Thread Number: 33929
Blue box MOD 0
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Post# 509798   4/6/2011 at 19:43 (4,761 days old) by supremewhirlpol ()        

It's time to start MOD0 on the Blue Whirlpool BD. This mod will change a good part of its operation. I'd say 70% - 80% is nothing but electrical. For that purpose, I'm going to be very vague on the electrical configuration of the components. Thus, schematics and wiring diagrams won't be posted. I don't want people who know nothing about electrics, machine controls, and high voltage to be attempting this. So now the question is, what is MOD0? What will it change about this machine? What do you think? Hint:What is the purpose of this box?




Post# 509800 , Reply# 1   4/6/2011 at 19:45 (4,761 days old) by supremewhirlpol ()        

What is special about this box?

Post# 509801 , Reply# 2   4/6/2011 at 19:50 (4,761 days old) by supremewhirlpol ()        

What is this device? What does it do?

Post# 509805 , Reply# 3   4/6/2011 at 19:52 (4,761 days old) by supremewhirlpol ()        

Here is front of the unit. What is this device? Think industrial Machine Controls.

Post# 509807 , Reply# 4   4/6/2011 at 20:04 (4,761 days old) by Pulsator (Saint Joseph, MI)        

pulsator's profile picture

Are you gonna give it a variable speed motor? Potentially giving a far wider range of spin/agitation speeds and perhaps making the spin speed quite a bit higher?


Post# 509814 , Reply# 5   4/6/2011 at 20:32 (4,761 days old) by supremewhirlpol ()        
Correct!

Oh hi Jaime!

 

Now that was good! Yes the AF-300 will make this machine capable of such a feature.  I want this machine to still function on 120V AC 1 PH, but use a 3 phase motor to make this machine have variable speeds.  The original motor is 1/2hp, 1725rpm/1140 rpm, keeping the pulley ratio and other mechanics the same the new motor is 1/2hp, 3600 rpm(nameplate).  More on that later.  Very good answer Jamie!  MOD0 is making the machine have variable speeds.


Post# 509824 , Reply# 6   4/6/2011 at 20:55 (4,761 days old) by combo52 (50 Year Repair Tech Beltsville,Md)        
FAST SPINNING WP BD WASHER

combo52's profile picture

Melvin be careful back around the time WP brought out the Calypso washer a WP engeneer told us about experments they did with DD washers to see how fast they could get them to spin. When they reached around 1000 RPMS the wash baskets would dissinergrate in a deadly way. See exploding Candy washers.

 

As I may have mentioned I modified my 1971 LK washer to spin at 700 RPMs when I rebuilt it 20+ years ago, and even for this I added extra bearings and reinforced the base plate. And the machine still walks badly if the load is even slightly off-balanced. The suspension system on BD machines is not designed for much speed, it would also be better to start with a washer that has good bearings etc. Still this sounds very exciting be sure to do videos with sound and be careful.


Post# 510340 , Reply# 7   4/8/2011 at 23:07 (4,759 days old) by supremewhirlpol ()        

Yes, John you are so right. I don't want this machine to fly apart, I'd surely have a bad day.

Post# 510341 , Reply# 8   4/8/2011 at 23:12 (4,759 days old) by supremewhirlpol ()        

Oh and yes, those who want details of the electrical modifications can always send me an email. There I will disclose how to make it work. Here are more pictures of the AF-300. A small unit to operate a 1/2 hp 3 phase motor.

Post# 510342 , Reply# 9   4/8/2011 at 23:14 (4,759 days old) by supremewhirlpol ()        
AF-300

nameplate

Post# 510343 , Reply# 10   4/8/2011 at 23:16 (4,759 days old) by supremewhirlpol ()        

heatsink->I'll probably put a fan in the control box.

Post# 510344 , Reply# 11   4/8/2011 at 23:17 (4,759 days old) by supremewhirlpol ()        

bottom

Post# 510345 , Reply# 12   4/8/2011 at 23:18 (4,759 days old) by supremewhirlpol ()        

terminal layout

Post# 510348 , Reply# 13   4/8/2011 at 23:21 (4,759 days old) by supremewhirlpol ()        
mounting the control box

I've drilled holes through the back panel to mount the control box to the machine.

Post# 510350 , Reply# 14   4/8/2011 at 23:23 (4,759 days old) by supremewhirlpol ()        
Control box mounted

using 4x 1/4-28 bolts and nuts

Post# 510352 , Reply# 15   4/8/2011 at 23:24 (4,759 days old) by supremewhirlpol ()        

.

