GROUP 4

CHARGING SYSTEM
 CONTENTS
4.1 Introduction
4.2 Purpose of Charging system
4.3 Charging System Components
4.4 Brush Type Generators
4.5 Brushless Type Generators
4.6 Charging System Principles of Operation
4.7 Voltage Regulator
4.8 Single-Phase AC Voltage Generation
4.9 Three-Phase AC Voltage Generation
4.10 Voltage Rectification
4.11 Three phase Voltage Regulation
4.12 Charge Indicator System
4.13 Generator Diagnosis
4.14 Servicing the Charging System
4.1 Introduction

• The charging system in an automotive vehicle plays a vital role in

supplying electrical power and charging the battery. It ensures that the
vehicle's electrical systems have a continuous source of energy while also
maintaining a charged battery for reliable starting and operation.
• The Charging system is an important part of the electrical system. It
provides electrical current for the lights, the radio, the heater, the engines
electrical systems, and other electrical accessories. It also maintains the
batteries in a charged state, recharging them as necessary.
• Therefore, the vehicle has a battery for a power supply and a charging
system to generate electricity by the engine running. The charging system
supplies electricity to all the electrical devices and charges the battery.
Cont...
The charging system must meet the following criteria (when the engine is
running).
• Supply the current demands made by all loads.
• Supply whatever charge current the battery demands.
• Operate at idle speed.
• Supply constant voltage under all conditions.
• Have an efficient power-to-weight ratio.
• Be reliable, quiet, and have resistance to contamination.
• Require low maintenance.
• Provide an indication of correct operation.
4.2 Purpose of The Charging System
The charging system serves several critical purposes, all of which are essential for
the proper functioning and reliability of the vehicle. Here are the primary purposes
of the charging system:
Power Generation: The charging system generates electrical power to supply
energy to various electrical components and systems in the vehicle. This includes
powering lights, ignition systems, entertainment systems, HVAC (heating,
ventilation, and air conditioning), power windows, and other accessories.
Battery Charging: One of the main functions of the charging system is to recharge
the vehicle's battery. The battery provides electrical energy to start the engine and
operates electrical systems when the engine is not running. The charging system
replenishes the energy used from the battery during engine starts and ensures that
the battery remains sufficiently charged for reliable starting and operation.
Cont...
System Voltage Regulation: The charging system regulates the voltage output
to ensure that it remains within a specified range. This prevents overcharging,
which can damage the battery and electrical components, as well as
undercharging, which can lead to battery depletion and system malfunctions.
Proper voltage regulation also helps protect sensitive electronic components in
modern vehicles.
Battery Maintenance: By continuously charging the battery during vehicle
operation, the charging system helps maintain the battery's health and prolong
its lifespan. Regular charging prevents the battery from becoming fully
discharged, which can lead to sulfation and other forms of damage.
Additionally, the charging system helps ensure that the battery remains in
optimal condition for reliable starting, especially in cold weather conditions.
Cont...
Load Management: The charging system balances the power
requirements of the vehicle's electrical loads with the capacity of the
alternator to ensure that the battery remains adequately charged. This
involves dynamically adjusting the alternator's output based on the
electrical demands of the vehicle, such as when additional accessories
are turned on or off.
Proper operation and maintenance of the charging system are essential
for the reliable performance and safety of the vehicle.
4.3 Charging System Components
Cont...
Battery: The battery serves as an energy storage device in the charging system. It stores
electrical energy produced by the alternator and supplies power to the vehicle's electrical
systems when the engine is not running.
Ignition Switch - it is a mechanical device used to connect or disconnect the current flow
in all circuits of the vehicle.
Fuse/Fusible Link - it is a safety device, which breaks when short circuit occurs.
Charge Indicator - The charging indicator, often displayed as a battery symbol on the
