The generator voltage regulator relay is an integral part of the electrical system of any car. It is used to maintain voltage within a certain range of values. In this article you will learn about what designs of regulators currently exist, including mechanisms that have not been used for a long time.
Basic automatic control processes
It doesn't matter what type of generator set is used in the car. In any case, it has a regulator in its design. The automatic voltage regulation system allows you to maintain a certain parameter value, regardless of the frequency at which the generator rotor rotates. The figure shows the generator voltage regulator relay, its diagram and appearance.
By analyzing the physics by which a generator set operates, it can be concluded that the output voltage increases as the rotor speed becomes higher. It can also be concluded that voltage regulation is carried out by reducing the current supplied to the rotor winding as the rotation speed increases.
Replacing the battery charging indicator relay
Work on replacing the VAZ 2106 charging lamp relay should be carried out in the following sequence:
- We unscrew the 2 fasteners of the charging lamp relay and remove the product from the installed studs.
- We mark the supply wiring with a marker or felt-tip pen to control the correctness of the reverse connection of the updated product. If the relay is incorrectly connected to the vehicle's power supply network, it stops functioning, which will create an emergency situation due to a sharp increase in the potential difference at the output contacts of the generator device.
- We disconnect the wire circuit, replace the relay with a working product and carry out the reverse installation.
When testing the charging lamp relay, it is strictly forbidden to make a short circuit between the output elements of the circuit, because this will cause defects in the current rectifier unit. Before testing the charge regulator relay, you must ensure that the alternator belt tension is optimal. Other energy resources should not be connected to the electrical circuit of the generator excitation winding, because the voltage drop on the VAZ 2106 charging relay under study may exceed the optimal values.
On the “classic” you can find 2 types of voltage regulator relays: built into the generator and external. The difference lies in the model of the generator that is installed on the car.
On older Zhiguli models (VAZ 2101, 2102, 2103, 2106, 2121 with carburetor engines) a G-221 generator is installed, and the external voltage regulator is a small “box”, which is secured with two nuts on the left mudguard of the body. It is precisely the replacement of such a regulator that will be discussed in this article.
On later VAZ models (2104, 2105 and 2107) there is a G-222 generator, and the voltage regulator is already built into the generator housing and is a small black “tablet”.
What is a generator
Any car generator consists of several parts:
1. A rotor with an excitation winding, around which an electromagnetic field is created during operation.
2. A stator with three windings connected in a star configuration (alternating voltage is removed from them in the range from 12 to 30 Volts).
3. In addition, the design contains a three-phase rectifier consisting of six semiconductor diodes. It is worth noting that the VAZ 2107 generator voltage relay-regulator (injector or carburetor in the injection system) is the same.
But the generator will not be able to operate without a voltage regulation device. The reason for this is the voltage change over a very wide range. Therefore, it is necessary to use an automatic control system. It consists of a comparison device, control, executive, master and special sensor. The main element is the regulatory body. It can be either electrical or mechanical.
Scheme and principle of operation
The operation of the stabilizer for all models is almost the same and consists in distributing the current supplied from the generator to stabilize it and further distribute it to consumers.
The operation of the stabilizer is almost the same for all models
The main peripheral consumers of the scooter include:
- battery;
- indicators;
- light bulbs;
- sensors;
- enrichment agent;
- other nodes;
- starting enrichment.
How does the stabilizer work? The main principle of its operation is to act as a transformer, which lowers the voltage to an optimal level acceptable for the operation of electrical appliances, and also stabilizes the network and prevents unexpected power surges.
If the relay malfunctions, the scooter’s devices fail, quickly wear out or burn out.
To avoid these problems and their undesirable consequences, you should know the basics of the correct operation of the electrical circuit and voltage components of the scooter (Figure 1).
Voltage relay pinout diagram and wiring for main scooter models
The pinout of the relay regulator is standard for all models of Chinese-made scooters.
Scooter relay-regulator pinout
The stabilizer has an aluminum body and plastic contacts, each of which has its own wire. Each contact has its own wire color. This makes it convenient to connect the device to the wires if the plastic connector is worn out. The wires must be connected to the contacts according to the electrical diagram (Figure 3).
