255EXT Cooling fans

[labmaster02]

I know everyone seems to complain about how loud the cooling fans are. I'm not so much concerned about the noise since I have a cooler that's louder than the welder anyway, but the fans seem to oscillate so much that the the whole welder is vibrating. I can feel it through the power cord and gas line and by just placing my had on top of the case. This can't be good for the future of the welder. Things will start to deterate. I was trying to find a replacement fan, but I can't find any info on the specs of the original. The largest flow I could find is 72cfm each that are the same physical size. I put them in the machine and they are much much quiter. This wasn't my intention though. The machine doesn't vibrate at all now. The replacement fans are ball bearing and much better quality. I can definitely feel the air flow from the rear and exiting out the front and sides. I'm just concerned if it's not enough. I don't run the welder anywhere near the limits so I'm not too worried about it right now. Does anyone know the cfm on the original fans? The fans are Bi-Sonic model YM2409PST1, DC 24v. Internet searches came up empty.

[Rambozo]

The two things to consider are airflow and static pressure. Easiest to just measure what you have since they are still functional. If you don't have a way to measure air, than you can measure RPM and current and that will get you in the ballpark if your new fans are a similar design.
You can get most of the datasheets from the Bi-Sonic website, but I think the number you have is an OEM number, so you might have to dig around a bit to find a match.

[labmaster02]

The model number I have is off of the fan. I figured if I found the Bi-Sonic web site I would get the info. The model number structure doesn't match any of theirs. I searched for all the same size an voltage fans and the one I bought is higher RPM and CFM than anything I could find. I wonder if it's something propriety to Everlast. I find it hard to believe they wouldn't have used a better and quiter fan if it was as good. The fans I bought were about $50 for four fans and the ones I bought are ball bearing and I think the ones I removed were sleeve. Of course price is always a factor. $50 added to the machine would be significant. As far as current, the ones I bought are .18A and the originals are .34A. I thought this was an indicator, but I found others with less current and higher CFM, go figure.

[Rambozo]

You can't directly compare CFM without taking SP into account. Typically a high SP requires more current than a similar bump in CFM. If your replacements are actually drawing about half the current of the originals, than you are moving less air. The reason for the different part number, is that many times the OEM will put whatever part number the customer wants. But I rather doubt this is a custom fan, more likely a standard model renumbered for the welder factory.

[zoama]

What are the fan dimensions?

[labmaster02]

92mm x25mm

[christian]

Gee, maybe I was hallucinating, as I ran a few beads on the same piece of aluminum tubing today and it seems quieter somehow. I mean, nothing like DC quiet of course.

[christian]

Hey,

Nice to hear of the good outcome and that it was a small enough problem to resolve with just parts sent to you.

I have a 210EXT (2015) that undoubtedly has the similar four fan configuration, which is whisper quite. I don't use a water cooler. And I enjoy listening to somewhat loud music when I'm DC TIG welding in a room size of 7' x 8', with an open door to a much larger room that has a high, dome-like ceiling, which makes for great 5.1 surround sound and 4.1 music, especially with four THX speakers in the upper corners.

Anyway, I've finally gotten around to doing some initial AC TIG welding practice on aluminum with my new, AC-capable 210EXT, which I really dig on DC. It's going well enough, but it does seem to be a much louder process than I may have thought, since some of the YouTube videos I've seen seem to show the AC process as being a little quieter. I'm using a variety of AC frequencies and wave forms to see what I like best, but they all seem loud. Maybe some of those YouTube videos are doing voice-over narration that includes reducing the audio volume of the puddle clips...

So, my question is, am I having auditory hallucinations about the sound level of the AC TIG process, or is it just the small room that I'm using? Or, does anyone tend to avoid small spaces for AC TIG?

Peace to you all,
C. Livingstone

[everlastsupport]

AC TIG is a lot louderr. Lower frequency is louder to me. Try 60Hz then 120Hz. But yes it is louder.

[Rambozo]

AC will create a tone at the frequency the machine is set for. The arc directly vibrates the air like a Tesla coil. Also the arc length has an effect as that causes the voltage to change. A long arc length will be louder. In theory you could modulate your weld frequency with music and the arc would play a tune while you're welding. Not very practical, better to use hearing protection when doing AC TIG , especially over an extended time. You will get a similar effect when using hi frequency pulse settings on DC.

[labmaster02]

The 255EXT manual Highly Recommends wearing ear protection while using high AC frequencies and high pulse.

[christian]

OK, thanks, I'm not hallucinating! Ha, ha, ha...

[christian]

OK, thanks.