How To: New Wire-5 project

[Robert Bergeron]

Currently working on making control panels . Have the Bakelite panels now . Had found the stove switches and fuse holders / brackets as previously said . This is what the control panel looks like on a software used in engraving . Something neat i had not noticed before is that the amperage of the fuses was engraved behind them on the panel . Makes sense . I did not know because i had always had a look at panels with fuses on them thus blocking the view .

[Robert Bergeron]

Interestingly enough , our C-5 Canadian charging panels were controlled by stove like snap switches . The generator and battery control panel in the Wire -5 trucks used the same switches . They were common commercialy available parts in the 30s and 40s . With a little fiddling this one will become a control panel switch in the near future . Stay tuned .

[Robert Bergeron]

Here is our first prototype generator control panel. Found real Balkelite sheats . My friend Yves C is working with hos homemade CNC machine cutter . Not bad for a first try i would say .

[Robert Bergeron]

Found this also ….

[Robert Bergeron]

I also have two of these stove switches coming in the mail . We are going to make a final choice when they all arrive . Height and diameter are of particular importance for our control panels .

[Harry Moon]

Originally Posted by Robert Bergeron

Here is our first prototype generator control panel. Found real Balkelite sheats . My friend Yves C is working with hos homemade CNC machine cutter . Not bad for a first try i would say .

you should consider etching out the holes too.

[Robert Bergeron]

You are absolutely right Harry and it is what we are going to do as soon as the switches arrive . On another subject i have just finished restoring a C-5 Canadian Charging panel . This one is different from my other panel . It has got extra posts . The current will not go through the posts were my fingers are pointing and work properly unless we install a wire between them . Q : Could a fuse of been used on this panel ?

[Robert Bergeron]

SW/BD CHARGING NO5 C MKI RMSA38 Serial No C445 . I am beginning to think this charging panel is a later variant ( MKI ) . It is very possible it was more complicated and had fuses and that my friend would be an excellent idea . My other panel has not such provision . I will check later if the designation is different .

[Robert Bergeron]

My other panel : SW/ BD CHARGING NO C5 ( Canadian ) serial No 23280. RCA 101975-501. So this is the early model and my other the subsequent model ( MKI ) .

[Robert Bergeron]

Note the absence of the second row of posts incorporated in the MKI version .He is below my panel a picture of Simon King’s panel .

[Robert Bergeron]

Source Sigs Museum Kingston . I might of just found myself a NO19 HP set Switchboard Charging panel with the extra posts …

[Bruce Parker]

Originally Posted by Harry Moon

you should consider etching out the holes too.

No etching!! The letters were printed on. The best solution is white ink (yes, there is such a thing) and a Leroy lettering set. It duplicates the lettering almost 100%. A coat of clearcoat and Bob's 'yer uncle (or at least Robert).

The early No.5.....I haven't see one like that before. If fuses are attached to those inboard posts they would probably be under the front panel (easy to check, or at least see where the wires go), but that would make them quite a chore to replace. I have doubts they would have used those post to wire fuses elsewhere as that would defeat the purpose of the switchboard and its mobility. The C5 for the Amplified set has two more posts top left in line with the regular ones.

[Robert Bergeron]

Thanks Bruce , i knew you were nearby . I am not etching the C5 panels but the truck control panels don’t worry . The C5 were definitely painted and that is why they are so faded now . As for the discussion on these it is because it is part of the complete Truck installation kit . No Wire-5 truck is complete without one . That so little is known about them surprises me . You mean to say Bruce that you have never seen one like my MKI ? This adds to the knowledge library then . Can you post a picture of the amplified set one please so we can compare ?

[Chris Suslowicz]

What's the wiring like behind the panel, around the extra pairs of studs?

My suspicion is that it's for something like a WS52 installation with extra battery pairs (possibly because they were short of the 200 Amp Hour units and had to make do with the 100/125AH ones instead). If so the upper and lower pairs of studs will be connected in parallel behind the panel.

It's also meant to be used with two chore-horse charging sets (according to my reading of the panel lettering). The upper two switches select which batteries are feeding the output terminals (left hand switch) and internal lighting (right hand switch), while the lower pair select the charging source (Chore Horse 1 or Chore Horse 2) for Battery 1 (Left) or Battery 2 (Right).

(On my British charging switchboard No.5, the charging sources are Vehicle Generator/Dynamo and Charging Set.)

Best regards,
Chris.

[Robert Bergeron]

Here you are Chris .

[Robert Bergeron]

Another shot without a tool obstructing the view of the wires .

[Robert Bergeron]

Finished painting the handrails and the antenna protectors just now while waiting for parts .

[Robert Bergeron]

I am happy to report that the nuts on the charging panel posts are a common thread .

[Chris Suslowicz]

Argh! OK, I'll have to get one of the switchboards out of the store and trace out the wiring - it's not at all obvious from the numbering on the "stove switch" tag, and the switches on the board are different from the GE version.

I'll see if I can do that tomorrow.

Chris.

[Bruce Parker]

Comparing Robert's multi post early one to a more typical Canadian C5 panel they are identical except for the pairs of posts which (I think) are labeled as Battery 1 and Battery 2. This seems to duplicate the posts running up the sides for the battery connections so it doesn't surprise me they were dropped. It does make me wonder why they were put there in the first place.

As Chris says, the British panel is different and calls for a vehicle dynamo instead of a second generator set and is set up a little differently. British left, Canadian right.

