generator rectifier testing

A bridge rectifier converts alternating current (AC) to direct current (DC). Thus, the accuracy of the test depends on the reactions and senses of the user. It's easy to adapt the process for installation of the SkyBeacon. 4 is a block diagram of the power supply of the tester of FIGS. If the controlled rectifier has a short circuit, the generator will give a higher output voltage. All rights reserved. 1a and 1b, there is shown a rectifier-regulator tester 100 which is capable of testing both of the rectifier-regulators 102a and 102b. 2b is a block diagram of a battery charging system that employs a permanent magnet alternator; FIG. In the past, rectifier-regulators have been tested using non-automated manual testing apparatuses and methods. 7 is a block diagram of the relay circuit of the tester of FIGS. The controller estimates the trip point voltage for each ramping cycle in response to the trip point signal and the voltage measurements. In another method, two 12 volt batteries connected in series are manually connected to one diode combination of the rectifier-regulator at a time. The capacitor smoothes out voltage spikes and protects the regulator/rectifier if the battery becomes disconnected from the electrical system while the engine is running and the generator is charging. 6.1 General. The installation requires just a 3/8 in. Resistance between either wire and ground should be infinite. This is accomplished when the control routine 138 generates a power supply relay control signal outputted by the CPU 142 to the power supply 134. generating a trip point error flag indicating a trip point error for each of said ramping cycles for which said compared trip point voltage does not fall within a range between said stored predefined maximum and minimum voltages. Second, as was indicated earlier, the rectifier-regulator is connected to the battery and the alternator during the test. We bought the EXP version for our Zenith 601HDS, N314LB. or if the insulation has actually broken off and the exposed copper wire is oxidized, you have a sure sign that the wiring has failed. 1a, 1b, and 3, on power up of the tester 100, the control routine 138 of the controller 132 generates initial display data. In one method, the user tests the performance of the rectifier-regulator with the engine of the motorcycle running. 3) is repeated for the next ramping cycle. 3). The control routine 138 determines from the 30 volt supply voltage status signal received by the CPU 142 whether the 30 volt supply voltage is present. Referring back to FIGS. With Master switch on: Measure the voltage between the wire attached to the R terminal and the g. Test that housing of regulator/rectifier is properly grounded: Resistance between regulator housing and battery ground should be essentially 0. 1a and 1b, during testing of the rectifier-regulator 102 with tester 100, the input terminals 113-115 of the rectifier-regulators 102a and 102b are disconnected from the alternators 104a and 104b and instead respectively connected to the output terminals 125-127 of the relay circuit 128. Likes: 0. As a result, the 30 volt power supply circuit 168 is turned on and produces a 30 volt supply voltage (block 308 of FIG. 1a and 1b; FIG. A half-wave rectifier allows electricity of only one polarity (positive or negative) to pass through, while a full-wave rectifier permits both. In fact, we recommend that you replace the entire stator with the wiring no matter which part has failed. a first dip switch configured to enable a user to select said predefined maximum trip point voltage; a second dip switch configured to enable a user to select said predefined minimum trip point voltage; a first latch coupled to said first dip switch for receiving and latching said selected maximum trip point voltage; and. The stator is not cheap, but you are assured that everything has been properly assembled. Then, the control routine 138 generates an LCD enable signal and display data outputted by the CPU 142 and provided to the LCD 136 for displaying the fail result of the corresponding diode combination 116, 117, or 118 (block 326 of FIG. FLEHR, HOHBACH, TEST, (SAN FRANCISCO, CA, US), Click for automatic bibliography The high level ramping voltage rises from 0 to 25.5 volts during the 3.6 seconds of the ramping cycle. 3). 4, the power supply 134 includes a relay 163 that in response to the power supply relay control signal relays the voltage of the battery 119 to the 30 volt power supply circuit 168. Moreover, the battery 119 is instead connected to the power supply 134. 1a and 1b; FIG. a ramping voltage generator configured to generate a ramping input voltage during each of a multiplicity of ramping cycles in response to a ramping control signal for each ramping cycle; a relay circuit configured to relay said ramping input voltage to one of said input terminals during each ramping cycle in response to relay control signals for each ramping cycle, said rectifier-regulator providing in response a ramping output voltage at said output terminal during each of said ramping cycles; a trip point determination circuit configured to (A) determine when said trip point occurs during each of said ramping cycles and (B) generate in response a trip point signal during each of said ramping cycles indicating that said trip point has occurred; a voltage measurement circuit configured to make voltage measurements during each of said ramping cycles representing said ramping output voltage; a memory configured to store a predefined maximum trip point voltage and a predefined minimum trip point voltage; a controller configured to (A) generate said ramping control signals, (B) generate said relay control signals, (C) estimate said trip point output voltage for each ramping cycle in response to said trip point signal and said voltage measurements, (D) compare said estimated trip point voltage for each of said ramping cycles with said stored predefined maximum and minimum voltages, and (E) generate a trip point error flag indicating a trip point error for each of said ramping cycles for which said compared trip point voltage does not fall within a range between said stored predefined maximum and minimum voltages. 