Post# 510353 , Reply# 16   4/8/2011 at 23:26 (4,759 days old) by supremewhirlpol ()        

Machine right side up->looks good!

Post# 510356 , Reply# 17   4/8/2011 at 23:37 (4,759 days old) by supremewhirlpol ()        

The box adds at least 30-50 LB. of weight to the machine. So it turns out that this box was never used. It was built ~1982 to operate some sort of pump. The box is rated for wet locations. The contactor has never been used, the contacts are not scored. The coil is 120VAC, perfect for my application. The fixture on the side of it has a small flasher module on the base of the light bulb, as the fixture was used to indicate if the pump was running or not. I'll keep the fixture on there for much of the same purpose, except a 35W HPS lamp and Ballast will be used.

Post# 510451 , Reply# 18   4/9/2011 at 15:37 (4,758 days old) by aldspinboy (Philadelphia, Pa)        

aldspinboy's profile picture

That is very interesting work Melvin.. keep it going and the best of luck to you.

The light bulb on the back is strange looking by far.

So where is that GE Interface with the run & stop buttons going ?

Boy Lights ,Varible Speed motor, now you have to come up with a new nomenclature for that machine !

 

 

 

Darren k


Post# 510502 , Reply# 19   4/9/2011 at 20:52 (4,758 days old) by supremewhirlpol ()        

Hi Darren!
The GE AF-300 goes in the control box, there is not enough space in the machine for it and all of the wiring and other required components


Control box now empty-> time to equip it!


Post# 510504 , Reply# 20   4/9/2011 at 20:54 (4,758 days old) by supremewhirlpol ()        

Previous components have been removed from the panel for mapping of new components.

Post# 510507 , Reply# 21   4/9/2011 at 20:56 (4,758 days old) by supremewhirlpol ()        
Oh Pewee!!...Where ya been son?

It's been a minute! You still mad at me?

Post# 510508 , Reply# 22   4/9/2011 at 20:58 (4,758 days old) by supremewhirlpol ()        

I desperately require your services...I think you'll like this job I have for you.

Post# 510509 , Reply# 23   4/9/2011 at 21:03 (4,758 days old) by supremewhirlpol ()        

Pewee is required for airflow as the AF-300 is cooled by air convection!

Post# 510510 , Reply# 24   4/9/2011 at 21:06 (4,758 days old) by supremewhirlpol ()        
Pewee GP!

Pewee,AF-300, main power contactor mounted

Post# 510511 , Reply# 25   4/9/2011 at 21:09 (4,758 days old) by supremewhirlpol ()        

Panel in control box->for now->waiting for motor!

Post# 510974 , Reply# 26   4/12/2011 at 03:05 (4,755 days old) by tolivac (greenville nc)        

I could see the GE AF300 VFD drive device useful for other projects--for that fellow who has acquired a surplus 35MM film projector for his home theater-they are becoming available from theaters converting from film to digital.Most of these projectors have quarter to half HP motors that need 3Ph 208-230V to run.this device may be the answer.Easier than replacing the motor.
If you have surplus 208-220V 400Hz surplus military equipment-this device may allow you to run it.Same if you have 50Hz equipment.


Post# 511174 , Reply# 27   4/12/2011 at 23:39 (4,755 days old) by AutowasherFreak ()        

Interesting project indeed, I can't wait to see the final results.

 


Post# 511183 , Reply# 28   4/13/2011 at 00:36 (4,754 days old) by DaveAMKrayoGuy (Oak Park, MI)        

daveamkrayoguy's profile picture
No matter what gets added, that is still a neat washer, indeed! Keep up your effort & keep us informed on your next improvements...!


Dave


Post# 511320 , Reply# 29   4/13/2011 at 16:24 (4,754 days old) by supremewhirlpol ()        

Hmmm...No motor yet. I'm starting to think UPS has gotten their GPS coordinates screwed up again!

Dave,
You say that this machine is neat. I thought it was boring, so I'm adding some things to make it quite eventful. Question: excluding the modifications I'm making to this machine, what is neat about it?


Post# 511718 , Reply# 30   4/15/2011 at 22:02 (4,752 days old) by supremewhirlpol ()        

Could this be the motor?

Post# 511720 , Reply# 31   4/15/2011 at 22:05 (4,752 days old) by supremewhirlpol ()        
Not packaged in the wooden crate I'd hoped for.

