Monday, June18, 2018

' Balmar 12 Volt Alternator Manual'

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12Volt Alternator Operation Manual
you for choosing a Balmar highoutput alternator This alternator is and engineered to provide the finest performance and durability for your most
alternators found standard on the majority of pleasure craft and marketed as lower
priced marine alternatives our marine alternators are built specifically to provide exceptional output at lower
engine rpms typical of marine diesel engines so you can enjoy shorter charge cycles greater economy life and less noise and fumes
When used in conjunction with Balmar Max Charge and ARS4 multistage new Balmar alternator can provide even greater efficiency when charging
deepcycle flooded standard flood
ed gel AGM Optima and other marine battery technologies When preset for your battery type the smart guide your alternator through a charging program
thats tailored to provide your batteries with the best In addition Balmar multistage regulators provide the ability to temperature sense at your an
condition occur with an alternator temperature sensor MCTSA installed the regula
tor will reduce field output to 50 percent to allow the alternator to cool under lesser load and the Dash Lamp cir
cuit on the regulator will activate to provide power for a visual or audible alert enabling the user to respond to the
source of the condition Together the Balmar highoutput alternator and multistage to assure the best charge possible
Contents Safety Introduction Before installing your new alternator please take a moment to consider the follow
Safety 1 ing guidelines for safe alternator installation and operation Failure to follow these
Basic Installation guidelines could result in injury or damage to your vessels electrical system
Alternator Addl Information 1 Always disconnect your batteries and turn your battery switch to its OFF position prior to
Sizing Battery Cables 3 installing your alternator
Alternator Drive 2 Remove any loose fitting clothing or jewelry which could become entangled in your motor or
Vottage Regulation 4 other machinery
Fan Rotation 3 Wear ANSIapproved safety glasses or eyewear
Grounding Pulleys 4 Ensure that the engine has cooled sufficiently before beginning Alternator Heat 5 DO NOT install your
highoutput alternator without ensuring that the system wiring is suffi
Meters ciently scaled to handle increased amperage loads
Tachometers 6 Be sure that your work area is sufficiently ventilated and that no fuels or solvents
are pres
ent in and around your work area
Ratios 5
MultiBank Charging Options6 7 DO NOT operate your charging system without proper fusing Failure to do so could result in
Switches severe injury andor damage or loss of your vessel DONT take chances with fusing
8 DO NOT attempt installation while using alcohol or medications which could impair your
Isolators judgement or reaction time
Digital Duo 9 Use the right tool for the job Use of improper tools could result in damage or injury
Digital Duo Charge II 8
Twin Engine Charging Issues 9 10 Take time to read the manual Equipment damage and possible injury may result from an
Centerfielder incomplete understanding of the proper installation and use of the alternator
System 1011 CAUTION The following instructions are intended for use by experienced marine
Alternator Terminals electrical installers If you are not sufficiently experienced with marine electrical
Warranty systems we recommend a qualified electrician be used for Installation Information
Page 2
Basic Mounting
Due to the many domestic and international of mounts
and factors such as year and location of engine manufacture and marinization Balmar
cannot guarantee a dropin replacement in every engine application Choose the model
that most closely fits your application Your installer may have to adapt the basic
mounts to fit your needs The majority of marine engines are equipped with one of mounting styles The following describes which alternator represents
specific mounting style
1 60 70Series Dual Foot w315 between legs Small Case Replaces most small case styles
using a saddle style mount eg Hitachi Lucas 61 71Series 1 Single Foot Small Case Replaces most domestic styles using a single 1
mounting foot eg Motorola 612 712Series 2 Single Foot Small Case Replaces most domestic styles using a single 2
mounting foot eg Delco
4 622Series 2 Pad Mount Series Small case Replaces Korean Mando type alternators using
dual 2 static pad mounting feet Found on many Mercruiser and Volvo Penta gas engines
5 94Series 2 Single Foot Series Large case See case dimensions on our website at wwwbal
marnet to determine if your engine can accommodate the large case 95Series Dual Foot w4 between feet Series Large case See case dimensions on our
at to verify if your engine compartment can accommodate the large case
7 96 97 98Series Dual Foot w4 between feet Series Extra large case See case dimensions
at to determine if your engine can accommodate an extralarge case you determine that the desired alternator will just not replace the existing
excellent option may be to leave the existing alternator in place and purchase a
dual groove crank pulley for the front of the engine in addition to the existing pulley
Have a special mount fabricated or use the Balmar remote Alternator Bracket 5276
to accommodate a larger you have determined that the new alternator is the correct replacement for your
existing model
1 Disconnect the batteries andor turn the switch to the OFF setting Disconnect the wiring from
