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Practical answers on running, caring for and choosing parts for water-cooled TIG torches and their cable sets.
A water-cooled torch needs a separate cooler (a pump, tank and radiator) that circulates coolant through the torch head and back along the power cable. The cooler is normally connected to the welding machine, so check that yours is designed for the torch and the machine.Some coolers include flow detection intended to stop the torch overheating if flow is lost, but check whether yours has it and do not rely on it alone. Water cooling is usually chosen for higher-current or long-duty work, but always check the torch's rating and duty cycle on its data plate and in the manual.
Switch on the cooler and machine and look over the hoses and fittings while the coolant is flowing under pressure. Check for drips at the torch head, handle and connectors, and make sure all fittings are tight and nothing is cracked, bulging or kinked.Also confirm the hoses are connected the right way round, so coolant reaches the torch head first. If you find a leak or the torch is running hot, stop and fix it before welding. Do not weld with a torch that is leaking or overheating.
The usual cause is poor coolant flow: a low coolant level, a cooler that is not running properly, a kinked or blocked hose, or debris in the narrow passages of the torch. Welding above the torch's rated current for long periods, or on a heavy duty cycle, also overheats it. Loose or worn front-end parts can add to the problem.Stop welding, check the cooler level and operation, look over the hoses for kinks and leaks, and compare your settings with the torch rating. If the fault persists, have the torch checked rather than carrying on.
An extra-flexible power cable is a softer, more flexible construction, usually with a silicone outer and braided cover. Makers describe it as lighter and easier to handle than a standard cable, which is less tiring on long jobs, and it stays more pliable in cold conditions. On a water-cooled torch the coolant returns along the power cable, so it is part of the cooling circuit as well as carrying the welding current.Whichever you choose, make sure it matches your torch type, length and machine connections, and check its rating on the data plate. A longer cable set gives more reach but is more to manage on the bench.
