We independently check the voltage regulator relay on the VAZ 2106

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Checking the generator voltage regulator may be necessary when problems with the battery begin to occur. In particular, it began to undercharge or overcharge. When such a malfunction occurs, it’s time to check the generator voltage regulator relay.

The relay should turn off at 14.2-14.5V

The task of this simple device is to regulate the voltage of the electric current that is supplied from the generator to the battery. When it fails, the battery is either not charged enough or, on the contrary, overcharged, which is also dangerous, since this significantly reduces the battery life.

Agree that such a prospect is not very good because of one small detail. This is why it is so important to monitor the operating condition of the voltage regulator (it can also be called a pill or a chocolate bar). But in order to properly check the voltage regulator, you need to know its type and several important features.

Types of Voltage Regulators

Having understood what types of these devices there are, what their features and properties are, a complete understanding of the procedures carried out during testing will come. This will also give the answer to what scheme, in what way and how to check the generator voltage regulator. There are two types of regulators:

In the first case, it is meant that the regulator housing is combined with the brush assembly directly in the generator housing. In the second case, the regulator is a separate unit, which is located on the car body, in the engine compartment, and wires from the generator go to it, and wires from it go to the battery.

A special feature of the regulators is that their housings are non-separable. They are usually filled with sealant or special resin. And there is no particular point in repairing them, since the device is inexpensive. Therefore, the main problem in this regard is to check the generator voltage regulator relay. Regardless of the type of regulator, the voltage symptoms will be the same.

Voltage regulator relay VAZ 2106 - types of device

The task of this element of the car is to provide automatic continuous modification of the excitation current strength so that the voltage at the generator is always within standard limits when its load and rotation speed change.

On “sixes” there can be two types of regulators:

• electromagnetic;
• electronic contactless.

The first device is outdated; it has not been produced as spare parts for the VAZ 2106 for a long time. You can only find such a relay on old cars, and even then it’s extremely rare. But a contactless electronic regulator can be purchased at any auto store. This device is very popular among motorists, as it does not require any special complex adjustments or critical settings.

If the old electromagnetic relay-regulator fails, it is simply replaced with a new electronic one - both types of devices are completely interchangeable, so the electronic circuit does not need to be changed or modified.

But before you decide to replace the described relay, professionals strongly recommend checking the old device to ensure its performance. Often the problem lies not in it, but in other mechanisms and components of the vehicle.

Symptoms of a problem

So, in case of low voltage, the battery simply will not charge. That is, in the morning you will not be able to start the car, the lights on the dashboard may not even light up, or troubles will arise while driving. For example, dim headlights at night, unstable operation of the electrical system (problems with electrical appliances - wipers, heaters, radio, etc.).

In case of increased voltage, there is a high probability of a decrease in the electrolyte level in the battery banks, or its boiling. A white coating may also appear on the battery case. When overcharging, the battery may behave inappropriately.

Signs, malfunctions and repair of the generator and voltage regulator

In addition, you can also identify the following signs of a faulty voltage regulator (in some cases, some of them may or may not be present, it all depends on the specific situation):

• the control light on the dashboard (although this may be a sign of other malfunctions, for example, that it has burned out, the contact has fallen out, and so on);
• after starting, the battery indicator on the dashboard does not go out, that is, there are obvious malfunctions in charging the battery;
• the brightness of the headlights becomes dependent on the engine speed (you can check this somewhere in a deserted place by placing the car against a wall and accelerating - if the glow changes, then most likely the voltage regulator is faulty);
• the car stopped starting normally the first time;
• The battery is constantly ;
• when the engine speed exceeds 2000 rpm, the indicators on the dashboard turn off ;
• the dynamic characteristics of the car decrease , this is especially noticeable at high engine speeds;
• In some cases, the battery may boil .

Replacing the VAZ 2101 – 2106 generator

The need to replace the generator on a VAZ car may occur when its windings burn out, an interturn short circuit occurs, the case breaks, and other reasons. But today, I would like to talk about replacing the VAZ generator in the case when its power is no longer sufficient...

Imagine the situation - you are the owner of a VAZ 2101 - 2106, you bought and installed a powerful amplifier, installed fog lights of 50 W each. A standard generator that produces a maximum current of 42A cannot cope with such a load.

And if all additional equipment is turned on, then there will be nothing left to charge the battery.

After all, judge for yourself, the high beam in the VAZ 2106 has become “heavier” by 100 W, while with a standard generator and on a penny it does not shine with its parameters.