the existing Loosen the mounting tensioning bolts and remove the existing Once the alternator is disconnected from the engine compare its
mounting points to those on
your new Balmar alternator In most applications the new alternator will replace the old alterna
tor without any modification In some cases a simple bracket can be fabricated by a local
machine shop Balmar offers a universal mounting arm which can replace your existing tension
ing arm if needed Others can be obtained through your local auto or marine supply
4 Attach the mounting foot of the new alternator to its engine mount Some shimming may be nec
essary to ensure that the alternator is securely mounted within the engine mount If your alterna
tor is a dual foot style use care when tightening the alternator in place that the two mounting
ears are not compressed The rear bushing is designed to slide to tighten the mount
5 Once in place inspect to ensure that the alternator pulley is properly aligned with the engine pul
ley If your belt configuration includes the pulley for the water pump make sure that all three pul
leys are properly aligned Some shimming or modification to the alternator mount may be
required to assure proper alignment
6 Connect the output cable see cable sizing below ground field wire stator
tach wire if needed and other necessary wiring Connect alternator to Balmar regulator wiring
harness as indicated in wiring diagram included on Page 12 The alternators positive and ground
cables should be sized according to the chart on Page 3
Page 3 Belt Cables
7 If a new regulator is being installed along with the alternator complete its wiring installation according to the instructions includ
ed with your the alternator is installed and the wiring connections are attached inspect the pulley for proper tension When
changing pulleys or when using the pulley torque
Belt Tension shaft nut to 5060 footpounds The shaft nut measures 1516
To install the belt
1 Loosen the adjustment arm bolt and alternator pivot assembly bolt
2 Fit a new highquality belt over the appropriate pulleys
3 Tension the alternator until the belt is securely tightened in place Re
tighten the pivot assembly and tension arm bolts To test tension place a
1516 wrench on the alternator shaft nut and apply pressure If the pul
ley rotates without moving the belt reloosen the bolts apply additional
pressure and retighten Repeat until the belt is properly tensioned
4 Verify proper tension by pushing on the outside surface of the belt The
belt should deflect approximately 14 to 516 under moderate pres
sure Your local auto parts store may carry a measuring tool designed to
gauge belt Ensure that the Mounting bolts at the alternators pivot point are securely
ease of belt installation you may want to invest in an inexpensive belt tensioning tool like that sold by JC
Whitney This simple tensioner provides positive support at the alternator while increasing belt
tension leaving two free hands to retension mounting and tensioning belts
Your belt will tend to stretch during the first several times you run your engine Make it a part of your normal pre
flight check to test belt deflection and readjust belt tension when needed If you notice an accumulation of black
belt on your alternator and surrounding engine area check belt tension If the belt is tensioned and you still experi
ence belt dusting it may be necessary to reduce horsepower load on your belt with the regulators Amp if equipped or you may find that a different
brand of belt may work more effectively with your See additional information on Page Installation Battery Cables
The addition of a highoutput alternator to your charging system may make it necessary to increase the size of your
battery cables to increase the systems amperage carrying capacity To determine the proper cable size consider
BOTH cable length and alternator capacity Both positive and
negative wire runs must be included in your computation Length feet 5 10 15 20 25 30 40 50 75
In other words when determining battery cable size we 75 8 6 4 2 2 1 10 20 40
need to consider the round trip distance Wire size may be 100 8 4 2 2 1 30 with the formula CMK x I x LE
whereas CM rep
125 6 4 2 1 10 30 40
resents the circular mil area of the conductor K milfoot resistance of copper I represents current and L 150 6 2 1
10 20 30 the length in feet of the roundtrip cable run and 175 6 2 1 10 20 30 40
E represents voltage drop in volts 200 4 2 10 20 30 40
225 4 1 10 20 30 40
When using this equation a K constant of 1075 milfoot resistance and voltage drop should be cal 250 4 1 20 30 40
culated at 3 the standard for critical functions affecting 275 4 1 20 30 40
the safety of vessel passengers In most cases it may be 300 2 10 30 40
much simpler to use the following chart as your guideline 350 2 10 30 40
Rotation Page 4
Alternator Drive Belts
Your new highoutput Balmar alternator will increase horsepower load when compared to your standard OEM alter
nator This additional load may require that you replace the standard drive belt with a heavierduty unit Many after
market belt manufacturers supply premium quality belts designed specifically for heavyduty marine and Among these are the Green Stripe belt by Gates
and the Top Cog belt from Dayco In addition many
auto parts suppliers such as NAPA carry extra heavyduty belts designed to support larger horsepower loads
As well as belt quality belt size can have a substantial impact on alternator performance As a we
recommend a minimum 38 belt measured across the back of the belt for our 80amp alternators Minimum belt
