UNIT 13 PHASE CONVERTERS OBJECTIVES After studying this unit, the student will be able to • describe the purpose of a phase converter. • give at least one major limitation of a phase converter. • discuss several conditions where it is advisable to install a phase converter. • name the two major types of phase converters. • select a phase converter and motor to power a load. • wire a phase converter circuit. Phase converters are used on farms to operate 3phase electric motors from a single-phase electrical suppi y, Figure 13-1. Three-phase electric motors, particularly in larger sizes, are generally less expensive and more maintenance free than single-phase motors of the same horsepower rating. Besides, large-horsepower, single-phase electric motors are not readily available. A farmer installing a grain dryer requiring a 20-hp motor probably will have to install a 3-phase motor. Ideally, this farm should be· supplied with 3-phase power, but the electric utility primary lines at the farm may only be able to supply single-phase power. Three-phase can usually be provided, if the farmer is willing to share the cost of extending the additional primary wire. If this cost is too great, a phase converter may be an acceptable alternative. 262 Unit 13 Phase Converters PHASE CONVERTER LIMITATIONS Phase converters are not the solution to all farm electrical power problems. Some types of loads are difficult to power with a 3-phase motor operating from a phase converter. These are loads which require high starting torque, such as silo unloaders, and gutter cleaners. The phase converter limits the starting current draw of the motor. When starting current is limited, motor starting torque is greatly reduced. However, many phase converter applications can be used for easy-starting fann loads, such as fans or pumps. A grain dryer is a typical example. Some equipment can be started empty, with the load applied after the motor has obtained full operating speed. Another limitation to the use of phase converters is t • A single-phase motor is available, but it has such a high starting current that the electric utility will not permit its operation because it causes objectionable primary line voltage drop. This voltage drop causes the lights to flicker at neighboring farms and residences every time the motor starts. A 3-phase motor operated from a phase converter draws less current, so that line flicker may not be a problem. • A single-phase electric motor for the job is not available, and a 3-phase motor is the only alternative. • Temporary 3-phase service is required until permanent, utility-supplied 3-phase service is available. • New equipment is provided with a 3-phase motor as an integral part of the unit, and replacement with a singlephase motor is either too difficult or more costly than a phase converter installation. • Several motors are required, and the cost of 3-phase motors plus a phase converter is less than it is for single-phase motors. Single-phase power 2 wires Phase converter disconnect I= =:1 = 3-phase motor starter Figure 13-1 A phase converter provides a means of powering a 3-phase motor from a single-phase electrical supply. that voltages between phase wires to the 3-phase electric motor are generally not exactly balanced. Voltage unbalance generally results in slightly unbalanced currents within the different motor windings. Slight unbalances need not be of concern if properly sized motor running overcurrent is provided. TYPES OF PHASE CONVERTERS Two types of phase converters are available: static, and rotary. Each type offers advantages for specific appiications. Static Phase Converter WHEN TO CHOOSE A PHASE CONVERTER The static phase converter, Figure 13-2, has no moving parts. It consists of a cabinet containing capacitors and, sometimes, an autotransformer. Static phase converters are selected for a specific size of 3-phase motor. It is possible to operate more than one motor from a single static phase converter, but extra capacitors are required, as well as careful balancing of the line currents. More than one motor for a static phase converter should not be installed unless recommended by the phase converter manufacturer. A simple static phase converter uses a bank of capac- There are various reasons for choosing to install a phase converter. • The cost of primary line extension to provide 3-phase power to the farm is much higher than it is for a phase converter installation. • The 3-phase electrical energy utility rate, plus the cost of rebuilding the farm electrical service, is enough higher than it is for single phase that the phase converter is the less costly solution. Single-phase /disconnect Ll I I L2 L3 l Capacitors 3-phase motor Figure 13-2 A simple static phase converter uses a bank of capacitors to develop the third phase. Unit 13 Phase Converters 263 itors to supply one of the 3-phase motor lead wires (a bank of capacitors