It’s these types of cases of replacing a VAZ generator that I want to talk about. Let's consider which generators can replace our long-suffering G-221.

Generators that replace G - 221

What models of generators are suitable for replacement in a VAZ 2101 - 2106 car?

• The first option is a generator from a VAZ 2105; it produces a maximum current of 55A. Not much, but if you don’t use a lot of additional equipment, then this is an ideal option. This generator replaces the G-221 generator without any modifications to the mounting. There are only minor changes in the connection to the electrical wiring; they are due to the fact that in the connection diagram of the G-221 generator the relay-regulator is placed separately, while in the five-wheel generator the relay regulator is combined with the design of the brushes.
• The next option for installing a chisel generator on a VAZ 2101 - 2106. It produces 55A, which is quite acceptable for a small amount of additional equipment.
• The third option for replacing a standard VAZ generator is a generator from a VAZ 21074, its marking is 372.3701-03. It is capable of delivering about 73A of current, which will be sufficient for the average motorist. The installation is practically no different from the previous one.
• The fourth option is to install a generator from an injection Niva. It produces about 80A, which will satisfy the requirements even if a large number of additional light bulbs and amplifiers are installed. It will not let the light go out at idle. But the installation does not require very big changes.
• The fifth and final option is to replace the standard G - 221 with a generator from a VAZ 2110, which produces 105 - 110A (depending on the specific model).
• There are other options (foreign cars, Chinese, our semi-underground companies), but you can consider them here endlessly.

We have listed the most realistic and easiest ways to replace a generator in a VAZ 2106 car. Next we will look at how to practically implement the installation of a generator from a VAZ 21074.

Installation of a generator from a VAZ 21074i to a VAZ 2106 (2101)

Information found on the six forum. First, it’s worth noting (as far as I understand), there are different models that fit these parameters, they recommend taking 2107-3701010.

If you chose 2107-3701010, then now I will quote the installation on the VAZ 2106. It is also much easier to find spare parts for the first generator.

• Photo from the back:

A little about the relay regulator. I have already read more than one negative review about the K1216EN1 relay regulator. In particular, thermal compensation is poorly implemented in it, that is, the charge voltage does not change depending on the ambient temperature.

So the author almost immediately replaced the standard RR with a 67.3702-01 regulator.

Installing a new generator instead of an old one is not difficult; everything fits into a standard mount. Now let's look at the connection.

The very first thing you need to do is disconnect and insulate the wires from the relay regulator. As for the connection on the generator itself, everything is almost the same as in the old one. Wires with a terminal in the form of a ring - in the old place, a bolt that was also on the old generator. The gray wire is isolated and not connected anywhere, the yellow wire is connected to the terminal.

Reasons for failure of the relay regulator

The reasons for the failure of the voltage regulator may be:

• short circuit in the circuit, including interturn short circuit of the excitation winding;
• failure of the rectifier bridge (diode breakdown);
• reverse polarity or incorrect connection to the battery terminals;
• penetration of moisture into the housing of the regulator and/or generator (for example, when washing a car or driving in heavy rain);
• mechanical damage to the unit;
• natural wear and tear of the unit, including brushes;
• poor quality of the device being directly tested.

There are a number of simple methods for checking the regulator, regardless of whether the unit is removable or not.

The simplest way to check the generator voltage regulator

The simplest method of checking the regulator is to measure the voltage at the battery terminals with a multimeter. However, it is worth immediately making a reservation that the algorithm given below does not give a 100% probability of failure of the regulator. Perhaps the generator itself has failed. But the advantage of this method is that it is simple and there is no need to dismantle the device from the car. So, the algorithm for checking the generator voltage regulator with a multimeter is as follows:

• Set the tester to DC voltage measurement mode at a limit of about 20 V (depending on the specific model, the main thing is that it displays values ​​up to 20 V as accurately as possible).
• Start the engine.
• Measure the voltage at the battery terminals in idle mode (1000. 1500 rpm). If the regulator and generator are working properly, the value should be within 13.2. 14 V.
• Increase the speed to 2000. 2500 rpm. In the normal state of the electrical circuit, the corresponding voltage will increase to 13.6. 14.2 V.
• When the speed increases to 3500 rpm and above, the voltage should not exceed 14.5 V.

If during the test the voltage values ​​are very different from those given, then most likely the machine’s voltage regulator is faulty. Remember that the voltage should not fall below 12V and should not rise above 14.5V.

