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Coolmate™ 3X cooler on Syncrowave 250DX Questions

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  • Coolmate™ 3X cooler on Syncrowave 250DX Questions

    I'm considering a 250DX and hoping someone has some experience with the newer machine with the cooling on demand. I've been using the Dynasty 200DX for the past couple of years and the cooler is extremely loud and one of the reasons I'm considering the Syncrowave.

    The specific question, it appears the Coolmate™ 3X cooler is what cycles on and off depending on what the torch is doing and is independent of the welder. Is that correct? In other words, if I were to buy the new cooler and find an older (used) Syncrowave 250DX, would I get the cooling on demand functionality?

    Also, does the cooler just plug into the back of the welder so it's just one switch to turn on the whole thing? That was another annoying feature of the Dynasty because the cooler and welder each have a switch on opposite ends of the machine AND two power cords.

    I'd like the welder to be relatively quiet when it's on and not being used as my duty cycle is something like 5% when doing custom bicycle frames. So having all that noise is annoying and turning it on and off is as annoying.

    Any feedback? Thanks.

  • #2
    PCW
    Welcome to the site.

    The Sync 250 with Coolmate 3X is not a cool on demand system.
    The cooler runs all the time the welder is turned on.

    What cooler do you have on the Dynasty?
    Maybe a coolmate 1 would be quieter.

    Andy

    Comment


    • #3
      Air cooled

      Maybe switch to an air cool torch or make your own cooler and try to use a low db pump and insulate the pump with noise dampening material. Just a couple thoughts. I dont like the fans unless it needs it. I also hate noise when I am welding.
      Last edited by mikeb9550; 11-18-2011, 05:06 PM.

      Comment


      • #4
        As Andy has indicated, the 3X cooler mounted under the power supply, plugs into the front of the Syncrowave 250DX/350LX. The cooler runs whenever the main power is turned on to the welder.

        The Syncrowave 250DX Tigrunners (vintage 2006-07 if my memory serves me correctly) were the only Syncrowaves with "cooler on demand". Here the cooler was mounted inside the power supply cabinet, not under.

        These units did not work out all that well for Miller, and they went back to the cooler under the power supply.

        Have to disagree with Andy on one point though. Every coolmate 1 that I've been around sounded like an airplane trying to take off. I've found the Coolmate 3 much less noisy than the Coolmate 1.

        My Syncrowave came with the built in cooler (2007 model). I have since, with Miller's assistance, replaced it with the Coolmate 3X. Although it does run continuously, I do not find the noise objectionable.

        I use a Coolmate 3 mounted under (on a cart) the Dynasty 200DX. Noise isn't so much an issue as is the airflow created by the fan. Have to be somewhat careful about positioning the cart if you have the welder right next to where you're welding.

        I don't think installing an internal cooling system (like in the 06/07 units) is a viable option for the older units. There's quite a bit of hardware that goes inside the cabinet.

        If noise is an issue (sounds like it is) for you, you may want to look at one of the older Bernard coolers with just a pump and a larger reservoir (no radiator). I have one and it's very quiet. Only hear the whirr of a pump vs the noise of air moving thru a radiator. The reservoir on that Bernard unit holds about 5 gal of coolant and I never had an issue cooling a 18 series torch on a Sync 250.
        Syncrowave 250 DX Tigrunner
        Dynasty 200 DX
        Miller XMT 304 w/714D Feeder & Optima Control
        Miller MM 251 w/Q300 & 30A SG
        Hobart HH187
        Dialarc 250 AC/DC
        Hypertherm PM 600 & 1250
        Wilton 7"x12" bandsaw
        PC Dry Cut Saw, Dewalt Chop Saw
        Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
        Thermco and Smith (2) Gas Mixers
        More grinders than hands

        Comment


        • #5
          I have a Coolmate 3 that I use with my Dynasty DX200.
          Yeah, it is kinda noisy and runs all the time.

          So what I did to fix that was install a switch box on the front of the cart (where all switches should be, no thanks to Miller)



          When I am welding small items not requiring the water cooling I just cut the switch off.
          When I need it I cut it on.
          The bottom outlet is hot 100% of the time regardless if the Coolmate is on or off.
          I use this outlet to power a drill, grinder, or what have you.
          Works well for me.
          pg
          Dynasty 200 DX_set up on 3 phase
          Coolmate 3
          MM 251 w/ Spoolmatic 30A
          HTP 625 Micro Cut Plasma Cutter
          Victor O/A Rig
          Bridgeport Mill_3 phase (w/ Acu-Rite 4 axis DRO)
          10 inch South Bend Lathe_3 phase
          Baldor Double Cup Tool Grinder_3 phase
          Baldor 10 inch Buffer
          Rockwell 12 inch Disc Sander
          Cyclone 2ft X 3ft Bead Blast Cabinet
          Quincy 325 2stg- Air Compressor_3 phase
          Graymills Built-in Parts Washer
          Rockwell/Delta Planer, HD Shaper, Uni-Saw etc.

