From ZM5 to ZM6: A Smarter, More Robust Regulator

After reviewing returned ZM5 units with faults, it became clear that many issues stemmed from installation-related problems. These included:

  • High-resistance cables or loose terminals
  • Faulty alternator diodes
  • Engine preheat systems
  • Extremely low battery voltage (flat batteries)

Despite these challenges, the core ZM5 design proved solid—one commercial operator has logged over 20,000 hours of trouble-free operation.

However, the ZM5’s compact circuit board limited our ability to add protective components. That led to the development of the ZM6, a major upgrade with 42 new features, designed especially with LiFePO₄ battery systems in mind.

What’s New in the ZM6

The ZM6 introduces significant enhancements:

  • Improved output stage for better field control and onboard protection
  • Spade terminals for easier, more secure connections
  • Temperature monitoring of battery or alternator with automatic current limiting (limp mode)
  • User adjustable current limiting mode
  • Low voltage cut-off at 10V ( so you dont damage your alternator and regulator)
  • Dual voltage support: 12V or 24V, N or P switching
  • Onboard 5A field fuse
  • Field “ON” LED indicator
  • Expanded LED indicators: from three to eight.
  • Enhanced heatsink protection for key components
  • User-selectable absorption time: 0–140 minutes in 20-minute steps
  • Selectable absorption and float modes for setup and operation
  • Onboard over voltage sensing with auto shutdown. 
  • External BMS control for field shutdown
  • Integrated “keep-alive” feature for reliable tachometer readings
  • Compatible with all battery types, including Lithium Ion

ZM5 Support & Transition

We’ve now ceased production of the ZM5 to focus on the ZM6. However, support and repairs for ZM5 units will continue for the foreseeable future, subject to parts availability.

ZM6 Field Testing

The ZM6 has undergone rigorous testing:

  • 200+ start cycles at 70A, switching every 20 seconds
  • 5000+ start cycles at 20A
  • 250 hours continuous operation at 20A

These results confirm the ZM6’s durability and reliability under demanding conditions.

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ZM6 Compatibility

  • Our ZM6 P version is a direct replacement for the BOSCH RE55 regulator
  • Our ZM6 P version is a direct replacement for the Next Step and Balmar regulator