Crackling noise coming from my TIG torch cable

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While adjusting the argon flow by pressing the pedal I noticed a noise best described as "electric crackling" coming from the torch cable (Miller Syncrowave 200).  It might have been there since the beginning but I never noticed it before because I was too concentrated on striking the arc.  It appears to be there only when there is no arc struck (then again it might be there after the arc is struck, it's just that I can't hear it).  For what it is worth, the torch cable was a bit tangled when I noticed it and then after rolling the cable on the rack and pressing the pedal, it could be heard very clearly (maybe it has to do with coils of cable being close to each other?).  I unplugged the torch and ground clamp then replugged them and it was still there.Is that normal, should I be concerned?Thanks in advance for any help in that matter.
Reply:I assume your are using high frequency start, and the torch is water cooled?Maybe HF is jumping across from one coil to another, and from the cable to the rack?  May have something to do with "contaminated" water, regular tap water with metal ions causing conductivity in the water.  Some people use distilled water for torch cooling to help prevent electrolysis corrosion of the cable and connections.
Reply:Thanks for the reply.  The torch is air cool but the Syncro has the high frequency start feature on it.
Reply:you are leaking HF through the insulation (rubber coating) to ground (real ground, not the work side of the connection), not a good feeling when it happens and the hose is across your body.
Reply:Originally Posted by ChamferTrodeyou are leaking HF through the insulation (rubber coating) to ground (real ground, not the work side of the connection), not a good feeling when it happens and the hose is across your body.
Reply:it's happened to me with brand new hose, so i just limit the time it's in HF without a weld arc. once the welding arc is established it doesn't leak through the rubber (path of least resistance).it isn't arcing coil to coil, just hose to earth, and of course the machine housing is earth grounded for safety.is this a relatively new hose? if not replacement may clear it up.how long? 12.5 or 25 footer? if 25', do you need all that length?
Reply:The hose is 12.5' (it's the one that comes with the machine, WeldCraft torch).  It is brand new, I used it for the first time last Friday (I received the welder 3 weeks ago but had to wait for my argon cylinder to come in).
Reply:I've never had one do this so I'm basically lost here. Do you have a protective cover on it ? I use a leather wrap on mine, cheap insurance. Don't know about the cheap vinyl ones but leather won't conduct as long it's dry.Anything worth doing is worth doing RIGHT
Reply:I hear slight electrical "crackling" on occasion..I have a 25 foot watercooled torch and in the humidity the tubes will sweat under the handle..I can take the cover off..Hit the pedal..And touch the copper tubes inside and hear it too..Nothing to worry about as far as I'm concerned.....zap1I 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:Originally Posted by zapsterI hear slight electrical "crackling" on occasion..I have a 25 foot watercooled torch and in the humidity the tubes will sweat under the handle..I can take the cover off..Hit the pedal..And touch the copper tubes inside and hear it too..Nothing to worry about as far as I'm concerned.....zap1
Reply:Originally Posted by olddadI've never had one do this so I'm basically lost here. Do you have a protective cover on it ? I use a leather wrap on mine, cheap insurance. Don't know about the cheap vinyl ones but leather won't conduct as long it's dry.
Reply:Yeah, Zap probably nailed it !Anything worth doing is worth doing RIGHT
Reply:If its leaking HF, you could see it with the lights out.If its leaking HF, I would replace it.  It may short through you next time.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:As someone who has been blasted countless times while TIG welding, I wouldn't worry about it unless it caused a problem starting an arc or shocked me enough to become a real annoyance. It's not exactly a pleasant experience, but isn't that bad either. I've been hit much worse by static discharges.Miller EconotigCutmaster 38Yes ma'am, that IS a screwdriver in my pocket!
Reply:Originally Posted by Joe HAs someone who has been blasted countless times while TIG welding, I wouldn't worry about it unless it caused a problem starting an arc or shocked me enough to become a real annoyance. It's not exactly a pleasant experience, but isn't that bad either. I've been hit much worse by static discharges.--------------------------------------------------------------------------------If its leaking HF, you could see it with the lights out.If its leaking HF, I would replace it. It may short through you next time.David __________________
Reply:unless you bring in the garage floor, a new hose won't help. it's NOT the hose, it's the increased potential between the HF travelling in the hose and the damp floor (damp concrete is 'salty', i.e. the moisture is an electrolyte).
Reply:Originally Posted by David RIf its leaking HF, I would replace it.  It may short through you next time.David
Reply:Low voltage shocks aren't dangerous but they can either catch you off guard and put you in a dangerous situation or piss you off.
Reply:Probably won't hurt ya much...like the others said, it's more annoying than anything.  I had a boss once who told me he could remove warts with the HF...and so I fell for it. It did leave a little hollow hole, in my skin and in my EGO. Really, try to keep things dry, as water is your enemy in more ways than one. 1cents"deader than downtown alviso on a friday night"