Sunday, November19, 2017 L-36.com

' Balmar 8 Series Alternator Manual'




NOTE: DO NOT HIT REFRESH!!! These files are big and can take a long time to load. This file is 2.02 MB. Give it time.
If there is text in the file, you can scroll it while the image loads. Enjoy

View PDF

Image Preview



Ad by Google

PDF to Text


80Series Alternators
50 65 and 100A Models
Model 81
Basic ERS
Regulator Included Model 812
I highoutput BALMAR Marine Alternator is uniquely designed and
TABLE OF
engineered to provide the finest performance and durability for your vessel most alternators found standard on the majority of
I craft BALMAR Marine Alternators are specially designed to output at lower engine rpms so you can enjoy less noise and II
Safety increased economy and shorter charge cycles III General SAFETY
IV Basic installing your BALMAR marine alternator please take a moment to
V Additional the following guidelines for safe alternator installation Failure to follow
these guidelines could result in injury or damage to your electrical system
Always disconnect your batterys ground cable and turn your battery switch VI to its OFF position prior to installing your Remove any
loosefitting clothing or jewelry which could become VII Warranty
entangled in your motor or other machinery VIII Quick Wear ANSIapproved safety glasses
Guide
4 Do not attempt installation if tired or fatigued
5 Ensure the engine has cooled sufficiently before initiating Drugs and alcohol do not mix with safe installation procedures Do not
CAUTION
attempt installation while using alcohol or any medication that could The following instructions are
impair your judgment or reaction time intended for use by Always use the right tool for the job In
addition to causing damage to the marine electrical installers If
alternator or your boat the use of incorrect or tools can you are not experienced at
result in personal injury installing electrical system
8 Take time to read the manual Equipment damage and possible injuries components we recommend a
may result from an incomplete understanding of the installation and qualified marine electrician be
operation of the alternator used to install this 19009 61st Ave NE Arlington WA
98223 On the Web PHONE 360 4356100 FAX 360 4353210 EMAIL 1
III GENERAL alternators are available in a wide range of sizes mounting and amperage outputs to replace or upgrade a
wide range of marine alternators All BALMAR alternators are P type positive on the field wire with max field current demand 6 amps
and 24 ohm rotors in 1214 volt are rated in relation to their outputs at our test bench at specific pulley rpm Circuit breakers fuses and wire
gauges should
be rated at or above maximum indicated alternator amperage Actual amperages produced by the alternators after installation may vary
due to factors such as battery capacity battery type wiring capacity engine room temperature and other variables In most output is determined by your
batteries absorption rates at their voltage set alternators are engineered for external regulation A basic singlestage regulator set at 141 volts is
included with Voltage can vary up to 3 plus or minus Caution should be used when running for long periods when used with gel While the standard
regulator supplied does provide an adequate charge control we recommend a multistep regulator for
optimized charging In addition to its ability to provide a smart charging protocol thats tailored to your battery type our Max Charge
has the ability to monitor and compensate for temperature variation in both the alternator and your batteries with optional Combined with amp
management soft ramp up and start delay the Max Charges advanced and help provide the tools to increase charging speed and reduce engine and
alternator marine alternators are designed to operate in a clockwise rotation facing the pulley and fan This clockwise rotation draws
cool air from the back of the alternator across the internal components to maintain proper operating temperatures Should the alternator
be used in a secondary position mounted in an opposing direction to the engine or should the alternator be mounted on an engine the alternators
pulley must be keyed andor pinned and the alternator must be equipped with a fan
Reverse Rotation Kits are available for most BALMAR 80Series marine alternators are isolated ground It is essential that the alternator is properly
grounded We you ground your alternator to the negative terminal of your house battery or your vessels ground buss with a cable thats
the same size as your output cable Running your grounding cable directly to the engines ground bolt also provides a good source of
ground The regulators grounding wires must be attached to the alternators negative terminal see Figure and Electrical Noise
As part of normal operation your BALMAR marine alternator will make a slight whining noise while under load This whining an indicator that the
alternator is charging In addition to a mechanical whine you may experience a small amount of sticking
or drag when the alternator is new This is caused by the wood separators in the stator With use the separators will wear and the sticking
will be nature electricity producing equipment like alternators may create electrical noise or interference that can be transmitted to and other
electronics Your BALMAR alternator has been designed to minimize electrical interference persists we recommend adding noise reduction filters to your
system One provider of quality noise reducing filters is Marine
Tech Inc at 800 7720796
Figure 1
