Zeftronics voltage regulator

Hey all,
I have a 1961 172B...Have an issue, but let me give you the whole story...settle in..

been flying great since I bought it, but on a recent trip, my generator light came on in flight. I landed and took a look (I am not qualified to make any real diagnosis) and then took it to the mechanics shop...I was in north Georgia at the time. The A&P took some voltage tests, diagnosed the regulator was the issue, and ordered a new one. The regulator that was in the plane was a $30 Delco Remy, and this is no longer made. The replacement was a zeftronics regulator ($200). So, the two A&P's can't figure out how to get the Zeftronics regulator working, as it seems you need an electrical engineering degree to install one of these things. They worked not his Zeftronics regulator for 6 hours...then they go to an auto shop and put in another Delco regulator and everything works. I fly home (to New Orleans area), and shortly before arrival the generator light came on. So, I pop the hood and the regulator is burned up...granted I knew it would be a temporary fix, and it was not the same model regulator that came out...so I start an internet search for the same model Delco regulator, but have no luck. So I call Zeftronics....they tell me they manufacture the regulator I need, but before I install it, I must test every aspect of my electrical system before install. My frustration grows from here, as they went from a 'plug-n-play' replacement part, to a part that requires EXTENSIVE knowledge of an airplanes electrical system, which I don't have.
I ordered the part as I had no other options and Femi at Zeftronics assures me its not difficult and it doesn't need a mechanic. So yesterday, I have 4 VERY capable pilots surrounding my firewall, trying to make sense of the 4-page manual of different electrical tests that must be done. We get Femi on the line, and all 5 of us Cessna pilots grow quite frustrated with how they have produced this otherwise simple product, that none of the meter tests seem to work. Femi says it could be my switch, or my wiring, or my generator, or any number of things...
I have had NO issues, the voltage regulator went out as its 17 years old, and I just want to plug in a new one. Anyone have any experiences like this with Zeftronics? Why on earth have they made something so simple, so damn difficult? At this point, we plugged in the regulator and the plane started up, the generator light went out at 700 rpm, and everything seemed fine (other than the fact my #1 com display is out -still works just can't see display) and also when I'm running above 700 rpm and turn off master, I would think the red light should come on, alerting I'm running off battery...? It doesn't.
Anyway, we flew it for a few minutes and the red light came on again so we landed and tied it up and I'm sitting here trying to figure out my next move. a $30 part went out, and so far I've spent $400 and the problem isn't even close to being resolved. I feel like I have to throw a bunch of new parts at the plane to get this thing to work. This isn't meant to speak negative of Femi, he has been trying to help over the phone...but why Zeftronics has made a product so difficult to install is beyond me.
More than grateful for any advice or help with this. What should I do...? Pay a mechanic an arm and a leg to go through the entire electrical system, and try to fix the problem...again?
Thanks for listening all...

I may.....repeat....may have a NOS Delco regulator for your airplane. If by chance you want to go that route, I'll put in the effort to locate it. It was for a 35 amp charging system on a 1962 C-182 which I believe is the same...(I'll check that out first)..just let me know.

_________________________
Do it right the first time.

YES YES YES YES Joeman434!! That would be so amazing.

The original part number for the Delco Remy Regulator that came out is:
1119 220

35 amp generator. Thanks for checking!!!

I too had a Zeftronics voltage regulator installed a couple of years ago and the AP had a bear of a time getting it to work. I don't know what all he did, but I think flashing the generator was involved, along with several calls and a visit to the company. Lucky I live only a few miles from where the Zeftronics regulator is made, so the visit wasn't a big issue.

Once he got it working, I've had no issues with it.

_________________________
1965 C-172F - N8186U

I have found the Zeftronics unit is not really different from anyone elses.
If you don't understand how the system works then you shouldn't be working on it. You need a good A&P that knows what he is doing. Keep in mind the regulator only regulates the voltage, everything else is wiring or generator based.
Sorry but having a bunch of pilots doesn't make a mechanic. You are in way over your head doing the work yourself.
You replaced the regulator and yet before getting home you burned that one up. Chances are you have a wiring or generator problem. Turning off the master while the generator is still producing is really not a good idea.
Heck you could have a problem as simple as bad wiring or fuse.

_________________________
1959 172 straight tail

FWIW...My GEN light popped on in-flight, and I had to replace the regulator in my '61 172B earlier this year.

I was lucky, my A&P/IA had a NOS Delco on-hand.

After installation, the GEN light was still on. The issue? After checking the brushes...a moment of clarity, it's a generator. The field needed to be flashed.

_________________________


1961 172B Skyhawk
Private ASEL - Tailwheel/Complex/High Performance

Is the 172B construction so different from later? I just had a faulty regulator in a '67 H and put in the Zeftronics - it was simply two screws out, plug old regulator off, plug new regulator on, two screws on.

_________________________
Never give up, never surrender. Activate the Omega-13.

It can be difficult to find some electrical problems, even for someone familiar with the charging system.

If you are burning up regulators, I'd venture to say, your problem is not the regulator.

_________________________
Wayne

Two wrongs don't make a right, but 3 lefts do.

Thanks for the feedback. Rick, the regulator from O'Reilley's is the one the A&P's put in while I had the initial issue in ATL. This regulator is quite a bit different once you take the cover off, than the original Reg. The coils are much smaller and the original has two screws to adjust voltage...but this one lasted my trip home...
Flubber, its not nearly that simple...it SHOULD be, but its not...
I am planning to fly the plane on the battery 20 minutes west to a an A&P that says he's familiar with the system...only bummer is the amount of money this gonna end up costing and he can't even look at it for 2 weeks minimum...

