Welder Chiller: The Ultimate FAQ Guide

This guide has all information you’re looking for about welder chiller.

From benefits, parts, classification to working principle – you will find all information right here.

Keep reading to learn more.

What is a Welder Chiller?

Welding chillers are cooling machines that you can use in the process of chilling welding machines during welding processes.

Welder chiller

What are the Benefits of Cooling the Welding Equipment?

You should keep your welding equipment under proper cooling to enable proper operations.

In addition to proper operations, you will also experience a series of benefits by cooling your welding equipment.

Here are the main benefits that you will enjoy just by ensuring that the welding equipment is cool.

• Quality Welding Process

You will produce uniform welding spots that will lead to the prevention of mushroomed or hot tips.

• Increased Durability

You will also have a very long weld tip life when you control the temperatures using the welder chillers.

It will help in decreasing the downtime that is associated with having a good weld tip.

• Maximum Uptime

You will have maximum uptime with the welding machines as they will be fully operational for a longer period.

Welder chillers will cool down the SCR’s thus preventing them from overheating and increasing the machine uptime.

What are the Parts of the Welder Chiller?

Welder chillers have similar parts as most of the chiller machines that you can install in different applications.

These parts work in conjunction with one another to produce a cooling or chilling effect on the welding equipment.

Here are the main parts of the welder chiller that you need to pay close attention to.

• Compressor Unit

The compressor unit is responsible for the compression of refrigerants in a bid to increase the pressure and speed.

High speed or pressure refrigerants have the capability of lowing throughout the system as it transfers heat.

• Refrigerant System

The refrigerant is fluid which can either be glycol or a mixture of glycol and water which will carry the heat.

It resides in a refrigerant tank which is also available in various capacities to hold enough refrigerants.

• Evaporator System

You will depend on the evaporator system to deliver heat from the welding machines and feed the refrigerants with the heat.

It will help in changing the state of the refrigerant from liquid to gas after feeding it with enough heat.

• Control Panel

You will use the control panel to control all the operations that occur within the welder chiller machines.

T will help you monitor everything and in case of a problem, you will receive the notifications on the control panel.

• Condenser Unit

Just from the name, you will realize that the condenser will help in condensing of refrigerant as it eliminates heat.

In this case, the most convenient fluid for condensing the refrigerant is water even though air does the work.

• Transportation Unit

In the transportation unit, you will have pipes, valves, and delivery units that will transfer the fluids through the system.

It stretches throughout the machine connecting the different parts of the machine together to produce chilling effects.

• Expansion Valves

Well, you will depend on the expansion valves to assist in controlling refrigerant pressure systems.

It will work according to the production specifications to feed the refrigerants back to the compressor unit.

How Does the Welder Chiller Work?

Welder chillers use the closed loop circulation system to circulate the refrigerant through the welder chiller system.

Implying that it collects and delivers het within the welder chiller to the point of elimination.

The process begins with the activation of the refrigerant as soon as the welder chill chiller detect temperature variation.

It has an automatic system that will detect temperature and spring into action.

The machine will release the refrigerant from the refrigerant storage tank and deliver it to the compressor unit.

You can either have the scroll, screw, or even the centrifugal compressor depending on the type of machine.

While in the compressor unit, the machine will compress the refrigerants and increase its pressure.

High pressure will translate to high speed which will move straight to the evaporator unit.

At the evaporator unit, the refrigerant will collect heat that comes from the welding equipment.

The heat will change the form of the refrigerant from liquid to vapor thus making it lighter in weight.

With the heat logged inside the refrigerant, it will flow to the condenser unit to deliver heat for elimination.

The condenser has constant flow of water or air that will carry away the heat from the refrigerants for elimination.

While in the condenser, the refrigerant will condense to liquid state as it releases the heat to the chilling agents.

Finally, it will go back to the compressor to continue with the chilling process.

You should note that the refrigerant will have to pass through the expansion valve which will reduce the pressure.

