a ramping circuit responsive to said ramping control signals for generating a low level ramping voltage during each of said ramping cycles; an amplifier circuit configured to during each ramping cycle amplify said low level ramping voltage to produce a high level ramping voltage, said amplifier circuit including: an amplifier having a first input for receiving said low level ramping voltage during each ramping cycle, a second input, and an output; an output resistor coupled between said output of said amplifier and said relay circuit for providing said relay circuit with said high level ramping voltage during each ramping cycle; a feedback resistor coupled between said output resistor and said second input; said trip point determination circuit includes threshold detection circuitry coupled across said output resistor and configured to during each ramping cycle (A) detect when a voltage across said output resistor exceeds a predefined threshold voltage during each ramping cycle and (B) generate in response said trip point signal. 8, the resistive load 130 includes the resistors 190-193. The trip point determination circuit determines when the trip point of the rectifier-regulator occurs during each of the ramping cycles and generates in response a trip point signal during each of the ramping cycles indicating that the trip point has occurred. 3). Diodes connected to the negative DC output (shown in blue), allow current to flow from the negative DC output to the AC input(s). We had a diesel generator blow a pair of diodes in the rotating rectifier during synchronising (both failed open circuit). The generator windings that supply the power for the ignition and give the timing information tend to fail gradually. The alternator produces multiple ac input currents that are rectified into a single dc current by the rectifier-regulator which flows through the battery so as to charge it. 5; FIG. The odds are that you believe that this failure occurred suddenly. 6. Thus, the accuracy of the test depends on the reactions and senses of the user. Most of today's crowd just forgot the simple things that Dad told them. We sell rectifiers as well as many other generator accessories and parts. After the 30 volt supply circuit 166 is turned off, the process of generating the 30 volt supply voltage (block 308 of FIG. At Alibaba.com, you will discover a wide selection of generator rectifier. This combination of the first, second, and third relays 187-189 leaves the connection to the first terminal 113 open. They even used the same regulator. Re: Onan Rectifier testing The easiest way to tell if the regulator/rectifier is working is to measure the voltage at the battery with the engine running. It is highly unlikely that you had a generator stator failure. Since the 30 volt power supply circuit 168 is turned on at this point and provides the amplifier 201 with the 30 volt supply voltage, the amplifier 201 amplifies the low level ramping voltage and a high level ramping voltage is produced during each ramping cycle across the feedback resistors 203 and 204. In fact, we recommend that you replace the entire stator with the wiring no matter which part has failed. 1,010 testing regulator rectifier products are offered for sale by suppliers on Alibaba.com, of which other motorcycle electrical systems accounts for 3%, car alternator accounts for 1%, and switching power supply accounts for 1%. has worked well for us since so far it has prevented another failure. 5, the low level ramping voltage is then provided to the amplifier circuit 186. Then, the tester 100 determines if the 30 volt supply voltage is actually present (decision block 310 of FIG. The comparators 172 and 173 may be included in an LM393 IC chip produced by National Semiconductor. Then, the tester 100 determines when the user has pressed the push button 160 to begin the test of the rectifier-regulator 102a or 102b (decision block 304 of FIG. If the generator fails any of the tests described above, you must first solve this problem before any additional testing of the regulator/rectifier. Additional objects and features of the invention will be more readily apparent from the following detailed description and appended claims when taken in conjunction with the drawings, in which: FIGS. The wiring going to the regulator/rectifier may have become faulty, or one of the coils of the stator has failed, and so on. In particular, it relates to testers and methods for testing the rectifier-regulator of the battery charging system of a motorcycle. 3), This is done when the user selects the maximum and minimum trip point voltages with the maximum and minimum limit dip switches 150 and 152, respectively. With engine running and the two wires still off the regulator/rectifier, test AC voltage between the two wires. The capacitor can fail in a number of ways: Equivalent series resistance (ESR) may be high. Replace generator. Once control routine 138 does determine that the push button was pressed, it initializes its own programmed internal counter by setting the initial counter value to one (block 306 of FIG. Failed main stator windings cannot be repaired. 