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BATTERY CHARGING CIRCUIT
INTEGRAL CONTROLLER (l.C.)
The Integral Controller (l.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:
~.o
.
14.0 volts DC
Charging Amperage: 0 • 10.0 amps DC
A separate group of stator windings supplies AC voltage to a
bridge rectifier which converts the AC current to supply the
I.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 replacing
the
r.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
will
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 function is now
handled
· internally. Whenever replacing an early stylr controller
with
the
~wer
four wire model, remove
the ballast
resistor
and its
wiring.
BRIDGE
RECTIFIER
--*~
GREEN!MlitE.
NEGATIVE({.
TERMINAL oFRECTIFIER
BRIDGE
RECTIFIER
. iNTEGRAL
CONTROLLER
INTEGRAL
. CONTROLLER
YELLOW/WHITE
~~W~l°6F
RECTIFIER
Testing the Battery Charging Circuit
1. Bridge Rectifier
Normal AC voltage running to the rectifier (while the
engine
is
operating at 1800
zpm)
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.S 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
17.0 volts DC
Full-load off the generator .
· 18.5 volts DC
2.
AC winding: 0.10.obm
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 RXl (+DC) and set the
needle to
z.ero.
b.
Connect the (
+)
positive lead from the ohmmeter to
point
#4.
Taking the ob:mmeter's negative (-) lead,
momentarily touch poirits
#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 #S 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 oppositf'.
test
results.
POINTl4
. BRIDGE RECTIFIER
POINTl3
POINTl5
MOUNTING HOLE
Engines &·Generators
; 25
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