Download Russian Regulators: Part VI for the Nippon-Denso 770

Russian Regulators: Part VI
Voltage Regulator (126000-0600)
for the Nippon-Denso
770-Watt Alternator
Ernie Franke
[email protected]
12-Volt Regulator (N-D Part # 126000-0600)
for the Nippon-Denso 55-Amp Alternator
• Background
– Voltage Regulators Paired with Specific Generators/Alternators
– Time-Line for Generators/Alternators/Regulators
– Performance Specs for the Nippon-Denso (N-D) Alternator
– Alternator Application in Ural Wiring
• What is it?
– Internal (Built-In) Voltage Regulator for the Ural Nippon-Denso (N-D)
Alternator
– Completely Solid-State
– Years of Application: 2004-to-Present
– Replaced the 14.377 (35-Amp) Alternator in Jan. 2004
– Retro-fittable to 14.377 (35-Amp) and Г-424 (11-Amp) Applications
• How Does It Work?
– Regulates Alternator Output Voltage to 14.5-Volts
– Provides Constant Voltage Regardless of Rotor Speed
– Supplies Exciter Current to Vary Magnetic Field of Rotor
• Circuit Description and Operation
• Replacement
– Widely Used in Nippon-Denso (Denso), Daihatsu, Kubota and
Suzuki Alternators
– Replacement Parts Readily Purchased On-Line
The Nippon-Denso 126000-0600 built-in, solid-state
voltage regulator is a widely-used, reliable unit.
Types of Generators/Alternators for Ural (Урал) and Dnepr (Днепр)
(01/10)
(
[email protected]
Generator/
Alternator
Type
Vintage
Nominal
Voltage
Г-11
(G(G-11)
Generator
DC
194119411951
6-Volt
(7(7-Volt)
Г-11A
11A
(G(G-11A)
DC
195219521957
6-Volt
(7(7-Volt)
195719571974
(Built(Built-in
Rectifier)
Nominal
Power
Regulator
7-Amp
4545-Watts
7-Amp
6-Volt
(7(7-Volt)
197419741998
Alternator/
Starter
Alternator
(Built(Built-in
Rectifier &
Regulator)
(P/N: 72181)
(P/N: 7218172181-A)
Generator
Г-414
(G(G-414)
DC
Generator
(P/N: 750181)
Г-424
(G(G-424)
(P/N: 3701000)
Hitachi
(Limited
Appearance)
14.3771
(P/N: 14.377114.3771010)
Nippon
Denso
(P/N: IMZIMZ-8.10378.103718092)
Current
Alternator
Alternator
(Built(Built-in
Rectifier &
Regulator)
Motorcycles
Ural(IMZ)
Dnepr (KMZ)
PPPP-1
PPPP-31 (1950)
M-72
Not Used
4545-Watts
PPPP-31 (1950)
PPPP-31A (1956)
M-72, MM-72M ,
M-61
M-72, MM-72N,
early KK-750
1010-Amp
6565-Watts
PPPP-31A (1956)
PPPP-302 (1963)
PPPP-302A
M-62, MM-63,
M-66
K-650, later KK-750,
K-750M, MWMW-750,
MWMW-750M, MTMT-8,
MTMT-9, MTMT-12
1212-Volt
1111-Amp
(aka 1414-A)
150150-Watts
PPPP-330
33.3702 (1992)
M-67, M67.36,
IMZ 8.103 Series
MWMW-650, MWMW-650M,
MTMT-10, MTMT-10.36,
MTMT-11, MTMT-16
199819981998.5
1212-Volt
(14(14-Volt)
1818-Amp
300300-Watts
Internal to
Alternator??
IMZ 8.103 and
8.107
“650”
650” Series
Not Used
1998.5
2004
1212-Volt
3535-Amp
500500-Watts
(aka 350350-W)
Internal to
Alternator
(YA212A11E)
IMZ 8.103, 8.103X,
8.123, 8.123X
“650 & 750”
750” Series
20042004-
1212-Volt
5555-Amp
770770-Watts
present
(14(14-Volt)
(14(14-Volt)
(14(14-Volt)
Internal to
Alternator
(126000126000-0600)
0600)
IMZ 8.103, 8.103X,
8.123, 8.123X
“750”
750” Series
Not Used
Not Used
Notes:
1.
