Common Applications for 3-Phase Converters

Agriculture

Kay Industries Agriculture Machinery Phase Converters and Farming EquipmentRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® PI Rotary Phase Converter


Kay Industries, Inc. has over 45 years of experience manufacturing phase converters for agricultural equipment. Phasemaster rotary three phase converters are successfully powering applications consisting of multiple large motors as found on grain drying fans and augers, pumps, and related equipment.

Phasemaster rotary three phase converters are widely used on and approved by some of the leading brands of agricultural equipment. Zimmerman, Mathews Company, Delux, Farm Fans, Super B, Kansun, & GSI are just a few of the leading brands that our units support.

 

Critical Selection and Application Criteria:

  • Dryer fans can be very large. Be sure to have adequate single-phase service. You must have at least 100 amps of single phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company.
  • Large fans usually consume the entire capacity of the converter leaving very little capacity for additional loads.

Outdoor installation in unprotected areas may require weatherproof enclosure.

Air Compressors

Kay Air CompressorsRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-A


Kay Industries is a true expert in the application of phase converters on air compressors. The Phasemaster® rotary phase converter can be used on all types of compressors: reciprocating, rotary screw, rotary sliding vane and centrifugal, as well as any other machine tools you utilize in your operation.

Many air compressor applications include a combination of machines, which often requires a phase converter to accommodate a wide range of load conditions. The Phasemaster rotary three-phase converter is ideally suited to these requirements and maintains a balanced output condition under both light and heavy load demands. As with other applications, the Kay Industries approach to phase converter sizing is very methodical, taking special care to match the proper three-phase converter to your load.

Many air compressor applications are unattended. That means they cycle on and off at various intervals according to the demands of the pressure switch. Phase converters for these types of unattended installations should be specified to include automatic controls so that the converter can be shut down when the compressor is not running.

The Phasemaster rotary phase converter has been tested, approved, applied on or recommended by some of the best known manufacturers of air compressors.

 

Known Operating Issues:

Air compressors can be among the most onerous loads to start, particularly if they are not equipped with unloading mechanisms to reduce allow the motor to start without pumping against the tank or head pressure of the compressor. An unloader is especially important if the compressor is called upon to keep up a rather high tank pressure (for example 100PSI or greater). In addition, it is imperative the utility supply voltage remain solidly within a few percent of its unloaded value. A “soft” utility supply where the supply voltage drops by 10% or more could cause the compressor motor to stall or trip an overload. Increasing the size of the converter by one rating above the motor size will usually fix the problem but is not an economical substitute for an unloader or a solid utility service.

 

Critical Selection and Application Criteria:

• Be sure to have adequate single-phase service. You must have at least 5amps of single-phase service for each 1HP of connected 3-phase load at 230 volts.

• Identify what machines will operate together. If the largest load is more than four times the HP of the smallest load, a voltage regulator should be installed in the converter.

Battery Chargers

Recommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-R


Power supplies, battery chargers and rectifiers are a very common application of the Phasemaster® rotary 3-phase converter. Kay Industries has extensive experience on a wide range of all types of power supplies. The Phasemaster rotary phase converter can supply true 3-phase power to chargers and power supplies as well as any and all the conventional tools found in a typical shop.
Kay Industry's approach to applying phase converters on this equipment is based on careful application and sizing. In our 40 years of experience manufacturing phase converters, we have amassed a tremendous amount of application and performance data on machinery from the biggest names in the welding industry.
MOST COMMON REQUIREMENT:

The single most common application of converters for battery chargers is for material handling equipment such as tow motors or fork lifts. The vast majority of these chargers call for a 30A, 208V, 3-phase circuit. The 7.5HP Phasemaster converter Model MA-1B accommodates this requirement quite well.

For other ratings, it is important to know the operating voltage and the actual power requirement of the charger.

Broadcast Transmitters

Kay Broadcast TransmittersRecommended Converter:

Phasemaster® Type T Rotary Phase Converter for Broadcasting


The Phasemaster® converter is usually the most cost effective alternative to utility three-phase when siting transmitters in remote areas. It enables station owners to locate transmitters in the most advantageous sites regardless of whether utility 3-phase is available. Over 1000 AM and FM radio, and television stations worldwide are operating successfully on Phasemaster converters.

A transmitter operating on a Phasemaster converter will produce its full rated output without distortion, harmonics, excess noise, or impact on your utility bill. Kay Industries maintains extensive compatibility, application and test data on most makes of broadcast transmitters and can recommend the proper unit for your application. Phasemaster converters are approved and recommended by broadcast engineering consultants and utility companies as well as all major transmitter manufacturers. Harris, Continental Electronics, Broadcast Electronics, Axcera, Thales, Nautei, Armstrong Transmitters, Acrodyne, and many more. To see if your transmitter has been approved, contact us today.

