Arc Welding Machines (Water-cooled) and Resistance Welding Machines
Improves Reduces Extends weld quality! spatter! life of tips!
Triple effect!! Proposal for Installation of Thermo-chiller
Supplies “cooling water” at a stable temperature anytime and anywhere!!
Circulating Fluid Temperature Controller Temperature stability Thermo-chiller HRSE/HRS/HRSH Series (Refrigerated) ±3.6°F[±2°C] (HRSE) ±0.18°F [0.1°C] (HRS, HRSH) Lightweight 77 lbs [35 g] (HRSE) 95 lbs [43 kg] (HRS012/018/024) Space-saving
NP-E13-8C Proposal for Thermo-chiller used with Arc Welding Machines (Water-cooled) Solves problems caused by insufficient cooling of “welding torches.” When a welding torch reaches a high temperature, various problems may arise. High temperature
Welding torch
Have you experienced any of the following problems? Effects of rising torch temperature ¡Process becomes unstable, which causes wavy beads (weld marks), and generates bubbles. ¡Requires work-hours for polishing due to excessive scattering of spatter to surroundings. ¡Tip life deteriorates due to softening.
These problems can be Cooling solved by thermo-chillers! Since the chiller supplies temperature controlled cooling water, the welding torch can always be maintained at a constant temperature.
Effects obtained by cooling and stabilizing the welding torch temperature ¡Stable power supply produces stable beads (weld marks). ¡Improved shielding reduces spatter scattering. Triple effect!! ¡Prevents softening of welding tips. Long life. ¡Stable torch temperature improves operability of tip replacement. ¡Can be used with large currents. The use of a “Thermo-chiller” promotes improvement in both quality and operability. Reduce your costs and problems at once!
Main welding system and machine structure
Thermo-chiller
Welding torch
: Cooling point
1 Reference This test data compares the effectiveness of a radiator type and a thermo-chiller when used in a cooling water Data circulating system. This reference data is based on SMC conditions, and the values are not guaranteed.
1 Comparison of Cooling Water Temperature ¡Continuous 30 min ¡Ambient temperature: 86°F (30°C) ¡Current value: 450 A 122 [50] Thermo-chiller CO2 welding machine 113 [45] Radiator return temperature Radiator type 104 [40]
95 [35] Radiator outlet temperature Return temperature 86 [30] Thermo-chiller return temperature 77 [25] Thermo-chiller outlet temperature Outlet temperature 68 [20]
41 [5]
Cooling water temperature °F [°C] 0 0 5 10 15 20 25 30 Time (min)
Radiator type Thermo-chiller Cooling water temperature increases. Cooling water temperature is always constant.
2 Tip Durability Comparison
Tip Hardness Comparison Change in the level of hardness was compared with a new product.
¡Current value: 300 A Radiator type Thermo-chiller ¡Tap welding: Measures tip hardness after 280 welds Difference compared Difference compared ¡Number of samples: 5 Hardness (HV) with new product Hardness (HV) with new product ¡New product hardness standard value: 178 HV Sample 1 158.9 –19.1 171.0 −7.0 Sample 2 165.2 –12.8 168.5 −9.5
Tip Roughness Comparison Change in the level of roughness was compared with a new product. ∗ The surface roughness is defined in JIS Standard (JIS B 0601-2001). New Product Roughness Parameters ( m) 2.5 mm 15 mm 15 mm µ A part B part A B Ra (Ave.) 0.0845 0.0728 Rz (Max.) 0.5843 0.5235 Tip cross Measurement directionǞ section Radiator type Thermo-chiller 450 A continuous 250 A continuous 450 A continuous 250 A continuous
(200 times) (200 times) (200 times) (200 times) Difference in Level of Roughness Compared with New Product Difference in Level of Roughness Compared with New Product 450 A continuous 250 A continuous 450 A continuous 250 A continuous Difference A Difference B Difference A Difference B Difference A Difference B Difference A Difference B Ra (Ave.) 0.2379 0.6232 0.1525 0.5201 Ra (Ave.) 0.0754 0.1546 0.0791 0.2726 Rz (Max.) 2.5286 4.6334 2.2117 4.1374 Rz (Max.) 0.8195 1.2486 0.7498 2.8755 Turns black due to carbon adhesion, and inner surface becomes rough. Less change in the level of roughness was seen compared with the radiator type. 2 Reference This test data compares the effectiveness of a radiator type and a thermo-chiller when used in a cooling water Data circulating system. This reference data is based on SMC conditions, and the values are not guaranteed.
2 Tip Durability Comparison
Tip Hole Size Comparison Radiator type Thermo-chiller 300 A tap welding 300 A tap welding New product
Lens Z20X100 Lens Z20X100 Lens Z20X100
Tip
Change in hole size is less than the radiator type.