width for 100 to 110amp alternators is 12 Any alternator larger than 110amps will require dual belts for opti
mal performance as well as acceptable belt life
The addition of a larger diameter alternator pulley can often improve belt Belt Manufacturer as it will increase belt wrap and surface
contact with the belt
Gates the increased pulley diameter will lessen the ratio between the
Dayco and flywheel pulley and reduce low end amperage output
Goodyear you find that your belt is undersized for your alternator the Amp Fenner mode available in the Max Charge MC612 12volt and MC
624 24volt multistage regulators enables you limit the maximum field potential of the regulator and limit load of the alternator This feature
accessible through the Max Charges advanced programming mode
can be adjusted in precise 2 increments so output can be adjusted to suit the system without losing more
charging current than necessary For more information see the manual included with your Max Charge MC612 or
MC624 regulator Many engine manufacturers can provide replacement pulleys to convert your drive system to
support dual belts
Sample Terminal the exception of our 6Series alternators which feature patent
ed Smart Ready internal regulation all Balmar highoutput alter
nators require external regulation in order to operate We recom
mend our multistage ARS4 and Max Charge regulators to balanced charging for most marine battery ordered with supplied wiring harness the voltage
can be mounted on a stringer or bulkhead up to four feet from the
alternator Excessive heat and exposure to coolant or saltwater can B
damage the regulator Consider that when determining regulator standard wiring harness measures
54 and features ring NOTE Some alternators may use ring terminals
rather than plugs for stator and field connectors at the alternator or plugs as seen at on which alternator is being used The flat plug indicated by
the letter A is used with our the grey rectangular plug indicated by the letter B is used with our 6Series and 9Series The black Tshaped plug
indicated by the letter C is designed for use with our 94Series alternators All
7Series 96Series 97Series and 98Series alternators use ring terminal alternators are designed to turn in a clockwise rotation Face the front of the
engine with the engine run
ning to determine direction of rotation Models in the 6Series and 7Series internal fan styles can typically be run
in either direction without difficulty Model in the 95Series 96Series 97Series and 98Series feature fans so reverse rotation is acceptable If using a
94Series alternator it may be necessary to replace the stan
dard fan with an optional fan to ensure proper cooling under load
Older 90 91 and 912Series alternators may also require a kit for rotation Keep in mind alternators with nonkeyed shafts will require pinning to
ensure proper performance A long
twist drill bit and a roll pin are included in the reverse rotation kit
Page 5 Balmar alternators are case grounded ie the alternator establishes its connection to the system ground
via the engine block While the ground is built into its engine mount we recommend that a secondary ground
cable be added to the ground terminal if equipped at the back of the alternator The installed ground cable
should be equal in size to the positive output cable as indicated on Page 3
Alternator models designated as Isolated Ground IG feature an independent ground terminal thats isolated from
the alternator case Typically Isolated Ground alternators are used in applications where the engine is not desired
to be a part of the grounding system This is commonplace in steel or aluminum hull boats or with engines that
depend on sophisticated electronic ignition systems In Isolated Ground alternator the ground cable
should be connected to the central ground small case alternators rated at 110 amps or less come standard with a single
groove 25 deep vee pulley The deep vee pulley is designed to provide optimal
power transfer for belts measuring 38 10mm to 12 13mm as the back of the belt Keep in mind 38 and 716 belts may sit low in
the pulley sheave This will not adversely affect the belts performance Higher
output alternators in small large and extralarge case series are with 12 dual groove pulleys Some models including may be equipped with multigroove
serpentine type your application require a different pulley than that provided as
standard Balmar may carry an optional pulley more suited to your needs
For a list of optional pulleys visit call Balmar Customer Service at Heat
During operation your alternator will become hot as a result of friction and the generation of inductive current In
some instances particularly during extended periods of heavy load alternator case temperature can exceed 200
degrees F If your system is operating with an ARS4 or Max Charge MC612 voltage regulator with Temperature Sensor MCTSA the regulator will
automatically reduce the alternator output by 50 percent if temperatures exceed set safe working limits While this is an extremely effective the
alternator it should not be depended upon as a part of normal operation Correction of conditions are strongly advised
Use extreme caution when handling the alternator or other engine components during or after use Should become so hot that it emits a burning smell or
if there is indication of discoloration at the pulley or pul
ley shaft shut off the alternator immediately and once it becomes safe to inspect the alternator check the ten
