New regulator design

[Len Averyt]

I have been working on the new regulator design
http://www.techknowman.com/Moto/Magna4.pdf Schematic
http://www.techknowman.com/Moto/Magna4-LO.pdf layout in progress.

The layout is just a beginning. i can pack it much tighter maybe even move components to the other side of the board.

This does not include the phase diodes to convert the AC from the generator/alternator to DC. I may make that a separate module or include it on this board.

I'm also looking at a different design based on an entirely different system. Back in the past I developed a AC to DC power supply that took 110-240VAC and converted it to 48VDC at 10Amps. this power supply was 2" square with a 2" square by 1/2" thick heat sink. It used a 8 pin dip PWM current mode regulator and a 100Amp IGBT. This was supposed to be patented by the people we built it for but I think they went under so I may be able to dust of my prototypes and modify it for our needs.

Since thats 480Watts, at 12V it would be 40amps. its efficiency was %84 or so.
I should be able to drop the high voltage parts for parts in line with our needs and save $$$$$

[TLRam1]

Looks good Len. When do you think you will have the first unit completed?

[Sledge Hammer]

Looks promising, Len. Are you going to mount the rectifiers on a separate board, maybe in the airstream?

[hootmon]

I just purchased a regulator from http://www.regulatorrectifier.com which is supposed to be an improved design for reliability and a 8% power output increase.  It is about $115 and has a 6 month warranty.
I am moving my regulator to just behind the right side cover. to hopefully improve the cooling of the regulator. I will attempt to send a picture when I finish.

Hootmon Harry

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[TLRam1]

Did your original go out? What year of bike and what's your mileage?

Keep us posted on your new one.

[hootmon]

When I purchased the '94, the Regulator was bad (Over charging) the bike indicated about 10K miles, but the speedometer cable was broke, so the bike probably had at least another 5K on it. I replaced the regulator with one from Old Bike Barn. That was ~3.5 years ago. The bike now has 50K on the odometer (I obviously fixed the speedo cable) and the regulator just dead (no voltage output).

[hootmon]

Well, I got my new Regulator installed behind the right side cover... I will post some pictures tomorrow... The regulator at 3K RPM puts out 15VDC (Not more than, but right at 15VDC)... Is that acceptable or too high? The battery is near full charge? Looking for some smart guidance here.. Not Smart @ss guidance    ... Thanx

[TLRam1]

I would say it is a tad high but wouldn't say it's too high although I don't have a voltmeter on mine for a history of where they are or if voltage changes due to state of charge. I think normal is 14.5 and lower.

I believe on some auto alternators if the battery is low you will have high amp output and lower voltage, as the battery charges your amps goes down and voltage goes up. This from a 3rd, 4h, 12th party, I can't remember, may just be ol wives tale.

[lragan]

I would say it is a tad high but wouldn't say it's too high although I don't have a voltmeter on mine for a history of where they are or if voltage changes due to state of charge. I think normal is 14.5 and lower.

I believe on some auto alternators if the battery is low you will have high amp output and lower voltage, as the battery charges your amps goes down and voltage goes up. This from a 3rd, 4h, 12th party, I can't remember, may just be ol wives tale.

Terry, you have it about right.  Modern charging systems in cages coddle the battery pretty well.  For optimum coddling, check out "Guy Gadois" reply #77 on page 6 of the "Apparent Regulator Failures" thread.  In particular, see http://www.panasonic.com/industrial/battery/oem/images/pdf/Panasonic_VRLA_ChargingMethods.pdf. 

(I am not sure how we wound up with two threads on this topic with essentially identical posts in each, but here we are!)

[hootmon]

As promised, I have posted pictures of my regulator re-location, but as I made posts in two different treads, please view the other thread for the pictures... Comments welcome...
http://www.magnaownersoftexas.com/forums/index.php?topic=2167.135

[hootmon]

lragan - If I read the information you provided correctly, it looks like there is supposed to be 2.45 volts per cell from the charger and on a 6 cell battery that would be ~ 14.7VDC, so my 15VDC seems to be within reason... Thanx for the info and let me know if you disagree with my interpretation of the data...

[lragan]

hootmon, 15 volts is within reason, but not definitive.  Under the circumstances, it is the best you can do, so I would ride with it.  Don't be surprised, however, when you put in a new battery, if the "full charge" voltage drops a bit.

Lawrence

[Len Averyt]

Still working on the design. trying to pack it down a bit smaller.
The rectifiers will be a seperate module. haven't really picked my favorite there yet.
I'll be doing some testing this weekend using my bike to get some data on ac frequency at normal (5K) rpms and such to find the best cost effective diodes / module to use.

I may still offer a seperate module for an independant 5Amp 12V supply that works only when the engine is running. It would tap the AC lines from the stator and would work independant of the factory regulator. this module will have its own diodes.

[hootmon]

Len;
   Don't know if you will find this helpful or an interesting read, but I posted the following on another thread and didn't see a comment from you, so I don't know if you saw it or not...

OK.. Back on topic here... I found this link where someone was investigating Regulator failures on VFR's...
Some of you electronic byte heads might really enjoy....
http://www.geocities.com/MotorCity/Speedway/6198/reg-rect.html