3 Shielding Gas Comparison
Radiator type Thermo-chiller 450 A 450 A
Shielding gas is turbulent. Shielding gas is stable.
3 Application ∗ The following are some of the application examples. Since the amount of heat generated changes Examples with conditions and usage rates, the effectiveness is not guaranteed.
Equipment Water-cooled Arc Welding Machine Equipment General-purpose TIG Welding Machine
Specifications CO2 welding (400 A) Specifications Rated output current value 300 A Chiller type HRS018-A-20-T + HRS-BP001 (Bypass piping) HRSE018-A-20-T Chiller type Welding of construction machinery parts HRSE012-A-20-T + HRS-BP001 (Bypass piping) Application Changed from radiator type to a thermo-chiller. Stainless tank welding Application The set temperature could be maintained, which Changed from radiator type to a chiller. Effect extended the life of the welding tip, and reduced costs. Stable water temperature reduced the consumption ⇒ Greatly reduced tip replacement costs of the tungsten electrode and power cable. The Effect durability of the collet also improved. By suppressing the increase of the torch temperature, Arc welding continuous manual welding became possible.
Water-cooled Arc Welding Machine Equipment (Tandem Welding) Equipment Plasma Welding Machine
Specifications Tandem CO2 welding (450 A) + CO2 welding (400 A) Specifications Plasma welding machine (300 A) Chiller type HRS050-A-20 + HRS-BP004 (Bypass piping) Chiller type HRS050-A-20 + HRS-BP004 (Bypass piping) Thick material continuous welding. Although two radiator types The cooling of the water-cooled torch used on a Application were used conventionally, the improved life of the tip and the Application muffler plasma welding robot. cooling system are integrated into one unit.
When a radiator was used, the water temperature increased Cooling water at a stable temperature can be supplied even in immediately after the welding started, and the tip eventually Effect plasma welding with high radiant heat. The costs of expensive disappeared. After the chiller was introduced, the water argon gas could be reduced due to turbulence suppression. Effect temperature stabilized immediately after the welding started, The wear of the torch tip was also suppressed. and the set temperature was maintained. The life of the tip was greatly improved. Furthermore, spatter was reduced, and a stable bead formation was obtained.
Arc welding (Tandem welding)
4 Proposal for Thermo-chiller used with Resistance Welding Machines Have you experienced any of the following problems?
Ground water Ground water Since the water is too cold, dew Algae grow and adhere to the condensation occurs in summer. inside of welding machines. \Cause of failures! \Cause of failures!
Radiator type circulation Tap water systems and cooling towers High tap water costs (running costs)! Water temperature increases in summer. \Quality deteriorates and shortens life of tips! These problems can be solved by thermo-chillers! The temperature of the cooling water can be controlled. (Maintains a constant temperature at all times.)
Ground water Tap water ¡Set to 68 to 77°F [20 to 25°C] ¡Circulates the water in the tank. \Cools without condensation. \Greatly reduces running costs. ¡ Stable water quality without foreign objects from the chiller. Prevents the growth of algae Radiator type circulation systems by periodic replacement of water. ¡The stable water temperature, even during the summer, improves tip life Cooling towers and operability. ¡Water temperature remains stable even in summer. ¡W ear particulate-free HRS series \Extends the life of tips. (Standard) does not require Reduces maintenance requirements! maintenance. ¡Even in poor surrounding environments, since the product is sealed, it is not affected by dust etc. Cooling locations AC: Electrodes (upper/lower), transformer (built-in) Difference between chiller DC: Electrodes (upper/lower), transformer (built-in), transistor (thyristor) and radiator type circulation systems The radiator type is not equipped with a compressor, and the circulat- ing water is cooled by a fan. Therefore, the temperature cannot be reduced below the ambient temperature. For this reason, the water Thermo-chiller temperature differs by season. Electrode
Air conditioner = Thermo-chiller 77°F [25°C] Transformer
Electric fan = Radiator type 95°F [35°C]
5 Reference Example of ∗ The following are some of the application examples. Since the amount of heat generated Data Improvement changes with conditions and usage rates, the effectiveness is not guaranteed.
