80790 Hammond Highway    Madelia, MN 56062
1-800-400-3946             1-507-642-3543

PHASE-O-MATIC

by KARAM MFG., Inc.

Wiring Installation Manual

Power Factor 0.98

Efficiency 88.5% at 100% Full Load

Efficiency 92.5% at 50% Full Load

 

American Made

 

Phase-O-Matic converters are available in the following sizes:

Converter Size

Voltages Available

5 HP

240 or 480

7.5 HP

240 or 480

10 HP

240 or 480

15 HP

240 or 480

20 HP

240 or 480

25 HP

240 or 480

30 HP

240 or 480

40 HP

240 or 480

50 HP

240 or 480

60 HP

240 or 480

  1. Install correct size single phase service to cover the total load.  Check with your electrician or power company for the size service and wire size.
  2. page 3

  1. Select a location close to the single phase transformer power source for installing the Phase-O-Matic Rotary Converter.  Try to keep it dust free.
  2. Select the right size wire for the total combination of the single and three phase loads beyond the transformer.
  3. Use a knife switch or a magnetic starter switch between the converter and the single phase power. Use a 3-phase fused disconnect between the converter and the load.  Consult your electrician or power company for their requirements.
  4. Use the correct size fusetrons, fuses, or heaters on the converter and all the other motors (See Tables 1& 2 on page 14).  Protect all motors according to manufacturer's instructions.
  5. Consult the National Electrical Code for sizing and installation of components for your system.
  6. page 4

    Connecting the Converter

  1. Study the wiring diagrams on the last pages.
  2. Bring single phase power from the starter switch to the converter connection box.  Connect single phase to lines  marked L1 and L2 only. Run the ground wire to the frame of the converter.  Make sure that all boxes and conduit are grounded.  Some localities have different wiring codes, so check your local rules.
  3. The third phase (manufactured phase) is coming out of the rotary converter and is marked T3.  This line (T3) along with the 2 single phase lines make up the 3-phase circuit.  Check the diagram which shows the wiring circuit.  NEVER USE THE MANUFACTURED PHASE (T3) TO RUN ANY CONTROLS, LIGHTS, OR SINGLE PHASE LOADS.  Have them on L1 and L2 only.  Always color code T3 all the way through the circuit.
  4. page 5

  5. Line voltage (L1-L2) must be at least 230 and not over 260 volts.  The manufactured phase (L2-T3) can run as low as 210 volts when under load and as high as 300 volts with no load.
  6. POWER PAC Hook-Up

    The two wires in the converter marked P-P (POWER PAC) must be hooked on the load side of the largest motor's magnetic starter, directly on the top screw of the heater strip on lines L2 and T3.

    When more than one motor of the largest size is to be used, the POWER PAC has to be wired to both motors as shown in the diagram.  The POWER PAC refers to a "pack of capacitors" within the converter.  Leads from the POWER PAC are labeled "P-P" in the converter junction box.

    The magnetic starter will disconnect the POWER PAC leads from the phase converter circuit when that motor is shut off.  Therefore the POWER PAC will operate only when the largest motor is running.

    page 6

    This is important.  If it is improperly wired, the voltage across L2 and T3 in the converter circuit will become higher than 300 volts and will burn out the converter when it is running without a load.

    NOTE:    To decide which lines are L2 and T3, use a voltmeter and have only the phase converter running (no load).  Check the incoming voltage at the top terminals of the magnetic starter of the motor you're going to hook the POWER PAC to (the largest motor).  The two lines with the highest voltage, normally 265-295 volts, will be L2 and T3.  The voltage across L1-T3 and across L1-L2 will be much lower, probably around 240-245 volts.  Therefore, hook the POWER PAC to the two leads with the highest voltage.  Be sure to hook the POWER PAC below the contactor to the screws feeding the heater strip.  If the POWER PAC is hooked on any combination other than L2 and T3, the result will be low voltage on T3 and THE WARRANTY WILL BE VOID.

    page 7

    How to decide whether or not to use the POWER PAC

    A POWER PAC is needed when the total horsepower of the motors being run is equal to or exceeds the converter size (remember for example a 20 HP converter can run up to a total of 40 HP), or when the line voltage is low, or if there is an imbalance in amperage between lines L1-L2-T3 and T3 is the lowest.

