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Author Topic:   Mercury Outboard Regulators
bprowell0411 posted 05-28-2007 04:12 PM ET (US)   Profile for bprowell0411   Send Email to bprowell0411  
I have a Saltwater Series 200 HP 2001 Merc with two regulators, I believe high and low. They are both located on the port side of the engine right on top of one another. The one on top started smoking this weekend after I had shut the motor off. I disconnected it and the motor ran and started just fine. I believe it just affected the charging of the battery so I switched to battery-1 and the boat ran fine all day the following day. I am going to replace it but I am afraid the stator may have been damaged also. What usually causes the regulator to fry? If I replace it will it just happen again? Also why are there two wires connected to the regulator at the bottom (the red and grey) and the one that got fried only had one wire connected, the red. The grey is just capped and of course the regulator was grounded. Any help would greatly be appreciated. Thank you.
jimh posted 05-28-2007 09:52 PM ET (US)     Profile for jimh  Send Email to jimh     
A GRAY conductor is usually associated with the tachometer circuit, and it most often derived from the battery charger rectifier input.

A solid-state rectifier will fail ("fry") in several ways. Generally the most common failure mode is to the peak-inverse-voltage (PIV) to be exceed, causing the rectifier junction to be destroyed. When this happens there are two possible failure modes: open circuit, or short circuit. If the device fails into an open circuit there is usually not much current flow. If the device fails into a short circuit there is usually a great deal of current flow. Flow of current generates heat, possibly enough heat to begin combustion of the materials used in the rectifier.

If your Mercury motor has a regulator and a rectifier in one assembly, there could also be a failure of components in the regulator portion of the circuitry.

Heat in electronic circuits, especially solid-state devices, causes problems. It may be that there was excessive heat which caused the device to fail.

Before just replacing an expensive assembly like a rectifier/regulator, it is prudent to check other components in the system to see if they are operating normally. The stator coil can be checked for continuity, resistance, and leakage to ground.

Some solid-state devices fail simply from old age, but usually there is some precipitating event which brings on failure. High temperature, a voltage spike, or excessive current could all have caused problems.

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