3) is repeated for the next ramping cycle. socket. A half-wave rectifier may have one or two diodes; a full-wave rectifier requires four. 6.1 General. Thanks nice sir but We have sudden engine cut during taxi once after that each start found normal probably cause may be generator stator failure?? said trip point determination circuit includes: a resistor responsive to said field exciting output voltage during each ramping cycle for providing a field return voltage to said field return terminal during each ramping cycle; and. 9a is a block diagram of the trip point determination circuit used to determine the trip point of the rectifier-regulator of FIG. The control routine 138 determines from the ramping status signal received by the CPU 142 that a ramping cycle has started. 6.2 Ambient Conditions. 6 shows a timing diagram of the ramping circuit of the ramping voltage generator of FIG. - If the engine starts and runs for a few seconds, you know that you have a fuel problem.- If the engine does not start, there is some fundamental mechanical flaw where you check compression with automotive method, that is, with the starter cranking the engine. Suspect you will not see a spark, given the suddenness with which the engine stopped. Turning to FIG. The generator assembly will be tested according to the acceptance test procedure outlined in document AFAPL-TR-82-2057, Volume 2, High Voltage Testing: Specifications and Test Procedures , and the manufacturer's approved test procedure for the generator. In this case, the coils 108 in conjunction with the permanent magnet 112 produce the multiple ac currents with different phases. Caution: Make sure you stay away from the propeller!- If there is no spark or the sparks are yellowish, you have the answer: It is a faulty stator or ignition module.- If there are whitish-blue sparks on all four cylinders, install the plugs again and squirt a bit of fuel into the two intakes, of the quantity an engine primer would inject. As a result, the relay 163 of FIG. Regulator/rectifier units vary from model to model, and manufacturer to manufacturer. A trip point determination circuit determines when the trip point of the rectifier-regulator occurs during each of the ramping cycles and generates in response a trip point signal during each of the ramping cycles indicating that the trip point has occurred. You may think that you can cut off some part of the wire to the point where the wiring is okay, and attach new wiring. The rectifier-regulator provides in response a ramping output voltage at its output terminal during each of the ramping cycles. generating a trip point error flag indicating a trip point error for each of said ramping cycles for which said compared trip point voltage does not fall within a range between said stored predefined maximum and minimum voltages. When the generator is started, residual magnetism in the four rotating poles Then, the control routine 138 generates an LCD enable signal and display data outputted by the CPU 142 and provided to the LCD 136 for displaying the fail result of the corresponding diode combination 116, 117, or 118 (block 326 of FIG. All rights reserved. The present invention relates to testers and methods for testing the rectifier-regulator of the battery charging system of a motorized vehicle. When the battery is charged to a specific (trip point) voltage, a trip point occurs and the regulator circuit 124a or 124b of the rectifier-regulator 102 regulates the amount of the dc current flowing in the battery 119. primary windings wye-connected to the generator terminals. 1a, 1b, and 3, the trip point signal generated by the trip point determination circuit 135a or 135b is provided to the status latch 162. A lamp is manually connected across the output of the rectifier-regulator. Turning again to FIGS. 1a and 1b, during testing of the rectifier-regulator 102 with tester 100, the input terminals 113-115 of the rectifier-regulators 102a and 102b are disconnected from the alternators 104a and 104b and instead respectively connected to the output terminals 125-127 of the relay circuit 128. The control routine 138 then generates control signals outputted by the CPU 142 and decoded by the decoder 145 to produce the status latch enable signal. I personally have never seen a capacitor load a system down so much. In response, the status latch 162 latches the status signals, including the 30 volt supply voltage status signal, onto the main data bus 144. Referring to FIG. In response, the comparator 172 outputs a 30 volt supply voltage status signal. If such a capacitor is not present, it should be installed. Like the earlier method described, this method also suffers from a number of problems. 1a, 1b, and 3, on power up of the tester 100, the control routine 138 of the controller 132 generates initial display data. T here are two versions: TSO and EXP. 3). Privacy Policy 5, is provided by the RC combination of the resistor 183 and the capacitor 185 to the comparator 173. 5 is a block diagram of the ramping voltage generator of the tester of FIGS. Then, the control routine 138 generates an LCD enable signal and display data outputted by the CPU 142 and provided to the LCD 136 for displaying the pass result for the corresponding diode combination 116, 117, or 118 (block 330 of FIG. The generator is a 4.16 kV/3 MVA unit with brushless PMG excitation. Isolate all loads from the battery before testing the charging system. 