Review and installation of a three-level voltage regulator on LADA

Lada K alina 2 . CHECKING AND REPLACING THE VOLTAGE REGULATOR ON THE CAR

You will need: a flat-blade screwdriver, 8", 12" wrenches, 7", "8", "24" socket wrenches, a hammer, a DC voltmeter, a megger.

The operation of the voltage regulator is to continuously automatically change the generator excitation current so that the generator voltage is maintained within specified limits when the rotation speed and load current change.

If necessary, you can check and replace the voltage regulator without removing the generator from the car.

Shown is working on a car without air conditioning. On a car with air conditioning, a generator of a different model is installed, and to remove the relay-regulator, the generator must be removed from the car. 1. Move the rubber boot aside and connect the “plus” wire and the “minus” wire to the generator housing.

2. Start the engine and turn on the headlights.

3. After 15 minutes of engine operation at medium speed, measure the voltage; it should be 14.4-15.1 V. If undercharging or overcharging is observed (the voltage does not fall within the specified limits), replace the voltage regulator.

4. The serviceability of the capacitor can be checked with a megger or tester (on a scale of 1-10 MOhm). Connect the tester probes to the capacitor contacts. Before connecting, the device shows infinity. At the moment of connection, the resistance decreases, and then again tends to infinity. In this case, the capacitor is OK.

The faulty capacitor is replaced together with the rectifier unit as follows.

1. Disconnect the wire from the negative terminal of the battery. 2. Disconnect the wiring harness block from the generator terminals.

12. Check the serviceability of the voltage regulator. Connect a 12V test lamp to the brushes. Apply a voltage of 12 V “plus” to the terminal, and “minus” to the “ground” of the brush holder. In this case, the control lamp should light up.

13. Set the voltage to 15-16 V - the lamp should go out. If the lamp is on or off in both cases, then the regulator with brush holder is faulty and needs to be replaced.

14. Install the voltage regulator in the reverse order of removal.

On Kalina cars, the generator is three-phase and produces alternating current. There is no need to go into too much theory; an ordinary motorist only needs to know how to independently diagnose and repair the installation. This means installing the generator and voltage regulator directly. The fact is that at the output of the power windings the voltage jumps in the range of 10-30 V, and to power the entire on-board network you need 12 V. The first step is to rectify the voltage and then stabilize it.

Generator operating principle

To visually visualize the operation of the installation, use the generator connection diagram. The second component of the installation is a voltage regulator, which is included in the power circuit of the rotor winding. The instrument panel contains a charge control lamp that:

Lights up when the ignition is turned on and there is a breakdown in the generator set.
Does not light up in normal mode and when there is a proper charge level.

A relay with normally closed contacts is used to power this lamp. Therefore, when the ignition is turned on, it lights up. Further, as soon as you start the engine, the generator begins to generate voltage. The relay winding is connected to the rotor power circuit; when voltage appears, the contacts switch - they open and the lamp goes out.

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.

Following these simple rules will allow you to increase the resource and service life of both the generator and the vehicle voltage regulator.

Main Generator Components

In general, a generator is a converter that creates electrical energy from mechanical energy. On all cars, the design and operating principle of these devices are similar. The design consists of the following components:

The stator winding, a thick copper wire is used for it, since it is with its help that voltage is generated.
The rotor winding is excitation. Without it, it is impossible for current to appear in the stator winding. In order for any potential difference to appear in the frame, the presence of two components is necessary - rotation and a magnetic field. Thanks to the generator belt on the Kalina, the rotor rotates. It is its winding that fulfills these two conditions - a magnetic field is created around it, and it rotates around its axis.
The rotor is equipped with slip rings, to which voltage is supplied using a brush assembly.
A pulley mounted on the rotor allows rotation to be transmitted from the crankshaft via the generator belt on the Kalina.
A mechanical or electronic voltage regulator changes the voltage on the rotor winding. Due to this, the generator produces a stable voltage.
The block of semiconductors (valves) mentioned earlier is necessary to convert three-phase alternating voltage into unipolar direct voltage.
Covers with bearings are designed for rotor alignment and normal operation of the unit.
The capacitor allows you to get rid of residual alternating current after rectification.

Video about the reasons why the battery on the Lada Kalina does not charge

Welcome! Voltage regulator - it is installed on the generator and is directly connected to it, thanks to it, the entire current that the generator gives out changes and flows more evenly, for example, the more you turn the engine of a car (increase the speed, that is), the generator will work stronger and much more give out current, all this happens because the generator is connected to the engine (namely, it is connected to the crankshaft), but the voltage in the on-board network will also change from this (The more current the generator gives, the stronger this current increases in the entire on-board network car), therefore, when the speed increases, the light will constantly burn stronger, and when it decreases, it will dim because the current strength will decrease, so no matter what happened, a voltage regulator was invented, thanks to which the current strength in the on-board network always remains the same, but it changes when you turn on additional devices that need more current, that is, for example, you turn on the high beam headlights of a car and the current supply increases through the regulator so that there is enough power for these headlights, in addition, the current supply flowing through The regulator is constant and does not jump higher or lower, so the headlights work in the same mode and do not shine either stronger or weaker.

