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' Balmar Max Charge Mc 612'




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Max Charge MC612 Regulator
Installation and Operators Manual
I Max
Charge MC612 is the most available Designed to continual
ly monitor battery voltage and charging the MC612 uses up to 12 time
and voltage increments to ensure your a full charge quickly and safely
The MC612 lets you choose from a variety of programs to best suit your charging needs Its
Universal Factory Program allows you to connect the MC612 to
your alternator right out of the box Six additional preset programs support most popular battery types including stan
dard and deepcycle flooded batteries AGM gel and Optima spiral wound technologies as well as special settings for
systems supplying halogen lighting An easytouse magnetic reed switch delivers quick precise regulator your charging system require adjustment the
MC612 provides additional advanced options
When used with optional alternator and battery temperature sensors the MC612 automatically monitors ambient alter
nator and battery temperatures and compensates by adjusting field output to match conditions Alarm outputs connect
to audible or visual alarms to provide warnings of dangerous
CAUTION
II SAFETY The following instructions are
Before installing your MC612 marine regulator please take a moment to con intended for use by these guidelines for safe regulator
installation Failure to work safely could marine electrical installers If you
result in personal injury or damage to your electrical system are not experienced at installing
1 Always disconnect your battery banks and ensure that switches are OFF electrical system components we
prior to installing your regulator recommend the use of a qualified
marine electrical Remove loosefitting clothing or jewelry which could become entangled in
your motor or other machinery
3 Wear ANSIapproved safety glasses
4 DO NOT attempt to modify the regulator Alterations could result in TABLE OF CONTENTS
damage to your charging system and will void your warranty I Introduction Do not attempt installation if tired or fatigued
II Safety III Issues Ensure the engine
has cooled before initiating Warranty Do not attempt
installation while using alcohol or any medication that IV Regulator Installation could impair your judgment or reaction time
V Alarm and Sensor Installation Always use the right tool for the job Improper tool use may damage VI Basic Programming
the regulator or your boat and could result in personal injury VII Advanced Programming Take time to read the manual Equipment damage
and possible IX injuries may result from an incomplete understanding of the installa Suggested Wiring Options
tion and operation of the MC612 regulator If you are unfamiliar with Express Installation marine electrical systems consult with a licensed
marine
19009 61st Ave NE Arlington WA 98223 PHONE 360 4356100
FAX 360 4353210 EMAIL WEB
Copyright 2001 Ballard Commercial Industries Inc Revised 3152003
III ISSUES
The following information is essential to the proper operation of your Max Charge regulator Do not install or operate before review
ing the POSITIVE BATTERY SENSE WIRE User supplied not in harness This wire must be connected to the regulator
and to a source of positive battery voltage see Figure 3 for mounting location to provide proper regulator operation
The regulator WILL NOT WORK if the sense wire is not connected to the regulator or the voltage source The Positive
BATTERY SENSE WIRE MUST BE FUSED A 1amp ATC fuse and holder are included with the regulator and harness
2 GROUNDING The Model MC612 must be properly grounded to regulate accurately The two ground wires located
in the harness must be securely attached to their terminals and at the alternators preferred ground to ensure proper
grounding A grounding cable between the alternator and the system ground is strongly VOLTAGE READINGS MC612 digital circuitry is engineered to
monitor battery charge state and compensate for changes in battery voltage during operation As a result it is NOT unusual to see changes in
the regulators Battery Voltage display These voltage changes reflect the regulators ability to make precise
corrections to optimize charging efficiency based on changes in system loads
5 ELECTRICAL TACHOMETERS Many factory and aftermarket tachometers require an AC pulse from the alternator
to drive the tachometer If you are using an electrical tachometer that is being driven off of your alternators stator
pulse plug the white stator wire into the terminal provided on the regulator and the tach feed into the Tach Out termi
nal If you are not using the stator pulse to drive your tachometer DO NOT plug the stator wire into the regulators
Stator connection
