Answers for buyers choosing a complete heavy-duty water-cooled TIG torch with its cable and hose assembly.
What is included in a complete water-cooled TIG torch package, and how does it differ from buying parts?
A complete package normally supplies the torch head and handle already joined to a cable and hose assembly, so the power, gas and coolant lines come as one matched set with their machine connections. Buying parts separately suits a repair or an upgrade to a torch you already own.
The exact contents vary, and consumables such as the cup, collet and tungsten may or may not be included, so read the product description or ask our team before ordering. A package does not include the cooler, the machine or the gas supply, which you need separately. Check the torch data plate and manual for the rated current and the connection details.
What do I need alongside the torch before I can start welding?
You need a TIG power source that suits the torch, a cooling unit to circulate coolant through the supply and return hoses, a shielding gas supply with a regulator and flowmeter, and a suitable earth return. Many torches also have a control connection for a trigger or remote, so check that your machine has a matching socket.
One maker's commissioning steps are to connect the coolant hoses to the cooler, connect the torch to the power source, connect the gas, check the coolant level and then check the cooling function before welding. Follow the manuals for both the torch and your machine, and have a competent person carry out the installation.
How do I check the torch connections will fit my machine and cooler?
Compare three things before ordering: the power and gas connections, the coolant hose fittings, and the control plug or socket. Machines and coolers use different thread types and fittings, so look in your machine and cooler manuals or on their data plates, and note the thread form and size rather than guessing.
If the fittings differ, a suitable adapter or connector kit may exist, but only fit parts that are rated for the current and coolant pressure involved. Mixing up the supply and return coolant hoses is a common mistake, and the hoses are normally colour-coded to prevent it. If you are unsure, our team can help you match the torch to your equipment.
What is the correct order for setting up a new torch for the first time?
Follow the maker's commissioning steps. One manual's sequence is to inspect all components for damage, close the gas supply, fit the electrode, collet and cup, connect the coolant hoses to the cooler, connect the power cable and the gas line, then check the coolant level and the cooling function.
Bleed any air from the coolant circuit when commissioning a new cable assembly, and check every connection for leaks before you strike an arc. Flush the gas line before welding. Switch off and isolate the machine before assembling or disconnecting anything, and have a competent person carry out the work.
Does a 100% duty cycle rating mean I can weld non-stop at any current?
No. The rating applies only at the current stated alongside it, and it assumes the cooler is working properly, with the coolant at the right level and flowing. Welding at a higher current than the rating will reduce the time the torch can run.
Duty cycle is normally defined over a ten-minute period, so a 100% rating means continuous use at that current and a lower percentage means rest periods. Ratings can differ between DC and AC and depend on the maker's test conditions. Check the data plate and manual for the current, the polarity and the cooling conditions that apply to your work, and size the torch with some margin.
Can I use a DC torch rating for aluminium on AC?
Do not assume so. Makers publish separate DC and AC current ratings for the same torch, and the AC rating is typically lower. Water-cooled TIG torches are normally run with the electrode negative on DC for steels and stainless steels, while aluminium is welded with AC, which loads the electrode and head differently.
Read the AC figure in the data sheet if you will weld aluminium, and choose the tungsten type and diameter to match. Do not exceed the lower of the torch rating and the machine rating. If the data sheet does not list an AC figure, ask the maker or our team before relying on a DC number.