Note! In order to change or check the voltage regulator, you will need: Two different types of screwdrivers, as well as two wrenches that will be “12” in size, and you will also need a DC voltmeter thanks to which you can clearly determine what voltage you have in your on-board network and whether it is jumping, and among electrical appliances, a megohm meter is also useful, thanks to which you can check the regulator’s capacitor for serviceability, thanks to which the current strength remains constant when supplied to the on-board network!

Summary:

Where is the voltage regulator located? It is located on the generator itself, as was already said a little earlier, a plus wire and a wire block are also suitable for it, so that the regulator does not become dirty; for this purpose it is also closed with a plastic cover, in more detail the pin that comes out of the regulator you can look at photo which is located below, in this photo you can just see the same plastic cover that closes the regulator, and in the other photo (Small) you can see that the cover has already been removed and only one pin sticks out, which comes from the regulator (This pin is on both indicated by a red arrow in the pictures).

Read more: Replacing the power steering pump Passat B5

When should you change the voltage regulator? It needs to be changed when it begins to pass alternating current into the on-board network (Alternating current is the current that rises or falls under the condition that the circuit leaves its direction unchanged), in other words, if the current strength fluctuates (And this should not happen), then the regulator must be replaced, if the current fluctuates, for example, the headlights may burn either worse or more intensely (Depending on the engine speed, at high speeds the headlights will burn stronger), and the regulator must also be replaced if it begins to produce either less current than necessary (In this case, you will have an undercharge of the battery), or more (With a stronger current, you may burn out the main part of the wiring in the car that will not withstand the heavy load, or if you have fuses, then at best they will have time to open the circuit and nothing bad will happen to the wiring).

Signs of generator failure

To diagnose the generator set, it is not necessary to remove it. Here are some typical symptoms of breakdowns:

The presence of a hum and whistle from the generator indicates that the bearings are damaged. If you start it, the rotor may jam and the belt may break.
Whistling, short-term ignition of the charging control lamp - the alternator belt on the Lada Kalina is worn out, or it has low tension. If the lamp is constantly on, there may be a break.
If the charging lamp is on, this means that there is no voltage at the generator output. The reason may lie in the windings, voltage regulator, slip rings, diodes, wiring.

Who to buy from?

If you need a new generator for your Lada Kalina car, then the motorist has four options where you can purchase it:

Visit the car market.
Search for the unit among the advertisements of ordinary owners of the Kalina brand car, placed in a newspaper or on the Internet.
Go to the website of an online store selling spare parts for cars.
Visit a store that sells spare parts for Kalina.

It is important to choose reliable suppliers who have all the documents to engage in sales activities. The most economical option would be to buy a used generator at a car dismantling point or as advertised by Kalina car owners. But there is no guarantee that the device will work for a long time.

Actions when charging disappears

The generator on a Kalina with air conditioning has more power than on cars without an air conditioning system. The design and faults are the same. What to do if charging is lost? Don't panic and check immediately:

Voltage regulator. The easiest and most expensive way is to replace it with a known good one. But you can also apply voltage of 12 V and 15 V to check operation. Regardless of whether the regulator is mechanical or electrical, it will behave the same. In the first case, voltage will be supplied to the excitation winding, but in the second - not.
Alternator slip rings and brushes. You can use a simple lamp probe to check the contacts. The length of the brushes must be more than 5 mm, otherwise they should be replaced.
The integrity of the field winding can be checked with a tester. Moreover, there is no need to remove the generator, just crawl up to the slip rings and check the resistance between them. Please note that they should not short to ground.
The condition of the stator winding and diode bridge can be assessed only after dismantling the generator.

What else could it be?

Often, the culprit for charging problems may not be the regulator itself, but its terminals; over time, like many on a car, they oxidize - which prevents the generator from working normally and recharging our battery, so first, before changing this unit, try to clean it, remove oxides and other deposits. By the way, this also applies to the battery terminals; they need to be cleaned and protected at least once a season.

Therefore, first of all, if the multimeter gives you 11 or slightly below 12V at the terminals of the machine, try cleaning the terminals and contacts first, then measure again. It is quite possible that this is the reason.

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How to dismantle the generator

Now we need to tell you how to remove the generator. To do this, proceed according to the following principle:

Disconnect the battery.
Disconnect all wires going to the generator.
Pre-treat threaded connections with penetrating lubricant such as WD-40.
Unscrew the nut from the top mounting of the generator. The bracket can also be removed.
Unscrew the nut from the lower mounting bolt. Hold the bolt head from turning.
Remove the Kalina generator belt from the roller. There is no need to perform any manipulations with the air conditioner and power steering.
Remove the generator from its seat.

