SpaCreek: THE 12 VOLT DOCTOR’S ALTERNATOR BOOK Edgar J. BeynThe 12 Volt Doctor's Alternator Book “The 12 Volt Doctor's Alternator Book continues inthe same familiar and wel loved style as “The 12 Volt Doctor's Practical Handbook" to help simplify the mysteries of the boat's altemator—the prime source af poser on almost every boat. ‘Simple drawing and clear instructions abound, helping you to identify your alternator and understand how it works. Get to know your alternator—it could save your battery's lif, aGreek) division of Liton —_ bi Cc PLATHEH NAVIGATION AUTOMATION. North American Division 222 Severn Avenue ‘Annapolis, Maryland USA 21408-2569 301 263-6700Published by C. PLATH NORTH AMERICAN DIVISION 222 Severn Avenue Annapolis, MD 21403 ISBN 0-911551-10-7 ©1986 Spo Creek Inc. Annapolis, Merylond Allright cesrved. Notice : Names, brands, and designs appearing in this bookare registered trademarks or service marks which belong to the respective proprietary companies. INTRODUCTION ‘Alternators are all around us. There is hardly an engine which does rot have one, running alongside in ears, trucks, buses, recreational vehicles, boats, aircraft, form machines, earth moving equipment, and all kinds of stationery engines. Obviously, the alternators are doing job very well since we hear 20 little about them. something does go wrong, most of the more popular models have their replacement available almost instantly, waiting on dealer shelves, in alternator shops, often even in department stores. How different things become though if you want something slightly out of the ordinary, an alternator with greater output, some added feature, unwsual application, or if you and your vehicle or vestel happen to be in a place where technical services are less abundant. Where you are the available technical service. Or when you want your alternator to do something new or different and, even though the expert may have fold you it could'nt be done, you ore not quite ready to give up. On top of that, it does not help that alternators on thelr way from the manufacturer 10 the engine or car factory take on a new name : Delco alternator may become a Buick or Perkins, « Motorola one may become known as a Volvo or Universal. Just try to find @ Hitachi or ‘Mitsubishi alternator in an auto store : there it may only be known ot @ Mazda, while at an engine dealer's it may be called Westerbeke or Yanmar. This book tries to make you see how alternators work, what they have in common, and how they differ in some details. The sketches should help to identify brands and types , if not models. dimensions should help when you hove to replace one w: IF you are lucky, you will never need the trouble shoot ‘emergency repoir instructions. But if you do, | hope they help. They should ot least make you more fluent on the subject. Annapolis, April 1986 Edgar BeynCONTENTS Introduction Nomes : Generator - Alternator, Difference Coils and Mognets Why Not Permanent Magnets Of Rotor Poles and Stator Cotls The Stator Alternating Current Three Phase Alternating Current Intermediate Summary Rectifying Diodes The Three Phase Rectifying Circuit Rectifying Diodes: Mechanical Auxillary Diodes ‘solating Diode Voltage Regulators Type P ard Type N Excitation tattery Wiring Diagrams, Schematics Voltage Regulator Testing : in Operation Test Regulator Separately Voltoge Regulator and Battery Charging Voltage Regulator Setting Marwal Alternator Controls Specific Veltoge Regulators Repoirs, Trouble Shooting ‘Alternator Output Test, Field Curent Test Voltage Regulator Seiting Tet Testing Alternator Off Engine Disassembling the Altersator Alternator Fi INDEX 16 - 31 37 40 43 4% 43 9 50 51 54 59 n 80 83 oy 92 102 m4 216 218 NAMES : GENERATOR - ALTERNATOR Have you wondered what the difference is or which might be the proper name ? Our subject is « generator. But just as with "light bulbs" which properly should be called "lamps", the popular name alternator in common use. The story behind it is the change, in the early sixties, from a generator with big coils and brushes but very modest.output to a new machine of different design. It wos then called a Self-Rectifying ‘AC Generator and some other complicated names. Improvements were ‘made in rapid suecession and the new machine needed a new name because it was much different from the old. Even though some makers sill avoid calling it anything but a generator, the name alternator has become official for the new design. THE DIFFERENCE Direct current generators have at least two brushes in contact with a commutotor :@ ring of copper contacts. The generated current hos to flow from the copper contacts fo the bruthes which had fo be big fo h current. Most elternators tll ave brushes, but for nt purpose, to cory a few Ampere of field current. Main feature of alternators is thatthe power generating coils of wire are fixed in one place instead of rotating. That improvement over the conventional generators has been mode posible by solid state since the stationary generating coils produce alternating current or AC, this alternating current must frst be converted to direct current before an be uted fo charge 0 bo! ry compact but powerful silicon diodes ate located directly within the alternator hous solidly connected directly tothe power generating coils . Details in the following sections will show you how that works,5 the tft iron becomes magic and alo farmes poles. Sof iron means any ton or wee which wll not become permanently ogre in sketch (Z) , the poles of a magnet with solid letters is shown near @ bar ot ot om which hon become magnate cr [uJ Ted by the dated Iter poles Note thet the Nentrond South poleset Ob ond Fee the some effet onite ton bor Cmpere this with the < poles dagen in peed. Seetch (6) - Opposite MAGNET poles at opposite ends Of the some coil will increase the magnetic flux and emphasize each others effect. Next step t look at sketch (4) again, We can improve that design by having fur cols irtaa of js wo. As before, we will connect nee which ove et Oppe= tite ends ofthe magnet, Sketch @ . This design will generate twice the pomer of th Sketch @ revel there a pulze ot CD, then at AB again except with opposite pol then ot CD with opposite polarity. We hove to make @ point here. Obviously it is an improvement to arrange 8 many coils os possible all the way eround the rotating magnet. Why is there a problem with that concept ? With our bar magnet as the rotor, pulses are generated in the coils at different times. The output at A and B will have to be rectified separately from the output of C and D, only then can the direct current output be connected to common DC output terminals. With each additional pair of coils, an ditional poir of rectifying diodes would become necessary. We will see how an improved rotor will simplify this complice To make ths important point clearer, consider sketch @) which has calls eonged around orotating permanent magnet. Since each col t Gonerete pubes of olterating Eurten the coil otput mut be tecified or converted fo direct Current with dade. Ae inthe previow examples, we can pein connect pairs of calls tn teres: the coe which oe the poles ofthe rotting magnet connect in series coils Tond 5, Zand 6, 3and 7, 4 and 8. cows But we can not connect the together, their output les each, or a total of 8 . netic rotor. The same ‘and (1) ‘show two different magnetic rotors. The coils in (0) af best can be wired in three separate groups of two coils, the same coils with the new rotor in 9 Ss rust be rectified first which requires two This points to our next sketch ©) com ll be wired together ond then require only one set of rectifying diodes, The rocoon i thot here al colle generate ther pula oF the sometime becove all have rotor maga ple po by ot the tae tive. The colle on be wired in ares highet voltage, or porallel br highew coment. The olterefors tn rect life ee mode with Reavy wise ond tom frre pr coll» bul then have many ssc coils wired Imsores, to llow high event but ot sitet high vltoge «We wil se ino moment excely ow tat done ond wha other tricks ore hed Inthe degre3 COILS_AND_MAGNETS Induction is the phenomenon which makes an electric pulse appeor ir wire when magnetism changes inthe vicinity ofthe wire. The emphri ikon "charge" #0 pulie ls generated when the magnetic eld becomes stronger or weaker or changes poles, You wil remember most ofthis and we should just mention thatthe ‘A mogaetiam con cone from permanent tragnets or electromagnet, that @ pulse iso momentary voltage which con @ create a momentary current : power. 8 Our first design at left shows 2 wire a coil around « bor of iron. More turns of the wire give higher voltge at the terminals A and B when the magnet is moved back and forth. Moving the horseshoe magnet back and forth is not very practical. Easier is to rotate bar magnet at in our second design. When a North pole posses the coil, A 1 pulse appears at terminals A and B , and when a South pole passes ext, another pulse oppears at A ‘ond 8 but in the opposite direction IFA is plus at first, it will be ® Ha scoaeacatearers CY teat & The iron bar is not only convenient to hold the wire coil, It also serves to collect and orient the magnetic field of the magnet cand improves the induction effect. Even better is our third design with the coil wound on a U shaped C S iron core which collects as much Of the magnetic field os possible by extending all the way from North to South pole of the magnet. When ® the mognet is rotated on the oxis, induction occurs in the coil. Now let's improve our design one step ato tm stay with the bor magnet os in sketch (2) to make the next point + In that design we had only one generating coil. An improvement is to have two cotls a ‘8 in sketch (4), each has « mognet pole passing by ot the same time. To create output voltage, we have both evils connected in series. At one stant, the voltage peak of one coil ‘odded to thot ofthe other coil. One lW thing to watch out for : both coils must tL have the wire wound in the same direction so that pulses are generated > inthe seme dive ion or polarity. ‘What about polarity? Look ot @ sketch () + the North pole of a Col magnet Ys moving in to the low end of @ coil os in(G)a «Let vs ose thot the coil ie wound to have this make the top terminal plus as sketched. Moving the North pole away will generate a pulse with minus at the top terminal 08 ot b - Moving a South pole in toward the same coil at € will agcin have minis at the top terminal, and the op Com whan that pole is moved awoy. Ifyou look at our design in sketch (6) nate thatthe two poles at opposite ends ofthe curved coil generate pulses in the same direction wthich then amplify esch other, the same elect thet from o stronger magnet Skatched gt the coils above, the the generator of sketch would look ike sketch (6) + oppeite magnet foles moving Together bt ot opposite end of the sone coil. "Al of thet is easier to sort out if you think about the way in mhich © permanent meget attracts @ piece of fot iron: opposite poles, attract each other, and os the magnet opproaches,7 WHY NOT eRMANENT MAGNETS? (Our naw ond improved rotor in sketch (7) has several magnetic North Se macnn ae acetal matic Na cd ee gee Se eee een pe retool eae eee cel eee amet eas ane ares eee ee eer eem eens Se aie aes eam cee meaner see eee cea ae asters ani ‘an electromagnet instead. An electromagnet is shown in sketch (2). Ra eens eete Reale eee eet. acre een oreo @ Merietcins mek cas | een ee eee a eri aa ae aaa shih lat becom eer toner aac a ao Saas eres me bh enter mi Interesting about magnets i thet thie North ond South ples clove fo pieces of iron create magnetic poles inthe Inga See the electromagnet in sketch @ ‘iv urns the ectongler preven oF ion ino magnets which have North ond South ples or shown inthe sketch tnd which ettract eachother, ee pposite poles ore known to. The magnetic fel, instead of spreading ut Into space from the ends of the magnet, pretest fellow the iron pieces which contain or conduct the magnetic flux» Patience please, follow this one step further :f we place two iron bars ‘across the ends of the magnet in sketch (1) , the bors develop two new North and South poles . Very similorly, wwe generate the needed poles at the edge of the alternator rotor with o single tromagnet. In tketch (2) , we ore splitting the magnetic flux into two channels to form two North poles which will not be as strong as the original N pole of the electromagnet. To make the number of magnet poles of the elherotr tr wiciey omg, 2 rong electromagnet is made with a 9 cglled field coil which is ploce round the eltercor shat ein sketch QBs Iatead ofthe fw Wr Inthe sketch, the field call typically has a few hundred turn of magnet wire which iso solid copper wire with o thin coating of lacquer or ‘varnish as inl made to ollow maximum umber of turns and minimum space taken up faced by two steel disks which, if they were left cs inthe sketch, would develop North and South poles at their edges as shown here. In reality, the edges of these disks ore shoped to have stor North and South poles , bent so that they form the outer edae of the rotor. Current forthe field coil is supplied through carbon brushes which ae in contact with insulated smooth copper rings which are called ship Flags . They are fastened to the shoft and rotate with it but are lectrically insulated. Other alterntor designs use a stationary field cil without brushes of alip rings. Here the magnetic flux of the field coil reaches the rotating magnet poles through © gop between stationary ‘ond rotating components.