Russian Regulators: Part III

Mechanical Relay-Type PP-330

for the
11-Amp Г-424 Alternator

Ernie Franke
[email protected]
 12-Volt Electro-Magnetic (Relay-Type) Regulator
(PP-330) for the Г-424 11-Amp Alternator
• Background
– Voltage Regulators Paired with Specific Generators/Alternators
– Time-Line for Generators/Alternators/Regulators
– Г-424 Alternator Performance
– Specs for the Г-424 Alternator
– Alternator Application in Ural (M-67, -67.3 and “650cc” Series) /
Dnepr (MT-10, -11, and -16) Wiring
• What Is the PP-330?
– External Voltage Regulator for 11-Amp Г-424 Alternator
– Electro-Magnetic (Relay-Type) Design
– Years of Application: 1974 -to- 1992
– Upgraded to 12-Volts from 6-Volt PP-302 Regulator
– Later Superceded by Solid-State (Electronic) 33.3702 Regulator in 1992
• How Does It Work?
– Regulates Alternator Output Voltage to 14-Volts
– Supplies Exciter Current to Vary Magnetic Field in Rotor
– Provides Constant Voltage Regardless of Rotor Speed and Load
• Circuit Description and Operation
• Replacement
– Replacement Purchased On-Line
The Relay-Regulator (PP-330, a.k.a RR-330) was the first
12-Volt regulator used on a Russian motorcycle
(Ural M-67 and Dnepr MT-10).
Types of Generators/Alternators for Ural (Урал) and Dnepr (Днепр)
( (01/10)
[email protected]
Generator/ Motorcycles
Type Vintage Nominal Current Nominal
Alternator Voltage Power Regulator
Ural(IMZ) Dnepr (KMZ)
Г-11 DC 1941-
1941- 6-Volt
Generator 7-Amp 45-
45-Watts PP-
PP-1 M-72 Not Used
(G-
(G-11) 1951 (7-
(7-Volt) PP-
PP-31 (1950)
(P/N: 72181)

Г-11A
11A 1952-
1952- 6-Volt
(G-
(G-11A) DC 1957 (7-
(7-Volt) 7-Amp 45-
45-Watts PP-
PP-31 (1950) M-72, M-
M-72M, M-72, M-
M-72N,
Generator PP-
PP-31A (1956) M-61 early K-
K-750
(P/N: 72181-
72181-A)
K-650, later K-
K-750,
Г-414 DC 1957-
1957- 6-Volt 10-
10-Amp 65-
65-Watts PP-
PP-31A (1956) M-62, M-
M-63, K-750M, MW-
MW-750,
(G-
(G-414) Generator 1974 (7-
(7-Volt) PP-
PP-302 (1963) M-66 MW-
MW-750M, MT-MT-8,
(P/N: 750181) PP-
PP-302A MT-
MT-9, MT-
MT-12

Г-424 Alternator MW-

MW-650, MW-
MW-650M,
(Built-
(Built-in 1974-
1974- 12-
12-Volt 11-
11-Amp 150-
150-Watts PP-
PP-330 M-67, M67.36, MT-
MT-10, MT-
MT-10.36,
(G-
(G-424) (aka 14-
14-A) 33.3702 (1992) IMZ 8.103 Series
(P/N: 3701000) Rectifier) 1998 (14-
(14-Volt) MT-
MT-11, MT-
MT-14, MT-
MT-16

Hitachi IMZ 8.103 and

(Limited Alternator/ 1998-
1998- 12-
12-Volt 18-
18-Amp Internal to 8.107 Not Used
Starter 300-
300-Watts Alternator??
Appearance) 1998.5 (14-
(14-Volt) “650”
650” Series
Alternator
14.3771 (Built-
(Built-in 12-
12-Volt Internal to IMZ 8.103, 8.103X, Not Used
1998.5 35-
35-Amp 500-
500-Watts Alternator
(P/N: 14.3771-
14.3771- Rectifier & (14-
(14-Volt) 8.123, 8.123X
010) Regulator) -2004 (aka 350-
350-W) (YA212A11E) “650 & 750”
750” Series

Nippon Alternator IMZ 8.103, 8.103X,

Denso (Built-
(Built-in 2004-
2004- 12-
12-Volt 55-
55-Amp 770-
770-Watts Internal to 8.123, 8.123X Not Used
Rectifier & present (14-
(14-Volt) Alternator “750”
750” Series
(P/N: IMZ-
IMZ-8.1037-
8.1037- (126000-
18092) Regulator) 126000-0600)
0600)

