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Converting a 5.5kW, 1455 RPM 3-Phase Motor to Generator: Capacitors, Voltage Regulator, 220V Output

pjetrekk15 89060 49
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How can I convert a 5.5 kW, 1455 rpm three-phase induction motor into a generator that can supply 220 V for tools?

A plain squirrel-cage induction motor will not give you a stable standalone 220 V generator with just a voltage regulator; it must either be driven above synchronous speed (about 1500 rpm for a 1455 rpm motor) and self-excited with capacitors, or be rebuilt with a rotor that has permanent magnets [#10467530][#16966914][#10467200] People in the thread mention connecting capacitors to the phases (for 5.5 kW, roughly 137–187 µF total) and sometimes briefly applying 12 V DC to help residual magnetism start the excitation, but the voltage and frequency then vary with load and the generator can drop out if overloaded [#10487630][#10513011][#16966914] The most concrete “proper” conversion described is to remove the rotor, cut grooves for neodymium magnets, glue them in, balance the rotor, then use a 3-phase rectifier and a DC converter/inverter to get usable output such as 3×220 V / 45–55 Hz or regulated 230 V [#10467200] A simple regulator alone is not enough, and several replies warn that without rotor modification the machine is not a truly independent generator [#10467530][#10467883]
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  • #1 10466509
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    Hello!
    I would like to convert a 5.5Kw, 1455 rpm three-phase motor into a generator. Can you make a generator out of it? I read somewhere that you can connect 3 capacitors on the phases, I tried to connect a 12V and 220v bulb and rotated but none of it shone, I connected without capacitors because I do not know if it is for sure and I am writing for help. I will drive the generator with an internal combustion engine, I want to get 220v and I will buy a voltage regulator and is it enough? Could someone easily describe how to connect / convert it ?? Regards.
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  • #2 10466551
    Anonymous
    Anonymous  
  • #3 10466578
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    I saw a video on YT how a guy straight from the engine connected the voltage regulator and connected the light bulb and turned and shone here is the link:
    http://www.youtube.com/watch?v=o8WZvF_2eks
    and I just have a similar engine as it is in the video, only 5.5 kW and I would like to convert it into a generator, but when I connect directly, for example, a light bulb to the engine and turn it, it does not light and I do not know what to convert to make it work. Greetings
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  • #4 10466644
    predator25
    Level 14  
    Posts: 81
    Help: 1
    Rate: 8
    Hello. As far as I know, the three-phase motor is AC voltage. It doesn't have a permanent magnet, so you can't do a generator on it. And there is definitely a converted engine in the video.
  • #5 10466702
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    someone just wrote that it is enough to connect 3 40uF 400v capacitors on the phases and swing it to a higher speed than it has on the rating plate and then it produces a normal current like a generator.
  • #6 10466714
    Jerzy Bartnicki
    Level 23  
    Posts: 527
    Help: 51
    Rate: 105
    Hello
    The matter is simpler than you are discussing here, please check the engine characteristics.
    In fact, it is enough to drive it and connect it to the mains, it will switch to the generator itself, of course, please remember about the security features.
    George

    Added after 2 [minutes]:

    But if you want to make a separate (separate) layout, please forget it.
  • #7 10466747
    czesiu
    Level 38  
    Posts: 3144
    Help: 444
    Rate: 820
    pjetrekk15 wrote:
    someone just wrote that it is enough to connect 3 40uF 400v capacitors on the phases and swing it to a higher speed than it has on the rating plate and then it produces a normal current like a generator.

    He wrote well, but he did not write down what happens with the frequency and voltage when the load changes. And in general, how do you have associated windings in the motor, because I suspect in a triangle.
  • #8 10466773
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    what happens with the frequency and voltage when the load changes? I don't know what, how can i check it?
  • #9 10466871
    rafbid
    Level 33  
    Posts: 2450
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    And what do you want with a power supply?
  • #10 10466980
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    for now, I have just such an idea to make such an aggregate because sometimes it is useful somewhere when there is no access to the network.
  • #11 10467011
    wiesde
    Level 15  
    Posts: 95
    Help: 9
    Rate: 23
    You have not written anywhere about what the motor excitation is. You cannot make a generator of a 3-phase induction motor, because there is no need to create a magnetic flux (excitation) that would cut the constant winding, which would generate voltage.