— Non 3. they ae spaced far enough from eachother fo have the regnate fox pas tcogh the striated of being sor tented by fewing relly bemecr rotor Noth ond South polar Inthe leroy, the ion core of he ser with i goneating oo minding woul be Iocated ivecly ot the magnet ples ofthe rr, with jus! enough Teeonce el he rotor spin ely Tonveen the magnet Poles, the wire windings of he Feld cot! oe sketched The ono he eal ire oe ped theugh wo holes end ‘are connected to the slip rings. Alternators which use a needle bearing SF the ping end of the sah wl hove the pln end he sha en sketched here. If a ball bearing is used, its inner race will be press fitted on the shaft and the outer race will then be located directly next foe to spins and wil sual as hove the sone dima the og Si that here oreo umber of alternators wth tony Feld coils. Although hey ets have ror witnSnler mage poles, the Id ctl wil rot reed lip rng or bes: Deli re shown ft he {posi olterndors which incledeseverl Belo ord Merchel models ‘Als oleh tose alter ith Feld brutes Reve ora linea sp rng ox sown ere ond witha rail bushy nd one Wk hope all rtgy boot likes large washer, with ov enfl esh in coma, th bash oriented pose foe sh Sind Inthe Notion rom corwertonal generates falters, ee wih for fdivdvl nage! poles eoch wood with wh own ld The outer dnerion of hav ety alteton aio he the proportions oF the longer ond nerower gorarer 10 (OF ROTOR POLES AND STATOR COILS For @ general understanding of alternators, this section is not essential. Bot fo be complete, «look ot the stator is needed, at that component which contains the power generating coils and which, in contrast to the Conventional generators, produces alternating current. The transition to tlternators on a broad scale become possible when capable and inexpensive solid state rectifying diodes became available. And with them, the "self rectifying AC generator" made use of several phenomena related to alternating current to improve its performance and reduce its Size. In this section, we will se how present alternators use three phase tlternating current, as well os high frequency AC, to meke conventional ‘generators obsolete. The sttor coils o stationary power generating ens produce putes of electricity when the magnetic poles of the rotor poss by. We have seen earlier (sketch OOO) ‘that impulses from N poles have the opposite polarity of those from 5 poles. Our goal is to have mony coils focated cround @ rotor with many magnet poles ox in sketch (I). We did rot connect the coils there because we have to do some thinking First. If we moye the magnet in sketch CD) olong the i ‘oils ond wont fo connect varies, 2 that wwe get highest generated voltage, we must connect 3 fzpe § PS ed by the dotted ins hes cae @ —_ plies gress, Ree inane Td Pl cinos hve Sons aro pl camino opie nds To hove the ail phn the sme ection a rey othe Stee ore caw Horet he sot twee ree mosicl wa tee, al cts osnd ini one Shstono ccmecion Sieger sketch @ , 2M comets nin Scionn changes back and forth. Or, shatch @) , windings and connectiono are Fay Bay Be Bee mmogne!pole- All thete stator winding mathods ore actuelly ued in alternoor The pparert waste of method GO) in relly is overcone by hovingcrther group of coils in the positions which were skipped . The output of the fro group of coll however mt be rectified opaately. THE STATOR Please allow me to sketch stator ond rotor details in this section in o straight line , rather than in the round as they actually are. It saver space and keeps the sketches simpler which, | hope, will help them make their point more readily. NOTE : STATOR AND ROTOR IN REALITY ARE CIRCULAR, NOT STRAIGHT AS SKETCHED IN THIS SECTION, We have the alternator rotor, sketch (@) , with evenly spaced magnet poles cround its edge, the poles are alternately N or S poles. To have the greatest possible magnetic flux pass through the generating ‘coils, they are wound on a core of laminated iron which has its pole ices extend very close tothe mognet poles of the rotor, sketch @) tate cropls i echer ord CO cape Har Season Nand 5 poles then is concentrated inthe iron stator. The sketch alo, shows the sall extension of The sal poles which help to hold the coi wires in place. Note thatthe rotor S poles are shown fnferconnected while the N poles are coming up from behind: this would be the oppea tance ofthe rotor when looking ct the South ple sde of the rotor see Hetch @ and © - a Te place generating coil windings on the stator in shgtch @), we can use ay of the methods in sketches, @@), (@) + of GD » Mos often, rrethod (3 appears to be practiced’? forexonple, wiresrourd In Tight turns whore N pole Ts shown ond left tors where S poles 12 ALTERNATING CURRENT IF the rotor in sketch @) hod) mognet poles, namely 5. North ples nd 5 South poles, then the stator would ave’ 10- generating cole I we wind them left, right, left, right, all in series, they will be about ‘rinsketch @2 except, of course» located all the way around the Stor ond rotors For each fun of the rotor, there wil be five plies with pos ot ternal Ay ond five putes with plus ot terminal Voltage of temfncl A. will change back ond forth om pls te minis. When A Tso Ts highest postive vlloge, B sot is highest negative veltoge- Our alternator generates celled fll phose alternating Siren or AC + “You probably hae seen curves which represent voltages of AC verus ime, For terminals Av and By such curves would look Ike th “As voltage climbs oA fo the meximum postive vT+ veltope, terminal B falls to the mentum negative veltope, The ectval elves depend onthe number of furs in the Cols, roor speed, ond Srenath of rotor rmognatism. In 12 Volb Glterotors, AC vlfone ot open terminals, with tw loed connected, coh tcsityepproach 100 Volt. How does th alterator AC compare with household 110 V AC? The Frequeney of out household AC 14.60 Hertz the termiols ct on outlet ge through the curves in sketch @) sity tines euch second. The frequency of an alternator with 10 rotor magnet poles has to make only six oll rvolutions por secon, or run ot 360 RPM to generate AC of 60 Hertz (Hz). Usually, alternators are belted with pulley sizes which roke alternators tum Wice sft ov faster than the engine. An engine operated at 2000 RPM wovid ave is elerater ron of 4000 RPM or ou8 tins per second, generating AC of 666 He. Asan average, the alternator frequency willbe about 10 fo 20 Fines that of hovseold AC.13 The main advantage of higher eqvency i smaller sie, oF greater power from o given sce of elterator. Miltary equlpmere offen cperctr ith 400 ic elterrating curert rif you have s chance, se how ach souler rotor or tonfomers ere when compared to 60 Hs unis of sane horsepower or wltages Th alternating corre’ from the alternator of ketch @) = @, traced in sketch)", is clled fll phot, You may have Mod the term split phase + deseribes the Kind of AC wpplied by mas 110 V AC cutlets, fr example in hovscholss Mest often il hase AC on in dketch’ @ but of 220 Volt oro, is plied bythe electrle company IF ut one ofthe two wires, for example terminal A, Is connacted 1 an outlet and the other outlet terminal connected to ground ( the so Called nesta wire)» then the vltoge between the ctl terminals con ‘cn ooch ¢ maximum of HOV, gee MAX “in etch» The outlet tories spit phove AC. The other terminl, B ofthe orftna fll pose B20 AC i oho ved, possibly for ome other Soret. The only Uitference beeen the sutleton A ond ony cutlet on B is that to AC pultes do not occur ot the some tine + sketch shows you hat time psies between moxinum ps (up in the sketch} vltoge at ond rroxinom pls vollage a "here i onster term: tee phase AC, the kind which our alternators are gororating lide before 1s bing ecified. If wo would rectify the wselslteratingcurent.for example by throwing mitch at the ight moment, soe sketch @ , the ret wold be « dhopped +e irect current os shown on the right. The AC pulses are switched and ‘0w all go in the same direction. This direct current is useful to charge botteries, it can be made into smooth DC when necessary. “4 THREE PHASE ALTERNATING CURRENT We have looked at the output of alternati yrrent (AC ) from a si gereretng coll, for example thot in sketch)» traced in sketch Free hed two coils instead, thelr output poles would be either Completely elke or conplately opporite to each other. But in each core, wre tan connect the coils in porelel by choosing the correct pals of terminals. The reslt would be alternating correo from a ingle coil. Buritwe hod tree soporte generating cole, spaced evenly 10 thot the AC pultes fom ecch occur ine l=2-3-1 22-2 fashion at in cs ton ected output from each col ts setched in @ » you an see thot the result truth closer fo smooth three! current, Even though the voltage of ech coil terminal is at 200, the horizontal axis, between pulses, the tociied outro all hee calls conbined, or connected o ane coneon oviut terminal thes ot lok Ike the wacings In sketch @) istoed, when the voltge fom the ist Seiler phese begin fo fall, the pute from the pent coil spear ond then Takes over to Keep the voltage ups Then tho pulse fromthe tied eo Rent ands on In RECTIFIED -I@ 3-PHase Ac ality, the voltage at the output ten snob Hpac nt ory rama I ek curve in sketch ‘The voltage difference vr between the crests ond valleys is called ripple. pple disappears almost @ entirely when the alter~ nator is connected to @ battery Tine15 Te guearee thee phones feleating cen, 8 hove fo modty the tor cota, teed 1 D125 Meise nnich ‘ voy ce Ate es c 7 — need three sopra sets A ® os shown by the numbers A SINGLE AQ SD S-PHASEA, in sketch @ + the & AL» generating coils of set T 2Te "1" are located at "1", + an identical set of «the ones in sketch @), it located at the places on the rotor cated by the numbers "2", and the third set at numbers "3", all three sting of individual coils which are then connected in series. To fit al these windings on a single alternator stator is not ecky. To make room forthe second end third sets of coils, the iron pole pieces of the stator ore made with two oditionel spoces +i sketeh GI). the poles 1 and 2 are made for a single set of generating coils os ina single phase alternator. Coils 3 ond 4 are wound three pole pieces each which have exactly the width of 1 end 2, all coils still ‘match the magnet poles of the rotor. IF we looked upward, as from the 2) ooran rot rn anol he ta, we ose ie wins fh Ht ae cae teh GS Sa ee icleigh ated ou kee inva te x Stiovnte peel Rhee pvr cou eas fhe mt red ata mer Hee esos ori, 23 _2t_3 1 2 