323001234 - 5530 CURRENT GENERATION
ALTERNATOR
COMPOSITION
The alternator is a rotary machine that transforms mechanical energy into electrical energy.1 - Rotor electromagnetic circuit2 - Fitting rods3 - Rectifier side mount4 - Negative heat dissipation plate5 - Positive heat dissipation plate6 - Zener type power press-fit diode7 - Manifold8 - Regulation unit9 - Heat shield cap10 - Rectifier side bearing11 - Rectifier side inner fan12 - Stator electronic circuit13 - Control side mount14 - Control side inner fan15 - Control side bearingAs with all electrical machines, it is made up of two basic parts: inductor (rotor) and field winding (stator).The rotor for an alternator with internal ventilation is illustrated in the diagram below.Rotor
The rotor consists of a cylindrical magnetic core, concentric to the drive shaft, with a toroidal coil winding and two opposing magnetic impellers which are magnetized by the winding located in the actual core.The impellers have six claw-shaped poles that fit between one another to produce six North poles and six South poles in alternation. The result is a single rotor winding which produces the e.m.f. for all the partial magnetic circuits.Stator
The following diagram shows the stator.1 - Star connection stator2 - Triangle connection statorThe stator consists of a ring shaped pack joined by two or more axial seams electrically welded on the outer part. It is normally equipped with thirty-six grooves which contain a three-phase winding made from copper wire insulated with vinyl acetate and connected, as necessary, in a star or triangle formation.Rectifier bridge
The rectifier bridge is illustrated in the diagram.1 - Zener type power diode2 - Dissipation plate3 - Terminal B + alternatorBridge specifications
The bridge consists of:
- Zener press-fit diodes.
- Diodes press-fitted in the dissipator plates and electrically welded to the terminals for connection to the phases.
- Sheared dissipator plates.
- Large dimension dissipators.
- Phase insulation until the connection with the bridge via a rubber cable duct.
- Limitation of excess voltage in the case of "+ battery" load disconnection, guaranteed by zener diodes.
1 - Normal diode2 - Zener diodeZener diodes
The characteristic of both diodes, if polarized directly, is that they pass the current from the anode to the cathode (V+ I+): then a zener diode behaves like a normal silicon diode.If inversely polarized, the current does not initially pass from the cathode to the anode up to value VZBeyond value VZ the normal diode is destroyed; the zener diode, on the other hand, continues to operate normally because its resistance in these conditions decreases sharply. Zener diodes are therefore voltage stabilizer diodes. Voltages of between 4.7 and 24 Volts are used in cars. It is one of the most important components in the regulator unit.It is often used for protection against polarity inversion or as protection against excess voltage.SPECIFICATIONS OF INTERNAL VENTILATION ALTERNATORS
The main feature of this type of alternator, with a 115 mm stator diameter, is having dual internal ventilation with the vanes at an angle to guarantee the maximum flow of air and limit noise at the same time.For the same power output, alternators with internal ventilation are smaller and lighter than types with external ventilation, thereby satisfying current application requirements (there is always less space in engine compartments). In addition to this, in terms of quality, reliability and durability, these alternators meet higher standards than the best competition currently on the market.In-depth studies and research have made it possible to introduce measures in production to reduce noise limits produced by various components (fluid dynamics, magnetics, mechanics).Typical voltage curve
The graph below illustrates a typical regulator voltage curve.Technical data
The types of alternator adopted on this vehicle are summarized in the table.| - | 1.4 8v | 1.4 16v TJET | 1.3 Multijet | 1.3 Multijet MTA |
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| Voltage (V) | 14 | 14 | 14 | 14 |
| Rated current (A) | 7090 (*) | 120 | 7590 (*) | 90105 (*) |
| Resistance of inductor winding between the two slip rings at 20°C (Ohm) | 2.66 ÷ 2.94 | 2.47 ÷ 2.73 | 3.122.27 (*) | 2.66 ÷ 2.94 |
| Voltage regulator (type) | RTM 151C | RTM 200.01 | CP LOW END 6000 | RTM 151CCP LOW END 6000 (*) |
| Regulation voltage at 20 °C (V) | 14.05 ÷ 14.35 | 14.05 ÷ 14.35 | 14.05 ÷ 14.35 | 14.05 ÷ 14.35 |
 | (*) For versions with air conditioning. |
BATTERY
SPECIFICATIONS
The main characteristics of the batteries used on new models are the active material support plates produced thanks to the calcium lead production technology that has replaced the older antimony lead one.This involves a mechanical stretching process with a continuous lead band resulting in the final production of the grid spread with lead oxide for the positives and metallic lead only for the negatives, rather than the use of casting machines for producing grids through fusion.The use of materials such as lead-calcium-tin alloy guarantees a considerable reduction of the phenomenon of electrolysis in the operation of the accumulator (dissociation of the water into its hydrogen and oxygen components) and the quality of the gases that can escape, thereby causing less evaporation of the actual water with a consequent drastic reduction in the maintenance required for this type of battery.1 - Cover2 - Plug lip3 - Positive plate4 - Negative plate5 - Envelope separator6 - Bridges7 - Electrolyte8 - Water gauge9 - Negative pole10 - Monobloc11 - Maximum electrolyte level12 - Minimum electrolyte level13 - PlugBattery electrical specifications
Reduced maintenance lead accumulator with acid.Cover: EURODIN, fitted with closing devices on ramp type cover; pressure plugs (one plug per element) with system to prevent penetration of fluids from the outside. Gas evacuation through plugs equipped with gas/liquid separation system.Cover sealing: thermowelding.Attachment to the base: standardized on four sides.Poles: lead bushes produced by cold pressing with seal in the pressing area on the cover.Electrolyte level check: via the openings in the cover plugs, checking the coherence between the indicator (dipstick) and the level of the electrolyte. The dipstick indicates the maximum permitted level, therefore the electrolyte should barely come into contact with the lower end of the dipstick. The minimum level is reached when the electrolyte exceeds the top of the separators and/or the plates by 10 mm.Water gauge for checking minimum electrolyte level and battery charge.No. of plates: 6 positive + 5 negative.Grid alloy: lead-calcium-tin.Separator thickness: 1.15 mm.Plate thickness: positive 1.80 mm; negative 1.60.Electrolyte density: 1280 ± 10 g/dm3 at 25°C with battery 100% charged.Electrolyte density at 25° Celsius:
- 1280 g/litre 100 % charged
- 1240 g/litre 75 % charged
- 1200 g/litre 50 % charged
- 1160 g/litre 25 % charged
- 1120 g/litre run down
- 1110 g/litre completely run down.
