ALTRONIC 24VDC Al TERNATOR ENGINE DRIVEN POWER PACKAGES. INSTALLATION INSTRUCTIONS!FORM Al T H 2m DESCRIPTION

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ALTRONIC 24VDC Al

TERNATOR

ENGINE DRIVEN POWER PACKAGES

INSTALLATION INSTRUCTIONS

!FORM Al

T H 2m01

WARNING: DEVIATION FROM THESE INSTALLATION INSTRUCTIONS MAY LEAD TO IMPROPER ENGINE OPERATION WHICH COULD CAUSE PERSONAL INJURY TO OPERATORS OR OTHER NEARBY PERSONNEL

1.0 DESCRIPTION

1.1 The Altmnic 24VDC alternator/regulator packages provide a reliable, engine-mounted source of DC power for Altronic DC-powered digital ignition systems, other Altronic engine accessories and Altronic Controls panels. There are two versions available.

VERSION I -The 590110 series (coupling driven) or 590116 series (belt driven) provide up to 70 watts

(3

amps) output at

1,000 RPM.

VERSION II - The 590111 series (coupling driven) or 590117 series (belt driven) provide direct power for the Altronic CD1, CPU-90 and DISN ignition system thus constituting

a

self-powered, digital ignition system. 1.2 The following components are required:

1. Alternator Unit

2. Regulator (581501 or 581502) 3. Cable Assembly

4. Battery Pack (591100) - used only with Version I series alternators

2.0 Al TERNA TOR UNIT

2.1 COUPLING DRIVEN UNIT: The alternator is available with several flange assemblies to facilitate mounting to most engines having a flange magneto drive. The alternator should be secured to the mounting using 3/8"- i 6 screws; tighten the screws securely.

2.2 BELT DRIVEN UNIT: The alternator must be driven with a pulley having an adjustable 5/8" 1.0. hub. Use a pulley diameter to achieve a speed necessary to satisfy the output requirements of the application - refer to the chart on drawing 509 059A (Version

I)

or 509 060A (Version ii). The alternator should be secured i:o

a

mounting bracket using two 3/8"-16 screws; tighten the screws securely.

2.3

The maximum recommended continuous operating

RPM

for the alternator drive shaft is 2,000

RPM.

3.0 REGULATOR

3.1 Be sure the regulator is the correct model for the alternator being used; the regulator part no. must match that printed on the alternator label.

3.2 Locate a suitable mounting position for the regulator unit within reach of the cable assembly and where the ambient temperature does not exceed 150° F. (65° C.).

3.3 Secure the regulator with four 1/4" screws.

4.0 BATTERY PACK (used only with Version I series alternator and 581501 regulator)

4.1 Locate a suitable mounting position for the battery pack unit within reach of the cable assembly and where the ambient temperature does not exceed 122° F. (50° C.).

4.2 The battery pack is furnished with shock mounts and 1 /4" mounting hardware. Tighten all four nuts securely.

5.0 WIRING HOOKeUP

5.1 Refer to the drawings for mounting dimensions for the various system components: - For alternator dimensions, see drawing 509 056A.

- For regulator dimensions, see drawing 509 057A. - For battery pack dimensions, see drawing 509 058.

5.2 Refer to the diagrams for the proper wiring hook-up for the particular alternator/regulator version being used: - For the Version I system, see drawing 509 059A or 509 063A (shielded system).

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VERSION I VERSION II

PILOT DIAMETER "D" FLANGE

MODEL MODEL ORIENTATION

590110-A 590111-A 3.250/3.248 (82.55/82.50) VERTICAL

590110-D 590111-D 3.000/2.998 <76.20176.15) HORIZONTAL 590110-G 590111-G 3.250/3.248 (82.55/82.50) HORIZONTAL 590110-GV 590111-GV 3.250/3,248 (82.55/82.50) VERTICAL 590116-G 590117-G 3.250/3,248 <82.55/82.50) HORIZONTAL 590110/590111 SERIES ,--, I I I I ~

I

D 2.12

1r

.98

0

(54) <25)

L=c_

~ I I -~ .535 Cl3.6) 590116/590117 SERIES D .6267 <15,92) ~DIA. t.oo I (25.4)----l v c If) _VL t:: _{ALTERNATOR P /N}_c::::==:::J USE ~~iJ~6~ c::::==:::J

MAX. S'rSTEM OUlPUT

JO we, 4 AMP.

lll!tr!.nJ,1u~At.

~ CERTIFIED

(!ti CLASS L GROUP D f7)

DIV. 2 T4 ... ~;~, (165.D NO. OF .44 SLOTS 1 2 2 2 2 / I V

01111

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REVISIONS

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TllLERANCES DESCRIPTION

NO. I DATE AL TRDNIC INC,

1 DE_i~-±.ros ! TITLE

.xx - ±mo INSTALLATION DRAVING 24 VDC ALTERNATOR

IJTP I

=

FULL I DRA'JING NUMBER

!

