Water cooler

[mtt.tr]

I'm not after one but want to test a few theory's of mine in regards to cooling. I think I have a system that would be small and cool quickly. But I need to test it.

My question, what temp is the water going back into the torch from the cooler.

I know this is vauge but if it works or doesn't I'll let you know.

Cheers

 

[mark williams]

Richard this is right up your street!

 

[hotrodder]

Dunno what actual coolant temps are typical for return flow but when everything is working properly the power lead/water return barely gets any warmer than ambient. All the different torch manufacturers have specs freely available which include max inlet coolant temps, pressures and flow rates. 65°C max inlet, min flow rate of ~1L/min are fairly typical. Inlet pressures are commonly a max of 3.5 bar / 50psi, sometimes they'll be along the lines of 2.5bar min / 3.5bar max instead of just a max pressure

Similar deal with commercially made coolers for example various sizes of Miller along with BTU/hr cooling capacity, flow rates and coolant capacity etc http://www.indura.com.pe/_file/file_2371_coolmate series miller - octubre.pdf The Lincoln coolarc 20 bolted to the bottom of my TIG is smaller and lighter than a Miller Coolmate 1. Coolant capacity is 1.7 litres, small finned tube heat exchanger (200 x 150ish mm, 2 rows thick) with a fan and doing pricework on ally at 200A the torch hoses don't get warm let alone hot

 

[mtt.tr]

Dunno what actual coolant temps are typical for return flow but when everything is working properly the power lead/water return barely gets any warmer than ambient. All the different torch manufacturers have specs freely available which include max inlet coolant temps, pressures and flow rates. 65°C max inlet, min flow rate of ~1L/min are fairly typical. Inlet pressures are commonly a max of 3.5 bar / 50psi, sometimes they'll be along the lines of 2.5bar min / 3.5bar max instead of just a max pressure

Similar deal with commercially made coolers for example various sizes of Miller along with BTU/hr cooling capacity, flow rates and coolant capacity etc http://www.indura.com.pe/_file/file_2371_coolmate series miller - octubre.pdf The Lincoln coolarc 20 bolted to the bottom of my TIG is smaller and lighter than a Miller Coolmate 1. Coolant capacity is 1.7 litres, small finned tube heat exchanger (200 x 150ish mm, 2 rows thick) with a fan and doing pricework on ally at 200A the torch hoses don't get warm let alone hot

Thank you that explains what I need

 

[hotrodder]

Cheers. As said Richard has some experience making coolers, dunno if he's ever monitored coolant temps at different amperages and duty cycles but he'll have played around with different types of pump which is the trickier bit... getting the flow rate without exceeding max pressures and/or without spending lots on the pump, use of pulse dampers with positive displacement pumps etc

 

[mtt.tr]

My theory is different to what I have seen but I hope would allow for much cooler fluid and much smaller in size.

Might not work but I make alsorts mostly non-related just how I see things. Some work, some don't. My first priority is to hopefully maximise cooling time if that doesn't work I won't progress to a machine.

Won't happen over night I have a million and one designs going on in my head

 

[Richard.]

I've used various pumps and design types all with there pros and cons. The type I made for mark was the popular rotory vane procon with 1/4hp motor. Very quiet in operation and up to 100psi if needed (way more than a tig torch needs) but the down side is the motor gets very warm which transfers heat to the pump and anything around it which is why these pumps like been left open. Pulse pumps are the type I've used recently ceme et3009 been the choice of the last project. 65psi and stays coolish while running so can be boxed up well. Down side is noise and vibration. Hotrodder's cooler uses the exact same pump but fitted with a pulsation damper so the vibration transfer to the torch is minimal. Regarding water temp the cooler the better. I like to keep them compact so water volume alone doesn't stop the rising temp so a heat exchanger is needed and even better a fan blowing air through it helps more. I'd say Luke warm is more than acceptable for continued running if it gets to the point where it's 40 degrees or more it will start to soften the pipes risking a blow. And duty cycle on the torch may be effected. These torches need good pressure but volume isn't that important through it. A trickle into the tank is sufficient so long as it gets round. If water temp gets too high the best thing is simply increase the resivour size. 4 Ltr of water takes much more energy to heat than 2.

 

[mtt.tr]

Cheers. Ill make some parts and do some testing

 

[Richard.]

This was the last one I built. Was a little bit of an involved project as I literally made everything inc the terminal box, heat exchanger, tank, frame box etc. This can be waaaaaaaay simpler with bought and bolted items but the guy wanting this wanted something a little more unique.

 

[mtt.tr]

That's what I expected.
Cheers pal

 

[mark williams]

That's a nice looking cooler Richard!