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Straight answers to the questions people ask when choosing and looking after a water cooler made for a particular maker's welding machines.
Often it does. Coolant has to be pumped further and through more hose, so the flow reaching the torch usually falls as the hose pack gets longer, and the cooling needed to keep the torch within its limits goes up. Some torch makers publish a minimum cooling power for each hose pack length.Check the torch manual for the cooling power and coolant flow it asks for at your hose length, and compare that with the cooler's data plate or manual. Fitting a longer torch lead than before is a good moment to re-check the match.
It is the amount of heat, normally given in watts, that the cooler can carry away from the circuit. It is only meaningful alongside the coolant flow rate it was measured at, because capacity depends on the flow through the system and on the surrounding air temperature.Flow in turn depends on the length of any interconnecting cable, the torch hose length and the hose bore. When comparing coolers, look at the capacity quoted at the same flow, and choose one comfortably above what your torch needs. The torch and welder manuals give the figure to aim for.
That depends on the machine and cooler. Many installations use a flow switch or flow guard that detects low coolant flow and signals the power source to stop or inhibit the arc, because a torch run without cooling can overheat very quickly. Some coolers also monitor coolant level and temperature.Do not assume protection is built in. Read the manual to see what your cooler monitors, how it is connected to the welder, and what the warning or trip indication looks like. Never weld with the cooler switched off or the flow alarm ignored.
Switch the welder off first, and let the coolant cool down if the machine has been running. Disconnect the coolant hoses at the quick connectors, and fit the plastic sealing caps or plugs supplied with the torch to the torch hoses so coolant does not run out. Keep a container and cloth handy for the connectors on the cooler side.Coolant on the floor or on the machine is also an electrical hazard, so wipe up spills straight away. Follow the maker's instructions for your torch and cooler, as the order of steps can differ.
Stop welding, switch the machine off and isolate it from the supply. Coolant leaking near live parts or onto the floor is an electrical shock hazard, and a leaking torch can also be a sign that it is overheating.Look for the source before you restart: loose or damaged hose connections, a split or ballooning hose, or a cracked fitting. Replace any damaged hose or torch part rather than taping it. After repair, run the cooler and check every connection for leaks with coolant flowing before you strike an arc.
No. Use the coolant the maker specifies for the cooler. Some makers say not to add water to a ready-mixed coolant, and not to use car antifreeze or ethanol-based mixtures, which can damage the pump and block narrow passages. Topping up with the wrong liquid also upsets the corrosion protection and the freeze protection.If the level is low, fill with the same type of coolant, up to the maximum mark on the tank and no higher. If you are unsure what is in the cooler, check the manual or drain and refill rather than mixing.