"-'-

01 _{1509 056A}

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2.25

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(114,3) ,;.;~, (127) (54=7,,, _ "' : : I \)<:'./~==t=-~-11 I L I I

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2.5

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(63,5)

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REGULATOR PART NO. 581501 581502

ALTERNATOR BATTERY REGULATED

APPLICATION

PART NO. PACK VOLTAGE

590110-x

590116-x 591100 27 ±10% BA TIERY CHARGING - SEE NOTE 1 590111-x

590117-x NOT USED 27 ±10% IGNITION POWER - SEE NOTE 2

NOTE:

1. MUST BE USED WITH A BATTERY BACK-UP: A) ALTRONIC BATIERY PACK 591100; OR

B) TWO BATTERIES POWER SONIC MODEL PS-1242 OR EQUIVALENT 12V, 4.0 AMP-HR., WIRED IN SERIES 2. POWER FOR AL TRONIC CD1, CPU-90, DISN SYSTEMS ONLY.

I I

REGULATOR P/Ni:====J USE ONLY w1rn,---i ALTERNATOR L____J

REGULA 1ID OUTPUT -27 \OC

mltr@111~0_1111:.

Gl>RARO, OHIO USA

~~

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NOTE: REGULATOR SHOULD BE MOUNTED IN A LOCATION WHERE MAXIMUM AMBIENT TEMPERATURE DOES NOT EXCEED 150'F. DIMENSIONS IN INCHES AND (MM).

I

REVISIONS

I

TO!E!ANCES

No. I DATE I BY I DESCRIPTION (El'lCa>i M ium:o>

l---'--l---1---1---1~~: !:m ll TITLE

AL TRON IC INC.

VOLTAGE REGULATOR

INSTALLAT10N DRAWING

WTP \SCALE FULL j DRAWING NUMBER DAlE

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ltron"~c®

PART NO. 591 100 BA TT ERV PACK

i='OO: ~WITH ALTeWATOO !?IN GOO 010

AM> ~TOO PIN 681 001

~

CERTIFlED CLASS I GROUP D DlV. 2 T~ i§I i§I I _(209,6). "

