2 INTRODUCTION

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2 INTRODUCTION

2.1 Overview

TIG torches TXH 121 -TXH 401 are intended for manual TIG welding and are available with

water or air cooled. Certain models are available with flex heads for unlimited movement in

confined spaces.

Accessories for the product can be found in the "ACCESSORIES" chapter of this

manual.

The TIG torch is supplied with:

• an electrode:

○ Ø 1.6 mm TXH121

○ Ø 1.6 mm TXH151

○ Ø 2.4 mm TXH201

○ Ø 2.4 mm TXH251

○ Ø 3.2 mm TXH401

• wear parts

• an instruction manual

3 TECHNICAL DATA

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3 TECHNICAL DATA

Operating temperature range -10 to +40°C

Transportation temperature -20 to +55°C

TXH

121

121r

TXH

121V

TXH

121F

121Fr

TXH

151

151r

TXH

151V

TXH

151F

151Fr



A / %

120/60

100/100

120/60

100/100

120/60

100/100

150/35

120/60

100/100

150/35

120/60

100/100

150/35

120/60

100/100

1.0-3.2 1.0-3.2 1.0-3.2 1.0-3.2 1.0-3.2 1.0-3.2

Ar/He

4 & 8 m 4 & 8 m 4 & 8 m 4 & 8 m 4 & 8 m 4 & 8 m

X - X X - X

15 15 15 15 15 15

113 113 113 113 113 113

TXH

201

201r

TXH

201V

TXH

201F

201Fr

TXH

251w

251wr

TXH

251wF

251wFr

TXH

401w

401wr

TXH

401w HD

401wr HD

- - - X X X X

- - - 70 70 70 70



A / %

200/35

150/60

140/100

200/35

150/60

140/100

200/35

150/60

140/100

250/60

200/100

250/60

200/100

400/35

350/60

300/100

400/35

400/100

1.0-4.0 1.0-4.0 1.0-4.0 1.0-3.2 1.0-3.2 1.0-4.8 1.0-4.8

Ar/He

3 TECHNICAL DATA

0463 349 001

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4 & 8 m 4 & 8 m 4 & 8 m 4 & 8 m 4 & 8 m 4 & 8 m 4 & 8 m

X - X X X X X

15 15 15 15 15 15 15

113 113 113 113 113 113 113

- - - 0.5 0.5 0.5 0.5

- - - 0.1 0.1 0.1 0.1

- - - 1 1 1 1

Duty cycle

The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or

cut at a certain load without overloading. The duty cycle is valid for 40°C/104°F.

Protection class

The torches protection class machine side (EN 60 529)



IP3X

Enclosure class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration

by solid objects of 2.5 mm Ø and greater. Omitting second characteristic numeral.

4 OPERATION

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4 OPERATION

4.1 General

General safety regulations for handling the equipment can be found in the "SAFETY"

chapter of this manual. Read it through before you start using the equipment!

Read the operating instructions for the welding components, e.g. power source and connect

accordingly.

4.2 Connections

Tighten the connections for the torch carefully to avoid overheating the connection,

connection interference, mechanical damage or leakage of liquid or gas.

Connect water connections to the torch so that the red terminal is always connected to the

corresponding red terminal and the blue terminals are always connected to the

corresponding blue terminals.

4.3 Choice of electrode

By alloying the tungsten electrode with 1% to 2% lantha or cerium the electron discharge is

increased, which gives better striking and restriking and therefore increased arc stability.

Alloyed tungsten electrodes have a longer service life, tolerate higher currents and are less

likely to leave tungsten residue in the weld.

Pure tungsten electrode (AC) Green WP Used when welding

light metal alloys

Cerium alloyed tungsten eletrode

(AC/DC)

Grey WC20 Used when welding

light metals such as

aluminium and

magnesium. Electrode

tip must be rounded

when welding

Lantha alloyed tungsten electrode

(DC)

Gold WL15 Usually used when

welding stainless steel,

steel, copper, titanium

etc.

Lantha alloyed tungsten electrode

(AC/DC)

Black WL10 Used when welding

light metal alloys,

stainless steel, steel,

copper, titanium etc.

Selection table

A / AC A / DC

W CeO2 La2O3 CeO2 La2O3

1.0

1.6

2.4

3.2

4.0

6.4/8.0

6.4/8.0/9.8

9.8/11.2/12.7

11.2/12.7

12.7

10-60

50-100

100-160

130-180

180-230

60-90

90-130

140-190

200-250

15-100

70-160

110-200

150-205

180-270

70-80

80-140

150-210

220-320

330-420

20-100

80-160

120-230

200-305

250-420

4 OPERATION

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4.4 Grinding

Grind tungsten electrodes according to the following table:

NOTE!

Tungsten electrodes must be ground lengthways. If they are ground incorrectly

the arc may be unstable. When the welding current is increased the angle must

also be increased.

When welding with alternating current (AC) the electrode end must be gently rounded.

Grinding the electrode is then unnecessary. Light grading of the edge is sufficient. The

electrode forms itself if it is carefully overloaded. If the tip becomes ball shaped while welding

using alternating current, this is a sign that the current is too high for the diameter of

electrode being used.