Nomenclature: The Cyrillic letter “Г” transliterates (Russian-to-Latin) to “G” or “L” or “T.” Thus we
see Г-414 or G-414 or L-414 or T-414, all for the same part.
2.
Cannot use Alternator with discharged battery or without battery.
Regulators are paired with specific generators/alternators.
Г-11
Generator
Ural (Урал) - Dnepr (Днепр)
Generator/Alternator Time-Line (01/10)
[email protected]
Г-11A
Generator
1951
Г-11A
(M-72)
Г-414 Generator
1957
Г-414
Г-414
(later K-750)
(M-63,
Г-11A
Г-414 K-750M,
(early K-750)
(M-62) MW-750)
1955
Г-424 Alternator
1998.5
Г-424
(M-67, MT-10, MT12, MW-750)
Г-11A
Г-11A
(KMZ M-72) (M-72N)
1950
Nippon14.3771
Denso
Alternator Alternator
1974
1960
Г-424
(M-T-10.36)
Г-424
(MW-650)
Г-424
(M-67.36)
Г-414
(M-66,
MT-9)
Г-414
(MT-8)
1965
1970
2004
1975
(M-72 thru M-66, MT-9) 6-Volts
Г-424
(MT-16)
1980
Г-424
(IMZ 8.103,
8.107,
“650”)
Г-424
(MT-11)
1985
1990
1995
14.3771
Nippon-Denso
(IMZ 8.103,
(IMZ 8.103,
8.107,
8.123,
“650 & 750”)
“750”)
2000
time
2005
12-Volts (M-67, MT-10 and beyond)
DC Generator
Alternator (AC Generator with Built-In Rectifier)
1974
Alternators have progressed in output voltage and power,
from the Г-11 (G-11) generator of 6-Volts/45-Watts in 1941,
Г-11A in 1952, Г-414 of 6V/65W in 1957, Г-424 of 12V/150W
in 1974, 14.3771 of 12V/500W in 1998.5, to the present-day
Nippon-Denso alternator of 12-V/770W.
Recent Ural Starter/Generator/Alternator Time-line (01/10)
Roughly
Wattage = 14 Volts X Amps
18 Amp
Hitachi
Starter/
Generator
(300 W)
Kick-Start Only
14 Amp
Russian
Г-424 Alternator
(150 W)
Gen/
Alt
Engine
Size
Start
Relays
55 Amp
35 Amp
Russian Alternator: 14.3771 Nippon Denso Alternator
(770 W, metal rear cap)
(Hand Grenade)
(500 W, black-plastic rear cap)
(Increased length
by 20 mm)
Voltage Regulator
internal to Alternator
New Transmission Case
(Flywheel Starter Added,
New Wiring Harness)
Electric-Start
(E-Start) Option & Retrofit introduced by CSMI
New Engine Design
(Alternator on top / Flywheel Starter
placed on bottom)
(IMZ-8.1037-18016-12)
650 cc
Factory Electric-Start
(E-Start) Offered
(Starter/Alternator at
Timing Gear)
Two Relays
750 cc Engine
New Wiring Harness
(9238000)
One Relay
One Relay
(RY-115)
Ignition
Type
Voltage
Regulator
No points-ignition Urals
Approved for U.S. sale
Type I
Type II
Type III Ignition
‘96
‘97
Ural imported to U.S. by CSMI (Classic
Motorcycles and Sidecars, Inc.)