Improves Life by Cooling the Electrode
Increasing the number of spots decreases the number of electrodes used. Example of electrode reduction ¡Spot welding machine (Nut welding) (Welding machines: 5, Electrode unit cost: $ 5) ¡Rated capacity: 75 kVA ¡Cooling water circulating system: Thermo-chiller HRS050-A-20 Cooling tower Cooling tower (Without chiller) (Without chiller) Thermo-chiller Water Electrode surface Electrodes used/ No. of spots temperature temperature month No. of 52.3 x 5 machines x 12 months 36.6 electrodes x 5 machines x 12 months electrodes used = 3138 electrodes/year = 2196 electrodes/year 95°F [35°C] 158°F [70°C] 2100 52.3 Electrode 500 x 3138 500 x 2196 cost = $10,980 Cooling water circulating system: = $15,690/year Thermo-chiller HRS050-A-20 Set Electrode surface Electrodes used/ No. of spots $4,710/year temperature temperature month reduction 68°F [20°C] 131°F [55°C] 3000 36.6
142% 30% increase reduction
Amount of Heat of Resistance Welding Machine and Chiller Selection
Graph of Amount of Heat by Welding Current Value Used (A) and Usage Rate
7000
Usage rate 10% 6000
Usage rate 7% [W] 5000
Usage rate 5% 4000 Usage rate 3%
ation amount 3000
2000 Usage rate 1% Heat gene r
1000
0
4000 6000 8000 10000 12000 14000 16000 18000 20000 Welding current value used [A]
The amount of heat of a resistance welding machine is determined by the welding current value used (A), and the usage rate.
Note for Selecting a Chiller Amount of heat of resistance welding machine < Chiller cooling capacity Note that the chiller cooling capacity is influenced by the ambient temperature. We recommend that the selection be performed with sufficient margin in consideration of the surrounding environment. ∗ Please contact SMC when selecting a chiller.
6 Application ∗ The following are some of the application examples. Since the amount of heat generated changes Examples with conditions and usage rates, the effectiveness is not guaranteed.
AC Resistance Welding Machine Equipment AC Spot Welding Machine Equipment (Multiple Units) Specifications Rated capacity: 50 kVA Specifications 30 kVA, 35 kVA, 40 kVA, 50 kVA Total of four units Chiller type HRS024-A-20 + HRS-BP001 (Bypass piping) Chiller type HRS050-A-20 + HRS-BP004 (Bypass piping) [Parts welding for large air conditioners] [Precision frame welding for medical applications] Since the water temperature increases in the current Application Reduction of water costs was demanded, because tap radiator type, the welding machine stops, and it takes time water was used conventionally. There was a requirement Application until it cools down. to cool four resistance welding machines with one chiller (individual operation). A proposal to reduce tap water Maintains the set temperature even after continuous usage was presented. Effect operation. The sufficiently cooled torch solved the momentary stops, which improved the operability. Tap water cost: 0 JPY; Reduced about 300,000 JPY per Effect year. Introduction costs were recovered in about two years.
Equipment Projection Welding Machine
Specifications Rated capacity: 110 kVA Chiller type HRS050-A-20 + HRS-BP004 (Bypass piping)
Ground water was used conventionally, which generated Application condensation. Problems with flow path clogging also occurred due to the foreign objects in the poor quality water.
Stable water temperature prevented condensation. Effect Stable water quality prevented further problems.
Equipment AC Spot Welding Machine
Specifications Rated capacity: 35 kVA Chiller type HRSE024-A-20-T + HRS-BP001 (Bypass piping)
[Auto parts welding] Application Water piping installation was required to change from air cooling to water cooling.
The water resource was secured without installing new ∗ The amount of heat generated changes with the Effect water piping. The increase in the torch temperature could also be usage rate and current value. suppressed.
7 Thermo-chiller Variations Temperature Temperature Pump Cooling Cooling capacity Pump Circulating Series Features range setting stability Power supply capacity method g/min type fluid °F [°C] °F [°C] [L/min] Tap water Thermo-chiller Magnet Single-phase 100 VAC ¡ With this chiller, 1.3 kW Standard type pump (50/60 Hz) Deionized cooling water can be 1.9 kW HRS Series 11 (Mechanical water supplied to anywhere 41 to 104 [5 to 40 ] 2.4 kW Single-phase 115 VAC Air-cooled ±0.18 g/min seal pump for it is necessary 3.2 kW (60 Hz) Ethylene Water-cooled [±0.1] [42 high pressure glycol because of its easy 32 140 5.1 kW Single-phase [0] [60] L/min] pump aqueous installation and easy 5.9 kW 200 to 230 VAC mounted solution operation. (60 Hz) (50/60 Hz) (Only 60 Hz) type) (15%) ¡ For a wide range of Thermo-chiller applications, such as Standard type laser machine tools, 18 g HRS090 Series analytical equipment, 41 to 95 [5 to 35 ] ±0.9 /min LCD manufacturing 9 kW equipment, mold [±0.5] [68 32 140 temperature control, [0] [60] L/min]