Performance features:

  • High efficiency design - patented construction minimizes noise and vibration and keeps losses to less than 5% of total system load
  • The output is regulated to keep AM noise to a minimum. Reduced outages from line noise
  • The converter's stored energy buffers the line and rides through short-term line disturbances

Critical Selection and Application Criteria:

  • Transmitter type, AM, FM or TV
  • Manufacturer's model number and KW power rating
  • Type and size of incoming utility service (amperage)
  • Transmitter input power consumption in KW at full load or 100% modulation
  • Other 3-phase loads associated with this application, AC, tower lighting, etc.

 

CNC Machine Centers

Kay CNC Machine CentersRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-R


CNC equipment is a very common application of the Phasemaster® rotary 3-phase converter. Kay Industries has extensive experience on a wide range of equipment from the simplest machines up through some of the most sophisticated CNC machinery. The Phasemaster rotary 3-phase converter can supply 3-phase power to a one-machine operation or to an entire shop.

Our customers include a variety of metalworking shops such as sheet metal, tool and die, precision machining, gear hobbing, welding, and stamping. The Phasemaster rotary phase converter can supply true 3-phase power to CNC lathes and mills, EDM machines (both traveling wire and sinker), air compressors, grinders, and any and all the conventional tools found in a typical shop.

Kay Industry's approach to applying phase converters on this equipment is based on careful application and sizing. In our 40 years of experience manufacturing phase converters, we have amassed a tremendous amount of application and performance data on machinery from the biggest names in the metalworking industry. To see a partial list of manufacturer's click here.

 

Critical Selection and Application Criteria:

Many CNC machines require a voltage regulator to keep the converter output voltage balanced over the entire load range. Supply complete details of machine electrical characteristics to factory for sizing. Oversize converters are often recommended for CNC machine tools.

Required sizing information:

The main spindle motor is the single-most important piece of information to size the converter. Always ask the manufacture to specify the main motor size in horsepower or Kilowatts. Do NOT accept an amperage value as the metric for sizing purposes.

Many offshore machines contain motors or controls components based on European or Asian voltage standards. It is vital to determine if the machine will tolerate North American voltages (240, 480, 600) or if a transformer is supplied with the machine to adapt to the foreign voltage standard.

Always verify if your site has adequate single-phase service for any equipment you plan to operate. Specifically you need at least 5amps of 240V single-phase per horsepower of simultaneously operating load equipment.

Compactors/Balers

Kay Compactors-BalersRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter


The Phasemaster® rotary phase converter can supply true 3-phase power to any single motor or combination of motors in all types of waste management equipment such as balers, compactors and shredders. Should these applications operate outdoor in unprotected settings, Phasemaster offers a family of designs to provide optimal performance regardless of equipment type or site conditions.

Phasemaster converters are operating equipment manufactured and installed by many of the best known names in the field.

 

Critical Selection and Application Criteria:

  • Be sure to have adequate single-phase service. You must have at least 100 amps of single phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company
  • Outdoor installation in unprotected areas may require weatherproof enclosure
  • An alternative for outdoor installations is the Type PI. It features a totally enclosed fan-cooled generator frame construction with a NEMA 3-R control and connection box. It can be installed outdoors without further weather protection.
Elevators

Recommended Converter:

Phasemaster® Type MA-A


This is a very common converter application. However, it requires extremely reliable input about the actual demand of the elevator motor. Most such elevators used in new construction in apartments, schools, churches, and for ADA retrofit applications are hydraulic. From the phase converter perspective this is simply a straightforward hydraulic pump application.

 

Kay Industries always recommends a rotary converter with automatic controls for elevators. This is because elevators by nature are subjected to many starts and stops and can run empty or fully loaded. A rotary converter is widely preferred over a static type because the rotary has far superior reliability over repeated start cycles and better performance over wide load variations.

 

 

The typical operating sequence for a converter operating an elevator is:

  1. The converter starts upon executing the elevator call button
  2. The converter starts in 2-5 seconds
  3. A time delay relay in the converter closes an output contact
  4. The output contact signals the elevator controller to start the motor
  5. Another timer keeps the converter running for an adjustable period of several minutes after the elevator shuts down. This feature allows for the fact that elevator operations have a tendency to cluster and thus eliminates the need to restart the converter for closely spaced operations.

