motorherz VR-2200 v.2 User manual

VOLTAGE REGULATOR TESTER
MOTORHERZ VR-2200 v.2
OPERATION MANUAL
VR - 2200 v.2
2018

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CONTENTS
Introduction ...................................................................................................................... 3
1. Description and principle of operation......................................................................... 3
1.1. Application .................................................................................................... 3
1.2. Voltage regulators overview.......................................................................... 3
1.3. Specifications................................................................................................. 5
1.4. Tester design.................................................................................................. 5
2. Device operation........................................................................................................... 8
2.1. Operating limitations..................................................................................... 8
2.2. Pre-operation.................................................................................................. 9
2.3. Preparing the tester to the diodes integrated control 9
2.4. The diodes integrated control ........................................................................ 10
3. Safety measures............................................................................................................ 12
4. Maintenance ................................................................................................................. 12
5. Transportation and storage ........................................................................................... 12
6. Disposal........................................................................................................................ 13
7. Manufacturer warranty................................................................................................. 13
APPENDIX A .................................................................................................................. 13
APPENDIX B................................................................................................................... 14

3
Introduction
This Operation Manual is intended to familiarize the staff and customers with the specifications, design,
principle of operation, terms of service, maintenance, storage and transportation of voltage regulators Tester
MOTORHERZ VR-2200 v.2 (hereinafter – tester), intended for diagnostic troubleshooting of the automotive
vehicles voltage regulators.
Tester meet the requirements of the general safety requirements according to GOST 12.2.091, and fire safety
requirements according to GOST 12.1.004.
Tester belong to the class 1 with regard to protection against electric shock according to GOST 12.2.007.0.
Personnel, admitted to the installation, use, maintenance and repair of the instruments, must be over the age of
18, must study this Operation Manual, be trained in accordance with the correspondent qualification profile and
safety trained with registration in the appropriate journal.
.
During manufacturing, some changes may be introduced to the instrument’s construction that do not influence
the specifications and, therefore, may be not specified in this manual.
1. Description and principle of operation.
1.1. Application.
1.1.1. Tester intended for diagnostic troubleshooting of the voltage regulator in modes A, B, C, D, E, F, which
include:
-Functionality check and stabilization (breakdown) voltage measurement of "A" and "B" type regulators
designed to operate at vehicle system voltage 12V and 24V;
-Functionality check of the "A" and "B" type generators of connection types (terminals): SIG, P-D, DFM,
BSS, LIN, LIN2, RLO, designed to operate at a vehicle system voltage 12V;
- Сheck of drive windings circuit of regulators FIELD at current 0,5А, 3А, 5А, 7A;
- Functionality check of circuit of regulator excitation CHOKE DRIVE;
- Functionality check of diode circuit of regulator excitation FIELD DIODE;
- Functionality check of circuit of regulator lamp alarm LAMP;
- By display demonstration of a short circuit in power circuit of drive windings SHORT BATTERY.
1.2. Voltage regulators overview.
1.2.1. Modern automotive alternators performed usually by using a semiconductor integrated voltage regulator.
Such regulator has small size, it does not overheat, is reliable enough to use.
1.2.2. Regulator maintains the system voltage within predetermined limits in all modes of operation: when
changing the speed of the generator rotor, electrical load and ambient temperature.
Modern regulators types have a digital communication channel with the onboard computer of the vehicle, by
which the alternator feedback is carried out vehicle system, read error codes and the change in voltage of the
alternator can be made on the same data bus.
1.2.3.Despite the variety of design concept, all regulators are working on the same principle. Alternator voltage
is dependent on three factors: its rotor rotational speed, the load current and the magnetic flux generated by the
excitation winding, which depends on the current strength in the winding (figure 1).

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Figure 1.
a) dependence of alternator voltage Ud and current rate Iвat rotor operating speed n in a drive winding;
b) dependence of alternator voltage Ud and current rate Iвat load current Iнin a drive winding.
1.2.4. Any voltage regulator contains:
- receiving alternator voltage sensing element, (usually volt box on a regulator input);
- comparison element, in which alternator voltage is compared with a reference value;
- changing the current in the in a drive winding regulating unit, if an alternator voltage is different from a
reference value.
1.2.5. Potential regulator defect may be:
-contact pollution and contamination; weakening of brushes hold-downs; mechanical and thermal components
damage; short circuit; resistors, diodes and semiconductor chip defects.
a) b)
Figure 2. Voltage regulators.
а) Ford/Magneti-Marelli with terminal FR-SIG-Ab) Mitsubishi/Hitachi with terminal P-D

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1.3. Specifications.
Table 1.
Parameter
Parameter value
1. Tester type
portable, desktop
2. Tester power supply
Alternating-current monophase
network with grounded conductor
2.1. Voltage, V
230±10
2.2. Frequency, Hz
50 ±0.5
3. Rated energy input, W, no more than
100
4. Congestion safety in power supply circuit fusible safety device (2А)
5 . Voltage at output ВATTERY / POSITIVE (+) ,
NEGATIVE (-), V
12/ 24
6. Setting range of the load current in a drive winding
FIELD , А
0,5/ 3,0/ 5,0/ 7,0
7. Setting range of regulator stabilization voltage, V
14/ 15/ 16
8. Relative measurement error of stabilization
(breakdown) voltage
voltage, V
limit, V
12
±0,1
24
±0,2
9. Voltage regulators testing time, s, max
30 (without time connection to the
voltage regulator probes)
10. Interval between integrated control cycles, s, min
60
11. Permissible contact time the tester probes FIELD
with outputs ВATTERY / POSITIVE (+) ,
NEGATIVE (-), s, max
5
12. Continuous operation of the tester, h 8
13. С Ingress protection IP 40, GOST 14254
14 Reliability:
- mean time between failures, h
- average service life, years
2000
10
15. Overall dimensions, mm, no more than
270х160х220
16. Weight kg, no more than
6,5
1.4.Tester design.
1.4.1. The tester has a block structure, in which has mounted electrical equipment containing the following
main components:
- power supply;
- impulse signal generation unit;
- signal processing unit, including analogue digital converter;
- ballast load unit.
- digital microprocessor control unit of analysis of computer regulators outputs with LIN/LIN2 and BSS.
1.4.2. To connect the tester to a monophase mains with voltage 220-240 V there is provided power cord and
plug with grounding contact in accordance with GOST 30849.1.
1.4.3. To connect the tester to checked item there is provided a set switching wires – probes. Tester VR-2200
v.2 set contains: 14 colored laboratory probes for connecting all regulator types.
Additional red cables from output BATTERY POSITIVE (+) are used for connection (+) few points of a tested
regulator at the same time.

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1.4.4. The housing has a sound collected from a bent sheet metal structure. The front part of the housing has a
control panel and display.
1.4.4.1. There is provided a holes on the side walls for ventilating electrical equipment disposed in the housing.
1.4.4.2. All operating tester units are in the internal cavity of the housing. A fusible safety device is mounted
on the rear wall in a special holder.
1.4.4.3. Fusible safety device holder is marked to indicate the rated current and type of fusible safety device.
The holder design eliminates access to parts of the tester, which can be life-threatening, when replacing a
fusible safety device.
1.4.4.4. The temperature of the housing bottom during continuous tester operation is normally not exceed +
60 °C.
1.4.5. A general view of the control panel display is shown in Figure 4.
Figure 3. Control panel display

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Table 2.
Pos.
Control element
marking
Type of
control
Color
Functionality
1
DC VOLTAGE
RANGE
Tumbler
iron-grey
Selection of voltage appropriate of checked
regulator (12V, 24V)
2
A/B FIELD
Tumbler
iron-grey
Selection of regulator checked type Аor В
3
DFM HIGH / DFM
LOW
Tumbler
iron-grey
Mode key of regulator control with output DFM.
4
LAMP
Probes
slot
green
Output of lamp signalling circuit
5
STATOR
white
Output of winding connection
6
FIELD
yellow
Output of drive windings circuit
7
ВATTERY
NEGATIVE (-)
black power supply circuit output NEGATIVE (-)
8
ВATTERY
POSITIVE (+)
red
power supply circuit output POSITIVE (+)
9LAMP
Indicator
red
Indication of functionality of lamp signalling circuit
10 CHOKE DRIVE
Indicator
red
Indication of drive regulator circuit functionality
11
ON/OFF
POWER
Tumbler
iron-grey
Tester power connection ON/OFF
12 FIELD DIODE Indicator
red
Indication of functionality of circuit of drive
windings diode
13 FIELD DIODE Button
yellow
Mode switch of control in drive winding circuit
14 DC VOLTS Digit
al display
red
Digital indication of measured parameter (Volt)
15 FIELD
Indicator
green
Indication drive winding circuit "FIELD" at
current – 0,5 A; 3,0 A; 5,0 А; 7,0 А.
16
SHORT
BATTERY
Indicator red
Indication of short circuit on
outputs POSITIVE and NEGATIVE
18 CHOKE DRIVE Button yellow
Check mode CHOKE DRIVE of active lamp
potential presence in circuit
19
FIELD CURRENT switch red
Adjustment of current value in drive winding
FIELD (0,5А, 3А, 5А)
20
VOLTAGE
CONTROL
SIG/BSS/LIN/RLO
switch green
Parameter set of stabilization voltage ( 13V; 14V;
15V )
21
BSS
Indicators
yellow
Indication of bus connection BSS
22
DFM
blue
Indicator of data output DFM control
23
LIN
green
Indication of bus connection LIN
24
LIN2 green
Indication of bus connection LIN2
25 DFM
Probes
slot
green Input DFM of regulator control
26
BSS/LIN
red Connection of digital bus
BSS/LIN
27 RLO black Input RLO of stabilization voltage control
28
SIG yellow Input
SIG
of voltage control
29 P-D white Terminal P-D of regulator control
30
STATOR 2
blue
Connection output of stator winding phase
31
STATOR 1
green
Connection output of stator winding phase

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Figure 4.
1.4.7. Electrical equipment provides the operator perform the necessary control operations at all steps of
diagnosis voltage regulators.
1.4.7.1. Electrical equipment complies with the GOST 12.2.007.0 requirements, has unit construction,
which is a great advantage for maintenance, repair and modernization of the tester.
1.4.7.2. Insulation between the live parts and the tester housing stands during 1 minute the exposure to the
sinusoidal alternating current of 50 Hz and 1500 V without damage (breakdown).
1.4.7.3. Resistance of the main insulation between the shorted circuits, insulated from the housing, and other
circuits available for touching from the outside and the housing, with the 500 V voltage - not less than 2 MΩ.
1.4.7.4. Electrical equipment of the test bench provides the following lockouts (protection modes) and
indications:
- short-circuit protection;
- short-circuit light indication on terminals BATTERY POSITIVE and NEGATIVE during control check;
- light indication upon contact of output FIELD сterminals BATTERY POSITIVE or NEGATIVE.
Note. The electrical circuit for the test bench is the developer’s intellectual property and is not shared with third
parties. If you have any questions, please contact your nearest Motorherz Equipment sales representative.
2. Device operation.
2.1. Operating limitations.
2.1.1. Tester is designed for indoor use.
2.1.2. Operating conditions: room explosive and fire danger class "G" - no explosion- and fire risk.

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2.1.3. Environment - temperature from plus 10 to plus 40 ° C, humidity (65 ± 20)%, atmosphere pressure (765
± 30) mm Hg.
2.1.4. Tester must be connected only to a single phase circuit with the protective grounding conductor.
2.1.5. Personnel, admitted to the operation of the test bench, must study this Operation Manual, be trained in
accordance with the correspondent qualification profile and safety trained with registration in the appropriate
journal.
2.2. Pre-operation.
2.2.1. Transportation of the tester to the installation site should be carried out in a manufacturer container.
2.2.2. The pre-operation procedure:
- Unpack the tester;
- Check the tester elements, control panel, digital display, power cord.
2.2.3. Do not install the test bench in immediate proximity to thermal devices, avoid exposure to magnetic
fields, steam, smoke, etc.
2.2.4. Do not block the ventilation slots in the side covers of the housing.
2.2.5. Do not place heavy objects on the tester and the power cord.
2.2.6. After storing the tester in a cold room or after transportation in winter conditions, it is allowed switching
the test bench on no earlier than after 3 hours of uncovered stay at room temperature.
2.2.7. Prepare the a dielectric material made lining (pad), on which voltage regulator will be installed during
checkout.
2.3. Preparing the tester to the diodes integrated control
2.3.1. Inspect the voltage regulator before control. If there are clear signs of strain, strong oxidation, melting,
broken outputs - the bridge needs to be replaced or repaired. If the above signs are absent, you can start
checking the voltage regulator.
2.3.2. It is necessary to identify correctly the alternator manufacturer and voltage regulator type. It is possible to
use the manufacturer’s alternators and voltage regulators catalogue with figures иinputs marking (Figure 5).
Figure 5. Terminals of cables and probes

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Symbolic notation of the modern generators voltage regulator outputs are shown in Appendix B.
A vehicle system voltage and avoltage of cut-off stabilization (such voltage has sizable fluctuation for different
diode types) are marked in catalogs.
2.3.3. Usable regulator must have a stabilization voltage corresponding to the specified in paragraph 2.4.3.2.
2.3.4. Сonnect the plug to the AC network 230 ±10 V, which has a grounding conductor. Tumbler POWER
(Figure 4 pos.1 ) must be switched off (position OFF).
2.3.5. Switch tumbler of range voltage of regulator vehicle system DC VOLTAGE RANGE (pos.11) in
position suitable for a tested regulator: 12V, 24V.
2.3.6. Switch tumbler A/B FIELD (pos. 2) of selecting of the testing regulator установите in position Аor
В. Regulator type depends on the polarity of the armature current control. Regulator type data are given in
generator manufacturer catalogs.
2.3.7. Turn on switch FIELD CURRENT (pos.19) on the min current - 0,5А.
2.3.8. Turn on switch SIG/COM/LIN/RLO VOLTAGE KONTROL (pos. 20) on the min voltage - 13 V.
Note. Tumbler in position DFM HIGH / DFM LOW (pos.3) is useful only or checking a regulator with
terminal DFM.
2.3.9. Connect a red probe with panel slot POSITIVE (pos.8), a black probe - with panel slot NEGATIVE
(pos.7).
2.3.10. Connect a yellow probe подключите with slot FIELD (pos. 6).
2.3.11. Connecting of other probes depends on design and codes for voltage regulator terminals.
2.3.12. Connect clips of probes to the correspond marked voltage regulator outputs.
2.3.13. Ensure the secure regulator fixation on a dielectric lining.
2.4. The voltage regulator integrated control.
2.4.1. The integrated control includes 6 modes of tester run (А, B ,C, D, Е, F), that can detect all of the major
regulators defects.
2.4.2. Make preparations for holding the tester control in accordance with article 2.3.
2.4.3. Mode А«Functionality check and measurements of stabilization (breakdown) of regulators of types А
and Вwith vehicle system voltage 12 V, 24 V».
2.4.3.1. Switch a power supply by turning tumbler POWER, from position OFF into position ON blinking
indicator FIELD will switch on иa value voltage stabilization will be shown on display.
2.4.3.2. Usable regulator must have a stabilization voltage corresponding to the specified in a housing or in
cataloges.
Tolerance is no more than 0,1 V for regulators 12 V; - no more than 0,2 V for regulators 24 V.
CAUTION !If there is a short circuit a indicator SHORT BATERY (pos.16). will switch on between
terminals BATTERY POSITIVE and BATTERY NEGATIVE Turn off the POWER of the tester with the
toggle switch immediately. During a contact of probes of terminal FIELD with terminal BATTERY
POSITIVE or BATTERY NEGATIVE (indicator switch on SHORT BATERY), overheating large power
wire ballast resistors will appear in a tester housing. The time of probes contact should not exceed 5 s for the
avoidance of tester crash.
2.4.4. Mode В«Functionality check of regulators of type Аand Вwith connections SIG, P-D, BSS, LIN,
RLO, designed for work at voltage 12 V.
2.4.4.1. Execute the instruction noted articles 2.3.5 – 2.3.10 and connect probes to the slots SIG, P-D,
COM/ LIN, RLO.
2.4.4.2. Turn tumbler vehicle system voltage of regulator DC VOLTAGE RANGE in position 12 V.
2.4.4.3. Connect wires or probes clips to the appropriate marked regulator outputs.
CAUTION !Do not connect outputs STATOR, STA1, STA2, COM/LIN, SIG, P-D with terminals
BATTERY POSITIVE and FIELD in order to avoid tester breakage.