Welding current Electrode angle

20 A

20 -100 A

100 -200 A

over 200 A

30°

30°-90°

90°-120°

120°

4.5 Bending of the flexible torch

The life of the flexible torch is limited, the

maximum bending angle should be 45

degrees.

The life of the torch head can be prolonged by

proper technique.

Always make sure that the torch head is

supported by the thumb when you bend. This

prevents damages at sharp bendings.

5 MAINTENANCE

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5 MAINTENANCE

NOTE!

Regular maintenance is important for safe, reliable operation.

WARNING!

The mains supply must be disconnected before cleaning.

CAUTION!

All warranty undertakings from the supplier cease to apply if the customer

attempts any work to rectify any faults in the product during the warranty period.

5.1 Daily

• Check that all cables and hoses are undamaged and that there are no kinks in them.

• Check that the gas nozzle is free from defects and suitable for the work in question.

• Check that the shielding gas flows evenly and without restriction.

• Check that the electrode is undamaged and that the electrode has been ground to the

correct angle.

• Check the water flow at the unit's return line.

6 FAULT-TRACING

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6 FAULT-TRACING

Read the operating instructions for the welding components, e.g. power source.

If the measures described below are not successful, please consult your dealer or the

manufacturer.

Problem Cause Solution

The arc does not

strike

• Cable or contact is poor.

• Torch electrode is badly

oxidised.

• There are impurities in the

shielding gas (moisture, air).

• The electrode used is too large

or stubby at low current.

• Check the cable and contact.

• Regrind along the length of the

electrode.

• Flush clean with gas.



• Replace with a smaller

electrode.

No trigger function • Control cable interrupted/faulty. • Check/repair.

Gas shielding is

poor

• There are impurities in the

shielding gas (moisture, air).

• There are impurities in the

base material (rust, lubricant).

• Insufficient or total lack of

shielding

gas.

• It is too draughty at the welding

site.

• Welding spray has fastened on

the gas lens or the gas hood.

• Flush clean with

gas.

• Clean the base

material.

• Check contents of the gas

bottle/hoses and the pressure

setting.

• Shield the welding area with

protective screens.

• Clean or replace.

7 ORDERING SPARE PARTS

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7 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised service

technician. Use only original spare and wear parts.

TXH 121, TXH 151, TXH 201, TXH 251w, TXH 401w is designed and tested in accordance

with the international and European standards IEC-/ EN 60974-7. It is the obligation of the

service unit which has carried out the service or repair work to make sure that the product

still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the back cover of this

document. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures

correct delivery.