‘98
Ducati
(Type IV with
electronics moved
into airstream)
Regulator Internal to Alternator
33.3720200 Solid-State
1994 ‘95
Type IV
Type V
‘99 2000 ‘01 ‘02
1998.5
Year
‘03
‘04
‘05
‘06 ‘07
Nippon-Denso 12-Volt Alternator (01/10)
• 14-Volt / 55-Ampere / 770-Watt Alternator (actually rated at 43-Amp)
• Used on;
– Ural: 8.103, 8.103X, 8.123, 8.123X, “750” Series
– Dnepr: Not Used (retro-fittable to Г-424 applications)
• Built-In Voltage Regulator
• P/N for Alternator-Only (minus cushion adaptor): 100211-1680
• Current Rating for 100211-1680 Alternator:
100211-1680 Alternator “+”
Cush Adapter and Pinion Gear
Engine (Crankshaft) Alternator (Rotor)
Output
Speed
Speed
Current
340-to-450 rpm
450-to-600 rpm
“Fault” Light Extinguishes
30-Amp
2,025 rpm
2,700 rpm
34-Amp
2,250 rpm
3,000 rpm
3,000 rpm
4,000 rpm
40-Amp
3,750 rpm
5,000 rpm
43-Amp
5,250 rpm
7,000 rpm
46-Amp
Not Much Increase above
>7,000 rpm
50-Amp
Motorcycle Speed
(mph / kmph)
Idle
22 mph / 35 kmph
24 mph / 38 kmph
32 mph / 51 kmph
40 mph / 64 kmph
56 mph / 90 kmph
>56 mph / 90 kmph
Nippon-Denso’s 100211-1680 alternator is nominally
rated at 43-amps @ 5,000-rpm, corresponding
to a motorcycle speed of 40-mph (64 km/hr).
Nippon-Denso Installation Wiring Diagram
L: Lamp- connect via the
warning lamp to +12v
“Fault” Light is Optional on N-D Alternator
(note: light was mandatory for initial rotor
current in previous 14.3771 35-Amp
alternator (Russian hand grenade))
B+ Battery: Main current
connection - connect to
IG: Ignition- connect to
the battery positive via
ignition switched +12V,
heavy duty wire.
provides about 0.25-Amp to
drive the regulator.
Rear 2-pin Connector
Access Hole for
Terminal “F”
of Rotor
B+
Grounding the “F” terminal gives “full-field” for testing.
Connections to the ND Voltage Regulator
Heat Sink
Regulator Case
Ground
Solid-state voltage regulator has only
two external connections;
L (output to the indicator lamp)
and IG (input from the ignition switch).
“L” Terminal provides
ground to light the
L “Fault” warning
indicator.
IG
(Terminal P (Terminal F
of Stator)
of Rotor)
The voltage regulator is the brain of the charging system,
monitoring both battery and stator voltages. Depending
on the measured voltages, the regulator will adjust the
amount of rotor field current to control alternator output.
... .
.
.
.
.
.
.
...
.
.
..
Inside the Nippon-Denso Voltage Regulator
Alternator
Rectifier
Diodes
3-Ø
Stator
Coil
Rotating
Magnetic
Field
Rotor
Coil
F
.
E
P
E
.
B+
Protection
Diodes
. .
B+
IG
IG
Ignition
Switch
Regulator
Red
“Fault”
Light
Sense
Monolithic
Integrated
Circuit
(MIC)
.
L
Fuse
in Fuse Block
Battery
L
. .
Grounding the “F”
Terminal gives “full-field”
for Testing
The regulator controls the amount of battery current
going to the field winding in the rotor.
Ural 750 Starter / Alternator Circuit (2004-2005) ver. 2.0 (01/10)
(IMZ(IMZ-8.1037170018.103717001-13, 2004 & 2005 Owners Manuals) [email protected]
Notes:
1. Two Start Relays (RY-115)
2. In-Line Fuse #1 deleted mid-2005
Right Handlebar
87
RY-115
Electric Start
Relay #1
(Normally Open)
grn / red
Momentary
“Start”
Button
86
“Start”
85
yel / red
30
red
Rocker-Arm
“Run / Kill”
Switch “Kill”
+
.
“Run”
pnk/ blk
Starter Motor
Ignition
Module
85
.
(face-side)
.
top
1
2
1
Run Lites
2
bottom
Ignition Key
3
Headlites
3
green
red
4
Brakes
85
86
30
87
black
white
blue
red
(back-side)
In-Line Fuse #1
red
Ignition
Switch
5
87
(+12V. in “Run” position)
red
6
30
red
gray
Red
(Alternator
Fault)
86
white
Neutral Switch
(on transmission)
Green
(Neutral)
Starter Solenoid
-
9-pin
Connector
Headlight Cavity
RY-115
Electric Start
Relay #2
(Normally Open)
large
black
+ Main
Output
IG
55 Amp
Nippon Denso
Alternator L
(0V.: Engine not running
+12V.: Engine running and
Alternator working.”)
Pos +
12 Volt
Battery
Neg -
L
(lamp) IG
(ignition)
Notes:
1.