sion of the drive belt Under and belts are the leading cause of overheating and alternator dam
age See the section later in the manual for alternator inspection your standard alternator with a highoutput Balmar alternator may dictate that your
standard amp
meter be replaced with a high amperage shunttype meter We strongly recommend replacing your amp meter
with a more fully functioning charging system monitor such as the Link Meter from XantrexHeart Interface In
addition to metering system current these system monitors will indicate battery condition and estimate battery
time remaining before charging is needed
issues Page Balmar alternators provide a source of unrectified AC voltage Tach Manufacturer from
the stator output This stator output provides the pulse Teleflex to drive most electric tachometers Most current Balmar
VDO feature 12pole stator outputs meaning 12 pulses of AC Stewart Warner during each alternator revolution Extralarge case
98Series ISSPRO older 9Series alternators feature 14pole stator outputs
Many standard and aftermarket electrical tachometers feature some level of adjustment to calibrate the tachome
ter to your alternators pole settings and pulley ratios If your existing tachometer does not provide any may be necessary to replace the existing
tachometer with an adjustable American Boat and Yacht Council ABYC in its standards for safer boating recommends that cable runs to
your battery banks be fused to protect the boat and owner against damage and injury Circuit protection as
described by ABYC standards can be accomplished by installing either a resettable circuit breaker or a fuse The
fuse or breaker you choose will depend on both the amperage rating of the alternator and the size of cable used
Blue Sea Systems a respected manufacturer of highquality fuses and circuit breaker devices recommends the fol
lowing when sizing the proper circuit protection for your system Fusing should be
1 The largest available circuit protection device smaller than the amperage capacity of the cable being protected
2 Larger than the maximum continuous current that will flow in the circuit
We find that a circuit protection device sized at approximately 140 of your alternators rated amperage is for the circuit being protected For more
info about circuit fusing see Ratios
In order to achieve optimal performance from your charging system it is essential to determine the capacity your
charging system is capable of supporting In general the size rating of the alternator should mirror the of the batteries being charged Differing
battery technologies will vary in terms of their acceptance rates For
example a deepcycle flooded battery is typically capable of accepting roughly 25 percent of its available capacity
at any given time As a result we want our alternators rated output to equal the acceptance rate of the battery
being charged when it reaches its full discharge rate In other words a deeply discharged 400 amp hour deep cycle
flooded battery would require an alternator rated at 25 percent of 400 amps or 100 amps to support that bank
In simpler terms a deepcycle flooded battery bank will require 25 amps of alternator output for every 100 amp
hours of battery rating Some newer battery technologies such as AGMs and spiral wound batteries can accept up
to 40 percent of their available capacities as such alternator output should be increased to reflect the optimal
ratio between alternator and battery to meet recommended ratios will commonly result in slower charge times heat and wear and reduced alternator
Bank Charging Options
When charging a single starting battery the alternator can be connected to the battery directly or via an More typically in a marine system the
alternator will be supporting a smaller starting battery and larger
house battery bank or a starting battery along with multiple banks for house loads inverter loads windlass or
thruster Many methods of multibank charge control are available ranging from manual switches to products like
Balmars Digital Duo Charge which automatically provides charging current to the starting battery whenever charg
ing voltage is present at the house battery
The following section outlines many of the most commonly used options for multiplebank battery management
Page 7 MultiBank Charge in two primary types ONOFF or ABBOTH manual switches offer a simple method for charging man
agement Possible installations include separate cables to each battery bank with ONOFF switches in line for each
bank or a common output cable to the common post of the ABBOTH switch with an output cable to each battery
bank Field disconnect switches feature terminals where the field output from the regulator to the alternator can when the battery switch is turned to
the OFF position This feature ensures that alternator output is as soon as the battery is disconnected NEVER operate the alternator with switches in
OFF so could cause alternator diode damage
Advantages Inexpensive No substantial voltage drop
Require user interaction and heightened system Can be accidentally shut down
causing potential alternator damage Does not allow for mixed battery Voltage Sensing Battery voltage sensed must always be that of battery being
charged Sense voltage at com
mon side of battery switch or at alternator positive combiners enlist highamperage solenoids to charge multiple battery banks Below a specific
voltage set
point the combiners solenoids remain open isolating the individual battery banks Once the baseline voltage is
reached the solenoids open combining all of the batteries into one big bank
