Automotive Electrical and Electronic Systems Classroom Manual Fifth Edition Update by John F. Kershaw
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Automotive Electrical and Electronic Systems Classroom Manual Fifth Edition Update by John F. Kershaw

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Charging System Operation 175terminal or side-terminal AC generator. Thesecharging systems are called external voltage regulator(EVR) systems to differentiate them fromintegral alternator/regulator (IAR) systems.Figure 8-64. Two basic circuits for CS AC generators(alternator). (Delphi Automotive Systems)• The L terminal connects the regulator to theindicator lamp and battery.The indicator lamp in a CS charging systemworks differently than in other Delco-Remy systems:Any defect causes it to light at full brilliance.The lamp also lights if charging voltage iseither too low or too high. If the regulator has anI terminal, its wire supplies field current in additionto that applied internally, either directly fromthe switch or through a resistor.MotorcraftMotorcraft, a division of Ford Motor Company,makes most of the AC generators used on domesticFord vehicles. Model and current rating identificationsfor later models are stamped on thefront housing with a color code. Motorcraft ACgenerators prior to 1985 are used with either anelectromechanical voltage regulator or a remotelymounted solid-state regulator. One exception tothis is the 55-ampere model of 1969–1971, whichhas a solid-state regulator mounted on the rearhousing. This model has an A-circuit; all othersare B-circuit. The Motorcraft integral alternator/regulator(IAR) model was introduced onsome front-wheel drive Ford models in 1985.This AC generator (alternator) has a solid-stateregulator mounted on its rear housing. SomeMotorcraft charging systems continue to use anexternal solid-state regulator with either a rear-Integral Alternator/Regulator ModelsThe Motorcraft IAR AC generators are rated at 40to 80 amperes. The sealed rectifier assembly is attachedto the slipring-end housing. On early models,the connecting terminals (BAT and STA) protrudedfrom the side of the AC generator in aplastic housing. Current models use a single pinstator (STA) connector and separate output stud(BAT). The brushes are attached to, and removedwith, the regulator. A Y-type stator is used with a12-pole rotor. Some applications have an internalcooling fan.Turning the ignition on sends voltage to theregulator I terminal through a resistor in the circuit.System voltage is sensed and field current isdrawn through the regulator A terminal until theignition is turned off, which shuts off the controlcircuit.If the vehicle has a heated windshield, output isswitched from the battery to the windshield by anoutput control relay. This allows output voltage toincrease above the normal regulated voltage andvary with engine speed. The regulator I circuitlimits the increase to 70 volts, which is controlledby the heated windshield module during the approximatefour-minute cycle of heated windshieldoperation. When the cycle times out, the chargingsystem returns to normal operation.DaimlerChryslerDaimlerChrysler Corporation manufactured all of theAC generators for its domestic vehicles until the late1980s, when it phased in Bosch and Nippondenso ACgenerators for use on all vehicles.DaimlerChrysler used two alternator designsfrom 1972 through 1984. The standard-duty alternator,rated from 50 to 65 amperes, is identifiedby an internal cooling fan and the stator coreextension between the housings. The heavy-duty100-ampere alternator has an external fan and atotally enclosed stator core. Identification also isstamped on a color-coded tag on the housing.All models have a 12-pole rotor and use aremotely mounted solid-state regulator. The brushescan be replaced from outside the housing. Individualdiodes are mounted in positive and negative heat