Critical Selection and Application Criteria:

Some brands of elevator motors carry horsepower ratings that are not consistent with national electric code tables for their full load current. For example a 20 HP motor may be represented as drawing 65 amps at full load. This current rating is actually closer to 25 HP than 20 HP. It is strongly recommended that the converter be sized for the HP equivalent of the full load amps rather than the stated motor HP.

Some elevator controllers include soft starters. A converter by nature provides a soft-start to a motor. We recommend across-the-line starting for elevator motors running on converters.

Food Processing/Restaurant

Recommended Converter:

Phasemaster® Type MA Rotary Phase Converter


Food Processing and Restaurant Equipment applications can be easily handled by a phase converter. This application category includes: mixers, ovens, meat cutters, pasta makers, dishwashers, walk-in coolers, ice makers, ice cream machines, and any other equipment that requires 3-phase power.

Phase converters are able to operate any of these load types as effectively as any utility 3-phase line. Refer to Kay Industries for specific sizing and selection recommendations.

Critical Selection and Application Criteria:

• Be sure to have adequate single-phase service. You must have at least 100 amps of single phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company

HVAC

Kay HVACRecommended Converter:

Phasemaster® Type MA-A


HVAC and general refrigeration applications can be easily handled by a phase converter. This application category includes: air conditioners, heat pumps, chillers, freezers, walk-in coolers, ice makers, ice cream machines, and any other equipment that uses 3-phase hermetic refrigeration compressors.

Phase converters are able to operate any of these load types as effectively as any utility 3-phase line. The typical HVAC application uses an automatically controlled rotary phase converter, Type MA-A. The converter is switched on by the thermostat and runs only when the air conditioner is on. Soft ice cream machines may be operated on a manually operated converter because the beater motors generally remain on at all times even with the compressor off. Converters for rooftop A/C units may be mounted adjacent to A/C in an outdoor enclosure.

Refer to Kay Industries for specific sizing and selection recommendations.

Critical Selection and Application Criteria:

  •  Be sure to have adequate single-phase service. You must have at least 100 amps of single phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company
Ice Cream & Gelato Machines

Recommended Converter:

Phasemaster® Type MA-A


Ice Cream / Gelato Machines and general refrigeration applications can be easily handled by a phase converter. This application category includes: ice cream machines, freezers, walk-in coolers, ice makers, air conditioners, heat pumps, chillers, and any other equipment that uses 3-phase hermetic refrigeration compressors.

Phase converters are able to operate any of these load types as effectively as any utility 3-phase line. The typical soft ice cream / gelato machines may be operated on a manually operated converter because the beater motors generally remain on at all times even with the compressor off. Refer to Kay Industries for specific sizing and selection recommendations.

Critical Selection and Application Criteria:

  • Most batch freezers from Europe are actually designed for 220V utility systems. It will function on 240V systems but if the utility input voltage is even a little bit high you could encounter erratic performance. For that reason we STRONGLY recommend placing a small buck-boost transformer ahead of the converter to drop the supply voltage from 240 down to 215-225V.
  • Many batch freezers feature a 2-speed beater and compressor motor plus possibly a display case. If this is the case, we recommend our optional –VS controller. This provides a special regulating accessory to balance the output voltage to achieve compatibility with the controller of the batch freezer.
Irrigation

Recommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-A
Phasemaster® PI Rotary Phase Converter


Phasemaster rotary 3-phase converters are widely used in all types of pump applications. Among the most common are in pivot irrigation, duplex lift stations, submersible pumps, decorative fountains, municipal water systems, and virtually any other motor driven pumping equipment.

Many pump applications are unattended. That means they cycle on and off at various intervals according to the demands of the pump controller. The control may operate from a float or pressure switch, timer or some other pilot device. Phase converters for these types of unattended installations should be specified to include automatic controls so that the converter can be shut down when the pump is not running.

3-Phase Converters must be sized according to the largest pump motor to be started. Submersible motors require a larger phase converter than conventional induction motors of the same horsepower.

Kay Industries offers both open drip-proof and totally enclosed rotary 3-phase converter construction for pump applications.

Critical Selection and Application Criteria:

  • Be sure to have adequate single-phase service. You must have at least 100 amps of single-phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company.
  • Specify pump operating voltage. 460 V, 3-phase output requires a step-up transformer if input is 230V, 1-phase
Laundry And Dry Cleaning Equipment

Kay Laundry and Dry Cleaning EquipmentRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter


These applications are among the most common and easily handled by the Phasemaster® rotary converter. A single converter can supply 3-phase power to both laundry and dry cleaning equipment in the same facility. Unlike other converter brands, the Phasemaster rotary converter can operate both electric and steam heated dry cleaning machines without rewiring the heaters.

