Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

[daveswaves]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

Hey Moody blue, my deep cycle/starting battery from walmart is non maintenance free. The caps pop off and you can top it off. I think thats what Mercury is referring to. The regulator circuits used on the snowmobiles or quads work fine. I do not like the 2 wire regulator that merc tried for a while, it just saturates the stator with DC to reduce the output. Any regulator you use will have to dissipate heat to get rid of the excess charge
heat sinking is important.. Here is a set up that has worked.

 

[Moody Blue]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

Revisiting this hopefully one last time. I did check out the Walmart batteries and they are classified as maintenance free even though it is possible to remove the caps. I'd really like to go with the regulator approach. Have found countless voltage regulator/rectifier models for Mercury outboards. Seems to be two general types available, a 5-wire and a 6-wire.

5-wire has yellow, yellow, red, black and grey.
6-wire has yellow, yellow, red(+), red(sense), black and grey.

My motor is a 1971 Merc 800 with a 9A stator, no factory regulator.

How are the two different types connected? Can they be interchanged?

 

[Moody Blue]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

bump

 

[Moody Blue]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

Well I've bought a Merc 883071 5-wire regulator and plan on installing this weekend. Pulled the cowling off the motor to have a look where I might install it. Not so simple

There is not much space in there at all. Was originally thinking that it would fit in place of the original rectiffier but no way. Now I need to find an alternate spot for it where it will get a good ground and heatsink.

Looking for some advice. Motor is a 1971 Merc 800.

 

[monk-monk]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

Moody blue...i told you i was gonna install a CDI unit...well, when i went to install it i seen the instruction warning against using the maintenance free battery, so i haven't installed it yet...BUT, i am going to install it tomorrow...right after i get back from Interstate Batteries...i contacted them and the man knew right away what i needed...asked if i was running a trolling motor, what amp hour my other equipment was pulling, what my engine charging source was etc...first thing in the morn im going to get the battery...will have the rectifier/regulator on by mid-afternoon...voltage gauge is installed...i will let you know...!!

 

[Moody Blue]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

After spending some time coming up with different approaches and mounting locations I think I came up with the perfect solution. I decided to install the regulator on a piece of 1/4" aluminum plate mounted to an aluminum angle which is bolted up where the original rectifier used to mount inside the cowling. The whole thing tucks nicely just below the fuel pump and the wiring is all close by. Requires no modifications to the existing components at all. The aluminum plate will act as a heatsink for the regulator.

If the weather holds, I hope to get it installed this weekend and will post photos of the install.

 

[Moody Blue]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

So the rain held off long enough to get it installed but haven't had a chance to try it yet.

Here are a couple photos of the installed regulator.



I applied a coating of heatsink compound to the case of the regulator before bolting it to the aluminum plate to help with heat transfer away from the regulator. I have no idea if or how hot it may get while the motor is running.

Hopefully this will take care of the 18V charging voltage problem.

 

[68gtoconv]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

Nice job on the install looks very professional.

Thanks to all who posted here, I'm having the same issues with my Bass Tracker mainly concerned about the high voltage damaging my fishfinder.

For reference my 1995 40hp 3 cly Merc has a 816770 recttifier installed.

Merc used a 883072T rectifier / regulator for Mercury engines with 16 amp or 40 amp charging systems 1992 - present

I haven't change mine out yet but all the wires are the same color so I'm just going to change the wire connectors and match up the colors.......

 

[j_martin]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

I changed out a 16 amp rectifier/battery frier in my XR4 for a 40 amp dual regulator system. Everything fits under the hood except the flywheel cover. Maybe someday I'll get a later bucket cowl for it. It's wired to charge all the batteries on the bass boat.

At WOT, the motor will seem slightly tired if the batteries are down. Really puts out the electricity. Probably takes about 7 hp just for the alternator.

I chit-canned the advance module and made a plate to mount the regulators on top where it was.

 

[Moody Blue]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

Posting an update for those who might find this link helpful.

Have run the motor all summer and everything operated as hoped. Voltage was kept at 14.4V max, even while running at WOT for extended periods. I wanted to take temperature measurements of the regulator to see how hot it runs but never had the opportunity. I have about 35-40 hours on it so far and it's held up well and I'm sure the electronics are alot happier.

 

[j_martin]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

Revisiting this hopefully one last time. I did check out the Walmart batteries and they are classified as maintenance free even though it is possible to remove the caps. I'd really like to go with the regulator approach. Have found countless voltage regulator/rectifier models for Mercury outboards. Seems to be two general types available, a 5-wire and a 6-wire.

5-wire has yellow, yellow, red, black and grey.
6-wire has yellow, yellow, red(+), red(sense), black and grey.

My motor is a 1971 Merc 800 with a 9A stator, no factory regulator.

How are the two different types connected? Can they be interchanged?

Sorry I wasn't paying attention. The only difference between the two is the black wire is ground in addition to frame ground. The five wire relies on mounting for ground.

The Newer 6 wire ones are a bit more reliable in a 20 amp circuit. Shouldn't make any difference on yours. Either one doesn't give off much heat. A stout aluminum mounting plate is plenty of heat sink.

hope it helps
john

 

[phebus1]

Re: Adding aftermarket VOLTAGE REGULATOR - anyone actually done this ???

The way I figure it, is that if I'm running a fish finder, stereo, gps, etc. the amount of charge coming from the stator isn't enough, so I just run all my accessories off a big battery as a total loss system and just plug it into a charger at night. That way the engine system is left to itself and I don't have to worry about a dead engine battery and starting issues.
What are the advantages to switchingto a regulated system? You have me intrigued.