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Welding Chiller-An Ultimate Guide by TopChiller

A Welding Chiller is a type of water cooling system used to improve the welding quality and life for different types of welding machines.

A welding machine uses extremely high temperatures to melt the base and broken parts together. Then, allows it to cool down which causes fusion, this is what the welding chiller plays its role.

Heat is a necessary element in the welding process but it can harm the sensitive components used in the welding process.

Here the need for a Welding Chiller arrived; the chilled water from a Welding Chiller enhances the life of important components of your application.

The purpose of the Welding Chiller in a welding process is to cool down the welding machine by providing constant cooling water for the welding process.

Let’s know more about it.

What is a Welding Chiller?

A Welding Chiller is a type of industrial process chiller, specifically designed to remove heat from your welding equipment and processes.

Water cooling is an essential part of welding processes and must be done properly for efficient working.

A Welding Chiller maximizes the uptime by avoiding SCRs from heating up.

It can provide constant temperature, constant current, and constant pressure as it is specially designed for welding machines and processes.

A Welding Chiller is manufactured with high-quality components that include a #304 stainless steel water tank, SUS304 circulating water pump, condenser, evaporator, radiation fan, compressor, and other controller components.

Achieving constant temperature helps to stabilize the current flow and it also increases the welding quality.

A Welding Chiller plays an important role as a cooling source for your welder machine and all welding processes.

Generally, a closed-loop Welding Chiller is suggested because of its accurate thermoregulation ability and requires less operational costs.

Welding Chiller Manufactured by TopChiller

What is the Working Principle of a Welding Chiller?

You can obtain uniform and high-quality welds by using a Welding Chiller. It is used for cooling your welding equipment.

The complete working of a Welding Chiller is explained below;

The chilled water in a Welding Chiller continuously passes through your application and evaporator of your compressor refrigeration system.

A Welding Chiller circulates the chilled water from different components and processes to dissipate unwanted heat from the welding machine.

The heat produced during the welding process of your application is driven through the cooling cycle of the refrigeration system and dissipated into the air.

The control panel of the Welding Chiller is responsible to control the cooling of the compressor according to the adjusted temperature value.

To make sure the temperature of cooled water of your welding application is controlled in set parameters.

A Welding Chiller provides a longer weld tip life by decreasing downtime of your welding application.

What are the Main Components of a Welding Chiller?

The main components of a Welding Chiller are described below.

• Compressor

The compressor in a Welding Chiller plays an important role to make sure about the circulation of refrigerants throughout the system.

It uses an electric motor as a driving force. It is installed between the evaporator and the condenser of a Welding Chiller.

• Condenser

A condenser is placed near the expansion valve and compressor. It is used to dissipate the heat from the refrigerant been used as a coolant.

There are two types of condensers. A water-cooled condenser and an air-cooled condenser.

• Evaporator

An evaporator is used to drive the heat from your welding application and then send it to the refrigerant for further process in the cooling tower.

It is located between the expansion valve and a compressor of a Welding Chiller.

• Expansion Valve

The expansion valve in a Welding Chiller is responsible for amplifying the volume of the refrigerant to absorb heat in the evaporator.

Different types of expansion valves can be chosen according to the needs of your application.

• Water Tank

This component is used to separate the inlet and outlet for the proper flow. They can be mounted to the condensers or evaporators in a water-type Welding Chiller.

• Power Unit

A power unit is another key component. It is highly responsible to control the flow of electric current to the Welding Chiller.

This unit includes power monitoring equipment, speed controller, circuit breaker, etc.

• Control Unit

A control unit keeps checking on the performance of a Welding Chiller. This unit is also responsible for making settings when required.

It has safety alarming features to prevent damage or loss to your welding application.

Welding Chiller Compressor

What are the Features of a Welding Chiller?

Some of the features of Welding Chillers are listed below:

• A Welding Chiller is equipped with an imported and precise digital display temperature controller.

Its temperature controller can accurately control the temperature ± 1 degrees Celsius. You can adjust the temperature controlling range from 5 ℃ to 30 ℃.

