Maiden voyage of my budget water-cooled setup

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Today, the last of the pieces (DINSE adapter) to assemble my budget water cooled torch rig arrived.Built a little stand for it to sit on top of the Syncro 200.I guess I could have tried to remove the lifting eye from the machine but I was in a hurry.The damage;Used Tweco TC 900 cooler     $250Used Weldcraft WP20             $87New WeldTec nylon cover        $37New DINSE adapter                $62LH extension hose                  $24RH & LH threaded couplings    $221 gallon low silicate coolant     $101 gallon distilled water              $1       Grand total                            $493I took a chance on the torch on ebay, the seller said he thought the leads were only 6' but they did not look that short judging from the coil (and the fact that I couldn't find a Weldcraft WP20 with hoses any shorter than 12'). I was right, 12 ft. hoses.When I fired up the cooler initially, it did not pump. I disassembled it and found 2 of the bottom copper loops in the radiator were split, probably from freezing (odd since the unit was 1/4 full of antifreeze mix when I bought it). When I called the seller on it, he offered to pay for repair at a radiator shop. Good guy! I soldered it myself with a propane torch and copper plumbing supplies, and it has held so far. Luckily the radiator is on the vacuum side so I think it will be okay.Hooked it up and ran some beads. Felt the torch head when I was done (the rubber part!) and it was nice 'n cool. SWEET! After running the pump for 10 minutes there was a drip of coolant hanging off the end of the pump. I wiped it off and within a few minutes it had not even formed a drip. Mayber there is a dried out o-ring in there. No leakage out the motor side of the pump so that seal seems okay.One problem I have occasionally (since before the new torch) is hard starting of the arc, and then an explosive discharge when the arc finally starts. I checked the HF start and it was on hot start. Possibly my tungsten is not close enough to the work?JoeLast edited by scudzuki; 02-03-2012 at 07:21 PM.Miller Syncrowave 200Mac/Miller MW130 MIGKalamazoo bandsawCincinnati Arrow 500 VMCColchester Dominion 15 x 36 lathe with 2 axis DRO
Reply:Here's the set up I did about 5months ago!  Cost me about $700 all together.I tig welded the bracket then bolted it on top after I took the eye hook off!  LOLIt sure is nice when there running cool huh! Attached ImagesAEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:Very nice, but why would you guys put a water tub ABOVE your welder?  The similar issue in wiring is not to put water pipes above a breaker panel, unless you have a safety trough there in case of a leak.  If it's temporary, then no big deal, but I'd move that down below, or to the side before you find out the hard way why you want to do that....  At least a secondary pan that can hold the fluid capacity of the unit as backup would be wise.  It looks like houseoffire may have a second tub that he made and painted red to match there, or maybe that is just a stop to keep the cooler from falling off.I've seen too many things that "will never leak" do just that to be complacent about it, myself.  My $0.02-DaveXMT304 with: 22A Feeder, or HF251 Hi Freq DC TIG air cooled
Reply:I have seen many coolers on top of the welder.Can't put it under the welder unless I build a cart.Ditto to putting it on the side.Stainless steel tank on my cooler, not likely to develop a leak.JoeLast edited by scudzuki; 02-03-2012 at 11:07 PM.Miller Syncrowave 200Mac/Miller MW130 MIGKalamazoo bandsawCincinnati Arrow 500 VMCColchester Dominion 15 x 36 lathe with 2 axis DRO
Reply:Originally Posted by scudzukiWhen I fired up the cooler initially, it did not pump. I disassembled it and found 2 of the bottom copper loops in the radiator were split, probably from freezing (odd since the unit was 1/4 full of antifreeze mix when I bought it). When I called the seller on it, he offered to pay for repair at a radiator shop. Good guy! I soldered it myself with a propane torch and copper plumbing supplies, and it has held so far. Luckily the radiator is on the vacuum side so I think it will be okay.After running the pump for 10 minutes there was a drip of coolant hanging off the end of the pump.
Reply:Very nice, but why would you guys put a water tub ABOVE your welder?
Reply:@Welds4You make a good point.I guess it won't take much to find a pan to put under it.I still think the logistically it will be pretty difficult putting the cooler anywhere but on top if it's going to be wheeled around.Again, I've seen several coolers in recent history sitting above or directly on top of the welder.Never gave it a second thought.JoeLast edited by scudzuki; 02-04-2012 at 12:02 AM.Miller Syncrowave 200Mac/Miller MW130 MIGKalamazoo bandsawCincinnati Arrow 500 VMCColchester Dominion 15 x 36 lathe with 2 axis DRO
Reply:Anyone have a good source for Procon pumps? I have a similar cooler that I got without a pump. So I need a new one.ChadMy JeepLincoln Power Mig 215 / Magnum 300 Mig Gun / SG Spool Gun / Dual TankLincoln X-TRACTOR 1GCMiller Digital Elite
Reply:I'd never consider putting a cooler on top of a 2-4K dollar welder.Only takes a couple drops of liquid to fry a component.On the Sync, the cooler (3X) is mounted under the power supply.On my Dynasty, the Coolmate 3 is mounted on a cart, under the power supply.The SS pan on that cooler may never leak, but hose fitings sometimes do.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:If a hose fitting  were to leak, there is not really any way for the coolant to get into the electronics from just dripping down!  Now if you were to spray directly into the face or back of the machine then there could be potentianl.So from that aspect we all must be aware of a burst hose!  Watch out for sharpies around you hose and you should be ok!AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:seems like a big *** gamble to me. why not hang it off the side with a support  or at least if your gonna keep it up top build a lil  roof like shroud that will deflect any water away from the machine350P 30A spool gun cut master 51  syncro 250 other stuff " take a dog off the street and make him prosper and he will not bite you sad the same cannot be said for man" i didnt use punctuation just to piss you off
Reply:Originally Posted by houseoffireIf a hose fitting  were to leak, there is not really any way for the coolant to get into the electronics from just dripping down!  Now if you were to spray directly into the face or back of the machine then there could be potentianl.So from that aspect we all must be aware of a burst hose!  Watch out for sharpies around you hose and you should be ok!
Reply:scudzuki  -  I have a Lincoln 355 TIG.  It came with a mount to horizontally mount the OEM heat-exchanger on top.  Top mountsare counter intuitive, but the factory does it.  Leaks are not the major concern; once you get the system tight, it will stay tight.The real concern, because of surface exposure, is inadvertentlylosing power to the pump.  I speak from experience because I havetoasted 3 TIG leads over the last 15 years.  The first clue thatsomething is wrong is water gushing from the base of the torch, in your hand and lap, by then all is lost.  It can cost $ 200.00 and waste an entire day to fix.     Every melt-down occured  immediately after: I had moved, or performed work close to the welder.  My advice, when a vital component is this exposedinsure that it cannot be turned off or unplugged without yourknowledge.   Shield the switch and tape the plug.   Opus
Reply:I put a locking plug on the back of my machine, the pump comes on whenever you turn the machine on!If you don't hear your pump come on then check it out prior to welding.AEAD 200LE, Lincoln precision tig 185, Millermatic 251, Spectrum 625 extreme, Victor torch , Smithy 1220LTD. and  Do all C-4 band saw ,  Always adding.
Reply:The Syncros have switched 115v outlets on the front of the welder.If the welder is on, the cooler is running.JoeMiller Syncrowave 200Mac/Miller MW130 MIGKalamazoo bandsawCincinnati Arrow 500 VMCColchester Dominion 15 x 36 lathe with 2 axis DRO