Advantages No user interface required No substantial voltage drop Available in 2 or 3bank models
Moderately expensive Does not allow for mixed battery Voltage Sensing Sense voltage at common side of combiner or at alternator positive diodes
direct charging current to the battery bank with the greatest demand Best suited for battery banks
that are comparable in size and degree of discharge Isolators are not necessarily the best choice when and start battery banks Only one battery bank
can be sensed by the regulator so under or overcharging can
be a substantial issue if batteries are dissimilar in capacity or degree of charge Diodes can drop voltage at the
battery side of the isolator by nearly a full volt which means that the alternator is forced to increase voltage far in
excess of that needed by the batteries
Advantages No user interface required Reasonably priced Available in 2 or 3bank models
Substantial voltage drop Can only sense voltage at one battery bank May drive voltage at sec
ondary battery bank to dangerously high levels May hold high voltage for too long at smaller bank Tendency to
under or overcharge secondary nonsensed battery bank Greater chance of early battery failure
Voltage Sensing Voltage must be sensed at most commonly used battery bank typically house Connect
sense wire to battery side of isolator or positive post of battery being Duo Digital Duo Charge connects between the house and start secondary
batteries keeping the two until the unit senses 13 volts 2624V at the house battery Once voltage is reached the Duo up to 30A to the secondary bank
Voltage is regulated at the secondary bank based on a preset by the user to reflect the secondary battery type Standard and deep cycle flooded gel
and AGM battery
types are supported Optional battery temperature sensing and solenoid drive are included 12 or 24volt settings
Advantages No user interface required Selectable programs ensure proper voltage control even with varied
battery bank capacities and mixed battery Amperage limits require smaller wire gauge Works
with DC or shorepower charge sources Simplifies charging control for alternator and regulator
30amp maximum output may not support larger secondary banks bowthruster windlass etc
without use of manual solenoid control See Digital Duo Charge on Page 8 for higher amperage option
Voltage Sensing Alternator and regulator supply house bank only Sense at house batterys positive post or at
the positive output of the alternator
MultiBank Charge Control Page 8
Sample Duo ChargeDuo Charge II Wiring Duo Charge II
Available Summer newest Digital Duo Charge II
connects between the house and batteries keeping the
two banks separate until the Duo
Charge senses charging at the house battery Once
voltage is reached the Duo Charge II
supplies up to 60 amps to the second
ary bank Voltage is regulated at the
secondary bank based on a chosen by the user to reflect
60amp for
the secondary battery type so both
Duo Charge II
house and secondary batteries charging current Standard
and deep cycle flooded gel Optima
and AGM battery types are battery temperature sensing
and solenoid drive control are includ
Advantages No user interface
required Selectable programs
ensure proper voltage control
even with varied battery bank
capacities and mixed battery con
structions Ensures optimal charg
ing based specifically on the
needs of each battery bank Works
with DC or shorepower charge
60amp for
sources Simplifies charging con Duo Charge II
trol for alternator and regulator
Digital numeric 4 LED display
provides detailed operational data
Forces user to
have fun and concentrate on boating rather than worrying about charging system
Voltage Sensing Alternator and regulator supply house bank only Sense at house batterys positive post or at
the positive output of the Engine
Should more charging power be required than is conveniently available from the engines primary alternator many
boaters choose to install a second alternator In these applications alternators can be used separately as dedicat
ed charge sources for the various battery banks or the outputs from both alternators can be combined to provide a
single source of charging This will require that the field wire from a single regulator be split to supply both This system is commonly used to
supply a large house bank with a Duo Charge unit providing charging cur
rent to the starting battery Max Charge regulator is recommended for dual alternator operation
Advantages Provides substantial increase in available charging amperage Builds in system redundancy
Requires addition of new bracketry and upgraded crankshaft pulleys Potentially expensive
Voltage Sensing Depends on whether alternators are dedicated to specific banks or if they are combined to
support a single bank Voltage must be sensed at the batteryies being charged
Page 9 Twin Engine Issues
Twin Engine Issues
Twin engine applications pose some unique challenges in addressing battery needs Some primary charging are as follows
1 Dedicate Alternator 1 to charge engine starting batteries May be done with a switch or by connecting the alternator output to
one engine battery and a Digital Duo Charge from the primary to the secondary engine battery Dedicate Alternator 2 to the
house battery bank
2 Combine outputs from Alternator 1 and Alternator 2 to provide increased charging amperage for the main house battery
bank and supply the engine and other secondary batteries via Digital Duo Charges or combiners Combining the output from