consists of several capacitors connected in parallel). The other two motor lead wires are supplied directly from the single-phase line. Excessive line current to the motor can occur with this type of phase converter. To minimize the risk of damage to the motor due to excessive current in one or more motor windings, two precautions are recommended. • Provide properly sized fuses or thermal overload relays in each of the three wires to prevent motor damage due to excessive winding current. • Load the motor to only 75% of its nameplate horsepower rating. The proper-horsepower 3-phase motor, operated from a capacitor-type static phase converter, can be determined using Equation 13.1. First, the horsepower rating of the farm equipment must be determined. Static phase converter Eq. 13.1 motor horsepower Equipment horsepower required 0.75 Problem 13=1 A large poultry house ventilation fan requires a 7 1J2 hp electric motor. A 3-phase motor will be operated from single-phase power, using a capacitor-type phase converter. Determine the minimum recommended hors power rating for the 3-phase motor for this applicatio Solution A motor operated from a capacitor-type static pha converter should be loaded to not more than 75% of i horsepower rating. Use Equation 13.1 to size the mote Static phase converter motor horsepower 7.5 hp --= 10hp 0.75 A 10-hp, 3-phase electrical motor should be selected power this load. The second type of static phase converter uses : autotransformer in addition to capacitors. The main a vantage of this type is that the amount of capacitance m the autotransformer voltage can be adjusted to balan motor line currents so the motor can develop its ft horsepower rating. As an example, a 10-hp submersib pump may be operated at full nameplate rating, providt proper balancing procedures are followed. Significa variation in motor load will require rebalancing. Tl manufacturer should provide adjustment instructions. clamp-on type ammeter is required to make this adjm ment. An autotransformer-type static phase converter shown in Figure 13-3. Three-phase motors operated from static phase co1 verters generally have reduced starting torque. The stat ing torque can be improved by adding extra capacito while the motor is starting. Once the motor reaches ft Disconnect 3-phase motor Phase converter Figure 13-3 264 Unit 73 An autotransformer-type static phase converter with starting capacitors Phase Converters l. ts r. J :o m i- td ;e 11 le d at 1e A t- is 1- t- s 11 operating speed, these capacitors are disconnected. Manufacturers provide some starting capacitors and the control circuit as an integral part of the phase converter. However, with extra starting capacitors, a 3-phase motor can develop about as much starting torque as it would if operating from a utility-supplied 3-phase supply. Two types of capacitors are used in phase converters: oil filled, and electrolytic. The oil-filled capacitors remain in the circuit continuously. They are large and can dissipate the heat produced by the alternating current flowing in the circuit. Electrolytic capacitors can only be energized for a short time, or they will become overheated and fail. This type provides a large amount of capacitance in a small size and, therefore, it is used as a starting capacitor. The electrolytic type must not be energized continuously. Static phase converters should be limited to applications where the load power requirement is fairly constant. Rotary Phase Converter The rotary phase converter consists of a rotating unit and a bank of oil-filled capacitors, Figure 13-4. The rotating unit is usually a 3-phase motor without an external shaft. The single-phase lines are connected to two leads of the rotating unit, as shown in Figure 13-5. The capacitors are connected between one of the single-phase leads and the third lead. The rotating unit acts as a generator and, with the aid of the capacitors, produces a third phase in the third lead. The 3-phase converter leads can then be connected by a 3-phase motor through a motor starter. Figure 13-4 Rotary phase converter (Courtesy of Ronk Electrical Industries) An advantage of the rotary phase converter is that more than one 3-phase motors can be operated from a single phase converter. The motors can also drive loads which have a fluctuating power requirement. This is the major advantage of rotary converters over the static type. The size of the rotary phase converter is determined by the horsepower rating of the largest motor to be started and the total of all motors to be operated. For example, assume that a farm materials handling system requires a single 10-hp motor and two 5-hp motors. This load can be supplied with a single rotary phase converter· with a single motor rating of 10 hp. This phase converter must also have a total connected load rating of at least 20 hp. When starting the motors, the largest is started first, and