0

1.86 (47,2) 9.55 (242,6) 1.86 (47,2) I I I

0

v--+--EP--0

~~~~~~~~~~~~~~~(,";;~)~~~~~~~~~~~~~~~~

NOTE: DIMENSIONS IN INCHES AND (MM).

6.25

(158,8)

NOTE: FOR REPLACEMENT BA TIERIES, USE 2 EA. POWERSONIC MODEL PS-1242 OR EQUIVALENT (12V, 4 AMP-HR).

I

REVISIONS l

I I

_DES_CRIPTl_ON - - - l NO. DATE BY 4-16-93 WTF' ADD CSA 2

PI

I I

I

4.00 (101,6) AL TRON IC INC. BATTERY PACK INSTALLATION DRA'NING

Wl1'

I"""'

FULL

I

PART NUMBER

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~

590110-x 590116-x ALTERNATOR 3-PIN CONNECTOR A - ALT. OUT B - ALT. OUT C - NOT USED _ GROUND

+

24 voe POWER TO AL TRONIC IGNITION AND CONTROLS FUSE (2) RA TING: 10 AMPS 581501 VOLTAGE REGULATOR 6-PIN CONNECTOR A - +24 VOLT OUTPUT B - GROUND C - + BATIERY D - NOT USED E - ALT. INPUT F - ALT. INPUT AMPS @ 24VDC 591100 BATTERY PACK BATTERY + BATTERY -5 4 3 2 0

+-VERSION I

+-

-+-RANGE OF µPtRATibN

+-500 1000 ALTERNATOR RPM 1500 2000 MAX. RPM TOLERANCES (EXCEPT AS NOTID) DECIMAL .xxx - ±.005 .xx - ±.010 TITLE

AL TRONIC INC.

24 VDC SYSTEM - VERSION I INSTALLATION DRAWING

REVISION

s

FRACTIONAL DRAWN BY WTP SCALE NONE DRAl'l1NG NUMBER

CHECKED BY DATE

NO. DATE BY DESCRIPTION MAITRIAL 2-1-01

509 059A

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t

590111-x 590117-x ALTERNATOR 3-PIN CONNECTOR A - ALT. OUT B - ALT. OUT C - NOT USED 581502 VOLTAGE REGULATOR 6-PIN CONNECTOR A - +24 VOLT OUTPUT B - GROUND C - NOT USED D - NOT USED E - ALT. INPUT F - ALT. INPUT ~---NOT USED

VERSION II

APPLICATION: CD1, CPU-90, DISN

NO. CYLINDERS CYCLE MIN. ALTERNATOR _{DRIVE RATIO}

*

ENGINE RPM

MIN. 4 OR LESS 2 1: 1 60 8 OR LESS 2 2: 1 30 10 OR LESS 2 2.5: 1 25 16 OR LESS 2 3: 1 25 8 OR LESS 4 1:1 60 10 OR LESS 4 1.25: 1 50 16 OR LESS 4 1.5: 1 50

*

ALTERNATOR RPM : ENGINE RPM. RATIO LISTED IS MINIMUM TO ACHIEVE PROPER OPERATION OF CD1, DISN AND CPU-90 MODEL -100; CONTACT FACTORY FOR CPU-90 MODELS -150 AND -200.

MAX. 1,800 900 750 600 1,800 1,500 1,200 _ GROUND

+

24 VDC POWER TO AL TRON IC CPU-90, DISN IGNITION TOLERANCES {EXCEPT AS NOTED) DECIMAL r=---~~ _REVISIONS

...

---~ .xxx - ±.005 .xx - ±.010 NO. DATE BY TITLE

AL TRONIC INC.

24 VDC SYSTEM - VERSION II INSTALLATION DRAWING

DRA\\N BY WTP SCALE NONE DRAWING NUMBER

MATERIAL CHECKEDBY OATE 2-13-01

509 060A

1 APPROVED BY

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590110-x 590116-x ALTERNATOR 3-PIN CONNECTOR TO IGNITION CONTROLS 30 VDC MAX. 4 AMPS MAX. FUSE (2) RA TING: 10 AMPS 6-PIN CONNECTOR A - +24 VOLT OUTPUT 8 - GROUND C - + BATTERY D - NOT USED E - ALT. INPUT

F - ALT. INPUT AMPS

@ 24VDC 591100 BATTERY PACK 5 4 3 2 0

+-500

VERSION I

+-1000 ALTERNATOR RPM

+-

+--... RANGE OF

~PERATION

+--1500 2000 MAX. RPM TOLERANCES

(EXCEPT l\S NOTED)

AL TRON IC INC.

.xxx ~ ±.oos I Tl TLE .xx - ±.010

24 VDC SHIELDED SYSTIEM - VERSION

INSTALLATION DRAWING

REVISIONS FRACllONAL ORA"" BY WTP SCALE NONE DRA'MNG NUMBER

CHECKED BY DA TE

NO. DATE BY DESCRIPTION MATERIAL 2-1-01

509 063A

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581502 / _{VOLTAGE REGULATOR} /

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CABLE - ~

VERSION II

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593027

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CABLE _APPLICATION: _{CD1, CPU-90, DISN}

593058

~

6-PIN CONNECTOR _{NO. CYLINDERS} _CYCLE MIN. ALTERNATOR ENGINE RPM

A - +24 VOLT OUTPUT DRIVE RATIO

*

MIN. MAX.

'

/ B - GROUND _{4 OR LESS} ₂ _{1: 1} ₆₀ _1,800 '-

rFii

/ C - NOT USED

-

._... 8 OR LESS 2 2: 1 30 900 D - NOT USED

E - ALT. INPUT _{10 OR LESS} ₂ _2.5:1 ₂₅ ₇₅₀

3-PIN CONNECTOR F - ALT. INPUT _{16 OR LESS} ₂ _3:1 ₂₅ ₆₀₀

A - ALT. OUT _{8 OR LESS} ₄ _1:1 ₆₀ _1,800

B - ALT. OUT

C - NOT USED 10 OR LESS 4 1.25: 1 50 1,500

CSA CERTIFIED 16 OR LESS 4 1.5: 1 50 1,200

..--I

I JUNCTION BOX I II

*

AL TERNA TOR RPM ENGINE RPM. RATIO LISTED IS MINIMUM TO ACHIEVE

A 8 PROPER OPERATIOI~ OF CD1. DISN AND CPU-90 MODEL -100; CONTACT

~

FACTORY FOR CPU-90 MODELS -150 AND -200.

1

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B c 0

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CSA CERTIFIED CONDUIT

TO IGNITION CONTROLS TOLERANCES

ALTRONIC INC.

30 voe MAX. (EXCEPT AS NOTED)

4 AMPS MAX.

DECIMAL _TITLE

24 voe SHIELDED SYSTEM - VERSION II

.xxx - ±.005

REVISIONS .xx - ±.010 INSTALLATION DRAWING

FRACTIONAL

ORA~ BY SCALE

NO. DATE BY DESCRIPTION WTP NONE DRA~NG NUMBER

1 MA1ERIAL CHECKED BY DATE 2 13 01

509

064A