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Machine B&S Challenger Surface Grinder - dust collector hookup

Machine
M

Mike R

Super User
Premium Member
So my B&S Challenger surface grinder has a dust collector hiding in the base cabinet. I've had the machine now October 2018 and haven't had a good dust collection system. I usually just wedge the shop vac in the back dust catcher and carry on. I do notice the film of dust that accumulates everywhere and I really need to wear a dust mask when using it, but I'd like to also reduce the amount of dust that ends up everywhere in the shop. Now, I usually only grind small things so, and pretty infrequently so this hasn't been a priority, but for some reason this year I've decided to invest time in my shop. Could be because I spent the last 4 years rebuilding a cottage!

Anyways, the machine is 3 phase, so I added a VFD to it to make it run back in 2018. I just received my new to me (from Vevor) VFD to be able to run the dust extraction motor (1/2hp 3450rpm) and looking at it and the one from 2018 - no doubt in my mind the same factory made them. Some cosmetic differences in plastic but I'm pretty sure they are the same (both are 1hp rated).
Just waiting on a new box to house the pair of VFD's as the salvaged one I had previously is just too small. I also need to decide if I can live with basic light switches connected to the control terminals for on/off control or do I need more industrial looking switches, or go another way and use some sort of simple toggle switches. I have many momentary big push button switches, need to see if they can be used. Also have a few E-stop type. Momentary on, E-stop off? I need to read the manuals...
Anyways I thought I'd share some pics of the dust extractor as I haven't seem many of the originals on the web. I'm going to try it out with the original fabric filters, but I did see one guy modify it to use shop vac filters instead. If it does not suck in the dust then there is no point trying to filter it better.
If it works, the I can also look at using the dust collector for the bench grinder / belt sander and D bit grinder located in close proximity.
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Mike R said:
I also need to decide if I can live with basic light switches connected to the control terminals for on/off control or do I need more industrial looking switches, or go another way and use some sort of simple toggle switches.
Click to expand...

The controls on the VFD are all low voltage low current. No need for industrial power switches. The VFD does the protected power switching internally. I'd suggest small toggle switches. You can get cheap ones if so inclined or beautiful high quality ones that look and feel great. EvenA the best low voltage toggle switches won't cost a fortune.
 
The choice of switch in this case is more about aesthetics and tactile feel versus its electrical properties. i.e. can I switch it off easily, will it be too easy / hard to switch, and does it look the part? I know I can use almost anything to make contact for the VFD's input terminals but I need to make it feel like its not half assed (3/4 assed may be good enough though!)
I have a bunch of standard light switches and can easily mount a double gang box on the front of the grinder, I think that may be the solution for now (or forever as the case may be). Of course I've been derailed from making further progress.
1. I need a longer bit of armored flex for the spindle motor - just a fraction too short when the head is moved all the way up
2. Other duties around the house call - leaking shower somehow can't wait and wants attention now by making its presence known on the ceiling of the kitchen :(

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Hi . Just a thought , would it be possible to raise the junction box up a bit of move it to the back of the base so you don't have to replace the armoured cable ?
 
I did look at moving the box, but it just didn't fit right anywhere on the back.
I added a small surface mount electrical box (like for a light switch) just on the back of the mill, about where the original was and ran the armored cable to that, and I will then run some cable from there to the box with the VFDs.
Tonight I did more work on this but need to finish still. Murphy's law stepped in to slow me down just enough.
Turns out the old VFD I have has a manufacturing defect I never noticed until today cause I just used the run stop buttons on the panel. I went to wire up a control switch to it and was struggling to get the wires into the terminal block.
I know I'm fat, my vision isn't what it used to be and I can be ham fisted, but I really just could not get the wire in the block.

Turns out the terminal block is soldered on the board backwards, so the entries are facing into the VFD, and the back of the terminal block does not have any opening for wire!
So you can see in the picture I had to route the control wires over the top of the terminal block and in from the back on the one on the right, the newer one from Vevor is ok and comes in where its supposed to.