then each of the others individually. Manufacturers may rate their phase converters in kilovolt-amperes (kVA) rather than in horsepower. Single-phase line 11 - Disconnect Fuses 3-phase wires Windings Capacitor bank Rotating unit Figure 13-5 A rotary phase converter consists of a rotating unit and a bank of capacitors. Unit 13 Phase Converters 265 Phase converter capacitors 3-phase motors Figure 13-6 Extra oil-filled capacitors may be required at each motor when a single rotary phase converter supplies severa 3-phase motors. The phase converter must first be turned on with the rotating unit reaching full speed before any motor is turned on. Then, each motor is started individually. Another motor is not turned on until the previous motor has reached full operating speed. Typically, a rotary phase converter can supply two times its individual motor rating. Extra oil-filled capacitors are usually required when several motors are operated from a single rotary phase converter, Figure 13-6. The manufacturer provides instructions for multi-motor installations. Three-phase motors operated from a rotary phase converter develop only about half as much starting torque as when operated directly from a utility-supplied 3-phase supply. However, starting torque can be improved by adding a starting capacitor unit to any motor requiring additional torque. These units generally consist of electrolytic capacitors which are disconnected automatically when the motor achieves full operating speed. Starting torque can also be improved by installing an oversized phase converter. A 5-hp motor will develop higher starting torque when operated from a 1 0-hp phase converter than from a 5-hp phase converter. The rotary phase converter has a minimum horsepower rating for a single motor installation. Generally, the smallest motor which can be operated alone is onefourth the horsepower rating of the rotary phase converter. The manufacturer should be consulted if smaller motors are to be operated alone from a rotary phase converter. 266 Unit 73 Phase Converters Problem 13-2 A grain dryer has a fan requiring a 25-hp, 3-phasl electric motor. The grain dryer has three additional mo tors rated at 5 hp, 3 hp, and I hp. Determine the mini mum size rotary phase converter required to supply al four motors. Solution The minimum size rotary phase converter is deter mined by the size of the largest motor which, in thi case, is 25 hp. The individual motor horsepowers mm be added together to make sure that they do not excee two times the phase converter rating, which is 50 hr 25 + 5 + 3 + 1 = 34 hp The manufacturer must be consulted to determine if extr capacitors are required for the additional motors. 480-volt Phase Converters The phase converters discussed thus far connect to 240-V, single-phase system and produce power suitabl for operation of 240-V, 3-phase motors. Phase conver ers are available which produce power suitable to opera1 480-V, 3-phase motors from a 240-V, single-phase SUI ply. Some require a transformer to step up the volta from 240 V to 480 V. PHASE CONVERTER WIRING Information pertaining directly to the wiring of phase converters is not contained in the National Electrical Code. All of the previous diagrams in this unit show the minimum necessary components of a phase converter installation: • A single-phase disconnect must be installed which will disconnect power from the entire installation. • The phase converter. • If more than one motor is supplied by the phase converter, a separate disconnect and overcurrent protection is required for each motor. • A controller for each motor. The wiring of a phase converter installation requires good judgment. NEC Article 430 provides most of the information necessary for a safe and efficient installation. The requirements of NEC article 460 must be met because capacitors are used in the phase converters. NEC Article 450 requirements must be met if a transformer is included as a part of the phase converter. tl Sizing the Wires e Two sets of wires must be sized in a 1-motor phase converter installation: 1) the 3-phase wires to the motor, and 2) the single-phase wires supplying the phase converter. The first step in the procedure involves the determination of the motor full-load current. This is found in NEC Table 430-150. For example, the full-load current of a 10-hp, 230-V, 3-phase motor is 28 A. The full-load current of the motor must be multiplied by 1.25 (125%) to determine the minimum ampere rating of the motor circuit wire, NEC Section 430-22(a). See Equation 13.2 ll ·s ;t d ,, the single-phase wires? To get a clue to the answer, look up the full-load current of a 10-hp, 230-V, single-phase motor in NEC Table 430-148. The single-phase, 10-hp motor would draw 50 A; nearly twice as much as the 3-phase, 10-hp motor. If the wire size were based upon the single-phase motor full-load current, then the minimum· single-phase wire