Converting a MEP-831A to standard generator

[kloppk]

edit: Kits in stock ready to ship.

 

[dav5]

2 Controller Kit spoken for. Leaves 2 of them now.

Kurt,
After I install your controller I will have a spare inverter that works only when battle short is on. I seem to remember you thinking that the problem with the inverters was that they weren't potted properly. Is it worth drying them out and potting them? I could use it as a spare on my 2nd 831A. OR should I just mount it near the entrance to my shop as a daily reminder to never ever buy another 831A. As much as I hate the original machine I am excited to convert it. Your governor controller and conversion kit plus that sweet little Yamaha diesel should result in a great generator. I should even be able to reinstall my original water heater elements at my camp now that 4.2 KVA is being produced

 

[kloppk]

Kurt,
...Is it worth drying them out and potting them? I could use it as a spare on my 2nd 831A...

It's worth a shot to dry the main circuit board and seal the 12 or so potentiometers on it. The rest of the board is well potted. It's just the potentiometers that aren't potted or sealed.
The main board is on the engine side of the inverter. As I recall you have to take the top panel and that side panel off to access and remove that board. I've always removed that board without the inverter in the generator. I don't know if the board can be removed without removing the inverter.
You can seal them with commercial conformal coat such as MG Chemicals 419D or just use some nail polish.

Kurt,
...OR should I just mount it near the entrance to my shop as a daily reminder to never ever buy another 831A...

This is the main board. Potentiometers are the blue & white items scattered all over the board.

 

[kloppk]

A friend of mine ended up with an extra new Alt Mecc generator generator head for doing the 831 conversion.
He has no need for it and is looking to sell it.
If interested contact Mark at: mark.neil@verizon.net
He's located in S.E. Massachusetts

update: sold

 

[dav5]

A friend of mine ended up with an extra new Alt Mecc generator generator head for doing the 831 conversion.
He has no need for it and is looking to sell it.
If interested contact Mark at: mark.neil@verizon.net
He's located in S.E. Massachusetts

I just finished installing the Alt Mecc head on my 831A. I haven't finished the electrical connections but the Alt Mecc gen head fits perfectly and is a breeze to couple with the Yanmar engine following Kurt's instructions. It is not a matter of if the OEM inverter is going to fail it is when.

 

[dav5]

I just finished installing the Alt Mecc head on my 831A. I haven't finished the electrical connections but the Alt Mecc gen head fits perfectly and is a breeze to couple with the Yanmar engine following Kurt's instructions. It is not a matter of if the OEM inverter is going to fail it is when.

I just finished the final electrical connections. There were a few minor hiccups but as usual Kurt immediately guided me through any issues. I am pretty handy but I am a complete dud when it comes to electronics. Kurt made it easy.
The generator is fantastic. It is way smoother operating than the original generator with the OEM controller and inverter. It isn't affected by moisture so I don't have to play games drying out the inverter before it will produce power. Another benefit is a 40% increase in output. Thank you Kurt.

 

[kloppk]

edit: Kits in stock ready to ship.

 

[kloppk]

edit: Kits in stock ready to ship.

 

[dav5]

Just to finalize. I installed the dual Noco charger and receptacle that LTD recommended . It fits on the wall where the inverter was. I also converted the exhaust to horizontal. The muffler adapter fits a 3 inch hole saw hole perfectly.

 

[dav5]

Just to finalize. I installed the dual Noco charger and receptacle that LTD recommended . It fits on the wall where the inverter was. I also converted the exhaust to horizontal. The muffler adapter fits a 3 inch hole saw hole perfectly.
View attachment 853236View attachment 853237View attachment 853238View attachment 853239View attachment 853240

All spoken for. None left

Here are photos of the mouse proofing. Now that it isn't belching black smoke I can give it a fresh paint job.

 

[kloppk]

Good news on two items!
1) Due to popular demand it looks like I'll be offering more of the Governor Controller kits to support swapping out the PMA/Inverter with a conventional gen head.
2) Also there is a proven solution to restoring the functionality of the MEP-831's factory Battery Charger when doing the head swap.

So if interested in reserving a kit be sure to PM me or post up here!
Kit as originally offered $180.
Kit $180 plus parts to restore Battery Charger operation $50 = $230.

 

[OverkillTASF]

I went to wire my head to a terminal block, but I have to finish making the connector that mates to the very short wires coming out of the head (Reminder here).

I've got the Northstar 1659201 head in there, which is the 4000/4500 surge head:


I should then run the blacks through two breakers (16 amp breakers per the manual) but I can't find any surface mount breakers that look "right".

I think for my 120 volt operation I need to, after the breakers, just short black #1/white #3 together, and white#2/red #4 together. At least that's what I get from this Utterpower bit....

Then I just... pick one of those to be neutral?

 

[OverkillTASF]

1) Due to popular demand it looks like I'll be offering more of the Governor Controller kits to support swapping out the PMA/Inverter with a conventional gen head.

I'm almost certainly going to get one of the governor controller kits, but do you have a post somewhere that covers the features / what's included?

 

[kloppk]

I'm almost certainly going to get one of the governor controller kits, but do you have a post somewhere that covers the features / what's included?

It maintains output frequency +/- 0.2 Hz
Restores operation of the AC Voltmeter.
Restores operation of the Load meter. Displays the kW load on the gen head leg with the greatest load.
Restores operation of the Contactor, Contactor OPEN/CLOSE switch and the Contactor Lamp.
Restores Overload and Short Circuit function. Opens contactor if either leg is overloaded or short circuited. No additional circuit breakers needed.
Optional components to restore operation of factory battery charger operation.

...Updated

 

[OverkillTASF]

> Restores Overload function. Opens contactor if either leg is overloaded or short circuited. No additional circuit breakers needed.
> Optional components to restore operation of factory battery charger operation.

For those keeping score at home.... While this might make me reliant on thinks that aren't COTS components, that's probably $70 saved right there at least.

I'm in - and it might help me finally accomplish what I set out to do (checks OP) April 24, 2016.

 

[kloppk]

I went to wire my head to a terminal block, but I have to finish making the connector that mates to the very short wires coming out of the head (Reminder here).

I've got the Northstar 1659201 head in there, which is the 4000/4500 surge head:
View attachment 856709

I should then run the blacks through two breakers (16 amp breakers per the manual) but I can't find any surface mount breakers that look "right".

I think for my 120 volt operation I need to, after the breakers, just short black #1/white #3 together, and white#2/red #4 together. At least that's what I get from this Utterpower bit....

Then I just... pick one of those to be neutral?

Correct

With a heavy duty toggle switch you can have the ability to switch from 120 to 120/240. I did that for one customers 831 that I did the head swap on. Wiring the switch was a bear.

 

[OverkillTASF]

Kloppk you taking orders yet?

 

[kloppk]

Kloppk you taking orders yet?

If your up for one I'll get the boards on order.
Will take about 7-10 days for the bare circuit boards to arrive and then a few days of assembly and test before they can ship.

 

[OverkillTASF]

Yessir! You must've missed my post. I'm definitely in need!

 

[kloppk]

Yessir! You must've missed my post. I'm definitely in need!

Sorry I missed your post. OK, I'll get on it!