Kay Industries has extensive test, application and selection data on virtually every major equipment manufacturer. Milnda, Unimac, Wascomat, IPSO, Speed Queen, Washex, Realstar, Union, Artic Chill, just to name a few. Please contact us to see if your brand is supported.

Product features:

  • High efficiency design. Our patented construction minimizes noise and vibration which keeps losses to less than 5% of total system load.
  • Flexible operation. The Phasemaster converter is specially optimized to handle the wide range of electrical loads typical of dry cleaning machines that have small solvent pumps as well as large compressor motors.

Critical Selection and Application Criteria:

  • Be sure to have adequate single-phase service. You must have at least 100 amps of single phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company
  • Must specify if dry cleaning machines have refrigeration or electric heat

Washer extractors with variable speed drives may require special converter sizing

Medical

Kay MedicalRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter


The Phasemaster® Type MA rotary phase converter can supply 3-phase power to large resistor and rectifier loads typical of lasers, x-ray machines, and similar equipment with large rectifier power supplies.

The Phasemaster rotary phase converter can supply true 3-phase power to x-ray equipment, ophthalmic lasers, mammography machines, linear accelerators used in radiation therapy and MRI equipment. Our rotary phase converters are successfully supplying 3-phase power to leading equipment such as General Electric, Siemens, and many others.

These applications on sensitive and precision machines requires a converter that can maintain a balanced output over a wide load range.

Critical Selection and Application Criteria:

Must know the actual power consumption in KW at rated output

Metalworking Equipment

Kay Metalworking EquipmentRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-R


Metalworking equipment is a very common application of the Phasemaster® rotary 3-phase converter. Kay Industries has extensive experience on a wide range of equipment from the simplest machines up through some of the most sophisticated CNC machinery. The Phasemaster rotary 3-phase converter can supply 3-phase power to a one-machine operation or to an entire shop.

Our customers include a variety of metalworking shops such as sheet metal, tool and die, precision machining, gear hobbing, welding, and stamping. The Phasemaster rotary phase converter can supply true 3-phase power to CNC lathes and mills, EDM machines (both traveling wire and sinker), air compressors, grinders, and any and all the conventional tools found in a typical shop.

Kay Industry's approach to applying phase converters on this equipment is based on careful application and sizing. In our 40 years of experience manufacturing phase converters, we have amassed a tremendous amount of application and performance data on machinery from the biggest names in the metalworking industry:  Cincinnati, Okuma, Hitachi Seiki, Bridgeport, Emco, Hobart, Miller, Lincoln, and many more.

Critical Selection and Application Criteria:

Many CNC machines require a voltage regulator to keep the converter output voltage balanced over the entire load range. Supply complete details of machine electrical characteristics to factory for sizing. Oversize converters are often recommended for CNC machine tools.

Pumps And Lift Stations

Kay Pumps and Lift StationsRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-A
Phasemaster® PI Rotary Phase Converter


Phasemaster rotary 3-phase converters are widely used in all types of pump applications. Among the most common are in duplex lift stations, submersible pumps, decorative fountains, municipal water systems, pivot irrigation, and virtually any other motor driven pumping equipment.

Many pump applications are unattended. That means they cycle on and off at various intervals according to the demands of the pump controller. The control may operate from a float or pressure switch, timer or some other pilot device. Phase converters for these types of unattended installations should be specified to include automatic controls so that the converter can be shut down when the pump is not running.

3-Phase Converters must be sized according to the largest pump motor to be started. Submersible motors require a larger phase converter than conventional induction motors of the same horsepower.

Kay Industries offers both open drip-proof and totally enclosed rotary 3-phase converter construction for pump applications.

Critical Selection and Application Criteria:

• Be sure to have adequate single-phase service. You must have at least 100 amps of single-phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company.

• Specify pump operating voltage. 460 V, 3-phase output requires a step-up transformer if input is 230V, 1-phase

Outdoor installation in unprotected areas may require weatherproof enclosure

Refrigerated Containers & Shore Power

Kay Refrigerated Containers & Shore PowerRecommended Converter:

Phasemaster® Type MA-A


We have extensive experience in providing "shore power" systems for 3-phase refrigeration equipment from ThermoKing and many other manufacturers. General refrigeration applications can be easily handled by a phase converter. This application category includes: freezers, walk-in coolers, chillers, air conditioners, heat pumps, ice makers, ice cream machines, and any other equipment that uses 3-phase hermetic refrigeration compressors.