The expansion valve will then complete the whole process by feeding the refrigerant to the compressors.

What is the Difference Between the Welder Chillers and the Water Recirculatory Welder Chillers?

Portable welder chiller

You can use welder chillers or water recirculatory welder chillers in the cooling process of welding applications.

The main difference between the welder chillers and the water recirculatory welder chiller is a refrigerant.

Welder chillers have refrigerants which they use in a closed loop to ensure that the cooling process occurs.

It works using similar principles like refrigerators to cool off the welding equipment.

On the other hand, water recirculatory welders do not have refrigerants but recirculate water which helps in the cooling process.

In other words, it depends on the cooling effect of the recirculating water to eliminate excess heat.

How Do You Size the Welder Chillers?

You should know that the size of the welder chillers usually varies according to the application requirements.

In this case, the rule requires you to have 1 ton of chilling capacity for 100KVA of chiller capacity.

Using this method, you will be able to calculate the size of welder chillers that you need.

You must, however, know the specific details of your application chilling requirements.

How do you Maintain Welder Chillers?

You should maintain the welder chillers on a regular basis to ensure that it actually lasts longer.

The maintenance process will be easier if you have a maintenance schedule and a maintenance check list.

Here are the main factors you have to do during the maintenance process of welder chillers.

• Conduct Regular Inspection

You must conduct regular inspection of the machine and record all the necessary details you see.

With that, you can have concrete information the parts that require regular inspection and replacements.

• Maintaining Proper Fluid levels

Here, you will maintain the right fluid levels by refiling the reservoirs when necessary.

You must also maintain proper treatment of the fluids on a regular basis to prevent corrosion and contamination.

• Proper Cleaning Routine

You should also maintain the machine by cleaning it on a regular basis to get rid of debris from the system.

It is important to dismantle the welder chillers once in a while to clean the hidden parts on a regular basis.

• Replacing Broken parts

You should also replace the broken parts with new parts to ensure that the chilling process continues smoothly.

Do You Supply Both Water-Cooled and Air-Cooled Welder Chillers?

Water cooled chiller

Air cooled chiller

Yes, we supply both water-cooled chiller and air-cooled chiller for welding depending on your requirements.

Most of the people prefer using the water-cooled chillers since it is quite and more efficient.

On the other hand, air-cooled welder chillers are noisier and not as effective as water-cooled chillers.

Apart from that, air-cooled chillers are more durable in comparison to the water-cooled chillers.

You can install it outside the factory with no need of mechanical house which is very important for water chillers.

You must understand that water-cooled chillers use water as chilling agent while air-cooled chillers use air as chilling agent.

What Factors Affect the Cost of the Welder Chillers?

There are quite a number of factors that will affect the overall cost of the welder chillers.

Here are the main factors to look at when considering the cost of welder chillers.

· Type of Welder Chillers

You can either opt for water-cooled or air-cooled welder chillers to help in the cooling process.

Apart from that, you can classify them according to the type of compressors.

Despite the mode of classification, you should understand that different types of welder chillers attract different price tags.

· Quality and Quantity

Here, the higher the quality of the welder chillers, the more money you will pay.

In addition to that, the greater the quantity you will purchase, the greater the cost of the machines.

Generally, the cost of welder chillers range between 5,000 to 80,000 US dollars.

How Do Cold Shot Welder Chillers Help in Minimizing Process Costs?

Cold shot welder chillers minimize process cost through proper maintenance of current flow.

Stabilization of current flow will improve machine efficiency thus reducing wastage.

Reduction of wastage will help in the conservation of resources thus reducing the overall cost of cooling.

Which Methods Can You Use to Adjust Thermal Conditions in Welding?

There are numerous conditions that you can comfortably adjust to help in controlling thermal conditions.

Here are some of the methods that you can use to adjust welding thermal conditions.

· Cooling Through City Water Systems

You can use this method to save on operational cost even though you might incur other costs along the way.

