255EXT Cooling fans

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.

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.

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.

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.

What are the fan dimensions?

92mm x25mm

2 wires or 3 ?

2 wires and I mistaken, the current on the new fan is .22a.

I found another fan. This one is .75A and 110cfm but it's 38mm thick and the original is 25mm. Can the machine handle the .75A draw over the .34A original?

You are messing with the warranty when it comes to this kind of stuff. Proceed at your own risk.

The problem I have is the original fans vibrate so bad and resonated through the whole welder. It was a wonder the screws stay in. I would love to change out the fans for the same ratings, but I can't find any. The original fans have sleeves not bearings. There's no way the welder will last with the way it is. I compare it to those cars that they turn the bass up on the radio and you can hear every panel vibrating. I love they way it welds but it's so iratating to listen to it even the fan on the water cooler won't drown it out.

Are all the original fans junk, or is it mostly a single bad one? If there are differences between them, you can always order a set of replacement fans from Everlast, then cherry pick the best ones to install. If you leave the machine stock you will have the warranty, but you feel that it's life will be shortened. If you change them to something out of spec you might increase the life, but may void the warranty. It's up to you, how you proceed. Another option is to re-balance the fans you have. Also there are vibration damping fan mounts. You might want to call Ray in the repair dept. and ask a few questions before you make a decision.

It's likely it's one fan running out of balance. I'd recommend that you call and discuss it. There should be no issue in replacing one or all of them if necessary. The 4 fan units I've seen are pretty quiet. It's actually the single fan units that are louder.

It is probably a fan that was tapped out of balance during install. My single fan unit is very loud, but I am welding so not a big deal. You can spin and see which one is out if it is shaking the unit most likely. Then call into tech support for a replacement. Maybe knudge to bad one also to straight a little until the other fan arrives. Maybe sure you tell tech support the fan count in case they are different between versions.

I tried to install grommets under the mounting post to hope and insulate the fans. I also tried to stop each fan individually to determine which one was suspect. This model has four fans. It didn't make any difference and I couldn't find just one fan causing the vibration. The vibration gets worse the longer it runs. Everlast has been very very good to me with warranty repair and I didn't want to wear out my welcome. I wouldn't do anything to jeopardize the integrity of the machine. Thanks for the responses.

You're not going to wear out your welcome. Just give tech support a call about the issue. We should be able to resolve the issue without a lot of problems...even if it requires all 4 new fans shipped direct to you from the factory if what we have won't fix it.

I talked to Tech support then shipping and they said they will send 4 new fans out today. If they are at their facility it should only be a couple of days.

Mark,
Thanks for your help

The new fans arrived today. I first tested them on a power supply, they felt pretty smooth. I installed them in the welder and I can't believe the difference. No vibration at all. It's going to be a pleasure welding again without the awful noise.
Thanks Everlast, great service!!

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

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

OK, thanks.

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.

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

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

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.

Change the frequency or the wave form and the sound will be a different pitch and a different decibel level.

It can be more than uncomfortable to listen to at times.

Yeah, I think that's what it was. I was trying all the wave forms and speeding up the Hz frequency to 250.

Man, I'm really diggin' this 210EXT. And I think I'm settling on the typical square wave at 120HZ for the moment. I won't be doing too much aluminum, but I dig being able to add another material to projects, beyond stainless steel, that is able to give an unpainted, brushed finish and be lighter too.

I'm likin' that CK SteadyGrip hand amptrol with it also.

Rock On, Everlast staff!

https://www.youtube.com/watch?v=8LAhKkPUo_A

Good stuff Rambozo.

Happy Thanksgiving to all!