A WEG motor?

Post# 511723 , Reply# 32   4/15/2011 at 22:11 (4,752 days old) by supremewhirlpol ()        
tisk tisk!!

You can ALWAYS count on something going wrong! This motor does not have a c-face!

Post# 511725 , Reply# 33   4/15/2011 at 22:15 (4,752 days old) by supremewhirlpol ()        

So it turns out the original motor has been discontinued by Elecktrim. The WEG is a substitute. Now, I have to change the front!

Post# 511726 , Reply# 34   4/15/2011 at 22:29 (4,752 days old) by supremewhirlpol ()        

Not really sure what I should do here...Specs don't match. According to the AF-300 mini it is rated for a 1/2hp motor and output amps are 2.5. Looking at the name plate of this motor, I'm within the continuous current output, however this motor is 3/4 HP. NOT what I ordered!

Post# 511730 , Reply# 35   4/15/2011 at 23:47 (4,752 days old) by cfz2882 (Belle Fourche,SD)        
i'd try it

since it's a two pole motor it might lack torque at low rpm-but only way to
know if that is a factor is to mount it up and try it out with as small as a
pulley as you can find.
i repair motors and see a few wegs-actually one of the better foriegn motors
avalible these days.
Cool and interesting project BTW!


Post# 511731 , Reply# 36   4/16/2011 at 00:18 (4,752 days old) by tolivac (greenville nc)        

We have some WEG 15Hp 3Ph 230V motors as replacements in some of our transmitter blowers-work OK.They replaced Westinghouse motors that were over 60Yrs old.those did still run-but the bearings were going.Guess it was just as well to get new motors than having the Westinghouse ones rebuilt.they sit in the storerooom.Good emergency spares.

Post# 511804 , Reply# 37   4/16/2011 at 14:14 (4,751 days old) by supremewhirlpol ()        

Well...It does work with AF300->no load. Before I mount it, have to change the front. Here is test video.

CLICK HERE TO GO TO supremewhirlpol's LINK


Post# 512034 , Reply# 38   4/17/2011 at 20:59 (4,750 days old) by supremewhirlpol ()        

SO it's time to remove the original motor.

Post# 512035 , Reply# 39   4/17/2011 at 21:00 (4,750 days old) by supremewhirlpol ()        

Better move it far away, otherwise it will just confuse you!

Post# 512037 , Reply# 40   4/17/2011 at 21:04 (4,750 days old) by supremewhirlpol ()        

After changing the front of the motor to a c-face->make holes in the motor brackets, adjust as needed. BAM!! He's mounted!

Post# 512040 , Reply# 41   4/17/2011 at 21:06 (4,750 days old) by supremewhirlpol ()        

I still need to button up some things with the motor, like proper wiring, the junction box, etc.

Post# 512041 , Reply# 42   4/17/2011 at 21:09 (4,750 days old) by supremewhirlpol ()        

It runs relatively quiet, doesn't vibrate the machine. Now need to get a pulley in metric units!

cfz2882: Thank for your help!


Post# 513224 , Reply# 43   4/23/2011 at 11:06 (4,744 days old) by supremewhirlpol ()        

Apparently getting anything in the US to fit parts that are in metric units is a REAL pain in the lower back side! Had to get a pulley machined to fit the motor!

Post# 513346 , Reply# 44   4/24/2011 at 01:18 (4,743 days old) by tolivac (greenville nc)        

It will be fascinating to see the 3450RPM motor function where a 1725RPM one would nomally be used-the VFD should take care of that!Will be very interesting to see how this extraordinary WP washer performs!Bet it could put the "spin" on the clothes as well as a good agitatin!

Post# 513370 , Reply# 45   4/24/2011 at 08:01 (4,743 days old) by Tomturbomatic (Beltsville, MD)        

The main fly in the ointment can be seen from the photo taken from underneath the plate on which the mechanism sits. Most other top loader automatics did not have that plate up in the cabinet like that that would crash into the corners and sides of the cabinet if a load became unbalanced. In machines that just had the round tub in the cabinet, there was more swing room for the tub. Kenmore used an off-balance switch; WP did not. Their neutral drain deposited the load at the bottom of the tub which helped spin stability and unlike tubs that spun the water out, there was less chance for the spinning water to carry small items into an unbalanced distribution situation.

