Merc XR2 upgrading from rectifier to regulator - advice needed.

[tristanlee85]

Everything is new though, new stator, rectifier, trigger, and switch boxes. All for the 40A system. These are the exact parts I installed. I knew replacing some new/some old could lead to issues so I made sure to get everything new at the same time.

[tlwjkw]

pretty sure tha "right" stator would have 2 yellow's, 2 reds, one gray, one black.. didn't do cdi junk so would'n't know what they sell.

did ya compare it ta ya old one???

[nitro_rat]

To the OP; your XR2 should have a 16 amp charging system. If you're running lots of expensive electronics your charging system is working at full capacity to keep all that stuff running but it's still just a 16 amp system. Adding a 20 amp regulator isn't going to accomplish anything except costing extra money and adding another failure point...

You should track your battery voltage when you're running all those electronics. Are you using more amps than the system puts out? In other words discharging the battery with the charging system working at 100%. If you are then you should be looking to upgrade your XR2 to 40 amp charging or upgrading your power to a newer motor that has 40 amp charging standard.

Just my two cents...

[tlwjkw]

look at his pictures.. not XR2 stuff.. water cooled 40

[nitro_rat]

look at his pictures.. not XR2 stuff.. water cooled 40

i can't see the pics...

[Merc 2.5]

look at his pictures.. not XR2 stuff.. water cooled 40

Ya I'm gonna agree. Sure looks like water cooled.40 amp Water cooled electrics is what u need get away from. Either run 16 or 40 but no water cooled crap from 2.4. Sry jmo

[rgsauger]

40 amp water cooled regs are CHIT !!! If you have 4 yellows, then treat them like two 20 amp circuits with two of those regulators. 17 volts is wayyyy high. I would buy two of those regs for $30 each. Run one reg to cranking batt and the other to trolling motor battery.

Don't run it until you get the volts down. Look at how a Promax is set up.

[rgsauger]

One yellow pair to first reg and the other yellow pair to second reg

[pjbrownva]

I wouldn't recommend running with wires disconnected. Some of the voltages can be rather high, an it seems to me that you're asking for some type of instability if you run with wires to your charging system just floating.

The advice of using newer regulator/rectifiers for a 40 amp system (such as 2 x 20 amp units) is probably sound advice.
You don't want to risk creating electrical gremlins with the over-voltage or with disconnected wires.

That would be my $0.02, based on some knowledge of electricity but without analyzing and carefully thinking through the circuits.
In general, having stator coils that aren't connected to anything isn't good. The flywheel magnets are still going to try to generate high A/C voltage (is that term a contradiction???), but because the wires aren't competing a circuit, no current will be able to flow.

I'm not positive, but I think that this will create high voltage in the coils, this keeps flip-flopping, which might generate heat since the voltage cannot generate current and has nowhere to discharge (any physicists... correct me if I'm off the mark, please!). Regardless of the actual physics, I really don't think it would be a good thing. (again... jump in and correct me, if someone else really *knows* this stuff better)

Ditch the separate rectifier, it's not needed, so you're just adding confusion to the system, and an unnecessary component if you ask me. On the old systems, the rectifier converts a high voltage AC current from the stator to a DC current. I'm not sure if or how the dc current is regulated. In the newer style systems, the A/C to DC conversion and the voltage regulation all occur inside the the electronics embedded in those boxes. That's where I'd put my money. Good luck!

[tlwjkw]

One yellow pair to first reg and the other yellow pair to second reg

he's still runnin' tha water cooled reg.. he jus put up a pic of what he thought he needed to replace it but thought he only needed one!

[rgsauger]

On the 9 and 16 amp units, many only run a rectifier and no voltage reg. Never hurts to run the combo unit. In your case, do the dual Vr's.

[tlwjkw]

Everything is new though, new stator, rectifier, trigger, and switch boxes. All for the 40A system. These are the exact parts I installed. I knew replacing some new/some old could lead to issues so I made sure to get everything new at the same time.

i would call cdi and ask them "jus what is this and how does it hook up to TWO yellows on my WATER COOLED reg/rec."???

it "probably" has ta be that a CERTAIN pair of yellows has to go to one (original) reg yellow and tha OTHER pair go to tha "other yellow" on your regulator maybe?.. do tha yellows on tha cdi stator have identifing numbers/markings?.. did ya read all instructions???

[tlwjkw]

i can't see the pics...

"I see".. no pun intended!

yeah, shows 4 yellow stator and tha plastic term strip right above tha water cooled reg.............

[tlwjkw]

jus courious.. do you have a serial number stamped on tha welsh plug?.. XR2's had 16 amp chargin' systems... unless someone has had their dick skinners on it already.............

[rgsauger]

My water-cooled reg literally caught on FIRE!!! Scared the chit out of me. 2.5 empty fire extinguishers and it was still blazing. Battery was feeding it power to a direct short. Look at how a 40 amp is set up on a pro max with dual regs