Water cooled Tig torch question

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I got a WP20 TIG torch and notice the power cable is very small gauge. I am curious if anyone knows what percentage of the current if any is carried through the water itself in the return line of the cooler.   Also it would seem if the water was going to carry current it should travel on the Supply side where there is more water pressure than on the return side?Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:It does not matter which direction the water is flowing regarding electrical conductivity. Most torch makers are specifying that you not pressurize the power cable. Maybe for fear of spraying hot water on you.That being said, I pressurize all my power cables.Last edited by shovelon; 10-03-2011 at 10:38 AM.Reason: speellinWeld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:The water itself does not carry an apreciable amount of voltage.  Pure water will carry no elecricity.  So the only way for water to carry electicity is if it has conductive elements desolved in it. All the water cooled tigs that I have run from the factory have had the presure on the elecrode side of the water circiut. In 50 years I have never run an air cooled torch out of dozens. I have just lately bought a miller with an air cooled torch but havent hooked up the tig yet.  Mac
Reply:just trying to figure how they get away with such a small wire.   Maybe the water flowing around the wire keeps it cool which prevents resistance build up that would occur on an air cooled cable thus you can flow more current without the issue of build up of heat in the cable?Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Warning:  The information I have is from reading the manuals for water-cooled torches as I research what I want for my own setup.Every installation instruction I have seen for coolers and torches says that they want the return in the power cable so that the coolest water goes to the the torch head, where most of the heat is.  The returning water then comes down the power cable to cool that.You can also get a fusible link for the power cable, where there is a small strip of copper in the water.  If the water stops, then the fuse, which is easy and inexpensive to replace fails, instead of the torch head or the power cable.
Reply:Originally Posted by soutthpawjust trying to figure how they get away with such a small wire.   Maybe the water flowing around the wire keeps it cool which prevents resistance build up that would occur on an air cooled cable thus you can flow more current without the issue of build up of heat in the cable?
Reply:i doubt the sizing relies on the water to conduct current. i use low conductivity antifreeze/coolant in my cooler (it also has some algae inhibitors). i suspect the coolant prevents the cable from over heating allowing a smaller gauge to more current. that's my best guess
Reply:i'm still connnnfused ( why return heated water through the power lead) that is heated via power going to the torchmine has been water in through torch then out through return hose been this way since i got the welder no problems over 20 yrsbut hey i'm just a dumb weldorLast edited by prop-doctor; 10-03-2011 at 12:24 PM.idealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:I'm guessing most of the heat is generated at the torch head and relatively little is generated in the lead.  So if you didn't have the coldest water at the head you'd have a higher risk of boiling it into steam.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Originally Posted by prop-doctori'm still connnnfused ( why return heated water through the power lead) that is heated via power going to the torchmine has been water in through torch then out through return hose been this way since i got the welder no problems over 20 yrsbut hey i'm just a dumb weldor