In-Line Fuse #1 (15A) for Turn Signal
and Neutral Indicator Lamp.
2.
Fuse Block #4 Fuse (5A) for Ignition &
Electric Start Relays.
large
grey
Chassis
Ground
Connector Pin
Fuse Block
Male
(+12V. when Ignition Switch on “Run”)
black
Terminal
Female
Ural 750 Starter / Alternator Circuit (2006-2007) ver. 2.0 (01/10)
(Electrex, Inc. Rev. E, 2006 GPTT, 2006 & 2007 Owners Manuals) [email protected]
Notes:
1. Single Start Relay (RY-115)
2. ND Alternator added 2004
3. In-Line Fuse #1 Deleted mid-2005
Right Handlebar
Momentary
“Start”
Button
grn/red
87
“Start”
86
yel/red
RY-115
Electric Start Relay
(Normally Open)
red
“Run”
pnk/blk
Headlight Cavity
D
E
10-pin Connector
F
G
.
+
Ducati
Ignition
Module
85
86
30
87
16 red
18 brn/red
18 brn/red
Neutral Switch
(on transmission)
Starter Motor
18 blu/wht
16 wht
8 red
18 brn/red
+ Main
Output
(+12V. in ”Run” position)
Green
(Neutral)
Fuse Block
18 blk/red
15A
18 pnk/blk
Ignition 14 blu
Switch
1
2
3
12 Volt
Battery
L
Neg -
L
(lamp)
IG
Chassis
Ground
(ignition)
18 blu
Connector Pin
12 red
Note: # in front of wire color is AWG wire size.
Ignition Key
Pos +
IG
8 blk
5A
5A
12 red
18 pnk/blk
15A
14 blu
6
55 Amp
Nippon Denso
Alternator
18 blk/red
Red
(Alternator
Fault)
5
Starter Solenoid
30
Rocker-Arm
“Run / Kill”
Switch “Kill”
18 pnk
85
Male
Terminal
Female
Parts for NIPPON-DENSO Ural / Dnepr 12-V / 40-A Alternator
Regulator
Stator
Connector
for IG/L
Rectifier
Front Cover
Rear Cover
Brush Box
with Brushes
Slip Ring for
Rotor Field
Current
Rotor
Parts for the Nippon-Denso 12-Volt alternator are readily available
from Tiedemann Auto-Elektric (Denmark) at www.auto-elektrik.de
and Metro Auto Industrial, Pomona, CA at www.metroautoinc.com.
Voltage Regulator for the Ural 100211-1680 Alternator
•
•
•
•
•
12-Volt Voltage Regulator
Output Voltage Set Point: 14.5-Volts
Repair Circuit: VR-H2005-26S; TRI254
Terminal Markings” IG (ignition) and L (lamp)
Low/High Speed RPM Charge Point (lamp on/off): 450/ 600
rpm Rotor Speed
• Ambient Operating Temperature (full load): -40°C to +135°C
•
•
•
•
•
(-40°F to +275°F)
Alternator Series: IR / IF (internal Regulator / Internal Fan)
Soft-Start for Field
Load Control: “Y” and Load Response: 7 sec
Principal Use: Fork-lift and Industrial
N-D Alternators Shut Down for:
–
–
–
–
Over-Voltage
Shorted “B” Lead
High Field Current (over-load)
Warning Light Will Illuminate
The questionable 14.3771 alternator was replaced with a
Nippon-Denso (N-D) alternator, adding to Ural’s reliability.
Nomenclature for Nippon-Denso (N-D) Alternator
•
•
•
•
•
•
Ural Announced: Starting January 2004, Motorcycles Equipped with DENSO 100211-1680
(Japan), with Built-In Regulator
Consists of N-D 100211-680 Alternator plus Cush Adapter Unit
Alternator Used In:
– Line of Toyota Forklift Trucks
– Ford, Kubota, New Holland Light Tractors
– Thermo King AG & Industrial
– Daihatsu Charadl Vehicle
– Chevrolet Sprint 1.0L (1988-87)
– Suzuki Samurai 1.3L (1995-86) and Sidekick 1.3L (1989)
Alternator (pulley-version, instead of Ural adapter) Used In:
Voltage Regulator OEM#’s: Nippon-Denso Part# 126000-0600
– Replaces:
• Toyota 27700-78301
• Iseki 281-271-001-0
• Daihatsu 27700-96301, 27700-87207
• Victory A8062902
Voltage Regulator 27700-96301 Used In:
– Alternators:
• Ishikawajima 18504-6220
• Mitsubishi MD604589
• Nippon-Denso 100211-1550, -1670, -1680
– Vehicles:
• Daihatsu
• Mitsubishi
• Subaru
• Suzuki
• Toyota
Parts for the Nippon-Denso 12-Volt alternator
(minus the cushion adapter) are readily available.
