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Converting a 005A with a Digital Controller

Guyfang

Guyfang

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That was in 1977. My Mentor was a French guy who had to leave France in a hurry in 1961 due to the attempt to over through Charles De Gaulle. He was a SP/5. He was teaching me to be more "Electrified", as he put it. He almost died that night. Not because of the fire, smoke or general mayhem. No. Laughter almost undid him. Gil just passed away a few months ago. I bet he is still laughing in Heaven.
 
peapvp

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Today is the day.

Larry's @Cowhunter 005A is running now with the DC 70 MeBay and everything works as intended

The wiring diagram is attached to this post as pdf

The only issue we ran into is the new coolant temp transducer. The MeBay cannot handle any resistance larger then 999 Ohm in their Sensor tables when defining the sensor for correct display.

We found a alternate Transducer from Amphenol WT083B001 from Mouser for around 9 bucks, which has the temperature / resistance curve the Mebay can handle.
We will post a update once the new sensor is installed and the MeBay Coolant Temp Sensor Curve has been updated

Note:
Please proceed at your own risk. Support and trouble shooting from our end is pretty much limited due to time constraints.
 

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Scoobyshep

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peapvp said:
Today is the day.

Larry's @Cowhunter 005A is running now with the DC 70 MeBay and everything works as intended

The wiring diagram is attached to this post as pdf

The only issue we ran into is the new coolant temp transducer. The MeBay cannot handle any resistance larger then 999 Ohm in their Sensor tables when defining the sensor for correct display.

We found a alternate Transducer from Amphenol WT083B001 from Mouser for around 9 bucks, which has the temperature / resistance curve the Mebay can handle.
We will post a update once the new sensor is installed and the MeBay Coolant Temp Sensor Curve has been updated

Note:
Please proceed at your own risk. Support and trouble shooting from our end is pretty much limited due to time constraints.
Click to expand...
I am glad you posted about the temp sender i was having the same issue and hadnt dug deeper into it yet.
 
peapvp

peapvp

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A few after thoughts on this project.

Normally we use only Made in USA products for obvious reasons. This was our first time branching out into uncharted territory when it comes to the origin of the MeBay Controller.

The MeBay Controller is a Domestic Chinese Product and when compared to other Domestic Chinese Controllers, it ranks in the upper price category in the Chinese Market. It is on average 50% more expensive then domestic Chinese low end controller.
As far as we can tell, the MeBay Controllers are available via eBay / Amazon in the USA only and are shipped via Postal Mail from China direct after purchase. We have not found a US Seller who has US stock of any of those controllers. At least at the time Larry ordered his DC 70 on Amazon in November 2024.

The available manuals for the Controller it self and the PC based Software to configure the Controller, are at times confusing, as the translations were apparently done by a translator whose English is his/her second language. It may have been translated by Google Translate etc.

The only software related issue I could find until this point, is the maximum Ohm Value for the Coolant Temperature Sensor which can be entered into the Parameter Software on the PC / Labtop.

The manual states a maximum of 9999 Ohm, but the software will allow only values to be entered up to 999 Ohm.

The manual also states that the outputs are Relay Dry Contacts with a maximum rating indicated in their wiring diagram.

If you find conflicting values for maximum current / voltage, use the lowest value you find.

It is also imperative that the DC 70 is supplied 24 VDC Power at all times, especially when the Genset is running and the E-Stop function is used to shut down the running Genset. As per MeBay manual, damage to controller may occur if the Controller looses power during a shut down.

Our Wiring diagram reflects that note in the Manual.

It is further vital to use a sufficient number of Suppression Diodes ( We used 1N5408 ) for all inductive devices, as the manual states here as well, that the lack of those suppressors could cause damage to the Controller.

Looking at the retail online pricing of around ~ US$ 225.00, it becomes clear that these devices use domestically produced semi conductors and passive components which are better then average for the Chinese Domestic Market, but are sub standard compared to parts made offshore by US Manufacturer.

The QA is more lenient in China and allows for lower pricing as they have less rejects in the QA process, which in turn then lowers the overall quality of the end product.

Please keep this in mind when deciding on retrofitting your genset.

We will update this Thread if more or important issues arise.
 
Scoobyshep

Scoobyshep

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peapvp said:
Today is the day.

Larry's @Cowhunter 005A is running now with the DC 70 MeBay and everything works as intended

The wiring diagram is attached to this post as pdf

The only issue we ran into is the new coolant temp transducer. The MeBay cannot handle any resistance larger then 999 Ohm in their Sensor tables when defining the sensor for correct display.

We found a alternate Transducer from Amphenol WT083B001 from Mouser for around 9 bucks, which has the temperature / resistance curve the Mebay can handle.
We will post a update once the new sensor is installed and the MeBay Coolant Temp Sensor Curve has been updated

Note:
Please proceed at your own risk. Support and trouble shooting from our end is pretty much limited due to time constraints.
Click to expand...
I am glad you posted about the temp sender i was having the same issue and hadnt dug deeper into it yet.
peapvp said:
A few after thoughts on this project.