• It is composed of stainless steel thick water tank, a coil evaporator, a built-in water replenishing device, etc., that is very easy to clean and maintain properly.
• The appearance and design of the Welding Chiller are very decent.
• The outer panel of a Welding Chiller can be disassembled quickly, which is convenient for use and maintenance.
• A Welding Chiller uses imported famous brand compressors having built-in safety protection systems.
• It offers low noise operation during cooling the welding process.
• A Welding Chiller has a highly durable power-saving feature.
• Its Built-in stainless steel material water pump, large flow, high efficiency, durability is matchless.

Welding Chiller Digital Display Temperature Controller

What is the difference between an Air-Cooled Welding Chiller and a Water-Cooled Welding Chiller?

You can easily differentiate between Water Cooled Welding Chiller and an Air-Cooled Welding Chiller with the help of given data.

Air Cooled Welding Chiller

• An Air-Cooled Welding Chiller uses ambient air and shielding gas to remove excessive heat from the welding torch.
• The power cable for air-cooled TIG torches is thick as compared to TIG Water-cooled torches.
• Air Cooled Welding Chiller Requires less maintenance cost.
• The torches used with it are easy to operate.
• It does not require a cooling tower.
• It is highly energy-efficient.

Water Cooled Welding Chiller

• Water Cooled Welding Chiller uses circulating water to remove excessive heat from the welding torch.
• Its welding torches use a thin power cable.
• A Water Cooled Welding Chiller requires high maintenance costs as compared to an Air-Cooled Welding Chiller.
• The torches used with Water Cooled Welding Chiller require a bit of precision to operate.
• It requires a cooling tower.
• Water Cooled Welding Chiller operates with high efficiency.

Water Cooled Welding Chiller

What are the Advantages of a Welding Chiller for your Welding Applications?

A Welding Chiller is used to meet the water cooling requirements of your welding applications. Some of the advantages are as follow:

• A Welding Chiller reduces high water and sewer bills.
• Another benefit is it reduces bad or irregular spot welds due to mushroomed tips.
• It prevents overheated transformers and power supplies during the process.
• It extends electrode life.
• A Welding Chiller reduces the downtime to redress and change welding tips.
• The nonferrous water circuit of this refrigeration system ensures the water quality if the water is dust-free.
• Easy to operate, maintain, and install.
• It provides durable cooling and reduces transformer, ignition tube, and SCR failure due to over-heating.
• It eliminates plugged water cooling lines by using closed-loop treated water for your application.

What Type of Welding Techniques Require a Welding Chiller?

Different types of Welding Chiller are available for various welding techniques. Some welding techniques are given below.

• Arc Welding

An arc welding is a cheaper process. It is the best option for those who want welding in a budget-friendly way.

An arc welding produces an electric current between the welding device and material.

• Gas Metal Arc Welding

It is abbreviated as GMAW. It is used in automated industrial applications. Gas

Metal Arc welding uses electrical and shielding gas for welding.

• Shielded Metal Arc Welding

SMAW is another popular and modern welding technique. It uses a consumable electrode coated with flux.

The electric current supply is driven into an arc and electrode from a power supply. It is then placed between two components and material to be joined.

• Flux-Cored Arc Welding

It is abbreviated as FCAW or FCA. This type of welding process needs continuous feed for the consumable electrode having constant voltage and flux.

It has a very high welding speed.

• Gas Tungsten Arc Welding

This technique is also known as TIG. This welding technique depends upon a non-consumable tungsten electrode.

It has a protection feature that protects the weld area using filter material and shielding gas.

Welding Chiller for Arc Welding

What are the Industrial Applications of Welding Chiller?

Different types of welding applications require different kinds of Welding Chiller such as resistance welders, induction welders, seam welders, and butt welders, etc.

A Welding Chiller plays a crucial role in cooling various welding machines and processes efficiently.