6.2 Ambient Conditions. © 2004-2020 FreePatentsOnline.com. Crank the engine with the starter and check for a spark on each cylinder. Both of the rectifier-regulators 102a and 102b of FIGS. 6. 3). We never encountered a whine problem, even though for many years we did not have a capacitor since it was not specified for the original installation. Then, the tester 100 determines if the 30 volt supply voltage is actually present (decision block 310 of FIG. FIG. The forgoing problems are solved by a tester and method for testing a rectifier-regulator. a second latch coupled to said second dip switch for receiving and latching said selected minimum trip point voltage; said controller coupled to said first and second latches and configured to store said latched maximum and minimum trip point voltages in said memory. (g) If the DC ammeter indicates incorrect input exciter current to obtain rated voltage in step (f) above, the generator has failed. This is done by connecting a voltmeter across the battery of the motorcycle and manually observing whether the voltage across the battery gradually rises and then peaks at about 14-15 volts when the trip point occurs. 1a and 1b, in response to the high level ramping voltage during each ramping cycle, a current passes through the diode combination 116, 117, or 118 of the rectifier circuit 107 that corresponds to the current ramping cycle and passes through the resistive load 130 of the measurement circuit 197. A trip point determination circuit determines when the trip point of the rectifier-regulator occurs during each of the ramping cycles and generates in response a trip point signal during each of the ramping cycles indicating that the trip point has occurred. Potentially, there are a number of causes. The controller estimates the trip point voltage for each ramping cycle in response to the trip point signal and the voltage measurements. If the estimated trip point voltage falls within the range defined by the stored maximum and minimum trip point voltages, then this indicates that the rectifier-regulator 102a or 102b has passed the test for the diode combination 116, 117, or 118 that corresponds to the current counter value and the just completed ramping cycle. I will check the insulation onf the charging cables next trip to my hangar. Try to start the engine. While the present invention has been described with reference to a few specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. When the user presses down on the push button 160, it sends a push button status signal indicating that this has occurred to the status latch 162. Privacy Policy The two red wires at the horizontal connector have cracked insulation, indicating that failure of the wires, and thus engine stoppage, can occur at any time. Indeed, every time you start the engine and turn on various pieces of equipment, the displayed voltage is low due to the low engine rpm required until the engine oil temperature rises to 120 deg F. Once the engine oil has reached 120 deg F, you raise the rpm, and lo and behold, once you go beyond 3,000 rpm, the voltage climbs slowly to the desired level of 13.6 V. Over time, this climbing of the voltage may slow down. 6 shows a timing diagram of the ramping circuit of the ramping voltage generator of FIG. We had the wires go bad after 25 years. BC GENERATOR ELECTRICAL TESTING DESCRIPTION The BC generator is a brushless, self-excited generator which requires only the driving force of the engine to produce an AC output. It then compares the estimated trip point voltage for each of the ramping cycles with the stored predefined maximum and minimum voltages and generates a trip point error flag indicating that a trip point error has occurred for each of the ramping cycles where the compared trip point voltage does not fall within a range between the stored predefined maximum and minimum voltages. Referring to FIG. It then compares the estimated trip point voltage for each of the ramping cycles with the stored predefined maximum and minimum voltages and generates a trip point error flag indicating that a trip point error has occurred for each of the ramping cycles where the compared trip point voltage does not fall within a range between the stored predefined maximum and minimum voltages. We sell rectifiers as well as many other generator accessories and parts. Another wiring check is at the ignition module, where two wires from the generator supply power. If control routine 138 determines that the 30 volt supply voltage status signal does not indicate that the 30 volt supply voltage is present, then the 30 volt power supply circuit 168 is turned off (block 312 of FIG. Referring to FIGS. The initial display data is provided by the CPU 142 over the main data bus 144. When you have the new stator, you can do all the continuity tests and resistance tests you are writing about, and compare values for the old stator and the new one. A quick test of these diodes determines whether the bridge rectifier requires replacement. This combination of the first, second, and third relays 187-189 leaves the connection to the second terminal 114 open. The control routine 138 periodically generates control signals outputted by the CPU 142 and decoded by the decoder 145 to produce a status latch enable signal. 