176 Chapter EightBATTERY OUTPUTTERMINALGROUND TERMINALFIELD TERMINALSFigure 8-65. The terminals on a DaimlerChryslerstandard-duty AC generator (alternator). (Daimler-Chrysler Corporation)sink assemblies, and are protected by a capacitor.The terminals on the standard-duty AC generator arelabeled BAT, GRD, and FLD (Figure 8-65).• The BAT terminal connects AC generator outputto the insulated terminal of the battery.• The GRD terminal is the ground connection.• The FLD terminals connect to the insulatedbrushes. On the 100-ampere model, the FLDterminal has two separate prongs that fit intoa single connector (Figure 8-66). The additionalGRD terminal is a ground path.DaimlerChrysler standard-duty AC generatorshave a Y-type stator connected to six diodes.Although both brush holders are insulated fromthe housing, one is indirectly grounded throughthe negative diode plate, making it a B-circuit.The 100-ampere AC generator has a delta-typestator. Each of the conductors is attached to twopositive and two negative diodes. These 12 diodescreate additional parallel circuit branches forhigh-current output.DaimlerChrysler eliminated the use of a separatevoltage regulator on most 1985 and later fuel injectedand turbocharged engines by incorporatingthe regulator function into the powertrain controlmodule (PCM), as shown in Figure 8-67.The computer-controlled charging system wasintroduced with the standard DaimlerChrysler ACgenerator on GLH and Shelby turbo models. Allother four-cylinder engines used either a newDaimlerChrysler 40/90-ampere AC generator or aFIELD TERMINAL(VOLT-REG)FIELD TERMINAL(IGNITION SWITCH)Figure 8-66. The terminals on a 100-amp Daimler-Chrysler AC generator (alternator). (DaimlerChryslerCorporation)modified Bosch 40/90-ampere or 40/100-amperemodel.The DaimlerChrysler-built AC generatoruses a delta-type stator. The regulator circuit isbasically the isolated-field type, but field currentis controlled by integrated circuitry inthe logic and power modules (Figure 8-68) orthe logic and power circuits of the singlemoduleengine control computer (SMEC) orsingle-board engine control computer (SBEC).In addition to sensing system voltage, the logicmodule or circuit senses battery temperature asindicated by system resistance. The computerthen switches field current on and off in a duty

176 Chapter Eight

BATTERY OUTPUT

TERMINAL

GROUND TERMINAL

FIELD TERMINALS

Figure 8-65. The terminals on a DaimlerChrysler

standard-duty AC generator (alternator). (Daimler-

Chrysler Corporation)

sink assemblies, and are protected by a capacitor.

The terminals on the standard-duty AC generator are

labeled BAT, GRD, and FLD (Figure 8-65).

• The BAT terminal connects AC generator output

to the insulated terminal of the battery.

• The GRD terminal is the ground connection.

• The FLD terminals connect to the insulated

brushes. On the 100-ampere model, the FLD

terminal has two separate prongs that fit into

a single connector (Figure 8-66). The additional

GRD terminal is a ground path.

DaimlerChrysler standard-duty AC generators

have a Y-type stator connected to six diodes.

Although both brush holders are insulated from

the housing, one is indirectly grounded through

the negative diode plate, making it a B-circuit.

The 100-ampere AC generator has a delta-type

stator. Each of the conductors is attached to two

positive and two negative diodes. These 12 diodes

create additional parallel circuit branches for

high-current output.

DaimlerChrysler eliminated the use of a separate

voltage regulator on most 1985 and later fuel injected

and turbocharged engines by incorporating

the regulator function into the powertrain control

module (PCM), as shown in Figure 8-67.

The computer-controlled charging system was

introduced with the standard DaimlerChrysler AC

generator on GLH and Shelby turbo models. All

other four-cylinder engines used either a new

DaimlerChrysler 40/90-ampere AC generator or a

FIELD TERMINAL

(VOLT-REG)

FIELD TERMINAL

(IGNITION SWITCH)

Figure 8-66. The terminals on a 100-amp Daimler-

Chrysler AC generator (alternator). (DaimlerChrysler

Corporation)

modified Bosch 40/90-ampere or 40/100-ampere

model.

The DaimlerChrysler-built AC generator

uses a delta-type stator. The regulator circuit is

basically the isolated-field type, but field current

is controlled by integrated circuitry in

the logic and power modules (Figure 8-68) or

the logic and power circuits of the singlemodule

engine control computer (SMEC) or

single-board engine control computer (SBEC).

In addition to sensing system voltage, the logic

module or circuit senses battery temperature as

indicated by system resistance. The computer

then switches field current on and off in a duty

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