Hi Jag, Is it a one wire, 2 wire, or three wire system? If its a one wire, the alternator needs about 1400 rpm in order to kick in. What alternator are you using? If you are using the one wire, one of two other things must happen. The sensor lug must be wired to the output terminal of the alternator, either internally or externally. Without this connection, the alternator does not know what the battery voltage is and the internal regulator will not function properly. In a two wire system, the other lug is the exciter which must be wired in series with the ignition switch. The exciter charges the field of the alternator and causes it to begin operating as soon as the engine is turning over. In a three wire system, the sensor is wired to the main fuse buss, sensing 12 battery volts there at all times (alternator output is 13.5/14 volts), the exciter starts the charging as soon as the engine turns over, and of course the #10 output terminal suppies power to the entire electrical system. I think your difficulty is somewhere in this wiring description. The main thing to check is if the sensor is connected to the output terminal of the alternator, either internally or externally. Good Luck!