Notes:
1. Nomenclature: The Cyrillic letter “Г” transliterates (Russian-to-Latin) to “G” or “L” or “T.” Thus we
see Г-414 or G-414 or L-414 or T-414, all for the same part.
2. Cannot use Alternator with discharged battery or without battery.
 Ural (Урал) - Dnepr (Днепр)
Г-11
Generator
Generator/Alternator Time-Line (12/09)
[email protected]
Nippon-
Г-11A 1974 14.3771 Denso
Generator Alternator Alternator
Г-414 Generator Г-424 Alternator

1951 1957 Г-424 1998.5 2004

(M-67, MT-10, MT-
12, MW-750)

Г-414 Г-424
(later K-750) Г-414 Г-424 (M-T-10.36)
Г-11A (M-63, (MW-650)
Г-11A (early K-750) Г-414 K-750M, Г-424
(M-72) (M-62) MW-750) (M-67.36) Г-424 Г-424 14.3771 Nippon-Denso
Г-414 (MT-16) (IMZ 8.103, (IMZ 8.103, (IMZ 8.103,
Г-424 8.107, 8.107, 8.123,
Г-11A Г-11A Г-414 (M-66, (MT-11)
(KMZ M-72) (M-72N) (MT-8) MT-9) “650”) “650 & 750”) “750”)

time
1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005
1950
(M-72 thru M-66, MT-9) 6-Volts 12-Volts (M-67, MT-10 and beyond)

DC Generator Alternator (AC Generator with Built-In Rectifier)

1974

Alternators have progressed in output voltage and power,

from the Г-11 (G-11) generator of 6-Volts/45-Watts in 1941,
the Г-11A in 1952, the Г-414 of 6-Volts/65-Watt in 1957, the Г-424 of
12-Volts/150-Watts in 1974, the 14.3771 of 12-Volts/500-Watts in 1998.5,
to the present-day Nippon-Denso alternator of 12-Volts/770-Watts.
 Alternator Specification: Г-424 (G-424) (1974-1998)
• 12-Volt / 11-Ampere / 150-Watt Alternator (a.k.a. 14-Amp)
• “Full-Time” (Continuous) Current Rating: 11-Amperes
• Alternator Г-424 Used on;
– Ural: M-67, M-67.36, IMZ 8.103 Series
– Dnepr: MW-650, MW-650M, MT-10, MT-10.36, MT-11, MT-14, MT-16
• Used with Mechanical (PP-330) & Solid-State (33.3702) Regulators
• 3-Ø (three-phase), 12-Pole Stator Winding for Smooth Output Voltage
• Built-in Full-Wave Rectifier (MSF-2A)
Ш +
~

The Г-424 alternator surfaced in 1974 on Ural’s M-67 and

Dnepr’s MT-10, as Russian motorcycles migrated to 12-Volts.
 Russian 11-Amp Г-424 Alternator
Current Generated by Alternator versus

Output Current (Amps)

Speed of Rotation of the Alternator
Engine Alternator Motorcycle
(Crankshaft) (Rotor) Speed
Speed Speed (mph/kmph
(mph/kmph))
Idle (900-
(900-to
- 1,000 rpm
1,200 rpm
-to-
to-1,333
10 mph/
16 kmph
14.3771 Alternator
rpm
2,500 rpm 3,333 rpm 25 mph/
40 kmph
3,500 rpm 4,667 rpm 40 mph/ Г-424 (G-424) Alternator
65 kmph

Г-424 alternator
rotor turns Speed of Rotation of Alternator
1.33X crankshaft
Speed of Rotation of Crankshaft
Indicator light may blink when motorcycle Crankshaft speed of Г-424 Alternator
moves at 20 mph (30 km/h) and at the to produce Rated Current (15-to-20 mph)
instance an additional load is connected!

