Would it be possible somehow to use a cool41 u31 with a tetrix 230 ac/dc? (The cooler is 400v and machine 230v, yes i know cool40 exists and is supposed to be used with tetrix 230, but auctions...) Could i give the cooler external 400v?
Its possible.
Simplest way is provide 400v directly to the cooler and it on/off manually.
For automatic switching you would have to have a look at the wiring diagrams. I think the welder provides power for the cooler so you might have to use the 230v output from the welder to switch a contactor to send 400v to the cooler.
First thing i would do is have a look inside the cooler as you might find it already has a 400v-230v step down transformer that you could just bypass.
You also need to work out if the welder 'knows' if it has a cooler connected as it might not actually give any output switching until it thinks the correct one is attached.
Wiring diagrams should tell you that.
It might be something simple like a bridged link in, something slightly more fancy like a resistor or even something complicated like canbus.
If you are going to use the simple manual switch on/off then its probably better to sell it to somebody who will pay the extra for the branded features/compatibility and just buy/build a generic one for yourself.
I'm modding an old EWM Cool 35 U 31 to work on the EWM Tetrix 230 ACDC.
The cooler was designed for old model tetrix 300 (3 phase), and the machine it will be fitted with, is a 240V model with the 240V output via the rear cooler power feed socket.
What I've found so far is that there is a step-down transformer inside, taking the 400V and stepping down to 240V (to drive the 240V AC pump), and 18V to drive the DC rectifying board to provide voltage for accessory items on the unit - 24V for the fan, and 15V for the water flow solenoid.
Machine switching features come from the 8-pin burndy control plug from the machine, triggering relays for fan and pump accordingly.
To answer OP-
I plan on installing a replacement 240V - 18V AC stepdown transformer. This should allow all features to be maintained using the factory board, no need for accessory switching, external power etc. For the cooler's 240V requirements, this can simply be tapped from existing 240V input supply from the machine, by an internal link within the cooler.
Something like this transformer should do the trick, by my reckoning:
I have the wiring diagram for the Cool 35 U 31 cooler that I will modify. I'd be interested to get some pics of the Cool 40 U31 cooler that is original equipment for the Tetrix 230 ACDC. I'd be interested to know how EWM modifies the coolers based on the 230V / 400V variants. The designer in me thinks it would just be a transformer swap, given that the 3 phase coolers run a 3 phase capable pump motor, which is wired for 240V- go figure!
Regarding my mods to an EWM Cool 35 U 31- Can confirm this above post.
I disconnected and insulated the 400V feed from the input lead of the cooler to the transformer.
By feeding 240V into the transformer, there is still an 18V AC output which drives the rectifier board, and subsequent switching, sensors etc.
It seems there is considerable consistency in the 8-pin burndy plug wiring between EWM models. So retrofit / modification of these units to work on other EWM machines is fairly straight-forward if you know what you are looking at, electrically.
I'm thinking of a way in which I can hack the control plug circuitry to work 'on demand'. i.e. if I wished to run an EWM cooler on my other machines with a simple 240V input plug, and pushbuttons for fan/pump over-ride control.
If the welders don't have any outputs for cooler connections maybe you could make up a sensor that you attach to the welder when you connect it to the cooler.
Maybe one of those simple current detector relay things that you get on ebay, rin a bit of welding cable through the loop and put a male/female dinse on it then you just plug it inbetween the welder and earth lead when you connect the cooler. Add a timer so it runs on for 30 seconds or so after the arc stops.
Or just open up all your welders and add a cooler control socket to them.
Could you piggyback the feed to the socket from the mains input via a relay switched from the cooling fan wires?
Although most decent coolers are pretty quiet so I wound not be too bothered about one running constantly.
From what I gather from the circuit diagram, the machine orders a prime and pressure test of the cooler - ie run pump and record a closed control circuit from a pressure switch.
Then the pump and fan is controlled by the machine (from what I gather - further testing needed) from an earthed 15V DC control circuit which is on the relay coil in the cooler.
Pulling 15V from somewhere, and having a simple pushbutton switch to earth would do the trick.
I probably wont bastardise any machine casings with sockets or anything suchlike. any off-spec use will be simple operation. Although firing the pump / fan relays with a hall effect sensor is a great idea.
I did actually find a cheap enough cool 40 u30 (the 230v version) very happy with that. Then a few weeks later I got a really good deal on a Fronius Magicwave 230i. Sold the ewm, so now im looking for a Fronius cooler