          Comment


          • #6
            I guess I don't see the "benefit" of PG's post.

            The on/off switch on my Coolmate 3 is located on the FRONT of the unit. The on/off switch for the Dynasty 200 DX is located on the BACK of the welder.

            Turning a cooler off for low amp work (when using a WC torch) is really bad advice. Using a water cooled torch, even at low amps, without a flow of coolant is a good way to ruin a torch. If you don't like the "noise" of a cooler, then use an air cooled torch for low amp work. A 20 Series and a 9 Series both use the same consumables.
            Syncrowave 250 DX Tigrunner
            Dynasty 200 DX
            Miller XMT 304 w/714D Feeder & Optima Control
            Miller MM 251 w/Q300 & 30A SG
            Hobart HH187
            Dialarc 250 AC/DC
            Hypertherm PM 600 & 1250
            Wilton 7"x12" bandsaw
            PC Dry Cut Saw, Dewalt Chop Saw
            Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
            Thermco and Smith (2) Gas Mixers
            More grinders than hands

            Comment


            • #7
              Originally posted by ASKANDY View Post
              PCW
              Welcome to the site.

              The Sync 250 with Coolmate 3X is not a cool on demand system.
              The cooler runs all the time the welder is turned on.

              What cooler do you have on the Dynasty?
              Maybe a coolmate 1 would be quieter.

              Andy
              Thanks, Andy. I'm glad to be here. I'm sort of confuxed then because this is what I'm reading on Airgas:

              • New! Integrated Cooler Option with Cool-on-Demand™ and Torch Detection monitors coolant flow and temperature-operating ONLY when necessary and preventing torch damage due to overheating. All-in-one design features a 3-year warranty- the first and ONLY cooler in the industry with a warranty beyond one year.
              • Syncro Start™ for customized arc starts allows the operator to choose from three different starting conditions to optimize the application according to tungsten diameter and material thickness.
              • Squarewave output with AC balance control features adjustable penetration and cleaning action while increasing arc stability on various aluminum alloys, and helps eliminate tungsten spitting and arc rectification
              • Large, dual digital meters are easy to view and presettable to ease setting weld output.
              • Last procedure recall automatically recalls the last procedure set-up when switching polarity.
              • Built-in preflow/postflow provides 0.2 - 5 seconds of preflow and 0 - 50 seconds of postflow.
              • Built-in cable hangers on both sides conveniently fold out of power supply so weld cables can be stored to prevent torch or cable damage.
              • Built-in consumable storage located on the front panel allows the operator to store and readily access the needed consumables to be more productive.

              Found here:
              http://airgas.com/browse/productDeta...t=MIL907194032

              They list the part as the Integrated Coolmate™ 3X Cooler.

              I wonder if this is "old" and not "new" as stated? Now I'm really confused.

              Comment


              • #8
                pcw,

                Did you bother to read the other responses?

                Cooler on demand was only offered for a few years (05-07).

                The "cooler on demand" used an INTERNAL SYSTEM, not the Coolmate 3X.

                Later units went back to the cooler mounted UNDER the power supply and used the Coolmate 3X.

                Check out Miller's latest advertising.
                Syncrowave 250 DX Tigrunner
                Dynasty 200 DX
                Miller XMT 304 w/714D Feeder & Optima Control
                Miller MM 251 w/Q300 & 30A SG
                Hobart HH187
                Dialarc 250 AC/DC
                Hypertherm PM 600 & 1250
                Wilton 7"x12" bandsaw
                PC Dry Cut Saw, Dewalt Chop Saw
                Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
                Thermco and Smith (2) Gas Mixers
                More grinders than hands

                Comment


                • #9
                  Originally posted by SundownIII View Post
                  pcw,

                  Did you bother to read the other responses?

                  Cooler on demand was only offered for a few years (05-07).

                  The "cooler on demand" used an INTERNAL SYSTEM, not the Coolmate 3X.

                  Later units went back to the cooler mounted UNDER the power supply and used the Coolmate 3X.