    All converters 15 HP and larger contain POWER PACS.  If the POWER PAC is not used, leave P-P wires coiled up in the junction box.

    page 8

    Operation of the Converter

    1.  CAUTION:  Always start the converter BEFORE any load is applied to it.  Make sure ALL motors are turned OFF.  Make sure that the converter has reached full speed BEFORE any motors are turned on.

    2.  CAUTION:  Do not leave the converter running without a load.  Extended running without a load can cause excessive heating and will void the warranty.

    3.  CAUTION:  If for any reason the covers are taken off the POWER PAC or connection box, discharge all capacitors before touching anything inside the box or wait three to five minutes each time the converter is energized and turned off.

    page 9

    Service/Trouble Shooting

    1.  Nothing happens:

            A. Check the power source (L1-L2) with a voltmeter...the voltage must be 230 or over, but not more than 260 volts.

            B. Check fuses or replace them.

            C. Check for loose terminals and wires.

    2.    Has electrical power but nothing runs,  all terminals and wires are tight and both fuses on the line are good:

            A. Replace both fuses for the converter.

    3.  Converter hums but does not run:

            A. Check all wiring connections to the converter.

            B. With the power off, check to see if the armature is turning free.  Dust should not be allowed to build up around the converter or inside the case.   Dust will stop the armature from turning because the converter has almost no locked rotor torque.

    page 10

    4.    Motor starts and runs properly except the heaters trip out:

            A. Check for undersized heaters. Heaters should be sized to trip at least 10% over the motor name-plate amperes.

            B. Check for overload.  Full load on the single phase motor lines L1 and L2 will be approximately 4 1/2 amperes per horsepower at 230 volts.

            C. Check voltage.

            D. Check for defective heater relays.

            E. Some models of electronic overloads may not function properly.  Please call for information.

    5.    Motor starter relay (starter switch) drops out and makes a loud humming noise:

        A. Make sure the magnetic coil on the switch is hooked across L1 and L2, NOT T3 the manufactured leg.

    page 11

    6.    Motor hums but will not run:

            A. Check the motor, it may be defective.

            B. Check the motor size against the converter size. The converter should be the same size or larger than the motor.

            C. Check load, belts, etc., you may find a tight belt, a defective bearing, or a jammed piece of equipment.

            D. Check TOTAL load.  The converter will not efficiently handle total loads (measured in horsepower) more than 2 times the converter rating.

    7.    Oil capacitors appear defective:

            A. Trace out circuits.  This condition only occurs when the converter system is incorrectly connected or when line voltage is excessively high.  It can operate under some circumstances when connected improperly.

            B. Check motor for severe overload.

    page 12

            C. If a capacitor is swollen or disfigured, it is defective and should be replaced.

            D. Check amperage in the leads going to the capacitor when in operation.  If the capacitor is open, no amperage will flow and the capacitor is defective.

            E. Remove the capacitor from the circuit and check for short circuits or grounds (use ohmmeter).

    8.    Bearings are standard and can be purchases and replaced in the field. This is a very small service risk.

    9.    The measured current in each of the three feed wires to any motor probably will not be in balance.  Current up to 25% over the nameplate rating in any one lead is acceptable.  The current input will shift around as other motors are added or subtracted from the total load.

    page 13

      Table 1

      (240 volt System)

      Converter Fuse table

       Table 2

      (240 volt System)

      Recommended Fusetron Size for Motors Operated with the Converter

    Converter HP

    Fusetron Size (amps)

    5

    30

    7.5

    40

    10

    50

    15

    80

    20

    100

    25

    125

    30

    150

    40

    225

    50

    300

    60

    400

    Motor HP

    Fusetron Size (amps)