dashboard, provides information about the status of the charging system. It alerts the
driver if there is a problem with the charging system, such as low voltage or a
malfunctioning alternator, it has of two (2) kinds, to wit:
• Ammeter - it is a device use to measure the amount of current flowing in a circuit.
• Charge Indicator Light - it is a device use to indicate whether the system is charging or
not.
Cont...
Voltage Regulator- is a device use to prevent the alternator from producing
excessive voltage. This will be attained by means of controlling the amount of
current flowing in the field winding of the rotor.
Alternator- it is an auto electrical component, which converts the mechanical
energy from the engine into electrical energy. It also keeps the battery in charge
condition and likewise handles electrical loads while the engine is running.
Diode Rectifier: The diode rectifier converts the alternating current (AC)
produced by the alternator into direct current (DC). It allows the flow of current
in one direction, ensuring that the electrical output from the alternator is in the
form of DC, which is required for charging the battery and powering the
vehicle's electrical systems.
Wiring and Connectors: Various wiring harnesses and connectors are used to
transmit electrical power between the components of the charging system,
including the alternator, battery, voltage regulator, and electrical loads in the
vehicle.
Figure. An AC generator www.bosch-
presse.de
Generator types
4.4 Brush Type
4.5 Brushless Type
4.4 bursh type generators
• Brush type generators, also
known as brushed generators, are
electromechanical devices used
for the conversion of mechanical
energy into electrical energy.
They operate on the principle of
electromagnetic induction, where
a conductor moving within a
magnetic field induces a voltage
across its ends. These generators
consist of several key
components, including a stator,
rotor, brushes, and a commutator.
components
• Brush Type generators consist of the following main
components:
Generator Housing
Stator Assembly
 Rotor Assembly
Generator Housing
• The generator housing serves as the protective enclosure for the
internal components of the brush type generator. It provides
several important functions:
1. Protection
2. Insulation
3. Cooling
4. Mounting
5. Accessibility
Stator Assembly
• The stator assembly is a critical component of brush type generators,
serving as the stationary part of the generator where electromagnetic
induction takes place. It plays a fundamental role in generating the
magnetic field necessary for the generation of electricity.It contains
three main sets of windings wrapped in slots around a laminated,
circular iron frame. Each of the three windings has the same number
of coils as the rotor has pairs of north and south poles. The coils of
each winding are evenly spaced around the core.
Two common methods of connecting the
windings are:
 Y Connection.
 Delta Connection.
The parallel path of the Delta
connection makes more current
available.
rotor assembly
• the rotor assembly refers to the
rotating component of the
generator that plays a crucial role
in the generation of electricity.
• The rotor assembly typically
consists of a shaft attached to a
rotor core. The core may contain
coils of wire (armature windings)
or permanent magnets,
depending on the specific design
of the generator.
• Two brushes are held by springs
against the slip rings. One brush
is connected through a switch to
the battery B+, the other to the
voltage regulator. The brushes
conduct only the field current
(2 to 5 amps)
4.5 Brushless Type Generators
• Brushless type generators, also known as brushless alternators or brushless
synchronous generators, are a type of electrical generator that operates
without brushes and commutators, which are commonly found in
traditional brushed generators. Instead, brushless generators use solid-
state electronic components to control the excitation of the generator's
rotor windings.
• Brushless Type generators are liquid cooled (coolant) and consist of the
following main components:
 Generator Housing
 Stator Assembly
 Rotor Assembly
Generator Housing
• Generator Housing Water
Cooled.
• The Water-Cooled Generator is
housed in an encapsulated metal
shell enclosure. The enclosure is
installed an aluminum shell.
• Liquid cooling minimizes noise
generation through elimination
of generator cooling fan.
Stator Assembly
• Although different in appearance the Stator
Assembly in a brushless generator performs
the same functions as the brush type.
rotor assembly

