BATIERY
CHARGING
CIRCUIT
INTEGRAL
CONTROLLER
(J.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: 13.0 - 14.0
volt.$
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
LC.
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
J.C.
unit.
NOTE:
When
the generator
is
first
started,
the
LC.
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
~er
four
wire
mode~
remove
the ballast
resistor
and
its
wiring.
BRIDGE
RECTIFIER
.
iNiEGRAL
CONTROLLER
INTEGRAL
.
~ON)'RDlLER
YELLOW/WHITE
POSl!/VE(+)
TERMINAL
OF
RECTIFIER
GROUND
TO
GENERATOR
CASE
Testing.
the
Battery
Charging
Circuit
1.
Bridge Rectifier
Normal
AC
voltage running
to
the rectifier (while the
eng1ne
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 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.
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
O.lQ
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 zero.
b. Connect the (
+)
positive lead from the ohmmeter
to
point #4. Taking the
o~eter'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 #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
oppositP
test
results.
POINTl4
.
BRIDGE·
RECTIFIER
POINTl3
POINTIS
MOUNTING
HOLE
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