Answers for choosing and setting up a complete water-cooled TIG torch package with head, cables and hoses.
What is included in a complete torch package?
A package normally combines the torch head and handle with the power cable, water hose and gas hose, ready to connect to the machine and cooler. The exact contents vary between packages, so read the listing to see the head style, cable length and the type of machine connections supplied.
What a package does not normally include is the cooler, the shielding gas supply, the power source or any remote current control. You will also need tungsten electrodes in the size you intend to use, and possibly adaptors if the machine's connections differ. Our team can help you check a package against your set-up.
Which head style suits my work: standard, flexible or pencil?
A standard rigid head is steady and robust, and is a good all-round choice for repetitive work. A flexible head lets you bend the neck to reach awkward joints, but the flexing mechanism is a wear point, so it is best for work where access is the problem. A pencil style body is slimmer and lighter, and is often chosen for fine, precise welding where you want a delicate feel.
These are general descriptions and the right choice depends on the joints you weld and how you hold the torch. If you regularly meet extreme access problems, ask about heads built for that. Check the head's current rating suits your machine.
How long should the cable be?
Choose the length that lets you reach the work comfortably without the machine and cooler needing to be moved. Longer leads give more freedom, but they are heavier, more awkward to manage and more likely to drag on the floor or snag.
Length also affects the gas. Long gas lines can produce a surge of gas when the arc starts, and a longer pre-flow setting or a shorter line can reduce it. Leave slack so the torch can move freely without pulling on the connections, and use a cable cover or support if the leads rub on the floor. Check the torch and cooler makers' guidance for any limits on hose length with your cooler.
Will the package fit my machine and cooler?
Check four things before ordering: the torch's current rating against your machine's output, whether your machine can use a water-cooled torch with an approved cooler, the connection types for power, gas and water, and the control connection if you use a torch switch.
The connections on the package must match the fittings on your machine and cooler, or you will need suitable adaptors. Cooler makers also state which power sources a cooler is approved for. Look at the data plates and manuals for the machine, cooler and torch, and ask if you are not sure which connections you have. Never force a connection that does not fit.
Which way round do the water hoses connect?
The coolant supply line must run from the cooler to the torch, and the return line must come back from the torch to the cooler. Cooler connections are usually marked for outlet and inlet, and the torch hoses are normally identified too.
It matters because reversing the lines can dislodge debris from the cooler or hoses and push it into the narrow passages in the torch head, restricting flow and causing overheating. Connect the hoses as shown in the torch and cooler instructions, switch on the cooler and check that coolant is circulating and nothing is leaking before you weld. If the connections are not marked, check the manuals before you run the cooler.
What should I check the first time I set up a new torch?
Fit the correct collet, collet body or gas lens, cup and back cap for your chosen tungsten size, making sure any seals and O-rings are in place and undamaged. Assemble the parts in the order the maker gives. A worn or cracked back cap O-ring can let air into the shielding gas and contaminate the weld.
Then connect the power, gas and water lines, switch on the cooler and gas, and look for leaks in the water and gas lines. Check that coolant is circulating before you strike an arc. Start with a test run on scrap, with a modest gas flow, before moving on to the real job.