I am just up the road from you at ASD what your ph? Send it PM.

There are TWO types of Z regulators, One with built in over voltage and one with out. IF your plane has OV protection at the key switch you need the Z reg w/o the OV protection. I had a similar problem when my mech reg was replaced with a new Z w OV included. I had both under dash and built in. Bad combo caused all kinds of issues. All I had to do was remove the Cessna OV protection and go with the internal Z w V Protection and all is well. I have the wiring for both the w and w/o Z regulator.

I was at the KBXA fly in today and will be at the L31 fly in 10/24. We have our poker run at ASD on 10/3 and I am putting it together. I will be there on 10/3

_________________________
Vettdvr

Single/Multi/instrument/type/commercial But then I am still learning.

$500, plane power alternator and voltage regulator kit, two hrs labor to install. Good to go......Life is too short for anything less

See why this is a great site, so much help and good advice

_________________________
Ya'll Fly Safe and Often

Just not worth messing with, poor guy has already spent $200 on a zeftronics regulator, $30 on a auto parts reg and 7 hrs ( $80 an hr?) mechanic labor $560 for a total of approx. $790 and no further ahead.


50 amp complete conversion kit $743

70 amp complete conversion kit $827


Less than $1000 installed, all brand new components, extra amperage for that future radio upgrade, no more dim landing lights. No more dead airplane in the middle of nowhere

I gotta agree with the full alternator kit. Half hour of TnGs at night can really drain the battery if you're not keeping the rpms up. Last plane I regularly flew with a generator was the C205, and it was a PITA at times. Glad my instructor had me practice night landings with no lights, cause I got to do one for real in the C205 when I only had around 100 hrs TT. No landing light, instrument lights, radios, nada, zero volts.

Find a mechanic that knows charging systems, and get it fixed once for good. As a friend just said on another forum, quality is always worth the price.

_________________________
1972 F33A Bonanza

If you go with the Plane Power alternator kit for gear driven generators it is the ER14-50, a 50 amp alternator. You can probably use the existing wire but will have to replace the fuse with a circuit breaker of 50 amps and a 5 amp field circuit breaker and switch. You will also need to install another no voltage light as the new regulator with the Plane Power uses a lighter lamp.
Aerotech of Louisville has the best price around, $50 to $100 cheaper than anyone else.
The kit comes with the alternator, instructions, STC,terminals, bushings, and regulator.
You need to supply the new wire.
I'm not sure about yours but the early generators were 20 amp with a 35 amp optional. So the wiring may not be up to snuff.
So if your fuses, circuit breaker hasn't been updated it will take a lot more than 2 hours to put in.

_________________________
1959 172 straight tail

Lets keep this simple. I use the Z reg on my plane with no issue. ON a Generator however there are a couple of potential pitfalls.

1) The generator must be polarized after install of new regulator. If this wasn't done on the Z reg installed IT WON'T work. If the battery was run down from cranking it won't charge up on start up.

2) The set polarization on a Z regulator set up is NOT the same as a standard Delco regulator

3) The Delco part number installed hasn't been found to cross ref identically with the Cessna part 0413205-1

If I were to guess I think a simple error was made on the Z install with reverse polarity and resulted in the Z circuit protecting the system and NOT charging.

This is where I "think" we should get back to basics. I have found a NEW Delco part matching that can be installed for trial but the gen/reg must be polarized properly or nothing works.

I would consider going back to correct 1350N regulator. There are two types of Z regs. One with OV protection built in and one without. Both can be used BUT if you use the new style as I did you must remove the factory installed OV protection normally found on the ignition key. It can also be found mounted on the regulator. Without removing this extra part the system will still not function properly.

I really think a simple error was made on polarity that has lead to a compiling of issues.

_________________________
Vettdvr

Single/Multi/instrument/type/commercial But then I am still learning.

Twenty five years with my 210 and many hours (second engine) my 50 amp generator is still doing fine. Two sets of brushes and two voltage regulators in all those years....I'm not going to complain or bad mouth a generator. Less than $200...??

I agree with Vette.....keep it simple.

_________________________
Do it right the first time.

I've owned 2 aircraft and installed the Zedtronics products in each, with good success and good customer support. I'm my current 1957 172, I've had my share of generator problems. Next time, I'm converting to the plane power system, although Im not finding the kit for only $500, as suggested above.

_________________________
Reformed Piper pilot, '57 Strait Tail 172, IFR, Guitar, Mandolin, Banjo, Kazoo

Blue Skies and Tailwinds...

I was wrong, kits start just over $700 now.

_________________________
Vettdvr

Single/Multi/instrument/type/commercial But then I am still learning.

After reviewing the information. Now my $.02 is on bad brushes in the alternator.

_________________________
Vettdvr

Single/Multi/instrument/type/commercial But then I am still learning.

"Now my $.02 is on bad brushes in the alternator."

I thought we were dealing with a generator...anyway, automotive brushes will work, but are of a different composition than aircraft brushes.
Remove the generator and motorize it....watch the brushes....that will tell the tale.

_________________________
Do it right the first time.

_________________________
Vettdvr

Single/Multi/instrument/type/commercial But then I am still learning.