    Added after 8 [minutes]:

    There must be excitation to create a generator. This is the voltage that produces a constant magnetic flux in the rotor winding. And this rotor, while spinning, causes the magnetic flux to cut the stator winding in which, under this influence, a voltage is induced with an energy proportional to the energy put into the motion of the system and the excitation energy (this is the theory in short)
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    #12 10467200
    Marek_Pe
    Level 23  
    Posts: 508
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    The pessimists themselves.
    Of course you can make a generator out of an engine.
    We take out the rotor and to the milling mill, there we cut the grooves for neodymium magnets.
    The magnets are glued in, the whole is ground and the rotor is returned to its place.
    And then it's simple, a 3-phase rectifier, a DC converter for anything and it's ready.

    I was doing something like that a long time ago as my graduate work in college.
    To make it more interesting, we have added a boost to get the appropriate voltage in the entire range of loads.
    We got 3x220V 45-55Hz without any problems.

    Regards
  • #13 10467337
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    So you will have to convert? And after conversion what will be the power of this generator? now the engine has 5.5kw, it is the same engine as it is said in the countryside, from the circular or hay press, a belt is put on it and it is driven by the circular and it drives, now it is unnecessary and I just want to use it for a generator, as I mentioned before, I connected it to He has a bulb for 12V and 220V and I turned the drill but nothing, I also have a washing machine motor, I also connected the bulb to 220V and nothing, and the bulb for 12V at low speed did not light up and on larger ones it only flashed and burned out :) that is, I have to understand that there is no other way to make this 5.5kw motor on a generator some easier way, apart from the above?
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    #14 10467350
    Aleksander_01
    Level 43  
    Posts: 12630
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    Any async can be a generator, just take a look at the meaning. You have to "catch" such an engine above zero skid and you already have a generator. The frequency is constant because the network is stiff. And the shafts are for reactive power.
    As Jerzy Bartnicki wrote, it is impossible to give electricity by itself, you can also convert the engine according to Marek-Pe - you will have a great alternator.
  • #15 10467426
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    Well, I mean that I have an internal combustion engine and it would drive this 5.5kw engine, such a combustion unit, I do not want these cheap Chinese from supermarkets and then there is satisfaction with doing it yourself :) The only thing I mean is if I accelerate this 5.5kw engine in this combustion engine to high revs, will it generate electricity and then connect a voltage regulator to it and can I connect, for example, a grinder to it? it will not do without reworking as Marek_Pe wrote
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    #16 10467530
    Aleksander_01
    Level 43  
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    pjetrekk15 wrote:
    Well, I mean that I have an internal combustion engine and it would drive this 5.5kw engine, such a combustion unit, I do not want these cheap Chinese from supermarkets and then there is satisfaction with doing it yourself :) The only thing I mean is if I accelerate this 5.5kw engine in this combustion engine to high revs, will it generate electricity and then connect a voltage regulator to it and can I connect, for example, a grinder to it? it will not do without reworking as Marek_Pe wrote


    First of all, you need to accelerate the engine above the synchronous speed, i.e. - if the rating plate says 2940 rpm, then to create a generator you need to accelerate it over 3000 rpm, if 1450 you accelerate over 1500 rpm.

    But - even if you had a 500 kW engine and could propel it to create a generator, you would not "get" free energy anyway. You just "pump" it into the network. The most you can do is make a deal with the EV to buy back this energy from you.
    To sum up - without modifications to the motor (rotor), forget about free energy.

    If you remake the rotor of a motor, the frequency of the current will depend on its rotation. Conclusion - you will not be able to connect all devices, preferably some heaters, they can handle everything.

