On Thu, 24 May 2012 06:00:23 -0500
John Thornton <[email protected]> wrote:

> Just to update the results of last nights test run of the cobbled up 
> generator setup. While we had a devil of a time trying to make the 
> diesel motor that we coupled up to the generator stay at 1800 rpm it 
> stayed close enough for me to rapid my Z axis up and down at 295 IPM 
> with the spindle turning 2k for about 5 minutes with no complaints
> from the Simodrive 611 despite the voltage varying wildly as motor
> powering the generator surged up and down.
> 
> So now I have two options as I see it and option B is preferred due
> to the noise of running a diesel generator.
> 
> 1) buy a 3 phase generator to run the shop.
> 
> B) figure out how to make my phase converter put out a proper 3 phase.
> 
> If anyone has any ideas on option B I'm all ears. I have a small line 
> reactor (rated at 3hp) that I can put on the phase converter output
> and see what that does. I see claims of true 3 phase power from
> rotary phase converters when searching for rotary phase converter and
> cnc so there must be a way cause these claims don't seem to be coming
> from small time shysters.
> 
<massive snip>

I built a 5 hp phase converter and it was OK but not perfect. Plans
came off the net. One leg was maybe 20 v out. Been a long time and I
really don't recall. When I got the Mazak I wanted something better so I
sprung for a commercial unit. Ray Henry recommended an outfit in
Birmingham ( AL that is ). 
I got a 30 hp unit. It is really close in voltage, a couple of volts
between phases. Inrush current on starting is massive but it has never
blown the motor starting fuses (125 A). Unfortunately the outfit either
went broke in the recession or they retired. 

Even a diesel gen set is an expensive way to get power unless you are
simply off the grid. As you said, they are noisy and also require
maintenance. 

If I had to do it again I think I'd give the home-built another shot. 
There ought to be a way to auto-tune the phase under load. :-)
HTH
Good luck!

Dave

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