Most installations that fail to operate from the start are due to some wiring problem or an incompatible alternator. Read the ERROR INDICATOR section below to determine if the regulator identified an error. Then proceed to the Troubleshooting Steps section to isolate and remedy the problem. If the problem cannot be remedied, consult technical support via email: support@amplepower.com.

An ERROR INDICATOR is provided that indicates errors that have been detected by the regulator. Errors are indicated by flash codes ...so many seconds on and so many seconds off. Under normal conditions, the ERROR INDICATOR is off. Seven abnormal conditions are reported by flashing the light at various rates as shown in Table 1, below.

Battery Voltage Runaway: The voltage runaway condition is raised when the battery voltage exceeds (by » 0.5 volt) the desired voltage determined by the regulator. The ERROR INDICATOR will turn on for 6 seconds and off for 3 seconds. This can be caused by other charger sources that do not follow the regulator’s charge sequence (such as shore power battery chargers), in which case it is best to turn the other charge sources off while the regulator is running.

Cannot Turn Off the Field Output: When the regulator cannot turn off the field output, the alternator charges at its maximum rate. Obviously, this can destroy batteries if not corrected. The signal for this condition is easy to determine since it is 1 second on and 1 second off. There are two causes for this error: one, a shorted driver in the regulator, that is, the driver no longer goes off when commanded; and two, the FLD wire is not connected to the alternator’s Field, which is more likely to be the case.

Cannot Turn On the Field Output: When the regulator cannot turn on the field output, it turns off the output drivers and delays for about one minute before attempting to regulate again. It will display an error code of 1 second on and 3 seconds off. The regulator will repeat this procedure indefinitely. There are three main causes for this: one, if there is no power supplied to the power input (B+); two, if the alternator field is shorted to ground; and three, if the field wire is shorted to ground by rubbing through insulation or loosening from the field terminal. The engine should be shut off and the problem solved.

Missing GROUND connection: This error can occur when the GROUND connection is missing or poor.

• Connect the negative probe of a digital voltmeter to only the battery negative. Use a separate long jumper wire if necessary, but do not use any other wires in the system.
• Connect the positive to the locations listed in Table 2.

 

Table 2 Your Voltage Measurements.

			Column A	Column B	Column C
		Connected?	Ignition Off	Ignition On & Engine is not Running	Ignition On & Engine is Running
Row 1	PARALLEL Terminal		o	o	o
Row 2	ON/OFF Terminal		o	o	o
Row 3	GROUND Terminal		o	o	o
Row 4	B+ Terminal		o	o	o
Row 5	FIELD Terminal		o	o	o
Row 6	ALT.GND Terminal		o	o	o
Row 7	LOCK Terminal		o	o	o
Row 8	BAT.VOLTS Terminal		o	o	o
Row 9	T- (BLK) Terminal		o	o	o
Row 10	T+ (RED) Terminal		o	o	o
Row 11	ABS Terminal		o	o	o
Row 12	ERROR LAMP Terminal		o	o	o
Row 13	STATUS LAMP Terminal		o	o	o
Row 14	LIMIT Terminal		o	o	o
Row 15	EQL Terminal		o	o	o
Row 16	House Battery +		o	o	o

 

Second, Analyze the Results.

Table 3, below, contains general information about valid results. Refer to the sub-sections following the table for the descriptions of problems. Check the valid values here in Table 3 against your measurements in Table 2. Place a þ check in the box provided if the value is valid.

Table 3 Valid Voltage Measurements.