• The brushless generator Rotor does not

contain the field coil.
• The pole-finger crowns rotate around a fixed
field coil and are magnetized by the flux field
of the field coil.
• The two crowns form claw-pole half sections
and are retained by a non-magnetic ring
positioned below the pole fingers.
Rectifier Assembly
• The Rectifier Assembly consists of six diodes, a pair of diodes for each
stator winding. Each pair contain one positive biased diode and one
negative biased diode. By using a pair of diodes that are reversed
biased to each other, rectification of both sides of the AC sine wave is
achieved.
• The negative biased diodes allow for conducting current from the
negative side of the AC sine wave and putting this current into the
circuit as positive current. The use of positive and negative biased
diodes provides for full wave rectification because both halves of the
sine wave are used.
Drive Belt
• It is the function of the Drive Belt to transfer rotating energy from the
engine to the generator. The drive belt rotates the rotor, spinning the
magnetic field.
• A loose belt can inhibit charging system efficiency and a belt that too
tight causes early bearing failure
4.6 Charging System Operation
The principles of electromagnetic induction employed in generators for producing DC
current.
Factors that are affecting the alternator output are
I. The speed of the rotor
II. Strength of the magnetic field, i.e.,
Number of turns of wire in the rotor winding, Amount of electricity applied to the rotor
coil, The air gap between the rotor poles and the
stator
III. The number of turns of wire in the stator coils
DC Generator
• The DC shunt generator is a type of direct current generator that operates based on the principle
of electromagnetic induction. It converts mechanical energy into electrical energy. Its working
principle:
• A DC (direct current) generator, also known as a DC dynamo or DC machine, converts mechanical
energy into electrical energy. It operates based on the principles of electromagnetic induction.
Here's working principle of a DC generator:
• Magnetic Field: The DC generator has a stationary part called the stator, which consists of a set
of permanent magnets or electromagnets arranged in a circular configuration. These magnets
establish a steady magnetic field within the generator.
• Armature: The DC generator also has a rotating part called the armature. The armature is a
cylindrical assembly made up of a laminated iron core with multiple evenly spaced conductive
coils or windings wrapped around it. These windings are connected to form a closed loop.
Cont...
• Rotation and Electromagnetic Induction: When the armature rotates within the magnetic field of the stator, the relative
motion between the magnetic field and the armature windings induces a voltage across the windings. This phenomenon
is known as electromagnetic induction. According to Faraday's law, the magnitude of the induced voltage is proportional
to the rate of change of the magnetic flux.
• Commutator and Brushes: The armature windings are connected to a split-ring structure called the commutator. The
commutator consists of multiple segments, with each winding connected to a separate segment. Carbon brushes are in
contact with the commutator and provide electrical connections to the external circuit.
• Generation of Direct Current: As the armature rotates, the commutator segments make contact with the brushes, which
enables the connection of the armature windings to an external load. As different segments of the commutator come
into contact with the brushes, the direction of the current flowing through the external circuit changes. This process
converts the induced alternating current (AC) into direct current (DC) by periodically reversing the current flow direction.
• Voltage Regulation: The voltage generated by the DC generator can be regulated by adjusting the strength of the
magnetic field in the stator (using permanent magnets or field windings) or by controlling the speed of the armature
rotation.
• Load Connection: The generated DC voltage can be utilized to power electrical devices and systems by connecting them
to the external circuit. The current and voltage characteristics of the generator depend on factors such as the rotational
speed, magnetic field strength, and load connected to the generator.
Figure. DC generator
 Operation of Alternator
Alternators produce electricity by means of the induction principles.
Hence, the essential parts of the alternator are:
a) A magnetic field, and
b) Conductors, which can move so as to cut the flux
In the alternator the magnet (rotor) revolves but the conductors (stator)
remain stationary.
• When a conductor moves in the magnetic field, Electromotive force is
created in the conductor.
• When the direction of the conductor movement changes, the direction of
the current that is generated by the electromotive force also changes.
Cont....
• Automotive AC generators, commonly referred to as alternators, are specifically designed for use
in vehicles to provide electrical power and charge the battery. Here's an overview of the
construction of an automotive AC generator:
• Stator: The stator is the stationary part of the alternator and consists of a stack of laminated iron
cores. The stator windings are wound around the iron cores and are usually in a three-phase
configuration. The stator windings produce a rotating magnetic field when energized.
• Rotor: The rotor is the rotating part of the alternator and is typically mounted on a shaft. It
consists of a field winding, which is excited with DC current. The rotor magnetic field interacts
with the stator's rotating magnetic field, inducing voltage in the stator windings.
• Housing: The alternator is housed in a durable and compact casing made of aluminum or other
suitable materials. The housing provides mechanical protection and serves as a heat sink to
dissipate generated heat.
• Pulley and Belt: The alternator is connected to the engine's crankshaft through a pulley and belt
system. The rotational motion of the engine drives the alternator via the belt, allowing it to
generate electricity.
Figure 8-13. AC generator Figure . The magnetic field of the rotor is
(alternator) and drive pulley. created
by current through the rotor winding.

