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Welder Chiller-The Ultimate FAQ Guide by TopChiller

What is a Welder Chiller?

A Welder Chiller is used for resistance welding, cooling all the welding equipment, and welding processes. It is very important in welding operations to control temperature.

Weder chiller is commonly used with TIG and MIG welding machines to provide cooling to the welding operation.

The cooling effect dissipates the heat and fumes generated in the welding procedures.

The Welder Chiller is designed for controlling the electrode temperature and preventing overheating of the welding instruments. It also aids in uniform spot welds and decreases downtime.

Welder Chiller

What is the Working Principle of a Welder Chiller?

A Welder Chiller works on the principle of vapor compression performed by the compressor.

The cooling water circulates in the tubes of the water chiller and the coils of the evaporator continuously.

Cooled water circulates between the equipment and evaporator and controls the temperature.

A circulating water pump pushes water to the tubes where it transits its phase and returns into warm water.

Hot water again enters the refrigeration cycle and repeats the cycle. In this way, water is used to provide cooling to the welding equipment and welding operations without spending cost on water consumption.

What are the Basic Features of a Welder Chiller?

There are many features of a Welder Chiller that aid in downsizing the heat and promote cooling in welding operations.

Basic features play a vital role in providing efficiency. Features include:

• Welder Chiller Capacity

Such cooling equipment varies in capacity. A normal-sized Welder Chiller provides capacity ranging from 1.6KW to 1.8 KW.

• Temperature Control

To maintain the temperature of some area, equipment, or process, it is necessary to maintain the temperature that a thermostat can easily do. The normal temperature range of a Welder Chiller is from 7℃ to 35℃.

• Water Flow Rate

Flow rate is another important feature that is controlled to prevent any damage. The chilled water is set at a flow rate of 480LPM.

• Build-In Water Tank

Welder Chiller comprises build-in water tanks for storage of circulating water. This saves water cost consumption.

• Cooling Efficiency Compressor

A high-quality cooling efficiency compressor is attached with Welder Chiller to provide efficient cooling during welding operations.

What are the Main Components of a Welder Chiller?

A Welder Chiller has the same composition as any other air or water-cooled chiller.

It consists of a cooling water tank, circulating water pump, compressor, radiation fan, and control panels. The components include:

• Refrigeration Compressor

A compressor is the heart of a refrigeration system. There are many types of refrigeration compressors such as rotator and centrifugal compressors that work by pumping the refrigerant.

• Water Tanks

Water tanks are an additional component of a Welder Chiller that works as a reservoir for warmed water. These tanks store the returned water and then use the same for repeated cycles.

• Radiation Fan

Radiation fan is used in Welder Chiller to provide cooling by using kinetic energy. It has a safety mesh and motors to evenly distribute the air for the welding process. This component is low in cost and suitable for commercial applications.

• Evaporator

The evaporator is a very beneficial component of a cooling system. A Welder Chiller uses an evaporator to absorb heat from the content that is to be cooled.

Welder chiller compressor

What does a Welder Chiller do?

A Welder Chiller is used to cool welding that is heat-generating and controls the temperature and protects the other equipment.

It operates by a refrigeration compressor that efficiently removes heat from the solution that can be a commercial refrigerant or simply water.

The welder chiller physically removes the heat and uses radiation fans to disperse the heat.

The metering device uses the thermostat to control the set temperature and flow rate of circulating water.

Water storage tanks act as reservoirs to save water from wastage.

A Welder Chiller provides efficient cooling during the welding process and saves the cost of water, downsizes water wastage, and serves as the best cooling solution.

What is the Purpose of a Welder Chiller?

The sole purpose of a Welder Chiller is to provide a continuous cooling source for the welder and welding process, keeping the temperature of used equipment and tasks at a limited value.

Its purpose is to provide a cooling environment to different welding machines, which include resistance welders, induction welders, spot welders, laser welders, and seam welders.

Which Coolant can be used in a Welder Chiller?

Water is the best and easily available coolant that can be used in a Welder Chiller.

It can be re-circulated, and no cost is required to spend if water is selected as a coolant but it has the drawback of freezing.

Other than water, many other coolants can be used that tolerate colder temperatures without freezing. Ethylene glycol is a coolant that can be used in Welder Chiller.

Welder chiller coolant

Which Industries use Welder Chiller?

A welder is a requirement of almost every field and industry.

Wherever a welder is used, a Welder Chiller is used to compensate for the heat generated by the welding process.