93 4 s ¢ 7 8 9 = Y =z uv =z Y z Y z but over by one, sketch @ . The first phose at "X*, second phase at at °Y", third phase ot "Z", the wire turns go around the numbered pale pieces like this = Xt ound 28-29-90, 1-2-9, 4-5-6, 7-8-9, vovee Y ! ground 29-20-1, 2-2-6, 5-6-7, 89-10, round 20-1-2, 24-5, 6-7-8, 910M, soos Placed side by side , the thee ste of coils would look about like thetch except that there are vsely five, hx, or seven tres in ach col, soy, eround poles 1-2-3 , before the wire confines to the text cal, Each of he thes stings of ctl, or eoch stor phate, hat Gre Yerminal et each end Thee esx ends of lacquer inwlated old copper wire altogether the ends ofthe three coll "oysters" which Conta the power generted by the llernaor, inthe frm of hee fhowe of cternetingcorent They are connected to the restifying Sede. Tox the sake of completeness, we should have a brief ook at to cther “keting patter ifr! from tht shown in hatch 32 The Motor wire windogs could clo be made os mentioned orlor ond shown in hetch QD) by minding al colle in the some ing one in-belween location, In this way, coil at °X would be made by Turns ound. 26-29-90, posing 1, 2,2, around 4-5-6, posing 718, 9, wround 10-11-12, posing 13, Vy 15, and w on unl Conete. Ail ols tn the Soe detion with poyme form In each fo makeup forthe bypased location. Finally, there ise winding etted! mich, Tom sre, was adopted 19 help get that much wire into such crowded space. The pattern is based Sin he fot thet hello turn fn real wll generate helt the voltage of @ fll turns All of ‘he windings ore mode ball 2 treat There tot the windings cotinve eround or seven times ntact, just °stg Zoning7 INTERMEDIATE SUMMARY We looked for the difference between alternators and generators. All ‘alternators are generators, bot with a twist : what rotates is the Field electromagnet while power generating coils are stationary, the stator. ‘An electromagnet is used, rather than a permanent magnet, since it can can be turned up or down or off, to regulate output. The stationary coils Of the stator make alternating current which is eatily rectified, or made into direct current, with modern solid state silicon diodes. Instead of plain single phase AC, the alternator makes three phase AC which, when Fectified, places the peaks so close together that alternator output comes close to straight direct current. To make three phate alternating current, many generating coils must be placed on the stator, and patterns are used to get them in place, around pole pieces of Sator core. Rotor magnet poles match the stator coils exactly, and many rotor magnet poles are generated with o single electromagnet which Consists of the field coil and two star shaped iron pieces, one making North poles and one making South poles at the edges of the rotor. Field ‘current reaches the field coil through brushes and slip rings. Or the field coil is stationary and only the iron magnet poles rotate, in alternators without brushes. 18~ RECTIFYING DIODES Only after silicon rectifying diodes became available did alternators stort to replace the conventional generators. A diode ot one time meant @ loss vacwum tube with anode, cathode, and a heating filament. Slightly ‘more recently, selenium rectifiers came into use but were large , with low copecity and much heat output. Germanium diodes were too vulnerable, but silicon diodes were able to do the job, to rectify the clternator’s AC directly within the alternator. fae Sketch @) shows the diode symbol, wi ‘end min ANODE CaTHopeE. "cathode" for the two terminals. Diodes are ‘ovailable in many shapes and sizes, some are shown here. They may earry a small diode symbol to identify the terminals, or may be ‘marked with a band or ring, oF may be shaped with one pointed end. Diodes for larger current often have cases (the name for the housing) with threaded stud for heat sink mounting. Such diodes are available with the stud os ‘erode or cathode. In alternators, diodes ot the one on the bottom are most often used and ‘ore pres fitted into aluminum heatsinks . This shope alto is made withthe knurled housing being anode or cathode. Silicon diodes have two main forthe two conditions which they face current rating in Ampere when they ore conducting inthe forward direction, and @ voltage rating usually called the peok invert voltage or PIV which they have to be oble to hold back without becoming conductive in the reverse direction. A rectifying diode may have a rating, for examle, of 30 4, 50 PIV. The plumbing equivalent to a diode is a check valve. To find ovt whether you understand how a diode works, look at the next ali twee sketches : in @) a diode ts SYK connected to a battery and a lamp or ‘= "light bulb" The halo around the lamp is meant fo show thatthe lamp is on brightly. Note the direction fn w the diode i connected inthis ci ings, h 20 Sketch @ shows the some diode inthe same circuit of lamp end betery, but here connected inthe opposite direction, and the Tomp dark. IF you think thatthe bight lamp in the egeut of lamp ond battery in Mletch @) is obvious, splendid + cary tne it thare ote dubls or questions, food about bate electricity, for example Inthe 12 Volt Doctor's Poetical Hondbook", this ovthor, Spa Creek Inc. Thete shetches will also give on idou howto test diodes vith its terminals: Arter test method is with 2 VOM ( Volt Ohm Meter} inthe Ohm mode. ’ single diode con be used to rectly the alternating current of @ generating oils In sketch GQ , terminals A ond 8. carry alternating current (AC) , ingulek sucesso, A aS Ie iot while B simon, then Ac De B is plus while A is minus, as @ ee setae Tine in sketch GO)» But ony he itive peaks ere conducted trough the diode which is comctd 1 Thee postive pede teech the pls feminal# voltage ot ht terminal own os 8 tol le in sketch GO) « Eventhough the single diode does rot produce trooth rect caren, TIME. this chopped DC tact charge tatterie ort con be rosie by ier Amore elegant method ist reetfy with fur dies ina called eid circuit or wih abeidge fiir which contains the fur dod !2 package. shows the a Sketch , tome generating coil with its alternating current terminals A ond B which are connected to the rectifying bridge S ]©_ et four diodes, They ore 5 rumbered : a plus peaka ot A is conducted on by diode 1, to reach the plus terminal, from there through the DC it, for example a bottery being charged, tothe minus terminal, through diode 2, to B which completes the circuit, tee sketch 3) « The other two diodes, shown by dotted lines, are blockking current ~ Then, when B is plus , its plus peok reaches the plus terminal through diode 3 the DC circuit is being completed by diode 4 which connects the minus terminal to A which is ‘irus of this moment. Sketch shows that this time, diodes Tend 2 are blocking » The net effect of this diode xrangement is shown in sketch @& plus peoks ot A ond of Bag raate sketch 4 / @) , peaks from 3 ae te ite te arrangement, we con expect twice the current from the same generating coil. Now, with three generating cll sets and the three phoses inthe clternator, all rectified with diodes in bridge circuits, we would need « total of iwelve diodes. This is rarely dane, first becouse it would be Uneconomical , but aio because there are two more elegant ond much Einpler methods, Sketch @@) on the next page shows voltages, plotted yersus time, just a in the earlier sketch 8) . Next to it, in sketch Gd), the three coils of o S-phose alternator ate shown and labelled A,B, ond C. The solid curve is for coll A, the dotted curve for coll 8, and the broken line for coil C. Note thot each curve shows the volage of one tend of its coll +f one terminal of a col is ot maximum plus voltage, oF Up in the graph, the other terminal ofthe same coil will be ot the 1 voltage, down in the graph, not shown but important fo Understand. Tn this example, we will have the alternator rotor turn clockwise, cos indiegted in hatch @) . The letters A, By and © mork the coil terminals which ate plotted in the graph. 22 ‘As the rotor turns, its North and South poles past coils A, B, C, ond ‘generate electrical pulses ina I~ 2~3~-1-2~3 fashion, Voltage ot the letter-marked terminal of each coil is plotted : note the small circles ch @ when voltage at coil terminal A iso maximum plus, the Terminals 8 ond’ Core recr maximum mim voltage. Note the Tine of eons and ve how you con find out fora sx ernnols whether thay ate pls or minus af that pocive moments When A iva nina pla, the thor ond af eal 8 man be ah manom mina, Hh te minus tion inkatch GB). Av the some tne, the sll ctce below A Colncies with eraer one around ociossing point of curves for Band C. The vltoges for Bord Cot thet iratont ov alk mrt follow the lie of arows ond mer the Yerminaly Terminal Bs mis end sing towerd zero, terminal i ins and sil fling toward ts maximum, tins voltagos You can row lao mork the other ees of eats 8 ond © with plus and minus signs. Interesting is that there are always two coil terminals close together in sketch @6) which have the tome sign, plus or minus. You can verify that : when next terminal B is at maximum plus, both terminals A and C ore minus : A sil falling further, C already in the process of rising toward the zero axis in sketch @) «Even though you may have theowa up your hands, or wore, you have arived in the middle of the most common of alternator stator designs. You ore Tooking atthe explanation why all thre sfotor windings may be connected of the tds to work together, fo generate tree fos elterating currd, with jut fives output fermncls which, of we will tee tne moment, con be rectiied with Six diodes, thes ina group, two groupe total, ‘Admitted, sketches @ ond @) are clttered. But you From where 12 Took, toke the peala at A, B from setch, @ and compare the ples tad ius signs of lft here. Storing the fop, oll A. isch maximum. In the sketch inthe middle, B eof rox trum indicated by the plain plus and Ininut tigre, and of the bottom, cal Ciset moxioumn, end soon, the cycle repeats itself. The (plus) signs in Enocket ore mecnt to indicate thot voltages there oe tof of maximum tet reer, ond ether onthe mayo or from marin or peck. Here agen, you can sae thot the sign othe oil toninal which are Clove together, af the corners of the friongle of cols match + atthe coll tthieh happens to be ot eaximum. And iF you look closely of the other two tells, with signs in brackets they ore Connected in series, jus ike baHeries tre connected In seres for toltoges You can see, with sme fatience, that one col ot maximum Fes the other two coll contribute by omtining ther laser voltage by corners of the triangle. The wiring method is called DELTA because of the triangle arrangement : "delta" wired alternator stator. 