Voltage Regulation Process
• Regulator Maintains pre-Determined Charging Voltage Level: 14.5-V
• When Charging Voltage Falls below this Point, Regulator Increases
Field Current, thus Strengthening the Rotating Magnetic Field,
Resulting in Increased Alternator Output
• When Charging Voltage Rises above this Point, Regulator Decreases
Field Current , thus Weakening the Magnetic Field, Resulting in
Decreased Alternator Output
The regulator monitors the battery voltage, controlling
current flow to the rotor assembly. The rotor produces
a magnetic field, which induces voltage into the stator.
The rectifier bridge converts AC stator voltage to DC output
for use by the motorcycle.
(Compression and enhancement of Automotive Series, “Understanding the Alternator,”
developed by Kevin R. Sullivan, Professor of Automotive Technology,
http://www.autoshop101.com/trainmodules/alternator/alt101.html)
A Peek inside the Alternator
•
•
Removing the Rear Case Reveals:
– Rotor Winding Assembly, which Rotates inside Stator Winding
– Rotor Generates a Rotating Magnetic Field
– Stator Winding Develops Voltage
– Current Begins to Flow from Induced Magnetic Field of the Rotor
As the Rotor Assembly Rotates within the Stator Winding:
– Alternating Magnetic Field from the Spinning Rotor Induces an Alternating Voltage
into Stator Winding
– Strength of the Magnetic Field and Speed of the Rotor Affect the Magnitude of
Voltage Induced into Stator
Removal the rear cover of the N-D alternator reveals
the rotating magnetic field coil surrounded by the
stationary three-phase winding.
Rotor Assembly
• Basic Rotor Consists of Iron Core, Coil Winding, Two Slip-Rings, and
Two, Inter-leaved, Claw-Shaped Finger Pole-Pieces
• Rotor Contains Field Winding Wound over Iron Core
• Surrounding the Field Coil are Two Claw-Type Finger-Poles
• Each End of Rotor Field Winding Attached to a Slip-Ring
• Stationary Brushes Connect Alternator to the Rotor
• Magnetic Field Saturates the Iron Finger-Poles
• One Finger-Pole becomes a North Pole and Other a South Pole
• Rotor Spins Creating Alternating Magnetic Field; North, South, North,
South, etc.
The rotor (exciter) field winding creates the rotating
magnetic field that induces voltage into the stator winding.
Stator Windings
Wye style has four stator leads. One of the leads is
called the Neutral Junction, common to all the
other leads.
• Stator Composed of Three Sets of Windings
• Each Winding Placed in Different Position Compared with the Others,
Staggered 120° Apart
• Laminated Iron Frame Concentrates the Magnetic Field
• Stator Lead Sends Output Current to Diode Rectifier Bridge
• Neutral Junction in the Wye (Y) Identified by the 6 Strands of Wire
The induced AC voltage in each lead of the stator winding
is fed to the diode rectifier assembly to convert to DC.
Diode Rectifier Bridge Assembly
• Two Rectifier Diodes Connected to each Stator Lead
• Six Diodes used to rectify the AC stator voltage to DC Output Voltage
• Full-Wave Rectification: Diodes Redirect both Positive and Negative
Polarity AC Voltage to Produce DC Voltage
The Diode Rectifier Bridge is responsible for the rectification
of AC voltage to DC voltage.
Slip-Rings and Carbon Brushes for Exciter Rotor
Two slip rings are located on one end of
the rotor assembly. Each end of the rotor
field winding is attached to a slip ring,
allowing current to flow through the field
winding.
Two stationary carbon brushes ride on the
two rotating slip rings.
Power for the rotor (exciter) coil is supplied, through
the carbon brushes and slip-rings, by the voltage regulator.