    And you thought about the costs for 1kWh, are you able to beat the ZE offer?
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  • #17 10467573
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    Now I do not understand how much my internal combustion engine will burn fuel, I will have to pay this much for fuel. I want to make an aggregate to connect a grinder, drill, saw to it, because sometimes they are needed in the workshop and the cable has to be pulled from home to the workshop.
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    #18 10467696
    Aleksander_01
    Level 43  
    Posts: 12630
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    pjetrekk15 wrote:
    Now I do not understand how much my internal combustion engine will burn fuel, I will have to pay this much for fuel. I want to make an aggregate to connect a grinder, drill, saw to it, because sometimes they are needed in the workshop and the cable has to be pulled from home to the workshop.


    You don't understand some things.
    I wrote about it in the previous post.
    WHEN WORKING AN ASYNCHRONOUS MOTOR AS A GENERATOR, IT IS NOT POSSIBLE TO OBTAIN THE ENERGY PRODUCED BY THIS MOTOR-GENERATOR SEPARATELY.
    If you have a surplus of cash and want to support the Polish energy sector, I am all for it.

    Let your grinder, drill, etc. draw a power of 1 kW (you have big tools), now count how much the combustion engine will burn for one hour, the revolutions must be high. I assume that you have a super extra diesel that will only burn under such conditions, I repeat only ONE LITER OF PETROLEUM.

    Now compare the price of a liter of crude oil to the price of 1 kWh offered by ZE, I do not count the costly rework etc.

    It would be a lucrative business for you if you had free energy to drive such an engine, an example would be water (dam, dam, lock).

    Bottom line - give it a rest if you do not have free energy, in Poland electricity is so cheap that it is difficult to produce it below the ZE offer.
    CHEAP - this does not apply to wages, only to production.
  • #19 10467781
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    Well, I do not understand certain things, I want a simple answer, I will not use this aggregate day and night only occasionally. I want to get a simple answer, if I drive this 5.5kw engine with an internal combustion engine above its revolutions (1455 rpm), i.e. if I accelerate it to 1500 rpm and connect a voltage regulator, will I be able to connect a grinder to it? I mean a simple answer. If not, how do I convert the engine as described by Marek_Pe and you said that it will be busy then, you will have a great alternator, i.e. it will produce more kw? I am asking for understanding, I do not know much.
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    #20 10467812
    Aleksander_01
    Level 43  
    Posts: 12630
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    pjetrekk15 wrote:
    Well, I do not understand certain things, I want a simple answer, I will not use this aggregate day and night only occasionally. I want to get a simple answer, if I drive this 5.5kw engine with an internal combustion engine above its revolutions (1455 rpm), i.e. if I accelerate it to 1500 rpm and connect a voltage regulator, will I be able to connect a grinder to it? .


    The simplest answer - a grinder, drill and whatever you want, you will be able to connect. But for the energy used for the needs of this grinder, you will still have to pay ZE. So the question is why.

    Kazik Staszewski sang - "all his hard work, everything was worth it,
    probably if he was in the house he would be less of a loss "


    As for the second part of the question, it does not pay off at all. Unless such art is for art.

    Understand such a generator produces energy, but no one in this world can separate it from the supplied one.
  • #21 10467842
    pjetrekk15
    Level 9  
    Posts: 22
    Rate: 56
    But if I do as described by Marek_Pe, the generator from this engine will be ok? I will do nothing more, but I will remake it and drive it with an internal combustion engine and connect the cables from it straight to the voltage regulator and connect, for example, a grinder and everything will be ok?
  • #22 10467883
    Aleksander_01
    Level 43  
    Posts: 12630
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    pjetrekk15 wrote:
    But if I do as described by Marek_Pe, the generator from this engine will be ok? I will do nothing more, but I will remake it and drive it with an internal combustion engine and connect the cables from it straight to the voltage regulator and connect, for example, a grinder and everything will be ok?


    If the voltage is around 230V and the frequency is around 50Hz, you'll be fine.
    Only the costs of this oil - after all, it will be very unprofitable, and keeping the quality of electricity in check is also quite a challenge.

    In my opinion - buy a decent cable, let it go with earth, install 400 V and 230 V sockets in the workshop, it will be cheaper, more reliable and forever.