Device diagnostics

A malfunction of the charging circuit elements can be detected while driving. With the engine running, look at the instrument panel. When the voltage drops, the charging relay turns on the light. The alarm indicates a possible failure of the PP.

To check the voltage regulator, you need a voltmeter. The tester can be purchased at a store or borrowed from a familiar electrician. The mode switch is set to the limit of 20 V. The common wire (black) is connected to the ground of the passenger car, and the red probe is placed on the “+” sign of the battery.

You can check the relay regulator with the engine running and the battery fully charged. The sequence of actions to diagnose the device should be as follows:

1. Use the ignition key to start the engine.
2. Turn on the load (high beam headlights).
3. Warm up the engine for 15 minutes.
4. We set the rotation speed to 2.5 thousand using the tachometer.
5. We take tester readings at the battery terminals.

After completing all the points, an analysis is carried out. If the needle on the instrument scale is within 14.2 V, then the regulator copes with its task. In this case, the voltage should not significantly depend on the number of revolutions.

Deviation of indicators from the norm indicates a breakdown of the regulator.

Remember that the electronic relay does not allow the terminals to be removed from the battery while the engine is running. This leads to voltage surges and failure of electronic devices.

Checking the combined relay-regulator

Checking the VAZ 2110 voltage regulator

To perform the corresponding check, it is necessary to assemble the circuit shown in the figure. To do this, use a charger or power supply with an adjustable load (it is important that it be used to regulate the voltage value in the circuit), a 12 V light bulb (for example, from a turn signal or headlight, with a power of 3.4 W), a multimeter, and the regulator itself voltage (this can be from a Bosch, Valeo or other generator). It is advisable to have the wires used for switching with “crocodiles”.

Checking the voltage regulator of the generator 37.3701: 1 - battery; 2 — ground terminal of the voltage regulator; 3 - voltage regulator; 4 – terminal “Ш” of the regulator; 5 — output “B” of the regulator; 6 — control lamp; 7 — terminal “B” of the voltage regulator.

If you assemble a circuit in which the voltage is at a standard value of 12.7 V, then the light bulb will simply glow. But if you use a voltage regulator to raise its value to 14.14.5 V, then if the relay is working, the light should go out. Otherwise the regulator is faulty. That is, when the voltage reaches 14.14.5 V (depending on the model of the machine and, accordingly, the regulator) and above, the light goes out, and when it drops to the same level, it lights up again.

Checking the VAZ 2107 voltage regulator

Checking the voltage regulator on VAZ 2108/2109 cars

Until 1996, a VAZ 2107 with a 37.3701 generator was equipped with an old-style voltage regulator (17.3702). The verification procedure is given above. After 1996, a more modern generator of the G-222 brand was used (integrated regulator RN Ya112V (V1).

As you can see, the verification algorithm for all regulators is almost the same. The only difference is the cutoff values ​​when the relay is activated.

Replacing the VAZ 2110 generator relay on your own

The amount of electrical voltage generated by a car generator is not constant and depends on the number of revolutions of the crankshaft. In order to stabilize it, a special regulator is designed. We will talk about it in this article using the example of a VAZ-2110 car.

The voltage regulator on most cars is connected to the on-board network according to the diagram below.

The operating principle of a voltage regulator (VR) is the same as that of a relay. In other words, it opens and closes an electrical circuit. That is why the device is also called a relay regulator. It is triggered when a predetermined voltage value coming from the generator changes.

The first regulators had an electromagnetic design. These were real relays. Modern devices are made on the basis of semiconductors. They are small in size, and in addition, they work much more accurately and efficiently. Some of them are even equipped with special alarms that allow the driver to monitor their performance.

The process of replacing the voltage regulator is not particularly difficult. All you need to do is purchase a new device, check it as described above and install it on the generator, fastening it with two screws. And don't forget to connect the yellow wire!

Initially, you need to carefully study the complete set of the regulator. Usually these are instructions, a device and connecting wires with holders that are required to fix the case.

Before installation, make sure you have an open-end wrench and a crosswise screwdriver on hand. Additionally, a knife and a voltage tester will not hurt. Clamping the terminals is done using pliers or take pliers.

Before starting installation work, disconnect the negative terminals from the battery. It is important to completely unscrew it from the battery.

Next, unscrew the generator nut using the appropriate wrench. To gain access to the casing, the block is removed, which is usually secured with three latches. To disconnect, you need to slightly pry the block from the edge. Next, the casing should be easy to remove.

