CONSTRUCTION
Circuitry: 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.
Housings: 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.
Wire connections: All 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.
TESTING:
Prior to shipment, all regulator assemblies are attached to a matching generator and the following tests are performed:
1. Unit turns on with battery load only
2. Unit turns on with full system load applied.
3. Maximum battery voltage does not exceed 7.25 volts.
4. Maximum generator output achieved.
5. No internal components grounded or shorted to chassis.
6. 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.