		Column A	Column B	Column C
		Ignition Off	Ignition On & Engine is not Running	Ignition On & Engine is Running
Row 1	PARALLEL	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. A if activated.	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. B if activated.	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. C if activated.
Row 2	ON/OFF	0.00 V	Same value as Row 16, Col. B and up to 35 V	Same value as Row 16, Col. C and up to 35 V
Row 3	GROUND	0.00 V	0.00 V to +0.05 V	0.00 V to +0.05 V
Row 4	B+	Same value as Row 16, Col. A	Same value as Row 16, Col. B	Same value as Row 16, Col. C
Row 5	FIELD	0.00 V	Up to 1.5 V less than Row 16, Col. B	Anywhere between 0.00 V and a little less than Row 16, Col. C.
Row 6	ALT.GND	0.00 V	0.00 V ± 0.05 V	0.00 V ± 0.05 V
Row 7	LOCK	Activated: Battery Voltage Not Activated: 0.00 V	Activated: Battery Voltage Not Activated: 0.00 V	Activated: Battery Voltage Not Activated: 0.00 V
Row 8	BAT.VOLTS	Same value as Row 16, Col. A	Same value as Row 16, Col. B	Same value as Row 16, Col. C
Row 9	T- (BLK)	Same value as Row 3, Col. A	Same value as Row 3, Col. B	Same value as Row 3, Col. C
Row 10	T+ (RED)	0.00 V	Sensor Connected: 2.98 V @ 77° F / 25° C ± 0.01V for every ± 1.8° F / 1° C Sensor Not Connected: 4.7 V ± 0.2 V	Sensor Connected: 2.98 V @ 77° F / 25° C ± 0.01V for every ± 1.8° F / 1° C Sensor Not Connected: 4.7 V ± 0.2 V
Row 11	ABS	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. A	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. B	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. B
Row 12	ERROR LAMP	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. A if activated.	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. B if activated.	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. C if activated.
Row 13	STATUS LAMP	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. A if activated.	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. B if activated.	0.00V if de-activated. Up to 0.5 V less than Row 4, Col. C if activated.
Row 14	LIMIT	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. A	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. B	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. B
Row 15	EQL	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. A	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. B	Activated: Battery Voltage Not Activated: Same value as Row 3, Col. B
Row 16	House Battery +	Any voltage that is within the range of your batteries.	Any voltage that is within the range of your batteries.	Any voltage that is within the range of your batteries.

 

Next Check the Alternator Wiring

• To operate properly, the regulator must be connected exactly as shown by the wiring diagram.
• Remove the in-line fuse to the regulator’s B+ tab.
• Test the alternator in place by momentarily connecting the field terminal to the battery positive, after first having removed the quick disconnect terminal to the regulator.
• The alternator should charge at its maximum output. Do not full field the alternator for more than a few seconds.
• If no charging is detected, then turn off the engine. Temporarily connect the regulator’s end of the field wire to the battery positive for P-Type or ground for N-Type. Measure the voltage on the battery. Unplug the field wire from the alternator end. Measure the voltage on the field wire at the alternator end. The voltage should correspond to the voltage on the battery. If there is no voltage then the wire is open-circuit. Check the connector and wire. Also give the connectors a tug to check that they are properly crimped.
• If everything checks out fine then reinsert the regulator’s in-line fuses and proceed below.

Voltages Seem Consistently High or Low

If the temperature sensor is connected, you could be seeing the effect of the temperature compensation. If the voltage between house battery negative and the GROUND terminal on the regulator is more than a few millivolts (say 50 mv) then, there may be a problem with the GROUND wire and/or connection.

Float Voltage Seems High

If the temperature sensor is connected, you could be seeing the effect of the temperature compensation. If the regulator just tripped to float, the batteries may be retaining a residual charge. Simply turn on a small load (about 10 amps such as the engine blower and cabin lights) and the regulator should start regulating.

Tachometer Drive Problems (Oscillates)

Some tachometers operate from a terminal on the alternator. The alternator signal is a half sine wave where its frequency is related to the engine RPM. The magnitude of the tachometer signal is dependent on the amount of current in the alternator field. Output current is also proportional to the field current, resulting in a conflict when field current needs to be low to regulate properly.

When the batteries are fully charged (especially gel batteries), little field current is necessary to maintain the float voltage at a proper level. Under these conditions, the regulator reduces field current to a level consistent with the output demand, so that the batteries will not be overcharged. The regulator is designed to be kind to the batteries first, and kind to the tachometer second. While special software in the regulator attempts to both regulate and still supply enough field current to keep the tachometer operating, the tachometer may still become erratic or even stop. This situation can be avoided by turning on a minimum load of a few Amps such as the running lights. This will load the alternator and result in more field current. (Be sure to turn off the load when it is no longer needed.)

At the end of the absorption cycle the alternator steps down to the float voltage over approximately 5 minutes. The tachometer may "pulse" at the time of the step about every 30 seconds. Do not be alarmed by this, as it is normal after the absorption stage. The minimum load mentioned above will alleviate any tachometer instabilities.

This can also happen when there is improper grounding of the alternator and/or wiring of the regulator’s B+ and GROUND connections. Check that everything is physically wired as specified.

 

Fuses Blow

• If any of the fuses are blown, then there is a short-circuit somewhere and it should be found and corrected.
• If the fuse on the regulator blows twice in a row when the engine is not running, then remove all connections to the regulator except the GROUND and the B+. If the fuse blows again, then the regulator is damaged. If the fuse does not blow then proceed.
• In the following steps, if the fuse blows then the regulator may be damaged. In this order connect ON/OFF, BAT.VOLTS, and FIELD.
• If the fuse only blows when the regulator is properly wired and the field connection is made, then check to make sure that there is a resistance (of 1.2 Ohms or greater) between the field wire and the alternator ground wire, GND.