Other costs that you might encounter include water usage, sewer usage and both water and sewer treatments.

· Recirculating Water Welder Chillers

It will help in the reduction of the cost of water and sewage treatment but not good for large scale welding projects.

It has limited heat dissipation factors that make it insufficient for large scale applications.

· Industrial Process Chillers

Here, you will use the closed loop set up as it cools down the welding equipment such as spot-welding applications.

You can modify it to handle different cooling capacities in both small- and large-scale applications.

Which Specifications should you Consider when Choosing the Welder Chillers?

You should consider following particular guidelines whenever you are choosing welder chillers.

Here are some of the main specifications you should follow when choosing a welder chiller.

· Cooling Capacity

You must know the right cooling capacity of the welder chillers before you proceed to choose a welder chiller.

The cooling capacity must be sufficient to accommodate the cooling needs of the welder chillers.

· Input Power

Here, you will look at the amount of power that the machine needs to work sufficiently to produce chilling effects.

It will definitely vary according to the different types of welder chillers available in the market.

· Source of Power

You should also look at the location of your welding business and consider the type of power the machine needs.

It is important to configure your machine to meet the right power specifications of the main source of power.

· Type of Refrigerants

Well, there are numerous types of refrigerants that you can use within the welder chillers to produce a chilling effect.

The main types of refrigerants that you should consider choosing are glycol or mixture of glycol and water.

· Type and Number of Pumps

You must also be very serious with the number and types of pumps that you want for your welder chillers.

It is important to consider such figures by looking at the scale of cooling that your welding application needs.

· Types of Constituent parts

In this case, you will also look at the size and type of constituent parts such as condensers, evaporators and expansion valves.

Your machine must possess all the constituent parts in the right working conditions.

· Safety or Protection Devices

You should consider having safety devices on your machine to protect the machine as well as the operators.

Most safety features will warn you before it shuts the machine down in case of impending danger.

· Dimensions

You should also look at the size as well as the weight of the welder chillers that you would like to have.

The bigger the machine that you want, the greater the chilling requirements that it can comfortably accommodate.

What are Small Capacity Welder Chillers?

Small capacity welder chillers are the small versions of welder chillers that you can move from one place to another.

Apart from the small size and portability, here are the other features of the small capacity welder chillers.

• Capacity ranging between 1 to 3 ton
• Nonferrous water circuit constructions
• Water or Air-cooled Options
• Ecofriendly Design with ozone friendly devices
• Scroll compressors that are reliable and energy efficient

What are the Best Scenarios of Using the Welder Chillers?

While it is very important to use the welder chillers in different applications, you should best use them appropriately.

You will use them most appropriately in particular scenarios such as:

· High Usage Welding Equipment

You will use the welder chillers in nearly 100% usage of welding equipment to minimize downtime and tool wear.

· Multiple MIG, TIG, and MAG Welders

You must also consider it in multiple welding systems by consolidating them together to avoid wastage.

· Robotic Welding Applications

You will also use it in applications that require constant cooling such as large robotic cooling applications.

· Resistance Welders

It is also a very important machine that you can simply use to reduce the cooling cost in the resistant welders.

Type of resistance welders that you can cool include spot welding, butt welding, seam welding and projection welding.

What are the Latest Advancements in the Welder Chiller Technology?

Whenever you are looking for a good welder chiller, you must also look at the level of technology.

In other words, you must consider the latest form of technology in the selection process.

Here are some of the technological developments in the market that you should consider.

• High Efficiency Coil Evaporators

It will help in saving the overall cost of energy as well as production throughout the machine’s life.

It employs aluminum fins and copper tubes inside the tank to reduce the heat gain.

• Smart Setpoint Capabilities

You need to ensure that the chillers do not cool below the ambient temperatures by using smart setpoint capabilities.

• Non-ferrous Water Circuits

It uses non-corrosive materials such as copper and stainless steel to resist corrosion.

It also runs with liquids such as glycol which do not encourage corrosion of materials.