Figure. Exploded view of the parts of the complete

rotor assembly. Figure. Rotor
Cont....
• Rectifier Assembly: Alternators produce AC voltage, but vehicles require DC voltage for their electrical
systems. The rectifier assembly, located inside the alternator, converts the AC voltage produced by the stator
windings into DC voltage. It consists of diodes arranged in a bridge rectifier configuration.
• Voltage Regulator: The voltage regulator is responsible for controlling the output voltage of the alternator to
ensure proper charging of the battery and supply of electrical power to the vehicle's systems. It monitors the
battery voltage and adjusts the field current in the rotor winding to maintain a stable output voltage.
• Cooling System: Automotive alternators generate heat during operation, so they are equipped with a cooling
system to prevent overheating. This can include a combination of internal and external cooling features, such
as cooling fans, ventilation slots, and heat sinks.
• Brushes and Slip Rings: In older designs of automotive alternators, brushes and slip rings were used to
transfer the DC current to the rotor field winding. However, modern alternators often employ a brushless
design, utilizing solid-state electronics and a rotating rectifier assembly that eliminates the need for brushes
and slip rings.
Cont....
The working principle of alternator :
• Rotation and Magnetic Field Generation: The alternator is driven by the engine through a pulley and belt
system. As the engine rotates, it spins the alternator's rotor, which is connected to the engine's crankshaft.
The rotor is equipped with a field winding that is excited with direct current (DC). When DC flows through
the field winding, it creates a magnetic field around the rotor.
• Induction of Alternating Current: The rotor's rotating magnetic field induces an alternating current (AC)
voltage in the stator windings of the alternator. The stator consists of a stack of laminated iron cores with
three sets of stator windings, typically arranged in a three-phase configuration. When the rotor's magnetic
field cuts across the stator windings, it induces a voltage in each phase of the stator windings. As the rotor
spins, the magnetic field passing through the stator windings changes, resulting in an AC voltage output.
• Rectification: Since most automotive electrical systems require direct current (DC), the AC voltage produced
by the alternator needs to be converted to DC. To achieve this, the alternator is equipped with a rectifier
assembly, typically consisting of diodes arranged in a bridge rectifier configuration. The rectifier assembly
allows the current to flow in one direction, effectively converting the AC voltage to DC voltage.
• Voltage Regulation: The voltage regulator is a vital component of the automotive alternator. It monitors the
electrical system's voltage and controls the amount of current flowing through the rotor's field winding. If
the system voltage drops below a certain threshold, the voltage regulator increases the field current to boost
the alternator's output. Conversely, if the system voltage exceeds a certain level, the regulator reduces the
field current to prevent overcharging.
Cont....
Load Balancing: The alternator's output is designed to balance the electrical load between the
alternator and the battery. During low-demand situations or idle, the alternator provides most of
the power, and any excess energy charges the battery. In high-demand situations, such as when the
headlights, air conditioning, and other electrical components are in use, the battery supplements
the alternator's output to meet the increased load.
Battery Charging: The primary function of the automotive alternator is to supply electrical power to
the vehicle's electrical systems while simultaneously charging the battery. The DC voltage produced
by the alternator is routed to the battery through a charging cable. The battery acts as an electrical
storage device, absorbing the excess electrical energy and storing it as chemical energy.
Overall, the working principle of an automotive alternator involves the generation of an alternating
current through the interaction of the rotating magnetic field of the rotor and the stator windings.
This AC voltage is then rectified to DC voltage, and the voltage regulator ensures proper charging of
the battery and supply of electrical power to the vehicle's systems.
4.7 Voltage Regulation
• The output from an AC generator can reach as high as 250 volts if it is not controlled. The battery and
the electrical system must be protected from this excessive voltage. Therefore, charging systems use a
voltage regulator to control the generator’s output.
• Voltage output is controlled by the voltage regulator as it varies the strength of the magnetic field in the
rotor. Current output does not need to be controlled because an AC generator naturally limits the
current output. To ensure that the battery stays fully charged, most regulators are set for a system
voltage between 14.5 and 15.5 volts.
• Voltage output is controlled by varying the field current through the rotor. The higher the field current,
the higher the voltage output. By controlling the amount of resistance in series with the field coil,
control of the field current and voltage output is obtained.
• An input signal, called the sensing voltage, allows the regulator to monitor system voltage. If the sensing
voltage is below the regulator setting, an increase in field current is allowed, which causes an increase in
voltage output. Higher sensing voltage will result in a decrease in field current and voltage output. The
regulator will reduce the charging voltage until it is at a level to run the ignition system while putting a
low charge on the battery. If a heavy load is turned on, such as the headlights, the additional draw will
sense the low voltage and will increase current to the rotor.
Cont...
• When the load is turned off, the regulator senses
the rise in system voltage and reduces the field
current.
• Another input that affects voltage regulation is
temperature. Because ambient temperature
influences the rate of charge that a battery can
accept, regulators are temperature compensated.
Temperature compensation is required because
the battery is more reluctant to accept a charge at
lower ambient temperatures.
• The regulator will increase the voltage output to
force a charge on the battery.cause a decrease in
battery voltage.
Figure. Field current is decreased as rotor speed
increases, to keep AC generator (alternator) output
voltage at a constant level
Cont...
• The working principle of a voltage regulator is to maintain a stable output voltage despite variations in input
voltage and load conditions. It ensures that the output voltage remains within a specified range, providing a
consistent and reliable power supply. Here's a general explanation of the working principle of a voltage
regulator:

• Sensing: The voltage regulator constantly monitors the output voltage and compares it to a reference
voltage. The reference voltage is a fixed value that represents the desired output voltage. The sensing
circuitry measures the output voltage and provides feedback to the voltage regulator.

• Error Amplification: The voltage regulator uses an error amplifier to compare the sensed output voltage with
the reference voltage. The error amplifier amplifies the voltage difference between the sensed voltage and
the reference voltage, producing an error signal.

• Control: The error signal from the error amplifier is used to control the voltage regulator's operation. The
voltage regulator adjusts its internal components, such as transistors or electronic switches, to regulate the
output voltage.
Cont...
• Feedback Loop: The error signal is fed back to the voltage regulator's control circuitry. Based on the
magnitude and polarity of the error signal, the control circuitry adjusts the voltage regulator's output.

• Compensation: To ensure stable and accurate voltage regulation, the voltage regulator may incorporate
compensation techniques. These techniques account for factors such as temperature variations, load
changes, and input voltage fluctuations that can affect the output voltage. Compensation methods may
include feedback loop adjustments, filtering, or other circuitry design considerations.

• Output Adjustment: Depending on the type of voltage regulator, it may provide means for adjusting the
output voltage. For example, some voltage regulators have a voltage adjustment pin that allows the output
voltage to be fine-tuned within a certain range.

• Protection: Voltage regulators often include protection features to safeguard the system. These features can
include overvoltage protection, overcurrent protection, thermal shutdown, and short-circuit protection. They
help prevent damage to the voltage regulator and the connected devices in case of abnormal operating
conditions.
Cont...
• -There are several types of voltage regulators used in automotive applications. Here are some common types:

• Mechanical Voltage Regulator: This type of voltage regulator was commonly used in older vehicles. It consists of
mechanical components, such as contact points and a bi-metallic strip. As the electrical load and system voltage
change, the mechanical voltage regulator adjusts the contacts to control the alternator's field current and maintain
a relatively constant output voltage.
• Electro-Mechanical Voltage Regulator: This type of voltage regulator combines mechanical and electronic
components. It typically includes a set of contact points controlled by an electromagnet. The electromagnet
adjusts the contacts based on the output voltage, providing a more precise regulation compared to mechanical
regulators.
• Electronic Voltage Regulator: Some vehicles employ a separate electronic voltage regulator that is not
integrated into the alternator. This type of regulator uses solid-state electronic components, such as
integrated circuits, to monitor the system voltage and adjust the field current of the alternator accordingly.
 Cont...
• - Solid-state voltage regulators, also known as electronic voltage regulators, are a type of voltage regulator that
utilize solid-state electronic components, such as transistors, diodes, and integrated circuits, to regulate the output
voltage. These regulators offer several advantages over traditional electro-mechanical regulators, including
improved accuracy, faster response time, greater efficiency, and enhanced reliability.
• Here are some key features and characteristics of solid-state voltage regulators:
• Regulation Accuracy: Solid-state regulators can provide precise and stable voltage regulation, maintaining the
output voltage within a tight tolerance range.
• Fast Response: Solid-state regulators have a rapid response time, allowing them to quickly adjust the output
voltage to changes in load conditions.
• Efficiency: Solid-state regulators are generally more efficient than electro-mechanical regulators, as they minimize
power losses through improved control and reduced heat dissipation.
• Overvoltage Protection: Many solid-state regulators incorporate overvoltage protection mechanisms to safeguard
connected devices from excessive voltage levels.
Cont...
• Thermal Protection: Solid-state regulators often include built-in thermal protection features that monitor the
regulator's temperature and prevent damage due to overheating.
• Compact Size: Solid-state regulators are typically smaller and lighter than their electro-mechanical counterparts,
which makes them suitable for space-constrained applications.
• Compatibility with Modern Electronics: Solid-state regulators are well-suited for powering sensitive electronic
components, such as microprocessors, sensors, and communication systems, as they can provide clean and stable
power without introducing electrical noise or interference.
• Pulse Width Modulation (PWM) Voltage Regulator: PWM voltage regulators are commonly used in vehicles with
advanced electrical systems. They control the alternator's output voltage by rapidly switching the field current on
and off. The duty cycle of the switching determines the average current flow and, hence, the output voltage.
• Specific type of voltage regulator used in a vehicle depends on the vehicle's make, model, and electrical system
design. Different manufacturers may use different voltage regulator technologies. Additionally, with the increasing
electrification of vehicles, advanced voltage regulation techniques, such as smart charging systems, are being
employed to optimize charging efficiency and manage power distribution.
4.8 Single-Phase AC Voltage Generation
• Single Phase AC Voltage Generation requires one stator frame with
windings and one magnetic field (North and South pole pieces).

