matt_isserstedt
Diamond
- Joined
- Dec 15, 2003
- Location
- suburbs of Ann Arbor, MI, USA
Background Syncrowave 250DX, bought around 2004 (??) new for a plant I worked in. Worked perfectly. Likely less than 20hrs of actual weld time total. I bought it at the auction when the plant closed. Sat for approx 4 yrs, 2008 until now, its wired and ready to go. This version has a cooler inside the case of the machine on the LH side, newer models have a "runner" cooler which is completely below the main cabinet.
Started my first weld and got the HLP-19 fault which is a cooler flow fault about 3 seconds after striking the first arc.
This is a water flow fault, no flow indicated.
Fairly simple circuit, tank to screen filter, to pump, to torch, to cooler, to pressure switch, back to tank.
There is a manual function where the pump and cooler fan are forced to run by holding the "process" button. The display indicates CLR and when water flow is verified, you get a "FLo" reading back.
Checked filter, cracked connections, seem to have good flow everywhere. Attempted to remove the pressure switch, I twisted off the plastic thread and had to order a new one from Miller, $17.
Pressure switch sits in a brass Tee, the output connection has a 1/16" orifice which builds pressure inside of the tee.
Installed new pressure switch this morning. On the very first try I got "Flo" but thats the only time it has worked. Tried various troubleshooting steps including visually verifying flow out thru the orifice, shoots a several inch stream out. Jumpered switch contacts on the pressure switch and immediately get the "Flo". Have 5vdc carrier signal on one wire, so the circuit has voltage. I plug the output port with my thumb and it immediately returns "Flo". Filter screen is very clear, very few cruddies but extremely minimal. Have used the Miller branded blue coolant/antifreeze from the start. The coolant does not seem "gummy" at all. Verified the lines going to and from the torch arent kinked.
Not sure what to do next.
Other ideas are blow out the cooler circuit with air but I would want to proceed gingerly as to not blow out pump seal, etc on the low-pressure system.
Part of me says jumper the switch and do some welding to build up some heat and see if that aids in dissolving a potential blockage...but don't want to melt down either.
Thought of some sort of flush/solvent but I don't really like that idea either due to potential of pump seals damaged etc.
Any ideas?