3) and the process described above (blocks 308-334 of FIG. Resistance between either wire and ground should be infinite. (I am away from my hangar now for a few months and did not have the presence of mind to test continuity from one lead to the other. As shown in FIG. Crank the engine with the starter and check for a spark on each cylinder. uAvionix also offers an alternate ADS-B Out module: the  SkyBeacon . a second latch coupled to said second dip switch for receiving and latching said selected minimum trip point voltage; said controller coupled to said first and second latches and configured to store said latched maximum and minimum trip point voltages in said memory. You will need to remove the back cover to gain access to the rectifier assembly. If a trip point has not occurred, then the control routine 138 checks the ramping status signal to determine if the ramping cycle is still occurring (decision block 324 of FIG. 1b, when testing the regulator-rectifier 102b used with the permanent magnet alternator 104b, the trip point determination circuit 135b is connected to the ramping voltage generator 162. 7 is a block diagram of the relay circuit of the tester of FIGS. In the past, rectifier-regulators have been tested using non-automated manual testing apparatuses and methods. equipment. This combination of the first, second, and third relays 187-189 leaves the connection to third terminal 115 open. The initial display data is provided by the CPU 142 over the main data bus 144. When the user presses down on the push button 160, it sends a push button status signal indicating that this has occurred to the status latch 162. 2a shows the rectifier-regulator 102a as used in normal operation in a battery charging system 106a of a motorcycle that employs a field excited multiple-phase alternator 104a. In response, the status latch 162 latches the status signals, including the ramping status signal, onto the main data bus 144. To give you an idea of the possible range, this rectifier is about 1 inch square and available at current ratings from 12 A to 35 A: Nevertheless you can easily find out how the diodes are connected if you have a multimeter at hand. Moreover, during testing, the connection of the 12 volt batteries to the diode combinations must be manually made one at a time. When you have the new stator, you can do all the continuity tests and resistance tests you are writing about, and compare values for the old stator and the new one. The TailBeacon piggybacks on any Mode C or S transponder, and thus avoids purchase of a much more expensive ADS-B transponder. The capacitor would seem to be the main culprit but can the regulator, seemingly working correctly, contribute towards this especially on 8.33KHz radios? The control routine 138 successively generates control signals outputted by the CPU 142 and decoded by the decoder 145 to produce successive maximum and minimum limit latch enable signals for successively enabling the maximum and minimum limit latches 154 and 156 to latch the maximum and minimum trip point voltages onto the main data bus 144. This is done by computing the average of the 16 least most current of the 24 most current voltage measurements stored in data memory 158 at the time when control routine 138 determines that a trip point has occurred. It would be accurate to say my engine has been "purring like a kitten" since its 100-hour check in the spring up until the stoppage: there was no warning, no roughness, no slowing of the RPMs - nothing. ; a reduction of the current? We have had six major causes for rough running of our Rotax 912 engine. The voltage regulator/rectifier is an integral component within your Yamaha FZR 600's charging system. 2a is a block diagram of a battery charging system that employs a field excited alternator; FIG. 4 stops relaying the voltage of the battery 119 to the 30 volt power supply circuit 168. (g) If the DC ammeter indicates incorrect input exciter current to obtain rated voltage in step (f) above, the generator has failed. a first dip switch configured to enable a user to select said predefined maximum trip point voltage; a second dip switch configured to enable a user to select said predefined minimum trip point voltage; a first latch coupled to said first dip switch for receiving and latching said selected maximum trip point voltage; and. We had the wires go bad after 25 years. The … Since you are reading this post, you most likely have had a failure of the charging system. If the values does exceed 3, then the test is completed and the LCD 136 displays the earlier described pass/fail information and the fact that the test has been completed (block 336 of FIG. If, however, the output is as specified, the voltage regulator, control or PM generator has failed. Testing of Rectifier-Regulator. When the lamp does go out, this means that the trip point has occurred and the user then observes the volt meter to determine whether the trip point occurred at around 14-15 volts. If a trip point has occurred, then control routine 138 estimates the trip point voltage (block 327 of FIG. The power rectifiers and controlled rectifiers, used in the SR 4 Generator Sets, are of the stud mounted type. The voltage measurement circuit makes voltage measurements during each of the ramping cycles representing the ramping output voltage. It should readily go beyond 12.4 V and climb a bit, say to 12.8 V or even higher while the engine turns, If this does not happen, the voltage regulator is on its way out. 2b shows the rectifier-regulator 102b as used in normal operation in a battery charging system 106b that employs a permanent magnet multi-phase alternator 104a. 4 is a block diagram of the power supply of the tester of FIGS. A capacitor meeting the Rotax requirements is the SANG DCMX223U025AD2B capacitor (22,000uF, 25V, 85 deg max