---------------------------------------------------------- RotaxEngines-List Digest Archive --- Total Messages Posted Mon 06/17/13: 4 ---------------------------------------------------------- Today's Message Index: ---------------------- 1. 04:08 AM - Re: Erratic voltage output (MacDonald Doug) 2. 05:58 AM - Re: Erratic voltage output (Roger Lee) 3. 07:03 AM - Re: Re: Erratic voltage output (paul) 4. 09:53 AM - Re: Re: Erratic voltage output (Bob Harrison) ________________________________ Message 1 _____________________________________ Time: 04:08:08 AM PST US From: MacDonald Doug Subject: RotaxEngines-List: Re: Erratic voltage output So, my troubleshooting saga continues.- The first thing I did was run an 18ga ground wire from the regulator body to the negative terminal of the ca pacitor which then goes to the firewall buss bar.- When this did not solv e the erratic output issue I replaced the regulator.- Neither of these st eps helped the problem.- =0A-=0AMy engine ground lead is an 8ga wire ru nning from a lug on the top of the right rear cylinder to the ground lead o n the firewall buss.- From the firewall buss, both the positive and negat ive leads are 8ga wire and go to my main buss which is mounted behind the i nstrument panel.- From the main buss the positive and negative leads are 8ga and run down the passenger side of the airframe to the battery which is located behind the passenger seat.- At the battery the ground wire attac hes to an airframe ground point on the battery mount frame then through an 8ga wire to the negative post.- The positive lead goes to the master sole noid and then to the positive post of the battery (all 8ga).- As per Roge r's suggestion, I have been pulling each of these main power leads one term inal at a time and thoroughly cleaning the connections.- So far I have go tten to the main buss and firewall buss but still need to clean the connect ions at the battery.- While I have found some oxidization, I have thus far found no corrosion which could be causing my erratic output issue.=0A-=0AToday after work I will pull the b elly pan off of the plane and clean all of the connections at the battery. - I also want to pull the connections of the charge lead from the voltage regulator to the-ALT circuit breaker and main buss to verify they are ok ay. -So far , however, I'm not seeing anything that could be the source o f my problem.- My CH-701 is almost three years old and has just shy of 20 0 hours on it.- This voltage issue is has come on gradually over the last few months as the output has been-stable until I noticed the needle gyra tions in about March when my flying hours began to pick up.=0A-=0AOne oth er thing I am going to try is a new capacitor.- Lockwood sells an afterma rket 22000MF cap for $35.00 so I figured I may as well try it.- My capaci tor is about ten years old with an unknown history so it is possible that i s has started to go bad.- I also might try a different ground wire locati on on the engine.- Perhaps the cylinder head is not an ideal ground locat ion.=0A-=0AAny other suggestions?=0A-=0ADoug M=0ACH-701 from scratch=0A NW Ontario, Canada=0A=0ATime: 11:10:19 PM PST US=0AFrom: "Paul Grimstad"

=0ASubject: RE: RotaxEngines-List: Erratic voltage output=0A=0AWe have been experiencing wild fluctuations on the amperage met er, running a=0A912uls with Dynon 180 EFIS engine monitor. The spikes range from +5 to -6.=0AVoltage is also high (high 13's), but then it seems to se ttle down after=0Atakeoff. I thought the high voltage maybe because we just installed a new=0Abattery.=0A=0AWe also just installed a new voltage regul ator and when we grounded the=0Aplane and took a look at the condition we f ound the two power leads going=0Ainto the regulator were completely melted and the heat was starting to melt=0Athe plastic mounting socket on the Duca ti voltage regulator. We replaced the=0Aspade connectors on the main power leads and replaced the wiring socket=0Aplug-in connector as well. =0A=0AWe had heard that the Rotax engine electronic system is very sensitive to=0Ath e requirement of the ground connection, so additionally we ran a 10ga=0Acop per wire from the base lug on the voltage regulator to the negative=0Atermi nal connecting stud at the battery/airframe. This has not solved the=0Aprob lem. I flew 7hours last weekend and near the end of the flight time, I=0Ano ticed the amp gauge still jumping up and down.