Wire Size
Proper wire size is essential for safe and operation The accompanying Voltage drop
chart provides a basic guide that should be used proper wire lengths for charging systems
see Figure 1 Wiring used should be marine quality
AWG boat cable rather than SAE automotive wire is normally tinned or treated to
protect against the corrosive marine environment Use
only wire that is marked with size and type In addition
to wiring all connectors used in vessel also be manufactured for marine use
When determining the proper wire size for wire length should be measured by the
distance required to reach from the positive power
source to the electrical device and back to the connection The chart to the right provides a
general guide for wire size If your specific falls between the values shown use the
larger wire size recommended Contact the ABYC BIA
or your marine electrician for additional information
Heat
During operation your alternator may reach temperatures of 200 degrees as a result of inductive currents In some instances extended periods of heavy
load temperatures can reach 225 degrees F Temperatures exceeding that may result in damage If
your system is operating with a Max Charge regulator with optional alternator temperature sensing the regulator will automatically shut
off the alternator when temperatures pass set values giving the alternator the ability to cool to normal temperatures before returning to
operation While this is an extremely effective device for alternator protection it should not be used as part of normal Continual alternator
overheating indicates ventilation or charging system problems and repair is strongly advised
Use extreme caution when handling the alternator or other engine components during or after use Should your alternator become so
hot that it emits a burning smell or if there is indication of discoloration at the pulley or pulley shaft shut off the alternator once it becomes
safe to inspect the alternator check the tension of the drive belt belts are a leading cause and alternator damage For more information see the
Maintenance section of this and Belts
A 25 deep V pulley is included with your alternator This pulley will accommodate from 38 to 12 single belts or metric are not created equally and in
most instances you get what you pay for Premium quality belts such as Gates TriPower or Daycos Topco or similar belts will provide a better value
over lesser quality belts in both dependability We strongly recommend you always carry a spare belt as part of your emergency kit Alternators rated
at 75amps or less
should use a minimum belt size of 38 Alternators rated at 100amps should use a minimum belt size of 12
IV BASIC Alternator installation requires substantial amount of mechanical and electrical If you are not alternator installations we strongly
recommend that you enlist the services of a qualified marine electrician Keep in mind performance is only as good as the wiring and battery
installation If you are unsure of the condition of your boats batteries
or wiring please have them inspected by a qualified electrician before proceeding with the alternator Mounting
Due to the many domestic and international of mounts and factors such as year and location of and marinization BALMAR cannot guarantee a dropin
replacement in every circumstance Choose the BALMAR 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 two alternator mounting styles shown in Figures 23 To determine your alternator requirement compare your
present alternator to those shown below The single 1inch model is typically a replacement for Motorola style alternators foot models generally
replace Delco style you have determined that the new alternator is the correct replacement for your existing model
1 Turn off batteries disconnect the ground and
detach the wiring from the existing alternator Figure 2 Figure 3
2 Loosen the mounting bolt 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 alternator without any modification In some
cases a simple bracket can be fabricated by a
local machine shop BALMAR offers a universal
mounting arm which may solve some mounting
challenges Others can be obtained through your
local auto or marine supply
4 Attach the mounting foot of the new alternator to Single Foot 1 Mount Single Foot 2 Mount
its engine mount Some shimming may be
necessary to ensure that the alternator is securely mounted within the engine mount If your alternator 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 pulley If your belt includes the pulley
for the water pump make sure that all three pulleys are properly aligned
6 Your new alternator is shipped with a simple singlestage regulator with six wires connected to its epoxy potting See Figure 4
The wiring is arranged as follows
a Brown Br Ignition source Wire Attaches to the auxiliary side of the vessels ignition switch or an independent oil pressure
switch to turn on regulator Used when the orange wire is NOT used
b Orange O Lamp Wire This wire turns on the regulator when connected to a warning lamp that is connected to the aux
side of the key switch optional Used when the brown wire is NOT used
c Blue B Field Wire Attaches to the positive
field terminal on the alternator as shown in
Figure 4
Figure 5
d Red R Sensor Wire Attaches to the
positive terminal of the battery positive
output of the alternator common terminal
of the battery switch or the battery side of
an isolator if used
Choose only one of
e White W Stator Wire Attaches to the
Stator terminal on the alternator as shown these two potential