The next step is to unscrew the screws, but first make sure that the plug is completely removed. Next, the nut is removed, the ends of which should be well processed with a file. This is necessary in order to improve the contact of the diode bridge with the bushing. The brush holder is mounted in place of the regulator. It is important to take care of its seal during installation in order to fix the device more securely.

The next step is to reinstall the plastic casing in its place and you can begin laying the regulator wire. Do everything carefully and take into account the placement of the main wiring of the machine.

To prevent the wires from dangling, secure them with plastic clamps.

Only after all the above steps are completed, the device itself is installed. Contact with ground must be reliable. Often, a shunt is used for this, which makes it possible to fasten the regulator and generator housings much better.

Once the device has been connected, you need to screw in the other wires from the kit. Upon completion of all installation work, the functionality of the device should be checked. It is important to load the battery to full - turn on the stove, radio, headlights, and so on.

The traditional voltage regulator circuit involves the presence of various diodes. Element performance may vary significantly. This is because there is often a sharp change in the voltage level in the system. In addition, the current must be taken into account.

Regulators often have radiators that are designed to cool the diodes. The device is controlled using a toggle switch. An electric drive strip is used to complete the circuit.

The vehicle's electrical circuit includes a device such as the voltage regulator of the VAZ 2110 generator. Its task is to limit the output voltage of the generator and bring it to optimal values ​​in accordance with the parameters of the on-board equipment. In this article we will tell you how this device works, what malfunctions are typical for it, how to check and replace. We will also give you detailed recommendations that will allow you to continue driving with a faulty regulator.

During operation, the voltage regulator may fail. In VAZ 2110 cars of all editions, a semiconductor relay is used, which contains graphite generator brushes. A relay malfunction can lead to the following consequences:

• Failure of all vehicle network devices. Usually, the first thing that happens is that all the lamps in the lighting devices burn out. If this suddenly happened, the relay has failed because the output voltage exceeded the rated values.
• Recharging the battery. Overcharging a galvanic cell is also unacceptable. This can lead to boiling of the electrolyte and subsequent damage to the battery.
• Low charge. As many car enthusiasts say, “undercharging” occurs. A weak battery will not be able to fully ensure reliable engine starting.

In total, there are only two malfunctions of the voltage regulator relay. These are: failure of the relay (charging does not occur, or the battery is overcharged) and its incorrect operation (the relay works, but passes too little voltage, which is not enough to charge the battery). All relay malfunctions can be identified by many external signs, as well as through diagnostics.

The most reliable way to check the voltage regulator is to measure the electrical value at the battery terminals with the engine running and idling. The normal voltage is considered to be between 13.5 and 14.2 Volts. If the voltage level exceeds these values ​​or is lower, it means that the voltage regulator is faulty and must be replaced.

In addition, there are other signs of a relay failure, after which the device usually begins to be checked:

1. The charging indicator light came on while the engine was running. As the speed increases, the lamp goes out.
2. Dim headlights when the engine is running. Likewise, as the speed increases, a brighter glow can be observed.
3. Too bright headlights and subsequent burnout of the lamps also indicate incorrect operation of the relay.
4. If the battery charge is sufficient for a small number of starts, it means that the relay does not fully provide the required charge.

After detecting all of the above faults, it is necessary to replace the relay. To do this, you need to know exactly which relay is installed on your car. The fact is that depending on the car model, different generators are used. Modifications of the VAZ 2110 also have different generating devices.

Conventionally, regulators can be divided into two types: for injection cars and carburetor cars. They have few design differences, but the parameters on the basis of which they work may differ.

After determining the type of relay, the exact same new regulator is purchased. Then, disconnect the negative terminal of the battery and remove the plug from the relay connector. Unscrew the two screws securing the relay and unscrew the ground wire nut. Remove the old brushes and install new ones in their place. Installation is carried out in reverse order.

This completes the replacement of the VAZ 2110 voltage regulator.

Relay regulator VAZ

Replacing the VAZ 2110 generator relay can be done in two ways: with removing the generator and without removing it. Both options can be done at home, although the second involves fewer manipulations with the car. But despite this, the first option may be simpler for some. Anyone can replace the VAZ 2110 generator regulator relay if they read and study the instructions below.

Relay replacement is needed in the following cases:

• ​ The brushes are worn out. By the way, this is the main reason. The fact is that due to their wear, contact with the relay is lost, so due to lack of power, the generator will stop working.
• ​ A breakdown is observed in the circuit, which leads to an increase in voltage in the system.
• ​ Wire breaks causing loose contacts.
• ​ Damage to the housing or fastenings. This is not something to joke about, as it can lead to an unwanted short circuit.

