Installation manual for three phase MOSFET regulator rectifier

To ensure the warranty and to install the rectifier properly, please read the entire manual before commissioning! Due to the wire coloring may differ from manufacturer to manufacturer, please always identify the wires with a digital multimeter and read the manual!

Before installing the rectifier, make sure that the cause of the failure in the charging system was due to the previous regulator rectifier (see also manual points 2 and 3). Existing failures (e.g. a short to ground) may also damage the new regulator rectifier!

1. About the regulator rectifier:

The regulator rectifier was designed for motorcycles with permanent magnet induction.

DO NOT USE IT for electromagnetic generators / alternators !

Compared to the thyristor regulator rectifier; this regulator rectifier with MOSFET technology:

-       Generates much less heat 

-       No thermal latching

-       The voltage regulation is more stable

Instead of classic diodes, Schottky diodes were installed in this regulator rectifier, which further reduces the heat generation.

Thanks to the MOSFET technology, the Schottky diodes and the large heatsink surface, the regulator rectifier can be used even where the cooling effect of the wind is limited.

The pod of the heatsink is filled with synthetic resin, which makes the rectifier completely waterproof. However, in extreme cases, soaking cannot be avoided (e.g. being washed by steam pressure washer)

The voltage regulated by the regulator rectifier must be between 13.9 - 14.6V.

It is recommended to use an "on-board" voltage meter on the motorcycle to continuously check the charge.

The rectifier can be used to operate lighting in a special system without a battery, if the generator / alternator is three-phases, and the battery is replaced by a high capacity electrolytic capacitor (e.g. Crossmotor)

2. The installation:

The regulator rectifier is made in a 5-wire [3 phases, 1 negative (B-), 1 positive (B+)] or 7-wire model [3 phases, 2 negative (B-), 2 positive (B+)].

It may happen that the original regulator rectifier connects to the motorcycle's wiring using 6 or 8 wires. In this case, the sixth (eighth) wire, which is ignition-switched 12V, is left unconnected (this is usually a thinner brown or black wire)

3. Guide to installation

1. Before installation, make sure that the cause of the failure in the charging system was due to the previous regulator rectifier:

•   Check the plugs and wirings, as poor connection can result in a significant voltage drop, insufficient charging.
•   Before installing the new regulator rectifier, check the generator / alternator with a resistance meter for ground fault, short to ground.
•   Check the voltage at the 3 phase lines with a digital multimeter, while the engine is in idle mode. The voltage should be measured between 15-25V with 1-2V asymmetry between phase lines acceptable.

2. Before replacing the regulator rectifier, check and identify [phases, negative (B-), positive (B+)] the wires connected to the regulator rectifier. 

4. After the insallation

After installing the rectifier, the battery voltage should also be checked (with lights on) at different RPMs. Charging is okay when the voltage is approx. between 13.9V and 14.6V.

If charging is above 14.8V, then first verify that the voltage meter (multimeter) measures properly (validate the voltage meter). Also, make sure the batteries are not discharged (the text "LOBAT" or the low battery symbol will appear on the screen), as discharged batteries in multimeters may cause a 2-3 V deviation from the correct value.

If charging is under 13.8V, it may be due to the following errors:

• High resistance / voltage drop/loss in the wiring
• Faulty battery (this can be checked by testing the rectifier on another battery, even on a car’s battery)
• Generator / alternator problem  (like a short to ground) 
• Ignition system without electromagnetic filtering may provide false measures

5. While using the regulator rectifier

DO NOT start the engine while the regulator rectifier plug is disconnected or the battery terminal is removed as this may damage both the rectifier and other electronic components. When the engine is running DO NOT remove the battery terminal or disconnect the regulator rectifier plug.

6. Guarantee / Warranty:

All regulator rectifiers are tested after manufacture.

We offer a 2 year warranty for the product. Installation must be done by a mechanic (with qualification), as this is the only way to guarantee the warranty in case of malfunction (please keep the bill, invoice of the installation). We are not responsible for any malfunctions due to improper installation (e.g. reverse pole connection) or use (e.g. removing the battery terminal, while the engine is running).

In the event of a short to ground generator / alternator, the fault could trigger a short to ground that could damage the voltage regulator. We assume no guarantee in this case.

The manufacturer only guarantees for the product. We cannot stand the guarantee of any other consequential, collateral damage.