Www.phase-a-matic.com 1 Phase-A-Matic, Inc. © 2005-2008

www.phase-a-matic.com

1

Phase-A-Matic, Inc. © 2005-2008

Static ConverterStatic Converter

PHASE CONVERTERSPHASE CONVERTERS

Rotary ConverterRotary Converter

Voltage Stabilizer / CNC PACVoltage Stabilizer / CNC PAC

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What is a Phase What is a Phase Converter?Converter?

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- Glad you asked.- Glad you asked.

A phase converter converts single-A phase converter converts single-

phase power into 3-phase power. phase power into 3-phase power.

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That’s where we can help!That’s where we can help!

If you have a 3-phase machine you

need to run at a single-phase location,

you need a phase converter.

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Tell Me About ItTell Me About It

Most industrial equipment is made Most industrial equipment is made

to run on 3-phase power. 3-phase to run on 3-phase power. 3-phase

utility power is found on industrial utility power is found on industrial

sites and many business properties.sites and many business properties.

• Residential locations

Whereas, single-phase utility power is Whereas, single-phase utility power is

found at:found at:

• Most farms

• Many businesses

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Tell Me More About ItTell Me More About It

3-phase power waveform

Almost all motors 5 HP and above are 3-phase only.

1-phase power waveform

3-phase motors have 3 windings, always in use.

1-phase motors have 2 windings, a run and a start winding.

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1-1-phasephase

Larger and heavier

Have capacitors

Have internal switching

Draw much higher current than 3-phase motors

Prone to problems

Shorter life

Smaller and lighter

No capacitors

No internal switching

Draw much LESS current than 1-phase motors

Very reliable

Extremely long life

1-phase Motors1-phase Motors 3-phase Motors3-phase Motors

versuversuss

3-phase 3-phase MotorsMotors

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Advantages of Using a Phase Advantages of Using a Phase ConverterConverter

No changing motors or switch gear

Simple and economical

Easy to install and use

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.

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.

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HOW WE STARTEDHOW WE STARTED

Phase-A-Matic, Inc. began in Phase-A-Matic, Inc. began in

1965 when Colin Johnstone 1965 when Colin Johnstone

needed to run a 3-phase lathe needed to run a 3-phase lathe

at his home shop. He made at his home shop. He made

an early model of the first an early model of the first

Static Converter, which ran his Static Converter, which ran his

lathe quite well. lathe quite well.

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HOW WE STARTEDHOW WE STARTED

A friend was impressed by A friend was impressed by

the ability to run 3-phase on the ability to run 3-phase on

single-phase, and wanted a single-phase, and wanted a

converter for his machine, converter for his machine,

too. It was apparent the too. It was apparent the

device was useful, and would device was useful, and would

sell.sell.

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Soon, Colin was driving to Soon, Colin was driving to

industrial sites, selling and wiring industrial sites, selling and wiring

in his new invention. In those in his new invention. In those

days, the converter was not yet days, the converter was not yet

a turnkey device, and needed to a turnkey device, and needed to

be installed internally to the be installed internally to the

machinemachine’s circuit. circuit.

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But he quickly found a way to But he quickly found a way to

overcome the obstacles, and overcome the obstacles, and

was able to sell a converter was able to sell a converter

that only needed external that only needed external

installation, making it attractive installation, making it attractive

to the consumer, and to the consumer, and muchmuch

easier on Colin. easier on Colin.

He obtained a patent on this designHe obtained a patent on this design

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This improved design This improved design

is well proven over 40 is well proven over 40

years with approx. years with approx.

200,000 sold. A few 200,000 sold. A few

short years ago he short years ago he

was able to buy back was able to buy back

the first one of these the first one of these

converters, still in converters, still in

perfect working perfect working

condition.condition.

First Converter Sold

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Today, this is what the Today, this is what the Static Converter looks like.Static Converter looks like.

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Current Product Line:Current Product Line:

Static Converter

Voltage Stabilizer

Rotary Converter

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For those who handle only the For those who handle only the Static ConverterStatic Converter, we are going to , we are going to

learn more about it. But first, a brief feature description of each learn more about it. But first, a brief feature description of each

style of converter is in order to acquaint you with the main style of converter is in order to acquaint you with the main

differences between them. You will most likely get requests for differences between them. You will most likely get requests for

them.them.