two alternators on two engines will require the use of Balmars Centerfielder described below This configuration will require
that both alternators are equipped with Max Charge regulators which are designed to provide suffi
cient field current to drive two alternators For additional information download
the Centerfielder instructional manual from the Balmar website Centerfielder enables twin engine systems to balance so available amperage from both
alternators can be combined to
support larger battery banks The Centerfielder monitors field and on port and starboard voltage regulators Max Charge MC612 or MC
624 regulators strongly recommended depending on system voltage When both regulators are up and running
the Centerfielder identifies the dominant regulator and splits its field to supply both alternators with the same exi
tation voltage This allows the user to supply output from both alternators to the same battery bank In systems the output can be directed to
additional banks via Digital Duo Charge or other control on Page 8 or Page 9 A typical system wiring design is shown below
System Page 10
System the causes of failures in an electrical system is a step by step process Before you begin your search
to determine if the failure can be attributed to the alternator or the volltage regulator we recommend you inspect
and clean all system electrical Most charging system problems will be corrected by performing the following steps
1 Remove and clean all charging system electrical connections from the alternator the batteries and wire runs this includes the
ground side Also check the voltage regulators harness for resistance Wires and terminals can and will become corroded and
may need to be cleaned or replaced Check all fusing in the regulator harness and alternator output cables
2 Charge all batteries to their proper fully charged state and determine if they are serviceable If your batteries are use your hydrometer to
determine their condition
3 Check and tighten alternator belt If the belt shows signs of wear or damage now is an ideal time for replacement Always
replace existing belts with the finest quality replacements determining that your batteries and wiring are in suitable condition use the following
tests to determine if
charging problems are a result of a faulty alternator or regulator The following tests provide an opportunity to iso
late the alternator regulator and wiring harness in order to determine which component may be In
order to perform these tests you will need a simple test lamp available at most auto parts or marine West Marine sells Ancor continuity testers for
just a few dollars A digital handheld multimeter can also be
helpful in checking for voltage drop and resistance in wiring and terminal connections A clamptype DC Amp meter
may be useful in diagnosing amperage issues A 10 long 14gauge wire with insulated alligator clips at each end
provides the ability to take measurements with your test lamp or multimeter with a centralized ground Regulator Diagnosis
The failure of the voltage regulator to provide field current to the alternator will cause the charging system to fail To
begin the voltage regulator tests check to see that the regulator display is lit when the engine is running If the reg
ulator display fails to light after the engine is started
1 Connect your ground extension wire as described above to your second ground terminal at the regulator Connect the other
end of the extension to the ground probe of the test light Turn your ignition switch to the ON position if the regulators brown
ignition wire is connected to an oil pressure switch connect a jump wire across the oil pressure switch
2 Apply the test lights positive probe to the red power wire in regulators black 4wire plug If the test light does not illuminate
follow the red power wire to its source at the battery alternator output or common side of the battery switch and test for
power there
3 If the red power wire has power at that location replace the 10amp fuse in the red power wire and recheck for power at the
regulator wiring plug If the wire has no power at the regulator end inspect for damage along the length of the wire and
as needed
4 If the red power wire lights the test lamp but the regulator display remains unlit apply the positive probe of the tester to the
brown ignition wire If the test lamp remains unlit follow the brown ignition wire to its source and test the source with your
test lamp If the source illuminates the test lamp repair or replace any damaged wire or connectors needed until the test lamp
indicates current at the regulator end of the brown ignition wire
5 If the regulator is a Max Charge MC612 follow the same testing guidelines for the Positive Battery Sense wire damaged wire connectors or
fusing as needed
If the regulator display is illuminated yet charging is not occurring be sure to wait beyond the 45second delay
before taking test readings
1 Apply the test lamps positive probe to the blue wire in the regulators black 4wire plug with negative probe connected to the
regulator ground If the test lamp does not illuminate the regulator may be damaged If the regulator is within the warranty
period see Warranty Info on Page 12 call our Customer Service Department at If the test lamp is illuminated the regulator is providing field
current and the charging problem is likely elswhere in the charg
ing system
3 Follow the field wire to its connection at the alternator Disconnect from the alternator and apply the test lamp to the wire If the
lamp illuminates the regulator and wiring harness are likely to be good