[Chris Suslowicz]

Well that was a mistake. Having extracted the switchboard from the shed and written it up, I previewed the post and then closed the browser!

The British Switchboard, Charging, No.5 is a simple beast. All switches are identical, two pole, two way, with two off positions. The connections on the rear of the switches are different to those on the Canadian switchboard and the screws have brass plate cable clamps to take the conductors directly. Connections are marked (clockwise from the 10 o'clock position) L (red), 1 (red) 2 (black), N (black) 2 (red) 1 (black).

Upper switches select "Charge Battery" in the 3 o'clock position (all others are "Off") Left hand switch is Battery 1, Right hand switch is Battery 2.

Lower left hand switch selects charging source; 9 o'clock is "Vehicle Dynamo", 3 o'clock is "Power Unit".

Lower right hand switch selects "Set Supply From" to "12V Output" terminals, 9 o'clock is Battery 1, 3 o'clock is Battery 2.

The "Internal Lighting" terminals are common to the "12V Output" terminals.

Robert's "Switchboard C5" is rather more complicated, and the extra battery terminals are clearly a later (bodged) addition, as one of the switches has had to be rotated slightly (presumably to clear the nuts/washers on the added terminal) and re-fixed using some modified washers as a mounting adapter! (I don't really see what the point of it was, other than to make Battery 1 and Battery 2 accessible from either side of the switchboard.

It's then "flipped" in that the upper switches select the "12V Output" source (left switch Battery 1 or Battery 2) and "Internal Lighting" (right switch Battery 1 or Battery 2), while the lower switches allow each battery to be connected to either of the charging sets.

The other strange part is that the 'inner' (added) battery terminals appear to be marked "Charge". I suppose a detailed look at the panel wiring is next.

Chris.

[Robert Bergeron]

Thank you for that Chris . Don’t mind the washers , i added them to help «*index*» the switch . The center shaft had broken in half and i had it soldered up. When reassembling the whole unit , the «*off*» positions were not at 12 & 6 ´clock as should be . I rotated the whole switch 1/8 of of a turn and it works . I had to look up the word «*bodge*» . Look forward to hear from you on the explanation about those extra poles .Spent the day soldering terminals and maintaining the No 19 set in my functionnal Wire-5 truck . Sweet time of the year when i don’t feel guilty working inside .I listened to the BBC and VOA on the No 19 set after . I strung a 100 feet long wire on some tree outside the workshop , so simple ! I have also been using this little baby ( pictured ) . A variometer to control precisely the voltage going to the CPP-2 power converter .

[Robert Bergeron]

Today , last day of the year : Cypher clerk work table brackets painted and ready .

[Robert Bergeron]

Happy New Year to all . The outside temperature now is -25 C. I have been working indoors the last few days to bring back to life a WS 19 set for the new truck . It works now ! Followed the instructions in the manual for running repairs and changed a few lamps . Also replaced two headset pigtails on the control box that were ruined ( pictures 2 & 4 ) . I am currently listening to a far away tele evangelist on 6200 MC in English as i write this . Scary stuff , he ´s talking about the end of the world no less ! iC works , A set works . Power on , red light on the power supply . Good to go !

[Harry Moon]

Originally Posted by Robert Bergeron

Happy New Year to all . The outside temperature now is -25 C. I have been working indoors the last few days to bring back to life a WS 19 set for the new truck . It works now ! Followed the instructions in the manual for running repairs and changed a few lamps . Also replaced two headset pigtails on the control box that were ruined ( pictures 2 & 4 ) . I am currently listening to a far away tele evangelist on 6200 MC in English as i write this . Scary stuff , he ´s talking about the end of the world no less ! iC works , A set works . Power on , red light on the power supply . Good to go !

you think that's scary? try listen to any canadian political leader?

[Bob Carriere]

Bonjour Robert

How are you powering your 19 set...... batteries or a 110v/12v power supply..?

Curious.....

[Robert Bergeron]

Hi Bob, thanks for your question . I use a 6 Amp regulated power supply . Converts 120 V AC to 14.8 V DC . The Amps are enough to do the tests on all functions . 6 Amps is all that is necessary to power the «*Receive «* function on the A set . Of course it would not be enough to transmit .I am going to use 12 V ( 14 V in reality ) batteries in the Wire -5 box when it’s done . I use a 100 feet wire as an antenna and get stations in North America , Europe, Africa , Asia and South America . All over the world basicly .

[Robert Bergeron]

Here we go : Complete , working No 19 set with all the accessories for the new truck . I have a few spare lamps also to keep it going .Two headsets and all the bell & whistles . All ready to be loaded in the box . Next summer we will be conducting a wireless exercise with the two trucks 100 Km apart and properly licensed operators .I will be working on one of my 12 V Canadian Chorehorses but Jordan Baker has a very good thread covering those already .

[Robert Bergeron]

This telephone switchboard is going in the box with the corresponding 6 field phones . Can someone tell me the voltage of the battery needed to operate the switchboard please ?

[Chris Suslowicz]

Without looking it up, 4.5 volts. Originally there was an open-topped aluminium box that held 3 'X' or 'S' cells and slid into the brackets o the floor of the case, but I suspect they started using 126 or similar batteries at some point.

I have the manual and will look it up in a moment.

There should be slip-on weights with built-in pulleys for each of the connecting cords, and you alternate red and black cords to reduce confusion.

Chris.