Integral Controller; Testing Battery Charging Circuit - Westerbeke 5.0Kw BCDR Operator's Manual

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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
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