rating would be 62 A. 50 1.25 = 62 A X The same result would be obtained by multiplying the 10-hp, 3-phase, 230-V motor full-load current by 2.2 (220%). The single-phase input wires to the phase converter supplying one motor are determined by Equation 13.3. Minimum ampere rating of phase Eq. 13.3 converter input wires, one motor = 2.2 X motor full-load current Problem 13-3 A phase converter supplies a 25-hp, 230-V, 3-phase motor. The circuit wires are copper with THWN insulation. Determine the minimum size of 1) the 3-phase wire from the phase converter to the motor, and 2) the singlephase input wire to the phase converter. Solution The full-load current of the motor from NEC Table 430-150 is 68 A. Determine the minimum ampere rating of the motor circuit wire from Equation 13.2. 1.25 J Minimum ampere rating of motor circuit wire = 1.25 X motor full-load current For the 10-hp motor in the example, the minimum rating of the wire is 35 A. Minimum ampere rating of motor circuit wire = 1.25 X 28 = 35 A t- te )- e 68 = 85 A The minimum size copper THWN wire from NEC Table 310-16 is No. 4 AWG, which is rated at 85 A. Determine the minimum ampere rating of the phase converter input wires from Equation 13.3 2.2 a le X Eq. 13.2 Using copper wire with TW insulation, look up the minimum wire size inNEC Table 310-16. The minimum wire size is AWG No. 8, which is rated at 40 A. The question now is, how much current will flow on X 68 = 150 A The minimum size copper THWN wire from NEC Table 310-16 is No. 0 AWG. A phase converter that supplies more than one motor is only slightly more involved than the case of a single motor. Consider an installation similar to that shown in Figure 13-6. The wires are shown in schematic form in Unit 73 Phase Converters 267 10 hp, 230 V, 28 A 5 hp, 230 V, 15.2 A 3 hp, 230 V, 9.6 A (4) Single-phase input wires (2) 3-phase feeder wires to group of motors The minimum feeder current rating is determined by using Equation 13.4 Minimum motor feeder ampere rating = (1.25 X 28) + 15.2 + 9.6 = 35 + 15.2 + 9.6 = 59.8 or 60 A (3) Wires to rotating unit 10 hp 10 hp 5 hp 3 hp Figure 13-7 Several different sizes of wire may be required for a phase converter installation involving several motors. Figure 13-7. The wires to the individual motors, as shown by (1) in Figure 13-7, are determined by using Equation 13.2, as discussed previously. The minimum ampere rating of a feeder wire, as shown by (2) in Figure 13-7, supplying two or more motors is required to be the full-load currents of the motors added together, plus one-fourth of the largest motor full-load current, NEC Section 430-24. Equation 13.4 is stated in a slightly different form. Minimum motor feeder ampere rating Eq. 13.4 = 1.25 X Full-load current of largest motor + Full-load current of all other motors If there are two or more motors of the largest horsepower, then multiply the current of only one of them by 1.25. Problem 13-4 The 230-V, 3-phase motors of Figure 13-7 are rated 10 hp, 5 hp, and 3 hp. Determine the minimum size copper THWN three-phase feeder conductor. Solution . The full-load current of each motor from NEC Table 430-150 is: 268 Unit 13 Phase Converters The minimum size motor THWN copper feeder wire from NEC Table 310-16 is No. 6 AWG. The wire from the phase converter capacitor panel to the rotating unit, as shown by (3) in Figure 13-7, will not carry more current than the motor feeder. Therefore, the minimum size for this wire is the same as it is for the motor feeder wire. The single-phase input wire to a phase converter supplying a group of motors carries almost twice the current as the 3-phase feeder supplying the motors. The singlephase input wire is sized at 2.0 (200%) times the sum of the full-load currents of all the motors, Equation 13.5 · Phase converter input wire ampere Eq. 13.5 rating for group of motors = 2 X Full-load current of all motors I Problem 13-5 Determine the minimum size copper THWN singlephase input wire size for the installation described in Problem 13-4. Solution Add the full-load currents of all motors and multiply by two, as in equation 13.5 Phase converter input wire ampere rating for group of motors = 2 X (28 + 15.2 + 9.6) = 2 X 52.8 = 105.6 or 106 A The minimum size phase converter THWN copper inpu wire from NEC Table 310-16 is No. 2 AWG, which i rated at 115 A . Most phase converter installations involve 230-\ 3-phase motors. Thus, the previous calculations .apply t< the sizing of the circuit wires. The procedure varies only slightly when 460-V, 3-phase motors are supplied from a 230-V, single-phase electrical supply. • For 460- V motors, find the motor full-load current in the 460-V column of NEC Table 430-150. • Use Equations 13.6 through 13.9 for determining the following. Single 460 V motor supplied by phase converter from a 230 V supply: Eq. 13.6 Minimum ampere rating of motor circuit wires = 1.25 x Motor full-load current