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Answers for buyers choosing and fitting the power adaptors and hose connections that join a TIG torch to the welding machine and cooler.
Water-cooled torches have a coolant supply and a return hose, and on some torches the hoses or the cooler connectors are marked or colour-coded. The markings are not the same on every make, so do not rely on colour alone. Identify each hose from your torch manual and match it to the cooler connections shown in the cooler manual.Connecting the hoses the wrong way round, or mixing up the water and gas hoses, can stop the coolant circulating properly and the torch may overheat. If you are fitting a new cable assembly, check the hose connections before you switch the cooler on.
Follow the tightening method in your torch and machine manuals, because it differs between makers. Some specify hand-tightening of power and control connectors, while others call for the correct spanners or pliers on the hose and power cable fittings. Do not use excessive force, and do not use tools where the manual says hand tight.Loose connectors can overheat, cause poor electrical contact, damage the parts and lead to water or gas leaks. A power connector that feels hot in use, or that no longer seats firmly, should be checked before you carry on.
Before welding, check that every power, gas and water connection is fitted correctly and undamaged, that the cooler has enough of the coolant the maker specifies, and that the coolant is actually circulating once the cooler is running. Insufficient coolant flow can damage a water-cooled torch.Some makers also give a procedure for removing air from the coolant circuit when a new cable assembly is fitted. Start the cooler before you weld and look for leaks at every joint. Follow the torch and cooler manuals for the exact procedure.
Yes, it is good practice. Torch makers advise flushing the gas line and purging the regulator and torch with shielding gas whenever fittings have been detached, so that air trapped in the hose and torch is pushed out before you weld. Otherwise that air can reach the weld.The flow rate and time depend on the torch, the hose length and the manufacturer's instructions, so follow your manual rather than a fixed figure.
In TIG welding, porosity is most often caused by contamination or by a loss of gas shielding. A leaking hose joint, a poorly seated adaptor or a loose fitting can let gas escape or let air be drawn in, so the weld pool is not properly protected.If you see porosity, check the gas connections and hoses as well as the usual causes such as dirty material and draughts.
Central plug-and-socket connectors come in several sizes, and each plug is made to pair with a socket of the same size. They are also made for different ranges of cable size, so the size is set by the machine's output socket and the torch's cable, not by preference.Check the machine's manual or measure the existing plug or socket, and match the new part to both. Do not force a plug that is not a snug, easy fit, as a poor contact can overheat. If you are unsure, our team can help you choose.