Converting a 005A with a Digital Controller

[peapvp]

As announced in a separate post several weeks ago, Larry @Cowhunter and myself have started on converting his 005A to a MeBay DC-70DR MK II controller based system

we will update this thread here over the next several weeks

Larry and his 005A are based in Southern California and I am in Kansas City. I am doing this remotely.

Why are we doing this?

Larry had his 005A converted to single phase zigzag as per instruction videos on YouTube from one of our infamous members, to power his workshop primarily

Larry ran into the same issues as most other folks who did the single phase conversion, namely setting the output voltage to 240VAC between the two phases, winding up with two blown A11 static exciter voltage regulators.
I have repaired both and they are running fine now.

As a general piece of advice:

Because the A11 can be adjusted to 240VAC, which is pretty much the top end of regulation, doesn’t mean that they should be set that high.
The 004A / 005A / 006A are RATED for 208 VAC and so this A11 in all three units. The same goes for the Tactical Precise Version.

During the course of the A11 repairs, I realized that Larry’s cubicle has seen much better days as nature had delivered a pretty good beating on this nearly 50 year old piece of equipment.

So the idea was born to strip all the old electronics out and start fresh.

After evaluating several modern day controllers, like the British made Deepsea controllers, Larry decided to go with a more economically priced Controller from MeBay, bought on Amazon and shipped from China.

the DC 70 DR MK II costs just around $ 200

Larry then sent the controller to me for programming

 

[Scoobyshep]

Wow that's pretty cool

Sent from my SM-S908U using Tapatalk

 

[peapvp]

The first step was the installation of a MPU

We found a Cummins 3034572 MPU on Amazon for 25 Bucks.

Larry then drilled two holes into the flywheel housing and installed the sensor on a plate, which made centering the sensor over flywheel real easy








the hole on the side is the “peephole”

we adjusted the gap to 0.021” which gives us a 1.3 VAC signal during crank
and a 20 VAC signal at 4.1 KHz @ 1800 rpm

the DC 70 can handle a signal from 0.5 VAC to 70 VAC up to 10 KHz

Task #1 finished

 

[Guyfang]

OK, here is a tip. When we converted hundreds of gen sets to MPU's, later on in life, we ran into a problem.

1. The metal filings. We did not do a VERY good job of cleaning them out of the bell housing. Later, sometimes several times on the same set, one little piece of metal would be attracted to the MPU magnet, and would make contact between the MPU outer housing and the magnet. MPU will not function then.

We did not use a plate, and it looks like a good idea. The Army just measured and drilled. Worked every time, BUT once, that I know. The one time, the last thread through the bell housing had a burr. For the next 2 years, (YES, 2 years) no one could get the gen set to run. Why? well the burr, would not let the MPU screw down far enough to "See" the ring gear. Everyone screwed the MPU in, and tightened it up to bottom out.Then back it off a half turn. The burr was the bottom. So after 2 years of people sending this gen set from one shop to another, my shop found the problem. I like the Peep hole!