The Г-424 alternator provides rated current (11-Amps) at

2,000 rpm of the crankshaft. Thus for urban driving
(low-speed & traffic lights), the alternator was sufficient to
supply the necessary charging current (prior to electric-start).
 Typical Current Consumption for Г-424 Alternator
• Typical Load Using Standard Lights and Low-Beam
– Running Lights
• Sidecar Front Right (A12-8 or #97): 10-Watt
• Sidecar Rear Right (A12-21-3 or #1156): 21-Watts
– Motorcycle Rear (A12-21-3 or # 1156): 21-Watts
– Speedometer Face (A12-1 or Sylvania 3893): 4-Watts
– Head-Light (A12-45+40 or H6024, 7” sealed): 40/45-Watts (Low/High)
– Ignition System: 18-Watts
– Total Consumption (assuming low-beam): 114-Watts (8.9-Amps)
• Typical Load Using Standard Lights and High-Beam
– High-Beam Indicator Lamp: 4-Watts
– Head-Light (A12-45+40 or H6024, 7” sealed): 45-Watts
– Total Consumption (assuming high-beam): 123-Watts (9.6-Amps)
• Typical Load Using Halogen Head-Light
– Halogen Sealed-beam (low-beam): 55-Watt
– Total Consumption (assuming low-beam): 129-Watts (10.1-Amps)

Clearly, even prior to electric-start, the current demands

are nearly equal to the output capability of the alternator.
PP-330: 12-Volt / 11-Amp Voltage Regulator
Top View Bottom View

Rлр Resistor
(13Ω)
14-V / 11-A

RаResistor
(80Ω) 83/B3/BZ

Ground

Vibration
Isolation

ЛК (LC) ~ Ш Ш ~ ЛК (LC)

The PP-330 utilizes two electro-magnetic relays to maintain

a constant output voltage from the alternator,
and to control a red “alternator fault” indicator light.
 PP-330 Voltage Regulator Application
With one end of the Г-424’
424’s Rotor grounded,
Red Regulator
the regulator must be connected between Master
“Fault”

.
Light the battery and the other end of the rotor. Switch
BЗ (BZ) (not used

.
with
PP-330 Electric-
Electric-Start)
(RR-330)

.
ЛК Ш
Rectifier Diodes to
convert generated AC
(LC) ~ (W)
to battery DC

.
Rotor
Coil
3-Ø
Stator Rotating ~ Fuse

..
Coil Magnetic in
Field + Fuse Block

Г-424 Alternator
. Regulator modulates exciter
current to control the
magnetic field
15-
15-Amp
Ignition
Switch

12-Volt
.+

Battery
-
Slip-
Slip-Ring Connections for
Rotor (exciter) Coil

The PP-330 voltage regulator varies the current

in the rotor coil (terminal Ш) to maintain a constant
output voltage at the “+” terminal.
•PP-330 Regulator Construction Rear Terminal
–Consists of Two Relays; (B3/83/BZ/LV)
–Voltage Relay PH : Maintains Rлр
Resistor
Alternator Voltage within Specified (13 Ω)
Limits (13.5-to-14.5-Volts) Relay Contacts (normally closed) RA Resistor
(80 Ω)
Over/Under-
Over/Under-Voltage
Relay PH PH
Relay Coils
–Lamp Control Relay PВЛ: Controls
Red, Dash-Mounted “Fault Relay Contacts М = Mass
(normally closed)
Indicator Lamp (when (Ground)
extinguished, alternator is
charging properly) Lamp Control
Relay PВЛ PBЛ
–Distinctive Feature of Alternator: Relay Coils
Very Weak Self-Excitation. Only
when Rotor Speed Exceeds
2400 rpm, Alternator Dash
Fully Self-Sufficient. “Fault”
Fault” Light
Until Then, Exciter Winding Ignition (ЛК)
ЛК)
Powered from Battery. Switch
–Caution: Alternator Cannot Stand
Working without Load (breakage or Rotor
disconnection of wires). Current
Open-Loop Voltage Capable
of Destroying Rectifier Г-424
Bridge. Alternator Stator Rotor
Windings (Rotating
–Helpful Hint: If Battery Magnetic
Discharged, Engine can be Started MSF-
MSF-2A Rectifier Field)
by Connecting Small Flashlight
Batteries (4.5-V) "plus" to terminal
W (Ш) and "minus" to Chassis +12-
+12-Volts Battery
Ground.
 PP-330 Voltage Regulator Operation
• Ignition Switch On / Engine Off:
– Current from Battery thru Ignition Switch and Rear Terminal B3 (BZ) of Regulator, to
Normally-Closed Relay PH and Compensating Windings Enters Excitation (Rotor)
Winding
– Caution: If Ignition Off & Engine Not Running, Battery Discharge thru Rotor Winding
May Overheat
• Ignition Switch On / Engine On - Idle:
– As Rotor Speed Increases, Terminal Voltage Increases
– When Voltage Reaches 13.5-to-14.5-Volts, Magnetic Forces Generated in Core
Exceed Armature Spring Tension, Opening Relay Contacts
– Exciter Winding Current Now Flows Thru Two Series Resistors, thereby Reducing
Current and Consequently the Alternator Terminal Voltage
– Electro-magnetic Force Decreases on the Armature and Spring Closes Contacts
– Current Entering Winding Excitation Increases, Increasing the Alternator Terminal
Voltage, thus, Turning On and Off the Charging Current
• Lamp Control Relay - PBЛ
– Connected to Alternator Terminal "~" phase
– When Ignition On
• Current from Battery thru Normally-Closed Relay PBЛ Contacts
• Current Flows to Light “Fault” Indicator
– When Alternator Output Voltage Exceeds Battery Voltage
• Relay Pulls In and Opens Contacts
• Lamp Goes Out

