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Exciter voltage, alternator fail? 200 1991

Driving home w/ headlights on last night I noticed my upshift arrow softly flickering - IME an alternator problem. No light in my in-car voltmeter so I hadn't noticed anything amiss. Via the dome light, voltmeter read just < 12V. Usual is ~14V. Battery dead by the time I got home 10 minutes later.

Charged the battery this morning and started. Same thing: < 12V. Alternator-warning light in gauge cluster not working. With car running,

- Grounded excite wire and alt-warning came on (= wire not broken)
- With excite wire removed, put 12V to excite post on alternator. Voltmeter showed ~14V.
- With excite wire back on, test light lit on excite wire but not post. Voltmeter < 12V

1. Replaced the voltage-regular with a used one, voltmerer < 12V
2. Replaced voltage regulator, voltmeter < 12V
3. Replaced unit with used alternator and new voltage regulator, < 12V
4. Pulled a known good alternator from another car, installed it, back to normal ~14V. Alt-warning light now lights when key turned to on.

(History: I'd replaced the alternator ~ 4 months ~2K miles ago with a newish used one because of a bearing squeal.)

OK, so I happened to run into 2 bad alternators - I assume failed diode(s). Why didn't the warning light come on when the car wasn't charging? Why didn't it illuminate when I turned the key to on?

I saw a schematic and notes from Art B (thread below)

https://www.brickboard.com/RWD/volvo/1385621/220/240/260/280/exciter_wire_confirmation.html

..."One particularly obscure trouble comes from the connection to the air conditioning relay. D+ is used there to allow AC only after the alternator is turning for about 10 seconds. Pretty difficult to trace on the maps, but look on the AC page. I think that map Paul linked is for an 85, but the AC worked the same. Here's a catalog of exciter wire connections in this generic view of Volvo 240 charging system. You see depending on year, the ABS, SRS, and A/C make use of that exciter voltage."
--
240 drivers / parts cars - JH, Ohio








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    Exciter voltage, alternator fail? 200 1991

    fwiw and I've posted this before

    I've never had the light come on when the charging was not working.
    Totally discharged the battery on the Hiway due to brushes chewing down to No Brush left we pop Out. NO Light On the Dash

    If you don't have a guage, you will never know.

    The only time I've had a flicker, and stopped and looked, was when the Main Big Red wire to the back of the Alt had pulled partially out of its terminal.

    Yes I had a spare crimp terminal in my box-O-tricks.








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      Exciter voltage, alternator fail? 200 1991

      I was going to say that the light has worked for me but as I thought I couldn't think of any specific examples. So you may be right.

      I've had all warning lights come on when belts broke; and the same thing when the alternator came loose 1-2 times - no lock nut on the pivot bolt.

      I've had the warning lights stay on until after start-up until I revved the motor up - from a bad connection or low battery.

      But, yeah, thinking about it I can't remember the alternator warning light coming on to tell me it wasn't charging.

      Thanks for the comments
      --
      240 drivers / parts cars - JH, Ohio








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        Exciter voltage, alternator fail? 200 1991

        Even without the D+ connection, the alternator in your Volvo 240 should generate power after reaching like 2000-2500-3000 RPM.

        You would use your trusty multimeter to verify:
        - You have continuity of the red exciter wire between the wire end lug secured to the alternator and at the other end on the connection to the back of the dash head.
        - You receive +12VDC at the D+ as the engine starts (or when D+ is to get the alternator excited).

        One fault cause can include broken welds on the dash head circuit board on the idiot light bulb array along the D+ path from the ignition switch. The circuit board uses a foil strips laid on a phenolic board. The welds can break from beating on the dash cap to get the temp gauge working.

        The problem I have now on my 1991 240 sedan.

        Yet my alternator does not charge. A futz here and there. We have 13.9 volts on a cold engine and battery of about 45 degrees Fahrenheit. May suggest a faulty diode or voltage regulator.

        I do not have an ammeter.

        cheers,

        dud.








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          Exciter voltage, alternator fail? 200 1991

          I used to think that too, since the old Delco "SI" alternators would do that, but I recently tried that in a 240 with the instrument cluster removed (so no warning light to provide exciter current) and got no, zero alternator function, even at about 3000RPM. I pigtailed a little 194 bulb into the correct terminals on the cluster wiring harness plug and got immediate charging output.

