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Water-cooled TIG torch packages with flexible heads and long flexible cables: how to choose, connect, check and look after them.
A water-cooled torch carries heat away with circulating coolant, so it suits higher welding currents and long, continuous welds. Air-cooled torches are popular for work at around 200 amps or less, while water-cooled torches are usually rated higher, and for shop work at 300 amps or more a water-cooled torch is generally recommended.Water-cooled cables are also usually lighter and more flexible because they need less copper, which is easier on the hand and wrist over a long day. Always match the torch rating to the current and duty cycle you actually run, and check the rating on the torch and in the maker's manual.
A water-cooled torch needs a cooling unit that circulates coolant through the torch and cables, plus a power source and shielding gas supply. The torch should never be used with the arc on unless coolant is flowing, because the torch can overheat very quickly without it.Check that the cooler is suited to the torch and the current you will run, and that the machine connections on your power source match the torch fittings. The torch and cooler manuals are the place to confirm hose connections and any flow protection your equipment uses.
Do not use plain tap water. Water-cooled systems need a specially treated coolant solution rather than tap water, because minerals and impurities can leave deposits that block the narrow passages in the torch and cables, and plain water gives no protection against corrosion or growth in the system.Use the coolant the cooler and torch makers specify, do not mix in automotive antifreeze, and keep to the maker's guidance on topping up and changing it. If you work in cold conditions, ask the maker about freeze protection that is suitable for TIG torches.
Make it a habit to inspect the torch before each use. Look over the hoses and fittings for tightness, cracks or bulging, and check there is enough coolant in the cooler. Then switch on the cooler and gas so the system is under flow, and look for leaks at the torch, cables and connections before you strike an arc.Coolant flow and pressure figures vary between coolers, so follow your cooler and torch manuals. If anything leaks, stop and repair or replace the part before welding.
It can. With a long gas line, the first gas released when the arc starts can be at a much higher flow rate than normal, which can cause turbulence and draw air into the shield. Two remedies are a shorter gas line, where your job allows, or a longer pre-flow so the line is purged before the arc starts.Use the lowest gas flow that gives good coverage, because too much gas also causes turbulence. A longer cable gives more reach from the machine, so choose the length you need rather than the longest one you could fit.
Stop welding, switch off the power source and have the problem put right before carrying on. A leaking or overheating water-cooled torch can be an electrical hazard as well as a cause of weld defects, because coolant and welding current should never meet.Common causes include loose connections, damaged or blocked hoses, low coolant and poor flow. Check the cooler level and the hoses and fittings, and replace damaged parts. If the cause is not obvious, follow the maker's instructions or have the equipment checked by a competent person.