MEP-003 Main AC breaker and R-3 adjustment questions

[dependable]

Been working MEP-003. Runs fine, makes good power but breaker switches off at under 100% load.

I guess these wear out, and this one has white powder on dried on it that either dripped down from above or oozed out as liquid. It also looks to be original breaker. So, I will probably order a new one. Has anyone else ever had to replace one of these due to early tripping? It actually seems to be getting worse as I test it, unless that is because of the R-3 adjustment I tried.

The other problem is R-3 adjustment, which I tried to do as I read on this forum that it is part of AC breaker feedback circuit. Followed the instructions in TM except I ran it on 120/240V instead of 120V as I have not got a 120V load to test with. Maybe that's the problem, but when I turn the R-3 while generator is running and loaded, there is no change in amperage throughout the range of the adjustment. It is running around 1.3 amps under as much load as the breaker will take, which is not quite 100%. TM says it should be around 0.6 amps.

With no power on, the R-3 measures .02-10.4 ohms as screw is turned though its full range. Can it still be bad and not work under power?

Could a worn out breaker effect R-3 adjustment?

Thanks.

 

[dependable]

Tested the R-3 and adjustment on my good 002. The test works the way I had it wired. I noticed on the 003, the wiper and max resistance terminal were fused, on the 002 the output was on wiper (variable resistance) terminal only. So I unsoldered in bridge wire on the 003's R-3 and am getting almost no reading it at all (before it was too high) I guess I will try another variable resistor in 003. But it tests good with DMM, so I am confused.

Anyone know a good place to buy these locking variable resistors? And what to ask for? (where I don't have to buy 100 at a time) Would like to sort out R-3 before I buy another breaker.

If I am reading parts TMs correctly the main breaker is the same for the 002 and 003. It is different for 400hz unit.

 

[dependable]

Been having fun and learning a lot. Swapped R-3s between old smokey 002 and the 003, they both work in the 002. It will chug along at 100% load with good R-3 reading. I did have to adjust it, as the lock nut was not tightened down. Static resistance in properly adjusted R-3 seems to be around .6-.9 OHMS. I guess they want to measure amps under load due to the variables with the current transformer.

The TM says they are 5W 10 OHM resistors. Have not been able to source, good thing they don't seem to be the problem (though I still need to buy one cause I broke one of the tangs.) The resistance is correct on CT1, which feeds to R-3. Have not yet figured where the wire that feeds that wire comes from, possibly terminal 15 off S6.(The main reconnection switch). Am beginning to suspect the same technition who mounted the new reconnection switch upside down may have missed something else. I may still need main breaker, (and an R-3) if anyone has one for sale from unit that was not too played out, please PM me. Any helpful advice appreciated.

Am going to put turn up pipes on the 003 before I work on it running again. With the ASK, the exhaust blows into the louvers and smokes anyone around it.

 

[LuckyDog]

opcorn:subscribed.

Interested to see how this turns out.

 

[1800 Diesel]

....The TM says they are 5W 10 OHM resistors. Have not been able to source, good thing they don't seem to be the problem (though I still need to buy one cause I broke one of the tangs.) .....

Will this one work? It's + or - 5% They also have + or - 1 %

http://www.digikey.com/product-detail/en/AHP500JB-10R/AHP500JB-10R-ND/2169363

 

[dependable]

Thanks, the spec is the same, but it is panel mount ,screwdiver controlled potentiometer with lock nut. I did check digikey and jamesco. All of your 002s and 003s have one. Let me know if you are parting any out.

 

[Munchies]

Having a resizing problem. Resistor shows in stock a few places. Hmmm its the forum software. Same image uploaded elsewhere is fine.
5905-01-046-6851

5905-01-046-6851 303-185137 58756 RESISTOR,VARIABLE,NON WIRE WOUND NE 5 KAMPI COMPONENTS CO. INC. 5905-01-046-6851 3055472-5194 1LFF5 RESISTOR VAR. NS 4 USS CO INC DIV USSCO INC. 5905-01-046-6851 010466851.5905 9H953 RESISTOR NE 1 SECO PARTS & EQUIPMENT COMPANY 303-185137 1UHB2 RESISTOR, VARIABLE NS 3 CONCORD COMPONENTS, INC. 72-5194 1UHB2 RESISTOR, VARIABLE NS 3 CONCORD COMPONENTS, INC. 5905-01-046-6851 1UHB2 RESISTOR, VARIABLE NS 3 CONCORD COMPONENTS, INC.

KAMPI COMPONENTS CO. INC. (Duns: 122679228) 88 CANAL RD FAIRLESS HILLS, PA, 19030-4302 UNITED STATES Phone:2675434002 Fax:2155315558 http://www.kampi.com

AMY POTTS amy@kampi.com DON CHANDLER don@kampi.com

 

[dependable]

Thanks, I emailed one of the contacts you supplied at Kampi. We will see if they are willing to deal with such a small order.

 

[dependable]

Well, I tried another breaker out of the old 002. Same bad R-3 reading. Same loading problems. The more I look at the workmanship on the reconnection switch installation, the more I suspect that is the problem. There are a couple 16g wires involved in R-3 circuit that go though S-6.

Looks like the load box is coming off the generator and on to the bench. I re did a reconnection switch form a MEP-018 making the reconnection box for my M1031, so I have some idea what I am getting into. It might not happen until winter.

The generator head does have paint coming off in a couple of places, like it got too hot at some point. But it is making 240V and set will run fine for a while with 70% load. Is it possible for windings to be partly burnt and still make good voltage?

Who knows what kind of mistake happened for it to require a new reconnection switch in the first place. This project has taken a lot of my time, but I learned a lot. Would hate to sort out switch box only to find I need a new gen head.

Anyone have a reconnection box they want to sell, please PM me. I see they have them at green mountain, but at that price I'll buy another generator.

I think the 002 and 003 reconnection boxs are the same except there are 8 wraps around current transformer on 002 and 4 wraps with the 003. If I am wrong on this, let me know.

 

[dependable]

I bought a complete reconnection box from someone parting out an 002. It looks unmolested and has good static R-3 resistance. I figured I would have to take four wraps off the current transformer so it have the four wraps instead of eight. But it only has four wraps like my 003. Both of my 002s have eight wraps. I wonder how often these parts got incorrectly interchanged? Anyone who has their 002 or 003 out and wants to check number of wire loops around CT1-CTV, I'd be interested to hear what they are. Can it not matter that much?

Next time I get some time I'll try this new box and let you know how it worked out.