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Answers for buyers choosing, running and looking after a water-cooled manual TIG torch with a hose pack.
Follow the coolant recommendation in the manuals for both the torch and the cooling unit. Plain tap water is not recommended, because dissolved minerals make it conductive and it can cause electrochemical corrosion and deposits that clog the narrow passages in the torch.Distilled water is sometimes used, but it has no frost protection and no corrosion inhibitors, so a purpose-made welding coolant is the usual choice. Avoid car antifreeze, which is not designed for this job. Keep to one type of coolant and do not mix different products unless the maker says it is safe.
A water-cooled torch carries the heat away in a coolant loop, so it stays cooler at higher currents and over longer arc-on periods. It is usually chosen for sustained high-current work, thick sections or production welding. Air-cooled torches are generally lighter and simpler, and suit lighter or intermittent work.The switch-over current varies between makers, so check the torch rating and duty cycle at the current you will actually use. You also need a cooling unit, which adds equipment to move and look after.
Look at the torch rating plate or data sheet. It normally gives a maximum current for a stated duty cycle and the type of current (DC or AC). The torch should be rated at or above the current you will weld at, for the arc-on time you expect, and the rating assumes the coolant is flowing as the maker specifies.Torches are built to a safety and construction standard for arc welding torches, but the actual figures are set by the maker, so rely on the data plate and manual rather than a rule of thumb.
Overheating in a water-cooled torch usually comes down to the coolant not flowing properly. Common causes are a low coolant level, a cooling unit that is not running, kinked or blocked water lines, loose front-end parts, or welding above the torch rating for too long.Stop welding if the handle or cable becomes noticeably hot. Check the coolant level, make sure the cooler is running and the hoses are free, and confirm the front-end parts are tight. Blockage can also come from debris inside the cable, so a torch that keeps overheating despite these checks should be inspected or serviced.
In many water-cooled torches the copper power conductors sit inside the water path. Repeated bending, twisting and whipping of the cable fatigues the fine copper strands. Broken strands can be carried by the water to the end fitting, where they may block the flow and cause overheating and torch failure.To get the best life, avoid sharp bends, kinks and pulling the pack by the torch head, support the weight of the cable where you can, and replace a pack that is damaged or has restricted flow.
An up/down control is a pair of buttons or a rocker on the torch that lets the welder raise or lower the welding current without leaving the joint. It is useful when the current needs trimming during a run, for example on varying thickness or when finishing a weld.It only works when the torch control connection and the welding machine are designed to work together, so check that the torch version you choose supports it. Handles often come with or without extra operating elements.