Electrical diagram for connecting the relay regulator
Generator operation
When the rotor begins to rotate, some voltage appears at the generator output. And it is supplied to the excitation winding through a control element. It is also worth noting that the generator set output is connected directly to the battery. Therefore, voltage is constantly present on the excitation winding. When the rotor speed increases, the voltage at the generator set output begins to change. A voltage regulator relay from a Valeo generator or any other manufacturer is connected to the generator output.
In this case, the sensor detects the change, sends a signal to a comparing device, which analyzes it, comparing it with a given parameter. Next, the signal goes to the control device, from which it is supplied to the actuator. The regulatory body is able to reduce the value of the current that flows to the rotor winding. As a result, the voltage at the generator set output is reduced. In a similar way, the mentioned parameter is increased in the event of a decrease in rotor speed.
Principle of operation
The autogenerator voltage regulator is designed to maintain the voltage of the on-board network within the required limits under any operating mode and at different generator speeds, load changes and changes in external temperature. It is also capable of performing additional functions - protecting the generator from overloads and emergency operation, automatically connecting the excitation windings or the generator failure alarm system to the on-board circuit.
The operation of any voltage regulator is based on the same principle and is determined by the following factors:
- Rotor speed.
- The current strength that the generator delivers to the load.
- An indicator of the magnetic flux created by the field winding current.
Higher rotor speeds determine an increase in generator voltage. An increase in current strength on the excitation winding makes the magnetic flux stronger, and at the same time the voltage. Any voltage regulator stabilizes it by changing the excitation current. When the voltage increases or decreases, the regulator decreases or increases the excitation current, regulating the voltage within the required limits.
The relay regulator itself is an electronic circuit with outputs to graphite brushes. It is installed both in the generator body itself next to the brushes, and outside it, and then the brushes are attached to the brush holder.
Two-level regulators
A two-level automatic control system consists of a generator, a rectifier element, and a battery. It is based on an electric magnet, its winding is connected to the sensor. The driving devices in these types of mechanisms are very simple. These are ordinary springs. A small lever is used as a comparison device. It is mobile and makes switching. The actuator is the contact group. The control element is a constant resistance. Such a generator voltage regulator relay, the diagram of which is given in the article, is very often used in technology, although it is morally outdated.
Electronic regulator
Two-level mechanical voltage regulators have a big drawback - excessive wear of the elements. For this reason, instead of an electromagnetic relay, semiconductor elements operating in key mode began to be used. The operating principle is similar, only the mechanical elements are replaced by electronic ones. The sensing element is made on a voltage divider, which consists of constant resistors. A zener diode is used as a driving device.
The modern relay-voltage regulator of the VAZ 21099 generator is a more advanced device, reliable and durable. The executive part of the control device operates on transistors. As the voltage at the generator output changes, the electronic switch closes or opens the circuit, and additional resistance is connected if necessary. It is worth noting that two-level regulators are imperfect devices. Instead, it is better to use more modern developments.
Operation of a two-level regulator
When the generator operates, a voltage appears at the output, which is supplied to the winding of the electromagnetic relay. In this case, a magnetic field arises, with its help the lever arm is attracted. The latter is acted upon by a spring, which is used as a comparing device. If the voltage becomes higher than expected, the contacts of the electromagnetic relay open. In this case, a constant resistance is included in the circuit. Less current is supplied to the field winding. The voltage regulator relay for the VAZ 21099 generator and other domestic and imported cars operates on a similar principle. If the voltage at the output decreases, then the contacts are closed, and the current strength changes upward.
Generator device
The design of a car generator implies the presence of its own rectifier and control circuit. The generating part of the generator, using a stationary winding (stator), generates three-phase alternating current, which is then rectified by a series of six large diodes and the direct current charges the battery. Alternating current is induced by the rotating magnetic field of the winding (around the field winding or rotor). Next, the current is supplied to the electronic circuit through the brushes and slip rings.