(Only 400 VAC etc. ¡ Compact: Thermo-chiller W377 x H615 x Standard type D500 mm, 40 kg 3-phase 200 VAC Tap water (HRS012/018/024) HRS100/150 Series (50 Hz) Deionized ¡ Timer function, Low 3-phase water liquid level protection, Air-cooled Mechanical 200 to 230 VAC Power failure auto- Ethylene Water-cooled seal pump (60 Hz) restart, Anti-freezing glycol 3-phase aqueous function, etc. 18 g ¡ Self diagnosis function 41 to 95 [5 to 35 ] 9.5 kW 380 to 415 VAC solution ±1.8 /min ¡ No heater required, 14.5 kW (50/60 Hz) (15%) [±1.0] [68 as circulating fluid 32 140 (60 Hz) L/min] is heated using [0] [60] heat exhausted by refrigerating circuit. ¡ Low-noise design: 70 dB (A) (HRS100/150) ¡ Outdoor installation: IPX4 (HRS100/150) (Only 400 VAC
Thermo-chiller ¡ Reduces power Inverter type consumption by 53% Tap water HRSH090 Series Complete with energy- 3-phase 200 VAC saving triple inverter! (50 Hz) Deionized ¡ Compact/Space- 16 3-phase water 41 to 104 [5 to 40 ] g/min saving: W377 x H1080 Air-cooled ±0.18 Mechanical 200 to 230 VAC Ethylene 9.5 kW 0.1] [60 x D970 mm Water-cooled [± seal pump (60 Hz) glycol ¡ Low-noise design: 32 140 L/min] [0] [60] 3-phase aqueous Max. 66 dB 380 to 415 VAC solution ¡ Max. ambient (50/60 Hz) (15%) temperature: (Only 400 VAC 113°F [45°C]
Thermo-chiller ¡ Complete with energy- Inverter type saving triple inverter! 3-phase 200 VAC Tap water HRSH Series ¡ Outdoor installation: (50 Hz) Deionized 10 kW IPX4 48 3-phase water 41 to 95 [5 to 35 ] 15 kW ¡ Max. ambient Air-cooled ±0.18 g/min Immersion 200 to 230 VAC 20 kW Ethylene temperature: Water-cooled [±0.1] [180 pump (60 Hz) 25 kW glycol 113°F [45°C] 32 140 L/min] 3-phase [0] [60] 28 kW aqueous ¡ Space-saving, 380 to 415 VAC solution Lightweight: 280 kg (50/60 Hz) 400 V as standard, Only 200 V as (15%) (200 V as an option) ( an option ) (HRSH250/300)
Thermo-chiller Basic type ¡ Simple function and performance. Thermo- HRSE Series Single-phase chiller basic type. 100 VAC ¡C omplete with energy- (50/60 Hz) Tap water saving triple control! 1.2 kW 6.6 Reduces power 50 to 86 [10 to 30] Single-phase Ethylene 1.6 kW ±3.6 g/min Magnet consumption by 33% Air-cooled 200 VAC glycol 2.2 kW [±2.0] [25 pump ¡ Compact/Lightweight: aqueous 32 140 L/min] (50/60 Hz) 32 kg (100 VAC) [0] [60] (60 Hz) solution Single-phase ¡M aintenance free: (15%) 230 VAC Magnet pump (50/60 Hz) ¡ Low-noise design: 55 dB (A) (Only 230 VAC type)
8 Related Products
Flow Switch: Monitors flow rate and temperature of the circulating fluid. For details, refer to the Web Catalog. 3-Color Display Digital Flow Switch for Water PF3W 3-Color Display Electromagnetic Type Digital Flow Switch LFE
Integrated flow adjustment valve and temperature sensor PVC Piping
Digital Flow Switch for Deionized Water and Chemical Liquids PF2D 4-Channel Flow Monitor PF2२200
Pressure Switch: Monitors pressure of the circulating fluid. For details, refer to the Web Catalog. 2-Color Display High-Precision Pressure Sensor for Digital Pressure Switch General Fluids ISE80 PSE56२ Pressure Sensor Controller PSE200, 300
Optional Accessories For details, refer to the Web Catalog.
Filter Replacement type Particle filter set dustproof filter set Removes foreign objects in the Suitable for use in excessively circulating fluid. dusty atmospheres. The disposable type filter saves time and effort of cleaning.
Front panel
60% ethylene glycol aqueous solution Bypass piping set Piping conversion fitting This solution can be used as a circulating fluid for Converts the circulating fluid port from Rc1/2 to ethylene glycol type thermo-chillers. (Capacity: 10 L) 5/8-18UNF.
Part no.: HRS-EP031 (1 pc.)
Rc1/2 2 8 0 m
5/8-18UNF A pprox.
Approx. 230 mm
230 mm Approx.
9 Safety Instructions Be sure to read the “Handling Precautions for SMC Products” (M-E03-3) and “Operation Manual” before use. Global Manufacturing, Distribution and Service Network Worldwide Subsidiaries
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© 2016 SMC Corporation of America, All Rights Reserved. All reasonable efforts to ensure the accuracy of the information detailed in this catalog were made at the time of publishing. However, SMC can in no way warrant the information herein contained as specifications are subject to change without notice. UX-RRD-2.5M