When using the alternator and regulator to drive your tachometer there is a possibility that you will see surface volt
age creeping in excess of target voltage when batteries are fully charged and there is no load on the system This
occurs as a result of the regulators effort to provide just enough voltage to keep the tachometer feed activated This
voltage creep can usually be reduced or eliminated by increasing the load on the batteries ie turning on a few cabin
lights or cabin fans until the batteries are allowed to accept charging voltage
4 DUALOUTPUT OPERATION When using the MC612 with a dualoutput alternator it is essential that the regulator
senses the largest battery bank The positive Battery sense wire must be attached to the alternator output terminal
connected to the larger battery bank or at the larger bank If your system includes a large house battery and a smaller
starting battery there is the possibility that the smaller battery may see excess surface voltage during charging
5 ALTERNATOR BATTERY TEMPERATURE SENSORS optional Alternator Temperature Sensor monitors for
conditions at the alternator If alternator temperatures outside of safe limits are detected the regu
lator will reduce alternator output to 50 and will activate an alarm circuit NOTE This option is not intended to be
used as part of regular operation If circuit is activated inspect and repair the system immediately Optional Battery
temperature sensing compensates for above or belownormal battery temperatures by automatically adjusting charg
ing voltage It is not unusual to see charging voltage rise safely above normal levels when battery temperatures are
below 26C or drop when temperatures exceed 26C
6 MAGNETIC REED SWITCH Not all magnets are alike You may find that one magnet will activate the reed switch
with little effort while another similar magnet may require a bit of maneuvering to find the switchs sweet spot If
you have difficulty adjusting program modes be sure to check for the dot at the top of the LED between the second
and third display digits to ensure that you are activating the switch
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
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 4356100 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 AUTHO
RIZED TO GIVE ANY WARRANTY
19009 61st Ave NE Arlington WA 98223 Phone 360 4356100 Fax 360 4353210
Email Web 2
IV REGULATOR Mount the regulator in a dry location
away from hoses and exhaust manifolds which may
cause damage to the regulator or wiring Avoid areas of
heat andor high vibration Strain relief should be added
at the alternator end of the harness to minimize risk of
wire damage
2 The RED wire in the harness powers the regulator
Attach at the positive output terminal at the back of the
alternator If an isolator is used this wire must be locat
ed on the battery side of the isolator THIS WIRE MUST
BE PROTECTED BY A 10AMP FUSE included in the
wiring harness
3 The POSITIVE battery sense wire monitors battery volt
age The positive and negative sense wires MUST be con
nected for the regulator to work The positive sense wire
may be connected 1 at the positive output terminal of
the alternator at the positive post of the battery if sin
Figure 1 Regulator wiring attachment
gle bank system or at the common terminal of the bat
tery selector switch or 2 on the isolator terminal for the largest bat Length 10 Ft 15 Ft 20 Ft 25 Ft 50 Ft 75 Ft 100 Ft
tery bank only if isolator is used This wire is user supplied and Amps
25 10 8 8 6 4 2 1
should be 16gauge minimum Spade and ring terminals and a 1A 50 8 6 4 4 1 20 30
mini fuse pigtail are provided FUSING IS REQUIRED Refer to regula 75 6 4 2 2 20 30 40
tor side label or Figure 3 below for terminal locations Caution 100 4 2 2 1 30 40
Sense wires MUST always see the battery being charged Be sure to 125 4 2 1 10 30 40
150 2 1 10 20 40
observe polarity when connecting When connected the Positive 175 2 10 20 30
Battery Sense draws approximately 053mA Note System voltage 200 2 10 20 30
must exceed 110 VDC for regulator to operate 225 1 20 30 40
250 1 20 30 40
4 The BROWN ignition wire activates the regulator when 12VDC is 275 10 20 40
applied to the system Attach the BROWN wire to a switched 12VDC 300 10 30 40
source The auxiliary side of the ignition switch or an independent 325 10 30 40
350 20 30
ungrounded oil pressure switch are both acceptable connection 375 20 40
points A toggle switch may be added to this circuit to shut down the Figure 2 Cable size chart Represents 3 voltage drop
alternator load in cases where maximum propulsion is needed Lengths should be measured in round trip Attach the 4conductor
harness plug to the regulator see output cable can result in
The second BLACK ground wire in the harness attaches to the