• As the North pole of the rotor pole piece approaches the winding of
the stator, induced voltage level in the stator begins to rise.
• The closer the North pole gets to the stator winding the higher the
induced voltage.
• As the North pole reaches 90 degree to the stator winding the
maximum amount of the flux lines are acting on the winding, induced
voltage is at its highest positive value (1/4 turn).
.
• The rotor continues to rotate and the North pole gets further away
from the winding.
• The voltage drops, until 0 voltage is induced through the stator (1/2
turn).
Continued..
• With the South pole now approaching the
winding voltage begins to increase negatively.
• When the South pole reaches 90 degree to the
winding, again the maximum amount of flux lines
is acting on the winding and induced voltage is at
its greatest negative value (3/4 turn).
• The South pole continues to travel farther away
from the winding decreasing the negative voltage
value until 0 voltage is again reached (1 full turn).
• Single phase voltage: It is the sine wave produced
by a single winding of the stator during a single
revolution of one pair of pole pieces.
4.9 Three-Phase AC Voltage Generation
• Most AC generators use either a twelve or a fourten-pole rotor.
• Each pair of poles (North and South) produce one complete
sine wave in each winding per revolution.
Continued...
• Voltage of each stator winding is added together to create three-
phase voltage.
• During one revolution a fourteen-pole rotor will produce seven sine
waves.(The stator has one winding (coil) for each pair of rotors.)
• The rotor generates three overlapping sine wave voltages cycles in the
stator (one rotor three sets of windings in the stator).
• The total output would be twenty-one sine wave cycles per
revolution. (3 sets of stator windings, each with 7 coils)
Figure Sine wave cycle of a fourteen-pole rotor and
three-phase stators
4.10 Voltage rectification
 Voltage rectification is the process of converting alternating current
(AC) to direct current (DC). This is accomplished by using a diode or a
combination of diodes to only allow current to flow in one direction.
There are two main types of voltage rectification:
1. Half-wave rectification: In this type of rectification, only one half of the
AC wave is allowed to pass through the diode, resulting in a pulsating
DC output. This method is simple and cost-effective but produces a
lower and less smooth output compared to full-wave rectification.
2. Full-wave rectification: In full-wave rectification, both halves of the AC
wave are used to produce a smoother and more constant DC output.
This can be achieved using a bridge rectifier circuit, which consists of
four diodes arranged in a specific configuration to allow current to flow
in only one direction.
Half-wave rectification
Full-wave rectification
The steps Involved in voltage rectification using a diode are as
follows:
1. The diode allows current to flow in only one direction, cutting off
the negative half of the AC wave in half-wave rectification or
converting both halves in full-wave rectification.
2. The output is then smoothed using a capacitor or other filtering
components to remove any remaining AC components.
4.11 Three phase Voltage regulator
• A voltage regulator is an electronic device or circuit that is designed to
maintain a constant voltage level, despite changes in input voltage or
current.
• A three-phase voltage regulator is a type of electrical device used to
maintain a balanced and stable voltage output in a three-phase power
system. It works by adjusting the voltage levels of the incoming power
supply to ensure that all three phases have the same voltage magnitude
and stay within acceptable limits. This helps prevent damage to
electrical equipment and ensures the reliable operation of the system.
Three-phase voltage regulators are commonly used in industrial and
commercial applications where a stable power supply is critical.
The process of a voltage regulator typically involves the following steps:
1. Input voltage monitoring: The voltage regulator constantly monitors
the input voltage from the power source, such as a battery or power
supply.
2. Voltage comparison: The regulator compares the input voltage to a
reference voltage. If the input voltage is higher or lower than the
reference voltage, the regulator will adjust the output voltage
accordingly.
3. . Regulation: The regulator uses a feedback loop to adjust the output
voltage by either increasing or decreasing it, in order to maintain a
constant voltage level.
4. Output voltage stabilization: The regulator outputs a stable and
regulated voltage, which can be used to power electronic devices or
circuits.
4.12 charge indicator system
• In a motor vehicle, a charge indicator system typically refers to the warning light on
the dashboard that alerts the driver to potential issues with the vehicle's charging
system. This warning light is often shaped like a battery and may illuminate in
different colors (usually red or yellow) to indicate different levels of urgency or
severity.
• Informs the driver of the operating condition or output of the charging system
• When the charge indicator light comes on while driving, it could indicate a problem
with the vehicle's alternator, battery, or electrical system. This warning light serves
as a signal for the driver to address the issue promptly to prevent potential
breakdowns or damage to the vehicle. It is essential for drivers to pay attention to
the charge indicator system in their motor vehicles and seek professional
assistance if the warning light comes on to diagnose and resolve any underlying
charging system problems.
Types:
· warning light
· voltmeter indicator
· ammeter indicator