Some of the welding applications that require a Welding Chiller includes:

• Laser cutting.
• Laser welding.
• Laser drilling.
• Laser marking.
• Semiconductor laser processing equipment.
• CO2 laser.
• YAG laser (working medium).
• Steel structure manufacturing industry.
• Automobile manufacturing industry.
• Security door processing industry.
• Gas shielded welding applications.
• Arc welding machine.
• DC welding machine.

Welding Chiller Applications

How to Select Right Welding Chiller for your Welding Application?

Selecting the right Welding Chiller for your Welding application adds to the economies of its use.

Choosing the exact Welding Chiller according to the needs and requirements of your welding applications is very helpful to obtain efficient and maximum output.

You need to consider the following points when choosing the right Welding Chiller for your application.

1. Will the condenser be air-cooled or water-cooled?
2. What are the available voltages for your Welding Chiller?
3. Will the Welding Chiller be a split system or a packaged system?
4. What type of coolant you will use?
5. What are the inlet and outlet temperatures you require for your Welding Chiller?
6. Will you require a freeze protection feature for the coolant?
7. What is the expected flow rate throughout your process?
8. Will the Welding Chiller requires a pump or not?

After the feasibility study about the selection of your Welding Chiller, finalize the selected one with the advice of experts.

What is the Best Location for a Welding Chiller?

As its name shows the Welding Chiller is used in the welding industry. The following points should be considered for locating your Welding Chiller.

• It should be near to the Resistance welding machine to avoid the unnecessary length of pipes for connection.
• The location should be such that sufficient light and ventilation must be available.
• If Water Cooled Welding Chiller is used, you can install the cooling tower outdoor, and a sufficient amount of tap water supply must be available near the cooling system.
• At least 2.5ft clearance must be available for maintenance and inspection purposes.
• A secure power supply panel must be closer to the location Welding Chiller. Make sure that there is no loose or hanging wire, it may cause an accident.
• Make sure that the roof of the location must be high enough.
• Transport your Welding Chiller to the location with the help of a crane.
• It should have a proper earth connection.

How to Size a Welding Chiller for your Application?

You can easily determine the size of the Welding Chiller for your application by general rule, for every 100KVA of welder you need about 1 ton Welding Chiller.

For example, if you need to pool 5 welders that are 100KVA each, you require a 5 ton Welding Chiller.

Some more details about the sizing of a Welding Chiller are given below:

You can calculate the BTUs per hour of a resistance welder by using simple formulas.

• Resistance Welding (BTUs per hour) = (Welder KVA) * (Duty Cycle) * (0.85) * (0.6) * 3415 BTU/hr.
• BTU/hour = (T1-T2) x gpm x 60 min/hour x 8.33 lb./gal x Cp

  Where,

Duty Cycle = (Welding time on) / (elapsed time).

T1 = Outlet Temperature (F).

T2 = Inlet Temperature (F).

GPM = Gallons per minute of flowing coolant.

Cp = Specific heat of coolant.

What Safety Measures can be taken for the Proper Working and Protection of your Welding Chiller?

For proper and efficient working, you need to take some safety steps the protect your Welding Chiller.

You can use some safety advice to keep your Welding Chiller working safely.

Some of those safety devices include high refrigerant and low refrigerant safety, automatic water refilling system, safety switch for low water flow, water-free safety system, and a digital temperature controller.

You can protect your system from being damaged with the help of proper maintenance services that include;

• Maintaining daily logs.
• Keep the tubes of a Welding Chiller clean.
• Reduce the condenser water temperature.
• Monitor the loops of condenser water.
• Check for refrigerant leakage.
• Maintain the flow rate of chilled water.
• Examine the compressor oil.
• Install variable speed drives.

Maintaining Daily Logs for the Protection of your Welding Chiller

How to Maintain your Welding Chiller?

You can use the following methods for the maintenance of the Welding Chiller.