24 Int least one respect, the delta symbol is misleading : it may make you think thet each A ~ BC output cycle is with one shaft revolution. Ther tat the case, ook ot sketch G})epuin © the rotor hed 10 mmogret poles, that fs, 5 North poles and 5 South poles, we would get of pulies, A~B~C-A-B-C-A-B=C-A-B-C=A~ a efor just one shaft revolution. There are alternators with 1A magnet poles which will generate 7 ful cycles ofall three phases with each revolution, ‘Another comment is necessary : in the voltage graph, sketch @) , voltoge peaks are shown ot letters A, B, ond C , all on the plus s hove the zero axis, and the corresponding points in the minus region where the other two voltage curves cross, see the small circles. Omitted tre [ost os many instances where each curve i of its lowest point, at is tmoximum minut voltoge. At thot potat, the other two curves forthe ther two cols cross in the plus region and again, al coils cooperate: You could circle those points inthe graph ond, agatn, mark the plus oF minvs polarities of the separate coils, to see again how each coil contributes when they ore connected to each other in "delta" Fshion. “The other stator wiring method ts shown here and, obviously, iscalled "Y" « Keep in ind that the Y symbol is only «@ grophic simplification which is meant fo indicate that one terminal of each stator coll is connected to a common junction a the center of the Y + In feality, the stator windings ore mode ‘exactly like those forthe "DELTA" ‘rrangement. The difference is how the coil terminals ore interconnected. With the Y wiring scheme, there ore ogain thee output terminels which supply S-phase alternating current. We can label them A, 8, and C cgein ond treat them exactly like we did before. In large power genera tors, a wire Is connected to the Y center junction and is called the naviral wire. In our alternators, the contral joint exists ia is umelly not accesible or connected to anything else. In th specific alternators we will see how you can easly tell ifa stator is connected "Y" or "DELTA" fashion, but forall practical purposes we an assure thot the two systems ore afk Should you wonder how the three generating coils cooperate in the "Y" wiring arrangement, look ot them separately, os though they ‘were not connected af the center of the then vse the voltoge graph e2ain, sketch @) . Keep in mind that we hod plotted the voltages at one end of each coll only. Sketch 2) shows the plus ond minvs signs for the three coils where A is at its maximum plus, B is minus ond ing toward zero, Cis minus and falling foward it maximum minus.25 tga When you now imagine the three center terminals connected together, you 2¢ that both coil B and Core connected in series ith coll A. At this rstant, coils B and C cold their generated pultes to thot of coil A. Al work inthe same direction. The assembly (=) hoppers to have one plus terminal et A ond B two minus terminals. e way in which the Y coils are combining theie effort by arrous, sketch @ . Long arrows mean voltage. The orrow always pointing irection toward plus. Again, you that the Y_ arrangement is a symbol only. In reality, the coils are made os we have sketched them earlier. Here, we are looking at a neot graphic shows the peaks only. To be complete, the output pulses ot the three terminals for one full phase would be; maximum voltage thisorder: At, C=, Bt, Ax, CH, Bs, and s0 on. Can you see these places the graph ? The mine paaks had not been circled. THE THREE PHASE RECTIFYING CIRCUIT 26 The basic reqirements ore simple : we have three terminals, A, B, ond , which each produce both positive and negative pulses of alternating current, To use all of these, each terminal GF well ot the nepotve terminal of the direct current output. That meas that ach AC terminal min have one diode which allows postive pulses foreach the plas DC (direct Corre) terminal and another die which Connect negative plies fo the negotve OC cutpet terminal. Thot means two dodes ot terminals A, 8, ond C, ono condicting fo plus, the other condcting fom min, on sketch GD. Remenber thatthe diodes ore conductive inne direction, when pls fe applied to their plus (anode) terminal but block Corret inthe other direction. Sketches Gand Flying diodes forthe “delto" and "Y" stators. As you can see, the rectifying circuits ore identical Th sketches oe simple Baca the three DC plus ond mines inal are not connected fo each other and to 0 comron pls ond minus outpt terminal. Such obviously necestary wiring often makes simple circuits more dificult to view . All you hove to do here js Interconnect the three plus terminals to @ plus output terminals, and do the some forthe three minus terinals Several examples ofthese diodes are shown agoin, with the additional wiring, for specific models of alterntors inthe second section of this book.a7 Sketch @ shows the stator coil ofan alternator in dete orronge The thee ator or Yamafure® terminals ore labeled AC fr elternoting furronts The dest conent or DC outpt terminals have pl and minut Sor. ‘ie hove seen tht the AC terminals in operation will have plus os wall es minus peok they go through thei alternating curtent phases. The fect tha here poke doo! oecut ot the se fine at any Termivel isthe reown why each AC terminal requires itz own To condcr plus or mus pula othe correct DC terminals, terminal neds one diode fo DC plus ond one diode Yo DC mines + use this sketch to trace the paths for electric current. Remember thot current flows through a diode only in one Also keep in mind that a current will flow through any lood (wuch os a battery being chorged, or 2 light) between plus and minus terminols ond the complete circuit outside of the alternator. Note that such circuit is complete only if you can trace from an AC terminal tough a diode in the proper direction, through the ‘external DC circuit, through another rectifying diode in the proper direction, and to another AC terminal. RECTIFYING DIODES : MECHANICAL The diodes in sketch @) ore shown into group ote thatthe thee fades near the minus frmel ell hove their onode in alectical contact th the mins terminal Siler, the ro diodes ear the pls Terminal hove thelr cathode in covfoct with the plo otput terminal Since dades prosuce some hes when current Is lowing they ore vay mounted on hoot sinks made of mel, Such best sink i made lorge trough 2 the ts wrface con bo cooled bya flow, Best thermal Contat is achieved ifthe thee odes are mounted directly Yo the heat in which then come part of he plutor mim terminal Sometimes, tina oder ore mounted dvecly fo the elterntor housings 28 We con make a rough estimate of the amount of heat which is generated by the rectifying diodes. For example, assume that the alternator is producing 50 Ampere which are being charged into 12 Volt batteries. ng diodes typically will have a voltage drop of about 0.5 Volt. The 50.A flowing through the plus diodes will generate 0.5 VX 50A = 25 W (Watt) of hect. Since the same current aio must past the minus diodes, another 25 W of heat are generated there, for @ total of 50 W « If that sounds Tike much to you (he heat of a 50 W light bull or solder iron}, let us compare it fo the total output ofthe alternator : Voltage at such relatively high current is likely 14 V or more, 10 thatthe alternator is generating VX 50A = 700W ‘The loss of the diodes therefore is less than 10% . Additional heat is ing generated by the current in the stator windings and by the strong ‘ond rapidly changing magnetic flux in the stator and nearby metal ‘components. AUXILIARY DIODES ‘Many alternators have three additional small diodes connected between the AC stator terminals and a separate plus DC output terminal . This ‘auxiliary terminal is often used to provide power to the field coil or to the voltage regulator. The advantage of this separate plus terminal is that its power output ceases when the alternator stops running. No switch is needed to disconnect regulator of field current, and there 1s no risk of electric current from batteries being wasted if any switch were left on ‘by mistake. Power for this purpose can not be token directly from the main plus diodes since often the battery remains connected fo the plus ‘output terminal of the alternator. Current from the auxilicry diodes and the auxiliary terminal completes its circuit through the three main minus rectifying diodes. Several of the alternator wiring sketches in the second part of this book show such auxiliary diodes. Their separate output terminal is ‘often called AUX, REGULATOR, +, D+, 61, IND . The section on testing tells how to identify it with a meter.~ ISOLATING DIODE Another method is ured to mpply current toa regulator without the need fora mitch. Sketch 4) shows the vival three AC. stator terminals and the three main plu rectifying diodes, An isolated AUX ou vial Aux @ me ‘ directly 19 the main a CD Waele ‘alternator's main us output mut ist bs MAIN re onather diode + le Cisoe. drove. ‘he 'xlstina diode, Batteries may remain connected to the alternator + battery current cannot reach the auxillary terminal which will have ne output power after the alternator has stopped . A regulator ‘may remain connected to the AUX terminal without switch and without ‘any wasted battery power. Itolating diodes may consist of one or two Individval diodes on a separate heat sink, most notably on Motorola alternators of 55A or smaller. Here, isolating diodes on a curved flat hat sinker mounted to ha bac Foun and, of cura, carry he in plus output term cuxiliory terials with isolating diode or with auxiliary eectifying diodes. ISOLATING DIODES, CHARGING DIODE: BATTERY ISOLATORS, Because of the diodes should rity of names and components, this application of mentioned here. Two or more diodes as in sketch may be connected BATT. 1 between the main alternator output terminal ond the oer @ reece Bar.2 alternator running, the two batteries inthe sketch will be charged through the diodes « The lower battery by state of chorge will receive greatest current. After the clternator hos been stopped, batteries are isolated by the diodes « no current con flow from one battery fo the ather if, for example, power ‘were taken from only one battery. The diodes have to be sufficiently large to cary the alternator output current. They are mounted on heat sinks, added to alternator-battery systems and never a port of the alternator itself.31 VOLTAGE REGULATORS Without @ voltage regulator, alternator output would almost always be wrong : too low et slow speeds, or too high at high speeds, overcharging batteries, burning out lamps and equipment with excessive voltage ond, possibly, destroying the rectifying diodes in the alternator. ‘Voltage regulators control the field current, they are always connected in series with the field coil. Voltage regulators are also Connected fo the alternator output terminal or to a battery plus terminal. to maintain 2 constant output terminal voltage by easing the alternator field current. The sketch shows Id coll with regulator. Field Increasing or ‘a simplified stator and diodes, ond a current from the plus terminal must pass the regulator which increases the ‘mognitude of field current if voltage drops below the voltage setting which the regulator attempts to maintain. In 12 Volt systems, this voltage 1g ually is 14.2 V . The sketch also shows o battery : alternators lmost always operate with o battery which contributes to the voltage tegulaliny function much like a gigantic filter capacitor. On your car, {you may notice that the battery often is very small, large enough to stort the engine, but too small te operate the headlights for any appreciable length of time. That is not necessary, tharks to the voltage regulator which responds with increased field current if o load, such as the lamp fond switch in the sketch, are switched on. The alternator output then is increased enough so that such demands are supplied by the alternator, rot the battery. ‘There ore several types of voltage regulators in use, some of the differences are obvious, others are more subtle : there are electromecha~ nical regulators built like relays with coils and contacts, or solid state Or transistor regulators, as well as some hybrids using both techniques. 