Many other industries use Welder Chiller, including laser industry, automotive industry, aerospace industry, shipping, and railroad industries and manufacturing plants.

Which Industrial Operations Need Welder Chiller?

Industrial operations require Welder Chiller for certain operations and processes such as manufacturing and repairing the equipment that involves the welding processes.

Laser industries use Welder Chiller for cutting several machinery parts and components by welding and laser technology.

This device cools the process continuously and maintains the spot temperature.

Welder Chiller is a basic automotive industry requirement, where cars and motorbikes are recreated and repaired by cutting and combing various parts to the vehicles using welding techniques.

What is the Capacity Size of a Welder Chiller?

A Welder Chiller has a capacity size that reveals its performing efficiency.

It can be maintained by regularly checking and monitoring certain components of the instrument. A Welder Chiller also provides cooling capacity.

The welder chiller can be increased and decreased depending upon the requirements. On average, the capacity size ranges from 2 to 30 tons.

What Technology is used in a Welder Chiller?

A Welder Chiller is one of the common devices used in industries with welders to cool down the environment, process, and equipment.

Digital devices have been used that work on recent technology, such as

• Digital Water Controller

Digital technology has taken control of the control panel. A digital controller displays the controlled readings control and monitors the water.

• Low Water Level Safety System

Water levels can be monitored in a Welder Chiller by the use of a safety system. This safety system warns about low water levels to protect the damage and insufficient cooling efficiency.

• Stainless Steel Brazed Plate Condenser

A brazed plated condenser is the recent technology used in Welder Chiller specifically to protect the damage that can result from excessive heat generated in the welding process.

Does a Cooling Tower fit best for a Welder Chiller?

A cooling tower is an important component of every cooling system.

But for a Welder Chiller, a cooling tower is not recommended due to some valid and authentic reasons.

The use of a cooling tower is not appreciated due to insufficient water flow. The flow rate can become unstable at times which can cause turbulence and other troubles in the process.

Welder chiller cooling tower

What are the Benefits of Using a Welder Chiller for your Industry?

Welder Chiller is very beneficial equipment that is used in industries at a large scale.

A wide range of chillers is available that is used in metallurgy and other repairing industries.

Welder Chiller is advantageous in improving product quality, process efficiency, and capital investment in industries that use welders, resistance welding, and spot welding.

It is the best way to provide continuous and timely cooling without compromising the process quality including repairing, welding, and molding, and other welding operations.

What are the Applications of Welder Chiller?

Welder Chiller is applied with a welder to provide cooling to several processes that occur with the help of welders such as in the MIG welders, TIG welder, seam welders, and induction welders.

Welder Chiller has wide applications in cooling various machines such as laser processing equipment with semiconductor laser, laser cutting machines, laser marking, and laser drilling.

What is the Temperature Range of a Welder Chiller?

The temperature controlling range of a Welder Chiller depends upon the cooling capacity which can be increased or decreased according to the needs of the welding process.

Normally, the average set temperature controlling range is from 5℃ to 30℃. This temperature is monitored by a thermostat and it displays on digital temperature control.

Why Does a Welding Line Need a Welder Chiller?

A Welder Chiller is a self-contained, closed-loop refrigeration system that uses city or well, water to provide a cooling effect to the welding processes and operations.

A welding line requires a Welder Chiller to maintain the low temperature, resulting in increased production, efficient performance, and welding quality with exceptional output.

What are the Customized Options for a Welder Chiller?

There are some components in a Welder Chiller that can be customized according to the commercial and industrial needs requirements. These customized options include:

• Compressor Coils

A compressor is a major component of any chiller that absorbs the heat from the process. Its capacity size can be increased or decreased depending upon the output required.

• Water Tanks

Depending upon the required cooling capacity of a Welder Chiller in an industry, the water reservoir sources that include water tanks for storage of circulating water can be increased.

Customized welder chiller

What is the Cost Range of a Welder Chiller?

According to the system, a Welder Chiller can be customized by adding digital control panels, protection devices, and pressure alarms that alert about the low water level.

The cost range of a Welder Chiller can be enhanced by adding customized options. Normally, the cost ranges from $1500 to $5000 with basic specifications and controls.

How to Overcome Summertime Cooling Deficiency in your Welder Chiller?

In the summer, radiating cooling is affected by the higher ambient temperatures that increase result in extreme temperatures during the extreme weather.

