Saturday, August 24, 2013

Brigeport Mill for the Garage - Part 3 Electrical system

One of the challenges of bringing home Industrial Equipment is the lack of three-phase service in residential neighborhoods. There are two basic solutions: Phase converters and Variable Frequency Drives (VFD's).

Phase converters have been around for a long time. There are so-called static converters, but they are basically just a staring capacitor that turns your three phase machine into a single phase and robs you of 1/3 of the available power.
There also Rotary Phase converters that use another motor to generate the third phase from the other two.

VFD's take the incoming AC signal, turn it into DC and then use PWM methods to generate three phases of "AC" at arbitrary frequencies. Since there is already an intermediate step between the incoming power and the motor, these devices can run off either single phase (usually for 3HP or smaller drives) or three phase power. These Single Phase VFD's make an attractive alternative to Phase converters.

I choose to use a VFD for a couple of reasons:
1)  Cost - the VFD setup was about $150 cheaper than a Rotary converter from a reputable source
2)  Features - a VFD can soft start the motor and also offers other logic features built in.
3) CNC - a VFD can be controlled from a CNC system later on

Here is a schematic of the System I am planning on building:

 The blue box represents the operator panel, which will most likely be mounted underneath the DRO
The rest of the part will go into a NEMA 1 enclosure that will mount on the wall just below the Garage Sub-panel.
Control Box hardware on sub-plate.