Transcript PHASE CONVERTERS

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www.phase-a-matic.com
Phase-A-Matic, Inc. © 2005-2008
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PHASE CONVERTERS

Static Converter

Rotary Converter

Voltage Stabilizer / CNC PAC
Phase-A-Matic, Inc. © 2005-2008
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What is a Phase
Converter?
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- Glad you asked.
A phase converter converts single-phase
power into 3-phase power.
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If you have a 3-phase machine you
need to run at a single-phase location,
you need a phase converter.
That’s where we can help!
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Tell Me About It
Most industrial equipment is made to
run on 3-phase power. 3-phase utility
power is found on industrial sites and
many business properties.
Whereas, single-phase utility power is found at:
• Residential locations
• Most farms
• Many businesses
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Tell Me More About It
1-phase power waveform
1-phase motors have 2 windings,
a run and a start winding.
3-phase power waveform
3-phase motors have 3 windings,
always in use.
Almost all motors 5 HP and above are 3-phase only.
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1-phase
versus
3-phase Motors
1-phase Motors
3-phase Motors
 Larger and heavier
 Smaller and lighter
 Have capacitors
 No capacitors
 Have internal switching
 No internal switching
 Draw much higher current
than 3-phase motors
 Draw much LESS current
than 1-phase motors
 Prone to problems
 Very reliable
 Shorter life
 Extremely long life
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Advantages of Using a Phase Converter
No changing motors or switch gear
Simple and economical
Easy to install and use
3-Phase Power Is Expensive And Cost Prohibitive: 3-phase utility power
is expensive to bring in to a location, and it’s expensive to run. There
usually is a flat monthly charge in addition to the actual power used.
Other Single-Phase Power Advantages: Where single-phase utility
companies charge penalties based on each high amperage peak on the
line, the Rotary Converter reduces these peaks, keeping them from
registering high on the demand meter, thus lowering the power bill.
Phase-A-Matic, Inc. © 2005-2008
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HOW WE STARTED
Phase-A-Matic, Inc. began in
1965 when Colin Johnstone
needed to run a 3-phase lathe
at his home shop. He made
an early model of the first
Static Converter, which ran his
lathe quite well.
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HOW WE STARTED
A friend was impressed by
the ability to run 3-phase on
single-phase, and wanted a
converter for his machine,
too. It was apparent the
device was useful, and would
sell.
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Soon,
Colin
was
driving
to
industrial sites, selling and wiring
in his new invention. In those
days, the converter was not yet
a turnkey device, and needed to
be installed internally
machine’s circuit.
to
the
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But he quickly found a way to
overcome the obstacles, and
was able to sell a converter
that only needed external
installation, making it attractive
to the consumer, and much
easier on Colin.
He obtained a patent on this design
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This improved design
is well proven over 40
years with approx.
200,000 sold. A few
short years ago he
was able to buy back
the first one of these
converters, still in
perfect working
condition.
First Converter Sold
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Today, this is what the
Static Converter looks like.
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Current Product Line:
Rotary Converter
Static
Converter
Voltage
Stabilizer
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As we just saw, the
three main products
currently manufactured
by PHASE-A-MATIC are:
TM