Normally we use only Made in USA products for obvious reasons. This was our first time branching out into uncharted territory when it comes to the origin of the MeBay Controller.

The MeBay Controller is a Domestic Chinese Product and when compared to other Domestic Chinese Controllers, it ranks in the upper price category in the Chinese Market. It is on average 50% more expensive then domestic Chinese low end controller.
As far as we can tell, the MeBay Controllers are available via eBay / Amazon in the USA only and are shipped via Postal Mail from China direct after purchase. We have not found a US Seller who has US stock of any of those controllers. At least at the time Larry ordered his DC 70 on Amazon in November 2024.

The available manuals for the Controller it self and the PC based Software to configure the Controller, are at times confusing, as the translations were apparently done by a translator whose English is his/her second language. It may have been translated by Google Translate etc.

The only software related issue I could find until this point, is the maximum Ohm Value for the Coolant Temperature Sensor which can be entered into the Parameter Software on the PC / Labtop.

The manual states a maximum of 9999 Ohm, but the software will allow only values to be entered up to 999 Ohm.

The manual also states that the outputs are Relay Dry Contacts with a maximum rating indicated in their wiring diagram.

If you find conflicting values for maximum current / voltage, use the lowest value you find.

It is also imperative that the DC 70 is supplied 24 VDC Power at all times, especially when the Genset is running and the E-Stop function is used to shut down the running Genset. As per MeBay manual, damage to controller may occur if the Controller looses power during a shut down.

Our Wiring diagram reflects that note in the Manual.

It is further vital to use a sufficient number of Suppression Diodes ( We used 1N5408 ) for all inductive devices, as the manual states here as well, that the lack of those suppressors could cause damage to the Controller.

Looking at the retail online pricing of around ~ US$ 225.00, it becomes clear that these devices use domestically produced semi conductors and passive components which are better then average for the Chinese Domestic Market, but are sub standard compared to parts made offshore by US Manufacturer.

The QA is more lenient in China and allows for lower pricing as they have less rejects in the QA process, which in turn then lowers the overall quality of the end product.

Please keep this in mind when deciding on retrofitting your genset.

We will update this Thread if more or important issues arise.
Click to expand...
I ordered one from china took 2 months with no shipping data. somewhere around month 1 I went through amazon and it took 2 weeks. now i have a spare.
 
peapvp

peapvp

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Update:

First things first. I updated the wiring diagram to REV 1.2
Corrections and additions in REV 1.2:

1. The PIN Labels for Low Fuel Level Switch FL-1 were corrected to C and D
2. We added the three color dots on the CR27 Half Bridge Rectifier in the drawing on CR27

We attached the latest Manual for the MeBay DC70D MK2 and DC70DR MK2 ( R indicates that it has built in RS 485 )

Larry ( @Cowhunter ) ran the Generator today for 30 minutes with 15 KW Load with no problems

We still have two things left do to:

Adjusting the CT Ratio from MeBay default 500/5 to show correct Amps / KW on display ( showing 2/3 of actual AMP / KW )
Parameter: Group 1) Basic Settings Parameter: #3 CT Rate
or

change the MeBay Controller from currently selected 3 Phase 4 Wire Mode to 2 Phase 3 Wire Mode ( Wiring Diagram Page 15 Bottom)
Parameter: Group 1) Basic Settings Parameter: #2 Gens AC System

In the next few days I will post the configuration for the Inputs for Coolant Temp Switch, Oil Pressure Switch and Low Fuel Level Switch as they can be selected as Normally Open or Normally Closed
 

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Last edited:
peapvp

peapvp

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Update:

Larry ( @Cowhunter ) and myself tied the last three missing items together.

First we uploaded the temperature / resistance for the new but not yet installed Amphenol Coolant Temp Sensor from Laptop to DC70DR MKII

IMG_3687.jpeg

Next we did the automatic flywheel teeth calculation

for this generator has to be able to produce power so MeBay can sense the Frequency and the rated rpm has to be set to 1800 rpm

Then the crank disconnect has to be set to #4 RPM / Hz

then, while Genset is running, press down key and start key for about one to two seconds

IMG_3703.jpeg

MeBay will display this screen for two seconds after successfully calculating flywheel teeth

IMG_3689.jpeg

Note: the bottom screen indicator will briefly show Alarming in red while calculating and displaying teeth count

this number will be automatically saved to engine parameter “flywheel teeth”

the mpu Larry installed is now activated and starts showing rpm starting at around 150 rpm when engine is cranked

Last item was the adjustment of the current transfer ratio

Larry connected his current clamp to all three phases and we compared those to what MeBay indicated on Gen Screen with CTR set to MeBay default 500/5

the correction needed was 1.36
500 x 1.36 =680

we entered 680 for ctr and now that is working as well

IMG_5730.jpeg

Note:
We used the existing Current Transformer with the multi turn wires going through it

76671305990__7A718B33-D974-4C84-9C4C-BB7F58C4929E.jpeg

we will post a separate update on the Amphenol Coolant Temp Sensor in the next few days
 
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