Relay replacement

• ​ Disconnect the negative terminal of the battery.
• ​ Unscrew the two bolts securing the generator.
• ​ Remove the yellow wire going to the relay from the generator.
• ​ Remove the relay. Examine it carefully. If the brushes are worn out, replacement cannot be avoided.
• ​ If any of the wires are broken or there are holes on its surface, then you can only get by by replacing them.

• ​ Check the new voltage regulator, and then attach it to the generator.
• ​ Reconnect the yellow wire and battery terminal.

As noted earlier, you can replace the relay with your own hands. The main thing is to familiarize yourself with the work process in advance so that questions do not arise later. To do this, you can find photos in various auto repair magazines. It’s much easier to use videos, of which there are many on the Internet. Our instructions will also help in this difficult matter. But the price of home repairs will not exceed 100 rubles.

The voltage regulator on a modern car automatically and continuously adjusts the excitation current of the generator. Moreover, this process proceeds in such a way that when the current load and rotation speed of the generator changes, the value of its voltage remains in a strictly defined range.

To analyze the condition of the regulator, you need to purchase a voltmeter, which has a measuring scale in the range of 15–30 volts. The check is performed as follows:

• start the car engine at medium speed and let it run for a quarter of an hour (the operation is carried out with the headlights on);
• A voltmeter is used to determine the voltage between the “ground” of the generating device and the “plus” on the battery.

• Failure of all vehicle network devices. Usually, the first thing that happens is that all the lamps in the lighting devices burn out. If this suddenly happened, the relay has failed because the output voltage exceeded the rated values.
• Recharging the battery. Overcharging a galvanic cell is also unacceptable. This can lead to boiling of the electrolyte and subsequent damage to the battery.
• Low charge. As many car enthusiasts say, “undercharging” occurs. A weak battery will not be able to fully ensure reliable engine starting.

Checking an Individual Regulator

Checking the voltage regulator of the G-222 generator: 1 - battery; 2 - voltage regulator; 3 - control lamp.

As a rule, separate voltage regulators were installed on old cars, including domestic VAZs. But some manufacturers continue to do this to this day. The verification process is similar. To do this, you need to have a power supply with a voltage regulator, a 12 V light bulb, a multimeter and a directly tested regulator.

To check, you need to assemble the circuit shown in the figure. The process itself is similar to the one above. In normal condition (at a voltage of 12 V), the light bulb lights up. When the voltage value increases to 14.5 V, it goes out, and when it decreases, it lights up again. If during the process the lamp lights up or goes out at other values, it means that the regulator has failed.

Checking relay type 591.3702-01

Relay test diagram type 591.3702-01

You can also still find a voltage regulator of type 591.3702-01, which was installed on rear-wheel drive VAZs (from VAZ 2101 to VAZ 2107), GAZ and Moskvich. The device is mounted separately and installed on the body. In general, the test is similar to that described above, but the differences are in the contacts used.

In particular, it has two main contacts - “67” and “15”. The first of them is a minus, and the second is a plus. Accordingly, to check it is necessary to assemble the circuit shown in the figure. The verification principle remains the same. In normal condition, at a voltage of 12 V, the light bulb lights up, and when the corresponding value increases to 14.5 V, it goes out. When the value returns to its original value, the light comes on again.

A classic regulator of this type is a device of the PP-380 brand, installed on VAZ 2101 and VAZ 2102 cars. We provide reference data regarding this regulator.

Testing a three-level relay

Regulated power supply

Some car owners install on their cars, instead of standard “chocolate bars,” three-level relays, which are technologically more advanced. Their difference is the presence of three voltage levels at which the battery power is cut off (for example, 13.7 V, 14.2 V and 14.7 V). The appropriate level can be set manually using a special regulator.

Such relays are more reliable and allow flexible adjustment of the cutoff voltage level. As for checking such a regulator, it is completely similar to the procedures described above. Just do not forget about the value that is set on the relay, and accordingly, check it with a multimeter.

Generator check

There is one method by which you can check the performance of a car generator equipped with a regulator relay 591.3702-01 with diagnostic elements. It is as follows:

• disconnect the wires that went to pins 67 and 15 of the voltage regulator;
• connect a light bulb to it (excluding the regulator from the circuit);
• Remove the wire from the positive terminal of the battery.

If, as a result of these actions, the engine does not stall, then we can say that the car’s generator is in order. Otherwise, it is faulty and needs to be checked and replaced.

What to do if the voltage relay fails?