Static Converter

Rotary Converter

Voltage Stabilizer
For those who handle only the Static Converter, we are going to
learn more about it. But first, a brief feature description of each
style of converter is in order to acquaint you with the main
differences between them. You will most likely get requests for
them.
We’ll start with the main comparisons of the Static and Rotary
Converters.
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STATIC
CONVERTER
Motor loads only
2/3 rated HP output*
- Runs light to moderate
loads only
*Runs delta-wound motors at
50% rated HP output
ROTARY
CONVERTER
LOAD
TYPES
OUTPUT
EQUIPMENT
TYPE
Motor, resistive & transformer
loads - virtually any 3-phase
load.
FULL rated HP and output
- Runs heavily loaded
equipment
- Runs CNC equipment with the
addition of the PHASE-A-MATICTM
Voltage Stabilizer
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First,
we’ll learn about the
Static Converter
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STATIC CONVERTER
WHAT IT DOES
A 3-phase motor has 3 identical
windings equally spaced. Any 3phase wye-wound motor, once it
is started, will run on singlephase across 2 of the windings,
and will provide 2/3 of its rated
horsepower. Example: a 15 HP
motor will provide 10 HP.
Continued…
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STATIC CONVERTER
WHAT IT DOES
Based on this principle,
the Static Converter
supplies the 3rd leg (B)
for start-up purposes
only.
Connection terminals are labeled A, B, C
The converter briefly produces “out-of-phase” voltage/current on
the 3rd leg (B) to start the motor. The Static Converter is not a true
converter in the sense that it does not generate on all three lines
to the motor continuously.
Continued…
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STATIC CONVERTER
WHAT IT DOES
Once the motor is up to speed, the Static Converter
switches out of the circuit and the motor continues
to run on the remaining 2 windings (A & C), at 2/3 of
its rated HP output (50% rated HP output on deltawound motors).
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But, doesn’t that “single-phase” the motor?
Not as some might believe.
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STATIC CONVERTER
A 3-phase motor, fully loaded and running on
regular 3-phase utility power requires all 3 legs.
If you disconnect or lose one of the legs of the
3-phase power, the amperage will rise very high
on the remaining legs and the motor could be
damaged.
This is what is known as “single-phasing.”
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STATIC CONVERTER
Using a Static Converter only
However, using single-phase power and a Static
Converter, as long as the motor is not loaded beyond
2/3 of its rated horsepower (50% for delta-wound
motors), the nameplate amperage rating of the motor
will not be exceeded.
The lifetime of the motor will not be shortened.
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STATIC CONVERTER
About Delta-wound Motors
We make references to delta-wound motors since we
do run across them. These motors are not as
commonly used as wye-wound motors. If the machine
is made in Germany or Italy, it almost surely will have
a delta-wound motor.
All other 3-phase motors are wye-wound motors,
which run at 2/3 rated HP on a Static Converter, while
a delta-wound motor runs at approx. 50% output. It is
always best to use a Rotary Converter on deltawound motors.
Phase-A-Matic, Inc. © 2005-2008
STATIC CONVERTER
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WYE AND DELTA MOTOR WINDINGS ON THE
STATIC CONVERTER
The wye-wound motor has 220VAC single-phase
connected directly to 2 of the windings (A & C).
220VAC
Single-phase
2/3 output
Therefore, it will provide 2/3 of its rated HP. The
other winding (B) has momentary 3-phase
provided by the Static Converter for starting
purposes only.
WYE WINDING
A delta-wound motor has 220VAC single-phase
across one of the windings only (A & C). The
220VAC
Single-phase
50% output
other 2 windings (B) are connected in series and
will receive very little of the single-phase power
input. Therefore, it will produce approx. 50% of its
rated output.
DELTA WINDING
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STATIC CONVERTER
Uses
There are 2 methods of using the
STATIC CONVERTER:
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STATIC CONVERTER
Uses
Method 1:
The simplest, easiest and most commonly used method;
installing the converter directly to the machine, producing 2/3 of
its rated HP.
Method 2:
Install to an additional “idler motor” to produce full or close to
full rated HP or output.
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STATIC CONVERTER
Method 1: Direct connection for 2/3 rated HP of motor
Method 1 is the easiest and the
most commonly used method:
that of connecting the converter
directly to the machine, producing
2/3 of the rated HP of the motor.
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STATIC CONVERTER
Method 1:
What kind of machines will it run?
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STATIC CONVERTER
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Method 1 Uses
- Mills
- Saws
- Lathes
- Meat saws
- Punches
- Planers
- Shears
- Jointers
- Routers
- Food mixers
- Presses
- Hoists
- Metal grinders
Lathe
Continued…
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STATIC CONVERTER
Method 1 Uses
- Metalworking equipment
- Woodworking equipment
- Food processing equipment
- Garbage disposals
- Meat grinders
- Sewing machines
- Wheel balancers
Grinder
Milling Machine
And numerous other uses!
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STATIC CONVERTER
Method 1 Uses
The STATIC CONVERTER
runs many more machines
than we have listed in this
presentation – the list is too
extensive to mention here.
Meat Grinder
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STATIC CONVERTER
Method 1 Uses
NOTE:
The
Static
Converter
applications listed in the previous
slides are general. For example,
most mills, but not every mill, will
work on the Static Converter.
Likewise, most of the machines listed
work fine on the Static Converter, but
not under every circumstance, nor
under heavy load.
Bandsaw
NOTE: It is always best to consult our application databank
Phase-A-Matic, Inc. © 2005-2008
STATIC CONVERTER
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Compatibility
Some conditions that are NOT
compatible with the Static Converter are:

Motor RPM rating less than 1200 RPM

Old “open frame” motors (with exposed windings – generally
manufactured before the 1950s)

3-phase electronic controls (VFD / Vector drives, etc.)

2-speed motors in which both motor speeds do not fall within
the minimum & maximum HP range of any one Static Converter
Consult databank / call Phase-A-Matic, Inc. technical support.
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STATIC CONVERTER
Compatibility
CAUTION:
Do not oversize
Customers often logically think that a larger HP size converter
will make up for the 1/3 power loss that is mentioned in our
literature. They also logically think “bigger is better” and that the
converter might have greater safety margin and reliability.
This is not true. It almost surely will result in failure.
Consult databank / call Phase-A-Matic, Inc. technical support.
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STATIC CONVERTER
Uses
Because not all applications are the same,
PHASE-A-MATIC, INC. recommends that
you always consult the Application Sizing
CD databank to size the converter to the
application correctly.
If necessary, call PHASE-A-MATIC™ for
help.
Drill Press
Bandsaw
Phase-A-Matic, Inc. © 2005-2008
STATIC CONVERTER
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Using Static Converter Method 1 will NOT run:
- Battery Chargers
- Plasma Cutters
- EDM Machines
- Rectifiers
- Heating Elements
- Rheostats
- Most CNC Equip.
- Lasers
- Transmitters
- Radar
- Welders
- Pumps
- Variable Frequency Drives (VFD)
Pressure Washer
Continued…
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STATIC CONVERTER
Uses
These machines require using the Static Converter Method 2
OR
Fitting the machine with a motor that is 50% larger
OR
Use the ROTARY PHASE CONVERTER
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STATIC CONVERTER
Question
I’ve seen the Static Converter
running air compressors using
Method 1. Air compressors run
heavily loaded.
How can it do that?
Air Compressor
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STATIC CONVERTER
Answer
You MUST reduce the pulley on
the motor by 1/3* in diameter,
thereby taking 1/3 of the load off
the motor. It will still build up the
same pressure, but 1/3 slower
(reduces CFM by 1/3).
*50% for delta-wound motors.
There are MANY air compressors on Static Converters.
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STATIC CONVERTER
Answer
This principle applies to any machine
that is belt driven and is heavily
loaded. The objective is to take 1/3 of
the load off the motor by reducing its
pulley size by 1/3.
OR, you can increase the size of the
opposite driven pulley by 1/3.
This same principle also applies to chain driven equipment.
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STATIC CONVERTER
Answer
Another alternative is to fit
the machine with a motor
that is 50% larger. The Static
Converter must be sized to
this larger motor that has
been installed, then the
compressor will run at its full
rated CFM output.
Air Compressor
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STATIC CONVERTER
Method 2: Produce full or close to full horsepower
The Static Converter is used to
start an “idler motor,” and the idler
motor both starts and runs the
machinery.
Continued….
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Phase-A-Matic, Inc. © 2005-2008
STATIC CONVERTER
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Method 2: Produce full or close to full horsepower
Using this method you can:

Run multiple machines

Run heavily loaded machines

Complete workshops can be
run using this method
Continued….
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STATIC CONVERTER
Method 2: Produce full or close to full horsepower
This method requires combining
the converter with an additional
3-phase motor that just idles,
and acts as a generator, or
rotary transformer to generate
the 3rd leg to the machine, thus
producing full or close to full HP.
The idler motor is sometimes referred to as a pony motor.
Continued….
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STATIC CONVERTER
Method 2: Produce full or close to full horsepower
As the term implies, the idler
motor (sometimes known as a
pony motor) just runs at idle
with no load connected to the
shaft. The 3-phase machine
draws the amperage it requires
to run at full or close to full
rated output, provided the idler
motor is sized properly.
Continued….
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STATIC CONVERTER
Method 2: Choosing an idler motor
A good quality 3450 RPM wyewound, 220V motor is the best
choice. A 1725 RPM motor can be
used on applications not heavily
loaded. The idler motor should be at
least 50% larger than the largest
motor you want to run to
accommodate the higher starting
current required for starting your
equipment.
Continued….
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STATIC CONVERTER
Method 2: Sizing the Static Converter
The Static Converter must always
be sized to the HP of the idler
motor.
Never size to the load motor(s).
Refer to Phase-A-Matic™
literature for further information.
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STATIC CONVERTER
LIFE EXPECTANCY
• It is not unreasonable to expect the converter to be in good
working condition and service for 20 or 30 years or more. We
continue to hear back from customers who have them still
running their equipment faithfully after 20 years and more.
• Improperly applied, it will fail and should not be expected to
do what it was not designed to do.
• Failure rate due to some fault of the converter alone has
been approximately 1 in 1,000.
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IDLER MOTOR
VERSUS
ROTARY CONVERTER
Question:
Idler Motor System
Rotary Converter
How does the idler motor system compare to the Rotary Converter?
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IDLER MOTOR
VERSUS
ROTARY CONVERTER
Answer:
Idler Motor System
1. Takes larger motor to produce
same amount of output
2. Higher idle current
3. Lower voltage output
4. Less stable voltage
5. Can be noisy
Rotary Converter
1. Produces greater amperage
per frame size – windings and
rotor are specially engineered
to generate for optimum output.
2. Low idle current
3. No lower voltage output
4. Quiet operation
Tell me more about the Rotary Converter….
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ROTARY CONVERTER
WHAT IT DOES
The Rotary Converter generates:
• True 3-phase 230VAC 60Hz power
• Full rated HP or output of the machine(s) when properly
applied
For 460V or other voltages, contact factory.
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ROTARY CONVERTER
WHAT IT DOES
The Rotary Converter Runs:
• Virtually any 3-phase machine including motor, resistive
and transformer loads.
• Multiple machines and load types, when sized accordingly
• CNC and other voltage-sensitive equipment in conjunction
with the PHASE-A-MATIC™ Voltage Stabilizer
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ROTARY CONVERTER
HOW IT’S MADE
Baldor Motor Generator
We start with a very high quality motor
generator, which is custom engineered
to our specifications by Baldor Electric.
It is a true phase converter and not
a modified electric motor as most of
our competitors use.
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ROTARY CONVERTER
HOW IT’S MADE
Many years of testing, changing and
developing the converter in conjunction
with Baldor’s engineers has produced a
very simple and trouble-free converter
with extremely low idle current and low
noise level. Many of our customers
confirm that our Rotary Converters are
the quietest and most trouble-free
available.
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ROTARY CONVERTER
LONG LIFE AND DEPENDABILITY
Simplicity of design; all soldered connections
Keeping the design simple reduces the risk
of electrical failure to almost zero since
these are some of the most common
causes of failure. We use only soldered
joints with no mechanical connections like
spade clips, terminals or screws which can
vibrate loose or corrode over time.
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ROTARY CONVERTER