Phase converters are able to operate any of these load types as effectively as any utility 3-phase line. The typical HVAC application uses an automatically controlled rotary phase converter, Type MA-A. The converter is switched on by the thermostat and runs only when the compressor is on. Converters for outdoor refrigeration units may be mounted adjacent to unit in an outdoor enclosure. Refer to Kay Industries for specific sizing and selection recommendations.

Critical Selection and Application Criteria:

  • Be sure to have adequate single-phase service. You must have at least 100 amps of single phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company
  • Outdoor installation in unprotected areas may require weatherproof enclosure
  • An alternative for outdoor installations is the Type PI. It features a totally enclosed fan-cooled generator frame construction with a NEMA 3-R control and connection box. It can be installed outdoors without further weather protection.
Soil Remediation

Kay Soil RemediationRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter


The Phasemaster® rotary phase converter can supply true 3-phase power to any single motor or combination of motors in all types of soil remediation machinery such as drilling equipment, soil vapor extraction equipment, portable thermal units, positive displacement and regenerative blowers, and waste management equipment such as balers, compactors and shredders.
Our rotary phase converters are successfully supplying 3-phase power to commonly used equipment in a variety of applications. Generally these applications operate outdoor in unprotected settings. Phasemaster offers a family of designs to provide optimal performance regardless of equipment type or site conditions.

Phasemaster converters are operating equipment manufactured and installed by many of the best known names in the field.

Critical Selection and Application Criteria:

  • Be sure to have adequate single-phase service. You must have at least 100 amps of single phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company

Outdoor installation in unprotected areas may require weatherproof enclosure

Stone & Tile Saws

Recommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-R


Stone & tile cutting and grinding equipment is a very common application of the Phasemaster® rotary 3-phase converter. Kay Industries has extensive experience on a wide range of equipment from the simplest machines up through some of the most sophisticated CNC machinery. The Phasemaster rotary 3-phase converter can supply 3-phase power to a one-machine operation or to an entire shop. The Phasemaster rotary phase converter can also supply true 3-phase power to any and all the conventional tools found in a typical shop.

Kay Industry's approach to applying phase converters on this equipment is based on careful application and sizing. In our 40 years of experience manufacturing phase converters, we have amassed a tremendous amount of application and performance data on machinery from the biggest names in the industry.

Critical Selection and Application Criteria:

Many machines require a voltage regulator to keep the converter output voltage balanced over the entire load range. Supply complete details of machine electrical characteristics to factory for sizing.

Welders

Recommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-R


Welding equipment is a very common application of the Phasemaster® rotary 3-phase converter. Kay Industries has extensive experience on a wide range of welding equipment. The Phasemaster rotary phase converter can supply true 3-phase power to Welding equipment as well as any and all the conventional tools found in a typical shop.

Kay Industry's approach to applying phase converters on this equipment is based on careful application and sizing. In our 40 years of experience manufacturing phase converters, we have amassed a tremendous amount of application and performance data on machinery from the biggest names in the welding industry.

Critical Selection and Application Criteria:

  • Our experience is that the success of the application requires a very stable single-phase input voltage. If the supply voltage from the utility company drops by more than 8-10% during the welding pulse, the converter may not be able to compensate for that drop. We will consult with you to provide recommendations based on your equipment.
Woodworking

Kay WoodworkingRecommended Converter:

Phasemaster® Type MA Rotary Phase Converter
Phasemaster® Type MA-R


Kay Industries is a true expert in the application of phase converters on woodworking equipment. A single rotary 3-phase converter can supply 3-phase power from any 1-phase source to a one-machine operation or to an entire shop. The Phasemaster® rotary phase converter can be used on all types of saws, molders, shapers, planers, edge banders, wide belt sanders, routers, dust collectors, air compressors, or any other machine tools you utilize in your operation.

Most woodworking applications include a combination of machines, which often requires a phase converter to accommodate a wide range of load conditions. The Phasemaster rotary three-phase converter is ideally suited to these requirements and maintains a balanced output condition under both light and heavy load demands. As with other applications, the Kay Industries approach to phase converter sizing is very methodical, taking special care to match the proper three-phase converter to your load.

The Phasemaster rotary phase converter has been tested, approved, applied on or recommended by of some of the best known manufacturers of woodworking equipment.

Critical Selection and Application Criteria:

  • Be sure to have adequate single-phase service. You must have at least 100 amps of single-phase service for each 20 HP of connected 3-phase load at 230 volts. Verify with your utility company
  • Identify what machines will operate together. If the largest load is more than four times the HP of the smallest load, a voltage regulator should be installed in the converter.

Phasemaster converters are recommended by these fine manufacturers:  Leguna, Delta, SCMI, Adwood, Multicam, Powermatic, Martin, Timesavers, and many more.