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2024/07/06 11:27:36
Phoenix1151

retrofit non-OEM voltage regulator in portable Powermate generator

OK, looking for guidance from generator guru's. I'm retrofitting a non-OEM 6.5 kw voltage regulator (20240416TT08-4C) to an old 5 kw generator (Powermate PC0545305.01). The original AVR (ICM #AB3101-240) isn't regulating and is an obsolete component (ICM were no help at all in suggesting a replacement). The old AVR used an external capacitor and a diode arrangement (diode bridge ?). The guidance I seek is with the wiring up of the new AVR. I'll give a written description then try to add a photo and schematic I sketched for further clarity.

The new AVR has a red (+ve) and a white (-ve) wire for the brushes, that much is clear. It also has a 4 wire connector with 2 blue, a white and a brown wire. Contrast that with the 5 wires from the generator in two separate connectors, one connector with 2 black wires and the other connector with 3 wires, 2 yellow and a green.

From the 3 wire connector from the generator, each yellow wire goes separately to one side of one of the two diodes whose other sides (+ ?) connect to a common flat metal bar with a green wire leading to the old AVR and another green wire leading to the capacitor. The blue wire goes to one of the brushes, loops to the capacitor then loops to the old AVR.

From the 2 wire connector from the generator, the black wires go to separate terminals on the old AVR.

From what I've seen in my research, the two yellow wires and blue wire appear to come from the excitation winding to provide a DC supply to the old AVR through the external diode bridge & external capacitor.  The new AVR has a large capacitor integral to it so I expect it has the diode bridge internal as well so not sure how to wire the new AVR.  Thanks for any useful reply.

Fire away! Schematic sketch and photo attached.
2 comments Leave a comment
Phoenix1151
OK, I THINK I have this figured out but I welcome confirmation or objection.

The separate red (+) and white wires with spade terminals from the new AVR go the appropriate brush terminals, that much was always expected.

The two blue wires on the new AVR go to one of the yellow wires and the center-tap blue wire from the 3 wire connector.

The white and brown wires from the new AVR go to the two black wires from the 2 wire connector.

In the generator end unit, the metal bar with diodes, the extra yellow wire and the external capacitor can be removed.

The above is based on the attached diagram for another AVR but they should all be similar.
2024/07/07 19:03:10
Phoenix1151
A question regarding the red (+) and white wires from the new AVR for the brushes:

Since they have a specified polarity for brush connection and supposedly supply DC voltage to the brushes, I would have expected to only measure continuity between them with the multimeter in one direction assuming diodes to produce the DC voltage would prevent bi-directional continuity. However, I get "continuity" with the multimeter probes in either polarity! Granted, the readings are 7 Mohms with matching polarity on the probes and 5.4 Mohms in opposite polarity which may affect what constitutes "continuity". Can someone explain this?

My background is in mechanical engineering, not electric/electronic and this is my first stab at trying anything like this.
2024/07/08 13:38:41

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