If you are new to electronics, then such an undertaking will be quite difficult.

As we mentioned earlier, the main element of the circuit is a certain number of diodes. Finding three-stage switches for them is quite problematic. In addition, you need to correctly calculate and install radiators for cooling. Otherwise, the risk of diode burnout increases significantly.

During the development of the regulator, long wires will be needed, because the connection is made directly to the device through the cover.

Additionally, you will need to make or find a suitable plastic case for such equipment. All internals must be securely fastened inside the device.

It happens that the relay fails at the most inopportune moment, when you still have a drive home and the battery is not charging. The battery capacity in economical mode can ensure fairly long engine operation, which will allow you to get to the repair site without any problems. Below we will provide a list of recommendations that will help you drive, as they call it, “on battery power” and not stall.

• If the battery is overcharged, the relay must be disconnected from the circuit. To do this, the contact wires are removed from it and left hanging. In the case of the “ten”, it is enough to unplug the plug with the wire from the generator brush connector. Thus, battery charging is turned off, and further movement will no longer harm the battery.

• Many experts suggest going the other way - turning off the generator excitation winding. To do this, remove the corresponding fuse. However, this can be done if you know where the fuse is located.
• If the battery is weakly charged, then there is practically no reason to panic. To get to your destination, you need to maintain high speeds in order to, at least a little, bring the voltage value to the nominal value. Before stopping the engine, it is recommended to maintain the speed at 3000 rpm for a few seconds using the gas pedal. This will prepare the battery for the next start.
• Avoid using music, power windows, headlights (especially high beams), and other electrical devices unless their use is absolutely necessary. This will save battery power well.

Relay regulator VAZ

• disconnect the negative terminal from the battery;
• disconnect the drive block from the terminal marked “D”;
• unscrew the nut, which is located under the rubber boot (it needs to be moved a little to the side);
• disconnect all existing wires in the contact pin;
• unscrew the nut in the generating device circuit (this fastener secures the terminal) and remove it.

Then you will need to remove the generator casing by unscrewing the nuts (there are three of them) that hold it in place, as well as dismantle the relay housing and remove the screw securing the disassembled mechanism from the rectifier compartment. Now the VAZ 2110 voltage regulator can be easily removed. You can install a new device instead. After replacing the relay, all the described steps are performed in the reverse order.

• If the battery is overcharged, the relay must be disconnected from the circuit. To do this, the contact wires are removed from it and left hanging. In the case of the “ten”, it is enough to unplug the plug with the wire from the generator brush connector. Thus, battery charging is turned off, and further movement will no longer harm the battery.
• Many experts suggest going the other way - turning off the generator excitation winding. To do this, remove the corresponding fuse. However, this can be done if you know where the fuse is located.
• If the battery is weakly charged, then there is practically no reason to panic. To get to your destination, you need to maintain high speeds in order to, at least a little, bring the voltage value to the nominal value. Before stopping the engine, it is recommended to maintain the speed at 3000 rpm for a few seconds using the gas pedal. This will prepare the battery for the next start.
• Avoid using music, power windows, headlights (especially high beams), and other electrical devices unless their use is absolutely necessary. This will save battery power well.

Recommendations for increasing the service life of the regulator

In order to increase the service life of the voltage regulator, it is necessary to adhere to several simple rules aimed at implementing preventive measures. Among them:

• do not allow excessive contamination of the generator, periodically inspect its condition, and, if necessary, dismantle and clean the unit;
• check the tension of the alternator belt, tighten it if necessary (either yourself or in a car service);
• monitor the condition of the generator windings, in particular, do not allow them to darken;
• check the contact on the control wire of the relay-regulator, both its quality and the presence of oxidation on it;
• Perform periodic voltage checks on the vehicle battery with the engine running.

With the generator removed

Poor charging of the car can be caused not only by the brushes, but also by the alternator belt. To eliminate this point, when replacing brushes

it should be removed to check the condition of the belt.

First, we dismantle the unit.

1. We unscrew the bolt securing the generator belt.
2. Move the unit towards the engine and remove the belt.
3. Unscrew the tensioner bar and remove it.
4. Disconnect the plug and terminals.
5. We take out the part.

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.

3-level voltage regulator for a standard VAZ 2106 generator

Hi all! What pelvis line has not encountered low onboard voltage? Especially in winter? - That's right, everyone has encountered this problem. Everyone solves this differently. Some people don’t decide at all, some change the brushes, some buy another, more powerful generator for 55A, 73A, 80A instead of the original 42A. By the way, in the future I will also change the gene to 80A or 100A, but that’s not about that now.

