Welding: Benefits of a Heated CO2 Regulator

Heated Regulators

• For all normal applications, a heated regulator of between 150 watts and 200 watts, working on regular mains 110-volt power, is entirely adequate. Such a machine will heat to room temperature a flow of between 1 and 25 liters per minute at a maximum pressure of 50 psi. Heated CO2 regulators typically have an integral thermostat and pressure gauge to maximize efficiency.

Standalone Heaters

• Heaters are available that are not part of a regulator assembly. Separate heaters are installed between the CO2 cylinder and the regulator. They perform the same function as an integral unit, heating the depressurizing gas to room temperature.

Primary Benefit

• A heated CO2 regulator allows the welder to work for extended periods -- in fact, until any other component of the operation runs out -- without freezing up. This not only minimizes wasted time and irritation, it serves to extend the working life of the regulator.

Freeze-Up Explained

• The CO2 is stored at high pressure inside the cylinder. The flow control device -- the regulator -- allows the gas to expand to its desired pressure, and that expansion creates “snow” if the set pressure is below 60 psi; above 60 psi no solids develop. The amount of solid that develops is dependent on the pressure of the gas in the cylinder; the higher the pressure, the more solid that will be present. Solids in the system clog the regulator with dry ice crystals; these crystals restrict gas flow and can cut off the puddle shield.

Weld Degeneration

• When MIG welding, the weld puddle must be protected from atmospheric contamination. This is achieved by using a shield of inert gas, in this case carbon dioxide, within which the welding process takes place. If the shield fails, welds become unstable, weak and porous. If the regulator freezes up, the flow of CO2 ceases and the weld is ruined. The single greatest benefit of using a heated regulator is that the potential for this problem to occur is minimized.