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A Lucas Alternator and Zener Charging Circuit

The document summarizes the author's tests of a simple charging circuit using a Lucas alternator, solid state rectifier, PRT zener diode, 12AH battery, and loads to simulate electrical components. Key findings include that the zener diode gets too hot at 5A dissipating 80W, the circuit provides between 1-2.5A of charging current to the battery depending on RPM and load, and ripple voltage increases with load. A triple zener configuration performed similarly to the single zener with less heating.

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derryuk
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308 views8 pages

A Lucas Alternator and Zener Charging Circuit

The document summarizes the author's tests of a simple charging circuit using a Lucas alternator, solid state rectifier, PRT zener diode, 12AH battery, and loads to simulate electrical components. Key findings include that the zener diode gets too hot at 5A dissipating 80W, the circuit provides between 1-2.5A of charging current to the battery depending on RPM and load, and ripple voltage increases with load. A triple zener configuration performed similarly to the single zener with less heating.

Uploaded by

derryuk
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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A Lucas Alternator and Zener Charging Circuit

Following on from my stator tests <http://www.scribd.com/doc/111789221/Lucas-Stator-Log-5-pdf> Ive built a simple circuit using a single zener diode so that I can make some measurements on its performance as a motorbike voltage regulator. The circuit consists of my stator test rig incorporating a 2 wire 120W stator (a 47205), a solid state rectifier, a PRT zener, a 12AH battery and a 2 amp load to simulate the ignition system. I also used a couple of digital multimeters and a Picoscope automotive oscilloscope to log the results. I finally added a 60W Halogen bulb to simulate night-time riding.

47205 alternator

Solid state Rectifier

PRT Zener

12AH Battery

2A Load

60W Bulb

I first measured the PRT zener voltage using a variable power supply. I set the PS voltage to 20 (to be above the PRT zener voltage) and increased the PS current from zero. Zener ID PRT Earth Positive 0.25A 14.1v 1A 14.4v 5A 15.8v

Although not measured, the temperature rise by the zener when conducting 5A is considerable. To help offset this I mounted the zener on a steel plate but even so the zener was too hot to touch at 5A (dissipating a nominal 80W.) I then ran tests on the complete circuit and noted the battery current. RPM 800 1500 3000 3000 Load 2A 2A 2A 2A + 60W Battery current -1A 1.8A 2.5A 1A

Here is the Picoscope output.

The flat part of the line represents the battery voltage and the peak (ripple) is from the alternator. Why is there ripple? Alternator voltage climbs from zero, to a maximum and then back down to zero. Because of the diodes in the rectifier, current can only flow from the alternator when its voltage is greater than that in the battery. Below, the red line shows the voltage measured after the rectifier and without a battery, the blue line is the voltage with a battery.

Just above tickover. Some charge is now flowing into the battery so the battery voltage rises in response. If you measured this with your multimeters it would read approximately 13.5V.

At this speed over time the battery voltage will rise to over 15V. This may be an issue depending on your battery type i.e. if it is fully wet then you will need to add water more often. The ripple is about 1V peak to peak. I am guessing but I suspect that at 6000-7000 RPM the voltage would be up to 16.

With the lights on. We still have 1A flowing into the battery and the battery voltage has dropped to a more reasonable level. Notice though that the ripple is now 2V pk-pk, perhaps a sign that we are close to the maximum output of the alternator. Triple Zener I also have a Lucas triple zener and did a quick test on that for comparison. The last line in the table below is the voltage with the three zeners combined. Zener ID Lucas 47266 01 83 Earth Negative 0.25A 14.4v 14.9v 14.6v 14.4v 1A 14.9v 15.2v 15.2v 14.8v 5A 16.8v 17.3v 17.2v 16.0v

The triple zener performance seemed very similar to that of the PRT, the voltage increased similarly but the zeners ran cooler. Review The circuit works but it is not a very good voltage regulator. We really need a system that limits the voltage to around 14.5 max.

Amplified Zener Whilst searching the internet for zener information I came across this circuit. Its a low powered zener combined with a power transistor (20A.)

Zener ID Amplified

Earth Positive

0.25A 14.6v

1A 14.7v

5A 15.2v

For anyone that likes to get their soldering iron out this may be for you. Conveniently the transistors case is connected to its collector which means that for positive earth bikes you dont need to use an insulation kit. You can tweak the output voltage of course by putting a 1N4001 diode in series with the zener. This will lift the output voltage by 0.6V.

Although the 2N6284 is a 20A device this needs to be derated to 10A for this installation and potential temperature rise. It will get hot so needs to be in the fresh air on a substantial heat sink like a normal bike zener. DerryUK October 2012

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