Pheer Grinders and VFD enclosures

AVigil

Adam Vigil working the grind
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Since the Pheer Grinders do not include an enclosure for the VFD I was wondering what you guys are doing for a case?

I am thinking of getting a VFD but will need a case for it.

So what are you putting your VFD in?
 
They include one if you buy one with it.
My solution, so far, has actually been a small tool box. One of those mini sized ones. It's big enough for the unit and I cut an opening for the wiring to come out on one end. There's a bit of airflow and space around it and I haven't noticed it warming up any more than open air so it seems to be happy enough. I flip it open, turn things on or make changes, then close the lid. It's not as good as a REAL enclosure, but for now it's keeping it clean. Possibly the reason this is working out for me is simply that I rarely run for a long time at once and every time I open the lid the warm air escapes and the temp equalizes.
 
I'd look for a steel enclosure, rather than GRP, myself. Steel is a better conductor and you'll probably need to get rid of the heat, generated by the drive, from the surfaces of the enclosure by natural convection.

I used a 400mm H x 300mm W x 200mm D IP66 ( 16" x 12" x 8", NEMA 4 equivalent) sheet steel enclosure for a 3 HP drive, and then lucked into a couple of 300 x 300 x 200 mm (12" x 12" x 8") enclosures with windows. I used them for a 2 HP drive and a 3 HP drive.

The 3 HP in the bigger enclosure and the 2 HP in the enclosure with the window seem fine. I have yet to give the 3 HP in the enclosure with the window a decent full-load test.

I struggled to find good information on the cooling abilities of unventilated enclosures. The few manufacturers that give the numbers seem, unsurprisingly, to make the more expensive enclosures. In the end I found a rule-of-thumb value on the web, did the sums and settled on the (cheap) enclosure for the 3 HP drive. It's spaced off the wall for mounting to allow cooling airflow up the back of the enclosure as well as the front and sides. The top and bottom were ignored for the cooling calculation.

It's probably the only occasion I'll ever be able to claim the Lancashire, UK climate is better than So Cal's; I didn't need to consider ambient temperatures above about 20 degC (68 degF).

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I used a 3-phase socket for the output, so I can run different machines from the drive(s). The remote control box is on around 20' of cable, so I can move it to the appropriate machine. It has start and stop buttons, a speed control potentiometer and a keyed reversing switch. If it's being used on a machine that can't be safely reversed, removing the key disables reverse.
 
Patrice Lemée;10966047 said:


Mother of all things great and small :eek:

I know nothing about wiring.... so if I go that route I appreciate your answers to the questions I will be asking :)
 
Enclosing a VFD in a small air-tight box is not a good thing. It needs the cooling of the air circulation. On a NEMA4 VFD, that has been engineered into it. In a open VFD, you have to find a way to remove the heat build up, or you will end up baking the VFD....which could lead to frying the VFD.

The best arrangement is to mount the VFD on a metal back plate that has a heat exchanger mounted on the outside. The larger the enclosure, the more air it holds, as well as larger surface area...... and the better the heat exchange to the metal back plate.

In Tim's photos, if the back of the box was cut out, and a cooling fin set was mounted on the other side from the VFD, it should never have a problem. Use heat sink paste to mount all the parts to the plate. Aluminum makes the best plate material,too. A bead of silicone sealant will seal the plate to the box dust and moisture free.

An alternate setup is to mount the VFD in a large box, and have filtered vents on the box sides. Use a small cooling fan to draw air through the filters and out the bottom. Placing this box in a dust free area may help, too.The VFD can be mounted in a cleaner area nearby, and the remote on/off switch and speed pot can be put in a small control box on your grinder.
 
I mounted my VFD in a Tupperware box, which is mounted to the wall, It's airtight. On the top and bottom I cut out circles to vent through respirator dust filters from a 3M half face mask (after I got my full face respirator). The heat flows up through the filters on top and bottom. No other fans or heat exchange used. Been going strong for the past two years. Outside of box doesn't seem to ever get warm. I have a remote on/off and speed pot.
Chip Kunkle
 
There are many different ways of doing it. Which of them is best for you depends on many factors, some of which may not be obvious.

Patrice has a solution that works for him. As far as I can tell, he has a truly superb dust collection system in his shop, which suggests that dust is not likely to be as great a problem as in someone else's shop. Using a toolbox, rather than a sealed enclosure, and air filters, is clearly enough for him. Elsewhere, without the excellent extraction system, the less-than-perfect sealing of a toolbox, combined with clogging of the air filters by dust, might not provide adequate protection.

I have a system that works for me. It's fully sealed. I am pretty sure it's adequately cooled for my climate/shop. If I'm wrong, the thermal protection on the drives will reduce the switching frequency and "should" power it down before it dies. If/when that happens, I can have a rethink and do whatever is necessary. I already have the heatsinks from a number of dead 20HP drives and had already considered Stacy's "cut a bit out of the panel and add heatsink" idea. I've kept it as a contingency plan, partly because it didn't seem essential and partly because the heatsinks seemed like prospective quench plates. I'd ruled out a filtered ventilation system on the enclosure, largely through concerns over temperature swings and humidity causing condensation during long periods of non-use, but also because it's just a hobby and I can't be bothered with regular filter maintenance. My setup would not be sufficient for a heavy user in a hot climate.

I know one or two guys who've done the Tupperware box thing. It makes me wince a bit, but seems to work for them. I don't know anything else about their shops, but they are hobbyists, rather than professional knifemakers.

How hard you use the machine does make a big difference to the heat generated in the drive, as does the switching frequency. At full-load (2HP), my Altivar 12 (in the red box) will produce 71 Watts of heat at a switching frequency of 16 kHz, but only 57 Watts at 4 kHz.

I've always tended to use the highest frequency available to minimize the apparent noise. It's a habit now and probably not necessary or even helpful. I don't think the first drives I used, back in the late '80s, would go as fast as 4 kHz, which is the minimum switching frequency for my current drives. The drives I've been using lately will automatically reduce the switching frequency as the internal temperature rises.

Generally, platen grinding uses most power, draws most current and generates most heat in the drive. If you find things are marginal, a low-friction platen material, which reduces the current draw, may sometimes be a better use of limited resources than modifying a drive enclosure.

If you need absolute certainty, there's really no alternative to a NEMA4 drive, but for those of us who are happy enough taking what is available, using and/or modifying it to achieve a desired result and taking the hit if they get it wrong, it's a case of working out which bits of the various systems you've seen are applicable to your particular case.

If you are going the sealed enclosure route, googling "electrical enclosure heat dissipation" will throw up some useful information. The Hoffman one is very good, but I can't get a direct link to it without going through Google.
 
Good info Tim, Thanks.

One thing to consider if using the enclosed system set-up is to use the largest container that is practical. The more air volume the better the heat convection. You can even put a small cooling fan in the enclosure to circulate the enclosed air. That should help considerably. I have some large sealed enclosures that I had purchased as industrial temperature controllers. They have almost a cubic foot of space in them, a sealed and hinged door,....and a glass window. Putting the switches and sped pot on the front was simple.They cost me almost nothing, so I stripped out the controllers and mounted open frame VFD drives in them with a fan. These are for 1HP and smaller motors, and there seems to be no problem with overheating. Look for second purpose enclosures that have good seals on the doors. Think about big sealed power contactor boxes, Big NEMA devices at surplus electronics sellers, Large equipment cases at the surplus store, big weather tight PVC electrical and utility cover boxes at the Big Box stores, etc.
 
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