805a and a 10 wire gen end

[Jasonk85]

Good morning gents,

I recently purchased an 805 a. I was hoping it was going to be a 12 wire gen and, but it is not. Everywhere I research says I cannot use a 10 wire for single phase. But in thinking about it, if I remove the tap plate and just connect the wires in the config in the pic, it might work as a zig zag style. What is everyone’s thoughts?? The T0 I confirmed is a single wire coming out of the gen end itself(thus the orange circle).

 

[Scoobyshep]

In a typical 12 lead zig zag, the normal paralleled windings are still in parellel. This diagram parallels a leg a with a leg c


I have my doubts of it actually working.

 

[Light in the Dark]

Check this out: https://www.steelsoldiers.com/threads/mep-804a-retapping.221544/#post-2588418

 

[Jasonk85]

Check this out: https://www.steelsoldiers.com/threads/mep-804a-retapping.221544/#post-2588418

Thank you! That helps a lot

 

[peapvp]

I find this interesting, we got all these folks having done god knows how many conversions, but no one has any pictures or video of it they can post.

 

[Jasonk85]

I find this interesting, we got all these folks having done god knows how many conversions, but no one has any pictures or video of it they can post.

I could post some pictures, but my unit doesn’t have a screen. So my plan is to cut out all the electronics and go with off-the-shelf parts. attached is a picture of it re-tapped in the bar diamond configuration, and I hooked up a power supply test out the output voltage.

 

[jamawieb]

I find this interesting, we got all these folks having done god knows how many conversions, but no one has any pictures or video of it they can post.

Just converted a 805a to single phaseand felt like I needed to prove the conversion is possible. This is for all the people that say the 10 wire can't be converted to single phase. I discussed this several times over the years. A good friend of mine, Jeff Brown developed a replacement board for the conversion and its pictured. Ive personally converted over 50, 804a &b -806a's to single phase. Ive helped several people convert theres to single phase. The only way this was possible was with Kurt Klopps Voltage Regulator. Several of us worked months on the conversion and it wasnt until Kurt developed the VR was it possible on the Military generators. The very 1st one I converted was a 804a and logged over 2000 hours in 2020, before I started selling the units converted.
Just to be clear Im not here to sale people the conversion or help people that want to profit off the conversion. This is to prove the 10head heads can be converted to single phase.

 

[LuckeyD]

Info for other is also good. Many want to do this. Any way to get details? What does the gen do on loads? A zig-zag can work. May have losses but as long as they don't create too much losses, and heat build up it should work out . Any way to document it and share with the members? Especially how it handles loads and provides feed back on the gages so other members can do the same. Still waiting on the TB job so others can also capitalize on his info. or how to contact his friend to obtain so others can think about using this.

 

[jamawieb]

Info for other is also good. Many want to do this. Any way to get details? What does the gen do on loads? A zig-zag can work. May have losses but as long as they don't create too much losses, and heat build up it should work out . Any way to document it and share with the members? Especially how it handles loads and provides feed back on the gages so other members can do the same. Still waiting on the TB job so others can also capitalize on his info. or how to contact his friend to obtain so others can think about using this.

You can contact me directly.

 

[LuckeyD]

Try the @LuckeyD thing. it makes us able to converse like email

 

[jamawieb]

Try the @LuckeyD thing. it makes us able to converse like email

If your interested in knowing how it works you can contact me directly. Im not interested in a pissing contest of who knows the most @LuckyD. Looks like youve been here since 2021, some of us have been here much longer and could care less about your ego.

 

[LuckeyD]

I sent you one of those conversation things. I have no ego. I have no gens, and really do not care at my age. Only done this stuff for real for 50+ years, most in GI Joe land, and was asked to become a member just before retiring-retiring. I'm pretty wore out, and some how I am still here.