Almost done, the control wires work, just need to add switches and a few cover plates.

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Almost done, the control wires work, just need to add switches and a few cover plates.

Are we making sparks yet ?
 
With me and electricity sparks are always possible, but yes, she sparks and in the good way. Still need 1 cover plate, somehow went to the hardware store 2 times to buy stuff, some of which was in the electrical aisles and I still zoomed past cover plates.

Its functional, but I'm disappointed in my switch selection. 16mm sounds so much larger than 5/8". Once I had them I just used them but my fingers have a slightly hard time pushing them in. I really need bigger buttons, but they are more $ and I can live with these for the amount of times I use the machine. Would be an easy change if I do get motivated.

Also a bit embarrassing, but I went to take a picture and the pile of junk that I had swept up and is in the previous pictures was still there (Jan 15 to Mar 6th) so had to pick that up before snapping a new pic. Not a record for me in terms of laziness but nothing to be proud of. And I wonder where my son gets his habits from....

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Looking good. I have an Ingar, which is a clone of this machine. I wish it had a dust collector. Don't worry about the extra trips to the hardware store, i think I do that every time I do electrical or plumbing lol.

I still need to wire up the control wires for my VFD too. Something I've been meaning to do....for a couple years now lol.
 
Yes Looking good , I've been following along on your build .

I have a " Freeport " 6" X 12" , it looks very similar to yours however I guess they all get copied to some degree . I've had mine running very s!owly just to check out the VFD and direction .

I see you have a one shot lube oiler , mine has grease fittings and has been greased when I got it . I thought it should use oil but haven't followed up on checking that out , if it should be oiled I'll have to partially take things apart to remove the grease and oil it .

I am just in the process of making an arbour to balance the grinding wheel .

Bill
 
Susquatch said:
I have a 6x12 Lee. Mine has no grease fittings and takes no grease. I'd be giving that a REALLY close look if I were you.
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Yes thanks , I couldn't understand why they greased it .

The only wheel hub I have has the 3 small weights in it and one of them was loose so was just floating around between the other 2 that were tightened down , that could have been a disaster waiting to happen .

Bill
 
Thanks for the kudos. I don't really know how effective the dust collection will be, but it has to be better than my shop vac hanging in the collector chute, turned on when I remember.
The dust collector is not quiet, but it definitely seems to pull a good amount of air.
Note that there are different table mechanisms even among the same brand and model. The B&S I have was available as having cast iron ways (with Turcite I think) or with roller bearing ways. Mine has the roller bearing ways.
Either type though - I agree - should not be grease. Same as a milling machine or lathe, no grease on ways, maybe on gears if specified.

I haven't balanced a wheel yet. Its ok, but definitely need to balance for a better finish and longer bearing life. Just needs to be added to the to-do list.
 
Payner said:
The only wheel hub I have has the 3 small weights in it and one of them was loose so was just floating around between the other 2 that were tightened down , that could have been a disaster waiting to happen .
Click to expand...

Don't be so quick to condemn it. There is a system for grinding wheels that is designed to use a loose ball bearing (or 3 or a dozen) to self balance. I don't have one and can't describe it precisely, but it works a lot like a transport truck wheel balancer. You might want to check on that. Maybe google "grinding wheel auto balance" or similar. Maybe another member can jump in to help?
 
Personally, I like having a contactor cut the power to the VFD so usually do latching on/off buttons (not always, but lately I have been on every one). I don't believe the cheap VFD I've been buying are UL or CSA, and if they say they are its because someone told them to put it on the package because it;s good for sales. This cheap electronic stuff is awesome for us, makes soooo much affordable ..... but I don't want power to it when I go to bed. Maybe the innards of the VFD's are great, don't know, but I've seen horrors in some of this low cost stuff

Last one I did for a new old lathe. I added other controls as well as the vfd panel, but all you need are the buttons.

The ones I used



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