Somehow, while delving into the drive, I found one topic where a person raised the issue of installing a 3-level voltage regulator from the front-wheel drive family 2110 - 12 (67.3702-01 Energomash) into a standard generator 2106, but judging by its BZ, so I didn't dare install it. This topic interested me because it is the most budget-friendly option for raising voltage of all, but there is very little information about this on the Internet, or rather there is none at all, I only found a couple of comments and one small diagram.

Actually, I went and bought this device, new brushes for the generator, and scribbled a diagram on my knee with my left hand

and went to install it. According to the diagram (maybe something is clear), it is clear that the polarity of the brushes will have to be changed, and for this they need to be prepared. Where there was ground on the brush, you need to bend the terminal and connect the + from the new regulator to it. You need to connect pin 67 to the male terminal, i.e. old contact, as it was before. Well, of course, we throw away the old chocolate bar, connecting the 67th contact from it with the black wire Ш from the regulator, and the 15th contact with + from the same regulator. Finished brushes

Source

Cost and interchangeability

Built-in relay voltage regulator 71.3702 for generator G-222

The average price for a voltage regulator, both built into the brushes and remote, is about 100 rubles.

Models of generators G-221 and G-222 are interchangeable, that is, you can easily install a new generator from the “seven” for a “penny”, but you should pay attention to the correct charge of the battery. To do this, it is necessary to modify the electrical wiring according to the standard connection diagram.

Depending on the situation, either install an external voltage regulator relay, or, conversely, remove the external one and leave one built into the generator.

The normal voltage in the car's on-board network is considered to be in the range of 13.5-14.5 Volts.

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.

Electric relay device

An automobile charging relay, a photo of which can be found on our Internet portal, contains the following elements:

1. Electromagnetic device - consists of a coil with a metal core that exhibits magnetic properties, and a wire of a certain cross-section that plays the role of a winding.
2. An anchor element is a product made from a special plate that directs the contacts to the desired action, depending on the impulse received from an electromagnetic type coil.
3. Position switch - combines the functions of switching, opening and closing contacts.

When voltage is applied through the electromagnetic winding of the coil, an electric field is created that attracts the armature element to the core, and the pusher, under the influence of the coil current, stirs the armature element, thereby switching the contacts of the “six” charging relay, the price of which is quite reasonable for Russian motorists. The correct connection of the charging relay can be seen in the image below

There are 2 main types of charging regulator relays used on “sixes”. These include:

1. Automotive relay-regulator charging VAZ 2106 non-contact type, having the nomenclature number 121.3702. This is a relatively new electronic device used to complete the power equipment of the Six. The main advantage of this device is its complete autoregulation.
2. The product under the symbol PP-380 with the same functions is installed on the “six” from the beginning of its release from the assembly line. The part is currently discontinued.

These charging relays are interchangeable, and, which is very convenient, without subsequent modifications and adjustments to the VAZ 2106 charging circuit, which is presented below

The VAZ 2106 charging circuit diagram includes a charging lamp relay (RS-702), which serves to receive signals from an indicator lamp on the instrument panel, which shows whether the charge current is flowing to the windings of the generator device and indicates its functionality. This charging lamp relay is located on the right fender liner in the engine compartment.

To check the functionality of the charging relay regulator of the VAZ 2106, you need to turn on the ignition, start the engine and achieve the required number of revolutions (2500-3000 rpm) of the power plant. Next, you should turn off all automotive electrical consumers (except for the ignition), and measure the potential difference at the output contacts of the product. The voltage at the ends should be 14.2 Volts.

If, when the charging relay is connected correctly, a problem is observed with its functionality, then this device should be repaired. To do this, you must have certain skills in electrical engineering and the ability to use an ampere-voltmeter and other measuring instruments and, possibly, a soldering iron. Otherwise, it is necessary to replace this element of the vehicle's electrical system, which can be purchased at a specialized store of automotive spare parts and components. Such a charging relay has a relatively low price, at least quite comparable with other components of the vehicle’s power supply system.

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.

How to determine the malfunction?

If, while warming up the car, you begin to notice strange actions on the dashboard (the voltmeter readings change greatly with minimal engine load or the battery charging light lights up), then this can only mean one thing - the alternator brushes are worn out and need to be replaced.

