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Practical answers on running, caring for and choosing parts for water-cooled TIG torches and their cable sets.
Use the coolant the torch and cooler manufacturers specify, normally a purpose-made torch coolant. Plain tap water is not suitable because scale and algae can build up and block the small passages in the torch head.Do not use car antifreeze, which can thicken and clog the lines. Distilled water is, at most, a short-term emergency measure. Do not top up a pre-mixed coolant with water, as that changes its mix and its protection against freezing. If you are unsure, follow the cooler 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.
