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Paul M 383
Joined: 19 Mar 2012
Posts: 97
Location: United Kingdom
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 Posted: Sun May 09, 2021 11:45 am Post subject: Voltage regulator connection |
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Has anybody seen this voltage regulator connection issue? One of the yellow generator connectors has clearly got hot and is too close to its slot in the plug.
It's definitely melted, not vibration or mechanical abrasion and looks like it's simply too close to the edge of its slot in the plug.
How to avoid re-occurrence?
(Apologies for the first image - auto focus  )
Many thanks in advance,
Paul M
XS Mono 912 ULS
G-PLPM
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Burrilla
Joined: 25 Apr 2015
Posts: 187
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| Posted: Sun May 09, 2021 10:31 pm Post subject: Voltage regulator connection |
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Most overheating at joints or connectors is due to contact resistance.
This could be a loose fit of the connector on the spade or poor crimp joint on the wire. Might even be due to the connector spade going down the side of the connector rather than between the tangs of the connector if it’s loose in the holder.
Alan
G-OBJT
Sent from my iPad
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brian.davies44(at)gmail.c
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| Posted: Mon May 10, 2021 12:36 am Post subject: Voltage regulator connection |
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Hi Paul,
That is the common failure mode for that connection. I am not sure that the
black connector block adds anything to the security of the installation. It
is an easy way to connect all of the regulator wires in one go but it masks
the physical state of the spade terminals. I always check that each
individual terminal is secure after installation. In my current new build I
am considering leaving the black plastic bit off and simply protecting each
individual terminal with heat shrink insulation. This would enable a good
physical inspection of each terminal during routine checks.
Brian Davies
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budyerly@msn.com
Joined: 05 Oct 2019
Posts: 289
Location: Florida USA
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| Posted: Mon May 10, 2021 5:45 pm Post subject: Voltage regulator connection |
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Yep,
Happens with a regulator going bad and or a poor crimped connector or shorting of the connector. Which ever it is, inspect and correct your wire first.
Consider buying a "spare" regulator. Each dynamo wire goes into the regulator circuit (GG). If that particular diode is dying in the regulator it can get really hot (short). A terrific read is the Contrails articles on the Ducati regulator.
Regulators like the Ducati are used in many different vehicles.
The main problem is too much draw. See my techniques article on the Europa Club site (AMP Zealot) or at mine. The other problem is heat. If the regulator is routinely above about 120F (50C) and the draw is high (over 15 amps) it's toast.
Cut your amps, monitor the regulator temperature.
Use of heat temperature indicating tapes is recommended. Or hook up a thermistor/sensor for your Volt Meter for recording.
Here's hoping its just a poor crimp.
Best Regards,
Bud Yerly
https://www.customflightcreations.com
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