Specifications
w
CI
:J!
II:
Q
5.0KW
Be
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: 13.0 - 14.0 volts
DC
Charging
Amperage:
0 - 10-
amps
DC
A separate group
of
stator windings supplies AC voltage to a
bridge rectifier which converts the AC current to supply the
I.C. unit.
The
I.C. unit senses the needs
of
the starting battery
and supplies a
DC
charge when one is needed.
If
you suspect
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 replac-
ing the I.C. unit.
NOTE:
When
the
generator isfirst
started,
the I.e. 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 adjust-
ment on the controller that will allow a DC voltage output
adjustment
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 style controller
with
the
newer four
wire
model,
remove
the
ballast resistor
and
its
wiring.
DC
~~~""'----""'I~
RECTIFIER
CDNTROLLER
VOLTAGE
OUTPUT
ADJUSTMENT
(ON
BACK)
+ -
GND
BRIDGE
RECTIFIER
o
BLACK
YELLOW
GROUND
TO
GENERATOR
CASE
AC
INTERNAL
CONTROLLER
DIAGRAM
NOTE:
Earlier model controllers had white/green
(-)
negative
and whitelblack ground connections that
are
interchangeable.
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 AC
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,r.ectifier; that is
+ and
-.
DC
voltage running from the bridge rectifier
(approximate):
No-load
off
the
generator
17.0 volts
DC
Full-load
off
the
generator
18.5 volts
DC
2.
AC
winding: 0.14
ohm
Lift the two AC wire leads off the bridge rectifier and
measure, the resistance between these two leads with an
ohmmeter. It should measure
0.14 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
(-)
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
brarufs
of
test meters
may
produce opposite test
results.
BRIDGE
RECTIFIER
POINT
#3
POINT
#4
Engines & Generators
50