Generator structure: 1.Nut. 2. Washer. 3.Pulley 4.Front cover. 5. Distance ring. 6.Rotor. 7.Stator. 8.Back cover. 9.Casing. 10. Gasket. 11.Protective sleeve. 12. Rectifier unit with capacitor. 13. Brush holder with voltage regulator.
The generator is located at the front of the car engine and is started using the crankshaft. The connection diagram and operating principle of a car generator are the same for any car. There are, of course, some differences, but they are usually associated with the quality of the manufactured product, the power and the layout of the components in the motor. All modern cars are equipped with alternating current generator sets, which include not only the generator itself, but also a voltage regulator. The regulator equally distributes the current in the excitation winding, and it is due to this that the power of the generator set itself fluctuates at a time when the voltage at the power output terminals remains unchanged.
New cars are most often equipped with an electronic unit on the voltage regulator, so the on-board computer can control the amount of load on the generator set. In turn, on hybrid cars the generator performs the work of the starter-generator; a similar circuit is used in other designs of the stop-start system.
The principle of operation of a car generator
Connection diagram for the VAZ 2110-2115 generator
The alternator connection diagram includes the following components:
- Battery.
- Generator.
- Fuse block.
- Ignition.
- Dashboard.
- Rectifier block and additional diodes.
The principle of operation is quite simple: when you turn on the ignition, the plus goes through the ignition switch through the fuse box, the light bulb, the diode bridge and goes through the resistor to the minus. When the light on the dashboard lights up, then the plus goes to the generator (to the excitation winding), then during the process of starting the engine, the pulley begins to rotate, the armature also rotates, due to electromagnetic induction, electromotive force is generated and alternating current appears.
The most dangerous thing for the generator is the short circuit of the heat sink plates connected to the “ground” and the “+” terminal of the generator by metal objects accidentally falling between them or conductive bridges formed by contamination.
Next, the diode passes plus into the rectifier block through a sine wave into the left arm, and minus into the right arm. Additional diodes on the light bulb cut off the negatives and only positives are obtained, then it goes to the dashboard assembly, and the diode that is there allows only the negative to pass through, as a result the light goes out and the positive then goes through the resistor and goes to the negative.
The principle of operation of a car DC generator can be explained as follows: a small direct current begins to flow through the excitation winding, which is regulated by the control unit and is maintained by it at a level of slightly more than 14 V. Most generators in a car are capable of generating at least 45 amperes. The generator operates at 3000 rpm and above - if you look at the ratio of the size of the fan belts for the pulleys, it will be two or three to one in relation to the engine frequency.
To avoid this, the plates and other parts of the generator rectifier are partially or completely covered with an insulating layer. The heat sinks are combined into a monolithic design of the rectifier unit mainly by mounting plates made of insulating material, reinforced with connecting bars.
Next, let's look at the connection diagram for a car generator using the example of a VAZ-2107 car.
Three-level regulation system
The quality of regulation of such structures is much higher than that of those previously discussed. Previously, mechanical designs were used, but today non-contact devices are more common. All elements used in this system are the same as those discussed above. But the operating principle is slightly different. First, voltage is applied through a divider to a special circuit in which information is processed. It is possible to install such a generator voltage regulator relay (Ford Sierra can also be equipped with similar equipment) on any car if you know the device and connection diagram.
Here the actual value is compared with the minimum and maximum. If the voltage deviates from the value that is set, then a certain signal appears. It is called a mismatch signal. It is used to regulate the current flowing to the excitation winding. The difference from a two-level system is that there are several additional resistances.
VAZ 2106 charging circuit and equipment composition.
The generator is driven by a mono-V belt from the crankshaft pulley. Depending on the number of revolutions, the output voltage can be in the range
It is also possible that the lamp itself may fail, but this can be easily checked by setting the charging current level using an on-board ammeter. The price of a new product ranges from 2,000 rubles and above. It is not allowed to operate the generator with the battery disconnected.
With its help, mechanical energy is converted into electricity. At the front of the generator there is a pulley and an impeller for blowing through the device body. That’s why it’s worth understanding how the VAZ generator connection diagram works and what alternatives there are.
