Primus W-10X^2 update "I need Control!!!"

[supremewhirlpol]

Now that I have added the Control Box and the motor, this machine is VERY heavy. This machine is so heavy that I had to have my brother lift on the other side just so that I tilt it on the dolley. The control Box weighs 60LB. and the motor weighs 105LB. I would say that so far this machine probably weighs in the upper 400LB. range. It is surely heavier than the original Primus W-10.

 

[supremewhirlpol]

Now CONTROL: Pete, If Janet came to visit me that would be SOOOOO awesome!!! But that didn't happen. Some type of control board? Very close! What came in the mail is!?, drum roll please: A Variable Frequency Drive module!!

 

[supremewhirlpol]

It even has a fan and heatsink.

 

[supremewhirlpol]

Model ATV18U54M2
Input is 230V 3PH True Sine Wave
output is 230V 3PH Modified Sine Wave
It's rated to run a 4HP motor, so it being oversized isn't a bad thing.

 

[supremewhirlpol]

This is a picture while testing it. I still have to properly program it, but I needed to test it to make sure that it worked. I found this one on Ebay for only $79.00. That is a steal, considering that other used modules were priced in the $300-$400 range. When power is applied to one of the inputs, the VFD will run the motor. When the motor is running, it makes a very high-pitched pulsing type of noise. I only wish that my cameras were here so that I could take a video of running the motor. This VFD module is one of the more expensive ones in that it is very versatile. I can have the motor do anything that I want. I can set profiles, braking, rampup and down, etc. and etc. Now That's CONTROL!!

 

[aldspinboy]

Melvin I am so happy for you... I hope everything works out nice washer.
Will you be able to work programs as you like it ? And speed and drum rotations ?

 

[supremewhirlpol]

Thanks Darren,
I'm still a little ways from programming cycles. I haven't put anything in the control box yet. There is still lots of electrical work that has to be done. I still need to get cards for the PLC: DC in, DC out, Analog DC out, contactor and thermal overload for the VFD, wire, triac card, a power supply 240V AC to 24V DC 15A. Yes the VFD allows me to make the motor spin as fast as I want and as slow as I want. I can make custom acceleration ramp profiles. I can change the rotation and apply braking. What is nice about this particular VFD is that I can set the motor for either constant torque or variable torque. The motor nameplate RPMs are 3520 at 60HZ. Being that everything else is the same, the VFD can go from 0.5Hz to 320HZ. I can make this motor scream if I wanted to. The PLC and User Interface Panel will allow the user to make custom cycles. I have to wire everything up before I can start programming the PLC. Programming the PLC to interface with a User Interface Panel will be a very tough chore. When the washing machine is finished, I can make it do anything that I want to, it's just a matter of programming the PLC.

 

[rollermatic]

melvin

those pics are fantastic! and all the work you've done! it's amazing how you put those huge motors on your machines!

next time i'm up you'll have to show me the finished product.

great pics!

 

[hotpoint95622]

hotpoint 95622

It’s good to see the progress of this machine, keep the updates coming.

I have just managed to complete a working PCB, have about 6 units that are no good, suppose you call it learning the hard way.

Next job is to iron out the bugs in the programmes, mostly to do with the interim spins.

Photo of working PCB.

 

[hotpoint95622]

hotpoint 95622

back

 

[hotpoint95622]

hotpoint 95622

powered up, I had to lable each out put.

 

[supremewhirlpol]

Pete,
The motor in the Primus W-10X^2 weighs 105LB. On the day that I welded the mounting brackets, moving that motor back a forth did get very tiring. But I suppose for me this project would not have been as interesting if I did not have to put in any physical labor. I have to say that that motor is heavy, but heavy is GOOD.

Lee,

Your control PCB looks very nice. Did you use a FPGA for your program? That board looks like it was professionally done. What controller chip are you using?

 

[favorit]

British cycle codes

Hi Lee,
it's a pity that British labelling codes for garments are no more used as a standard code everywhere ...

I can see a boilwash (1), a 60°C cottons (2) , a 40°C cottons (5), wool (7), separate rinse and spin, separate spin.
What's that full circle key over the (1) for ? Maybe to switch cottons ---> minimum iron ( 1->9, 2->3, 5->6 ) ?

 

[hotpoint95622]

hotpoint 95622

Hi, Supremewhirlpol

I’m using a Microchip microcontroller PIC16F872 and programming it using microchips MPLAB IDE software with code basics I picked up in a book called PIC in practice by D W Smith, so it’s all my design and how I want it to work, well one day maybe. Most of the bugs are the intermittent spins, got the wash right and the heating cycles good as well.

Link to the microchip website.

Hi, Favorit

That full circle is the reset key, which has been a god send as the programs have bugs and some times need to stop it quick. I never intend to put the others on 3, 4, 6, 8, and 9 as I have never used them and asked people which programs they used the most, which seems to be 2, 5 and 7. I also think it a shame the old codes are gone, so ease the old dial a fabric.

http://www.microchip.com/

 

[hotpoint95622]

hotpoint 95622

screen capture from PC, small sample of the code.

 

[favorit]

Liberator and Zanussi

Thanks Lee for pointing it out.

Another question : once I saw in an old thread a Liberator that looks somewhat like a Zanussi, but it makes no sense, at those times Hotpoint had a plant in Llandudno .... what's that ?

 

[supremewhirlpol]

Hotpoint 95622,

What language is that? Are you using relays as well? I plan on using SSR's.

 

[hotpoint95622]

hotpoint 95622

Hi, Yes zanussi did make some of the liberator range badge as Hotpoint, as for why, I suppose it was to do with supply and demand; Hotpoint could not make enough units so contracted some out to zanussi. If only I could find an original Hotpoint liberator deluxe.

Language, it’s microchips own instruction set, I’m no expert, learning from books as I go along, to be frank I am amazed that it works to any degree a bit trial and error. Using relays at first, as my skill improves I will swap relay for SSR’s and hope to construct my own speed control board, must walk before run though. Also have plans for a board with a time line indicator on.

Photo of motor speed control relays.

 

[hotpoint95622]

hotpoint 95622

photo 2, while feeding wires in. 2 relays on the right are motor isolation and the change over for direction.

 

[americansuds]

Wow...that's gonna be fun to drive. Custom wash-it-all! Does anyone ever remember a commercial machine that was called a Duplex? I saw one in KC in the early 80's, it was a frontload machine with only two baffles in it, nice reddish-coppertone color to it as well. Never have been able to find anything more about them.