FLOW CHARACTERISTIC

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FLOW CHARACTERISTIC

Flow characteristic

P = Pressure

Q = Flow rate

ORDERING NUMBERS

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ORDERING NUMBERS

F=flexible body, V=valve, w=water cooled, HD=Heavy Duty

Ordering no. Type Torch head OKC

OKC

Connec

tion

ESAB

std

Connec

tion Tig

150i/

200i

Water

Switch Valve F head 4m 8m 4m 8m 4m 8m 4m 8m

0700300522 TXH™ 121 X X X

0700300523 TXH™ 121V X X X

0700300524 TXH™ 121 X X X

0700300525 TXH™ 121F X X X X

0700300526 TXH™ 121F X X X X

0700300527 TXH™ 121 X X X

0700300528 TXH™ 121V X X X

0700300529 TXH™ 121 X X X

0700300530 TXH™ 121F X X X X

0700300531 TXH™ 121F X X X X

0700300532 TXH™ 121 X X X

0700300533 TXH™ 121F X X X X

0700300534 TXH™ 121 X X X

0700300535 TXH™ 121F X X X X

0700300536 TXH™ 151 X X X

0700300537 TXH™ 151V X X X

0700300538 TXH™ 151 X X X

0700300539 TXH™ 151V X X X

0700300540 TXH™ 151F X X X X

0700300541 TXH™ 151F X X X X

0700300542 TXH™ 151 X X X

0700300543 TXH™ 151V X X X

0700300544 TXH™ 151 X X X

0700300545 TXH™ 151V X X X

0700300546 TXH™ 151F X X X X

0700300547 TXH™ 151F X X X X

0700300548 TXH™ 151 X X X

0700300549 TXH™ 151F X X X X

0700300550 TXH™ 151 X X X

0700300551 TXH™ 151F X X X X

0700300552 TXH™ 201 X X X

0700300553 TXH™ 201V X X X

0700300554 TXH™ 201F X X X X

0700300555 TXH™ 201 X X X

ORDERING NUMBERS

0463 349 001

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0700300556 TXH™ 201V X X X

0700300557 TXH™ 201F X X X X

0700300558 TXH™ 201 X X X X

0700300559 TXH™ 201F X X X X

0700300560 TXH™ 201 X X X

0700300561 TXH™ 251w X X X X

0700300562 TXH™ 251wF X X X X X

0700300563 TXH™ 251w X X X X

0700300564 TXH™ 251wF X X X X X

0700300565 TXH™ 401w X X X X

0700300566 TXH™ 401w

X X X X

0700300567 TXH™ 401w X X X X

0700300568 TXH™ 401w

X X X X

F=flexible body, V=valve, w=water cooled, HD=Heavy Duty

Ordering no. Type Torch head OKC 50 Connection

ESAB std

Water

Switch F head 4 m 8 m 4 m 8 m

0700300620 TXH™ 121r X X X

0700300621 TXH™ 121Fr X X X X

0700300622 TXH™ 121r X X X

0700300623 TXH™ 121Fr X X X X

0700300624 TXH™ 151r X X X

0700300625 TXH™ 151Fr X X X X

0700300626 TXH™ 151r X X X

0700300627 TXH™ 151Fr X X X X

0700300628 TXH™ 201r X X X

0700300629 TXH™ 201Fr X X X X

0700300630 TXH™ 201r X X X

0700300631 TXH™ 201Fr X X X X

0700300632 TXH™ 251wr X X X X

0700300633 TXH™ 251wFr X X X X X

0700300634 TXH™ 251wr X X X X

0700300635 TXH™ 251wFr X X X X X

0700300636 TXH™ 401wr X X X X

0700300637 TXH™ 401wr HD X X X X

0700300638 TXH™ 401wr X X X X

0700300639 TXH™ 401wr HD X X X X

0459839087 Spare parts list

ORDERING NUMBERS

0463 349 001

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Ordering no. Type Torch head OKC 50 Connection

ESAB std

Water

Switch F head 8m 12m 16m 8m 12m 16m

0700300682 TXH™ 251WF X X X X X

0700300683 TXH251™ WF X X X X X

0700300806 TXH401™ WF X X X X X

0700300662 TXH™ 201

Wheel Remote

X X X X

0700300663 TXH™ 251W

Wheel Remote

X X X X X

0700300659 TXH™ 251W

Wheel Remote

X X X X X

0700300660 TXH™ 401W

Wheel Remote

X X X X X

NOTE!

CAN based adapter, is to be used for connection of above TIG torches with

remote function, see Accessories in Section 4“ACCESSORIES”, page25.

Spare parts may be ordered through your nearest ESAB dealer, see the back cover of this

document. When ordering, please state product type, serial number, designation and spare

part number in accordance with the spare parts list. This facilitates dispatch and ensures

correct delivery.

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service

technician. Use only ESAB original spare and wear parts.

Technical documentation is available on the Internet at www.esab.com

WEAR PARTS

0463 349 001

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WEAR PARTS

Tungsten electrodes Eco

Ordering no.

150 mm

Ordering no.

175 mm

Tungsten

electrodes Eco

Diameter Colour Code Current

0151 574 245

0151 574 210

0151 574 211

0151 574 009

0151 574 010

0151 574 011

0151 574 012

Wolfram, pure

Ø 1.6

Ø 2.0

Ø 2.4

Ø 3.2

Ø 4.0

Green

0151 574 237

0151 574 242

0151 574 238

0151 574 239

0151 574 240

0151 574 037

0151 574 038

0151 574 039

0151 574 040

Cerium 2%

Ø 1.6

Ø 2.0

Ø 2.4

Ø 3.2

Ø 4.0

Grey

WC20

AC/DC

0151 574 230

0151 574 231

0151 574 232

0151 574 233

0151 574 234

0151 574 235

0151 574 050

0151 574 051

0151 574 052

0151 574 053

0151 574 054

0151 574 055

Lantan 1.5%

Ø 1.0

Ø 1.6

Ø 2.0

Ø 2.4

Ø 3.2

Ø 4.0

Ø 4.8

Gold

WL15

AC/DC

WEAR PARTS

0463 349 001

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Nozzles, collets, collet bodies and gas lenses for TXH torches

Bold = standard delivery

Item Size Denomination Ordering no.

1 Long

Medium

Short

Back cap 0365 310 051

0365 310 050

0365 310 049

2 Heat shield 0366 960 017

3 Ø 1.0

Ø 1.6

Ø 2.0

Ø 2.4

Standard collet 0365 310 028

0365 310 029

0365 310 030

0365 310 091

4 Ø 1.0

Ø 1.6

Ø 2.0

Ø 2.4

Standard collet body 0365 310 037

0365 310 038

0365 310 039

0365 310 091

5 Ø 0.5

Ø 1.0

Ø 1.6

Ø 3.2

Gas lens body 0157 121 016

0157 121 017

0157 121 018

0157 121 041

6 Ø 6.4 (No.4)

Ø 8.0 (No.5)

Ø 9.8 (No.6)

Ø 11.2 (No.7)

Ø 12.7 (No.8)

Ø 15.9 (No.10)

Standard ceramic cup 0365 310 044

0365 310 045

0365 310 046

0365 310 047

0365 310 048

0588 000 440

7 Ø 6.4

Ø 8.0

Ø 9.8

Ø 11.2

Ø 12.7

Gas lens cup 0157 121 032

0157 121 033

0157 121 034

0157 121 039

0157 121 040

WEAR PARTS

0463 349 001

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ESAB TXH 121 User manual

Brand: ESAB

Model: TXH 121

Category: Welding System

Type: User manual

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