Disassembling the device

To disassemble the generator, you need to perform several simple manipulations:

Remove the drive pulley. Try not to lose the key.
Unscrew the nuts from the back cover that secure all parts of the structure.
Remove the voltage regulator. At the same time, evaluate the condition of the brush assembly.
Disconnect all parts of the generator.

After this, you can begin to carry out repairs.

Bearings often fail, especially the one located in the front cover. The reason for this is excessive belt tension. To make a replacement, you need to unscrew four screws and press the bearing out of its seat. Instead, install a new bearing. To increase reliability, change both rollers at once.

If you need to replace the roller or brushes?

When, during operation of the engine, the owner of a Lada Kalina hears a distinct “rustle” coming from the rotating roller of the tension unit, then a detailed inspection of this element will be required and, if necessary, replaced.

To carry out this repair operation, it is recommended to stock up with ordinary keys and a screwdriver with a flat-tipped tip. All replacement procedures do not cause any difficulties, so we act with confidence.

First, we resort to loosening the degree of belt tension. To do this, unscrew the stem.
Using the designated screwdriver, carefully pry up the protective cap of the roller and unscrew the bolt holding the bearing.
From the worn-out roller we remove the bushing together with the washer (they are necessary for installation in conjunction with a new product).
The entire assembly is mounted in its proper place and secured with a bolt.
We tighten the belt and start the engine. We make sure that the new product functions correctly.

One of the factors characterizing weak battery charging is wear on the brushes of the generator set. In order to eliminate this negative aspect, the generator brushes will need to be replaced. To monitor their condition, they will need to be dismantled. Replacing generator brushes is available both on a removed generator set and on one installed on a Lada Kalina car.

In order to achieve safety of work and eliminate the risk of a short circuit in the circuit, before repair work it will be necessary to disconnect the network from the battery (remove the terminals). Now you need to dismantle the protective cover and remove the plug. This can be done conveniently using the previously designated screwdriver.

At the final stage of the process, unscrew the bolts, after which we remove the regulator itself with the brushes present on it. Replacement of generator brushes is complete. Brush wear is assessed by measuring their height. This parameter should not be less than 5 mm. If the brushes are worn out, then replace them and the regulator included.

Installation and repair features

Installation occurs in reverse order. If necessary, the generator is replaced or repaired. In some cases, repair will be impractical, since there are many unusable components, including stator and rotor windings. Restoration will be expensive; it will be much easier to completely replace the generator on Kalina. The cost of a new generator in stores is 4-5 thousand rubles. At "showdown" you can buy it 2-3 times cheaper.

As already mentioned in previous articles, the main malfunctions of the generator are failure of the diode bridge, brushes with a voltage regulator, or even an open circuit in the winding of the device. Below I will give some of the types of diagnostics using a multimeter that anyone can perform independently if they have this device.

Let's sum it up

As it turned out, repairing or replacing the generator in a LADA Kalina car does not require much effort, so such manipulations are accessible even to inexperienced owners; a connection diagram is used to make the task easier. An important point in operation is periodic diagnosis of the condition of both the unit itself and its component elements, including the tension system. Timely prevention will significantly extend the life of the unit, and the owner of LADA Kalina will have considerable savings.

Checking the rectifier unit (diode bridge)

To perform this diagnostic, it is necessary to remove the diode bridge from the Kalina generator; this was described in more detail in previous articles in this section.

Then we connect the tester with the black wire to the negative plate of the block, and the red one in turn to the three contact terminals of the diodes. This way we check all the rectifiers in the block. The values on the device should be in the range from 400 to 800 Ohms. Personally, on my Kalina, during this test, all diodes showed a resistance within 535 Ohms. But the repair instructions from the Third Rome publishing house talk about numbers of 580-620 Ohms. I will say right away that when I rang two serviceable generators, the values specified in the manual were not achieved, although there were no problems with charging, so I personally doubt the accuracy of the data in this instruction.

Then we carry out the same operation, only swapping the contact wires of the multimeter. In this case, the device, with working diodes, will show infinity, that is, its readings will not change:

Approximate prices

In Russia, you can buy a generating device for a Kalina car for approximately the following price:

In the car market - for 4,000-5,000 rubles .
In a specialized store - for 5,000-6,000 rubles .
On the Internet - for 3,500-5,500 rubles .
According to an advertisement in newspapers - for 3,500-4,000 rubles .

Price depending on the newness of the device:

New - from 3,800 to 7,000 rubles .
Used - about 2,000-3,000 rubles .

Cost depending on current strength:

85 A – from 3800 rubles.
90 A – 4000.
100 A – from 4500 rubles.
110 A – 5000.
115 A – from 5500 rubles.
135 A – 6300 rubles.

Checking the serviceability of the voltage regulator with brushes

To do this, you need to connect a 12 Volt light bulb to the two ends of the brushes, and apply 12 Volt voltage to the regulator contacts. If this device is working properly, the light should light up. When the voltage supplied to the regulator increases to 15-16 V, the light should go out.

In case of detected malfunctions in various devices, we replace them. More details about this are written in previous articles from the “Generator” section.