                  Check out Miller's latest advertising.
                  Yes, I did and that's why I'm confused. Did you look at the link to Airgas? It appears to be the new under mounted cooler in the picture but the description sounds like this internal system... But then the description says that it's the Coolmate 3X. It also says "new" which would sounds like was only "new" in 05-07. Is that correct? I'm trying to piece this all together but it sounds like that description on Airgas is incorrect huh?

                  Also, thanks for the info on the Coolmate 1 versus Coolmate 3. It sounds like my concern here is a non issue if I were to go to a Coolmate 3 on a 250DX because it wouldn't be as noisy as the Dynasty 200DX / Coolmate 1 from your description.

                  Do you have a preference between the 200DX and the 250DX on thin material (say 0.020-0.035" steels)?
                  Last edited by pcw; 11-19-2011, 03:56 PM.

                  Comment


                  • #10
                    Ditch the noisy fan and make a large capacity coolant reservoir? If you are only using it 5% of the time, 5 gallons would take all day to get noticeably warm. Then it cools overnight.

                    Most have one motor, powering both fan and pump. Take the fan blades off and see how hot it gets over your normal day? You won't damage anything as long as you have flow. Yes, it will get warmer but if you are boiling the coolant, it will cool even better. Won't be comfortable.

                    Comment


                    • #11
                      On thin SS, using the high speed pulsing on the Dynasty, is where the unit shines.

                      I'd say the Airgas ad is wrong. Looks like a salesman tried to combine features from a 2007 machine with the features of a new machine.

                      What "really" throws me a curve is the comment about torch hangers on both sides. On the integrated cooler machine, one side was designed as a fill for the internal cooler. The upgrade kit that Miller offers to replace the internal cooler with a 3X, includes a torch hanger to replace the fill spot.

                      With the issues Miller had with "coolant on demand" with the 05-07 units, I seriously question if they'd go back there.
                      Last edited by SundownIII; 11-19-2011, 06:51 PM.
                      Syncrowave 250 DX Tigrunner
                      Dynasty 200 DX
                      Miller XMT 304 w/714D Feeder & Optima Control
                      Miller MM 251 w/Q300 & 30A SG
                      Hobart HH187
                      Dialarc 250 AC/DC
                      Hypertherm PM 600 & 1250
                      Wilton 7"x12" bandsaw
                      PC Dry Cut Saw, Dewalt Chop Saw
                      Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
                      Thermco and Smith (2) Gas Mixers
                      More grinders than hands

                      Comment


                      • #12
                        I have a coolmate 4 and I took the fan blade off and now all you here is the pump.


                        before it was insane loud, now it's hardly noticeable.

                        btw I have a sync 200 and welded max amps to max duty cycle and it doesn't get hot, just warn

                        If your handy you could mount a thermostat to turn the fan on at a determined coolant temperature.
                        MM 211 W/ Spoolgun
                        Diversion 180
                        Spectrum 375 X-TREME
                        Portable Victor O/A
                        Palmgren Bench Drill Press
                        14" Evolution Dry Saw
                        IR 60 Gal. 3 HP Compressor
                        Speedglas 9100x
                        My Brain

                        Comment


                        • #13
                          Seems to me that all you'd have to do with a 250DX, is make a simple adaptor at the machine's 14 pin, inbetween where the remote inserts into the welder, and add a 24Vdc micro relay. so when the remote is activated, the relay would close to turn on the cooler. When released, the relay would open to turn off the cooler.
                          could probably use a timer relay to time the cooler to turn off in 5 seconds or so to cool down the torch.

                          Seems simple to me anyways.

                          Comment


                          • #14
                            Or tap into the gas solenoid, this way you get coolant any time you have gas. I would be concerned with post-flow as there is scant coolant in the torch and it could boil off. This could cause corrosion issues with the copper body.

                            Now if you had an electromagnetic clutch for the fan only, engaging it by pin 14, this would be best.

                            By far, the easiest is to remove the fan. With a gallon of coolant, there is at least 400 BTUs of sink before the coolant gets uncomfortably warm. Over one hour, that is 120 Watts which is about the torch heat off welding at 100 amperes in DCEN.

                            Comment


                            • #15
                              Me also

                              Originally posted by benny365 View Post
                              I have a coolmate 4 and I took the fan blade off and now all you here is the pump.


                              before it was insane loud, now it's hardly noticeable.

                              btw I have a sync 200 and welded max amps to max duty cycle and it doesn't get hot, just warn

                              If your handy you could mount a thermostat to turn the fan on at a determined coolant temperature.
                              This is what I was planning to doing. Fan will kick in when it hits it temp. You can get a digital adjustable relay cheap. That way you can adjust when you want it to kick on.

                              Comment

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