Tighten the bottom fastening nut until it stops. These could be: fog lights; preheater; refrigerator, TV, additional heater. At the front end of the rotor shaft, a pulley and a cooling fan impeller are secured with a nut using a segment key.
Related article: How to connect a 2-key switch
The VAZ charging circuit includes a relay for the RS type charge warning lamp that turns the warning lamp on and off on the instrument panel, which indicates the presence or absence of charge and the serviceability of the generator. If there is no resistance, there is a short circuit to the device body. It is also possible that the lamp itself may fail, but this can be easily checked by setting the charging current level using an on-board ammeter.
This checks for an open circuit in the coil. In such cases, the easiest way is to replace the entire rectifier unit. Sometimes you need to solve the problem of how to check the VAZ generator for the functionality of the network regulator, which can be found on the left mudguard in the engine compartment. The middle part is the stator on which the windings are located. It is difficult to call any one element the main one, since when any one fails, the power supply system is turned off.
Generator operation diagnostics
As soon as the on-board voltage drops below 12 volts, the relay contacts open and the lamp lights up. After replacing the generator and connecting it according to one of the provided diagrams, it is enough to check the functionality of the system as a whole. To prevent the device from overheating during long-term operation, the case has many small holes for ventilation. The generator belt tensioner helps ensure normal rotation of the rotor.
The most important points in generating electricity are the presence of a magnetic field and movement. Using a spanner wrench, remove the bottom mount of the product and pull out the bolt. After all, during operation it heats up. How to check a VAZ generator
Modern voltage regulation systems
If the voltage regulator relay for the generator of a Chinese scooter is two-level, then more advanced devices are used on expensive cars. Multilevel control systems can contain 3, 4, 5 or more additional resistances. There are also tracking automatic control systems. In some designs, you can refuse to use additional resistances.
Instead, the frequency of operation of the electronic key increases. It is simply impossible to use circuits with electromagnetic relays in servo control systems. One of the latest developments is a multi-level control system that uses frequency modulation. In such designs, additional resistances are required, which are used to control logic elements.
How to remove the relay regulator
Removing the generator voltage regulator relay (“Lanos” or domestic “nine” is not important) is quite simple. It is worth noting that when replacing the voltage regulator, you only need one tool - a flat-head or Phillips screwdriver. There is no need to remove the generator or the belt and its drive. Most of the devices are located on the back cover of the generator, and are combined into a single unit with a brush mechanism. The most common breakdowns occur in several cases.
Firstly, when completely erasing the graphite brushes. Secondly, in case of breakdown of a semiconductor element. How to check the regulator will be discussed below. When removing, you will need to disconnect the battery. Disconnect the wire that connects the voltage regulator to the generator output. By unscrewing both mounting bolts, you can pull out the device body. But the voltage regulator relay for the VAZ 2101 generator has an outdated design - it is mounted in the engine compartment, separately from the brush assembly.
Electrical circuits of the VAZ 2106 car
Its design consists of a pair of brushes made of graphite, springs that allow them to be pressed more tightly to the rings on the rotor, as well as a brush holder. Loosen and remove the drive belt. Disconnect the block with wires from the generator connector. Contents: How to connect a standard generator G Replacing a VAZ generator with a G Refining the generator G for a VAZ Checking the functionality of the power supply system Electrical diagram of a VAZ As a matter of fact, if we look at the electrical diagram of a VAZ, which we have given below just in case, it turns out that it differs only from the diagram the presence of additional electrical appliances, which entailed some changes. Conclusion Now you know what elements the VAZ generator consists of
The rectifier unit looks like a large horseshoe into which semiconductor elements are pressed. Consequently, electrical energy is generated. To do this, it is necessary to de-energize all current consumers of the car and increase the engine speed to 2.5 thousand.
Therefore, install a mudguard that will protect your car from moisture.