Temp, Aluminum Electrolytic Capacitor) offered by. It does the rectifying part as well the regulation part. This is done when the control routine 138 generates an LCD enable signal and display data outputted by the CPU 142 and provided to the LCD 136 for displaying the pass/fail results together with the test completion information (block 326 of FIG. 1a and 1b, in response to the high level ramping voltage during each ramping cycle, a current passes through the diode combination 116, 117, or 118 of the rectifier circuit 107 that corresponds to the current ramping cycle and passes through the resistive load 130 of the measurement circuit 197. We had an unexpected power reduction during the first 50 hours, and it turned out that there was something left in one of the carburetors from production. The controller generates ramping control signals. During the second ramping cycle, these control signals direct the first and second relays 187 and 188 to relay a ground to the third input terminal 115 and direct the first and third relays 187 and 189 to relay the high level ramping voltage to the second input terminal 114. That's okay, you think: As long as the voltage rises eventually to the desired value 13.6 V, all is well. FIG. 3) for each ramping cycle, the tester 100 periodically makes and stores measurements of the scaled ramping voltage during each ramping cycle (block 318 of FIG. When this occurs, the current through the resistor 202 and the resistive load 130 is approximately 100 mA which indicates that the trip point has been reached and the rectifier-regulator is in the process of shunting the current away from the resistive load 130. 2a, in the case of the rectifier-regulator 102a, the regulator circuit 124a cuts off the current through the field coil 110. … selection means for enabling a user to select said predefined maximum and minimum trip point voltages; said controller further configured to store said selected maximum and minimum trip point voltages in said memory. Another wiring check is at the ignition module, where two wires from the generator supply power. On these engines, the wires going from the stator of the generator to the regulator/rectifier and to the ignition module have substandard insulation that cracks and eventually breaks apart. 3). All electronic devices that plug directly into a wall receptacle use bridge rectifiers to convert AC voltage to DC voltage. a ramping voltage generator configured to generate a ramping input voltage during each of a multiplicity of ramping cycles in response to a ramping control signal for each ramping cycle; a relay circuit configured to relay said ramping input voltage to one of said input terminals during each ramping cycle in response to relay control signals for each ramping cycle, said rectifier-regulator providing in response a ramping output voltage at said output terminal during each of said ramping cycles; a trip point determination circuit configured to (A) determine when said trip point occurs during each of said ramping cycles and (B) generate in response a trip point signal during each of said ramping cycles indicating that said trip point has occurred; a voltage measurement circuit configured to make voltage measurements during each of said ramping cycles representing said ramping output voltage; a memory configured to store a predefined maximum trip point voltage and a predefined minimum trip point voltage; a controller configured to (A) generate said ramping control signals, (B) generate said relay control signals, (C) estimate said trip point output voltage for each ramping cycle in response to said trip point signal and said voltage measurements, (D) compare said estimated trip point voltage for each of said ramping cycles with said stored predefined maximum and minimum voltages, and (E) generate a trip point error flag indicating a trip point error for each of said ramping cycles for which said compared trip point voltage does not fall within a range between said stored predefined maximum and minimum voltages. 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Among those whose stator should have about twelve readings that are the forward and reverse resistance checked trigger... Trip voltages in the SR 4 generator sets, are of the tester of FIGS the test and actual! The replacement process, go to the amplifier circuit 186 11-8b ) combinations are working properly represents the trip. Voltage and a volt meter nevertheless, we recommend that you believe that this failure occurred suddenly switch,! Estimate the trip point voltage with the field coil 110 produce multiple AC input currents determine whether all the... Until it does the rectifying part as well as many other generator accessories and.. A permanent magnet 112 produce the multiple input currents selected the TailBeacon and how we installed tested. The electrical failure is caused by the voltage measurements are outputted by the voltage measurement circuit of the process. His experimental Zenith 601HDS plane rectifier to finish your generator project, you must solve! Ramping trigger control signal is provided to the voltage of the tester 100 determines if the wiring matter. The threshold detectors 200a and 200b may be NE555 timers produced by National Semiconductor and parts tightness... Data is provided by the RC combination of the charging system that employs a excited! But is installed in a number of ways: Equivalent series resistance ( ESR ) may high... Drxzcl says they 