Practical answers on choosing, connecting and looking after water coolers designed to work with one maker's welding equipment.
Can I fit any water cooler to my welder, or must it be one made for it?
Not always. Some coolers are designed to work with particular power sources: they are supplied or switched through a control socket and cable, and the welder reads the flow sensor. Maker manuals for this type of cooler say it must be used with a power source that lists it as an approved accessory.
A cooler with its own mains lead and plain hose connections may suit other equipment, but it may not give the welder the flow signal that stops the arc on a fault. Check the welder's manual for the coolers it lists, and the cooler's data plate for voltage and connections, before connecting anything.
How do I check a cooler is right for my torch?
Compare the cooler's rating with the torch's rating, not just with the power source. Makers state the maximum welding current a cooler is rated for, usually at a stated duty cycle and ambient temperature, and a cooling power in kilowatts at a stated flow, often about one litre per minute. The torch manual gives its current rating and the coolant flow it needs.
Hot workshops, long hose sets and heavy duty cycles all reduce the margin, so leave some headroom. If you are unsure, our team can help you match the two.
Can I top up or mix coolants in a cooler like this?
Use only the coolant the manual for that particular cooler specifies, because makers differ. Some specify their own ready-mixed glycol coolant; others allow clean tap or distilled water where there is no risk of frost, with a water and pure ethylene glycol mixture below freezing. Several makers specifically warn against automotive antifreeze and against pre-packaged welding coolants, which can damage the pump and block the heat exchanger.
Do not mix types or brands, and do not top up with something just because it looks similar. If you do not know what is in the tank, drain it and refill as the manual says.
How is a cooler like this powered and connected?
It depends on the design. Some are supplied from the welding power source through a multi-pin socket and control cable; others have their own mains lead, sometimes with a voltage selector, plus a control lead to the power source.
Either way, make the connections with the power source switched off and disconnected from the supply, and have any supply connection made by a qualified electrician. A voltage selector, where fitted, must match the supply and should never be changed while the power is on. Follow the cooler manual for the exact arrangement.
What should I check each day before welding?
Check the coolant level before use, as makers advise a daily check, and keep it topped up, especially after disconnecting the hoses or changing the torch. Look over the hoses, couplings and torch for damage, kinks or leaks, check the cables and connections, and keep the fan and air slots clear of dust.
Periodically, with the unit switched off and isolated, clean dust from the cooling element and case, and flush or change the coolant if growth appears. Intervals vary by maker and workshop. Hot coolant can burn, so let it cool before servicing.
Can I switch the flow sensor off?
Many coolers have a flow sensor that stops the welding output when coolant flow is low or absent, to protect the torch. Some have a switch to turn it off, intended for short-term use such as priming a new system with coolant. With the sensor off, a missing flow is not detected, so a torch can overheat and be damaged quickly.
Switch it back on before welding. If it keeps tripping, look for the cause instead of bypassing it: low level, a kinked hose, a blocked or leaking torch line, or a torch rated too low for the current.