Watch the dynamic forces as you go about this exciting project. Even increasing the Maytag to a 757 rpm spin speed makes the front panel flex like a speaker cone during spin.

Are you planning to increase the spin speed after a couple of minutes of regular spinning to have a lighter-weight load for the components to handle? I don't remember this exactly, but I read that when Bendix was putting the Duomatic through "shake down" tests, they discovered that to minimize the tub swing at the beginning of the spin periods which would send the suspended mechanism crashing into the cabinet, they had to prevent the motor from going into the start windings as it slowed from the increased load because the start windings put too much torque on the basket and exaggerated the swing as the still water heavy and less than perfectly balanced load gained speed. I know that you are dealing with a top loader and they were dealing with a front loader, but I am curious about those initial wobbles and swings the tub can take as it builds up speed.

As you think about high speed spinning, you should also consider the construction of the tub and compare it with that of the Frigidaires in the gauge of the steel, the huge hub in the Frigidaire's tub and the compromising of strength due to perforations in the WP's tub. The neutral drain's leaving the load at the bottom of the basket will lessen the effect of a missing ballast ring or the GE's cast iron tub cradle in its machine with high speed spinning , but I think the force caused by the increased speed is going to cause the tub to separate from the central tube where the drive force originates. Slowly increasing the speed after some of the water has been spun out might lessen the strain at that point.

Another thing to consider is that increased motor speed while the machine is in agitation can put serious stress on the tranny.


Post# 513799 , Reply# 46   4/26/2011 at 00:04 (4,742 days old) by supremewhirlpol ()        
The good and the bad...

The good is that agitation is almost that of a DD machine given a new belt. The bad is no spin. Tub tries to engage but does not spin even with help. I suspect the spin tube and assembly needs replacing.

Post# 516433 , Reply# 47   5/8/2011 at 20:33 (4,729 days old) by supremewhirlpol ()        
Spin tube stuck!

Transmission comes out nice, spin tube not so...

Post# 516434 , Reply# 48   5/8/2011 at 20:35 (4,729 days old) by supremewhirlpol ()        

This machine has been repaired before...Should have been sent to scrap 25 years ago!

Post# 516435 , Reply# 49   5/8/2011 at 20:39 (4,729 days old) by supremewhirlpol ()        

Think it's time to find a donor machine and send the innards of this one to scrap. Bearing must be ceased, it's impossible to get the spin tube out without damage to the tube on the baseplate

Post# 516500 , Reply# 50   5/9/2011 at 07:27 (4,728 days old) by combo52 (50 Year Repair Tech Beltsville,Md)        
GETTING A STUCK CLUTCH OUT

combo52's profile picture

Melvin There is an easy way to get that out all you have to do is call me. The WP BD machines are a little work to rebuild [ see post to Dave -87 ] but that blue machine is actually in very good shape for its age. But there are quite a few tricks that are not in the repair manuals to rebuilding old machines.


Post# 516553 , Reply# 51   5/9/2011 at 10:26 (4,728 days old) by mickeyd (Hamburg NY)        
Melvin and John

mickeyd's profile picture

Can you explain to someone not gifted in mechanics, why a portable BD Whirlpool can spin at 900 rpms without and difficulty? Is it just tub size that makes it possible? Could be mistaken about the exact rpms, but it's so much faster than the spin on the standard-sized model.


Post# 516554 , Reply# 52   5/9/2011 at 10:32 (4,728 days old) by mickeyd (Hamburg NY)        
Is there a way

mickeyd's profile picture
to adapt the engineering in the portable to the standard machine?

Post# 516555 , Reply# 53   5/9/2011 at 10:33 (4,728 days old) by macboy91si (Frankfort, KY)        
BD Portable

macboy91si's profile picture

Hey Mike, the portable has no baseplate like this machine. It is wholly suspended from the bottom plate of the machine by 3 stand-up springs. Banging on the cabinet is fairly common on them, but the smaller diameter tub also isn't as violent as it's much larger siblings.

 

-Tim


Post# 516559 , Reply# 54   5/9/2011 at 10:49 (4,728 days old) by mickeyd (Hamburg NY)        
Hi Tim

mickeyd's profile picture

It's really cool-looking under there. Those springs are rubber coated, I think. and they look like minaturized tripods from the "machines" in the newer version of "War of the Worlds." When I first went down and under the WP, I gasped!

 

Filter on slow--Gentle cycle. Some BLUE for YOU, Melvin




This post was last edited 05/09/2011 at 11:14

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