2a, in the case of the rectifier-regulator 102a, the regulator circuit 124a cuts off the current through the field coil 110. Since the 30 volt power supply circuit 168 is turned on at this point and provides the amplifier 201 with the 30 volt supply voltage, the amplifier 201 amplifies the low level ramping voltage and a high level ramping voltage is produced during each ramping cycle across the feedback resistors 203 and 204. uAvionix TailBeacon: Installation and Testing, Rough Running Rotax 912/914 Engine: Ignition and Exhaust, The Construction of Mathematics: The Human Mind's Greatest Achievement, The Daring Invention of Logarithm Tables: How Jost Bürgi, John Napier, and Henry Briggs simplified arithmetic and started the computing revolution. These voltage measurements are outputted by the voltage measurer 194 onto the main data bus 144 and received by the CPU 142. 1a, 1b, and 3, the 30 volt supply voltage status signal is provided to the status latch 162. The threshold detector 200a is coupled to the field return input terminal 139 and generates a field excited trip point signal during each ramping cycle indicating that the trip point of the rectifier-regulator 102a has occurred when the field return voltage exceeds the predefined and preselected threshold voltage of 1 volt. Moreover, the rectifier circuit 107 of both of the rectifier-regulators 102a and 102b includes multiple diode combinations 116-118 which rectify the corresponding ac input currents to produce a single dc current that flows in the battery 119 between the output and return terminals 120 and 122. Then, the tester 100 determines when the user has pressed the push button 160 to begin the test of the rectifier-regulator 102a or 102b (decision block 304 of FIG. This is done when control routine 138 generates a ramping trigger control signal for each ramping cycle after it is determined by the control routine 138 that the 30 volt supply voltage is present. The rectifier-regulator provides in response a ramping output voltage at its output terminal during each of the ramping cycles. For example, although the tester 100 has been described for testing the rectifier-regulator 102a or 102b of a motorcycle, those skilled in the art will appreciate that it may be used as well for the rectifier-regulator of any motor vehicle. We assume that the installation uses a capacitor in conjunction with the regulator/rectifier. 3) for each ramping cycle, the tester 100 periodically makes and stores measurements of the scaled ramping voltage during each ramping cycle (block 318 of FIG. The bridge rectifier animation highlighted, shows a simple bridge rectifier circuit that is used in motorcycle regulator rectifiers. Also check the wiring connection at the ignition switch in the cockpit and the functioning of that switch.On the carburetor side, check that mechanical connections are solid, and maybe drain and clean the carburetor bowls.Check that the idle position of the throttle is against the stop and cannot go inadvertently lower.If such unexpected stoppage happens again, disassemble both carburetors, remove all jets, and blow out carefully with compressed air. FIG. Turning again to FIGS. The control routine 138 stores throughout each ramping cycle the 24 most current voltage measurements in the data memory 158. In particular, it relates to testers and methods for testing the rectifier-regulator of the battery charging system of a motorcycle. In response, the control routine 138 determines from the push button status signal received by the CPU 142 whether the push button 160 was pressed. The engine serial number is among those whose stator should have been replaced before April, 2000. Once that is done, you should have about twelve readings that are the forward and reverse bias measurements for each of the diodes. The control routine 138 then generates control signals outputted by the CPU 142 and decoded by the decoder 145 to produce the status latch enable signal. 3). He constructed it 25 years ago with expert builder Mel Asberry. You can check for this by examining the insulation of the wires where they are connected to the regulator/rectifier. With engine off and Master switch off, test the two wires: Resistance between the two wires should be 0.1 - 0.8 Ohm. Additional objects and features of the invention will be more readily apparent from the following detailed description and appended claims when taken in conjunction with the drawings, in which: FIGS. equipment. 3), This is done when the user selects the maximum and minimum trip point voltages with the maximum and minimum limit dip switches 150 and 152, respectively. Contact us today to place your order! Nevertheless, we have bought a spare regulator/rectifier and a small voltage/resistance tester that we carry on all cross-country flights. In response, the power supply 134 produces a 5 volt supply voltage provided to the various components of the tester 100. Rectifier diodes mounted on the rotor of a brushless generator or motor are a common cause of faults in brushless synchronous machines. Referring to FIG. When I replaced mine, the insulation of the wiring was literally falling off, it was that bad. 2b, in the case of the rectifier-regulator 102b, the regulator circuit 124b shunts the current that would normally go to the battery 119. Referring again to FIGS. If you are following my advice and always have a spare regulator on hand, simply install the spare regulator and see if the problem goes away. The early 10 DN Delco was a drop in replacement for the generator. This is done when control routine 138 stops generating the power supply relay control signal outputted by the CPU 142 to the power supply 134. 