The basic circuit design is similar to that of a
modern automotive voltage regulator. All internal solid state components are
sized specifically for the application and are designed with a minimum 100%
overrated safety factor. The regulator components are assembled onto a printed
circuit board which is then mounted inside an appropriate metal housing. The
circuitry is encapsulated in a high temperature epoxy potting compound which
is impervious to water, oil or dirt and insulates the components from
vibration and prevents tampering.
The metal housing is specific to each application but in all cases acts as a
heat sink to keep the internal components cool. It is normal for the housing
to get hot during operation. Splitdorf regulators are housed in a brass cap
which fits inside the generator. Autolite regulators are mounted in a solid
aluminum housing which is CNC machined and powder coated to look just like the
original cutout cover. Harley Davidson and Bosch housings are aluminum and
will fit inside the original cutout cover.
wires are high temperature silicone jacketed and are color coded for easy
identification. Wire connection methods differ slightly, depending on the
application. Splitdorf regulators have identifying labels and soldered on ring
terminals for easy installation. Some Autolite and Harley Davidson
applications will require crimping and soldering one wire terminal after
installing the regulator on the generator. All wire connection methods and
locations are thoroughly detailed in the installation instructions.
Prior to shipment, all
regulator assemblies are attached to a matching generator and the following
tests are performed:
Unit turns on with battery load only
Unit turns on with full system load applied.
Maximum battery voltage does not exceed 7.25 volts.
Maximum generator output achieved.
5. No internal components grounded or shorted to chassis.
Unit turns off, no reverse current flow allowed.
In developing this
regulator, numerous prototype regulators were thoroughly tested in a series of
extreme conditions on a test stand, including prolonged overload and
over-temperature tests, and every conceivable improperly connected situation
was attempted. The only damage to a generator during testing occurred as a
result of a 3 hour full load test while maintaining an ambient temperature of
180 degrees F around the generator and regulator. The generator failed due to
excessive heat, but the regulator was removed and installed on a second unit
and worked perfectly.
Prototypes have been
running on a variety of machines since May of 2004. All prototypes have
performed very well, with no failures to any regulators, generators or
batteries as a result of installing this regulator.