• Cleaning of the condenser coil. (Monthly)
• Replacement of filter drier. (Annually)
• Chilled water line chemical dozing. (Annually).
• Checking of Evaporator for any water leakage (Daily).
• Checking of control and safety devices for proper operation(Monthly)
• Welding Chiller Control panel and side panels for proper installation. (Monthly)
• Welding Chiller body inspection for security (daily).
• Welding Chilled water pipes for any damage or leakage. (Monthly)
• Carry out draining, flushing, refilling of the chilled water system. (Annually)
• Make the documents of all of these steps in the logbook to keep a historical record.
• Get all the equipment calibrated which requires calibrations (Six monthly).
• All the welding nozzles and other equipment attached to the welding plant must be checked for proper inspection, cleaning, and Normal flow of water or air used for cooling.
• The checklist may be varied for different Welding Chillers.
• Always follow the maintenance instructions given in your Vendor Maintenance Manual.

Welding Chiller Inspection

How to Troubleshoot your Welding Chiller?

Some common issues and their causes in a Welding Chiller are given below;

1. Fault

Fast tungsten burning rate in TIG welding

Probable Causes

• Excessive heat in the torch body, air-cooled torches get extra hot.
• If using Water Cooled Welding Chiller, it may be due to low coolant or blockage in the system.

2. Faults

No pumping or insufficient fluid flow.

Probable Causes

• Fluctuation in line voltages.
• Insufficient fluid in the reservoir.
• Blocked process line.
• The coolant does not suit the requirement.
• Pump failure.
• Process pipes are too narrow.
• Blocked fluid filter.

3. Fault

No or insufficient cooling.

Probable Causes

• Improper or fluctuating line voltages.
• Blocked air filter.
• Coolant lost heat transfer properties.
• Refrigerant ambient temperature is too high.
• Evaporator freeze.

4. Fault

The Welding Chiller does not power up.

Probable Causes

• The improper voltage or loose connection.
• Wrong phase sequence.
• Blown circuit breaker or fuse.
• The power switch is in an off position.
• The power switch is faulty.
• Frequency is not within the limit.

FAQ of Welding Chiller

What is the Significance of a Welding Chiller?

Welding Chiller is essential for resistance welding at the industrial level for efficient welding joint otherwise welding product may be deteriorated or altered.

What type of Welding Chiller can be used in Welding Applications?

Both Air Cooled Welding Chiller and Water Cooled Welding Chiller are suitable to be used in welding applications.

How can you protect your Welding Applications from Damage?

Your welding plants are equipped with electronic components, like high-power SCR, which draws over current and leads it to overheat.

It may cause damage to your welding equipment, so Welding Chiller is a good solution for this problem.

How can you improve the Efficiency of your Welding Applications?

The Welding process produces excessive amounts of heat; if this heat is not dissipated by Welding Chiller then your welding machinery will consume more power and become less efficient.

Hence, a Welding Chiller can be used to improve the efficiency of your welding applications.

Can Recirculating Water Cooler be used in Welding Industry instead of Welding Chiller?

This system of cooling will result in a high cost of sewage water treatment and is not suitable for large welding industries due to the low rate of heat dissipation.

So, for industrial process Welding Chiller is suggested.

What Capacity of Welding Chiller Available in the Market?

In portable range 1 to 30 tons, in large structure 40, 50, 60 tons, and in modular structure more than 60 tons capacity Welding Chiller available in the market.

Can a Normal Process Chiller be used as a Welding Chiller?

Yes, your normal Process Chiller can be customized to be used to fulfill the needs of your welding industry.

Can a City Water Cooling System be used for Welding instead of Welding Chiller?

It is not recommended because of the high water bill and heavy sewage cost to remove the used water, maintenance cost is also increased.

What is meant by Variable Frequency Drives (VFDs) in Welding Chillers?

A Welding Chiller consumes a large amount of electricity that increases the operation costs, with the help of variable frequency drives you can save energy varying motor speed.

How do Refrigerant Leaks affect the Welding Chiller?

The refrigerant leaks from the compressor can highly affect the cooling capacity of the Welding Chiller.

It may cause by loose or vibrating valve stems.

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