in Figure 5 If an electric tachometer is power sources
used an additional white wire should be
run from the other stator terminal to the
tachometer as shown in Figure 4
f Black Bk Ground Wire Attaches to the
negative ground terminal as shown in
Figure 4
7 Once the wiring is connected attach the
regulator to the alternator by bolting the angled
tab at the bottom of the regulator to one of the
14 head bolts located next to the cover plate
at the back of the alternator as shown on the
inset in Figure 4
8 Once the regulator and control wires are in
place the alternators positive output and
negative ground cables should be attached
Positive output cable should be connected at the
the bolt shown on Figure 4 The other end of the
cable should be connected to the positive
terminal of the battery or the common output Mount regulator on
terminal of the battery switch if used with rear of alternator as
multiple battery banks Refer to the Voltage Loss shown Regulator
Table FFigure 1 to determine proper cable can be mounted on
gauge right or left side of
the The ground cable must provide a sure
connection to the batteries negative
terminal This can be accomplished
by grounding the alternator directly
Figure 5 Alternative
to the negative battery terminal or to Regulators
your engines grounding bolt Be sure Max Charge MC612
your cabling is the same size as that Max Charge MC412
of the positive output ARS4
BRS2
Smart Regulator Wiring
Should you choose to upgrade your system
to include the intelligent Max Charge regulator or other
BALMAR models use Figure 5 as your wiring
guide In addition to its smart the Max Charge regulator has
the unique ability to automatically and alternator temperatures for temperature of normal values when used with
optional temperature sensors To install temperature sensor
1 Attach the positive and negative
wires to the Alternator temperature
Sensor terminals on the Max Charge
regulator see the Max Charge
manual for terminal locations
2 Attach the heavy lug terminal to the mid case mount on your alternator Due
to the number of alternator some installations may vary
Figure 6
Pulley 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 the shaft nut to 5060 footpounds The shaft nut 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 Retighten
the pivot assembly and tension arm bolts To test tension place a 1516
wrench on the alternator shaft nut and apply pressure If the pulley rotates
without moving the belt reloosen the bolts apply additional pressure and
retighten Repeat until the belt is properly tensioned See Figure 6
When installation is complete run the engine Visually inspect the engine for evidence of poorly aligned pulleys and belts Use caution to avoid hot
or moving parts Turn off the engine after approximately 15 minutes and belt tension
V ADDITIONAL INSTALLATION isolators may be used with any BALMAR alternator Its capacity must equal the maximum alternator output To compensate for
volt drop sensing must be on the battery side If a dualoutput alternator is used for more than two battery banks each output must have
its own dedicated standard inline Amp meters are UNDERRATED for our alternators and should be removed from the system Replace your existing
amp meter with a standard volt meter Should you wish to read output Amps a high capacity 0100 or 0200 amp external should be installed Digital meters
like the Link 10 or Link 20 by Heart Interface are excellent tools for charging system alternator tachometer is energized by the pulse frequency
generated by the alternator which in turn is dependent on the speed BALMAR 80Series alternators feature 12pole construction Most standard tachometers
are engineered for engines pulley to crankshaft ratios of 18 to 28 to 1 on alternators with 12 poles
The AC terminal or stator terminal may be used for electric tachometers not equipped their own
Figure 7
sending unit Tachometers will have to be adjusted and calibrated as necessary We the engine up to a cruise RPM 2000 marking the throttle position
BEFORE the is disconnected After the installation is complete run throttle up to mark and set to its appropriate RPM If you cannot set your existing
tachometer a like the Teleflex Model 82430P should be considered as a replacement Should bouncing
of the tachometer be observed when the batteries are fully charged turning on some DC loads
will often cure the most efficient output connection is a direct wire between the alternator and the battery If your
battery switch is closer to the alternator than the batteries you may connect the output cable to
the common output terminal DO NOT turn the battery switch off when the engine is damage to the diodes and the regulator could fusing of the charging
system is required by ABYC standards BALMAR recommends that the alternator outputs be protected by
a fuse or manual reset circuit breaker BALMAR 75 100 and 150amp circuit breakers are available at your local marine supply or may
be special ordered through BALMAR See Figure 7 If the alternator is connected directly to the battery the breaker should be located
close to the battery the causes of failures in an electrical system is usually a trial and error process We recommend that you begin
your search by determining if the failure can be attributed to one or more of the most common causes of charging system wiring damaged connectors
worn or damaged belts worn or overly sulfated batteries or bad grounds
A general inspection of the following conditions prior to testing will ensure the accuracy of your test results Before testing
