After installation of the solid state
voltage regulator on a properly functioning three brush generator, the charging
rate will be variable and automatic based on demand, and limited only by the
design and condition of the generator. This will eliminate the problem of either
overcharging or undercharging of the battery, and any guesswork needed when
adjusting the third brush, regulator or cutout settings.
The solid state voltage regulator
requires permanent removal of the third brush and the cutout relay. Minor
wiring changes within the generator will convert the generator to a 2 brush
configuration. The field winding circuit will be connected to the regulator, as
will the battery and generator armature. This will allow the solid state voltage
regulator to accurately control the voltage applied to the field windings, which
will in turn control the current and voltage output of the generator. Based on
the battery voltage, the generator will now charge only as much as needed. When
the lights are on, generator output increases in an effort to maintain the
desired battery voltage. When the lights are off, the charge rate tapers down as
the desired battery voltage is quickly obtained, then a very small charge is
applied to maintain the battery. If the battery is low, a high charge rate will
be applied until the desired battery voltage is obtained, at which point the
charge rate tapers down to a trickle charge. Depending on the condition and size
of the battery and generator, it may take some time to reach a fully charged
status.
The solid state voltage regulator will limit the maximum battery voltage to
approximately 7.25 volts, but will adjust the generator current output up or
down as needed to supply various loads in the electrical system. By accurately
controlling the battery voltage and charge rate, undercharging, overcharging,
overheating, and boiling of the battery is virtually eliminated. The result is
longer battery life and reduced damage from battery acid vapors and leaks.
This will also allow the use of gel type batteries which are very sensitive to
overcharging and high voltage inputs.
No field adjustments can be made to the regulator. All settings are carefully
pre- determined for each application and set prior to final assembly.
The original mechanical or electrical cutout relay is replaced by a high
capacity diode within the circuitry of the regulator. The diode works as an
electrical check valve, allowing power to flow out of the generator to the
battery, but not in reverse. This eliminates the need to clean and adjust the
contact points of the old cutout relay. It will also eliminate the possibility
of the cutout sticking shut, which would drain the battery when the motor is
shut off.
Normal operation of the regulator will by nature generate heat within the
internal components. The electrical components must be kept cool to avoid
damage. The regulator housing is designed as a heat sink, drawing heat away
from the internal components. Higher output generators require larger heat
sinks. It is normal for the regulator housing to get warm, even hot at times
during operation.