32 Then there are external voltage regulators mounted a distance from the clternator and connected by wires, and internal regulators located in the tlternator housing. Plus a rumber of regulators pretending to be internal but just attached and sometimes recessed and flush with the alternator housing, usvally easy to remove or replace, some as a unit with the bruthes. Then there is the electrical arrangement of field coil and voltage regulator : always in series, but with regulator either at the plus side or the minus side of the field coil. ‘sketch @) shows a relay type voltage regulator with coll. The relay consists if 9 magnet coil and a moving with electrical contacts. The arm is position at sketched. The IGN ("lgnition") terminal is usvally connected fo battery and alternator plus terminal through the key switch, as is the IGN FiecD : GRD com ay () Cor = plus terminal of the magnet coil. Spring tension on the arm is made strong enough 1 that voltages atthe magnet coil below the regulator setting will not generate enough magnetic force to move the arm. With such low walls, ful eld curent can tlw between ls ernie, the rormally closed contact, arm, F FIELD terminel, Feld coil, and grou coral LD terminal, field coil, and ground, IF voltage rises, for example due to increased alternator speed, force fom the magnet ctl becomes stronger utili evenucly pls he arm and opens the contact and Interrupts field eurent. This drop in field current causes a drop in alternator output voltage which, in turn, reduces the force of the mognet coll: giving into spring tension, the cam moves back to its normal position, closes the upper contact ond reconnect fll field current. Again, alternator output voltage rises ond We Process repects itself : magnet coil pulls, contact opens, field ae ond alterna up volo land meget cll es oof he arm 0 ‘operation still provides smooth proportional voltoge regulation becavm the regulator contact pers ond close vary gock Itoscillates, and Feld curent, even thoug if33 these very short swit cycles. Very often, the pring tension which fonds to hols the om fa ormel poston con be adated and con be vied to chong the voltage setting ofthe rgultor upward or down incremed sping terran erase the Hine in each siting ect wth the upper conect closed ond field current connected, eavtng on iereose of the voltoge which the reguctr malas: Kimilor design is shown in hatch QB), here with more ofthe insInthe corer isthe move coll: one and of Is tad tothe sel froma which isthe pus torminal. The here has two contacts which a at A. The pivot is at the uppe spring steel. Through the steel frome and pivot, the lower moving contact is connected to plus. The upper moving contact is insvlated ond Connected with a wire to ground. In operation, inereosing voltage lets the magnet coil attract the arm, break contact between the plus contact and fixed contact A, and makes contact between A. and the minus contact, The fixed contact A is connected to the alternator field coil. Two adjustments are shown which both influence the regulator voltage setting. A small bolt B holds the fixed contact and ollows tan adjustment” ofthe cir gp between mognet coil ond the moving orm. IF fixed contact A is moved downward, it brings the arm into closer proximity of the electromagnet, with the effect that less current through fhe coil will be able to attract and move the arm : this will lower the voltage setting. On the right, a coil spring D outside the pivot holds the arm in contact between plus and A. The small screw C allows the lower hook’ to be moved and spring tension on the orm to be changed. Turning the serew in and moving hook & down increases cot! Spring tersion ond, os the arm oscillates, increoses contact time between the moving plvs contact and fixed contact A which Increases the reguletor voltage setting. 34 (Often there are two relay coils and sets of contacts within the housing of a voltage regulator unit. In addition to the actual voltage regulator, there often iso field relay which may be connected to an R or RELAY terminal on the alternator, usvally connected fo the stator windings. This relay closes its contact when the alternator begine to generate alternating current. It connects the regulator plus terminal directly to battery and ‘alternator plus terminals ofter the engine has been started. It disconnects the regulator after the engine has been stopped and prevents drained batteries . Until the field relay closes contacts, the initial field current is supplied from 3 key switch. A typical arrangement is shown in sketch 69) « The voltage regulator coil is at the right, with two contacts being attracted by the coil, with fixed contact between them, connected to from the ignition key switch to terminal 4 (typical Deleo-Remy voltage regulator) nd allowing minimal Feld curent fo flow through a resistor R.. Then, os the alternator turns at sufficient speed, alternating current from stator to terminal 2 causes the veluy contact Io close, aking & direct comection from battery plus terminal to terminal 3 and to cotl ‘and contact of the voltoge regulator. At that point, power from {terminal 4 is no longer needed. After the alternator hat stopped, the fleld relay contacts open again and prevent continved flow of field current. indicator light or "idiot light" is connected in n key and terminal 4. It lights only w Serent flows between key atch ond terminal 4 ond goes out when telay connects terminal 3: at that point, plus voltage reach the {3H Both from the key switch and from terminal. 3. Current stops fo Cercttowoh the light since both of ts terminals area the ame po35 Regulators with three relay units were in use wi relay wos needed to disconnect the output terminal from the battery ot low speeds and when the generator was not running. This output relay is not needed with alternators since the re: diodes prevent current in reverse when the alternator is off. Still, some such voltage regulators output relay have been used with some alternators during a generators. A third id state or transistor regulators, some very brief look ot transistors is needed and at their way of operation. Transistors have three terminals : an inlet and outlet and a terminal which is called the base and which controls the transistor's conductivity. With the base, transistors can be turned on and off and change their resistance. The two types are called NPN. and PNP transistors, N ond P stand for Positive ‘ond Negative and describe the junctions, look it up in a text on solid state electronics. Sketch (69. shows the two types of transistors, with terminals C (Collector), € (Emitter), and B (Base), together with o potentiometer as @ source of base current. The arrows show how each + + + + Orr je oN le. 4 = PNP + = NPN | ry 2 ON OFF ! 1 @-+ ! Traitor con be tured on or of, or made more ols conductive. for example, the wiper of the potentiometer (variable resistor) on the NPN traitor wre moved up closer fo the pls terminal, more bose Content would flow which makes the Mosier more conductive, letting rector crn! fan between smite ond collector Tohondle typical elterotr eld curent which amount Yo several Ampere power ironitor i needed which in rn needs larger teve cuents fe be fully turned on, Unaly therefore, @ second Narsitor ibused o contol bse arent ofthe power ressor. Finally, an elomert vey sed in solid tote vologe regslo= tors iso Zener oda whieh becomes cndvetive in revere (pus on Cathode, minus on anode) ete specific voltage, fr exemple 10 Vol Gnd which isused tn ho vltoge tnsng iret, improving the potentiometer nstateh 160 7 The syrbol for a Zener diode i shown ilar aymbols hove alo been ved, ‘at left. Other, FE allore mocitictions of the diode symbol shown 36 The voltage regulator in sketch @) hos @ power transistor A. which is capable to handle the needed current for the field coil. Since such power tromistors usally require relotively lorge base currents to be turned on, ‘a small tronsistor B is connected in a so called Darlington circuit to switch bate current for the power transistor. Much less base current is ‘needed for transistor 8 : that base current fs swpplied through resistor E, At low battery voltages, Zener diode D does nat conduct and transistor C is off. As bottery voltage rises, diode D begins to conduct and through potentiometer P , base current turns transistor Con : it conducts current thrush € to cround, shorts the bate of B to ground which turns off B ond A , and interrupts field current. Similar to the vibrating contact In the mechanical regulators, this transistor regulator switches Beck ond forth between moe and lest conductive totes ofthe tosses. ere ore two plus terminals : the one atthe right often is supplied by cxxiliey diodes, relay, key switch, cil or fuel prosure switch or by alternator output with isolating diode. Voltage at this terminal often i different from battery vltoge. The pls terminal et lft senses bottery voltage ond often remains connected permanently to the battery since only very little current is uted by this terminal. af mb of vrtions ofthis crt is posible, A few onal examples ore among the specific alternators in the seco half of the books No shown heres tor nesensy oe ne potechvea7 ‘components. Most important is @ diode which will allow reverse voltage spikes to bypass the power transistor instead of ruining it. Such J- spikes are generated when inductive loads, such as coils in solenoids, relays, compressor + clutches, field coils, are switched off. The sketch af left shows how such diode is connec= warand B* include a reverse ina common housing usvally diode. Some transistor voltage regulators have adjustments which allow changing of the voltage setting, usvally in the form of a screwdriver acc tim potentiometer. But the trend toward regulators located wit alternator housings has made such adjustment provisions rare. Especially 1s solid ttate regulators also have changed from "discrete" components eee hie of on hes Satsr ae Teaver att sr vpred aif of he vole sting i ‘ soon in eich @) » ate vltoge i ofen a aioe, nth tcl cree el cgetietbeld of shun 018°, conectd in he sre race se teas che a veranda a wiht ae leaner ener sage Higher by Or Tener cacao lee eet ve sd ae M netios of coals TYPE_P_AND TYPE_N Regulators control field current by being connected in series with the alternator field coil. There are two possible orrangements, both are in use. The voltage regulator may be on the positive side of the field coil, source of positive voltage and the positive field coil terminal, or the regulator may be on the negative side of the field coil, between the negative field coil terminal and negative system ‘most often is ground. We will call the first arrangement type P for Positive, the second arrangement type N , a8 shown in sketch 63 . Do rot confuse with positive ground (rere) of negative ground (most commen) wiring systems. The two ore not related. 38 With the more usval negative ground system, and with brushes atthe terminals of the Feld cotl, alternators with type P arrangement, with the regulator on the plus side ofthe Field coil, one brush will be grounded. Incontrost, type N alternators will have none of the brushes connected directly to ground, see sketch G2. Tn general, electromechanical or relay type regulators will be external, located at a distance from the alternator and connected by Wires to the alternator, ond External solid state or ta mechanical version, have housings and terminals like the mechanical enion and operate as type P . But more recent external solid state regulators may be of type N iF you need to know, a test or close inspection will tell the difference. Internal voltoge regulators, including those which are attached , Inserted or somehow a part of the alternator itself ore most often a type N, withthe notable exception of the smaller Motorola elternators with attached regulator. In the description of alternators and their regulators, we will se these terns: POSITIVE GROUND : rore, has battery plus terminol connected to ‘engine block or starter housing NEGATIVE GROUND : most common, has bottery minus termine! connected to engine block or starter housing . Alternator minus terminal may be connected to elternator housing, grounded through metal bracket. ISOLATED GROUND = neither plus nor mi pomanently connected fo ground or storter housing or engine block. Both pls and minus starter wires (cables) ae switched by solenoid for fengine starting. Sometimes, only duting sorting, battery minus becomes engine ground. TYPE P ALTERNATOR/REGULATOR : external or attached voltage regulator is connected to plus field coil terminal or plus brush. Minus brush usvaly grounded or fo minus. TYPE _N. ALTERNATOR/REGULATOR : voltage regulator is connected between minus field coil terminal and ground or minus. Plus brush or field terminal is connected to auxiliary plus terminal or system plus. Minus brush or field coil terminal not connected to ground or minus but to regulator. EXTERNAL VOLTAGE REGULATOR : teparate unit connected to the lternator by one of more wires. INTERNAL VOLTAGE REGULATOR : located within the alternator back housing, or attached to the alternator. ELECTROMECHANICAL