Coolant safety method for welding apparatus

A method of operating a water saver apparatus coupled to supply and return coolant lines of a welding machine, said method comprising:

• generating a first signal indicative of a supply flow rate of coolant in a supply coolant line to welding components;
• generating a second signal indicative of a return flow rate of coolant in a return coolant line from the welding components;
• determining whether a leak threshold value has been exceeded utilizing the first and second signals;
• in response to a determination that the leak threshold value has been exceeded, generating a valve shut-off signal to shut off the flow of coolant;
• and
• recording a number of times the leak threshold value has been exceeded.

A method of operating a water saver apparatus coupled to supply and return coolant lines of a welding machine, wherein said water saver apparatus includes a processor, said method comprising:

• a first flow sensor generating a first signal indicative of a supply flow rate of coolant in a supply coolant line to welding components;
• a second flow sensor generating a second signal indicative of a return flow rate of coolant in a return coolant line from the welding components;
• determining whether a leak threshold value has been exceeded utilizing the first and second signals;
• in response to a determination that the leak threshold has been exceeded, generating a valve shut-off signal to shut off the flow of coolant;
• and
• automatically calibrating the processor to compensate for flow sensor drifts.

A method of operating a water saver apparatus coupled to supply and return coolant lines of a welding machine, said method comprising:

• generating a first signal indicative of a supply flow rate of coolant in a supply coolant line to welding components;
• generating a second signal indicative of a return flow rate of coolant in a return coolant line from the welding components;
• determining whether a leak threshold value has been exceeded utilizing the first and second signals;
• in response to a determination that the leak threshold has been exceeded, generating a value shut-off signal to shut off the flow of coolant;
• and
• said water saver apparatus automatically shutting off coolant flow after a predetermined period of inactivity of said welding machine.

A method of operating a water saver apparatus coupled to supply and return coolant lines of a welding machine, the water saver apparatus including a supply rotor and a return rotor, said method comprising:

• generating a first signal indicative of a supply flow rate of coolant in a supply coolant line to welding components in response to rotation of the supply rotor;
• generating a second signal indicative of a return flow rate of coolant in a return coolant line from the welding components in response to rotation of the return rotor;
• determining whether a leak threshold value has been exceeded utilizing the first and second signals;
• in response to a determination that the leak threshold has been exceeded, generating a value shut-off signal to shut off the flow of coolant;
• and
• determining occurrence of a check valve error and signaling an alarm in response to sensing coolant flow through the return rotor and absence of coolant flow through the supply rotor.

A method of operating a water saver apparatus coupled to supply and return coolant lines of a welding machine, said method comprising:

• a first flow sensor generating a first signal indicative of a supply flow rate of coolant in a supply coolant line to welding components;
• a second flow sensor generating a second signal indicative of a return flow rate of coolant in a return coolant line from the welding components;
• determining whether a leak threshold value has been exceeded utilizing the first and second signals;
• in response to a determination that the leak threshold has been exceeded, generating a valve shut-off signal to shut off the flow of coolant;
• and
• a third auxiliary flow sensor detecting a low return flow in the return coolant line and, in response to detection of a low return flow rate, generating an alarm.

A method of operating a water saver apparatus coupled to supply and return coolant lines of a welding machine, the water saver apparatus including a supply rotor and a return rotor, said method comprising:

• generating a first signal indicative of a supply flow rate of coolant in a supply coolant line to welding components in response to rotation of the supply rotor;
• generating a second signal indicative of a return flow rate of coolant in a return coolant line from the welding components in response to rotation of the return rotor;
• determining whether a leak threshold value has been exceeded utilizing the first and second signals;
• in response to a determination that the leak threshold has been exceeded, generating a value shut-off signal to shut off the flow of coolant;
• and
• automatically shutting off coolant flow after a predetermined period of inactivity of said welding machine and automatically permitting resumption of coolant flow in response to an input signal indicating resumption of welding activity by said welding machine.