Coolants for welding equipment
During high-amperage welding with currents of over 300 amperes in combination with long duty cycles, extreme heat is generated at the front end of the welding torch and the wear parts such as the gas nozzle, contact tip, contact tip holder and gas diffusor. Considering also the reflected heat of the workpiece, a welding torch without sufficient cooling would very quickly reach its limits. When welding with such high currents and long duty cycles, it is necessary to change from an air cooled torch to a liquid cooled torch. However, the coolant required for this application should not consist of water but of a coolant specially designed for welding equipment.
With the coolants BTC-20 NF and BTC-50 NF ABICOR BINZEL offers two non-flammable welding torch coolants – "NF" means non-flammable – with a particularly low conductivity. In addition, the coolants for welding equipment offer a high level of protection against corrosion and algae formation and are durable in the system for a long time.
BTC-20 NF and BTC-50 NF are particularly long-lasting welding torch coolants for all liquid cooled welding equipment and cutting systems.
All informationen at a glance
- Why special coolants for welding equipment?
- Effects of BTC-20 NF and BTC-50 NF
- Applications of ABICOR BINZEL coolants for welding equipment
- Composition of BTC-20 NF and BTC-50 NF
- ABICOR BINZEL NF standard: welding torch coolant
- When do I have to change coolant?
- Videos about welding torch coolant
- Blogs about welding torch coolant
Why special coolants for welding equipment?
There is still a widespread opinion that water can be used for cooling a liquid cooled welding torch. Some welders still use water and are surprised when torch failures occur regularly.
The reason why tap water is definitely not recommended as a coolant is its conductivity. This value is relatively high at around 700 microsiemens (µS) and more. The disadvantage: if electricity flows through water – and this happens when the coolant passes a power cable – this leads to the conversion of electrical energy into chemical energy, also known as decomposition voltage. In this process, charged oxygen atoms are generated, which causes severe oxidation of the metals. This accelerated process is called electrical corrosion, which leads to clogging of the welding torch and deposits in the cooling system caused by the detached oxidation particles. Not only the welding torch and its fine cooling channels are affected, but also the power source is heavily loaded by the particles. The reason: particles circulating are transported to the pump, tank and cooler, which can lead to wear and untimely failure.
Since some cooling tanks are translucent and organic particles can get into the tank when the coolant is changed, the use of water or other unsuitable coolants often leads to algae formation, which can also get into the cooling circuit of the torch or power source and cause blockages.
Welding torch cooling with water destroys the torch, the power source and other metal parts of the welding system that get in contact with the liquid. The BTC-20 NF and BTC-50 NF coolants protect all components of the torch system from electrical corrosion, including the power sources and welding equipment.
Equipping an air cooled welding power source with a liquid cooled torch is easy with the mobile cooling units CR 1000 and CR 1250: In just a few steps, the water supply and return as well as the flow switch can be connected to the existing system and the »cool« welding process can start.
Why non-flammable coolant?
The importance of safety is increasing everywhere, and the requirements for manufacturing companies are also becoming stricter. Non-flammable coolants from ABICOR BINZEL for welding torches and power sources or welding equipment guarantee triple safety:
- for the welder at the workplace
- for the complete welding torch and cooling system
- for the environment
Effects of BTC-20 NF and BTC-50 NF
Both coolants from ABICOR BINZEL have a very low conductance of maximum 4 µS, which reduces electrical corrosion of all metal parts of the welding torch and cooling system. Therefore, the system components are all protected from electrochemical decomposition by the use of these coolants and thus have a longer service life.
When ordinary tap water is used for the cooling of welding torches, current flows through water and causes a chemical reaction. In the cooling circuit, materials with different electrochemical potentials are used so that a dissolution or decomposition process takes place: So-called base components such as brass dissolve and move towards more precious components such as copper, which are installed in the welding torch. The dissolved particles lead to clogging of the welding torch and the aforementioned failure of the torch.
BTC-20 NF protects the complete cooling system and is frost-proof down to minus 17 °C, BTC-50 NF even to minus 45 °C. Therefore, BTC-50 NF is well suited for outdoor use or transport at minus temperatures and additionally prevents liquid residues in the welding torch and cooling system components from expanding and bursting, which can occur with water in the cooling circuit.
Applications of ABICOR BINZEL coolants for welding equipment
Depending on the application, different demands are placed on the welding torch coolant. BTC-20 NF is ideal for standard welding applications in the production hall. It is frost-proof down to minus 17 °C and like all NF products, non-flammable. If the torch coolant is transported over land or sea, or is required for offshore use, temperatures down to the minus range are possible. For such applications, we recommend the BTC-50 NF, which is frost-proof down to minus 45 °C – and of course non-flammable like all NF products from ABICOR BINZEL.
Composition of BTC-20 NF and BTC-50 NF
ABICOR BINZEL coolants are composed of ethanediol and specially filtered, biologically treated water.
The properties of coolants for welding equipment:
- Reliable cooling of all liquid cooled welding and cutting systems
- Protect the complete cooling and torch system from electro-corrosion and algae formation and the subsequent damages
- Very low conductivity of less than 4 µS
- Long service life in the cooling system
- Guaranteed absolutely non-flammable
- Residual liquid in the cooling circuit is no problem even at sub-zero temperatures
- Safe handling, transport and storage
- Guaranteed silicone-free
ABICOR BINZEL NF standard: welding torch coolant
All coolants from ABICOR BINZEL comply with the NF standard. NF stands for non-flammable and exceeds the provisions of the GHS (Globally Harmonized System for the Classification and Labelling of Chemicals) as well as the CLP regulation (Recommendation for the Safe Handling of Hazardous Substances) for the classification of flammability. The coolants BTC-20 NF and BTC-50 NF, as well as the anti-spatter agent ABIBLUE NF and the welding protection spray Super Pistolenspray NF, were tested for flammability in extended, standardised welding tests under various practical conditions.
For manufacturing companies, BTC-20 NF and BTC-50 NF from ABICOR BINZEL guarantee non-flammability of the coolant when used properly and provide the best cooling for the complete welding process.
When do I have to change coolant?
There is a variety of information about the right time to change a coolant. However, there is only one answer: depending on the frequency of use and the duty cycle of the welding torch and of course before the recommended conductivity is exceeded. And the conductivity can be measured. An appropriate measuring device is Primo 5 from Hanna Instruments, which is also offered by ABICOR BINZEL.
Testing the conductivity of coolants
ABICOR BINZEL recommends limit values for the different welding processes according to which the coolant should be replaced:
- MIG welding and MAG welding = above 350 µS/cm
- TIG welding = above 250 µS/cm
- Plasma welding = above 30 µS/cm
On average, coolant needs to be replaced at regular intervals of about 1 month to once a quarter. To check the conductivity, simply immerse the measuring device Primo 5 into the filler neck for coolant – either on the cooling unit or on the power source – and the value is shown on the display of the measuring device. This gives a quick and easy overview of the coolant status in the cooling system of the welding equipment and welding torch and whether the coolant should be replaced.