No generator can do without a rectifier unit and a voltage regulator. In this case, significant current flows through the valves and they are damaged. How is it better than the standard six? GENERATOR VAZ 2101 BATTERY CHARGING LAMP AND PRINCIPLE OF OPERATION
Read more: Measuring electrical laboratories
Device check
The relay-regulator of the voltage of the VAZ 2106 generator, “kopecks”, and foreign cars is checked equally. As soon as you remove it, look at the brushes - they should be more than 5 millimeters long. If this parameter is different, the device must be replaced. To carry out diagnostics, you will need a constant voltage source. It would be desirable to be able to change the output characteristic. You can use a battery and a couple of AA batteries as a power source. You also need a lamp, it must run on 12 Volts. You can use a voltmeter instead. Connect the plus from the power supply to the voltage regulator connector.
Accordingly, connect the negative contact to the common plate of the device. Connect a light bulb or voltmeter to the brushes. In this state, voltage should be present between the brushes if 12-13 Volts are supplied to the input. But if you supply more than 15 Volts to the input, there should be no voltage between the brushes. This is a sign that the device is working properly. And it doesn’t matter at all whether the voltage regulator relay of the VAZ 2107 generator or another car is diagnosed. If the control lamp lights up at any voltage value or does not light up at all, it means that there is a malfunction of the unit.
Signs that a check is needed
If the battery on your scooter often runs out, and it is still quite new, this means that there is a problem with the operation of the relay regulator. As practice shows, it burns out quite often. If the device is faulty, the battery stops charging completely and loses its capacity. This means you won’t be able to start the scooter with a button; you’ll have to start it with a kickstarter.
Another characteristic sign of incorrect operation of the device may be the frequent burnout of incandescent light bulbs. They themselves are durable and have a good durability, but are quite sensitive to voltage changes. This happens because the optimal voltage in the scooter network is considered to be 12-13 V. Increasing this value even by 2 V reduces the service life of electronics and components by 2 times.
The greater the deviation from the norm, the greater the likelihood that something will burn out in the scooter. Therefore, when starting the scooter from the starter due to a power surge and a faulty relay, the bulbs usually burn out.
Signs of a malfunctioning regulator are identical for all models of Chinese scooters. They are especially typical for charging relays for scooters of Chinese models with an engine capacity of 50 cc. Therefore, before making a decision to replace something in electronics, testing systems and devices should begin with the relay regulator.
For all models of Chinese scooters, the symptoms of a malfunction of the regulator are identical.
conclusions
In the electrical system of a car, the voltage regulator relay of the Bosch generator (as, indeed, of any other company) plays a very important role. Monitor its condition as often as possible and check for damage and defects. Cases of failure of such a device are not uncommon. In this case, in the best case, the battery will be discharged. And in the worst case, the supply voltage in the on-board network may increase. This will lead to the failure of most electricity consumers. In addition, the generator itself may fail. And its repair will cost a tidy sum, and considering that the battery will fail very quickly, the costs will be astronomical. It is also worth noting that the Bosch generator voltage regulator relay is one of the leaders in sales. It has high reliability and durability, and its characteristics are as stable as possible.
Remote controller
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This often happens to drivers. The brushes of the generating device burn out. The regulator is built in along with the brushes. We have to change everything together. And here’s some advice from experts: it’s better to install an external regulator than a built-in one. The models released recently have not been praised very much.
Okay, do you think I’ll install an external one, but how do I connect it? It turns out that there is a convenient scheme that makes it easy to carry out all this modernization.
Some important points:
- do not confuse the chips on the regulator numbered 67 and 15 (the first should be connected to the generating device, and the second should go to the fuses);
This is what the connection diagram looks like
In the lower photo we see a diagram that shows the connection of the already built-in regulator relay.
It is suitable for connecting to “fives”, “sevens”, VAZ 2104, if the PG is installed from a VAZ “kopek”. As you can see, the remote-type regulator relay is connected via two terminals. Pin 15 goes to the fuse.
The second pin 67 is connected to the generator. The wire is connected to the brush chip.
Also, the remote-type relay must be connected to ground - any part of the body.
A relay is nothing more than a switch that serves to close and disconnect individual zones of an electrical circuit that occur at specific electrical values. A machine relay is otherwise called a load voltage switch, and this is 100 percent true. When the power supply unit, fan or starter consumes more current than necessary, the relay trips.