We’ll start with the main comparisons of the Static and Rotary We’ll start with the main comparisons of the Static and Rotary

Converters.Converters.

As we just saw, the As we just saw, the

three main products three main products

currently manufactured currently manufactured

by by PHASE-A-MATICPHASE-A-MATICTMTM are: are:

Static Converter

Voltage

Stabilizer

Rotary

Converter

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Motor, resistive & Motor, resistive & transformer loads - virtually transformer loads - virtually any 3-phase load.any 3-phase load.

STATICSTATIC

CONVERTCONVERT

ERER

ROTARY ROTARY CONVERTECONVERTE

RR

LOAD LOAD TYPESTYPES

- - Runs heavily loaded Runs heavily loaded

equipmentequipment

-- Runs CNC equipment with Runs CNC equipment with

the addition of the the addition of the PHASE-A-PHASE-A-

MATICMATICTMTM Voltage Stabilizer Voltage Stabilizer

Motor loads onlyMotor loads only

OUTPUTOUTPUT FULL rated HP and FULL rated HP and outputoutput

- - Runs light to moderate Runs light to moderate loads onlyloads only

EQUIPMENEQUIPMENT TYPET TYPE

2/3 rated HP 2/3 rated HP outputoutput**

*Runs delta-wound motors *Runs delta-wound motors at 50% rated HP outputat 50% rated HP output

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we’ll learn about the

Static Converter

First,

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STATIC CONVERTERSTATIC CONVERTERWHAT IT DOESWHAT IT DOES

A 3-phase motor has 3 identical

windings equally spaced. Any 3-

phase wye-wound motor, once it

is started, will run on single-

phase 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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Continued…

Based on this principle,

the Static Converter

supplies the 3rd leg (B)

for start-up purposes

only.

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.

Connection terminals are labeled A, B, C

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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 delta-

wound motors).

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But, doesn’t that “single-phase” the motor?

Not as some might believe.

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STATIC CONVERTERSTATIC 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 CONVERTERSTATIC CONVERTERUsing a Static Converter onlyUsing 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 CONVERTERSTATIC CONVERTERAbout Delta-wound MotorsAbout 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 delta-

wound motors.

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STATIC CONVERTERSTATIC CONVERTERWYE AND DELTA MOTOR WINDINGS ON THEWYE AND DELTA MOTOR WINDINGS ON THE


The wye-wound motor has 220VAC single-phase

connected directly to 2 of the windings (A & C).

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

DELTA WINDING

A delta-wound motor has 220VAC single-phase

across one of the windings only (A & C). The

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.

220VAC

Single-phase

2/3 output

220VAC

Single-phase

50% output

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STATIC CONVERTERSTATIC CONVERTERUsesUses

STATIC CONVERTER:

of using theThere are 2 methods

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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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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.

Method 1: Direct connection for 2/3 rated HP of motor

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Method 1:

What kind of machines will it run?

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STATIC CONVERTERSTATIC CONVERTERMethod 1 UsesMethod 1 Uses

- Mills - Saws

- Lathes - Meat saws

- Punches - Planers

- Shears - Jointers

- Routers - Food

mixers

- Presses - Hoists

- Metal grinders

Continued…

Lathe

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And numerous other uses!

- Metalworking

equipment

- Woodworking

equipment

- Food processing

equipment

- Garbage disposals

- Meat grinders

- Sewing machines

- Wheel balancers

Grinder Milling Machine

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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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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

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STATIC CONVERTERSTATIC CONVERTERCompatibilityCompatibility

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 CONVERTERSTATIC CONVERTERCompatibilityCompatibility

CAUTION:

Do not oversize

Consult databank / call Phase-A-Matic, Inc. technical support.

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.

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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.

Drill Press

If necessary, call PHASE-A-MATIC™ for

help.

Bandsaw

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Using Static Converter Method 1 will NOT run:

Pressure Washer

- Battery Chargers - Plasma Cutters

- EDM Machines - Rectifiers

- Heating Elements - Rheostats

- Most CNC Equip. - Lasers

- Transmitters - Radar

- Welders - Pumps

- Variable Frequency Drives (VFD)

Continued…

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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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I’ve seen the Static Converter

running air compressors using

Method 1. Air compressors run

heavily loaded.