VOLTAGE REGULATOR : relay type with coil end contacts, always external. SOLID STATE VOLTAGE REGULATOR : has no moving contacts, made from discrete transistors ond components, or consisting of integrated circuit).EXCITATION 40 ‘Many alternators take the power for their field current from their own ‘generated output. They ore mainly the alternators with isolating diode or Mith auxiliary diodes. Both designs use the diodes to make external relays Unnecessary. They can then use very compact solid state regulators wi Find space within the alternator. When such alternator is not running, the isolating diode, for example, prevents current from the battery to be wosted on field current. The battery can remain connected to the alterna= tor output terminal at all times. However, a slight drawback of this design is opparent immediately after the alternator stars to run : there is to field current because there is no power being generated, and that is because there is no field current. One hes fo come first, and from an outside source # the battery. The process is called excitation. Excitation current i usally taken from an ignition switch or engine key switch and is supplied to the field coil through a resistor. Often, a charging light, alternator pilot light or idiot light is used and then ‘contributes to the excitation current, as in sketch 63) « Once the allt rotor isin full normal operation, regulator and field coil get their power from the auxiliary (AUX) terminal . But directly after startup, excitation current from the ignition switch (IGN SW) through resistor ® and the indicator light LAMP must reach the AUX terminal to start the gener process. It takes less than o second fo start, and the needed current Is less than one amp. Then, the AUX terminal corries output voltage and the lomp finds itself with about bottery voltage at both sides: it stops to light. The resistor is used so that the alternator is being excited even if the lamp burns out. The resistor is necessary to prevent high battery charging current to flow through thin wires from AUX terminal through ‘the ignition switch to the battery. The resistor is usually between 50 ond 150. Ohm, Note that regulator ond field coil are of the type P in sketch. ‘One peculiarity with charge indicator lights is that sometimes they will not comletely extinguish even though the alternator performs quite normally. One explanation is shown in sketch (4) where you see same ‘excitation circuit with ignition switch, resistor R, charge indicator ight, connected to the AUX terminal of the alternator. Once the ‘generating process hos been cycled info operation, alternating current AC is being rectified: only the three positive rectifying diodes orea shown which connect fo the auxiliary terminal, as does the light. On the way to the battery, alternator output current must alzo pass the isolating diode which electrically is between AUX terminal and the alternator's OUTPUT terminal. And this diode, or o pair in porallel, creates a small Ten. AC om cigar Ac Ac BAT. OTPUT sou. AUX ‘DIODE voltage drop, about one vot or lest: the AUX terminal ond the Side ofthe lamp will be about one volt higher thon the OUTPUT terminal and the left side ofthe lamp. While thot will not stort « cold lamp fo slow, i may keep one glowing which jst hod been at fll brightness. ‘Acother explanation is unvaval resitance inthe components and ites between the AUX auxiliary termina, isolating diode, outpot terminal, wires ond posible main switches on the way tothe battery or to the point where the ignition switch wire is token off. Such resistance will then create a snilor voltage crop and can keep the charging light glowing if the alternator is of this design. The most practical cure, if ro other corectve steps ore necessary, is to switch to @ lamp ("light bulb") with slightly higher design voltage or slightly higher Watt rating. ’A diode can alo be used to supply excitation current, shown in sketch @) « The diode will opply almost full battery voltage to the cuxiliry ferinal and will tend fo ereate much greater excitation currents than resistor and light, neither good nor bod. However, such diode prevents al feedback tothe ignition switch, an advantage when (6: Exe. DioDE aux FI a Ber. 5 pets certain accowories are powered fom the switch: fr example, fel toler valves may close more inmediatly when the nth is being opened - Note tha field coll ond rogulator in sketch @) ore the type N rrangemert, with he replator between fel ctl end ground, a BATTERY IMPORTANT + Alternators ore designed fo operate in conjunction with a bottery . They must be connected to a battery while running. Interrup~ fing the running alternator from the battery , even for only a fraction of ‘azecond, can have the alternator output voltage rise high enough to ‘cause one or more of the rectifying diodes to fail. Alternator and battery cooperate with each other. The battery usvally {upplies powor to stort the engine and excite the alternator. The alterna for then recharges the battery . Starting batteries have to supply very high current to the storter motor, but usually only for a very short time, te that the needed Ampere hours are small and the battery itself can be felatively swoll. Still, relatively high currents can be drawn from the tlternator-battery combination indefinitely, o long as the alternator is running of sufficient speed and such current is within the alternator's capacity. | For example, a large engine in a car may need 200 Ampere for its starting motor, supplied by @ 12 V battery. Ifthe engine starts after 10 seconds of cranking, the Ampere hours taken from the battery ore : 200A X (10/60/60 )hours = 0.56 Ampere hours, which i les than one hundredth of the total storage capacity of a typical 60 Ampere hour battery. The battery will be recharged quickly after starting and will estentially be fully charged ot all times. then electrical equipment is being switched on, drawing, for ‘example, 30 Ampere, the voltage regulator instantly increases the alternator output current by 30 Ampere so that the battery remains unaffected . In foct, as long os the copacity of the alternator is greater than 30 A ond runs fost enough, it will supply the 30 A draw ond at the same time continue to charge the battery. That is becouse the voltage regulator ually is adjusted to maintain a voltage at the alternator ‘output terminal which is slightly higher then the voltage which the battery can ever achieve, even when fully charged. ‘The alternator output voltage is usally mot regulator ot ined by the voltage 14.0V- 14.4 V for 12 Volt systems , 28.0 - 28.8.V for 24 Volt systems , and B7.4V ~ 38.4 V for 32 Volt systems. The 12. battery typically shows a voltage of 13.2 fo 13.8 when it is completely charged. Depending on electricity use, including current crawn at idle speeds or while the engine is off, the voltage setting of the alternator is. @ compromise which may mildly overcharge the battery,4 Frat charge it quite enough. The fist cave is noticeable when wote in the cells of the battery has to be replenished frequently. Undercharged batteries will not reach a voltage typical for full charge, and the smaller ‘amount of stored electricity, in Ampere hours, will make itself known when current must be drawa from the battery *. ‘The connection to a single battery can be made directly, as shown at top in sketch @),, by 0 wire heavy enough fo cory moxie alternator output, usally a size 10 or 8 AWG, stranded copper, but sometimes consisting of two porallel wires of smaller cross section. The oS BATS : fost of may be poTertly connected tothe clfenatr output terminel« No current con flowin revere The rectifying diodes prevent tht Sometimes, switch is vsed ar shown a te lower sketch y such switch is only uefl or necestry If electrical equipment must be switched ond it other wire between mitch and battery is improcticel Such mala Switch may be uted to disconnect battery fom stare solenoids Tre is some risk that the switch may be accidentally opened while the elterator is operating, This con destey one or more ofthe rectifying diodes. ’A main switch soften ed when there ore two or more seperate Lotteries connected toon alternator. Such atch, Top in sketch G2) s a single pole ~ double throw ( SPDT ) switch which should be a "make Before break type + when switching from "1™ to "2" it makes the conection to terinel 2” before breaking the connection to terminal I~ The siteh postion which har all tree Terminals interconnected, uscally ramed "ALL" or "BOTH" should be used before starting engine ond Barr.1 3—@ BAT. 2. sw Bart Bar 2 alternator, to connect all botteries to the alternator before starting, tnd after charging them with the alternator, select the battery to be used. fs Se eS diodes, or battery isolators, shown at the bottom in sketch 67 and in sketch @ » Such der ‘connect a diode between alternator See) terminal an the plus terminal of a single battery. Charging Se ee ay coat snc te er Se seo ee a. hoe motch or exceed the anticipated maximum charging current. Such diodes ‘are mounted on “heat si of finned aluminum since some heat is being cee io ed iim en ee a Eas ces caw na Sie gpl ‘a larger bot bank which acts as a single battery of larger storage aga uy eae Se tne Se ag alternator and the batteries, diodes can be connected directly to the twitch terminals_os shown, and the diodes pouibly located behind the 3 which carves the switch Pent The chergng diodes or iuolting diodes (tame name, but diferent from the Isolating diode uted in some alterotors) couse o small voltage step or threshold when current is flowing. The difference between anode and cathode voltage is cbout 0,6 V forall silicon diodes regardless of Example t if « charging current of 30 Ampere is flowing through @ diode, the generated heat will be cbout AX U.6V = 18 W (Wen) « The small voltage crop at charging diodes can be confusing to the ‘operation of voltage regulators: if battery voltage is sensed by « wire comected "upstream" of thot diode, the voltage regulator wil sense a voltage 0.6 V higher than the acival battery voltoge. Since the ‘egulator maintains the alternator output terminal voltage, vsvaly ot 14,2, 0 voltage of 0.6 V les reaches the battery. Better isto connect the voltage regulator “downstream of the charging diode or directly to the corresponding battery terminal. Since that however may connect the ‘equator fo a fll battery where another empty battery must also be chorged, 0 simple trick can be ured to compensate for the voltage crop ‘eros chorging diodes or splitters.45 Sketch @ shows on alternator connected through charging diodes fo two batteries. To compensate for the voltage drop at the charging diodes, nother diode (ertow'!) is comacted inthe pls somting wie of the Baw. t Bat.2. voltage regulator. This diode can be much smaller in current rating than the charging diodes but will have @ very similar voltage drop or threshold which is independent of the amount of current. The voltage ct the regulator will be 0.6 V lower than that ofthe alternator output terminal, or about the average of the two batteries, a long as some charging current is Flow With external voltoge regulators, this compensating diode will be 087 to install: look up the brand of regulator and tee what letter or numbers ere used fo label the terminals. A suitable diode isthe type 1NS400 or an equivalent, rated 3 Ampere. LD ie cathode will be pointed or marked witha band, see sketch (8) . Even simpler isthe case of mechanical regulators which may have a voltage adjustment stew, of which otherwise ore adjusted by bending, with sitable pliers, the spring support arm, see sketch 58. Increated spring tension usually coves higher alternator output terminal voltage. A voltmeter is essential to make proper adjustments : 14.0 to 14.4 V at the terminals of a 12V battery after several hours of runing time, litle loss of water from the botteries. Read about battery charging and battery maintenance Alternators with attached solid state voltage regulators or with ternal regulators often do not have a seperate battery sensing wire or terminal : look up the specific alternator or a sini model in the next section ofthis book Some alternators make the exception : Motorola clternators with attached regulators have sense terminals ofthe single regulator plus wire (red) is accesible ot the outside, and many Deleo~ Remy alternators with internal voltage regulator have two lug terminals marked "I" and "2" , Terminal 2 senses battery voltage. * more on batteries, battery charging, switches, diodes, wiring, trouble shooting in "The 12 Volt Doctor's Practical Handbook." Edgor Beyn, Sed edition 1983, Spa Creek Inc. Annapolis MD . WIRING DIAGRAMS, SCHEMATICS errr rr ring diagrams oe mos vefl if they clearly show how the components Wiring Seon oe ceil are connected to eachother. To explain £10 JA Slpmricvter fonction, a witing scotch wil nly show the components which ere significant ond otherwise nly show hew the connections to the rex ofthe B whole tom are made, Inctor word, to explin veltoneregvltors, only regulator and Fed ctl With conection fo pls ord mince mut be shown, perhaps ith ignition evitch, charge light, ond the battery plus terminal. This, hopefully, will keep yn _ the sketches simple ond understandable. Rg Al wires or other metal conductors are shown cat tolid lines. If two wires cross each other without be shown RRLLL— being connected to each other, they wi asct A Joints of two, three, of mo Comacted wires or other conductors ate shown ‘ond C.