The relay consists of an electric type magnet, an armature and a switch. In this case, the electromagnet is a cable twisted around an inductor with a magnetic rod, and the armature is a special plate that controls the contacts.
As soon as electrical voltage passes through the magnet winding, an electric field is created. A special pusher presses the armature against the core and, thereby, the contacts switch.
Attention. There are two types of relays used on VAZ cars. This is a non-contact relay-regulator and MER (electric). It is the diagram of the last relay that is shown in the picture below.
The non-contact relay or NERR is a fairly new unit that does not require any additional adjustments or regulation. As for the MED, this is an old-style device, the production of which has currently been suspended.
So, the BRN or built-in regulator is a device consisting of a microcircuit, a transistor and a housing with brushes. If the built-in regulator fails, it is replaced with a new one, or an external one is installed.
The external regulator is easy to install if you strictly follow the instructions.
Modernization involves dismantling and disassembling the generating device.
GU or generator
The generator in any automotive electrical circuit performs the dominant functions. The normal functioning and operation of the machine depends on it. Reliable PG is installed in all foreign cars and models of the domestic automobile industry.
For example, a GU is placed on the “six”, the charge of which satisfies the need for electricity of any standard component. If you do not overload the generating device of the “six”, then the car is capable of driving many, many more kilometers. However, it is important to carry out preventive procedures in a timely manner - monitor the belt tension and the condition of the brushes.
The GU is connected according to the classical scheme. Using the VAZ 2106 generator as an example, let’s consider its functioning. This GU is marked as G-221. It is an AC synchronous electric machine with ELMG excitation. A VB (rectifier) with 6 diodes is built inside the GU.
| 1 | generator rotor winding |
| 2 | generator |
| 3 | generator stator winding |
| 4 | generator rectifier |
| 5 | accumulator battery |
| 6 | ignition switch |
| 7 | battery charge indicator lamp |
| 8 | battery warning light relay |
| 9 | fuse box VAZ -2106 |
| 10 | throttle |
| 11 | temperature compensation resistor |
| 12 | additional resistors |
| 13 | voltage regulator |
A simple and understandable scheme that does not require any subtleties or specific knowledge. On the “six” the PG is located on the engine on the right. It is attached to the tension bar with a nut and to the bracket with its claws.
As you can see, the diagram shows an external regulator. It is marked with the number 13. The generator is indicated with the number 2, the fuse box is indicated with the number 9.
Removing and installing the voltage regulator
Replacing the external voltage regulator VAZ 2101-2106
1) Using the “8” socket, unscrew the two nuts and remove the regulator.
2) Disconnect the two wires.
3) Attach the new regulator to the mudguard and connect the wires: orange to terminal “15”, and gray to terminal “67”.
Voltage regulator relay connection diagram
ATTENTION! Before starting the engine, make sure that the contact between the voltage regulator housing and the vehicle ground is reliable, and that the wires to terminals “15” and “67” are connected correctly.
Issues of selection, diagnostics and replacement of voltage relay regulators
Various malfunctions can occur in relay regulators, which in most cases are manifested by a lack of battery charging current and, on the contrary, an excessive battery charging current. The simplest check of the regulator can be carried out using a voltmeter - just start the engine and let it run for 10-15 minutes at a frequency of 2500-3000 rpm and with the headlights on. Then, without reducing the speed and without turning off the headlights, measure the voltage at the battery terminals - it should be 14.1-14.3 volts (twice as high for 24-volt ones). If the voltage is significantly lower or higher, then this is a reason to check the generator, and if it is in order, replace the regulator.
The replacement should be a relay-regulator of the same type and model that was installed previously
You especially need to pay attention to the order in which the regulator is connected to the on-board network (to which terminals of the generator and other elements), as well as to the supply voltage and currents. Replacement of the part must be carried out according to the instructions; work can only be carried out with the engine stopped and the terminal removed from the battery
If all recommendations are followed and the regulator is selected correctly, it will immediately begin to work, ensuring the normal functioning of the electrical system.