MTBF (Mean Time Between Failures)
Failure rate (MTBF) is so low it's almost
impossible to determine. We find that
within the first 12 months approximately
1 in 150 might have a problem; usually
within a few weeks or months. After the
first 12 months, it might be one or less in
5,000 over a 30 year period.
Continued…
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ROTARY CONVERTER
MTBF / LIFE EXPECTANCY
We continue to hear of our Rotary
Converters that have been in service
for 25 or 30 years, and which are still
working flawlessly. The converters
could easily operate another 25 or 30
years. There is very little to go wrong
with the Rotary Converter.
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ROTARY CONVERTER
USES
The Rotary Converter is virtually
unlimited in what machines it can run.
Space is too limited to list them all. It runs
from very basic to the most sophisticated
of today’s modern machines. However,
some of these machines are voltagesensitive….
Continued…
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CNC PAC
Rotary Converter / Voltage Stabilizer
To run CNC/PLC* and other
voltage-sensitive equipment:
The converter must be used
in conjunction with the
Voltage Stabilizer.
*CNC = Computer Numerical Control
PLC = Programmable Logic Control
Continued…
Phase-A-Matic, Inc. © 2005-2008
CNC PAC
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Rotary Converter / Voltage Stabilizer
The Rotary Converter and Voltage Stabilizer combination
of matched HP rating is known and sold as the
CNC PAC™
For example:
The CNC PAC-10 consists of:
R-10 Rotary Converter & VS-10 Voltage Stabilizer
CNC = Computer Numerical Control
PLC = Programmable Logic Control
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VOLTAGE STABILIZER
WHAT IT DOES
Designed to reduce phase imbalance on
Rotary Phase Converter Systems
The Voltage Stabilizer provides
+/- 5% voltage stabilization under
most normal conditions.
Continued…
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VOLTAGE STABILIZER
WHAT IT DOES
In applications with high single-phase
voltage (greater than 230V), the no load
or light load output voltage may be
excessive. Some CNC/PLC equipment
will not work properly at the higher output
voltage.
Continued…
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VOLTAGE STABILIZER
WHAT IT DOES
Normal operating voltage of the Rotary
Phase Converter is 230VAC. The output
voltage of the Rotary Phase Converter is
normally higher than the input voltage
under no load and light load conditions.
For other voltages, contact factory.
Continued…
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VOLTAGE STABILIZER
WHAT IT DOES
The Phase-A-Matic™ Voltage Stabilizer
is designed to reduce this higher voltage
to nearer the input voltage. It will also
keep the output voltage stable during
peak loads, thus helping CNC/PLC
equipment and other voltage-sensitive
equipment to operate properly.
Continued…
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VOLTAGE STABILIZER
WHAT IT DOES
Running Small Motors On The Rotary Converter:
Without a Voltage Stabilizer, running
very small motors alone on a Rotary
Converter that is 3 times larger (or
more) may not reduce the output
voltage sufficiently, in which case the
smaller motor may run hot.
Continued…
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VOLTAGE STABILIZER
WHAT IT DOES
For these cases, to reduce cost it is
possible to use smaller dedicated
Voltage Stabilizers sized to the
requirements of the problem motor or
motors as needed.
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PHASE-A-MATIC, INC.
CONCLUSION
You’ve just been shown the highlights of
our current line of Phase Converters.
Our brochures and other training literature are available for
more in depth coverage. Phase-A-Matic, Inc. also makes
available an Application Sizing Help and Guidelines CD. This
CD includes the PHASE-A-MATIC™ extensive databank of
known applications.
Phase-A-Matic, Inc. © 2005-2008
PHASE-A-MATIC, INC.
CONCLUSION
Hopefully, this has given you the
overview needed to be on your way
in helping to assist the customer in
their acquisition of the right converter
- to the benefit and satisfaction of
everyone.
Phase-A-Matic, Inc. © 2005-2008
TM
Customers
our
PHASE CONVERTERS!
Phase-A-Matic, Inc. © 2005-2008
This concludes the presentation.
We’ll be pleased to answer
any questions you may have!
Phase-A-Matic, Inc. © 2005-2008
Phase-A-Matic Team:
Colin Johnstone,
Owner
Donna Johnstone
From the California desert:
Mike Jones,
General Manager
Phase-A-Matic, Inc.
39360 3rd St. E. Ste. 301
Palmdale, Ca. 93550
661-947-8485
800-962-6976
www.phase-a-matic.com
Phase-A-Matic, Inc. © 2005-2008