How can it do that?

QuestionQuestion

Air Compressor

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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.

AnswerAnswer

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STATIC CONVERTERSTATIC CONVERTERAnswerAnswer

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 CONVERTERSTATIC CONVERTERAnswerAnswer

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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Continued….1

The Static Converter is used to

start an “idler motor,” and the idler

motor both starts and runs the

machinery.

Method 2: Produce full or close to full horsepower

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Using this method you can:

2

Run multiple machines

Run heavily loaded

machines

Complete workshops can

be run using this method

Continued….

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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.


3Continued….

The idler motor is sometimes referred to as a pony motor.

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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. 4Continued….

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Method 2: Choosing an idler motor

A good quality 3450 RPM wye-wound, 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.

5Continued….

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Method 2: Sizing the Static Converter

The Static Converter must always be sized to the HP of the idler motor.

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Never size to the load motor(s).

Refer to Phase-A-Matic™

literature for further

information.

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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 MOTORIDLER MOTOR

Question:

Idler Motor System Rotary Converter

How does the idler motor system compare to the Rotary Converter?

ROTARY CONVERTERROTARY CONVERTERVERSUSVERSUS 52


IDLER MOTORIDLER MOTOR

Answer:

Idler Motor System Rotary Converter

ROTARY CONVERTERROTARY CONVERTERVERSUSVERSUS

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

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 CONVERTERROTARY CONVERTERWHAT IT DOESWHAT IT DOES

The Rotary Converter generates:

• True 3-phase 230VAC 60Hz power

For 460V or other voltages, contact factory.

• Full rated HP or output of the machine(s) when properly applied

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ROTARY CONVERTERROTARY CONVERTERWHAT IT DOESWHAT 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 CONVERTERROTARY CONVERTERHOW IT’S MADEHOW 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 CONVERTERROTARY CONVERTERHOW IT’S MADEHOW 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 CONVERTERROTARY CONVERTERLONG LIFE AND DEPENDABILITYLONG 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 CONVERTERROTARY CONVERTERMTBF MTBF (Mean Time Between Failures)(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 CONVERTERROTARY CONVERTERMTBF MTBF // LIFE EXPECTANCYLIFE 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 CONVERTERROTARY CONVERTERUSESUSES

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 voltage-

sensitive….

Continued…

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CNC PACCNC PACRotary Converter / Voltage StabilizerRotary Converter / Voltage Stabilizer

To run CNC/PLC* and other

voltage-sensitive equipment:

*CNC = Computer Numerical Control

PLC = Programmable Logic Control

The converter must be used

in conjunction with the

Voltage Stabilizer.

Continued…

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CNC PACCNC PACRotary Converter / Voltage StabilizerRotary Converter / Voltage Stabilizer

CNC PAC™

CNC = Computer Numerical Control

PLC = Programmable Logic Control

For example:

The CNC PAC-10 consists of:

R-10 Rotary Converter & VS-10 Voltage Stabilizer

The Rotary Converter and Voltage Stabilizer combination

of matched HP rating is known and sold as the

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VOLTAGE STABILIZERVOLTAGE STABILIZERWHAT IT DOESWHAT IT DOES

Continued…

Designed to reduce phase imbalance on

Rotary Phase Converter Systems

The Voltage Stabilizer provides

+/- 5% voltage stabilization under

most normal conditions.

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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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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.

Continued…

For other voltages, contact factory.

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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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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…

Running Small Motors On The Rotary Converter:

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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.PHASE-A-MATIC, INC.

CONCLUSIONCONCLUSION

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.


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PHASE-A-MATIC, INC.PHASE-A-MATIC, INC.

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.

CONCLUSIONCONCLUSION


PHASE CONVERTERS!

TM

Customers our


This concludes the presentation.

We’ll be pleased to answer

any questions you may have!


From the California desert:

Phase-A-Matic, Inc.39360 3rd St. E. Ste. 301Palmdale, Ca. 93550661-947-8485800-962-6976www.phase-a-matic.com

Phase-A-Matic Team:

Colin Johnstone, Owner

Donna Johnstone

Mike Jones, General Manager


Documents

Www.phase-a-matic.com 1 Phase-A-Matic, Inc. © 2005-2008