Adapting a 3 phase industrial machine to single phase

[Gareth Blackstock]

Hello,

I am hoping this is in the correct forum. To start, I acquired a film processing machine that runs on 3 phase. Now before getting the machine I fully understood it's power requirements and the cost of getting 3 phase installed at my house. I figured as processors are mostly a few pumps and lots of motors, I would be able to find a "workaround" like finding what motor draws the most and replace it, or re-wire the machine.

Examining the machine, I discovered there are 4 motors, and 2 pumps, only one motor is 3 phase, all others are single phase. There are two 3 phase connections, one that was hardwired and cut, the second is a 3 phase plug on the machine. I have attached some pics to show the different power inputs. I have inquired locally of some sparky's to see if they would help, I even offered to pay more than their call out fee, but all declined. One said that if I did the wiring he would attend to test it for safety before flicking the switch.

Here is the question: If I replace the biggest current and voltage drawing motors, at least the 415v 3 phase, and the plugs and fuses...can I fool the machine into running happily on single phase? If the machine did not need to draw 415volts could it still run on reduced voltage or would the collective draw of the other motors still require alot of voltage, hence needing 3 phase regardless? Or can replace the biggest voltage drawing motor and simply purchase one of the converters linked below? That way the heavy duty motors are replaced and I can still utilise the original wiring.

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Single to Three Phase Converter - TorTech Pty Ltd

Single to Three Phase Converters - For locations where three phase power is not available to your property or area, our Converters are designed to produce a balanced 415 Volts AC Three Phase output power from a 240 Volts AC Single Phase supply or 480 Volts Dual Phase / Split Phase / Rural…

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The machine I think is very well made, these were very expensive when new. The wiring looks to be professionally installed, and it appears the manufacturer installed quality items. I would hate to have to rip it all out and re-wire it for single phase wiring... which I reckon I am capable of doing, basically wiring the motors and pumps to a switch board, similarly to how it already is, installing my own switches, however I would perhaps lose some existing capabilities. Running the machine essentially needs a motor to run the processor, the two pumps can be left off while the processor is running, they simply filter the developing liquid, this can be done later. Once the film is developed a vacuum motor needs to run, as does a hot air blower, and a take-up motor (winds the film onto a spool)

I cannot afford to spend $$$$ but a few hundred is certainly doable.
These are the motors and pumps, one I cannot access but I think it is also a 3 phase motor.
Main drive motor:
Brand: Parvalux S/N: 12L1
Volts: 200/220 Amps: .9
Phase: 1 H/P: 1/6
Watts: 125 RPM: 3000

Dryer motor:
Brand: BKP S/N:
Volts: 415 Amps: .75
Phase: 3 H/P:
Watts: 180 RPM: 1440

Take-up motor:
Brand: Parvalux S/N: SD 8S
Volts: 200/240 Amps: .33
Phase: 1 H/P: 1/6
Watts: RPM: 1400

Pumps: x2
Brand: Emapompe S/N: PO90
Volts: 220
Phase: 1

Main fuse board

3 phase power input -fuses top left, main power switch bottom right

This is the 2nd 3 phase power input, these wires connect to the main fuse board, first pic

The below connector block links all the various motors and pumps

 

[James]

A rotary phase converter is probably your best bet. Much simpler than transformers and vfd.

 

[Gareth Blackstock]

Yeah the rotary converters looked like the best choice from the start, but the cost is too high. This machine is for private use, not within a businesses financial sphere... I have to explore cheaper "work arounds" hence the alternative like single phase connection, remove all 3 phase motors. How hard would it be to wire in a step up transformer to act between house mains supply to VFD to 3 phase machine?

 

[DPG]

Some interesting design decisions to be made. I would suggest that this is not the forum for those as is well out outside of normal electrician territory.

I disagree Mikey - there are members on here with extensive knowledge of this sort of thing.

 

[James]

Honestly, by the time you have installed a vfd and a 3phase step up transformer, you will have got above the cost of a rotary phase converter.

also, your bespoke system may well encounter problems with the unusual issue that a vfd is designed to run a single motor and by design this will have a near perfect power balance across phases.
your machine with single phase loads switching on and off may well trip the vfd into fault.

 

[Gareth Blackstock]

Thanks for the good info guys, it helps me work out how to connect the machine. Mostly i am inclined to simply replace both 3 phase motors with single phase equivelents, and circumvent the 3 phase controller board and re-wire all other 240 volt motors individually.

The machine is an old film processing unit, basically low amp 240volt motors, 2x 240volt pumps, 2x 240volt heater elements....