-A zigzag line indicates 0 row of loops mean a coil, as ino {elay, solenoid, field col, generating coil. 1 capacitor i shown by the two parallel plates. If it is anlectrolytic type, © + sign wil show polerity. The synbol for “ground” is shown ? est often, will Be identical with the mins pole ofthe system. ’S cave ot housing is shown by o broken line, to = Indicate which components ore locoted within. If the housing is etal, it may be connected fo ground | orseve cx ground, ox shown here bythe connected CAMP ground symbol. The circle al croe shows 7q_ © lamp with its two terminals. The SS shows a single pole ~ single throw switch. Symbols kotor type of vies wl be obvious. Nex, @—w—> 0 plus terminal shows a resistor which is then further Connected to components which ore rot shown : text will explain, or ane of the abbreviations may tll REG BAM re te snow iv evertuely comected- -Mony ofthe abbreviations ore shown here + VW = 2 from regulator to battery, alternator, Ampere, Volt, RIGA) Watt, Ohm, resistor, ignition, alternating current, AC Sina tat Feld, ground, ond evitch, Letters N ond P A will refer to fleld-and-regulator arrangements of E GRD type "N" or type "P" , as used in this book. This SW_N P._ cetigation of alternator types is notin goneral use.CONNECTED ISOLATE D While we are in the middle of it, symbol the sketches on the following poges allow us to leave out the clutter of repeated explana= tions . Symbols for wires, coils, resistors, contacts, let the sketch show more clearly what is the point. Such symbols are used for field coil, at left, with + and ~ signs which let you see if it is a type "P" or "N regula~ tor of alternator. The coil symbol is alto vied with relays : see the ones with N.O. and N.C. contacts. The normally open (N.O.)is being pulled closed, making contact, when the coil is energised. The other, with normally closed (N.C.) contact opens or disconnects when the relay coil becomes magnetic with current ond pulls the contoct arm. Note the different symbol fora resistor which is @ zigzag line , often labeled R, with values in Oh The switch SW in most voltage regulator sketches is the ignition switch, sometimes an cil or fuel pressure switch, usvally with other funelions (such os ignition) not shown in these sketches. res or other metal conductors are shown «solid lines. Where such lines cross each other, they make electrical contact only if there's 0 block dot . Otherwise, they cross while remaining electrically isolated from ‘each other: see the sketches here. The plus (+) symbol is used for several erent positive terminals including the actval battery plus terminal, the plus or more positive fend ofthe field coil, of the plus auxiliory or ‘main output terminal of an alternator. The list on the following page explains. The symbol for round, GRD, is often used to avoid tring wiring to battery tr means "minus" in negative ground systems ‘ond isolated ground systens. It does nat apply {0 positive ground systems which are not covered in this book. 8 VOLTAGE REGULATOR TESTING eo Ifa regulator had failed altogether, the effect would be noticeable very quickly + alternator output would stop, and voltage would fall os Slectricity is drawn from the battery alone. Or voltoge would briefly tise. before damaging the alternator. 'Not quite 20 obvious is @ regulator which just performs a bit out of its expected range. Only the symptoms may be noticed : batteries Which ore incompletely charged, or which need water added to the cel ‘often. Testing such regulator is still relatively easy. First, the most direct ond obvious + TEST : VOLTAGE REGULATOR IN OPERATION Ina car, you can test the voltage regulator while you have to stop at aed light. With the engine ot slowest idle, notice the rate at which the turn signal flashes , or listen to it click. Or note the rel brightness of the heat color reflected from some car ahead of you. Now accelerate the engine fond note ony changes + if the turn signal clicks at a faster rate, or lights become more white, less yellow in color, voltage has increased. You could row race the engine to make sure that there is no forther increase Inrote or brightness. Not necessary, and probably the light up there hos and you are on your way again. fest con be more refined with the use of a voltmeter. At very low speed, the regulator may call for more alternator output than is poutble at such speed. Voltage is then below the setting of the voltage regulator, below that voltage Bes which the regulator attempts to mrointoin. At this stage, the voltmeter, connected fo battery posts or other place of the system, should show the battery voltoge. If you row increase engine speed, voltage should gradually increase, as shown in the sketch. "RPM The rote of increase, and the alternator speed ore not specified. Voltage will climb more rapidly if the alternator is big, the battery relatively small, and speed high. But ‘much more important is that once voltage reaches about 14.2 12 Volt system, or about 28.5 V in 24 V systems, it will not rise ony further . That is becouse the regulator should not let it rise further.” TEST REGULATOR SEPARATELY. We want to test whether the voltage regulator responds to voltage changes. One porsible voltage source is shown in sketch (2). I consists of a battery and a battery charger. The battery charger is Torge enough to be able to overcharge the battery : thot is precteely the condition, read "voltage", where we want the voltage regulator to switch off. Best is @ plain, unregulated or ron-automatie battery charger rated, for exemple, 15 Amp., and a battery , not too large, which is already nearly fully chorged. A voltmeter fs needed to show the voltage at which the regulator switches, In place of the alternator field coil we use 0 lamp bulb") : you can easily solde wwites directly 19 most lamps. Hook to regulator and battery, and connect the other regulator terminals as shown. Note thet we ore dealing with 0 type P regulator, such os the great majority of external voltage regulators. ‘At first, the lamp will light up. IF it does not, disconnect the charger for a moment. The battery voltage should be lower than the switching voltage of the regulator. Now let the charger Feed the battery. The voltmeter should show slowly inereating volves, such of 13.5 t0 14 Vole with o 12 Volt battery. Then, os we reach values between 14.2 to 14.6 V (12 Volt systems), the lomp should suddenly become dark: a the regulator switches “Mield current” off. ‘Switch off the battery charger and watch the meter : os voltage falls, the lamp should suddenly become bright TIME again. The voltage curve is shown in sketch @) , together with the switching voltage (he broken line) and phates where the lamp is bright or dark ‘50 Se oe eee ee ear ins coon ns ase ‘pretending that the lamp is the Field coils Sketch @) shows the Saet Se O oes renter aac eee meena housing. Increase battery voltage Se rca omy ahi see sch aalcen. ony VOLTAGE REGULATOR AND BATTERY CHARGING ‘The voltage regulator setting, that is the voltage which the alternator output terminal, is always slightly higher thon the highest voltage which the battery, standing by itself, can reach. That mears, the battery is going to be overcharged slightly after it has reached full charge. Before it reaches full charge however, the charging rate depends on the voltage regulator setting and may at times be too slow. As you ‘can s08, the regulator setting is a compromise : high enough to create « large enough battery charging current before the battery reaches full charge, yet low enough to minimize the effects of overcharging, after the battery has reached full charge. ‘The recommendations of alternator manufacturers are toward @ voltage regulator setting which during average ute ofthe electrical spttem causes some noticeable consumption of water in the cells of the battery, meaning thot the batteries are being lightly overcharged. This then makes certain that batteries from time to time during their normal opacity is being lost, the battery is get Ii Anper hoor rng i dactecing. Since bere ge ad evrvaly {ail by gradval loss of storage copa plete recharging will ‘contribute to this process and reduce the useful life of the battery. We have seen how the voltage setting of mechanical, relay type voltoge regulators can be changed, namely by changing spring fertion at the armature of such voltoge semsitive relay. Although some tolid state regulators have provisions for voltage adjustments, usually in the form of screwdriver adjustments of small potentiometers or resistors,La 31 the majority do not. In most applications, such adjustment is not needed, Solid state regulators are usally manufactured with a range of voltage settings and the same regulator may be available under different model rumbers with different voltages. VOLTAGE REGULATOR SETTING to change the setting of any regulator, be sure that s sound. The following instructions are intended mainly for solid state regulators without voltage adjustment, and for circumstan- ces where batteries are obviously not being completely charged even though an alternator is in operation. Review the tection on voltage regulators and battery charging. Read in detail about battery charging cond, especially, be awore that the voltage regulator can not handle charging of batteries which are being drained while the alternator is ‘ot running. In such coses, foster recharging results but is invariably leading to overcharging unless the alternator is being stopped in time. All voltage regulators respond to an increase of battery ty to reduce 5 the regulator. It is impractical to inerease the battery voltoge. We will limit efforts to the practical and discuss how to fool the regulator with a manipulated lower botter voltage which will cause the voltage regulator to attempt to maintain ‘an inereased alternator output voltage. Although a resistor in the wire between regulator and 4BATT will have a voltage drop, a resistor in this application will give poor results because the voltage drop will vary with eurrent, The true vo Baro tae eh oa v) battery voltage V', sketch (3), will dop to an uncontrolled voltage (Wh which will fll the coptloorincreees field curanr. Rather, @ diode is vied os in sketch 6) «Silicon diodes typically hove woltage dhop of 0.6 V which is constant within a wide range of curens. Here, v-0. Bar oo Rea teeta e ae the regulator responds to a voltage which is 0.6 V below the actual batery voltage. The regulator attempts to maintain an alternator output voltage 0.6°V higher than it did without the diode. 