5460 DV cooler FLOW ALARM !!

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anyone ever have an issue with this flow alarm?the cooler is filled to the top and I have water flowing in and out.... but this damn alarm keeps going off. first time it's done this in about 4 years... I know you can switch it off... but I'd rather figure out why it DO dat. Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Have you "tied up" any of the hoses going to the TIG torch somehow?  plastic zip tie? 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Originally Posted by OscarHave you "tied up" any of the hoses going to the TIG torch somehow?  plastic zip tie?
Reply:No dice I cut the zip tie and it still doing the same thing. Like I said it’s got flow in/outAnd if you take the top cap off you can see water coming out of the blue tube which I assume is normal. Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Hmm... Ever let the coolant get so dirty that while it may be clean now, perhaps it clogged up the pressure/flow sensor?  The blue tube is the pressure-bypass, hence doesn't go through the pressure/flow sensor that I know of . So yea, that tube is not the water return into the tank coming from the tig torch.  There is a separate hose for that.   Time to take off the cover....Last edited by Oscar; 05-10-2020 at 04:40 PM. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Originally Posted by OscarHmm... Ever let the coolant get so dirty that while it may be clean now, perhaps it clogged up the pressure/flow sensor?  ....
Reply:I also find it very odd that HTP puts a flow alarm shut off switch on the front. Why would anyone want to shut it off? it’s there for a reason.... SupposedlyEven though it’s not very accurate.  Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:I only use water in my HTP cooler. As my shop is heated and I have animals in the shop and don't like antifreeze that may leak and them get into.  I had the alarm go off once, disconnected the torch from the cooler and ran the cooler with a bypass hose and it was fine. Blow out the tig torch hoses with air and hooked them back up and its been fine.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:At least ya got it working right again.  I suppose people might not want to hear that buzzing sound when they first turn it on each time as it fills the hoses because the baby is in the stroller right next to them sleeping while they TIG weld,  1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:I’d like to replace it with one of those paddle wheel site glasses. If I can find one reasonably priced.
Reply:Originally Posted by metalman21Do you mean like this?: https://www.amazon.com/Miller-212745.../dp/B004HECI8MIt is for a Miller Coolmate 3, same as my Binzel and it is just spliced into the hose. I think if you shop the internet might find the kit for less.
Reply:Originally Posted by OscarAt least ya got it working right again.  I suppose people might not want to hear that buzzing sound when they first turn it on each time as it fills the hoses because the baby is in the stroller right next to them sleeping while they TIG weld,
Reply:I was set to buy that cooler but read where the alarm was sensitive, especially with 25' hoses. A lot of the stuff I weld is all around the bench, the hoses get looped, turned etc. Those flow indicators do make a little bit of noise. I ran the Binzel with the paddle wheel removed and noticed the difference but not really that much. I rather see the thing spinning.Curiously I have a Coolmate 4 and it has no such flow indicators or alarms. Still works fine after about 20 years.I also use distilled water in the coolers. I add a couple cap fulls of bleach.Ernie F.
Reply:Originally Posted by John TYeah,...Looks like there’s plenty of room for an electric computer fan instead. But I’m not quite sure how I would wire it/power it. I think most of those fans are  12v And need a step down transformer ?. Maybe someday.... I’m too busy to think about that right now Sent from my iPhone using Tapatalk Pro
Reply:Originally Posted by metalman21I was set to buy that cooler but read where the alarm was sensitive, especially with 25' hoses..
Reply:Originally Posted by OscarYou think they sensitive to 25 foot'ers, try 50ft'ers! The one I have with the Invertig 221 isn't that sensitive, just normal I guess if you step on a hose, but those are 25ft regular length tig hoses.
Reply:Originally Posted by OscarYou think they sensitive to 25 foot'ers, try 50ft'ers! The one I have with the Invertig 221 isn't that sensitive, just normal I guess if you step on a hose, but those are 25ft regular length tig hoses.
Reply:Originally Posted by Capt BThat's the only issue I have with mine so far is stepping on the hose it goes off for a sec with 25ft lead.
Reply:Originally Posted by John TThat’s why I asked about the flow rateoz per min. I don’t think these pumps are putting out what some others do. I tested mine last night but I don’t want to speak before a test it again. I’ll tell you this,It was NOT 1 quart per minute...Which is generally the rule of thumb for tig coolersSent from my iPhone using Tapatalk Pro
Reply:Originally Posted by Capt BWhen I get a chance I'll check the flow rate on mine as well.
Reply:Im getting about 20oz per minute normally And 23 oz with the blue bypass hose pinched off. Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:The pump sticker says 8L per min. Clearly that can’t be correct.  That would be about 281 oz. per minute!Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:I’ve got another question...What is the purpose of this bypass hose?Seems to me all it’s doing is choking down the flow and “ bypassing it” back into the tank. WHY is this needed?I have a suspicion that this is the reason why the flow rate is low. Any thoughts?I’ve got a good mind to cut it out and eliminate it. ALSO. Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Interesting thread. You make me want to check the flow of my Pro-con pump. I know what the pressure is but not the flow.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Originally Posted by TJSInteresting thread. You make me want to check the flow of my Pro-con pump. I know what the pressure is but not the flow.Throwing caution to the wind I cut out the bypassAnd I’m still getting around 23 ounces per minute. So I guess that’s what the pump is putting out. The question is now,Is there any adjustment on this pump. Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Looking forward to any flow readings from anyone that owns an HTP coolerOr any cooler for that matterSent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Originally Posted by TJSInteresting thread. You make me want to check the flow of my Pro-con pump. I know what the pressure is but not the flow.