Page 11 System the regulator and harness are tested and proven good disconnect the negative probe of the test
lamp from
the regulator ground and connect the negative probe to the field terminal of the alternator Connect the to the blue field wire coming from the
1 Monitor the test lamp If the lamp does not illuminate the alternator may not be completing the connection to ground Check
the ground connections at the alternator to system ground If you know how you can use your multimeter to check for resistance
between the alternator and ground
2 If the meter indicates substantial amount of resistance between the alternator and the system ground a wiring or terminal con
nection issue is indicated Recheck system ground cabling and wiring
3 If an internal fault is indicated as a result of testing remove the alternator and contact Balmar Customer Service or your local
alternator shop for If the test lamp is illuminated when connected inline between the the regulator field wire and the alternator field terminal
a metallic object a screwdriver blade works well near the front of the alternator pulley shaft or the rear bearing cover of the
alternator If the screwdriver blade is magnetically drawn to the alternator the alternators internal components appear to be
functioning correctly
5 If the test lamp is lit and magnetism is detected you can remove the test lamp reconnect the blue field wire and start the
engine Once the engine is started and the regulators initial start delay is complete voltage should climb to levels set by the
Diagnosis Independent of Regulator
The alternator can be tested independently of the regulator and wiring harness by connecting the alternators directly to battery voltage Once
connected to battery voltage the alternators pulley shaft and rear bearing
cover should generate a substantial magnetic pull If no pull is present an internal wire or may be at fault To test the alternator only
1 Connect one side of the test lamp to a source of positive battery voltage Connect the other to the alternators field terminal If
the test lamp illuminates and the alternator indicates magnetic current start the engine This is known as full fielding the alter
2 With the lamp connected and the engine on voltage at the alternators positive output terminal should steadily climb The Lamp
will act as an inline resistor so voltage rise should be moderately controlled Once charging voltage is indicated check output
voltage with your multimeter the engine can be shut down A steadily climbing voltage at the alternator output indicates good
alternator alternator and regulator tests indicate proper operation further investigation into battery damage or wiring failure
is recommended If charging system performance continues to be compromised we strongly advise that you seek
the assistance of a certified marine electrical For additional assistance or contact
our Customer Service department at Balmar 200405 Ballard Commercial Industries Inc Arlington WA
98223 March Smart Ready Internally Regulated 6Series alternators require slightly different diagnosis to determine if the Smart
Ready internal regulator is functioning correctly To test the internal regulator
1 Disconnect the external regulator wiring harness from the alternator wiring plug containing the
field and stator wires Turn the ignition switch to the ON position
2 Contact the positive probe of your test lamp on the FIELD terminal of the wiring
plug Connect the testers negative probe to ground If the internal regulator is
functioning properly the test light will If testing the operation of the internal regulator with a multimeter adjust the
meter to read 12V DC before placing probes at the field terminal and ground If
the regulator is working correctly the meter will show approximately 3V DC
Wiring By Alternator Series Page 12
6Series Alternators 7Series Alternators
BALMAR warrants to the original the product is free from any defects in material or
workmanship for a period of one year from the date of
purchase If any such defect is discovered within the
warranty period BALMAR will replace the regulator
free of charge subject to verification of the defect or
malfunction upon delivery or shipping prepaid to BAL
This warranty DOES NOT apply to defects or physical
damage resulting from abuse neglect accident
improper repair alteration modification or unreason
able use of the products resulting in breakdown
cracked or broken cases nor are parts damaged by
fire water freezing collision theft explosion rust
corrosion or items damaged in shipment in route to
BALMAR for repair BALMAR assumes no 9Series Alternators 9Series Alternators ty for consequential damage or loss or expense aris
Single Output Dual Output ing from these products or any labor required for serv
ice or repair
BALMAR WILL NOT repair or be held responsible for
any product sent without proper and
return address or RA number clearly marked on the
package You must include proof of date and place of
purchase photocopy of purchase invoice or we can
not be responsible for repairs or replacement In order
to expedite warranty claims more efficiently BALMAR
asks that prior to returning a defective product for
repair you call their customer service department for
a warranty return authorization number
If factory service is required you can contact our BAL
MAR Customer Service Department Monday through
Thursday 730 AM to 530 PM PST1360 4356100
ext 3
Material required for the repair or replacement for the
94Series Alternators 95Series Alternators defective part or product is to be supplied free of