How to determine a generator malfunction

In some cases, a good warm-up of the engine allows you to “extinguish” the indicator. At the same time, the car drives on the autobahn quite calmly and normally, without any signs of malfunction. But you shouldn’t be such an optimist, because your car may break down at the most inopportune time. Don't forget to check the condition of the alternator winding and belt, although the absence of sparks and smoke suggests that the brushes are the cause of the breakdown.

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.

Replacement result

After replacement, errors may appear about a low battery charge or a malfunction of the generator; there is no need to immediately try to find the cause of the failure. This phenomenon is not uncommon, since new brushes have just begun to break in. What are the causes of Chevrolet Niva generator breakdowns? Chevrolet Niva replacement brushes are soldered to. After some time, everything will return to normal, and you can safely continue to operate the car.

Replacing the VAZ-2107 generator brushes is perfect as a training demonstration for those who do not yet consider themselves specialists, but are just learning the basics of car repair and maintenance. This information can be used not only to repair the “Seven”, but also for other models (VAZ-2110 and 2114). Now let's proceed to a more detailed study of the issue.

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.

Generator brushes - why are they needed?

Quite often (especially in older models) there are cases when, with a sharp increase in driving speed, various seemingly inexplicable things happen: the light of the dashboard or headlights dims, the cigarette lighter and (or) radio work intermittently. Drivers who have not been hardened by many years of experience in the cold lake may mistakenly think about burnt fuses, wiring, or shorted devices. It can take a whole day or more to work through all these versions. But what will be the driver’s surprise when the true cause of the malfunction becomes clear, that the whole essence of the problem is due to some small pieces of black metal called generator brushes.

Generator device

Based on 9th or 8th grade physics lessons, everyone knows that any generator must include two main parts, one of which is movable (rotor), and the second, correspondingly, stationary (stator). Each part has a copper (in most cases) winding. Under the influence of magnetic force, the rotor begins to rotate, powered by electricity through the armature and two other metal parts. And they are called generator brushes. Due to the constant impact of friction, all parts gradually wear out due to the constant rotation of the rotor. This happens in any case, regardless of the quality of the material of the parts (and it is really strong).

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.

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.

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.

Replacing brushes on a VAZ-2107 and other similar models - is there a difference?

To begin with, it is worth clarifying that generator brushes are the parts that require replacement most often. For this reason, developers create special generator designs so that the driver can make the replacement without any problems. The process of their wear is quite long, it depends on the life of the car, as well as on the intensity of the load. When purchasing a used car with a fairly high mileage, you should not wait until the parts wear out and stop functioning fully. It's better to replace it right away. Fortunately, the low cost allows this.

Replacing old parts

People who are far from the structural features of their vehicle may well think that the production of different models at the same plant makes the replacement process the same (we are talking about popular domestic models). To be honest, this guess is correct. One can say even more: almost all models with an internal combustion engine have the same replacement process.

Tip: You can install brushes from VAZ on some Audi or BMW models, and they will function perfectly. The appearance, however, is slightly different with a rougher edging, but this does not affect the operation.

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.

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" - it doesn't matter) 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 of the VAZ 2101 generator has an outdated design - it is mounted in the engine compartment, separately from the brush assembly.

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.

Purpose of the device

The generator voltage depends on the following factors:

1. Rotor speeds.
2. Current load.
3. Magnetic flux values.

A sufficient condition for the generation of electrical energy is the rotation of the rotor of the VAZ 2106 generator in a magnetic field. Magnetic flux crosses the stator windings. AC voltage is generated. The generator diodes rectify the current.

The role of the electromagnet is performed by the excitation winding. It is laid in the grooves of the rotating part. The excitation voltage is supplied to it through the brush assembly. By changing the strength of the current passing through the winding, generation is controlled.

The VAZ 2106 (RR) voltage regulator controls the rotor winding current. The block changes the resistance of the excitation circuit depending on the network voltage level. The generator responds as expected. This way the device returns the generator voltage to normal.

Increased demands are placed on the operation of the control unit. They are determined by working conditions and technical characteristics of consumers. All equipment that is connected to the passenger vehicle network is designed for 12 volts (V). The VAZ voltage regulator must maintain a range from 13.2 to 14.4 V. This gap should not depend on the number of rotor revolutions and ampere load.

The voltage regulator relay should turn on automatically after starting the engine. In addition to its main purpose, the device performs additional functions:

• protects the generator from overloads;
• recharges the battery;
• protects devices from overvoltage.

Proper operation of the PP will protect electrical equipment from overvoltage. Failure to charge will shorten the battery life. Low mains voltage will make it difficult to start a cold engine.

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.