Everything You Need to Know About Water Welders

Discover everything about water welders, including how WeldSaver™ systems work, key features, applications, and why they're vital in robotic welding.

Jun 23, 2025 - 14:51
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Everything You Need to Know About Water Welders

Water welders play a crucial role in automated welding environments. These advanced systems are designed to monitor and regulate coolant flow, detect leaks, and ensure optimal temperature during robotic welding operations. As modern manufacturing becomes more automated and precise, maintaining the integrity of cooling systems is vital. Even a small leak or temperature spike can cause costly damage or downtime. That’s why water welders like the WeldSaver™ are becoming essential across various industries. This article explores what water welders are, how the WeldSaver system works, its benefits, and how it improves welding system performance, reliability, and safety, all while reducing unexpected failures and improving productivity in industrial automation.

What Is WeldSaver™?

WeldSaver™ is a high-performance water welder and coolant control system developed by Proteus Industries. It is designed to detect cap loss, measure coolant flow, and shut down water flow within milliseconds to prevent damage to equipment. The product is available in two models: WeldSaver 5 and WeldSaver 6, each designed for different automation levels and control preferences. Its core functions include acting as a leak detector, flow monitor, and shut-off valve. These systems support integration with Programmable Logic Controllers (PLCs) and various fieldbus networks, making them adaptable to robotic welding cells. With added features like eVac™ coolant retraction in the WeldSaver 6, it offers enhanced protection for spot-welding equipment.

Key Features & Functions

A. Flow Meter & Valve

WeldSaver utilises vortex flow sensors to monitor coolant flow in real time, displaying values in litres or gallons per minute. The system features a built-in control valve that can be operated remotely via a browser interface or a programmable logic controller (PLC).

B. Real-time Monitoring & UI

Its user interface supports EtherNet/IP, PROFINET, and DeviceNet. WeldSaver 6 offers a local display and keypad for added control.

C. Leak Detection & Response

Using a patented algorithm, it detects leaks in under 0.3 seconds and shuts off the valve in less than 1 second.

D. eVac™ Coolant Retraction

This feature (WeldSaver 6 only) retracts coolant after cap loss to avoid spills and equipment damage.

Installation & Integration

Installing a WeldSaver water welder requires careful setup of both plumbing and electrical systems. For plumbing, ensure the correct configuration of the supply and return lines, including proper to-robot and from-robot connections. Always flush the system to remove debris before starting. Electrical integration includes a 24 VDC power supply and Ethernet connectivity via an RJ-45 connector. The system supports communication over common industrial protocols, such as EtherNet/IP and PROFINET. Configuration is straightforward, with browser-based access to adjust alarm thresholds, view live data, and test functions. WeldSaver’s flexibility makes it easy to incorporate into existing robotic weld cells with minimal interruption to workflow.

Applications & Use Cases

Water welders, such as WeldSaver, are widely used in robotic welding systems across the automotive and heavy industrial sectors. They help prevent equipment damage during tip or cap changes by automatically detecting leaks or abnormal flow. This ensures the welding guns don’t overheat and avoids unexpected coolant dumps on the shop floor. WeldSaver seamlessly integrates with robotic weld cells, offering real-time monitoring and automation compatibility. By improving process reliability, it helps reduce downtime, increase operating efficiency, and extend the lifespan of welding components. This makes water welders essential for high-volume, precision-driven production lines.

Advantages & ROI

Using a WeldSaver water welder delivers clear operational and financial benefits. Its ultra-fast leak detection helps prevent serious equipment damage, saving thousands in repair costs. The ability to integrate with existing Programmable Logic Controllers (PLCs) and support remote monitoring makes it ideal for smart manufacturing setups. The eVac™ feature prevents messy and damaging coolant spills, especially during gun or tip changes. These features collectively reduce maintenance time, improve uptime, and offer a high return on investment by protecting vital welding infrastructure.

Choosing the Right System

Choosing between WeldSaver 5 and WeldSaver 6 depends on your operational needs. WeldSaver 5 is ideal for basic coolant control, while WeldSaver 6 includes eVac™ and a local keypad display. Valve selection also matters: pneumatic valves support higher flows, while solenoid valves are compact but limit flow slightly. You’ll need to match the system to your welding setup’s flow requirements, temperature range, and integration preferences. Consider fieldbus support (EtherNet/IP, PROFINET), plumbing compatibility, and available space. Selecting the right water welder ensures optimal performance, protects your robotic welding cell, and effectively supports your automation goals.

Maintenance & Support

WeldSaver water welders are low-maintenance but require regular care to perform at their best. Periodic flushing is recommended to remove contaminants from coolant lines. Proteus offers rebuild kits to replace seals and components as needed. Built-in diagnostics and browser-based interfaces simplify routine checks and adjustments. Proteus Industries, based in Mountain View, California, offers calibration, support, and technical assistance through a global distributor network. Maintaining your WeldSaver ensures accurate leak detection, efficient coolant flow, and long-term reliability. With proper upkeep, these systems can deliver years of dependable service in high-demand robotic welding environments.

Conclusion

Water welders, such as WeldSaver, have become a critical component of modern robotic welding systems. They ensure coolant flow is precisely monitored, leaks are detected instantly, and equipment is protected from damage. The combination of flow control, leak detection, and automation-friendly design makes WeldSaver ideal for industries seeking higher uptime and operational safety. Whether you choose the WeldSaver 5 or 6, both systems offer unmatched reliability and integration. For manufacturers focused on performance, efficiency, and safety, investing in a robust water welder system, such as WeldSaver, is a smart choice that pays off in the long run.