• Hermetic Scroll Compressors

It has orbiting scrolls which are mounted on antivibration dampers that protects against overheating.

Apart from that, it will protect against excessive currents as well as high exhaust temperatures.

• Top Exhaust; Close Side Clearance

Instead of having the top side clearance, you can increase the number of exhaust systems on the sides.

Do You Have Remote Controlled Welder Chillers?

Yes, we do have remote control welder chillers which you will operate from a remote distance.

Most remote-control welder chillers are on the outside of the building.

You can simply control it using a remote controller from a safe zone within the building.

You can also use it in centralized monitoring or control systems which you can only access from remote locations.

What Issues can Arise Due to Insufficient Cooling of Welding Machines?

Welding processes produce a lot of heat that might lead to a lot of problems.

You will use the welder chillers to help in the elimination of excess heat.

In the absence of the welder chillers, you might experience a series of problems such as:

• Cracks and holes on the equipment
• Inconsistent welding quality
• Stuck or sticking clips
• Undersized welds
• Excessive wearing of welder tips
• Excess component temperatures leading to component error codes

Which Types of Welding Machines Typically Need Welder Chillers?

You will use the elder chillers typically to reduce heat in different welding applications.

Implying that you can use it to eliminate heat in different welding machines.

Here are some of the welding machines that you can chill using the welder chillers.

• Resistance Welding Machines
• Seam Welding Machines
• Butt Welding Machines
• Induction Welding Machines

What are the Benefits of Incorporating the Right Water Welder Chillers in Welding Processes?

Whenever you are choosing a welder chiller, you should consider choosing the right type of welder chiller.

This is especially true for the water-cooled chillers even though the air-cooled chillers require proper selection.

Here are the benefits of incorporating the right water welder chillers during the welding process.

• Reduces the high cost of paying for water as well as sewer bills
• Extends the life of the welding electrode
• It reduces irregular or bad spot welds as a result of mushroomed tips
• It eliminates downtime that you could spend in changing or redressing the welding tips
• Prevents overheating in transformers or in the electric supply systems
• Reduces ignition tube, transformer, SCR failure from excess heating
• Eliminates the need of a water supply plug by using the circulated closed loop circulation water system

What are the Typical Applications of the Welder Chillers?

Inside welder chiller

The main function of the welder chiller is to cool equipment that you will use in the welding process.

It simply means that, most of the applications will revolve around welding but in different industries.

Here are some of the typical applications of the welder chillers.

• Resistance (Spot welders)
• Furnaces and Induction Welders
• Laser Systems
• MiG and Tig Welders
• Abrasive Cutting
• Pharmaceutical and Chemical Industry
• Food and beverage industry
• Laboratory Applications
• Medical Equipment such as X-rays
• Hydraulic Fluid Cooling Systems

Do You Customize the Welder Chillers According to the Customers Specifications?

Absolutely, we do customize the welder chillers according to the specifications of the customer.

All you have to do is provide us with the information about the type of welder chillers that you need.

Some of the details that you will provide to us for customization are:

• Dimensions of the Welder Chillers
• Cooling Capacity
• Type of Materials such as Stainless steel
• Temperature Range
• Electric or Voltage Specifications
• Interlocking and alarm systems
• Number as well as types of pumps
• Split systems depending on the location of the welder chiller

Do You Supply Non-Refrigerated Welder Chillers?

Yes, we also supply non-refrigerated welder chillers that have the ability of cooling water to 5 degrees Fahrenheit.

This is usually above the room temperature and it makes the cooling process using the welder chillers possible.

They come complete with the following parts:

• Finned Radiator
• Water Tank
• Water Pumps
• Control Systems

You can get this type of welder chiller in varying sizes ranging from 24,000 BTU/Hr to 1,000,000 BTU/Hr.

At TopChiller, we design and manufacture a range of chiller systems such asglycol chiller, water chiller, and air chiller amongst others.

Contact us now for inquiries on welder chiller.