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  #31  
Old 1 Day Ago
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bustert bustert is offline
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+++1 mr. doc
where is the residual magnetism stored.
1. armature ?
2. field shoes ?
having a bulb for gen output has nada to do with residual, look at the circuits
if the vr was hooked up in reverse or proper polarity was not present, you probably smoked the vr.
in reverse polarity, the main contacts in the vr vibrate violently and will burn them up. if the vr is reversed wired, then there is a high chance the resistor on the back of the vr is smoked. this resistor is used to bias field forcing for the field coils which increases magnetic flux in the shoes which excites the armature to saturation to increase output, with resistor in circuit, less output, resistor shunted, more output.
http://xlforum.net/forums/showthread.php?t=1973669

REGULATOR POLARITY - Some regulators are designed for use with negative
ground systems, while others are designed to be used with positive ground systems. Using
the wrong regulator on an application (which happens fairly often) will cause the regulator
points to pit and burn badly, resulting in a short regulator life. Not polarizing a generator
can also cause these same problems.
OK, SO HOW CAN I TELL BY LOOKING AT A REGULATOR WHAT POLARITY IT IS?
Normally, when they were new, most regulators were marked. The other way to tell
is that positive ground regulators will have copper-colored current and voltage regulator
coils, while the negative ground regulators will have cadmium or straw-colored coils.
GENERATOR POLARITY - This is simply the direction the current is flowing between
the battery and the charging system. As we learned earlier, the pole pieces in a
generator will store up magnetism. When a generator produces voltage, the leftover magnetism
will cause the current to flow in
the direction it last traveled.
When a generator has been removed
for repair, the magnetism is
sometimes lost in the pole pieces. So
when the generator is reinstalled, it must
be “polarized.” This means the magnetism
must be reinstalled in the pole
pieces to insure the current travels to the
battery in the right direction.

Last edited by bustert; 1 Day Ago at 15:37..
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There seems to be a little mystique about the little black boxes known as the regulator and a couple of old wives tales on how they work so this I hope will clear some things up. If we can understand something better, we are more apt to diagnose and repair it. The generator adjusts itself to the load and no excess current is sent to ground.
First of all, the generator is actually an alternating current devise (ac). Since silicon rectifiers were not invented yet, the ac was changed to dc by the commutator and brushes. As the commutator is rotated in the magnetic field, a current is induced into the armature windings and is sent to the commutator segments and brushes to the output. The current and voltage will peak as the magnetic field peaks and starts to decay to a negative value on the ac wave form, but just before the it transitions to a negative direction, the brushes switch the ends of the armature coil where the current and voltage is now rising to a peak positive value. These peak values from the armature windings are combined to create a high steady value instead of a series of high/low pulses.
THE BALANCING ACT

The regulator consists of three sections: cut out relay, current regulator and voltage regulator.
1. CUT OUT RELAY: Generator at high speed is equal to exceeds battery voltage, charging takes place, but at low speeds, generator output is below battery voltage and will discharge the battery through the generator so the cut out relay opens to prevent this from occurring.
2. CURRENT REGULATOR: Limits the generator out put amperage to prevent the armature winding from burning out.
3. VOLTAGE REGULATOR: Maintains the voltage to a set level to charge the battery with out damaging it.

The cut out relay has two coils, one for the battery and one for the generator that perform a balancing act of two magnetic fields. The coil on the battery holds the contact open so no current can back flow to the generator and its ground brush. When the generator out put exceeds the battery voltage, the magnetic field on its coil over comes the coil on the battery and closes the contact allowing current to flow. When the generator out put goes below battery voltage, the magnetic field on the battery coil over comes the generator coil and the contact opens to prevent back flow.
The voltage regulator has a shunt winding of fine wire connected across the generator and an accelerator or series winding that speeds up the action of the vibrating contacts. A flat steel armature attached by a hinge is above the coil core and has a set of contacts. When the voltage regulator is not operating, the tension of s spiral spring holds the armature away from the core so the contacts connect the generator field coils to ground. When the generator voltage reaches a set value, the magnetic field over comes the armature spring tension and pulls the armature down and the contacts open which inserts a resistance into the generator field circuit and the field current is reduced. The reduction of generator voltage reduces the magnetic field of the regulator shunt winding and the magnetic field is weak enough to allow the spring to pull the armature away from the core and close the contacts. When the contacts are closed, the field coils are grounded and cause the generator out put to increase. Remember in the generator the field coils are fed from the output of the armature current. This cycle is repeated many times a second and keeps the voltage at the desired level.
The current regulator has a few heavy turns of wire, which carries the full generator output amperage. A flat armature with a hinge is over a coil core and has a set of contacts. When the regulator is not operating, a spring holds the armature away from the coil core and the contacts are closed. The generator field circuit is completed through the contacts in series with the voltage regulator contacts. When the generator current reaches its set value, the magnetic field of the coil pulls the armature down over coming spring tension. This action inserts a resistance in the generator field circuit and the generator output is reduced. The reduction in current from the generator reduces the magnetic field of the current regulator coil and the weak field is overcome by the spring tension and the contacts are closed. This grounds the generator field coils and the generator output increases. This cycle is repeated several time a second and keeps the amperage at a set level. This also prevents the generator from burn out due to high current through the armature windings.

All mechanical adjustments and contact cleaning must be done with the battery disconnected. “ The cut out relay must never be closed by hand with power connected or it will over current the regulator and damage it. This is what smokes the resistors on the back of the regulator.”
Very slight adjustments can be made to the voltage regulator point gaps to change the settings. The same is true for the current regulator. However, you must use a calibrated current source to correctly set it or you could over max the generator and burn the armature windings.
There are ways to test the regulator on the machine. Do not over look the battery! A high battery temperature will reduce its resistance and the regulator will over charge it. Shorted plates will also affect the regulator but not effect the rest of the electrical system until the battery output is too low.
Remember, the machine will primarily run off the generator output and only draw power from the battery if the generator cannot keep up.

What’s up next, possibly a 101 on the electronic version. Yes they can be repaired if you want to take the time and effort!!
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Thanks everyone for all the help


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