The Stovebolt Site Forums The Shop Area The Electrical Bay Another VR Sitch

Wow. I just read the subject "Voltage Regulator Cutout Relay" below, and I don't know if I'm CUTOUT for this stuff.

But let me explain my situation anyway, please. Ok, so this VR, or maybe I should say charging system, has operated in this fashion since I purchased and installed the VR a couple of years back, and I don't have much time on the system. I should say also that while it's in my "42", we are dealing with a 12 volt system and my engine is a 1959 235 with ( I think ) that era of generator.

So I'll start the truck up and the ammeter needle generally goes far on the plus side, needle is steady, and slowly works its way back close to the middle. I figure everything's normal, but then the needle will get a little jumpy and then often plunge to around -5 A. I little rev of the engine then results in a slightly negative drop. Turning the lights on when this condition is present will drop the needle to -10/15 A. It will self correct after a while and go to the plus side, and lights will brighten up, etc. Then the process will repeat itself. Around dusk last night I took the cover off of the VR and figured I'd see if I could get some sort of visual indication of what is going on. Well I did. The engine's running, she's charging, and I'm watching the regulator. Suddenly I notice like a tiny fireworks display between the points of the "voltage" regulator. I look at the ammeter and she's discharging. Then the "fireworks" go away and I see she's charging. Then I see that if I press a bit on the plate to hold the points together the lights brighten up and presumably she's charging again.

Alright, so this is simple, right? I should clean the points, set the air gap, and maybe apply a little more spring pressure I think. Or, will there be unintended consequences? Am I missing something (don't answer that ! )?

Here are pics of my (cheapo, I think) regulator.
http://i1293.photobucket.com/albums/b585/Milibolt/Electrical%20systems/IMG_1479_zpsjvviw4oq.jpg
http://i1293.photobucket.com/albums/b585/Milibolt/Electrical%20systems/IMG_1478_zpsuvsxgstp.jpg

Thanks guys.

Tony

Tony,

Which of the sets of points are sparking? Looking at the picture, the one on the left is the cutout, the center is the current regulator and the one on the right is the voltage regulator.

Chad

Chad,

The voltage regulator (on the right).

My regulator that I adjusted was new and I didn't need to clean the points. But, you should be able to use a piece of heavy paper to clean the points. Not supposed to use anything too abrasive or the points might stick.

Chad

Right. Thanks Chad, for your input. I'll give it a go, before I do something goofy

Tony

Use a piece of business card or a slice cut out of a file card to burnish the points. DO NOT use sandpaper (even crocus cloth) as it will leave enough roughness to make the points stick.

The voltage regulator point is directly behind the Field wire connection, and should start to function when the terminal voltage at the battery posts reaches about 14.5-14.7 volts. It sounds like it's adjusted a little on the low side. Monitor the voltage at the battery (not the Bat terminal of the regulator) and slightly increase the spring tension on the VR points until you get a good readout. The battery MUST be fully charged to get a good setting. Be aware that a digital meter IS NOT the best tool for the job. The VR points vibrate several times a second, and they generate enough electrical "noise" that a digital meter can go bonkers- - - -gibberish instead of a steady reading. Use an old-fashioned analog meter with a sweep needle if possible. The voltage setting will drop slightly as the steel cover is put onto the regulator, so adjust it a couple of tenths of a volt higher than you expect you'll need.
Jerry

Hey Jerry. How are you doing?

I cleaned the points with fine grinding compound (like for valves). Got the points smoothed out (a little pitting was too deep) and shiny, then cleaned with electrical contact cleaner. Reinstalled the point until it was just lightly pressing against the spring loaded point. Ran the engine and it seemed like that was the culprit, but maybe I'm a little too high on the amps now.
I've shut it down and have the tender on the battery. I will follow your advice Jerry, and get the battery fully charged and test and adjust as you suggest. Just to get this straight, I adjust the points to obtain the 14.5-14.7 volts at the battery (plus a tenth or two), then button it up ?

Thanks.

Tony

Yes, you can carefully slip the cover back onto the regulator in between adjustments, but be very careful not to short anything out. That cover can definitely make lightning strike if you touch the wrong spot. The center point set is the current regulator, which prevents the generator from overloading itself when recharging a very low battery. It's usually set to 30-35 AMPS, (not volts) by leaving the headlights on for an hour or so, then quickly checking the current output at fast idle immediately after startup. It's also possible to use a carbon pile load tester to put a heavy load on the battery and adjust the current control with the load applied and the engine revved up.
Jerry