Secondary Ground Terminal Both BLACK wires attach to preferred ground terminal on the alternator A user supplied ground
strap between the alternator and the system ground at the engine is also strongly Connect BLUE field and WHITE stator wires to plug or ring
terminal connectors at alternator May vary by alternator type
7 If you are using an electrical tachometer that is being driven off of your alternators stator pulse plug the WHITE stator wire
into the terminal provided on the regulator and the tach feed into the Tach Out terminal If you are not using the stator pulse
to drive your tachometer DO NOT plug the stator wire into the regulators Stator connection as the attachment of the stator
wire to the regulator tells the regulator that it is necessary to continue to provide a voltage pulse to maintain a tach signal
even if the batteries are fully charged
When using the alternator and regulator to drive your tachometer there is a possibility that you will see system voltage creep
ing up when your batteries are fully charged This occurs as a result of the regulators effort to provide a blip of voltage to
the alternator to keep the tachometer feed activated This voltage creep can usually be reduced or eliminated by applying a
load to the Figure 3 Regulator terminal layout
V ALARM AND SENSOR Temperature Sensor MCTSA Optional
The Alternator Temperature Sensor enables the regulator to sense when alternator safe limits The MC612 responds by reducing the field current at the
alternator and activat
ing the alarm output To install the Alternator Temperature Sensor
1 Attach the positive and negative wires to the Alternator Temperature Sensor terminals on the
MC612 See Figure 4 Observe proper polarity at the terminals
2 Attach the heavy lug terminal to a location described below on your alternator Flat washers
are included with the temperature sensors to ensure solid mounting connections The following
are typical installation locations
MID CASE MOUNT Small Case Alternator Remove 1 of 4 532 Allen bolts install probe
resecure bolt See Figure 5 Figure 4 Proper attachment
MID CASE MOUNT Large Case Alternator Remove 1 of 4 316 Allen bolts install probe of optional battery and alter
resecure bolt nator temp sensors at the
The alternator temperature sensor is not
intended as a method to maintain alternator Optional temperature sensors are not a guarantee
of protection against damage from overheat your system as quickly as possible if the sensor
alarm is Temperature Sensor MCTSB Optional
When equipped with an optional Battery the MC612 will automatically compensate for
variation above and below normal MC612 is equipped with dual battery sensors to
enable sensing at two separate batteries To ensure
proper operation be sure the battery terminals are com Figure 5 Mounting temp sensor Figure 6 Mounting temperature sen
pletely clean and free of corrosion prior to installation midcase on small case alternator sor on battery negative terminal post
To install the Battery Temperature Sensor
1 Secure the 38 copper probe to a clean negative battery terminal see ALARM OUTPUT
Figure 6 The 20 leads may be shortened or extended if needed Note An improp
erly installed or corroded battery terminal may generate heat and severely diminish FUNCTIONS
charging and impede accurate temperature sensing Alarm Output Dash Lamp
2 While observing polarity connect the battery temperature pins to the positive and 05 amp when in alarm mode
negative terminals as shown on Figure 4 Low battery voltage 030
High battery voltage 040
Note Battery 1 terminal is capable of temperature compensation and activating warn
High temperature at battery 1 020
ing alarm Battery 2 terminal activates the warning alarm only The upper voltage limit
High temperature at battery 2 021
for battery temp compensation is 148 volts If higher limits are desired adjust voltage lev High temperature at alternator 022
els in the Compensation Limit CL mode of the advanced programming adjustments
Aux 1 Advisory Output
Lamp Alarm Outputs
05 amp when in alarm mode
Two output terminals one for system alarms dash lamp and and another for advisory
Alt output at full Aux 1 are included These terminals output battery negative 05amp Small engine option activated 051
max when in alarm condition Refer to Figure 7 for common system conditions that may Equalization mode an alarm When in the alarm mode
the 3digit numeric display will indicate the
exact cause for the alarm in Long Display Specific advisory codes are shown in Figure 17 Figure 7 Dash Lamp and Aux 1
advisory output Engine Mode
The MC612 can be switched to provide a halfpower setting by installing a toggle switch between the positive and negative terminals
