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RV6A Starter Contacter Problem

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jghrv6a(at)gmail.com
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Posted: Tue Mar 05, 2013 5:25 pm Post subject: RV6A Starter Contacter Problem

Anybody had a problem with Van's Aircraft starter contactor ES 24021? It's reputed to be a Cole Hersee product designed to make and break 750 and 100 amps respectively using a 3-4 ohm coil. The original lasted about 100 hours before failing to provide12 volts to the "output terminal" when the starter switch triggered the internal connection for the high current terminals. This was confirmed by the sound of the moving "slug" and voltage measurements made at the "S" and both "high current" terminals. Hitting it with a hammer would make sometimes make it conduct properly but it eventually failed completely. Drilling out the rivets to inspect the contacts showed a mild discoloration and minimal overlap between the moving and fixed contacts but nothing else. 



Now the replacement is doing the same thing after about 50 hours. An external diode protects the starter switch contacts. There has never been a problem with the pinion-ring gear engagement or disengagement, so the contactor is wired to the normal stud on the starter motor solenoid and the "jumper wire" was left in place. Any suggestions as to cause &/or solutions? Are there starter contractors that rotate the moving contact to even out wear etc.?



Jack H.

RV-6A

O-320 D1A with the standard Sky Tek

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nuckolls.bob(at)aeroelect
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Posted: Tue Mar 05, 2013 7:38 pm Post subject: RV6A Starter Contacter Problem

At 07:23 PM 3/5/2013, you wrote:

 --> AeroElectric-List message posted by: Jack Haviland <jghrv6a(at)gmail.com>



 Anybody had a problem with Van's Aircraft starter contactor ES 24021? It's reputed to be a Cole Hersee product designed to make and break 750 and 100 amps respectively using a 3-4 ohm coil. The original lasted about 100 hours before failing



 . . . .



 Now the replacement is doing the same thing after about 50 hours. An external diode protects the starter switch contacts. There has never been a problem with the pinion-ring gear engagement or disengagement, so the contactor is wired to the normal stud on the starter motor solenoid and the "jumper wire" was left in place. Any suggestions as to cause &/or solutions? Are there starter contractors that rotate the moving contact to even out wear etc.?



   That's a really old legacy design. Haven't really

   heard of your situation before. Just for grins,

   it would be interesting to try this style contactor.

   They're about 40 years 'younger' in design than the

   beer-barrel contactors. MUCH higher contact pressures.



   [img]http://images.apwcontent.com/is/image/Autos/misw1951c_is?$[/img]  



    This form factor is common to several off the shelf

    contactors you should be able pick up at a local

    car-parts store.



 

 

   Bob . . .    [quote][b]

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jghrv6a(at)gmail.com
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Posted: Wed Mar 06, 2013 4:03 am Post subject: RV6A Starter Contacter Problem

On Mar 5, 2013, at 10:36 PM, "Robert L. Nuckolls, III" <nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:

 	  Quote: 	
		  Just for grins,  it would be interesting to try this style contactor.  They're about 40 years 'younger' in design than the  beer-barrel contactors. MUCH higher contact pressures. 	




Thanks Bob - I'll give it a try.

Jack H.



 [quote][b]

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nuckolls.bob(at)aeroelect
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Posted: Wed Mar 06, 2013 6:47 am Post subject: RV6A Starter Contacter Problem

At 06:01 AM 3/6/2013, you wrote:



  	  Quote: 	
		  On Mar 5, 2013, at 10:36 PM, "Robert L. Nuckolls, III" < nuckolls.bob(at)aeroelectric.com (nuckolls.bob(at)aeroelectric.com)> wrote:



  	  Quote: 	
		  Just for grins,

   it would be interesting to try this style contactor.

   They're about 40 years 'younger' in design than the

   beer-barrel contactors. MUCH higher contact pressures. 	


 Thanks Bob - I'll give it a try. 	


   Great. Keep us apprised of your experience. Note

   further that SOME off the shelf parts will have

   a diode built in. If so, they'll probably say so

   on the bottom with some words like "transient

   protected", "diode installed", etc. If in doubt,

   it doesn't hurt to install your own diode outside

   the contactor. Two diodes is fine, no diodes is

   really hard on your switch.



 

   Bob . . .    [quote][b]

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