CDI rect/reg. woes

[andy6374]

In previous post I discussed how I recently installed a new CDI 9 amp stator. I noticed that my batteries were charging at 16-17 volts at idle and 18+ volts at WOT. I replaced the rectifier (no need for a regulator as it is a 9 amp stator) but this didn't help.<br /><br />I finally installed a CDI rect/reg # 194-5279, per the advice of people on this forum and the engineers at CDI/Rapair. It controls the voltage at idle very very well. But at WOT I am still getting 16.5 volts (sometimes it will go down to 15.5) but for 95% of the time it is charging at 16.5 volts. This an improvement over 18+ but still not what I am looking for. I thought this would have solved my problem. Thoughts??<br /><br />-Could it be that my batteries are brand new.<br />-Should I just charge both batteries, instead of one. But I shouldn't have to. It isn't regulating enough, like it should, right?<br /><br />-andy

 

[ronmold]

Re: CDI rect/reg. woes

dumb question, how did you hook it up and what are you using for a volt meter?

 

[andy6374]

Re: CDI rect/reg. woes

Well... stator yellow to the rect/reg yellow (both of them), tach gry to the rect/reg gry, red from starting solenoid to red rect/reg. I had one extra red which I tapped out per the instructions that came with the rect/reg.<br /><br />I had three indenpendent sources for voltage measurement. 1.) my volt gauge, 2.) my fishfinder. 3.) my digital multimeter.<br /><br />-andy

 

[andy6374]

Re: CDI rect/reg. woes

I meant to say taped off, not tapped out...

 

[dakk1]

Re: CDI rect/reg. woes

Would a voltage reducer solve your problem?<br /><br />Dave..

 

[andy6374]

Re: CDI rect/reg. woes

Well, the voltage regulator in theory should reduce the voltage if it is too high. That's its purpose.<br /><br />Question still remains, why is it overcharging. Could it be bad stator windings?<br /><br />-andy

 

[dakk1]

Re: CDI rect/reg. woes

Yes, as you say, in theory. But, problem remains. So, to protect your expensive electronics, a voltage reducer would be installed between your battery and electronics. Just a thought. May not be suitable for your application. I have the same stator as you but since I'm in the middle of a rebuild, I have bigger fish to fry, so to speak. I may be dealing with the same issues at a later date. Good luck. <br /><br />Dave..

 

[ronmold]

Re: CDI rect/reg. woes

That CDI unit IS a voltage reducer! It sounds defective, the electronics inside should never let the voltage above 14.3. Above idle my volt gauge never moves except when I use the power trim then it goes back to 14. Did it work good at first and then fail? Does it have a good ground?

 

[andy6374]

Re: CDI rect/reg. woes

I installed as you have...Aluminum plate<br />(4" x 4" x 5/16") mounted to powerhead and rect/reg mounted to aluminum plate. This should be as good of a ground as any.<br /><br />It has never worked at higher speeds, or at least the first and last time I tried. It works at idle speeds.<br /><br />I have tried contacting CDI/Rapair and they haven't responded yet.<br /><br />(Maybe it is the stator windings that have the problem. The CDI stator is only a 9amp stator, ie I shouldn't even need a voltage regulator.)Lets not concentrate on this idea.<br /><br />-andy

 

[Laddies]

Re: CDI rect/reg. woes

Andy, I think thet one red wire is a sennsor wire and the other is a charge wire for the regulator so try to hook it to a 12 volt source and see if that helps

 

[andy6374]

Re: CDI rect/reg. woes

Laddies-<br />Of the two red wires, one is 12 gauge while the other is 18 gauge. So the 12 gauge wire is the one that runs to the starting solenoid and then to my battery. And you are suggesting (if I understand) that the other red wire is a sensor or 12v source. If it is a source you are thinking that if I somehow use it, it could help lower the voltage. Not a bad idea...but surely unnecessary, as I have no need to give power to anything at the engine or only when the engine is running.<br /><br />I heard from CDI and they told me it is one of three things (actually four). Either I am getting a bad reading (which I'm not since three different measurements yielded the same result), a grounding problem, or a battery problem. Or I could send back the rect/reg and they would verify the 14.2 regulation point.<br /><br />They said that die hard marine deep cycle batteries are not true Marine Acid deep cycle batteries and that they have thin plates. This a problem if it has a losse plate in it, it will act like a bad ground.<br /><br />They also recommended Checking the yellow wires from the stator for a grounded connection (what does that mean, no continunity) and to Check the actual current output on your system to the battery while the engine is running at various RPMs. <br /><br />I hate to say it, but i think either the stator windings or the rect/reg is bad.<br /><br />Opinions welcome, needed. <br /><br />Thanks to everybody here for suggestions and help and listening to me complain about this overcharing issue for 2 weeks on end now-<br /><br />andy

 

[Laddies]

Re: CDI rect/reg. woes

Andy on a diode type reg if the sensor wire is not connected (18 g) then the regulator things the battery is low and will charge at max. voltage at lest the is what I was taught a number of years ago, I guess Rapair might do things differantly but I think if the small wire was not needed they would have saved the cost of the wire and connecter

 

[andy6374]

Re: CDI rect/reg. woes

Laddies-<br />So, should I run the extra red wire to the starting solenoid. This should have the effect of the extra 12 volt source, right?<br /><br />-andy

 

[Laddies]

Re: CDI rect/reg. woes

That is where merc picks it up at

 

[andy6374]

Re: CDI rect/reg. woes

Well, I got it to work. Never goes over 14.2V. What I did over:<br />-Did the wiring again (no different than the first time).<br />-After re-wiring, I wrapped all the soldered and crimped connects with electric tape. I think this might be what the problem was. Maybe one of the connections was grounding out on the powerhead.<br />-Put some heat sink compound in between the aluminum plate and rect/reg.<br /><br /><br />-andy