of the alternator temperature sensor circuit When activated by closing the switch the regulator reduces the alternator output by a
maximum 50 This mode is ideal for smaller engines that are not capable of providing suitable horsepower to drive both the alterna
tor and propeller at full output When in Small Engine Mode the regulator will send a signal to the Auxiliary 1 Status Output
VI BASIC Model MC612 provides a wide range of operational programming and diagnostic data through its 3digit numeric LED an initial startup period
the numeric LED will cycle through the Short Display shown in Figure 8 on the following page The
short display includes manufacturer model battery type charging cycle actual voltage and target voltage This display cycles during regulator
operation
In addition to its Universal default factory program which can be used safely with most battery types the MC612 features pro
grams for gel standard lead acid deepcycle lead acid AGM absorbed glass mat Optima spiral as well as halo
gen 4
The MC612 is equipped with a magnetic reed switch embedded in the epoxy potting the regulators programming The switch works in two specific actions
described in
the shaded box below
Refers to the activation and immediate deactivation of the switch
by lowering the magnetic programming tool onto the upper corner of the switch and
immediately deactivating the switch by removing the magnet from the switch An LED
dot between the second and third digits on the display will indicate switch activation
RELEASE Typically used during programming this action requires
holding the magnet to the switch until desired values are shown on the display Once the
desired setting is reached the magnet is removed to deactivate the switch
Note Program function will alternately cycle up or down each time the programming mode is activat
ed If you miss your desired program value release the switch wait for the program mode display eg
PRO and reactivate the switch The direction of scroll will reverse Any advanced programming values
will be retained within the regulators memory until the preset battery programming is reset
To set the regulator for your desired battery program
1 the switch The display will show the Pro mode indicating that the
Program mode has been activated
2 HOLD while the display scrolls until the numeric Note Reed switch is
equivalent to your battery type is displayed on the Figure 8 Normal short display
potted between left side
LED screen See Figure 10 to determine which of display and the edge
selectable preset program is most desirable for your
of the circuit board
battery technology Figure 11 provides detailed
Switch activation is
information regarding preset programs
indicated by lit dot
3 RELEASE when the desired value is attained between second
4 Once a value has been chosen the display will and third LEDs
return to the Pro mode At this point you can
adjust up or down by repeating Steps 1 through 3
until your desired program is selected
If no changes are made the program you have selected
will be locked into permanent memory until modified The
SAV code will be displayed indicating the program has
been locked into Stages
The MC612 uses up to 12 individual stages to ensure
proper charging Each stage may contain a specific volt Figure 9 Location of magnetic reed
age or time value or a combination of values These switch Long display preset are displayed in both Short and Long Display
ming and advanced programming are
modes and are described in Figure 12 accessed by activating switch Figure 10 Preset program codes
Primary Program Settings PRG1 PRG2 PRG3 PRG4 PRG5 PRG6 PRG7
Universal Deep Cycle Gel Absorbed Optima Standard Halogen
Factory Flooded Cell Glass Spiral Flooded Voltage
Mode Program Lead Acid Mat AGM Wound Lead Acid Sensitive
Start Delay Seconds 45 45 45 45 45 45 45
Ramp Up Seconds 60 60 60 60 60 60 60
Bulk Voltage Max 1410 1460 1410 1438 1460 1440 1400
Bulk Time Minimum 36 min 36 min 36 min 36 min 36 min 36 min 36 min
Absorption Voltage 1390 1440 1390 1418 1440 1420 1380
Absorption Time Minimum 36 min 36 min 36 min 36 min 36 min 36 min 36 min
Float Voltage 1342 1335 1370 1338 1340 1340 1350
Float Time Maximum 6 hr 6 hr 6 hr 6 hr 6 hr 6 hr 6 hr
High Voltage Alarm 1520 1560 1510 1538 1560 1540 1500
Low Voltage Alarm 1280 1280 1280 1280 1280 1280 1280
Max Battery Temperature 125F52C 125F52C 125F52C 125F52C 125F52C 125F52C 125F52C
Max Alternator Temperature 225F107C 225F107C 225F107C 225F107C 225F107C 225F107C 225F107C
Equalization User Prog Yes Yes No Yes No Yes No
Figure 11 Preset program values Voltages shown may vary by 3 from values shown Caution Some battery technologies may be
damaged by equalization voltage Contact your battery manufacturer for specific requirements regarding
5
Long Display
To access the Long Display switch with the
