Chopper command 6V Conversion

 

Here are full details for a 6V Conversion for those of you in the UK. US and other countries can follow these for guidance but part numbers will obviously not apply.

Chopper Command Police is available in the UK From Index Catalogue shop. Order number 436-299 19.99
The power supply I used is available from Argos Order Number 982-6838 9.99
2.5mm chassis socket with break contact from Maplin Electronics Supplies Order Number FT97 0.49

AC Chassis socket

1.   Remove batteries

2.   Dismantle Chopper Command Base Unit

3.   Drill Hole in REAR of Loose Cover to accommodate 2.5mm AC socket

4.   File away any excess and drill two smaller holes to accommodate the retaining screws for the socket. Bolt AC Socket in place see diagram below

Rear of my C.C. with AC socket attached.


Rear illustration of AC socket and locations of terminals

5.   Following the above diagram showing the rear connections of the AC Socket, disconnect Positive (Usually red) battery lead from the battery compartment. This lead must be lengthened in order to stretch round to the AC socket. Solder extra length of wire to end of positive lead and wrap connection in insulation tape. Connect other end of lead to Terminal 1 of jack socket

6.   Connect Terminal 2 of AC socket to positive terminal of battery compartment using a new piece of wire.

7.   Connect Terminal 3 of AC Socket to negative terminal of Battery compartment using a new BLACK wire.

8.   Fit batteries and check Chopper Command operates correctly.

9.   Fit jack plug of power supply into jack socket making sure power supply is NOT YET CONNECTED to the mains. Chopper Command should fail to operate. This is because inserting the jack plug bypasses the battery compartment.

10. Plug power supply to the mains and switch on. Make sure if it is a variable one that the power switch is set to 6.0 Volts. Chopper Command should function in correct manner. However due to overheating problems please continue to read this document.


Wiring. Note: all new wires are RED/GREEN stripes.

The above arrangement disconnects the batteries (if fitted) when the power supply plug is pushed into the jack socket. This is in no way meant to be detrimental to the work already accomplished by other C.C. users  Whilst other instructions are probably not going to kill anyone it should be remembered that is not a good idea for an external power supply to be wired directly across an internal battery pack. Placing external power in parallel with dry cell batteries, however flat they may be is a potentially dangerous situation.

Unfortunately my images show that I used the same colour wire for ALL my connections. This was all I had in the house at the time plus I knew what I was doing. It’s still a bit naughty and when I get the time I’ll replace with the correct colour wires. I have subsequently made the same mods for two of my friends and used the correct colour wire for each connection. Once the wires have been soldered in place they can be routed round the side of the battery compartment to make things nice and neat before replacing the cover and screwing it shut.

Overheating

Having made my conversion and using a 6V 1200ma power supply for half an hour or so I noticed that part of the landing pad was getting hot. This seemed strange. The only components near there were for the sound effects and I had these switched off. I opened the access panel for the sound effects and found a small regulator. Whilst this had a small heat sink on it, it was not dissipating the heat fast enough.

Switching the Mains adapter down to the 4.5 V setting seemed to run the regulator at a cooler temperature without compromising the performance of the helicopter. Failing that a piece of aluminium could be fitted to the top of the regulator to increase the surface area of the existing heat sink allowing the heat to dissipate quicker. This could be scavenged from the lid of an old tin can and cut to shape with vents in it. Gaudy but effective!!!!!!

I guess that when a new set of D cells are put into a Chopper Command and it is switched on it is probably only pulling 6V for a short amount of time after that the battery power will fade off slowly until the battery becomes flat, making the average current over the life of a set batteries about 4 or 5 volts.

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Disclaimer
The instructions on this page are to be used as a guide.
Modifications to Chopper Command are done so at the owners risk. Myself or any of the people associated with this site cannot be held responsible if you use the toy or modify the toy in a manner that is not in accordance with the manufacturers instructions.

 

 

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