1 Remove and clean all charging system electrical connections this includes the ground side Also check the harness for
resistance The wires or terminals may become corroded and need to be cleaned or replaced
2 Charge all batteries to their proper fully charged state and determine if they are serviceable If your batteries are flooded
type use your hydrometer to determine their condition
3 Check and tighten alternator belt If the belt shows signs of wear or damage now if 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 isolate the alternator regulator and
wiring harness in order to determine which component may be If you are using the Max Charge regulator please
refer to the instructions included in the Max Charges instruction manual
Regulator Field Test
The following tests are intended to help determine what part of your charging system may be experiencing difficulties When
testing voltage ensure that your voltmeter is adjusted to its 12V setting Use the space below the Expected Reading to keep
track of your own readings
First Test Engine Off The functionality of the regulator harness and alternator can be tested by determining if a magnetic field
exists at the alternators pulley shaft To test
1 With the ignition in the OFF position place the head of a steel screwdriver near the nut on the pulley shaft There should
be no evidence of a magnetic field pulling the screwdriver toward the alternator
2 With the ignition in the OFF position and your voltmeters negative probe applied to the alternators grounding bolt check
for voltage on the RED sensing BLUE field and BROWN ignition wires by inserting the positive lead of the voltmeter
alongside each wire at the terminal at the back of the alternator or in the case of the brown wire at an applicable wire
connection The voltmeter should read
Red Wire Brown Wire Blue Wire
Expected Reading 12 V 0V 0V
Your Reading
115 128 VDC battery voltage at rest no charging occurring If your batteries are isolated and your RED sensing wire shows voltages other than
those shown above make sure that the wire is connected on the battery side of the isolator The RED wire must see the battery directly
3 Once you have measured voltage at the three wires and have determined that there is no magnetic field at the pulley shaft
or rear bearing turn your ignition switch to its ON position without turning on the engine If your regulator is activated by
an oil pressure switch turn on your engine Caution if the engine must be run during these tests use extreme caution to
avoid contact with moving parts or hot engine or alternator surfaces
4 Place the head of a steel screwdriver near the nut on the pulley shaftDO NOT attempt this test with the motor running
There should be evidence of a magnetic field pulling the screwdriver toward the alternator If magnetic field is present the
regulator is working properly as well as the alternators rotor and brushes
5 With the ignition in the ON position engine not running except in cases of oil pressure switched circuits measure the
voltage at the same three wires as before The voltmeter should read
Red Wire Brown Wire Blue Wire
Expected Reading 12 V 12 V 7 12 V
Your Reading
115 128 VDC battery voltage at rest no charging occurring If your batteries are isolated and your RED sensing wire shows voltages other than
those shown above make sure that the wire is connected on the battery side of the isolator The RED wire must see the battery the voltage is measured
with the ignition on and the engine off the engine can be started for the final regulator test To
collect your final readings
1 With the ignition in the ON position and the engine running measure the voltage readings at the Red Blue and Brown
wires The voltage values should read as follows
Red Wire Brown Wire Blue Wire
Expected Reading 12 14V 12 V 4 12 V
Your Reading
135 145 VDC battery voltage when completes the regulator test If the voltages measured at your regulator match those target readings shown in the
tables above
and if the alternator produces a magnetic field the regulator and harness are working correctly The presence of a magnetic field
is also an indicator that the alternator rotor and brushes are functioning correctly If one or more of the voltage readings different than the target
readings shown above the regulator or harness may be damaged or defective
Alternator Field Test Figure 8
By eliminating the regulator from the charging circuit it is possible to determine if
charging failure is caused by the alternator Testing the actual output of is known as Full Field Testing This can be accomplished by jumping current
to the field terminal at the rear of the alternator This both the regulator and the harness making it easier to isolate to the alternator CAUTION
Voltage is unregulated during this test and
could damage sensitive electronics Ensure that all voltage sensitive equipment is
turned off and any connections between the alternator and the regulator prior to starting the engine To test the alternator
1 Disconnect the BLUE field wire from the alternator Attach shielded alligator
clips to both ends of a test wire
3 Attach one end of the test wire to the alternators field terminal and attach the
other end to the positive output of the alternator see Figure 8 If an isolator
is used jump to the field from the battery side of the isolator CAUTION Do
not allow the wire to contact the case while it is attached to the positive post
4 The motor should be run long enough to determine that charging voltage is
present Unregulated voltage can rise quickly Do not allow extended