=0A=0AI have spoken with seve ral knowledgeable Rotax guys and both asked me if I=0Aran the ground from t he base of the voltage regulator directly to the engine=0Ablock?=0A=0ASo, t his afternoon I removed the wire socket plug connector and inspected=0Athe wire ends and crimped connectors. There was no sign of heat damage, so I=0A reconnected the primary connection plug. I made up another ground wire with =0Asoldered wire ends and waterproof shrink tubing. I then installed the ne w=0Aground wire from the mounting bolt on the base of the voltage regulator =0Adirectly to the engine block. Tomorrow I will run the engine and see if the=0Aproblem is solved.=0A=0AHope this helps, I will let you know how it g oes.=0A=0APaul Grimstad,=0A=0ATeam RV12=0A=0APortland, OR----- ________________________________ Message 2 _____________________________________ Time: 05:58:21 AM PST US Subject: RotaxEngines-List: Re: Erratic voltage output From: "Roger Lee" Hi Doug, The ground wire on the cyl. head should be just fine. Many of us use it and it seems to work without any issues. I have those capacitors and they are $20. Same as Lockwood or anyone else unless you go to the super-sized model with finger nuts on top instead of soldering the terminals on, but those are about triple or more the price. -------- Roger Lee Tucson, Az. Light Sport Repairman - Maintenance Rated Rotax Repair Center - Heavy Maint. Rated Home 520-574-1080 TRY HOME FIRST Cell 520-349-7056 Read this topic online here: http://forums.matronics.com/viewtopic.php?p=402853#402853 ________________________________ Message 3 _____________________________________ Time: 07:03:13 AM PST US Subject: RE: RotaxEngines-List: Re: Erratic voltage output From: paul SSB3b3VsZCBwdWxsIGFuZCBpbnNwZWN0IHRoZSBzcGFkZSBjb25uZWN0aW9ucyB0byB0aGUgdm9s dGFnZSByZWd1bGF0b3IuwqAKSm9obiBzdWdnZXN0ZWQgdGhlIGNhcGFjaXRvciBtaWdodCBiZSBh biBpc3N1ZS4gwqBJIGRvbid0IGtub3cgd2hlcmUgdGhhdCBpcyBsb2NhdGVkLiBDYW4geW91IHRl c3Qgd2l0aCBmcmVlemUgc3ByYXk/CgotLS0tLS0tLSBPcmlnaW5hbCBtZXNzYWdlIC0tLS0tLS0t CkZyb206IE1hY0RvbmFsZCBEb3VnIDxkb3Vnc25hc2hAeWFob28uY29tPiAKRGF0ZTogMDYvMTcv MjAxMyAgNDowNyBBTSAgKEdNVC0wODowMCkgClRvOiByb3RheGVuZ2luZXMtbGlzdEBtYXRyb25p Y3MuY29tIApTdWJqZWN0OiBSb3RheEVuZ2luZXMtTGlzdDogUmU6IEVycmF0aWMgdm9sdGFnZSBv dXRwdXQgCiAKU28sIG15IHRyb3VibGVzaG9vdGluZyBzYWdhIGNvbnRpbnVlcy7CoCBUaGUgZmly 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Doug. For my experience certainly take the plug and socket to the regulator apart (no matter what type)and inspect the spade connectors and the nylon shrouds . I found mine had a bad connecting spade which had created so much heat the plastic/nylon plug and socket had welded together and started turning to carbon which must have been near to causing a fire. The plug, socket and females are mostly of "Durite" name and part No.0-011-06 ( Six way Nylon) Made by Gordon Equipments Ltd . for UK users. An example of cheep kit doing a lousy job if ever there was one! Regards Bob Harrison Europa 914 Rotax. -----Original Message----- From: owner-rotaxengines-list-server@matronics.com [mailto:owner-rotaxengines-list-server@matronics.com] On Behalf Of Roger Lee Sent: 17 June 2013 13:58 Subject: RotaxEngines-List: Re: Erratic voltage output --> Hi Doug, The ground wire on the cyl. head should be just fine. Many of us use it and it seems to work without any issues. I have those capacitors and they are $20. Same as Lockwood or anyone else unless you go to the super-sized model with finger nuts on top instead of soldering the terminals on, but those are about triple or more the price. -------- Roger Lee Tucson, Az. Light Sport Repairman - Maintenance Rated Rotax Repair Center - Heavy Maint. 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