Reply:Well I guess I skipped the obvious by not looking on the front plate. Looks to me like my pump is going bad. Don’t mind me I’m just talking out loudThat’s the way I work things outLoL!The dogs just kind of got used to itSent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:Originally Posted by Capt BThat's the only issue I have with mine so far is stepping on the hose it goes off for a sec with 25ft lead. I haven't had any issue with getting leads twisted setting it off yet.
Reply:Cooler #1, purchased new 2013 with my Invertig 221, 25ft tig torch hoses:  17oz/min.  Basically filled up a plastic water bottle in 1min. Bypass hose in place.Cooler #2.  Bought as a used demo unit.  Seen better days but I cleaned it up nicely.  Bypass eliminated, thru 50ft tig torch hoses, 10.7 oz/min, lol.But get this!  I use a short hose (4" long) to eliminate the restriction of the hoses/torch, and yup.  Nearly filled up a 16.9oz water bottle in about 2 seconds on cooler #2!  (ok it wasn't exactly 2.0, but it so damn fast, I had to shut it off right away for fear of overfilling it so damn fast and spraying coolant everywhere!).  I have a feeling the other cooler will be nearly as fast if you remove the restriction that must be in place:  the tig torch and it's hoses!  lolYes, my lines are reversed because the are reversed inside too, lol.Last edited by Oscar; 05-14-2020 at 06:39 PM. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Cooler #1 with short 4" hose on outlet.  15oz in about 4.5s.  The other cooler with the bypass eliminated filled it up about the same (not full, but roughly the same in about 1.5s less.  So cooler #1 without restriction:  200oz/min = 6.25 qt/min.  Cooler #2 without restriction:  300oz/min = 9.38 qt/min.John, thanks for making me do this test, as I have realized that I need to change out my coolant!  It's getting murky! 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Originally Posted by John TLooking forward to any flow readings from anyone that owns an HTP coolerOr any cooler for that matterSent from my iPhone using Tapatalk Pro
Reply:Originally Posted by OscarIt's supposed to do that! That's not being "sensitive", it's called "doing it's job" John, I'll check mine in a little bit.
Reply:Originally Posted by John TWhat is the pressure?I’ve got a spare gauge I was thinking about testing that alsoSent from my iPhone using Tapatalk Pro
Reply:I am sure the pump companies have a standard for testing output. I doubt they use a tig torch and hose set up. So with Oscar's short hose test that maybe what you are looking for in regards to output John. I am going to test my set up at the return and see what volume I get. A while back I converted my Hobart stainless cooler set up from the super loud oberdorfer pump to a soda procon pump. Best thing I ever did to this thing.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Originally Posted by TJSA while back I converted my Hobart stainless cooler set up from the super loud oberdorfer pump to a soda procon pump. Best thing I ever did to this thing.
Reply:Ended up re-doing the plastic tubing.  The originals are now 7 years old and had seen better days.  Just have to be careful on the high-pressure side!  Those have to be tight or they'll spray water everywhere once the TIG torch hoses are present to cause the restriction.  20ft roll of 5/16" ID tube is $7 at Lowes. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:OscarDo you have the dual voltage cooler or ?Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:yea, Both of mine are DV coolers. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:I assume the overflow line is the bypass from a relief valve which would set the supply pressure to the torch hoses. Without pressure relief, you could risk damaging the pump or blowing hose connections apart if you restrict the line and the pressure spikes.I would also guess that the rated pump flow includes both the flow that goes to the torch and the bypass flow. Different amounts of restriction would cause different amounts of bypass making it difficult to specify theflow rate going to the torch. A 25’ torch will have less restrictive hoses than a 50’ and will therefore see more flow at 40-something psi.Sent from my iPhone using Tapatalk
Reply:Originally Posted by djd775 A 25’ torch will have less restrictive hoses than a 50’ and will therefore see more flow at 40-something psi.
Reply:Originally Posted by John TIs that fact or opinion?I've never owned a 50' setup
Reply:Got it Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:I’ve got (another) stupid question...How do you plumb a psi gauge inline?If I  t-off the pump return line, I get zero reading. If I plug the return line with my thumb(Deadhead), I get a reading .......Sent from my iPhone using Tapatalk ProMiller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221  True Wisdom only comes from Pain.
Reply:I would leave everything connected including torch and just install a tee somewhere on the output line inside the machine to feed the psi gauge that way you will get pressure during normal operating conditions.Lincoln 350MPMillermatic 350PSyncrowave 2501969 SA200HTP Invertig 221
Reply:Originally Posted by Capt BI would leave everything connected including torch and just install a tee somewhere on the output line inside the machine to feed the psi gauge that way you will get pressure during normal operating conditions.
Reply:So not sure if this was mentioned yet or not, but I saw on another thread that someone called the store and they told them to just fold over the blue hose and zip tie it. Apparently that fixed the issue.Also not sure it's been said, but those pump values are only max, so no resistance flow and pressures... as pressure increases flow will decrease.I got a screen shot of them talking about the alarm but not sure how to post the pic here.... the title of the thread is "whats the best water cooler", not sure what forum.
Reply:Currently having this issue.  Not sure why it began.   However ,if I crimp the blue by pass tube,  the alarm stops, release it it screams again. For a while I could shake / slosh the cooler and it would stop.  Perhaps it is a malfunctioning sensor issue?  I am using a number 9 torch.  Mine 221 rarely get used.Last edited by tapwelder; 12-19-2020 at 12:16 AM.
Reply:Originally Posted by tapwelderCurrently having this issue.  Not sure why it began.   However ,if I crimp the blue by pass tube,  the alarm stops, release it it screams again. For a while I could shake / slosh the cooler and it would stop.  Perhaps it is a malfunctioning sensor issue?  I am using a number 9 torch.  Mine 221 rarely get used.