magnetic programming tool while the Short Display is cycling
The numeric LED return to the beginning of the cycle The long
display will begin with the same elements shown in Figure 8
Additional information as detailed in Figure 13 will follow
The display will scroll throught the long program once to the short for these codes can be found in Figure 14 To
reset advisory codes access the Advanced Programming mode
as described at the beginning of Section VIII AP mode will
cycle three times and return to normal mode Codes will reset when AP mode is complete
Figure 12 Charge stage codes as seen in Long ADVANCED
programming AP program Any changes in AP will be based
on the battery the basic battery program
will automatically clear any settings To access
1 With regulator in Long Display
mode ACTIVATEHOLD until the
Pro display code appears
RELEASE The PrA display Figure 13 Long Display LD attributes as displayed on digital numeric readout
code will appear CODE 001 Factory use only CODE 022 Alternator exceeding
recommended
temperature limits
CODE 002 Factory use only
CAUTION If the switch is held too long the regulator will return to
C CODE 010 Wire short at battery 1 tempera CODE 024 Factory use only
ture sensing terminal CODE 030 Voltage too low at battery
the preset program adjustment mode Once in advanced program CODE 011 Sensor wire not found at battery CODE 031 Factory use only
mode the display will cycle through the various advanced program 1 temperature sensing termi CODE 032 Factory use only
ming modes see Figure 15 Advanced Progamming mode will cycle CODE 012 Wire short at battery 2 tempera CODE 040 Voltage too high at battery
CODE 041 Factory use only
three times before returning to standard operating mode ture sensing terminal
CODE 042 Factory use only
CODE 013 Sensor wire not found at battery
Start Delay PrA Mode 2 2 temperature sensing termi
CODE 050 Open field
CODE 051 Small Engine Mode 45second delay prior to charging can be increased or CODE 014 Wire short at alternator tempera
CODE 052 Amp manager is in operation
ture sensor in duration To adjust CODE 015 Sensor wire not found at alternator Underlined codes
represent those pertaining to
temperature sensor terminal Alarm Output dash lamp operation
1 ACTIVATEHOLD switch when DLc is highlighted on the CODE 020 Battery 1 exceeding recommend Codes highlighted by an
asterisk pertain to
Advanced programming display Beginning at 45 the dis ed temperature limits Aux 1 advisory output
CODE 021 Battery 2 exceeding recommend
play will begin to increase in onesecond increments ed temperature limits
RELEASE when desired time is shown
Figure 14 codes
2 To change direction of scroll ACTIVATEHOLD until values
begin to rise RELEASE and wait for DLc display RE
ACTIVATE and HOLD until desired value is met Limit PrA Mode 3
When equipped with optional Battery Temperature Sensor the
MC612 will automatically voltage to battery default mode the regulator is
limited to maximum compensat
ed voltage of 148 volts to mini
mize the likelihood of Limit allows the
user to advance or compensated voltage
to suit specific charging system Figure 16 Indicates Figure 15 Advanced Programming PrA
needs Compensation Limit mode
Limit adjust voltage compensation limits
1 ACTIVATEHOLD switch when CL is displayed see Figure 16 Value 148 will be highlighted Display will scroll upward
RELEASE when desired value is shown
2 To reduce compensated voltage limit ACTIVATEHOLD until voltage limit value is displayed RELEASE When CL is again dis
played REACTIVATE and HOLD Regulator display will scroll in opposite direction RELEASE when desired value is Voltage Adjustment Bulk Absorption Float
PrA Modes 4 6 8
User adjustment of charging voltage above or below preset levels is possible in PrA modes 4 6 and 8
To adjust voltages in bulk absorption or float stages
1 ACTIVATEHOLD switch when the desired code is displayed see Figure 17 Bvbulk Avabsorp
tion or Fvfloat voltage Standard preset program voltage will be highlighted Display will scroll
upward RELEASE when desired value is shown
2 To reduce voltage ACTIVATEHOLD until voltage values begin to climb RELEASE When voltage
mode is eg BV REACTIVATE and HOLD Voltage values will scroll in opposite
Figure 17 Voltage adjust
direction RELEASE when desired value is reached
ment Bulk Voltage Minimum Time Adjustment Bulk Absorption Float PrA Modes 5 7 9
Minimum charging time above or below preset levels is adjustable in PrA modes 5 7 and 9 in tenths of an hour To adjust minimum times in bulk
absorption or float stages
1 ACTIVATEHOLD switch when the desired code is displayed see Figure 18 Blcbulk
and F1cfloat time Standard preset program times will be highlighted Display
will scroll upward RELEASE when desired value is shown
