Curious Tig function question

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Okay, I'm pretty new to this and trying to understand the process. I've been welding on friends machines off and on for a few years and finally scored an amazing deal on a Miller Dynasty 200DX. Friends convinced me that I should get a water cooled torch so I got a Weldcraft WP-20 and a Coolmate 1. I'm waiting on the Q5W Din connector to hook it up but when looking at the connectors it seems like they are empty tubes. Considering the arc that is created I expected to find some wire in there but I didn't. It seemed to me that the only way current could travel to the torch was if it was in the water, or in the gas. Or am I just missing something? The braided lines with the torch are for water to the torch, water return and Argon. Is there metal around the argon tube? Can someone just explain how that works? Where is the power? The ground lead is enormous but there seems like nothing copper in the torch cables. I'd just like to understand the process as I'm a curious cat. Thanks, Gregor
Reply:There is a flexible braided conductor inside the cable-hose.More than a few seconds of heavy current flow without coolant flow and it goes into overheat and tube meltdown.Good Luck
Reply:Is it the same for an aircooled torch? It's amazing to me the disparity between the ground and the torch leads. Thanks!
Reply:Originally Posted by sakuramaIs it the same for an aircooled torch? It's amazing to me the disparity between the ground and the torch leads. Thanks!
Reply:My air cooled tig torch uses a regular stranded copper power cable, nothing special.  It has a seperate hose for the gas, which is also just a regular rubber hose, nothing special.In my water cooled torch, water travels to the torch from the cooler pump via a hose, which is nothing special, just a flexible braid covered hollow tube.  The water returns from the torch to the cooler tank via the power/water line.  The power/water-return line looks like the water supply hose, but has a thin stranded copper cable inside it that the water flows around, which cools the cable.  The cable is bonded to the metal connectors at the ends of the hose.  The connectors transfer power from the machine Dinse power/water connector to the inner cable, then to the torch/tungsten.  The Dinse connector slits off the power and water, sending the water back to the tank via a short hose, which is just a hose, nothing special.  There is a separate hose for the gas.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Thanks for the replies - it makes sense now. It's surprising that so much power can travel through such a small wire. I suppose a lot of it is the new inverter technologies. It's fascinating that the power and water are together in one hose. Since it seems that even a few seconds without the cooler on will melt the hoses are there any ways of preventing this since it seems inevitable that I'll forget it at some point just like I occasionally forget to turn on the argon. Ideally I'd like to have the Coolmate and Dynasty switched on together but different voltages would seem to make that impossible. I've heard of fuseable links to protect the lines - any other things that work besides a really good memory which I can't seem to find.
Reply:You could switch them together, but it would be an overly complex electrical project.I think you just need to build a habit/ritual of turning it on first, and turning it off last.Maybe a reminder on a cover on the Dynasty?
Reply:Originally Posted by sakuramaSince it seems that even a few seconds without the cooler on will melt the hoses are there any ways of preventing this since it seems inevitable that I'll forget it at some point just like I occasionally forget to turn on the argon.
Reply:No water flow and this happens FAST!!!http://weldingweb.com/vbb/showthread.php...light=Meltdown...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:This looks like the best solution I've found for now. Maybe a note on the torch too.
Reply:Somebody should sell those!  And quite nice in matching Miller blue too.
Reply:Originally Posted by sakurama. . .it seems inevitable that I'll forget it at some point just like I occasionally forget to turn on the argon. . . .any other things that work besides a really good memory which I can't seem to find.
Reply:Originally Posted by sakuramaThis looks like the best solution I've found for now. Maybe a note on the torch too.
Reply:My Dialarc has the cooler plugged into an accessory 110v outlet on the machine, so the cooler comes on whenever the machine is on, unless I unplug it.   My Thermal Arc is not so easy, there is no accessory plug, so I have to remember to turn on the cooler.  I have forgotten a few times, but so far no hose damage, knock on wood.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:On a welder that i used to use, we just taped a note to turn on the cooler right over the top of the switch for the welder, so that you had to lift up the note before you could turn on the welder.Ian TannerKawasaki KX450 and many other fine tools