52 «terminal regulators os in sketch @, the diode must be able to 3 fuld coment « Ad Ifthe raul voltage io be ino Me thon 0.6 V, two or more diodes are used in series, each ty ituting its threshold voltage ond lifting the alternator output voltage BNEV. Alo, each must have 0 current rating in Ampere equal to, or thon maximum Feld current. ‘One of the most common type N rool sheen In hatch @. ternator outpt voltage is being ines about 0.6 V when @ ‘Alton diodes connected between ‘BATT ond spade lug terminal "2" siifewn, with the cathode toward the regulator. In this cose, 8 wi SEecther type N regulators, the apply of pls field curent comes from MGlode tro or cuxiliry Terminal ond is nt supplied though the sensing feoninal. Therefore, the diode current rating is ot as ritical os Ani the type P regulators. However, should the diode feil by becoming Tomondvetive, or should the connection break, the alternator will Inereate its output fo near maximum, Bar sw The sketch alto shows 0 charge indicator light LT wit normal method fo excite the alternator through termi switch SW, the mass The main reason to lif alternator output voltage with @ diode ot the voltage regulator is to overcome the effect of charging diodes, alto called splitter diodes or isolators which are connected between alternator ‘output terminal and two or more seporate batteries which must be chorged from one alternator but must be kept isolated from each other. Since ‘uch larger diodes introduce the same 0.6 V threshold between alternator ‘ond batteries, a regulator often measures « voltage which is 0.6 V higher than actual battery voltage.MANUAL ALTERNATOR CONTROLS 54 SE wi SUtnerneter srt in opeaton st the sme Hine. Sbseqverh, wie cia tnen ets lon center rnin ine witch may become eae ster Inauch cans ony, moruol elferator consol reused a ,r——“ECsC Spatuorourpu voltage by voltane reauletor — Vou lead - ocid batteries is not Sg er the state of charge ofthe — ,l the vlages without any creat eens totter is eur flly charged, sept teteny fe ecly empty In 00 80 20 % Neteh(). the opprovinate shoe ofthe cure i shown against osale of prcun of fll charge. hr Te charge the battery, current most be made to flow in he — ._rtr—=C‘itemrmrL ‘being used. To make such charging current flow, the alternator must | ‘pply a voltage to the battery which is higher thon the voltages in sketch 8) .The excess voltage beyond the battery's stondby voltage ‘the chemical reactions which take place at the battery plates ‘bring cheging, end ust cose charging euret fo flow according to | rrr ————— the resistance of the circuit. Although the internal resistance of batteries a, Sor cil windings inthe tern rel prof ts eeu . ows the extn voltage is paar ernerne tend oe Sritery charge impgvesy nthe exonple inaetchCO. ychoging are,55 ‘at 60.A ( Ampere ) and gradually falls, At the end of the first hour, charging current hos decreased fo about 40 A, and so on. To estimate if such o rote is adequete fo charge a given battery, we must know the ‘capacity of the battery which is given in Ampere hours ( Ah ) and its state of charge or "condition". For example, a battery of 120 Ampere hour capacity or size, half charged or at 50%, has room for 60 Ah ( Ampere hours ) and could be charged with 15 Ampere for 4 hours to reach full chorge. Another example : a battery of undetermined si or capacity has been used to power a piece of equipment witha current of 10 A for « period of 8 hours. To fully recharge that battery, 80 Ampere hours mist be charged Insketch(), the Ampere hours which ore being charged can be estimated easily. For each hour, we Find the average current ring that hour. That is opproximately the current which was flowing atthe middle of that hour. For each hour, the approximate amounts in Ah are shown. The total charged ot the end of the third hour re the three values oded together, or 96 Ah « A similar estimate can sometimes be made by just having an occasional look at an ammeter during battery charging. You should make such estimote during chorging, and an estinate af Ampere hours consumed from the battery, before considering the use of @ manvol alternator control. The example in sketch (5)is from o relatively large alternator, os indicated by the high initial current of 60 A, ond fore bettery or bank of batteries of large storage copacity or Ampere hour rating, as shown by the relatively slow decline of curent which fs sill en average of 30 A during the second hour of alternator operation. If at the end of the third runing hour, mote than 50 Ampere hours remain to be recharged, the task to do so may become unfolerably slow because the current will continue to decrease and hourly averages will fall frther Manwol alternator controls originally vied variable power resistors or theostas. Fixed power resistors or lamp with switches can also be used. More recently, slid stote cyrtent regulators have reploced some ofthe older techniques, Sketch” (0) shows how o manuel sltemotor ‘contol is connected fo regulator and field cotl ina type P alternator, Although a selector Switch cam be used fo connect the contol or the regulctor to the field coil, such snitch fz usvally not necessary with the present solid stote regulators. in-use, extra field current fom the contol causes on increase “ ees ral alternator contols decreate the tl be Im cotat to ome nyt tre ond there ood onthe regulator. This i Only if the voltage regulator isa mechanical, reloy ype, Wh eagultes field curent by switching @ Feld contact between plut and ground, one extra precaution Is needed. ‘Ae thown in sketch (11), 0 diode must be connected ot the regulator field terminal. The diode prevents Feld current from the menval contol from rounded or shorted out when the mechanical regulator, 0s USSG, connects Ral eminal to good when i seer o vltge wthigh normally meons thet the ottery s fll, For a regultor with 0 velloge setting of 14.2 Volt, voltage of 14.3.V will have It switch. The dode must be able to cory ful field current It doesnot affect, regulator setting since It doesnot affect regulator plus voltege. Al Irechanicl regulotors ore external and umelly ore type « Sketch, (2) shows how manvl corrals ore connected to type N regulators. », increased field current flows through the field Call if current Is allowed to bypos the regulator onthe way Yo minus or around. Many ofthe type NI regulators are internal ond olmast all of them thom are solid state types. The sketch is meant to show one ofthe very Popular Delco internal regulators. The dotted line shows the field current Path through the regulator to ground. The alternator contro! here ond ‘lways is electrically paralle! to the voltage regulator . sl 2eeaton, on Inerease in fc crertumelly wil Iereoe clterctor output voltage slightly shove the regulator voltage setting hich causes the ruler fo wich of. Feld eum ie then olly by manval alternator control. Again, load on the regulator ceases. Onlya7 when the manwal alternator control is switched off and voltage falls below the regulator setting will the voltage regulator turn itself on gain, to supply and regulate Field current. With manual alternator controls comes the risk of overchargi batteries. Mild overcharging with some gas development in the cells ie carried out on purpose, in the form of s0 called equalizing chorges which ‘are scheduled for stationary batteries, and with voltage regulator djustments in fleet vehicles which result in o few ounces of water lost from batteries each month. However, more severe overcharging can rewlt in damaging loss of battery electrolyte and can generate excessive heat. Ussally, manual alternator controls find their opy relatively large batteries must be recharged withi ime. Their application fo systems where battery copocity in Ampere hours is less than three times alternator output copacity is not ‘advantageous because it does not allow full use of alternator capacity. Therefore, in practically all instances where a manual alternator contro! is useful, the battery capacity will be large enough to prevent serious battery overcharging « Finally, there is an alternator control on the market which senses battery voltage and, indirectly, the state of charge of the battery while chorging current is flowing. The control allows manual selection of alternator output current but switches itself off automatically, either when the battery reaches full charge, oF iF a charging current is chosen manually which is too high for the size of the battery.39 SPECIFIC VOLTAGE REGULATORS We have looked at voltage regulators in an earlier section, to see that all of them regulate field current in response to battery voltage. The voltoge regulators all have in common to be connected in series with the alternator field coil. All regulate field current, with the ultimate goal of maintaining a specific voltage ot the alternator output terminal. Most, if rot all regulators work by rapidly switching the field current on ond off, achieving greater average field current and alternator output by incteesing the "on" time in their on-off switching cycle All voltage regulators hove at least three terminals: think of them BATT ond the AUX plus terminal. The ‘switch SW is closed when the alternator starts to run. Excite current flows through the light ‘ond turrs the light on bright. The same current flows through regulator ‘and field coil and causes the initial alternator output. This in turn causes the AUX terminal to rise to full positive voltage which makes the light go off : it now has about full battery voltage at both sides.65 . 66 Sketch (@ shows feld ctl and voltage regulator ino type N circuit. Sketch (2. shows a Motorola regulator with internal excite resistor. Pet i tele need a apa Operation is identical to seprate resistors os In sketch I). Yellow wire “BATT through switch and lomp to the auxiliary plus terminal which i is normally connected to ignition or engine key switch or oil pressure shown here with a diode trio The initial lamp current excites the Ac a Diope. c. ee clternator . Rectified AC through the diode trio then brings the Ito full plus voltage which extinguishes the switch, Red wire to AUX terminal at back of alternator, black wire to ; tinue, usally stud terminal on hovsing. Green wire fo field spade imately fll battery voltage of both terminals, current ly na re to Field spade lug through the light fos ond the light becomes dork Under regulator. Type Pon sketched, Very popular on 300 58 A rat ence CG nd (Othe eunttry terminal could be ‘lterators with isolation diodes, see olfernator sketches. operating with either a diode trio or with isolating diode or diodes. The A similar regulator, sketch (13 , is made as an ee a Meee eee a } extemal regulator, nounted separately fom the alferntor end connected merrl (attached) repvetor white sketch (0) is ypical for many Delco alternator. Such extrnal excite current cirvits cn be used with, or added toll of the sinple 3terminal volage regulators. A resistor con be Caed in place ofthe light, oro combination of Tight ond resistor ore fn ses 12° lamps ore used in 12 Volt yates. Lmp wattage determine Ween rl whch alr "ae R RV a +BaT nee AUX by wires. Two yellow leads on the excite resistor , to the ignition switch , the other to field as shown. Or can be connected with one yellow wi to AUX, the other yellow wire 10 ignition switch which then ‘connects to BATT. or Sketch (O-ows ignition or oit pressure switch, resistor R with light i Li'in porllely connocted to AUX terminal of alternator. With alternator off bu awitchon, AUX terminal should ise to obout I Yo 2 Volt. Since regulator-field coil resistance (AUX to ground resistance) varies between Slteraton, only oppenimete values ere given here # T2Velt sytem * R about 75 to 300 Ohm, LT a 12 lamp, about 5 W. 24 Valtaytem 1 R gbout 150 0 600 Ohm, LT 24 V lamp, obout 5 W. | If only a light is ured, increase wattage to excite ot lower RPM. Also increate wattage or connect resistor if light does rot fully extinguish when alternator is running and cherging of working normally.