1 .warning light
The warning light glows when the alternator output drops to a
specified level
 2 .voltmeter indicator
o A battery has 12.6 volts when fully charged
o Alternator output must be higher:
 13–15 volts
o A voltmeter shows the voltage
3 .Ammeter Indicator
o Shows the current output in amperes
o Reads to the right if the battery is being charged
o Reads to the left if the battery is discharging

The indicator is on during the following conditions:

 Key on, engine off
 Generator not charging
 Failure of drive belt
 Interruption of field coil
 Controller overvoltage
 Break in charging
4.13 Generator Diagnosis

•Before beginning diagnostic procedures on the charging system do the following:

•• Run engine at idle speed for about 5 minutes.
•• Switch off all electrical loads.
•
•This is done to ensure the battery is charged to such a level that the generator will not be fully utilized and that
loads required during starting (e.g. starter, secondary air pump) will be already switched off.
•The generator may be tested using:
 DISplus
• VAT testing equipment (voltage absence tester)
•Testing Generator with DISplus
•Two modes of testing are available when using DISplus.
 Testing using Test Plan
 Testing using Preset Measurement
Testing Generator Using Test Plan
Test plans available:
 Generator (Checks voltage and current output)
 Wiring from generator to battery (Performs voltage drop test)
 Charge indicator lamp (Condition of bulb, wiring and signal to bulb)
 ON delay and Start ON delay (If applicable)
 Ground side circuit wiring (Voltage drop test)
4.14 Servicing charging system
Precautions in Charging System Service

The following safety precautions should be observed in charging system servicing, to wit:

• Remove the battery terminal before working on any part of the charging system.

• The battery must be installed with the correct polarity; an incorrectly connected battery can

damage the diodes even before the engine is started.

• If the battery is to be charged with a battery charger while it is installed in the vehicle, the

terminals should be disconnected

• A battery charger connected with incorrect polarity, or producing a high voltage, it can damage the diodes and other semiconductor
components.

• The alternator should not be run on open circuit at any time. Circuit connections should not be

• broken when the alternator is operating.

Charging System Checks

If the charging system seems to have a problem, the following should be checked:

• • The drive belt should be in good condition and at the correct tension to prevent slip at high

• speeds.

• • The alternator indicator lamp (on some alternators) must be functioning to give initial

• excitation of the field. It should also be of the correct wattage.

• • The battery should be in sound condition. Check the state of charge, cleanliness of the

• terminals.

• • All circuit connections should check but care should be taken that the circuit is not accidentally
earthed, or damage to the alternator or regulator will result.
Common Problems

• There are common problems of the charging system, to wit:

• • If a warning light remains on after the engine is started, then the alternator is not charging;

• • A battery that remains flat could be due to the condition of the battery, or the alternator output

• could be too low; and

• • A battery that needs frequent topping-up indicates excessive alternator output.

• *Check the alternator and battery by quick check by connecting a voltmeter between the output
terminal and earth, or across the battery terminals and the fully charged battery should read
around 12.6V and the working alternator should produce a voltage reading between 13.8 to 14.2
v