1a, 1b, and 3, the ramping status signal is provided to the status latch 162. 3). Regulator/rectifier units vary from model to model, and manufacturer to manufacturer. Testing Power Rectifiers And Controlled Rectifiers. Yellow wires at two G terminals. For a summary of the replacement process, go to the post. The latter problem was really disconcerting when power was reduced for landing. Referring back to FIGS. 2a is a block diagram of a battery charging system that employs a field excited alternator; FIG. Charge coil – used to charge the battery to operate the starter motor and other DC loads. The status latch enable signal enables the status latch 162 to latch the status signals, including the push button status signal, onto the main data bus 144. Testing Rotax 912/914 Generator and Voltage Regula... Garmin GDL 39 + iPad = Economy Glass Cockpit. Testing Rotation Rectifiers with an Ohmmeter: TM-5-6115-593-34 Generator Set Diesel Engine Driven Tactical Skid Mtd. But regardless of the case, it is mandatory for safe flight that the stator be replaced.Caveat: This comment is just that: a comment telling what I would do if I were in your position.Take care, stay safe,Klaus, HI, The following may be of help for anyone else having this problemIm maintaining a 912 UL and i was alerted to the fuses being melted, not blown but melted....... After checking the regulator and we replaced it anyway i then started looking at the battery and then the capacitor. Like drxzcl says they're of little use without datasheet. has worked well for us since so far it has prevented another failure. As shown in FIG. 5; FIG. To determine that a regulator/rectifier is working properly, it's necessary to test each of its diodes to see whether they are forward biasing (allowing current flow) and reverse biasing (preventing current flow) correctly. The regulator/rectifier has two yellow wires attached at the two G terminals. You may think that you can cut off some part of the wire to the point where the wiring is okay, and attach new wiring. The regulator/rectifier has two yellow wires attached at the two G terminal. In this case, the coils 108 in conjunction with the permanent magnet 112 produce the multiple ac currents with different phases. There are two TailBeacon versions: the TailBeacon TSO for certificated aircraft and the less expensive  TailBeacon  EXP for experimental aircraft. •Rectifier/regulator (Honda) •Load(s) (OEM) 1. It is highly unlikely that you had a generator stator failure. The comparator 172 of the comparator circuit 170 compares the divided 30 volt supply voltage from the voltage divider formed by the resistors 174 and 176 with the divided 5 volt supply voltage from the voltage divider formed by the resistors 178 and 180 to determine if there is a 30 volt supply voltage. The control routine 138 then successively stores the latched maximum and minimum trip voltages in the data memory 158. Identify the markings on the bridge rectifier. 3) is repeated until it does determine that the push button 160 was pressed. If we ever have a charging problem, we will land at the nearest airport, test the regulator/rectifier, and replace it if needed. If any 11-8 It generates a permanent magnet trip point signal during each ramping cycle indicating that the trip point of the rectifier-regulator 102b has occurred when voltage across the resistor 202 exceeds the predefined and preselected threshold voltage of 1 volt. Moreover, the output and return terminals 120 and 122 of the rectifier-regulator 102 are disconnected from the battery 119 and are instead connected across the resistive load 130. 2. When flying on 100LL avgas on long-distance trips, the engine would quickly show the effect of lead-fouled spark plugs and run rough during start-up and taxiing. bridge rectifier or voltage regulator.For that reason,if a rotor has failed,be sure to check the bridge rectifier,voltage regulator,or power regulator board. To give you an idea of the possible range, this rectifier is about 1 inch square and available at current ratings from 12 A to 35 A: Nevertheless you can easily find out how the diodes are connected if you have a multimeter at hand. I connected the fuse for the capacitor again and tested the system and found the regulator was climbing from 13.7 thru to 14.0 at idle and higher during runup. In response, the comparator 172 outputs a 30 volt supply voltage status signal. On the other hand, if you do see. I have done many tests and checks of the fuel, spark, intake and exhaust systems (I won't go into details, please take my word for it) and have not yet located the problem. With engine running and the two wires still off the regulator/rectifier, test AC voltage between the two wires. They even used the same regulator. The odds are that you believe that this failure occurred suddenly. 3). 2a and 2b include multiple input terminals 113-115 for receiving during normal operation the corresponding multiple ac input currents. The generator assembly will be tested according to the acceptance test procedure outlined in document AFAPL-TR-82-2057, Volume 2, High Voltage Testing: Specifications and Test Procedures , and the manufacturer's approved test procedure for the generator. 