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Very strange over charging

contractor20

contractor20

Cruisin' Guzzisti
Joined
Oct 28, 2008
Messages
304
Location
Bairnsdale Victoria. OZ (west of NZ)
I'm still struggling to get over not being able to take my T3 to the recent Victorian Spaghetti Ralley(OZ). :( :( :(
THE CAUSE!! .....Over voltage charging.
Just cobbled the bike together with a new Clff Jeffries ign' module after burning out the dyna on one channel and nearly holing a piston. Bike fired up nicely but the recently installed volt gauge showed >16volts at moderate revs ( 2000-2500)after the charge light went out at about >1300rpm.
The Altenator is right on spec with 0.5 ohms on each of the phases and 3.4 ohms on the rotor. The contact rings are in spec and I'm using an Ingrams 9692 diode board (with an added 3 diode bank to pick up the harmonic phase) and a Bosch RE57 regulator as outlined by Pete Roper and hosted on Greg Benders web site.
The battery is a 32 amp gel cell
I have checked all the usual earth connections (new loom) and have a 20 amp frame earth and a starter cable sized earth to the engine. This setup has been operating for 15000km
Figured it must be the regulator and fitted up a new one .........exactly the same result!!!!!
Could I be that unluckyto buy a dud reg? At first i didn't believe the gauge so checked with digital m/meter
HELP!! :?
 
contractor20 said:
I'm still struggling to get over not being able to take my T3 to the recent Victorian Spaghetti Ralley(OZ). :( :( :(
THE CAUSE!! .....Over voltage charging.
Just cobbled the bike together with a new Clff Jeffries ign' module after burning out the dyna on one channel and nearly holing a piston. Bike fired up nicely but the recently installed volt gauge showed >16volts at moderate revs ( 2000-2500)after the charge light went out at about >1300rpm.
The Altenator is right on spec with 0.5 ohms on each of the phases and 3.4 ohms on the rotor. The contact rings are in spec and I'm using an Ingrams 9692 diode board (with an added 3 diode bank to pick up the harmonic phase) and a Bosch RE57 regulator as outlined by Pete Roper and hosted on Greg Benders web site.
The battery is a 32 amp gel cell
I have checked all the usual earth connections (new loom) and have a 20 amp frame earth and a starter cable sized earth to the engine. This setup has been operating for 15000km
Figured it must be the regulator and fitted up a new one .........exactly the same result!!!!!
Could I be that unluckyto buy a dud reg? At first i didn't believe the gauge so checked with digital m/meter
HELP!! :?
Click to expand...

Like you mentioned the regulator is suppose to "Regulate" the DC voltage and supply a constant current.

At different rpms the alternator generates different voltages .... more you rev more the voltage increases in AC volts!
With the extra diode to filter the harmonics you also have a tendency to render the AC voltage, coming out from the alternator, at a higher DC voltage. (RMS value)
The regulator has 3 wires , input, ground, output.
Are the input spec of the regulator compatible?
You may be putting in too much DC voltage in the regulator?
Just a thought
 
There is only one thing that can happen here: the regulator is energizing the stator all the time and does not turn off. Assuming that the regulator has not failed in the on position, there must be a voltage drop at the regulator. So either the ground is not 100% or there is a voltage drop in the input lead. Get your voltmeter out and measure the volts directly at the regulator. With the engine off it should be identical to battery voltage.
 
:oops: :oops: :oops:
regulator plug had been wired in reverse!!! Dont know when this occured. Tis a mystery beyond belief as I'm the only pair of hands wot works on the old girl.
Thanks everyone for your offerings. mumble mumble :whistle: :whistle:
 
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