Operating instructions
o
~
:z:
[;)
m
BC
GENERATOR
SINGLE
PHASE
INTEGRAL
CONTROLLER
(I.C.)
The Integral Controller (I.C.) is an encapsulated, solid-state
unit that supplies a DC charging voltage to the generator's
starting battery while the generator is opening.
Charging Voltage:
13.1
• 13.4 volts DC
Charging Amperage: 0 • 17.0
amps
DC
A separate group
of
stator windings supplies
AC
voltage to a
bridge rectifier which converts the
AC
current
to
supply the
I.e.
unit. The
I.e.
unit senses the needs
of
the starting battery
and supplies a
DC
charge when one is needed.
If
you
susp~ct
that the I.C. unit is faulty (that is,
if
the battery's charge is
low), check the charging circuit and it's components as
described in the following steps. Check all connections for
cleanliness and tightness including the ground before replacing
the I.C. unit.
NOTE:
When
the
generator
is
first started,
the
L
C.
unit will
produce a
low
charging
rate.
This
charging
rate
will
rise
as
the
generator
is
operated.
The
Integral Controller is mounted inside the generator hous-
ing in the
12:00 position. There is a voltage output adjustment
on
the controller that
wi1I
allow a DC voltage output adjust-
ment
of
± 2 volts.
NOTE:
New
four
wire
controllers eliminate
the
ballast resistor
circuit since
the
ballast resistor's junction
is
now handled
internally.
Whenever replacing
an
early stylr controller with
the
newer four
wire
model,
remove
the ballast resistor and
its
wiring.
VOLT
~
+
-
GND
GREEN
RED
GROUND
TO
GENERATOR
CASE
VOLTAGE
OUTPUT
AOJUSTME.NT
AC
BRIDGE
RECTIFIER'
Testing
the
Battery
Charging
Circuit
1.
Bridge
Rectifier
Normal
AC
voltage running to the rectifier (while the
engine is operating at
1800 rpm) is measured across the
two AC connections on the bridge rectifier. (As
illustrated).
AC
voltage running to the bridge rectifier (approximate):
No-load
off
the
generator
16.0
volts A C
Full-load
off
the
generator
17.5 volts
AC
Normal DC voltage running out
of
the rectifier (in volts
DC) is measured across the two DC connections
of
the
bridge rectifier; that is
+ and
-.
DC
voltage running from the bridge rectifier
(approximate):
No-load
off
the
generator
Full-load
off
the
generator
2.
AC winding: O.lOohm
17.0 volts
DC
18.5 volts
DC
Lift the two
AC
wire leads off the bridge rectifier and
measure, the resistance between these two leads with an
ohmmeter. It should measure 0.10 ohm. No continuity
should exist between these two leads and the ground or
the main AC stator windings.
3. Testing
the
Bridge
Rectifier (meter used - Simpson 260)
a.
Set your ohmmeter's scale on
RXI
(+ DC) and set the
needle to zero.
b. Connect the
(+ ) positive lead from the ohmmeter to
point #4. Taking the ohmmeter's negative
H lead,
momentarily touch points
#1, #2, #3, and #5. The ohm-
meter should register no deflection for any
of
the
points touched.
c.
Remove the positive (+) lead from point
#4
and
connect the negative
(-)
lead; momentarily touch
points #1, #2, and
#3.
The
ohmmeter's needle should
deflect when each point is touched.
d.
Leaving the negative ohmmeter
(-)
lead on point #4,
. touch point
#5
with the positive lead. No deflection
should take place.
e. Place the positive (+) lead on point
#1
and the negative
(-)
lead on point #3. The ohmmeter again should not
register any deflection (no deflection indicated infinite
resistance). Reverse these connections and the
ohmme-
ter should again register no deflection.
If
the rectifier
fails any
of
the previous tests (A-E), replace the recti-
fier because it is
defective,
NOTE:
Different
types
and/or brands
of
test meters
may
produce opposite test
results.
POINT
1/1
POINT
14
.
BRIDGE-
RECTIFIER
POINT
#5
MOUNTING
HOLE
Engines & Generators
Revised August 2003
31