5904_vfd.txt  010408  PDB

5904_vfd_01.jpg shows the lathe base cabinet with all the old drive parts 
removed, didn't think to take a picture of it before I started.  The enclosure 
to the left is the box with the VFD mounted to the back side of the 
lathe.

5904_vfd_03.jpg shows the new mounting bracket parts ready to assemble. All the
holes and slots were done on the Bridgeport the pieces are sitting on.  Nothing 
was scribed and punched, all layout was done 'by the dials' ala poor man's jig 
bore.

5904_vfd_05.jpg shows the parts all assembled and ready to be installed.  9 inch
channel was used for the motor base, the side pieces are 3x3x1/4 inch angle.  
Some milling was required for clearance of other features such as the base 
cabinet lower cover mounting studs. The two tapped holes on the back of the base 
are for brackets for forced cooling fans and a braking resistor (future).

5904_vfd_08.jpg shows the bracket and motor mounted in the base cabinet ready to
go.  The new motor location is about where the original
countershaft/clutch/brake assembly mounted.  The motor T leads will get into
thecontrol cabinet via a short piece of sealtight, the fitting is visable just 
below the motor pulley in the back of the base cabinet.  The sealtight coming 
from the control cabinet goes up to the original drum switch which now is wired 
to the vfd's forward and reverse inputs.  The red wires visable are the 
temporarily connected speed control pot wiring.

5904_vfd_09.jpg is a front view of the new motor etc.  The old motor and
brackets are visable in the background on the left.  I bought a new belt even
though it turns out I could have made the original belt work but it was starting 
to show it's age.

5904_vfd_11.jpg shows the vfd enclosure mounting from a different angle, I
couldn't get much closer due to a wall just to the right.  I bought this vfd 
from a fellow RCM guy (thanks Iggy), its a 2.2 kw (3hp) Mitsubishi 230 volt 
single phase input in a nice Rital enclosure complete with a lockable 
disconnect, local/remote selector, pilot light, etc.  The ironic thing is I have 
3 phase at this shop.

5904_vfd_15.jpg shows the speed pot enclosure and mounting parts.  The die cast
enclosure was a project box from Fry's, very nicely made and easy to machine.  
The large disc was machined from aluminum and will be held into the original 
speed control boss on the top backside of the headstock.  Bolt and bushing are 
next to it.

5904_vfd_16.jpg shows the speed pot and enclosure mounted to the top of the 
headstock using the mounting boss for the original speed adjuster.  I've since 
made a nice large brass knob for the pot and a temporary hand printed legend 
plate for speeds in both straight and back gear.  The extra space in the box is 
for future use, maybe a digital speed display or a big E-stop button or a jog 
button...time will tell.