HUGE 40HP Rotary Phase Converter Built from SCRAP?

In this episode we build a 40HP rotary phase converter to power our CNC machines!
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Intro 0:00
Pulley Installation 8:00
Mounting Plate Fabrication 11:40
Frame Fabrication 23:06
Electrical Component Overview 28:02
Panel Layout 31:25
Enclosure Fabrication 39:36
Temporary Panel Connection 45:16
First Test! 49:10
Capacitor Balancing Overview 51:15
Connecting Machines! 56:00
Royalty Free Music Courtesy of KZbin
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Rocan Motor Company

[@RocanMotor]

To all those watching- We had some mic issues filming this, but on our next video we have improved our audio greatly with some new mics and some changes to our post processing. Thanks for tuning in!

[@3cl1]

We built a pony motor start stand for a 30hp idler, currently only using a 10 hp idler. Very nice build.

[@alex4alexn]

cant wait to see you fix those boards! very cool build

[@RocanMotor]

Thank you!! I'm wrapping up the video showing the board repair and HL-1 Startup- it may be a few weeks, but do stay tuned! Lots of big changes coming to the channel- moving forward Rocan Motor Company will be my full-time job, so plenty of content to come!

[@arijon98]

It clamps on the shaft? Awesome.

[@RocanMotor]

With remarkable force! Split collets are really great.

[@theessexhunter1305]

Very impressive, from a crusty old miller from the UK I wish you well

[@RocanMotor]

Thank you for the kind words!

[@badguyjr007]

Congratulations on the 3 phase. Excited to see you fix the Hass

[@RocanMotor]

Thank you! The lathe is up and running and we are working on the video showing the drive repair. Very exciting times for us!

[@nikolausluhrs]

This is great content keep it up!

[@RocanMotor]

I appreciate it! Comments like this really help to keep me motivated!

[@2OO_OK]

The bigger motor may have a threaded plug on the bottom side of the bearing bell ends that you greased. Take those bottom plugs out when greasing and the old grease and bearing wear particles will get pushed out of the motor.

[@RocanMotor]

I'll have to check! I appreciate the comment, I was looking for a second port/ for the grease to come out but didn't see one. Didn't cross my mind to look underneath. Thank you!

[@LCalleja]

Grate video and a nice big motor:)

[@RocanMotor]

Thank you Luke!

[@Joesrustbuckets]

Great vid buddy, I’d luv to be able to do something similar, but don’t have the confidence 🤙

[@RocanMotor]

Thank you Joe!! I say give it a shot with a smaller 3 phase motor. A phase converter this large is a bit daunting (and deadly), but the same principles apply to all 3 phase motors and with some research and planning you could have a working phase converter in a weekend. Also, it doesn't need to be expensive- local ads (marketplace, craigslist, etc) turn up free 3 phase motors and components all the time.

[@nicolaschampagne8988]

quality video ! how much did it cost in total? thanks for sharing

[@RocanMotor]

Thank you! I tallied it all up and the final cost was roughly $800 for everything. That includes just about everything except for the 4/0 quadruplex cable to connect it all. The motors were free as was the steel for the frame. 40hp rotary phase converters generally are $5000 or more, so overall I'm happy. A smaller unit can be built for much cheaper- the pulleys required for the large motor for example are roughly 25% of the cost, and the large contactor was another 25%.

[@chrisjh777]

Do you leave the pony motor belt connected after start? Others I have seen use an idler pully connected to a lever so the belts can be slackened after start, think clutch.

[@RocanMotor]

I considered an electromagnetic clutch, similar to an AC compressor in a car, but ultimately opted to keep it simple and left the belt turning whenever the system runs. The losses are negligible.

[@chrisjh777]

​@@RocanMotor0:42

[@jimkibler786]

I doubt you’ll ever pull more than 30 amps with your vf2. In my experience power requirements are over rated. Also with a properly designed phase converter, start-up with capacitors wouldn’t be a problem with a motor of this size.

[@RocanMotor]

I'm my testing of the VF-2SS so far I'd agree. Regarding the capacitor start, the current draw for a motor this size was in the 300 A range, supposedly, which I hadn't confirmed through any math of my own. That's for a brief moment of course, and likely okay, but I had the pony handy so this seemed simpler at the time.