gle-phase fusible safety switch or a suitable circuit breaker. This disconnect switch must be rated in horsepower, NEC Section 430-109. A circuit breaker rated in amperes is acceptable, but is less desirable as a disconnect. The disconnect switch must have a single-phase horsepower rating not smaller than the sum of the horsepower ratings of the motors to be supplied, NEC Section 430-112. Problem 13-6 Determine the horsepower rating required for the phase converter disconnect supplying motors with ratings of 25, 5, 3, and 1 horsepower. Solution Minimum ampere rating of phase Eq. 13.7 converter input wires, one motor = 4.4 X Motor full-load current Two or more 460 V motors supplied by one phase converter from a 230 V supply: Individual motor circuit wires; use Equation 13.6 Minimum motor feeder ampere rating Eq. 13.8 = 1.25 X Full-load current of largest motor + Full-load current of all other motors Phase converter input wire ampere . Eq. 13.9 rating for group of motors = 4 X Full-load current of all motors PHASE CONVERTER DISCONNECT l 1 A means must be provided to disconnect all ungrounded single-phase input wires for the phase converter, NEC.Section 460-B(c). This disconnect can serve as the motor circuit disconnect provided only one motor is supplied by the phase converter. This disconnect must also be within 50 ft (15.24 m) and within sight from the motor controller, NEC Section 430-102. Individual motor circuit disconnects are required when one phase converter supplies several motors, NEC Section 430112. These individual motor circuit disconnects are in addition to the phase converter main single-phase disconnect (as shown in Figure 13-6). The main phase converter disconnect should be a sin- Disconnect switch rating = 25 + 5 + 3 + 1 = 34 hp Choose a disconnect switch which has a single-phase horsepower rating not smaller than 34 hp. Single-phase horsepower is used because the switch is installed in the single-phase input wire. Single-phase and 3-phase horsepower ratings are not the same. A 3-phase disconnect switch with a 10-hp rating cannot be used as the disconnect for a 10-hp, singlephase motor. The single-phase motor draws 1.73 times as much current as the 3-phase motor. Therefore, a single-phase, 10-hp disconnect switch must have a higher current rating than a 10-hp, 3-phase disconnect switch. Table 13-1 gives approximate equivalent single- and 3Table 13-1 Approximate equivalent 3-phase and singlephase horsepower ratings for 240-V safety switches Horsepower Three phase Single phase 3 7 1/2 10 15 20 30 40 50 60 75 100 125 150 200 1 112 3 5 7 1/2 10 15 20 30 35 40 60 70 85 115 Unit 73 Phase Converters 269 phase horsepower ratings. For example, a disconnect switch rated at 100 hp, three phase can usually be used as the disconnect for a 60-hp, single-phase motor load. OVERCURRENT PROTECTION Overcurrent protection must be provided for each ungrounded single-phase input wire to the phase converter. Time-delay fuses are usually installed in the phase converter disconnect switch. The time-delay fuse size is determined by the same procedure used to size the single-phase input wires, Equation 13.3, 13.5, 13.7, or 13.9. The next standard fuse size larger than the value determined by one of the input wire ampere rating equations may be chosen to protect the input wires. In Problem 13-5, the proper size time-delay fuse for the No. 2 AWG copper single-phase input wires is 110 A. Overcurrent protection for individual motor circuit wires is determined by the procedures required in NEC Article 430, as discussed in Unit 17. MOTOR CONTROLLERS The controller for a motor supplied by a phase converter is permitted to be any appropriate type described in NEC Article 430. Some types of motor controllers do not provide adequate overload protection for the motor. It is extremely important in a phase converter installation that some type of overload protection sensing motor current be provided. Three types of motor controllers that provide this protection are: • Magnetic motor starter with properly sized thermal overload relays • Manual motor starter with properly sized thermal overload relays • Safety switch with horsepower rating equal to or greater than motor horsepower, and time-delay fuses sized not greater than 1 .15 (115%) times the motor full-load current A rotary phase converter must always be turned on and reach full operating speed before any motor supplied is turned on. Should there be a temporary power interruption, it is important that the motors be turned off, or the phase converter may become damaged when power is restored. A manually operated controller will not turn the motors off during a temporary power outage. When power is restored, the motors will try to start. Magnetic motor starters must always be used to control motors supplied by a rotary phase converter. Also, do not use 270 Unit 73 Phase Converters 2-wire control, because this will