unregulated charging to occur without carefully monitoring voltage levels
If the alternator fails to generate voltage during full field testing an alternator malfunction is likely Contact your local shop or Balmars
technical service staff for Conclusion
If your readings differ substantially from the Expected Readings listed in the charts above the regulator may be there may be a continuity problem
Contact our technical support staff at 360 4356100 Keep your recorded readings in the
spaces provided below the Expected Readings so you can share them with the technical support person
If the preceding tests do not prove the existence of a failure within the regulator or alternator we recommend you contact a
licensed marine electrician who can test your system for wiring and circuit damage or other system failures that could for charging difficulties If
you determine that repair service is necessary for either your alternator or regulator please
gather the following information before contacting our service Model of Model of voltage regulator
3 Voltage readings on red brown and blue wire at regulator with engine off key on
4 Voltage readings on red brown and blue wire at regulator with engine running at a fast ideal 1400 rpm
VII LIMITED PRODUCT WARRANTY
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 BALMAR
This warranty DOES NOT apply to defects or physical damage resulting from abuse neglect accident improper repair alteration modification or
unreasonable 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 for consequential damage or loss or expense
arising from these products or any labor required for service 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 cannot 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 BALMAR Customer Service Department Monday through Thursday 730 AM to 530 PM PST1360 435
6100 ext 3
Material required for the repair or replacement for the defective part or product is to be supplied free of charge upon delivery of the defective
regulator to
BALMAR 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
THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS
NO PERSON AGENT DEALER IS AUTHORIZED TO GIVE ANY WARRANTY
BALMAR 19009 61st Ave NE Arlington WA 98223 Ph 360 4356100 Fx 360 4353210
Email Web 7
VIII QUICK INSTALLATION This BALMAR marine alternator is intended for installation by a qualified marine electrician If you are not marine
electrical we strongly recommend investing in the services of a qualified technician The following is a of a typical alternator installation Your
installation may vary based on engine type and age This basic guide is meant
for quick reference and should not be used without first reading the rest of the manual To install the Turn off the battery and disconnect the
ground wire Disconnect the wiring from the existing Loosen the mounting bolt and remove the existing Compare existing mounting points to
those on your new BALMAR alternator In most applications the new alternator will replace
the existing alternator without any modification Some cases may require some bracket modification BALMAR offers a universal
mounting arm which may solve some mounting challenges 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 necessary to ensure a secure mount
5 Inspect to ensure proper pulley alignment If your belt also drives the water pump ensure all pulleys are properly aligned
6 Your alternator is shipped with a simple singlestage regulator The wiring is arranged as follows
a Brown Br Ignition source Wire Attaches to the auxiliary side of the vessels ignition switch or an isolated ground oil
pressure switch to turn on the regulator Used when the orange wire is NOT used
b Orange O Lamp Wire This wire provides power to the regulator when connected to a warning lamp optional Used when
the brown wire is NOT used
c Blue B Field Wire Attaches to the positive
field terminal on the alternator as shown in Figure 9
Figure 9
d Red R Sensor Wire Attaches to the positive
terminal of the battery positive output of the
alternator common terminal of the battery
switch or the battery side of an isolator if
used
e White W Stator Wire Attaches to the Stator
terminal on the alternator as shown in Figure
9 If an electric tachometer is used an
additional white wire should be run from the
other stator terminal to the tachometer as
shown in Figure 9
f Black Bk Ground Wire Attaches to the
negative ground terminal shown in Figure 9
7 Once the wiring is connected between the
regulator and the alternator the alternators
positive output and negative ground cables should
be attached Positive output cable should be
connected at the the bolt shown on Figure 9 The
other end of the cable should be connected at the
positive terminal of the battery If your battery
switch is closer to the alternator than the batteries
you may connect the output cable to the common
output terminal Refer to the Voltage Loss Table
Figure 1 to determine proper cable gauge
8 The ground cable must provide a sure connection Mount regulator on
to the batteries negative terminal This can be rear of alternator as
accomplished by grounding the alternator directly shown Regulator
to the negative battery terminal or to your engines can be mounted on
grounding bolt Be sure your cabling is adequately right or left side of
the alternator
sized to match your amperage load
CAUTION Always follow the safety
guidelines outlined on Page 1
19009 61st Ave NE Arlington WA 98223 On the Web PHONE 360 4356100 FAX 360 4353210 EMAIL

Ad by Google

Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.