charge upon delivery of the defective regulator to BAL
MAR 19009 61st Ave NE Arlington WA 98223
Customer is responsible for all return charges and any air or rush delivery expense BALMAR
reserves the right to determine whether to repair or
replace defective components
BALMAR 19009 61st Ave NE Arlington WA
98223 Ph 360 4356100 Fx 360 4353210
Email Web Alternators 97Series Alternators 98Series Alternators Please note
Included information is
believed to be correct at
time of publication
Products may change in
design or output without
prior notice If actual pin
locations or features differ
from that shown contact
Balmar Technical support at
3604356100 Balmar is
not liable for damage or
injury derived as a result of
information included in this
document See our website
at for new
and updated product infor
6Series Alternator Wiring Addendum
Isolated Ground Terminal Isolated Ground Alternators
IG MODELS ONLY 621Series Alternators
Ignition BROWN Positive Battery Sense RED Positive
Battery Sense RED
Connects to red wblack wire REQUIRED when REQUIRED
when internal
Ignition BROWN
in Yanmar harness for internal regulator is used
regulator is used
Connects to ignition
internally regulated operation source if internal regulator
See reverse side of addendum for is used see reverse
suggested wiring when used with
external Diode Trio
Field Wire BLUE Field Wire BLUE
to ext regulator to ext
Stator Wire Stator Wire
White in 12V White in 12V
Orange in 24V Diode Trio Positive Output Orange in 24V Diode Trio
Positive Output
External Regulator D Circuit External Regulator
D Circuit
Terminal Terminal
Harness Plug Harness Smart Ready alternators
feature a simple singlestage regulator that can be used as a stand alone unit or as an emergency backup unit in
621Series with a smart external regulator When used with an external regulator it is necessary that the brown ignition wire in the alternator plug
Include a 1inch spacer with an integrated bushing This
be disconnected from ignition voltage We recommend the use of a doublethrow toggle switch as discussed on reverse to control regulator activity
spacer can be used to modify the alternators 1inch mounting
foot to be compatible with 2inch mounting Case Ground nonIG alternators the ground wires in the regulator wiring harness can be connected to one of
the unused threaded holes in This is a pushin spacer thats designed to fit tightly inside the
the alternators tensioning arm with an 8mm bolt To ensure proper grounding screw in and unscrew the bolt a few times before securing the bolt
mounting foots 12inch
with the ground wires attached This will help remove any paint which could compromise grounding to the alternator case
bore To ensure a proper
The function of the D circuit is to provide a low voltage DC source in applications where lamp functions are driven by that source This function
fit the bushed spacer
is typical in many Volvo engines The D circuit should NOT be used unless required to drive your engines charge lamp circuit DO NOT
should be compressed into
attempt to use the D terminal as a connection point for your ground wires Doing so could damage both the alternator and regulator
place with a Cclamp or
Color version of this document available at bench vise
Suggested Smart Ready Back Up Regulator Wiring
6Series Alternator Wiring Addendum
To Ignition Source Switch or OilPressure Switch
On non models ground wires and
grounding cable should be connected at the mounting
Ground BLACK bolt at the pivot point of the alternator DO NOT
Double Throw Switch two in 12V attempt to connect the ground wires or grounding
cable to the D terminal at the back of the 6Series alternator is Doing so
could result in serious damage to the
designed for use with Balmars alternator and voltage Charge MC612 12volt or
MC624 24volt multistage 1 2 Ground Post
voltage regulators The diagram
IG models only
below provides a guideline for
wiring connections between the
MC624 and the Voltage
In addition to its ability to be Ignition BROWN Sense RED
Switch Ext regulated this alternator
PowerSense an internal Smart Ready
regulator thats intended to provide an
immediate backup in the event of the loss
of the external regulator When Smart Ready regulator in the external multistage regulator we Field the use of a double
throw switch to BLUE
direct switched voltage to the brown in the regulator wiring harness and in wiring plug
The addition of the double throw switch enables
the user to quickly switch from to internal regulation in the event of
a failure of the external regulator DO NOT
both Ignition switch wires to separate
of switched voltage
For additional wiring details see reverse
side of this addendum
D low volts
To External Regulator
6Series Alternator Wiring Addendum
Using internal regulator in conjunction with an isolator
3Amp 200Volt
To House Axial Diode
Battery Bank To Ignition Radio Shack 2761143
When using the 6Series alternators internal regulator in conjunction with an application
utilizing a battery isolator
To Engine 1 Connect the red wire included in the alternators fourwire plug to the battery Bank terminal supplying the house battery bank
2 Connect a wire equipped with a 3amp 200volt axial diode Radio Shack Part 276
1143 between the alternators positive output terminal and the brown wire connected to a To System
switched voltage source ie ignition switch or oil pressure switchThe banded end of the
diode goes towards the B alternator terminal Use heat shrink to cover the diode leads

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