Skeletons in my Closet!

[supremewhirlpol]

H/C water valves

 

[supremewhirlpol]

something is missing here...

 

[supremewhirlpol]

I'm missing the neutral wire! Interesting that I found it at the front of the machine!

 

[supremewhirlpol]

I feel better about the terminal block now.

 

[supremewhirlpol]

There's a unbalanced leg switch and the speed changer motor that I have to trace wires to now...

 

[supremewhirlpol]

Time to wire the contactors...

 

[supremewhirlpol]

Contactor for VFD:
110VAC coil : 220VAC load

 

[supremewhirlpol]

VFD wired to contactor to terminal block

 

[supremewhirlpol]

I got the feeling that who ever was playing with this machine is the past almost got their ### handed to them. This connector is from one of the elements going to the thermostat.

 

[supremewhirlpol]

Connector on the thermostat is even worse! Almost ready to test, except, I have one wire left.

 

[starrail]

Primus

I got here loking for information on Primus W series washer/extractors. Its good to know at least one other person has Primus knowledge. I hope to gain more.

Jack aka [email protected]

 

[supremewhirlpol]

Hi Jack, I sent you an email.

Ok, I've got the switching logic down now. Apparently that dark Blue wire was important! I ended up having to do some wiring due to the centrifugal switch of the motor and terminal box no longer being present. Wiring is a mess currently.

 

[supremewhirlpol]

There are 3 contactors, one for the pump, one for switching terminal that was on the original motor, the other contactor is for the VFD. This is a picture of the pump contactor buried in some of the wiring.

 

[supremewhirlpol]

This is the switching contactor. It serves as the replacement for the terminal box in the original motor. The terminal box on the original motor is controlled by the centrifugal switch. It controls the other side of the Calrods, the water valve solenoids, the timer motor. Its configuration may change as I test this machine. It was difficult to figure out what was happening in side of the box, due to the wiring schematics being very vague.

 

[supremewhirlpol]

The VFD contactor: nothing changed here

 

[supremewhirlpol]

A test video of the switching logic has been uploaded.

 

[supremewhirlpol]

Let the Programming begin shall we?

The ABB 140 series VFD is very versatile for industrial machine controls. Has 8 application macros, 42 groups of parameters with >= 10 programmable parameters per group. Can take PID controls, serial RS-232, RS-485. I would post the manual pages, but I'm sure that would be violating some stupid copyright law, so I will post the parameters that I have programmed. When I do post the parameters, they will go in the follow order: Parameter Number, description, parameter. This will take a while:

 

[supremewhirlpol]

VFD Programming

Programming the Basic parameters:
Group 99: start-up data:
9902 - Application Macro

The ACS 140 series has 8 macros with predefined advanced settings for common applications. These are here to help make things simpler.

Default = 0(FACTORY MACRO) You can keep this setting if the i/o arrangement and drive configuration fits your needs.

I use Macro 3 = ALTERNATE

 

[supremewhirlpol]

Here is the specifics on the macro I've chosen

 

[supremewhirlpol]

continuing:

 

9905 - Motor Nominal Voltage

This is the voltage found on the nameplate of the motor.

230VAC

9906 - Motor Nominal Current

This is the current rating found on the nameplate of the motor.

1.6A

9907 Motor Nominal Frequency

This is the normal operating frequency of the motor. I could push the over what the motor is rated for, like what happines in the modern FL machines, but the is not necessary. It creates more problems in the long-run. I keep the value at the default, which is 60Hz.

9908 - Motor Nominal speed

This is the speed (RPM) rating found on the nameplate of the motor. There are 2 speed ratings on the nameplate, one for 50Hz, one for 60Hz. This motor will operate at a max of 60Hz, I use that rating. 3425 RPM.

Group 10: Command Inputs
1003 - Rotation direction lock
3 = Request

Group 11: Reference Select
1105 - EXT REF1 MAX The maximum frequency reference in HZ

I leave the default setting = 60Hz.

Group 12: Constant Speeds
1202 - Const speed 1 11.61Hz -tumble
1203 - Const speed 2 48.96Hz -Spin
1204 - Const speed 3 15Hz (DEFAULT)

My calculations for determining the speeds that I need are approximate.


Group 13: Analog inputs
1301:Minimum AI1
Minimum value of AI1 in percent. Defines relative anaog input value where frequency reference reaches minimum value

0%

Group 15: Analog ouputs
1503:Ao Content Max
Define output frequency where analog output reaches 20mA

I leave this at the default = 50Hz

Group 20: Limits
2003:Max Current
Maximum output current of the VFD
Range: 0.5 * I_n - 1.5 * I_n, where I_n is nominal current of the ACS 140
This is set to 4.5 A

2008:Maximum Frequency
This is the maximum output frequency of the VFD
The range is 0-300 Hz

Over driving the motor is not necessary

I set it to 60 Hz

Group 21: START/STOP
2102: Stop function
These are the conditions during motor stopping
I choose 1 = coast, rather than using dynamic braking

Group 22:Accel/Decel
2202:Accelerate Time 1
Ramp 1: time from zero to max frequency
10.0sec

2203ecelerate Time 1
Ramp 1: time from max frequency to zero
5.0sec

2204:Accelerate Time 2
Ramp 1: time from zero to max frequency
60.0sec

2205ecelerate Time 2
Ramp 1: time from max frequency to zero
60.0sec

Group 26:
2606: U/f below field weakening point
I keep this value at the default, as I want constant torque
1(LINEAR)