It affects the welding quality and reduces the life span of various components such as welding electrodes. To overcome the summertime cooling deficiency, excessive water should be used.

Insufficient water levels can cause a cooling deficiency in your Welder Cooling. Monitor water levels regularly to compensate for the cooling capacity and excessive heat with extra water consumption.

How to Maintain Welding Electrode Performance in your Welder Chiller?

A Welder Chiller operates by water as a cooling liquid in the tubes that also pass through the welder electrodes.

Water quality is a major factor that can compromise the electrodes. Low-quality water contains impurities, dirt, and minerals that also change the pH of water.

If neutral pH water is not used, there are higher chances of corrosion to the electrodes. Check the water quality to maintain welding electrode performance.

The water should be non-corrosive and non-toxic. Its pH should be neutral so that there is no chance of damage to electrodes and they perform well.

Welding electrode

How to Prevent Internal Condensation in your Welder Chiller?

Internal condensation can occur due to the unstable temperature of the Welder Chiller that can also affect other parameters of the process such as flow rate, water level, and evaporation.

To prevent internal condensation, try to maintain the air flow rate of the Welder Chiller.

Use filters in the cooling system to filter the moist air that can be the cause of condensation.

Use dehumidifiers as additional equipment to reduce moisture and humidity.

The use of insulated condensation-resistant surfaces inside the system can also prevent internal condensation.

What is the Chiller Sizing for a Welder Chiller?

Chiller sizing is defined as the capacity of a Welder Chiller system to provide enough cooling for heating processes.

The Welder Chiller size can be managed as per the requirements of the operation.

Normally, the 1-ton Welder Chiller is recommended to use for every welder with 100kVA.

It depends on a lot of factors such as temperature difference and the amount of heat to be reduced.

What is Dew Point of Temperature in a Welder Chiller?

Dew point is defined as the temperature at which the air needs to be cooled at a constant pressure.

At the dew point, the relative humidity is 100% once the dew point is achieved completely.

In a Welder Chiller, if the dew point is achieved any further increase in the dew point is not considered good as it results in extra moisture, humidity, and internal condensation.

What is the Effect of Temperature Control on the Welder Chiller?

Effect of temperature control plays a major role in stabilizing the temperature of the Welder Chiller.

A major temperature difference causes an effect on the performance.

A huge difference in the temperature of inlet and outlet water results in unstable temperature differences which affect the overall efficiency of a Welder Chiller.

To maintain a stable temperature of the water, temperature difference adjusted to 1℃ is considered good. Controlled temperature improves the cooling efficiency of the Welder Chiller.

Why Filters are used in a Welder Chiller?

Filters are used to pass air and water through them to filter the moist air and dirt particles.

Dirt particles compromise the water quality which can cause corrosion.

A mesh of filters is used in the Welder Chiller that filters the passing air.

It filters the moist air and dirt particles in the water to maintain the stability of the entire process.

Unfiltered dirty air can cause damage to the welding electrodes and welding tip and cause corrosion. Moist air can cause internal condensation resulting in unstable parameters.

Welder chiller filter drier

What is the Composition of Water Pump in a Welder Chiller?

A water pump is equipment that is used to circulate water in a closed-loop system.

The water pump comprises Welder Chiller piping, valves, air handling units, and expansion tanks.

The pump body is commonly composed of cast iron, stainless steel, bronze, plastic, or other manufacturing material.

Low-alloy steels, iron-base alloys, and stainless steel alloys also make water pumps.

It is composed of a motor pump that pushes water through the fittings and around the system, including the distribution lines and storage tanks that are at relatively high altitudes.

Which Types of Welding Machines can be Connected to a Welder Chiller?

The basic principle of using a Welder Chiller is to maintain a low temperature for welding processes and to dissipate the heat that is generated as a result of welding operations.

Different types of welders and welding machines are connected to a Welder Chiller to get cool temperatures to increase the process efficiency. These welding machines include:

• TIG welding machines
• MIG welding machines
• GTAW welding machines
• Spot welding machines
• Electro-slag machines
• Induction welding machines
• Automotive industry machines
• Laser cutting and repairing machines

TIG welding machine

What is the Role of Welding Control in a Welder Chiller?

A welding control is a device that consists of a resistance detection unit for measuring resistance across the electrodes. Resistance control is necessary for controlled current flow.

To control the flow of current intra electrodes, welding control improves the quality of the process.

The welding control device monitors the current flow and maintains stability.

Increased resistance can affect the performance efficiency because of a low or insufficient supply of voltage which can halt the entire process of welding and cooling.