Just want to see if others may benefit from what you have done. Some folks want to be paid for what they have done, others want to share. Some just want to say, Dig me, and some just want to show what they did. It is your choice, you did the work, and you know how it all goes. I make suggestions on what the gen does now you have done this because I have had to do the same for the folks that made these gens and engineers that supported them for our active force. I'm kinda in a rut since this was normal for me, so if I sound gruff, it is after many years of doing this stuff. so do you want to share?

 

[Scoobyshep]

If your interested in knowing how it works you can contact me directly. Im not interested in a pissing contest of who knows the most @LuckyD. Looks like youve been here since 2021, some of us have been here much longer and could care less about your ego.

This isnt about an ego urination contest. This is a place to share knowledge. Personally i find this particular thread interesting because this is the first proven time of making this work. I personally have been in the trade for going on 30 years and have never seen this particular configuration.

when the low zig zag was first brought up here there were concerns and opinions flying about. some additional things needed changed besides just the head configuration. Some of the instrumentation wiring needed altered because the avr was less than agreeable. as load increased the voltage became unstable.

So thats one thing to consider, voltage droop on loads, I would be interested on additional stresses on the AVR and whats happening to the windings in the head.


Just throwing some thoughts out there, Anyway congratulations on your accomplishment

 

[LuckeyD]

Jason 85 did this too. There are two who have done this. Was asking info so others can do this. I think Mr. jamaweib got it wrong with the questions I asked or the way I asked. They were the same I always got asked. Many members want to do this because of the normal entrance used across the US. I tried the conversation thing, but no answer and this is as direct we can do. Only asking for the others. I live in 50 cycle land with a 380V 3 phase entrance. Like most in my area. I can't use these gens very well here. We also can not contact folks directly, but we can use the conversation area. The info would answer what you and others have already suggested. There should be losses from original design, but how much is the question. Then there the other things you mentioned. If it turns out very usable, others will want to do this and a "How To" paper would answer many questions. I would make available for Mr. Guyfang for the TM section. Last one I did I was under orders to do something never done, and we went into the main gen stator. Got one but the 009 went south. If I had something to test with I would have already done so and made a paper on what I found. Lets see what they may want to share. Maybe nothing, who knows.

 

[jamawieb]

Initially this concept was brought up on the smokstak forum. Its called the Bar Diamond or Collins connection. When I initially completed the conversion in 2019 we couldnt get the generator to generate power. The problem was solved when Kurt Klopp developed his Voltage Regulator. The original regulator monitors all 3 phases to generate. Kurts reads off 1 phase which solved the issue. The connections on the board are 10-4; 7-1; 5-9; 6-8; and 2-3. This all can be completed by modifing the top reconnection board. Early models were just jumper leads between the studs, then I started modifying the original boards and riverting bus bars to make the connections.
You do not need to move any control wires beneath the board. All gauges work as they are inteneded without any modifications. The very 1st 804a that was converted was back in 2020-2021. I logged over 2000 hours of testing. Everything from 0-20kw was put on the machine during a 8 month period.
When loaded there is no voltage drop, the 804 will handle 16kw all day but soon as you reach over 16.5kw or above, the generator will trip the overload in about 9 minutes. Generator temperatures were recorded during the testing because I was also worried about over heating the generator head and there were no significant changes. The generator now has around 5500 hours and no known issues. Same conversion for the 805a. Im in the process of converting a 806a with hopefully similiar results. I do not have an oscilloscope so I can't discuss the sine waves. I would confidently say they would be pure because Ive sold alot of converted models and Ive never seen an issue arise with any sensitive electronics. I sold a 805a to a crypto mining facility and know they needed clean power to run several of their computers and other hardware.

 

[LuckeyD]

Sounds Great. Time now to gather other info. Idea is to put together a paper for others to follow. Would you mind if others contact you for your TB1 Assy board? Some members will want to do this but have no idea what they are doing. The easier the info is to follow, the better the results. I'll try contact Mr. Klopp about his regulator. Don't matter who make up the info for others to follow, the idea is to have something for members to use as most do not have that much experience. They like pictures. You posted one that shows the TB1. If I put together the paper, may I use this Pic from your post?