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Answers for buyers choosing and looking after compact and extended-neck water-cooled TIG torches in the 180 amp class.
A short, button-style back cap and low-profile consumables shorten the overall head so it fits into small, low-clearance spaces. Makers note that short and medium back caps are used with tungsten electrodes cut down to a shorter length, whereas long back caps take a standard full-length electrode.What you give up is gas coverage and convenience. Smaller cups generally give less shielding coverage than larger ones, so you may need to slow down, watch the heat input and check the weld for discolouration or porosity. Your torch manual will say which cups, collets and back caps fit your head size.
Use the coolant specified in the manual for your cooler and torch. Makers advise a specially treated torch coolant rather than plain tap water, because untreated water can lead to algae growth and scale inside the torch and cable. Treated coolants also protect the pump and head from corrosion and may give frost protection.Do not assume that any antifreeze is suitable: some mixes can harm seals, block passages or affect the pump, so only use a product the cooler maker approves. Check the level regularly and change the coolant at the interval the maker gives.
Never start welding with a water-cooled torch unless the cooler is filled and running. Makers advise checking that coolant is circulating while you weld, and with many coolers you can see a strong return flow into the coolant tank when the system is working.If the torch or cable becomes unusually hot, stop and let it cool, then check the coolant level, the flow, any kinked or blocked hoses and whether the coolant is contaminated. Persistent overheating means the torch should be checked by a competent person rather than used until it fails.
Check that all coolant connections are leak-tight each time you set up, and look at the O-ring on the torch body before each start-up to make sure it is undamaged. Makers also advise inspecting coolant hoses, seals and connections regularly and replacing any that are damaged or leaking. A leak at the head, neck or hose should be fixed promptly because it can also lead to weld defects.When you disconnect the torch, seal the coolant hoses with the plug supplied so coolant does not spill. Before any maintenance, isolate the power source and shut off the gas.