2 To reduce minimum time ACTIVATEHOLD until time values begin to climb RELEASE When pro
gramming mode is eg B1c REACTIVATE and HOLD Minimum time values will
scroll in opposite direction RELEASE when desired value is reached Figure 18 Time Manager AP PrA Mode 10
Absorption time shown
The Amp Manager function enables you to reduce the alternator output by limiting alternator field This
feature can be used as a method to minimize alternator overheating when alternator is undersized to the
battery bank as well as minimizing difficulties with chronic belt slippage Amp Manager adjustments are
made in 2 increments To adjust Amp Manager values
1 ACTIVATEHOLD when display cycles to AP See Figure 19 PrA Mode 09 AP will be fol
lowed by OFF code RELEASE
2 ACTIVATEHOLD OFF display cycles to 249 The value 249 represents full field output The
numeric value on the display will decrease until you RELEASE To reverse direction of scroll RE
ACTIVATE and HOLD when AP appears RELEASE when desired value is reached Figure 19 Amp Manager
Note The value 185 represents approximately 75 field output 125 represents approximately mode
50 field output and 65 represents approximately 25 field Mode EQ PrA Modes 11 12
Allows increase in charging voltage to minimize battery sulfation Equalization is ONLY suggested for
batteries noted as equalization friendly in Figure 11 on Page 4 Consult your battery equalization time and voltage Equalization must be initiated
through the It is NOT a standard mode of operation Once equalization voltage and time values are
saved into the regulators programming the equalization process will start immediately Once has occurred the regulator will revert to its preset
program status The user will need to reacti
vate equalization mode for subsequent For system safety equalization voltage is limited
Figure 20 EQ voltage mode
to 158 volts NOTE BOTH EQUALIZATION TIME AND VOLTAGE MUST BE SET TO INITIATE CHARGE
To adjust equalization voltage PrA Mode 11
1 PrA display cycles to Ev followed by OFF code
2 OFF display cycles to numeric voltage values When the ommended voltage is reached RELEASE
To adjust equalization time PrA Mode 12
1 PrA Display cycles to Ec followed by OFF code
2 OFF display cycles to numeric equalization time values When the manufac
Figure 21 EQ time mode
time value is reached 7
Field Threshold Control FbA FFL PrA Mode 13 14
The regulator utilizes a number of factors when determining when to change between charging stages
A primary factor considered is the amount of energy the alternator is having to expel to meet This alternator workload can be determined by
monitoring the percentage of field current the
regulator is applying to the alternator When determining when to change from Bulk to and then from Absorption to Float stage the regulator looks to
see how hard the alternator is
working In preset programming target field voltage under 75 is considered the standard threshold
for advancement to the next charging stage among other factors
In applications where the alternator is oversized for the battery load it may be necessary to reduce Figure 22 Field Threshold
the threshold below the standard 75 to ensure that the batteries continue to charge efficiently adjustment Bulk to
Inversely if an alternator is undersized for the battery load the threshold can be raised to reduce Absorption display is shown
undue load on the alternator Two user adjustments are provided in Advanced Programming mode
Field Bulk to Absorption FbA and Field Float FFL Directions for adjustment are applicable to
either mode of adjustment To adjust
1 ACTIVATEHOLD when display cycles to FbA Bulk or FFL Float See Figures 22 23 PrA
Modes 13 14 Value of 220 will be displayed Values will scroll downward RELEASE when
desired value is reached
2 To reverse the direction of scroll REACTIVATE and HOLD when the FbA or FFL codes are high
lighted RELEASE when desired value is The value 220 represents approximately 165 field output 110 represents approximately Figure 22
Field Threshold
50 field output and 55 represents approximately 25 field output adjustment Field to Float
display is shown
VIII SYSTEM majority of charging difficulties can be attributed to damage corrosion or wear at wires or wiring connections Before attempt
ing to troubleshoot potential alternator or regulator issues be sure to address the following
1 REMOVE AND CLEAN all charging system electrical connections positive and negative Check the voltage regulators harness
for resistance Wires and terminals can and will 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 flood
edtype use your hydrometer to determine their condition
3 CHECK AND TIGHTEN alternator belt If the belt show 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 fol
lowing 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 regula