How to Protect your Welder Chiller through Winters?

It is very important to protect the Welder Chiller from summertime insufficient cooling and freezing malfunctioning in winters.

Try the following considerations to protect your Welder Chiller:

• Run the Welder Chiller 24 hours a day and monitor the recirculation status of water. Continuous recirculation of water can prevent it from freezing in winters.
• After the performance of welding operation in laser machines, empty the water from the laser head and Welder Chiller to avoid its freezing inside the fittings and valves.
• Use a commercial anti-freezing agent in the water storage tanks.
• Anti-freeze contains corrosive ingredients, so dilute the agent according to the requirements.
• Use excessive water to prevent freezing of water at low levels.

How a Water Level Alarm does Operate in a Welder Chiller?

A water level alarm detects the level of circulating and reserved water in the storage tanks by using a magnetic float that rises and falls with the level of water in the container.

Water level alarm warns if the water level is below the set level.

Once the water reaches the set level, the magnetic switch is activated automatically and it displays the level digitally.

This alarm also warns when the water level is lowered below the sufficient capacity required for a complete circuit to run and prevent water from freezing at low temperature.

Welder chiller water flow switch

What is the Importance of Temperature Protection in your Welder Chiller?

A temperature protection device monitors and maintains the temperature in a Welder Chiller.

This device prevents the freezing of chilled water in the circulation cycle.

The temperature protection method protects the entire system by dropping the freezing temperature for a predetermined period before shutting down the whole chilling system.

In this way, the process does not halt and the temperature protection system maintains the stable temperature and flow rate of circulating water in the pipelines and circulation tubes.

Is there any Flow Protection Equipment for a Welder Chiller?

A Welder Chiller is always equipped with flow protection equipment to control the direction and flow of circulating water.

For that purpose, a check valve is used in the chilling system. In case of reverse movement of circulating water or due to any damage to the pipelines the flow can be controlled by the check valve to automatically prevent the reverse flow rate.

A pump is also used for flow protection in the Welder Chiller to maintain the pressure and flow rate inside the pipelines.

A pressure difference controller is used with a pump to avoid any damage.

How can you Maintain your Welder Chiller?

Maintaining a Welder Chiller is very necessary to extend its services over the years.

This can be done by regularly checking the flow rates, the temperature of chilling water, and the pressure of inlets and outlets.

A daily checklist is mandatory, which involves monitoring and controlling the parameters.

Check that there is no blockage in the pipelines and distribution tubes are clear before turning on the system.

Check the pipes for any leakage or not. Check the level of circulating water and use an anti-freezing agent in winters to avoid freeze in the circulation tubes and compressor coils.

Monitor and regulate the temperature of components even during the summer season to improve the performance of welding electrodes and tips that enhance the life span of Welder Chiller.

Welder Chiller Electrical Connection Routine Inspection

What Considerations you are Required while Setting Up your Welder Chiller?

There are a few considerations that should be kept in mind while setting up or connecting a Welder Chiller with any welding machine.

Check for the following considerations such as:

• Space and Location

Check the space and location of your Welder Chiller. Choose an area that has sufficient space to accommodate the Welder Chiller with the welding machine. Remember that it should be near the welding equipment.

• Water Level

It is very important to note the level of water in the reservoir and circulating lines. Check the flow rate of water as well. A floating magnetic device can also monitor insufficient water.

• Control Panel

It is very important to check that the control panel if they are operative enough to display flow rates, levels, and water levels.

What Annual Preventive Maintenance Procedures are Performed for your Welder Chiller?

Annual preventive maintenance procedures are necessary to extend the service and system proficiency.

It is mandatory to do the monitoring by yourself or by hiring a professional for this purpose.

• Inspection

Inspect all the working components of the Welder Chiller including the compressor loops, evaporator tubes, pipelines, and condenser. Check the water quality as well. Inspect the refrigeration lines, circulating pipelines, and reservoir tanks if they are damaged and need any repairing. Also, check for wholes and damages in the valves and fittings.

• Cleaning

Clean the filters that are used to filter air and water. Use new filters if the older ones are damaged. Clean all the distribution lines with fresh water and non-corrosive agents to prevent rust.

• Monitoring

Monitor the daily logbooks and check the faults that occurred in the past service time. Monitor the water supply temperature, Welder Chiller status, and compressor run time. Check all the alarms and control panels annually.

Welder chiller preventive maintenance