          So it seems the Bosch units - at least on a 83 240 - do not self-excite.
          --
          Bob: Son's XC70, my 83 240, 89 745 (V8) and XC60. Also '77 MGB and some old motorcycles








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            Rev it to 3K 200 1991

            The problem is, some can while others don't, according to Bosch. The yes or no depends on whether the ferrous material in the rotor was magnetized enough in service to lift the field strength over the charging threshold. Here's what Bosch says about self-excitation and the need for the pre-excitation circuit:

            "Why is pre-excitation necessary in the first place? The reason is that in normal alternators, the residual magnetism (remanence) in the iron core of the excitation winding is not sufficient at the instant of starting or at low engine speed to cause the self-excitation required for building up the magnetic field and thus to generate the required voltage. In the excitation circuit of an alternator there are a power diode (negative diode) and an exciter diode connected in series for each phase. Self-excitation cannot start until the alternator has at least overcome the voltage drop (2 x 0.7V = 1.4V) of these diodes. This is precisely what the pre-excitation current does. With sufficient current consumption of the generator warning lamp, it causes a sufficiently large magnetic field to, so to speak, help the self-excitation to 'get going.'"
            --
            Art Benstein near Baltimore

            It's always darkest before dawn. So if you're going to steal your neighbor's newspaper, that's the time to do it.








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              A read for a winter night on both coast! Right or wrong? 200 1991

              Hi there I am bored tonight and thought I could share my thoughts on your topic about alternators types.

              It's my understanding that there are different types of alternators too.

              The difference being in the way that some get their first "nip" of exciter current delivered from an outside source, like ours, into carbon brushes on slip rings.
              That wee bit of current makes a magnetic field in the (rotating) "rotor" to cut though the outer windings of the stator, that's "stationary."
              Once there is an output from the stator windings, that current is fed back into the rotor, by the voltage/current regulator device, as it monitors the system for "total" voltage fluctuations.
              All excess current flows where needed out on the battery wire. There it can go and be "used" or "absorbed." Hence, battery maintenance is included.

              Then there are those doing it internally.
              I propose they "Picked off" the B+ terminal from the battery. This done inside the alternator, with limiting done inside the alternator and those are termed a "single wire hook up!"
              Most likely without an idiot light being involved on the outside.

              They all have to work the same from that point on out in its generating principles.

              The outcome of how the idiot lights works only depends which type source or its direction, that comes to the bulb. The bulb doesn't care, it just get hot and is a voltage drop or current resistance in our case.

              If the Bulb burns out or wire breaks, whoops!
              Which is why there is a test mode we take for granted.
              Past that, don't trust it! Get a voltmeter!

              It's the Dash Cluster circuity that varies like where certain types of diodes are used and their placements in relation to charging units and provide charging indicator designs.
              An example:
              In older VW clusters, they used a Zener diode for voltage stabilization and a license plate light bulb (encased together in a unit) used like a temperature compensator, to control the gas gauge meter. Heat dissipation varies current flow through the meter.
              Very cheap and effective, but that was the VW Bug! One problem, No bulb to light, no gas gauge either. Sounds familiar!

              Any idiots light designs don't work if there is a small amount of voltage generated in the stator winding.

              The reason is the voltage opposes the flow of current through the bulb and it dims. The lights brightness varies quickly until it's not seen.
              It's like gradually making a poor ground circuit on a light bulb.
              The voltage restricts current just the same as a corroded wire does.

              On other alternators, the light can/could be switch on or off, while lighting a bulb, once it's below or above certain threshold level.
              I do not know if that is done, at all, or within any regulator design or not?
              Never studied or done surgery on a single wire Delco brand alternator or if a cluster system using an idiot light with single wire alternators.

              An example of our battery warning light is like a car with one or both dim headlights.
              We have all seen them on the highway, but we know you do not see them well or do they see with them, very well.

              Same goes for the idiot light but it's subject to reverse interpretation of a working headlight!

              A dim battery light that you cannot really see in daylight or at night, hello!
              It could be burning only slightly, indicating lack of enough charge. So, it might be just maintaining a few amperes and the battery will slowly drain away.

              If you cannot see it, it will not indicate to you whether it's fully charging as well.
              That's why it's been termed, over many automotive years, as an "idiot light" for that very Lack of Reasoning from the bulb or its reader!

              Today's cars are supplied with voltmeters, except those "economy models," that also have only "four lug nuts" on their wheels!

              Over those years, there has been battles over which is better, an ampere meter or a voltmeter.

              Over the years voltmeters have won because, in essence, they are more accurate!

              Their safer than some ammeter circuits and cheaper to design into a vehicle.
              They can be place "almost anywhere" permanently to monitor a systems health.

              Ammeters are directional devices with limited capacity or are shunted in certain locations. Amounts or their readings are mostly ignored just as much!
              Mostly because they suffer rapid fluctuations in order to provide very useful information and in turned is looked upon as, tell me, "IS" it in or out of the battery only?

              A voltmeter works like your coolant temperature gauge.
              That is, it shows when its "normal" with numbers, colored bands or a relative steady Position! But will show is it too low or in rare cases, too high.
              Very much like blood pressure for our bodies!

              I Hope this help explained the frustration of an "idiot" battery condition light in our cars.
              Of course it was an optional dealer item like Coco Mats in the late Seventies!

              Ha ha, as I remember, they looked were made out of Hemp too! Was that Yuppie cars or was it Hippie cars back then?
              That's only my understanding, I am no guru on alternators but I have leaned over a few ugly grills and peered into some strange thinking!

              I am aware though of 2002 Range Rovers using the alternator for a tachometer source.
              Picking a winding diode inside for a DC signal source.

              Talking about the changing clusters in other posts and an alternator ($450 new or $300 rebuilt) being special! The tach is engineered for alternator pulley speeds to be actual engine speed! Crazy?

              No wonder their cars are so expensive! Electrics in those things really suck!

              This on top of a CPS, but theirs is mounted off the front crank pulley. Easier to get too, but their several ignition coils are, you guessed it, on the back of their extra Special modified "Chevy" engine where our CPS is even harder to get to.

              I don't know, is a large flywheel more accurate than a crank pulley with these Sensors or apparently no difference? They both work?


              Phil








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                Does the spectre of Lucas Auto Electrics haunt RWD & Newer Volvos? 200

                I have to ask.

                The quarter-century age, the miles, and such, causing our RWD Volvo electrics of suffering Lucas Electrics on English and other autos.

                And I have this exact same problem on my 1991 240 sedan right now.

                Uncertain of the exciter voltage getting to the alternator. Yet I have a few of the dash head KP position III (or dentent just before engine start or engine run position) lights out, suggesting broken welds on the dash head circuit board.

                If the so

                DO NOT BEAT ON YOUR VOLVO 240-700-900 DASH. You may break solder welds as I have.

                Some of us may beat on the Volvo 240 dash so the gas gauge works. Ha.

                The from the factory, came with the car, Bosch alternator does not charge, and if it does, on a cold day on a cold car, we get 13.9x volts asof a few days ago, where we should get the full 14.5VDC. So, I have a faulty alternator. Diode pack or voltage regulator, I'll bet.

                You may be able to discern a fault by mere electrical pressure (voltage) alone. Though an ammeter can be more useful than the battery charging dash light to extinguish as the alternator takes over from the battery.

                With new-used off a 1995 900 series Volvo, a Bosch alternator, from the local yunk yard, should be good to go.

                The wire harness showed excellent continuity and balanced potential to ground last I checked it in the 1991 240.

                Yet I'll check again as I swap alternators in teh next day or so.

                Did you know a failing throttle position switch on a 1990 Volvo 240 also feels like a fuel delivery system failure. Complete with the bogging and more. So, I'll fix my li'l red 1990 240 DL wagon!

                cheers,

                MacVolvoButtermilk BOYEEEEEEEEEEEEEEEEEEEEEEEEEE.
                --











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                  Does the spectre of Lucas Auto Electrics haunt RWD & Newer Volvos? 200

                  hello sages- would like to clear up the precise definition, purpose and location on the 240 of the so called exciter. have often heard ponderous answers to these questions with nothing definitive. thought exciter in an electrical ciruit meant a device which kick started an electrical flow to a load source where the start up load was high or demanding. old examples would be an electric motor which has to start under load like a swimming pool filter motor which uses a capacitor(momentary start up transformer which delivers higher voltage/amperage to getthe motor going). another would be the old vibrator in tube radios in the 50s. anybody remember how those items in cars and houses would hum for a few seconds when turned on . transistors changed all that. pre 64 auto generators(carbon pile type) would not start charging at idle only at running rpm and needed an exciter. modern alternators have an exciter too but not sure why since they invert to much more efficient alternating current instead of direct current. some old fuds here may remember when car alternators first appeared in1960 they were called alternating current generators. would appreciate your comments on my analysis and errors if any. thanks tons oldduke








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                    Does the spectre of Lucas Auto Electrics haunt RWD & Newer Volvos? 200

                    Well to give an answer and it's only my opinion here!

                    For those Lucas ideas of electrics, one has to be thankful that they stayed on British made cars and motorcycles!
                    They had good intentions but they made things a little more complicated than needed to be and like some other things British, a little to fragile.


                    Your comparison of a capacitor start electric motor to the exciter circuit has some relationships but are there for two slightly different reasons. Even though, both help increase electric magnetic field strength!

                    The capacitors store up electrons and unleash them, into a seperate set of tigher windings, on every cycle of the alternating power coming in on the AC line.
                    This is done to increase torque until the rotor reaches approximately 2/3's of its rated rpm. After that a start only switch drops out that circuit out. There are three ways this is accomplished.
                    It is done either by a centrifugal weight or a relay. The relays can be built to that senses the counter EMF or a drop of current drawn in that start winding circuit of other windings.

                    Today, alternators are the reverse of electric motors in that they produce three pluses of magnetic current per revolution. Diodes pass and block opposing cycles and route them to be Direct Current.

                    The old generators produced only one wave of current per revolution so they had to be made bigger to put out the same amount of current as a alternator. They never got that big!


                    Generators had external current controlling relays. Battery current going into the armature (an alternators rotor) helps create the magnetic field and it's output.

                    Sounds familiar, to an exciter, huh! Both by the way, are called "field" connections? As in magnetic fields!

                    These relays were more mechanical and like the electric motor starting relays. They opened upon current or voltage rise!

                    They were problematic due to that opening or closing, sort of vibrating if you will and like any mechanical switch burned the contacts or wore out of adjustment.

                    Today's voltage regulator only looks at the voltage of the system and controls the exciter current, which in turns controls the output!

                    On our cars the initial exciter current is drawn though out little light bulb and applied to the rotor though brushes.
                    Once that wee bit of current is borrowed and begins to work at producing an output. That output flows pushes against the batteries input.

                    The alternator "idiot" light goes off!
                    Believe me it does not take very much to do that! That's the problem now and was then with generators!
                    Ammeters were the norm because they had relays dealing with current back then so they used those in conjunction of the relay function.

                    Back to the alternator. The rest of the current generated is fed around in the same direction as the initial battery power came into on those very same brushes.
                    When this happens, it now becomes and is called, self-exciting!

                    There are exciter diodes because all current pluses, generated, are Alternating Current pluses.

                    This exciter circuit only deals with making that small amount of current.

                    There are bigger diodes send, the much larger current, out to the system!

                    The voltage regulator is very sensitive to voltage. A tenth of volt in a voltage change moves the amount of "exciter current" quite a bit!
                    The transitors in the VR are not all that big, to make the field strength larger, therefore a large output control is accomplished by wee bits of current change!

                    You have to ask Art Benstein that question!

                    The advantage is....No burning contacts or mechanical relays were used after the late seventies or early eighties, even for alternators used in Volvo's. Thank goodness!

                    I don't think you can even buy a mechanical voltage regulator for anything except for restoration competition purposes?
                    Even then, I would put the solid state one inside that large can!

                    Hope that answered your questions, Old Duke!

                    From, Old Phil!










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                      Does the spectre of Lucas Auto Electrics haunt RWD & Newer Volvos? 200

                      Hiya Uncle Old Phil and Uncle Old Duke and Brickhead Folks,

                      Ooooophs, one of the reason I did not go British (Racing Green). I do like the Triumphs and MGs and Austins with them toque-yy I-6 OHV tractor engines, though. I do like the cars, yet the electrics could be a real bother.

                      Like the I-6 OHV in the mightiest Volvo ever built: The Volvo 164 (with manual transmission)

                      Something like Lucas Electrics auto lighting does more sucking in the dark than making light or something.

                      Anyone ever futz with three phase AC wired to the Wye or Delta and working with large SCADA controlled motors?

                      Gonna put on a spare BOSCH new, a junkyard pull from a 940(?) on the 1991 Made in Sweden 240 today.

                      The TPS (throttle switch) is on order for the 1990 240 DL wagon, made in the now shuttered Halifax Canada Volvo plant, like most of ours.

                      You folks ARE Rock and/or Roll!

                      Long live craft ales and such!

                      cheers,

                      Brick (Volvo 240) Head.







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