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Answers to common questions about complete water-cooled TIG torch packages with flexible cables and machine connections.
TWI notes that lower currents use smaller electrodes and air cooling, while higher currents need a larger torch and water cooling. A water-cooled torch suits heavier material, higher currents and long, continuous welding, where an air-cooled torch can get too hot.The trade-off is extra equipment and upkeep: you need a cooler unit and coolant, and a little more maintenance. Compare your highest welding current and your typical weld time with the torch rating on the data plate or in the manual before you decide.
You need a TIG machine with a compatible torch connection, a coolant circulating unit, shielding gas and coolant. A water-cooled setup has more connections than an air-cooled one: the power lead, a gas connection and two water hoses, one carrying coolant to the torch and one returning it.The power cable is cooled by the returning coolant, so it must never be run dry. Check how your machine and cooler connect and whether the cooler can be powered from the machine, and read the manuals for both before first use.
Use the coolant that the cooler and torch makers specify. Torch makers advise against car antifreeze, which can coagulate and clog lines, and against ordinary tap water, which can corrode the system. Do not dilute a pre-mixed coolant, as that weakens its protection.Many TIG coolers call for a low-conductivity coolant, partly because of the high-frequency arc start. Check the cooler manual for the right product and the change interval, which depends on the maker and how heavily you use it.
With the cooler on and coolant circulating, check the hoses and connections for leaks and that they are tight, before you strike an arc. Check the coolant level, and look at the hoses for cracks, bulging or thin spots. Make sure the hoses are connected the correct way round, as the coolant should reach the torch head first.Do it at the start of every shift. Never weld with a torch that is leaking or that has no coolant flowing.
Poor coolant flow is a common cause of torch overheating, and the power cable inside the hose can be damaged quickly if the coolant stops. Blockages, air in the pump, a worn hose or low coolant can all reduce flow even when the cooler seems to be running.Some coolers or machines have a flow switch that shuts the torch down if flow is inadequate. If the torch gets hot or the cooler pump runs hot, stop welding, find the cause and fix it. Follow the maker's minimum flow figures for your torch and cooler.
Yes. Water or coolant on the floor near welding equipment is a shock hazard, so fix leaks promptly and wipe up spills before welding. Keep connectors, the machine and the cooler dry, and replace any hose that is cracked, bulging or leaking.If you find a leak at a torch connection, switch the machine off and isolate it before dealing with it. Where a torch repeatedly leaks or overheats, it should be replaced or repaired by a competent person following the maker's instructions and your risk assessment.