tor and wiring harness in order to determine which component may be In order to preform these tests you will need an independent a digital type In
an emergency a 12V light bulb or test light can be used
to help determine if power or working grounds exist An amp meter and a with a thermometer are also helpful diagnostic tools
Regulator Test
After inspecting and repairing wires and connections belts and batteries set your BlueBlack to 12V and connect the
voltmeters negative lead to the BLACK ground wire Figure 23 Inserting voltmeter probes
at the regulator see Figure 23
1 With the ignition OFF check voltage on the RED sensing BLUE field
and BROWN ignition wires in the regulator plug
2 With the ignition in the ON position engine not running check for voltage
on the RED sensing BLUE field and BROWN ignition wires The volt
meter should read
3 With the ignition in the ON position with engine running at 1400 rpm
fast idle check for voltage on the RED sensing BLUE field and
BROWN ignition wires in the regulator plug
Compare your readings with the table at right If readings on RED or BROWN
wires do not match values shown check 10amp and 1amp fuses wiring back to their sources If RED and BROWN match expected read
ings but BLUE does not unplug and replug fourprong plug and retest If the
BLUE wire shows zero voltage and the display is not lit check connections and
fusing on the Positive Battery Sense wire Check voltage at the base of the
Positive Battery Sense terminal with your test meter
VOLTAGE TEST voltage is not present on the RED the BROWN and the Positive Battery Sense Wire the regulator will not work If voltage is as
expected at the RED the BROWN and Positive Battery Sense wire and there is zero or an unexpected voltage reading at the BLUE
wire contact our technical support staff at 360 4356100 or email us at all voltages at the regulator meet expectations yet the alternator is not
producing charging current we will want to test the alter
nator The following describes the recommended methods for determining alternator TESTING
Test A The alternator and regulator can be tested for function by determining if a magnetic field exists at the alternators pulley shaft
or rear bearing To test
1 With the ignition in the OFF position place the head of a steel screwdriver near the nut on the pulley shaft or near the rear
bearing of the alternator There should be no evidence of a magnetic field pulling the screwdriver toward the Engage the ignition WITHOUT starting the
engine to activate the voltage regulator If an oil pressure switch is used a jumper
across the switch will activate the regulator
3 After allowing time for the regulators startup delay place the head of a steel screwdriver near the nut on the pulley shaft or
near the rear bearing of the alternator There should be substantial magnetic pull If a magnetic field is present the voltage
regulator alternator brushes and rotor are likely to be working B If there is little or no magnetic pull at the pulley shaft or at the rear bearing
initiate the following test
1 With the key off and the engine off remove the large harness plug from the regulator
2 Insert the end of a short length of electrical wire to the RED connector slot of the regulator
harness and the other end of the wire to the BLUE connector slot See Figure 24 This
bypasses the regulator and tests the alternator and the harness
3 Using your steel screwdriver inspect for a magnetic field as described above
4 With your voltmeter check for voltage on the blue wire at the alternator If voltage does
not exist the harness may be at fault If voltage does exist at the harness but no magnet
ism is present the alternator is likely to be a magnetic field is present Both harness and alternator brushes and rotor appear to be work Bl
R
ing properly If no magnetic field is present proceed with the next test
Test C Testing the actual output of the alternator is known as Full Field Testing This can be Figure 24 Jumping power wire by jumping a positive
12VDC current to the field terminal at the rear of the alter field
nator This test eliminates both the regulator and the harness making it easier to isolate your investigation to the alternator CAU
TION Ensure that all voltage sensitive equipment is turned off prior to starting the engine Voltage is unregulated during this test
and could damage sensitive electronics DO NOT let the engine run any longer than necessary to detect charging If the system is
not charging remove the alternator and have it inspected by a qualified alternator shop or call Balmar for warranty test the Clip a jumper wire to
the positive post of the alternator or on the battery side of the isolator if an isolator is in use Use a
SHIELDED alligator clip for post attachment Unintentional contact between the alligator clip and the alternator case could