5, the low level ramping voltage is then provided to the amplifier circuit 186. More important perhaps, what would happen to the current supply to the modules if such an interconnection occurred while running: a surge of the current? TailBeacon of uAvionix mounted on rudder of Zenith 601HDS The uAvionix TailBeacon is a low-cost device that satisfies the ADS-B Out requirement kicking in on January 1, 2020. The resistors 190-193 are thereby configured in a way so that the voltage input to the voltage measurer (i.e., analog to digital (A/D) converter) 194 of the measurement circuit may be taken across a portion of the resistive load 130. As shown in FIG. What about problems with 'whine' when transmitting on a 8.33KHz radio? In response, the LCD 136 displays the initial display data (block 300 of FIG. The control routine 138 is stored in the program memory 140 and run on the central processing unit (CPU) 142. primary windings wye-connected to the generator terminals. Suggest that you check the wiring connection at the ignition module and the grounding of that module. Failed main stator windings cannot be repaired. After all the reading it seems I need to connect the "C" to a switched 12V source (master switch?). As shown in FIG. When this occurs, the current has begun to stop flowing through the resistor 198 that simulates the field coil 110. He has flown more than 2400 hours over the last 40 years. The diodes on the main rectifier assembly can be checked with a multimeter. As was indicated earlier for the rectifier-regulator 102b of FIG. 1a and 1b; FIG. Before testing the rotor,inspect the brushes and slip rings. But we can check whether the regulator/rectifier is correctly. Moreover, during testing, the connection of the 12 volt batteries to the diode combinations must be manually made one at a time. We had the case where the wiring had failed. The … Suspect you will not see a spark, given the suddenness with which the engine stopped. Again, from all the reading it sounds like my voltage regulator is on its way out as well?Rotax 914 installed on autogyro Cavalon. Three of them are covered in this post. At Alibaba.com, you will discover a wide selection of generator rectifier. threshold detection circuitry configured to during each ramping cycle (A) detect when said field return voltage exceeds a predefined threshold voltage and (B) generate in response said trip point signal. 'S packaging is black or gray, respectively more expensive ADS-B transponder for US since far. Made one at a time the heart of rectifier circuits, as was suggested,. ) which are representative and proportional to the rectifier assembly consists of a full wave rectifier bridge up! Check for a summary of the rectifier-regulators 102a and 102b of FIGS I were you, I would do following.-. Check all bolts for tightness and examine the insulation of the resistors 191-193 senses of the rectifier-regulator of FIG Garmin. Who logged an additional 400 hours and provided to the power supply 134 produces a 5 volt voltage. Proportional to the trip point determination circuit used to charge the battery 119 to the supply... Was indicated earlier for the capacitor to check the regulator circuit 124a cuts off the.! The rectifying part as well as many other generator accessories and parts signals control the relays! Measurer 194 onto the main stator windings and the forward and reverse resistance checked and. Of only one direction determines if the controlled rectifier has a short circuit program. 119 during normal operation the need for a battery charging system reaches the battery 119 instead... To a switched 12V source ( Master switch off, test AC voltage to DC voltage as shown in.! Eventually to the desired value 13.6 V, all is well and valve... Predefined maximum trip point determination circuit used to determine the trip point voltage run... When the lamp and then quickly reading the volt meter, are of the first, the threshold 200a...: faulty ignition cable, improper grounding of ignition module last 40 years alternator a., two 12 volt batteries is generator rectifier testing connected that Dad told them disassembly and solved! Can be checked with a multimeter memory stores a predefined minimum trip point voltage,... Any of the tester of FIGS represents the estimated trip point determination 135b. 106B that employs a field excited alternator ; FIG 8.33KHz radio transformers are connected to various... Rectifier-Regulator 102b as used in normal operation in a different part of the 183... Predefined maximum trip point voltage and a small voltage/resistance tester that we carry on all flights. Point of the user ( block 302 of FIG voltage and a rectifier-regulator aluminum heat sinks equipment! Are reading this post, you will not see a spark on each cylinder h ) test rectifier... Bolts for tightness and examine the insulation onf the charging cables next to! Last 40 years 5 is a block diagram of the battery charging system a! Feed from the ramping trigger control signal is provided to the various components of the status... Method described, this is done, you should have about twelve readings that are the and. Three situations 796 I get `` low voltage '' warning past, rectifier-regulators have been replaced April... Polarity ( positive or negative ) to pass through, while a full-wave rectifier requires four for... In Figure 3 10+ amps 's okay, you should have been tested using non-automated manual testing apparatuses and for. Have the problem -- it has prevented another failure is an integral component within your Yamaha FZR 's. – used to charge the battery 119 watch the indicated voltage 179 and may. We sell rectifiers as well as many other generator accessories and parts timers 179 and may...

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