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A diode capable of carrying the charge current, with proper heat sinking, put between the regulator output and the battery would drop around 0.6V, getting you down to 14.2.
Stator went bad. replaced. Then charge light on/off intermittently but regulating at 14.3 volts. Didn't want to chance smoking the new stator so replaced the Electrex RR51 regulator with a new ElectroSport ESR510 from Regulatorrectifier dot com. This regulator is regulating at 14.8 volts.The only electrical difference between the two regulators was the black sense wire did not exist on the Electrex model but does exist on the new ElectroSport model. I believe this sense comes from the headlamp circuit.
No. Since the regulator has a sense line on the battery/ignition side, it will just up the output to compensate for it.
I see your point, I'm not used to regulators with separate sense wires. But it seems like one could connect the sense wire to the regulator output to make it behave like one without a sense wire, and then if the output were high, a diode connected after the sense wire could be used to drop it a little.
I would think the voltage drop across the headlamp would cause it to always be lower than actual battery voltage. This might tend to keep the reg. at full output.
Well, normally, high voltage from the regulator is just a bad ground, but you said you have that covered. <shrug> I dunno.
What is the voltage at the sense wire? If you have a poor path there, that voltage will be too low and the regulator output will go up to compensate.
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It would certainly try to keep the headlight at the setpoint (14.2 or so?) For any power supply or regulator that has a sense wire, that wire should be connected to the thing that needs the accurate regulated voltage. If you connect it to the headlight supply, for example, the regulator will do its best to keep the headlight voltage at the setpoint. But the battery is probably the thing that's most sensitive to the charge voltage, so you'd think that the sense wire should be connected to its positive terminal, or near it.
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