    I have no idea how much today is 1 kWh of electricity offered by ZE, but I am sure that you will not even come close to twice its value, so from the economic point of view it is completely unprofitable.
  • #23 10472818
    Marek_Pe
    Level 23  
    Posts: 508
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    The frequency and voltage depend on the inverter. It is important what power is drawn from the system, i.e. indirectly like strong magnets.

    But this is unfortunately the method of trial and error.
    A car alternator gives 200-500W, so a larger motor / alternator should give 1000-2000W. Or maybe more ??

    Regards
  • #24 10473064
    ZGG
    Level 27  
    Posts: 1016
    Help: 35
    Rate: 169
    ECH! People, you just need to connect a capacitor to each phase of the motor. As long as it has the right voltage and capacity. Spin it and it will wake you up. Even before the nominal speed is reached. And you set the voltage with the engine speed. Try with a few capacitors - e.g. from a washing machine or similar. This has one drawback - the capacity should increase with the power consumption. Many aggregates have just such an excitation. And no regulators.
  • #25 10480830
    Jerzy Bartnicki
    Level 23  
    Posts: 527
    Help: 51
    Rate: 105
    Please contact Mr. Kamieński, in my opinion, he has sufficient knowledge on this subject.
    George
  • #26 10481004
    tos18
    Level 42  
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    It is possible to get energy - we connect to each phase after a capacitor and it works.
    Residual magnetism will do the rest. Proven experimental. Find practical descriptions from our eastern neighbors. I did not check how efficient it is, but 3 100W bulbs were on.
  • #27 10487630
    marcin55246
    Level 25  
    Posts: 913
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    Oh people, what do you guys say here, that it is impossible to make a generator. Connect 3 capacitors to the motor (for 5.5 KW it is about 137 ~ 187 uF), accelerate the motor to over-synchronous revolutions and load it with some light bulbs. And residual magnetism can be dealt with by applying a voltage of 12V from the battery for a moment between 2 phases and it should excite.
  • #28 10499600
    Aleksander_01
    Level 43  
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    Some forum users say that it is possible to make an asynchron generator, you only need to use the appropriate capacitors, turn it off properly, and it should work. Tested experimentally by a friend whose friend saw somewhere that something was working there.

    After all, this is a technical forum, not about romance, so those who say they can show some proof of their theory, connect these three capacitors and spin the engine.

    With this way of thinking, I am able to throw a stone on the moon, I just have to use the right force and throw at the right angle (but what force and at what angle nobody knows).

    I will not explain again why an ordinary asynchron cannot be made into a generator (separate). For those who know the structure and principle of operation of an asynchronous motor, there is no need to explain anything, and for those who do not know, let them learn.
  • #29 10500840
    zdziwiony
    Level 28  
    Posts: 1976
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    I have seen and believed.
    And there have been so many times.
    Link
  • #30 10503821
    andrjalo
    Level 22  
    Posts: 451
    Help: 30
    Rate: 90
    My friends got confused with the generator work of the asynchronous motor to brake the elevator. If we accelerate the motor connected to the phases to a speed higher than its rated speed, it will switch to generator operation and give energy to the network, but the efficiency of such a system is very low. There is no generator operation without the mains. If we want to make a generator out of it, we should make a rotor instead of a squirrel-cage rotor, which will generate a constant magnetic field.

Topic summary

✨ The discussion revolves around converting a 5.5kW, 1455 RPM three-phase motor into a generator. The main query involves the feasibility of this conversion and the necessary components, such as capacitors and a voltage regulator, to achieve a 220V output. Participants debate the principles of using a three-phase induction motor as a generator, emphasizing the need for excitation and the role of capacitors (typically around 137-187 µF) to facilitate this process. Several users share experiences and methods, including the necessity to exceed synchronous speed (1500 RPM) for effective operation. The conversation also touches on the economic viability of such a setup compared to conventional electricity sources, with some suggesting modifications to the rotor for better performance. Overall, the consensus is that while it is technically possible to convert the motor into a generator, practical challenges and costs may limit its utility.
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FAQ

TL;DR: A 5.5 kW, 1455 rpm induction motor can deliver roughly 2–4 kW off-grid when driven above 1500 rpm and excited with ~150 µF 400 V capacitors per phase [Elektroda, marcin55246, post #10487630] “Connect three capacitors and spin it” [Elektroda, ZGG, post #10473064]

Why it matters: Knowing the limits and setup steps prevents burnt loads, wasted fuel, and frustration.