result in damage to your electrical system
2 Disconnect the fieldstator plug from the rear of the alternator and attach the other end of the jumper wire to the alternators
Field terminal F Attach a female spade connector to the field end of the wire for a solid connection CAUTION Do not allow
the wire to contact the case while it is attached to the positive post The case is grounded and severe damage could occur
3 The regulator is now bypassed When the ignition is engaged and the motor is started the voltage should rise and charging cur
rent should be present
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 field testing a malfunction of the alternator is likely Contact your local shop or Balmars
technical service staff for your readings differ substantially from the Expected Readings listed in the charts above the regulator may be or
there may be a continuity problem Contact our technical support staff at 360 4356100 If you determine that repair service is nec
essary for either your alternator or regulator please gather the following information before contacting our service Make and model of
Model of voltage regulator and date of mfg date punched on rear side label of 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
Wiring Options SingleDual Outputs
Suggested Wiring Options 11
Max Charge MC612 Quick Installation MC612 can be installed with very little difficulty if installation instructions are followed carefully If you are
marine electrical we recommend a licensed marine electrician See Page 2 before starting To install
1 Mount the regulator in a dry location well away from hoses and exhaust manifolds which may cause dam
age to the regulator or wiring Avoid areas of heat andor high vibration
2 The RED wire in the harness powers the regulator Attach at the positive output terminal at the back of the alternator If an
isolator is used this wire must be located on the battery side of the isolator On a 12V system this wire can carry 8 amps
and must be protected by a 10amp fuse A fuse is
included with the wiring harness
3 The POSITIVE battery sense wire as shown in the illus
tration at right monitors battery voltage The positive
sense wire should be connected 1 at the positive out
put of the alternator 2 at the battery if only one bat
tery is being used 3 at the common terminal of the
battery selector switch for multibank charging or 4 on
the isolator terminal for the largest battery bank if iso
lator is used This wire is user supplied and should be
16gauge Spade and ring terminals and a 1A inline
fuse are provided The positive battery sense wire MUST
be connected for the regulator to work Refer to regula
tor side label for terminal locations Caution Sense
wires MUST always see the battery being charged Be
sure to observe polarity
4 The BROWN ignition wire activates the regulator when
12VDC is applied to the system Attach the BROWN
wire to a switched 12VDC source The auxiliary side of
the ignition switch or an independent ungrounded oil pressure switch are both acceptable connection points A toggle
switch may be added to this circuit to shut down the alternator load in cases where maximum propulsion is needed
5 Attach the Fordtype harness plug to the regulator see The second BLACK ground wire in the harness attach
es to the Negative Battery Sense Terminal
6 Plug duplex plug with BLUE field and White stator wires into rear of alternator
7 Plug the other end of the WHITE wire into the Stator Terminal on the regulator
see side label for locations of these and other terminals Tach Terminal on
the regulator provides pulse for electric tachometer if desired
The MC612 is factory preset for use with most battery types For optimal charging
we recommend choosing one of the six selectable programs dis
cussed on Page 4 of the installation manual Program choices are 1 Universal
Factory Program 2 Flooded DeepCycle 3 Gel Cell 4 AGM 5 Optima 6
Standard Flooded and 7 for Halogen and voltage sensitive applications To enter
a battery program
1 Activate the preset program mode by placing the magnetic screwdriver or
pencil magnet as shown at left The white dot at the top of the display indi
cates the switch is activated
2 The Pro display appears followed by the cycling of the battery type codes
When your desired battery type is displayed release the switch by removing
the magnet
3 Should you need to alter your choice activate the switch again with your
magnet and release as soon as your desired program is displayed
4 The Pro code will display followed by the SAV code once the switch is
released The regulator is now set for your battery type

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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.