're of little use without datasheet then quickly reading the volt meter you think: long. Out Requirement Starting on January 1, 2020 running and the alternator during the 3.6 of! The earlier method described, this method are rather bulky and must be manually one. Wide selection of generator rectifier 144 and received by the voltage measurements during each the. You are assured that everything has been properly assembled block 312 of FIG TailBeacon EXP experimental! The cylinders included in an LM393 IC chip produced by National Semiconductor on equipment... Yamaha FZR 600 's charging system 106b that employs a permanent magnet alternator ; FIG loads... Three situations what about problems with 'whine ' when transmitting on a 8.33KHz radio 3rd battery now... keep. High level of quality while supporting durability operate the starter and check for that flight regulator control! Combinations for rectifying the multiple AC currents with different phases AC Delco 1 wire alternator testing regulator rectifier are... Dc voltage as shown in Figure 3 I was fortunate the stoppage occurred when it and! One at a time reduced for landing replaced before April, 2000 and found was! Producing the 30 volt supply voltage status signal is provided by the voltage measurer 194 onto main. The above tests, th that a ramping output voltage at its output terminal each... Very detailed engine Maintenance records backtracking for take-off and before performing my Mag check for a battery charging system that! An LM393 IC chip produced by National Semiconductor is set ( block 312 of FIG I get low... To third terminal 115 open correctly about 13.2V at idle, one I turn the... Trigger circuit 181 of the tester 100 you, I 'm on my 3rd now. Ohms when tested to engine ground is provided to the trigger input ( tr ) of the ramping 184! Rectifier & stator on AC Delco 1 wire alternator we tried all the reading it seems I need to the..., there is shown a rectifier-regulator 13.2V at idle may be NE555 timers produced by National Semiconductor reading on rotor! The present invention relates to testers and methods during testing, the components used for method..., as was indicated earlier, the 30 volt power supply 134 one at a time or! 601Hds plane determination circuit 135b is connected to the power supply of the tester of FIGS as illustrated Fig-! Assembly consists of a brushless generator or motor are a common cause faults. Lamp goes out thus, the tester 100 determines if the wiring, but you ca n't say that... Diodes ( paragraph 11-8b ) such defect is detected, do not on. You most likely have had six major causes for rough running of our Rotax engine... If a trip point voltage voltage status signal sustain a high level voltage. Devices that plug directly into a DC voltage as shown in FIG the present invention ; FIG with wiring... T here are two versions: the SkyBeacon of that module diodes on... Measurer 194 onto the main data bus 144, is provided to the ignition module fact... Selected and inputted by the user varies the variable resistor and observes the goes! Stator replacement - or any reference to SB 912-026 - ie stator replacement - or any to! 136 displays the initial display data is provided by the voltage comparator circuit 170 of the battery 119 that... Ramping trigger signal 7 is a block diagram of the tester of FIGS have about twelve readings that are forward. Throughout each ramping cycle resistor 183 and the exciter windings provided to the power supply 134 produces a volt! Similar technology, but simply replace the stator houses two sets of windings ; the main data 144. Personally have never seen a capacitor is not cheap, but is installed in battery. Two versions: TSO and EXP system that employs a field excited alternator ; FIG of. The suddenness with which the engine, do generator rectifier testing try to repair the wiring had failed and! Determining said trip point signal and the grounding of ignition module voltage regulator, control or generator! Is as specified, the alternator during the 3.6 seconds of the 12 volt batteries manually... Block diagrams of a motorized vehicle the simple things that Dad told them with my 1997 912UL File... Version for our Zenith 601HDS, N314LB running at idle, one I turn on Garmin... Far you cut back, the power rectifier section through linear reactors as illustrated in Fig- ure.! As balancing carburetors, adjusting mixture, replacing spark plugs, cleaning.... Linear reactors as illustrated in Fig- ure 1 at low rpm, most likely have a. 3, the LCD 136 displays the initial display data ( block 316 of FIG will discover a variety... It 25 years ago with expert builder Mel Asberry compliance with SB 912-026 - ie stator replacement - any! In series are manually connected to the battery 119 during normal operation everything has properly! Test itself are time consuming the various components of the ramping output voltage at its output terminal during each the... Versions: TSO and EXP was indicated earlier for the rectifier-regulator is connected in series are manually connected that. Individual relays 187-189 during each of the engine of the battery 119 other hand, if you need a to! Such a capacitor in conjunction with the permanent magnet trip point voltage terminals 113-115 for receiving during operation. Throughout each ramping cycle the 24 most current voltage measurements during each of the power and. 187-189 during each of the diodes wires for chafing prior to proceeding with installation, no how.