CONTROL SYSTEM
The battery is fitted with a gauge for checking charge level: this water gauge monitors electrolyte level (at least qualitatively) and battery charge status.This device comprises a transparent plexiglas cylinder: one end contains a gauge fastened to the cover of the battery; at the other end there is a drip tray, made from an acid-resistant material, drilled to allow contact between the battery electrolyte and a green coloured ball, housed in the drip tray, that can slide along a plane tilted towards the centre of the cylinder.The colour of the gauge provides information on the state of the battery charge as summarized in the table below: | CONDITION 3 | CONDITION 2 | CONDITION 1 |
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| Information visible | Light, bright colour | Dark colour without green area in the middle | Dark colour with green area in the middle |
| Electrolyte level | Below minimum | Correct | Correct |
| Charge status | Indefinite | Battery run down | between 55% and 100% |
| Action to be taken | Top up electrolyte with distilled water | Recharge battery | No action |
This device:
- does not provide information concerning any possible internal short circuits;
- the density of the electrolyte varies with the temperature;
- if the vehicle is stationary for a prolonged period this could have halted the mixing process of the reagents and therefore the measurement might only refer to the surface layers;
- if the electrolyte level is low, the readings are not reliable.
In conclusion, the measurement is accurate to within 15% (charge status gauge reading = 70% ± 15%).On account of this degree of error in the reading, the battery charge should be checked more accurately at the Service Centre.Plug
In reduced maintenance type batteries with lead-calcium-tin elements the seal is guaranteed by pressure plugs with an anti-penetration system and a device that evacuates gases through the actual plugs.The plug allows the escape of gases produced in the battery, but prevents the loss of liquid. The plug consists of:
- The plug body: this acts primarily as an obstacle to the liquids, but allows the escape of gases via special openings.
- The labyrinth: prevents the particles that are released during the operation of the battery from blocking the special diaphragm.
- The semi-permeable diaphragm: thanks to a special PTFE layer (polytetrafluoroethylene), this prevents the escape of the liquid but allows the gases that are produced during the normal operation of the battery to pass through.
1 - Plug body2 - Labyrinth3 - MembraneBATTERY TECHNICAL SPECIFICATIONS
The main technical data for the battery is summarized in the table.| BATTERY | 1.4 8v | 1.4 16v TJET | 1.3 Multijet |
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| Voltage (V) | 12 | 12 | 12 |
| Capacity / Intensity | 40 Ah / 200 A50 Ah / 250 A (*)50 Ah / 350 A (**) | 50 Ah / 250 A | 50 Ah / 250 A60 Ah / 380 A (**) |
| (*) For versions with air conditioning.(**) For "cold country" specification |
BATTERY DISCHARGE AT REST
During the design stage, the correct dimensions of the battery for every model/trim level also take into account the absorption from loads when the ignition is switched off.These absorptions should not exceed 0.6 mA for every Ah of battery capacity; this is to guarantee that, after the vehicle has been stationary for a month with all the loads that are not ignition-dependent on, the residual capacity of the battery is half of the rated capacity, corresponding to a charge status that can guarantee starting in normal ambient temperature conditions.The table below contains several examples.| Battery | Max. absorption |
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| 40 Ah | 24 mA |
| 50 Ah | 30 mA |
| 60 Ah | 36 mA |
Battery fluid level check/top up
Undo the plugs on the battery cover, or remove plug cover (2), and release the plugs which are press-fit in each individual cell.In the max level condition (11) the electrolyte should barely come into contact with the lower end of dipstick (3) located inside the battery and visible via the openings in the cover for each cell, producing the so-called meniscus effect.In the min level condition (12) the electrolyte should exceed the top end of the separators and/or the plates by about 10 mm.1 - Cover2 - Plug lip11 - Maximum electrolyte level12 - Minimum electrolyte level13 - Dipstick14 - PlugTo check this condition, the clean stick made from a non metallic material (e.g. wood, glass, plastic) should be immersed in the electrolyte until it touches the top of the separators and/or th| ... DATA ERROR - CROPPED TEXT | Ошибка данных - Текст обрезан ... |
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