Tig Cooler Build / Beer Cooler Autopsy

[WorkshopChris]

A cooler has been on my list to build for a while, its not a priority as i still have to restore my miller 500A to go with it.

But having seen beer coolers mentioned on a few post recently in relation to torch cooling i thought it would be good to investigate.

I was skeptical to start with as having worked in a pub in the past i couldn't see how one of the small cooler would be much use.

Then Friday i spotted one locally for a good price that had a additional pump fitted, they are normally used to pump cooled water around a insulated jacket to cool casks.

A standard cooler contains no pump just a number off cooling loops to act as heat exchangers. Under normal circumstances the beer is not pumped as the keg is pressurized with Co2.

I have only got as far as opening it up to take a few photos.

At the moment i am not expecting the pump to be of any use, as its just a tiny washing machine pump.

Once i have cleaned it up i will test to see how much pressure and flow we have.







So we have a compressor pump, heat exchanger and fan.


With a plastic double walled insulated tank.

The copper refrigerant coils run round the outside, with the stainless exchanger coils in the middle.



Then in the top sit the pump and an agitator.


Once i get it cleaned up i will report back and update with the tank capacity and the pump performance.

 

[eSCHEn]

Watching with interest

 

[Rrunnach]

My first job when my time was out, new company had an age old tig welder, two part BOC job, fixed to wall. TIG torch cooler, was an old radiator from a mini. Of course, small reservoir and pump required, too.

 

[arthur]

Looks interesting, I just placed an order for a Binzel CR1000 as of late alloy work is getting a tad toasty!!

 

[piman]

Hello Chris,

I think you may be surprised how effective those pumps are. We use them to chill 800 litre stainless steel beer tanks . I don't suppose you'll need to use the refrigeration set up if using it to cool a tig torch.

Alec

 

[WorkshopChris]

I will have a play tomorrow i filled the tank earlier ready to clean it, a very momentary flick of the pump switch shot a jet of water straight past me!!!

The outlets are an odd size measuring about 7.7mm so not 5/16" or 8mm. will see what fits best.
I have some various adaptors so will see how long it takes to pump a litre through a 6 and 4mm pipe.

Will see how clean i can get the tank after a few water changes then let it circulate with a filter in line.
I want to get it completely clean before it goes any where near a torch.

I think you may be surprised how effective those pumps are. We use them to chill 800 litre stainless steel beer tanks . I don't suppose you'll need to use the refrigeration set up if using it to cool a tig torch.

I must admit i am a little more hopeful now i have seen the pump running, but still not sure how much pressure/flow it will develop once it's flowing through the waterways of a tig torch.

 

[arthur]

Keen to see how you get on, I looked at building a cooler, loaned one from a mate and in the end just thought sod it. The one I just ordered runs at 3.5bar so a reasonable pressure i thought..

 

[Richard.]

The water should go straight from the pump to the tig torch. Then back to the return. The last thing before hitting the tank is the exchanger. That looks like a long big bore exchanger pipe. Does that pump pack enough power to send it round that after an 8 Mtr run through a tig torch. I have no clue what those pumps are capable of so Im also keen on watching this project.

 

[Richard.]

3.5bar

Perfect. Roughly 40-45psi.
Nice amount of pressure to cool any tig torch sufficient.

 

[WorkshopChris]

Ok got a bit more done over the last few days.

Took the top of and cleaned the tank replaced the sealer and put it back, after changing the tank fitting for the overflow as that was leaking.


Tank capacity from empty is approximately 17 Ltr.
The cooler lowered the tank water from 10 deg down to 2 in about 5 minutes.

Overall build quality is quite good, The compressor and tank agitator run as required by the thermostat. the tank is a moulded thin plastic with polystyrene insulation. the lid is double skinned. Only problem i had when disassembling was the brass strips that hold the piped down were fitted with steel screws that had corroded.
I am still waiting to get some 10mm nylon pipe so just used a few odd bits to test the pump.

As i expected once pushing through the tig torch only managed 300ml per min, with no pressure( you can hold the flow with your finger over the end to the tube.)

So back up plan was an additional 110v pump i have had sitting in the might come in handy one day pile.

Wanted to get this tested today so gave it a go 1st test it popped a hose off as i didn't have any clips, so had to run a bypass hose into the tank to reduce pressure.

With this pump running i got 1 Ltr per min through the torch with the bypass valve fully open. Didn't have a pressure gauge, will have to test once i get some more fittings.

So so far looks as if i will be able to use this set up, i am planning on adding a flow switch with audible alarm, and maybe a second thermostat as i think if the cooler was used as is you could get condensation at the torch end if its running just off freezing. I imaging if i could keep the tank temp about 10Deg while running would be ideal.

 

[WorkshopChris]

Also managed to borrow a forklift today to get the tig out of storage and into the workshop ready to rebuild.







Once i get this rebuilt and the cooler running will need to find a torch to take the 500amp.

 

[the snooper]

coolers with a pumped send and return usually cool the python as its called, the bundle of tubes running along the bar, without it the first pint or so would always be warm, especially when there are no under bar coolers

 

[WorkshopChris]

coolers with a pumped send and return usually cool the python as its called, the bundle of tubes running along the bar

Thats why it's no good in this application its only designed to flow a low volume of water around a circuit it doesn't need to be under any pressure. Unlike the very restrictive internals of a typical tig torch.

 

[Richard.]

Nicely coming on Chris. I've T'd off the feed before to reduce pressure down the torch hose and it's a good way of controlling flow and pressure. You'll find if you add a 8mtr torch you can up the pressure a bit to compensate for the double distance it needs to go.
I look forward to seeing the finished set up.

 

[the snooper]

Thats why it's no good in this application its only designed to flow a low volume of water around a circuit it doesn't need to be under any pressure. Unlike the very restrictive internals of a typical tig torch.

Fit a relief valve that releases back into the reservoir a simple gate Valve so you get what ever you need

 

[Richard.]

T piece with ball valve back to the tank does as good a job as any. It's all I've ever done.