cause immediate restarting of the motor. Time-delay relays may be used with 2-wire control to prevent immediate restarting of the motor. When power is lost, the magnetic motor starters will shut off the motors so they cannot restart when power is restored. The motors must be restarted manually; or an automatic restart control can be added to start each motor, in sequence, once the rotary phase converter has been restarted. INSTALLING EXTRA CAPACITORS Extra capacitors are often required when two or more motors are operated from one rotary phase converter. These capacitors are most easily installed at the magnetic motor starter. A disconnect is required for the capacitor bank unless the capacitors are on the load side of the motor running overcurrent protective device, NEC Section 460-8(b )( 1 ), Exception. The capacitors may change the amount of current drawn by the motors. The amount of current from the supply up to the capacitors will be affected, but not the current flow from the capacitors to the motor. The capacitors are to be connected to the load side of the thermal overload heaters (Figure 13-8). Therefore, the current A B C B Gdc5ers Rotary unit contacts Thermal sensing heaters capacitors figure 13-8 Extra capacitors, if required, should be connected on the load side of the thermal sensing heaters in the motor starter. flow through the thermal overload heaters may be affected. The overload heaters' sensing current setting may need to be adjusted if the addition of these capacitors significantly changes one or more of the motor line current values, NEC Section 460-9, Exception. GROUNDING A grounding path must be provided for all exposed metal parts of the phase converter installation, including phase converter, capacitors, disconnects, motor controllers, and motors. Procedures for grounding are covered in NEC Section 250, as discussed in detail in Unit 10. REVIEW Refer to the National Electrical Code when necessary to complete the following review material. Write your answers on a separate sheet of paper. 1. Is the purpose of a phase converter to provide a means of operating a 3-phase electrical motor from a single-phase electrical supply? 2. Name the two types of phase converters. 3. Capacitors are used in phase converters. Which type of capacitor can carry alternating current continuously? 4. Is it true that a 3-phase electric motor supplied by a phase converter generally does not develop as much starting torque as it would if operated from utility-supplied 3-phase power? 5. Which of the following is the major reason for choosing a phase converter rather than utility-supplied 3-phase power? a. Its overall cost is lower. b. The power supplier does not produce 3-phase power. c. A single-phase motor of the required size is not available. d. The farm is not wired for 3-phase power. 6. A grain dryer fan requires a 15-hp electric motor. Determine the minimum size 3-phase electric motor and capacitor-type static phase converter required to power this load. 7. Identify the static phase converter which, through proper adjustment of the number of capacitors, allows a motor to develop full nameplate horsepower. 8. If a farmer wants to operate several motors from one phase converter, then which type of phase converter should be chosen? 9. A phase converter is used to supply, 7 IJ2-, 3-, and 2-horsepower, 3-phase, 230-V electric motors. Determine the minimum size copper THW single-phase input wires. 10. A farmer can buy a used 30-hp rotary phase converter from a neighbor. If the phase converter is in good operating condition, should this phase converter be used to supply a 5-hp, 3-phase motor? 11. Would a I0-hp rotary phase converter be adequate to supply the motors in Problem No. 9 of this review? 12. Which of the following types of controllers should be used for a motor supplied by a rotary phase converter? a. Circuit breaker Unit 73 Phase Converters 27 7 b. Fusible switch c. Manual motor starter d. Magnetic motor starter 13. A 3-phase, 3-pole disconnect switch can be used on the input wires to a phase converter if a single-phase, 2-pole disconnect is not available. Determine the minimum 3-phase horsepower rating required for a 3-phase disconnect used on the input wires to a rotary phase converter supplying motors rated at 15, 10, 3, and 2 horsepower. 14. A phase converter supplies one 15-hp, 230-V, 3-phase electric motor. Determine the recommended size time-delay fuses used to protect the single-phase converter input wires. 15. Extra oil-filled capacitors are required for a phase converter supplying several motors. Refer to the diagram and indicate the most appropriate location (A, B, C, or D) to connect the capacitors to the motor circuit. From phase -------- --------- To other converter motors Motor disconnect Motor circuit fuses B Motor starter contacts Moto r current thermal sensing elements 3-phase motor 272 Unit 73 Phase Converters L C D