Thanks @dmittz for the replies. Your project looks absolutely fantastic. I love the look of the wiring and enclosure etc. It would be awesome to hear some additional details about the VFD if you wouldn't mind sharing. Make/Model... Would love to see the inside of the box too. I'm interested to know how the automation guy did the RPM as well.
And just to understand how you have the buttons set up... I see a Motor Run and Stop as well as a potentiometer (lower right) and the emergency stop. So does that mean to power on the VFD, you'll set the 4 position 220 switch to the Mill/VFD position and then use the motor run/stop buttons to turn on/off the spindle/VFD? And the potentiometer to control the speed of the spindle by varying the frequency? If so, I assume the physical on/off switch (upper left of the head) doesn't do anything now or is just always in the on position. I guess i'm indirectly asking if you're planning on using the gearing in the head at all for high/low speed torque scenarios or if you're leaving the gearing to a mid-range setting and then using the potentiometer to adjust torque/speed.
I opted against using the potentiometer method to control the speed of my motor as I figured the gearing in the head of mine would be a better (or at least more native) method of controlling the torque/speed of the spindle than manipulating the speed of the motor by varying the frequency/Hz. I'm not suggesting that's a wrong approach as i've read of others doing the same although mostly on machinery that had lower torque requirements. Things like wood lathes and drill presses. In my situation, that effectively means I need 3 positions to control my mill (On (fwd), Off, On (rev)). It's hard to make out in my picture from earlier in the thread but there's a grey 3 conductor wire that goes to a 3 position switch on mine. I programmed the VFD accordingly based on which position it was in.
Thanks again for sharing the great content.
Yes, to power the mill the switch is set to 'milling' which powers the VFD
SO the buttons are motor on, motor off, emergency stop disconnects power to the motor but not VFD. The variable speed can be used to apply between 0% and 100% speed/power to the motor. And the tach displays the motor speed.
The belt system is fully functional. and can be used to adjust speed mechanically, the variable allows adjustment between belt ranges or for less demanding milling/drilling can be used as the sole speed control if desired. For max torque the motor would be run at 100% speed and the belt engaged at the proper speed range.
The switch on the side of the head is still functional. It is a secondary off switch and also determine if the spindle/motor is turning forward or reverse.
Some of pictures inside the box: