Construction
The basic circuit design is similar to that of a modern automotive voltage regulator. All internal solid state components are sized specifically for this application and are designed with a minimum 100% overrated safety factor. The regulator components are assembled onto a printed circuit board which is then housed inside a brass cap, and encapsulated in a high temperature epoxy potting compound which is impervious to water, oil or dirt and insulates the components from vibration. Four clearly labeled and color coded wires with terminals allow for easy and positive electrical connections.
Testing
To date, none of the prototype or production regulators have exhibited any type of failure. Every regulator assembly is individually tested at full and no load conditions prior to shipment.
In developing this regulator, numerous prototype regulators were thoroughly tested in a series of extreme conditions on a test stand, including prolonged overload and over-temperature tests, and every conceivable improperly connected situation was attempted. The only damage to a generator during testing occurred as a result of a 3 hour full load (6 amp) test while maintaining an ambient temperature of 180 degrees F around the generator. The generator failed due to excessive heat, but the regulator was removed and installed on a second unit and worked perfectly.
Prototypes have been running on a variety of machines since May of 2004. All prototypes have performed very well, with no failures to any regulators, generators or batteries as a result of installing this regulator.