    0.5

    2.5

    0.75

    3.5

    1.0

    4.5

    1.5

    6.5

    2.0

    9

    3.0

    12

    5.0

    20

    7.5

    30

    10

    35

    15

    50

    20

    70

    25

    80

    30

    90

    40

    125

    50

    150-200


     

     

     

     

     

     

     

     

     

     

    page 14

     Table 3

    (240 volt System)

    Converter Model #

    Converter Main Disconnect Switch

    Utility Transformer

    RT 5

    100

    10

    RT 7.5

    100

    15

    RT 10

    200

    25

    RT 15

    200

    37.5

    RT 20

    400

    37.5

    RT 25

    400

    50

    RT 30

    400

    75

    RT 40

    600

    100

    RT 50

    600

    100

    RT 60

    600

    125

    page 15

    Table 4

    Installation Chart  (240 volt System)

(for 480 Volt System Divide Amperes by 2)

Converter Size

Largest 3 PH Motor Permitted

Total 3 PH Motor Nameplate Amperes   *

Converter 3PH Output Line (T3) Amperes

Total 1 PH Input Line Amperes (L1, L2) *

L1, L2   Wire Size

**     

5 HP

5 HP

30.4

30.4

52

6

7.5 HP

7.5 HP

44

44

75

3

10 HP

10 HP

56

56

95

1

15 HP

15 HP

84

84

143

3/0

20 HP

20 HP

108

108

184

4/0

25 HP

25 HP

136

136

231

350 MCM

30 HP

30 HP

160

160

272

400

40 HP

40 HP

208

208

354

700

50 HP

50 HP

260

260

442

2-300

60 HP

60 HP

308

308

524

2-400

* Total 3 PH Motor Nameplate Amps times 1.7 = Total 1 PH Input Line Amps (Amps to be wired for on Lines L1 and L2).

** This chart is calculated for a reasonable voltage drop on motor start, based on 100 foot distance for 90C THWN copper wire.  Wire in accordance with the National Electrical Code for distances over 100 feet.

 

    page 16

    Figure 1

    page 17

    Figure 2

    page 18

    Figure 3

    page 19

    Table 5

Nameplate Information for 240 Volts

Converter Size (RT-)

Full Load Single Phase Amps

Full Load Three Phase Amps 

Three Phase Idle Amps

Single Phase Input Volts

Three Phase Output Volts   

HP

Max Load HP

5 HP

53

30.4

4

240

240

5

10

7.5 HP

76

44

6

240

240

7.5

15

10 HP

97

56

8

240

240

10

20

15 HP

145

84

12

240

3/0

15

30

20 HP

187

108

16

240

240

20

40

25 HP

235

136

20

240

240

25

50

30 HP

277

160

24

240

240

30

60

40 HP

360

208

25

240

240

40

80

50 HP

450

260

34

240

240

50

100

60 HP

533

308

39

240

240

60

120

    page 20

    Table 6

Nameplate Information for 480 Volts

Converter Size (RT-)

Full Load Single Phase Amps

Full Load Three Phase Amps 

Three Phase Idle Amps

Single Phase Input Volts

Three Phase Output Volts   

HP

Max Load HP

5 HP

26.5

15.2

4

480

480

5

10

7.5 HP

38

22

6

480

480

7.5

15

10 HP

48.5

28

8

480

480

10

20

15 HP

72.5

42

12

480

480

15

30

20 HP

93.5

54

16

480

480

20

40

25 HP

117.5

68

20

480

480

25

50

30 HP

138.5

80

24

480

480

30

60

40 HP

180

104

25

480

480

40

80

50 HP

225

130

34

480

480

50

100

60 HP

266.5

154

39

480

480

60

120

    page 21

American Made

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Give us a call (1-800-400-3946), e-mail , or stop at Maloney Enterprises for more information on the many services we provide.

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