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Yesterday was the second time (after several weeks of normal operation in between) that the following symptoms arose:

After approx one hour in flight, the low voltage lamp lighted up, EFIS showed 12,1 v, hence the light. The voltage slowly decreased to 12,0, 11,9 V at a rate of 0,1V ~ every 5sec.
All of a sudden, voltage regained its normal in flight lelvel of 13,7v. This voltage drop reappeard every now and then for periods of 3 secs to 30 secs for approx 1% of the remaining flight time.

Switching the transponder off didn't prevent the sudden voltage drop, but after the inital drop from 13,7 to eg 12,2, the further decrease of voltage was very much slowed down to ~0,1V very 20 s.

System: Rotax 912 S, no additional alternator, EFIS+EMS, Transponder, Radio on. Voltage drop while actuating the electrically driven flaps is known and normal.

Conditions: 75%, OAT 15°C, oil temp 9x deg.C, 5000ft

My question: this temporary error points to the regulator in my opinion. As I will almost certainly find no anormaly while test running the engine on the ground and there is therefore no possibility to immediately verify the success of my work, I want to make sure that I am curing the right disease.

Could this error be caused by improper/broken/loose electrical connections (between whom)? Or is it the regulator for sure?

The plane is a MCR01. The cooling is rather too effective, I have to block 60% of the coolant air intake in winter and never see oil temps above IIRC 110deg C at 75% and OAT of 25 deg C. This however doesn't say anything about the temps at the back of the engine where the regulator sits ...

Thanks for reading
  • Re: Failure mode alternator regulator, temp. error

    by » 8 years ago


    Check the wires going into the regulator's black all in one connector. I have had loose connections there.

    clean all the ground connections from the regulator to air frame and tighten the connections.

    I think the regulators either work or don't , so intermittent makes me think a connection.

    Thank you said by: Alexander Kluge

  • Re: Failure mode alternator regulator, temp. error

    by » 8 years ago


    I agree with Kevin, but while you're at it tighten all aircraft grounds. All connections are may be hand tight, but wrench loose. Put a screwdriver or wrench on all of them.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


  • Re: Failure mode alternator regulator, temp. error

    by » 8 years ago


    I would not suspect the regulator as the primary fault.

    If the Reg goes offline, you are running on the battery.
    Unless the battery is near the end of its useful life, you should not expect to see 12.0- 11.9v for at least 10-15 minutes or more.
    11.9v is a 70% discharged battery.
    If the voltage continued to drop at your reported rate,
    the battery would be dead in a few minutes.

    I suspect that the battery has a bad connection to the buss, or you are getting a false voltage reading

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    Clicking the "Thank You" is Always Appreciated by Everyone.


  • Re: Failure mode alternator regulator, temp. error

    by » 8 years ago


    [quote]Unless the battery is near the end of its useful life, you should not expect to see 12.0- 11.9v for at least 10-15 minutes or more.
    11.9v is a 70% discharged battery.
    If the voltage continued to drop at your reported rate,
    the battery would be dead in a few minutes.

    I suspect that the battery has a bad connection to the buss, or you are getting a false voltage reading[/quote]

    I don't get the "10-15 minutes" in your first sentence. The voltage dropped from charged 13,7V to 12,3V very rapidly, in 1-2seconds and continued to drop slower and slower, asymptoting to something like 12,1V. This was with EFIS and Radio on, but nothing else (except charging the old handheld Garmin GPS in the panel). But before it could drop any further, it regained 13,7v. The episodes of battery use were too short for the voltage to drop further down.

    When I added the transponder, the voltage dropped faster and only got slower at 11,9-11,8. Againt, the battery use episodes were to short to see what happens further down.

    Are you saying that the system voltage in case of a fully charged intact battery should start to drop in case of improper charging (like mine), but from a way higher level (as eg 13V)?

  • Re: Failure mode alternator regulator, temp. error

    by » 8 years ago


    I am going to reverse my previous opinion. ( I was Wrong! :oops: )
    I think it may be the Regulator/Charging system.

    All this assumes that the voltage readings are true and correct.

    13.7 is the float voltage of the battery.
    At 13.7 it might take days to forever to charge the battery.
    You should be seeing voltages in the lower 14-volt range under normal operating conditions.
    You might see 13.7 at idle RPMs but not at cruise RPMs.
    14.2 is a typical voltage, not 13.7. It makes a BIG Difference!

    Were the charging system to suddenly quit, The voltage would be expected to drop to the 12.6 to 12.5 range within a minute, possible a few seconds under a heavy load.
    Assuming you have enough battery to power the plane for at least 30 minutes, the voltage should not drop to the 12.0-volt level (50% discharged) for at least 10-15 minutes.

    It would appear that the charging system is on its death bed and is able to supply enough power (Amps) to supply the panel loads, but not enough to recharge the battery.
    occasionally the regulator quits (Overheats?) and you are then running on a weak battery for a few seconds until the regulator recovers. The cycle repeats.

    While hangared, Engine OFF, Panel ON, you should see ~12.5 volts.
    If the voltage is dropping rapidly, keep watching for a few minutes.
    This similates a regulator failure.
    If it get down to 11.5, Stop!, and ground charge the battery.
    After 3-5 mimntes, try to crank the engine.
    Do all this with a voltmeter attached to the battery posts.
    The physical posts, not the battery clamps.

    I would not leave the pattern until this issue is resolved.
    You may only have very few minutes of power if the regulator does not recover promptly.

    Concentrate on getting a 14+ volts on the buss.

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    Clicking the "Thank You" is Always Appreciated by Everyone.


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