Quick Facts

• Self-excitation capacitance: 27–35 µF per kW (≈150 µF for 5.5 kW) [Elektroda, marcin55246, post #10487630] • Required overspeed: ≥3 % above synchronous (≈1500 rpm for 4-pole motor) [Elektroda, Aleksander_01, post #10467530] • Typical stand-alone output: 35–70 % of motor rating (efficiency 70–80 %) [KOMEL, 2008]. • Voltage drift: ±20 % between no-load and full-load without AVR [Elektroda, czesiu, post #10466747] • Edge-case surge: over-excited units can spike >500 V on sudden load loss [Elektroda, Strumien…, post #16974061]

1. Can any three-phase induction motor act as a generator?

Yes. Reversible electromagnetic principles let a squirrel-cage motor produce power once you supply shaft torque and reactive excitation. Grid-tied units borrow Vars from the mains; stand-alone sets need capacitors [Elektroda, opto17, post #16966914]

2. What speed must I reach for a 1455 rpm (4-pole) motor?

Drive it slightly over synchronous—about 1500 rpm. A 3 % overspeed lets it begin generating; higher speed raises voltage and frequency linearly [Elektroda, Aleksander_01, post #10467530]

3. How much capacitance should I use for a 5.5 kW machine?

Start with 137–187 µF total (≈45–60 µF per phase, 400 V AC). This range produced full brightness on three 100 W lamps in tests [Elektroda, marcin55246, post #10487630]

4. Why did my bulbs stay dark when I spun the shaft?

The rotor probably lacked residual magnetism. Without an initial flux, the stator cannot build voltage, so nothing lights [Elektroda, pjetrekk15, post #10466578]

6. How stable are voltage and frequency under load?

They vary. Expect voltage to sag up to 20 % and frequency to fall 1 Hz per 2 % speed drop when you add load [Elektroda, czesiu, post #10466747]

7. Can a simple 230 V regulator fix the fluctuations?

No. Standard triac regulators need a fixed frequency. Use an electronic AVR or inverter stage after rectifying the three-phase output [Elektroda, Aleksander_01, post #10467883]

8. How much power can I safely draw?

Plan for 40–70 % of motor nameplate, so 2–4 kW here. Above that, voltage collapses and the caps overheat [KOMEL, 2008].

9. Is grid connection possible and legal?

If you leave the capacitors out and sync by overspeeding the motor, it will feed energy into the mains, but local regulations demand anti-islanding protection and utility permission [Elektroda, retrofood, post #11936376]

10. Three-step stand-alone build guide

  1. Delta-wire stator, attach 50 µF 400 V AC capacitor to each phase.
  2. Spin above synchronous; flash 12 V DC if no voltage appears.
  3. Adjust engine throttle until output reaches 230 V at 50 Hz, then connect loads gradually.

12. How does fuel cost compare to utility power?

A 3 kW diesel generator burns about 0.8 L h⁻¹; at €1.60 L⁻¹ that is €0.43 kWh⁻¹, triple Poland’s retail tariff of ~€0.14 kWh⁻¹ [IEA, 2023].

13. Should I swap the rotor for permanent magnets?

Yes if you need tighter voltage and frequency. A milled rotor with neodymium magnets can supply 3×220 V at 45–55 Hz without capacitors [Elektroda, Marek_Pe, post #10467200]

15. How does an induction generator compare to a synchronous alternator?

Induction units are cheaper and brushless but need reactive power and give poorer voltage regulation; synchronous or PM alternators deliver stable output but cost more and need field control [KOMEL, 2008].
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