Relay-Regulator PP-330 consists of two relays;

voltage relay PH and lamp control relay PBЛ.
Application of PP-330 Voltage Regulator with Г-424 Alternator
Voltage
Regulator
Fuse
Block
Ignition Switch
”Run” Position Ground
Red
“Alternator Failure”
Indicator Lamp Lamp Control
Over/Under-
Over/Under-Voltage Relay PBЛ
Lamp Control Relay PH
Relay PBЛ
83/B3/BZ

Full-Wave Terminal
3-Phase Control
Rectifier
Ш
~
ЛК Rotor Power (positive)
Terminal
Over/Under-
Over/Under-Voltage (Field)
Relay PH Excitation
Stator
Terminal

Alternator
Terminal Block Battery

Г-424 Alternator
Ural (Урал) M-67 and M-67.36
Turn
Signal

Flasher Unit
Regulator

Foot
Brake-Light
Switch

Ignition Alternator (Г-424) Battery

Switch

Horn
Button
Ignition Coil
(B204)
Horn

Hi/Lo Beam
Switch

Breaker Points
(PM-302/PM-302AA)
 Regulator
(PP-330)

Alternator
(Г-424)

Horn
Button
 Dnepr (Днепр) MT-10 (1974)
Turn
Signal

Flasher
Master
Switch
Battery
(2X 3MT-6)
Foot
Oil-Pressure Brake-Light
Switch Switch

Voltage Regulator
(PP-330)
Neutral Switch

Alternator
Horn (Г-424)

Horn
Button Ignition Coil
(B204)
Breaker
(PM-302/PM-302A)
Dnepr (Днепр) Early MT-11 and MT-16
with PP-330 Regulator, later replaced with 33.3072 (solid-state)

Neutral
Oil-Pressure Foot
Switch
Sensor Brake Light
Switch
Regulator
(PP-330)

Brake

Horn Master
Switch

Battery (2X 3MT-6)

Flasher Ignition
Turn Coil Trouble-Lamp
Signal Socket
Alternator
Breaker (Г-424)
 Migration from the Mechanical (PP-330) to Electronic (33.3702) Regulator

Fuse Block Fuse Block

BЗ (BZ)
1
to to 1
Ignition
Module
2 PP-330 Ignition
Module
2
33.3702
thru 3
(RR-330) thru 3
Kill ЛК Ш Kill ЛК Ш
Switch
4
(LC) ~ (W) Switch
4
(LC) (W) +

2 2
Master Master
3 Switch 3 Switch
(deleted for (deleted for
electric-start) electric-start)

Alternator Ignition Alternator Ignition

Fault Switch Fault Switch ~
Indicator Indicator (not used)
(Dash) (Dash)

+ ~ Ш + ~ Ш
Г-424 (G-424)
Alternator Г-424 (G-424)
Alternator

~ Г-424 - -
+ Terminals + +
Diagram is
Ш useful when '+' (output) goes to the battery
unmarked 6MTS-9 6MTS-9
wires are (12-Volt) or 'W' (field) goes to the regulator (12-Volt) or
removed from 2X 3MT-6 '~' is not used. Used only with 2X 3MT-6
unmarked
terminals! (6-Volts the old electromechanical (6-Volts
each) regulators (PP-330). each)