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' Balmar 12 Volt Alternator Manual'



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Due to the many domestic and international configurations of mountsand factors such as year and location of engine manufacture and marinization Balmarcannot guarantee a dropin replacement in every engine application Choose the modelthat most closely fits your application Your installer may have to adapt the basicmounts to fit your needs The majority of marine engines are equipped with one of fouralternator mounting styles The following describes which alternator represents eachspecific mounting style 60 70Series Dual Foot w315 between legseplaces most small case stylesusing a saddle style mount eg Hitachi Lucas Mitsubishi61 71Series 1 Single Footeplaces most domestic styles using a single 1mounting foot eg Motorola Prestolite612 712Series 2 Single Footeplaces most domestic styles using a single 2mounting foot eg Delco622Series 2 Pad Mounteplaces Korean Mando typeernators usingdual 2 static pad mounting feet Found on many Mercruiser and Volvo Penta gas 2 Single Footebsite at wwwbalmarnet to determine if your engine can accommodate the large case Dual Foot w4 between feetebsiteat wwwbalmarnet to verify if your engine compartment can accommodate the large case96 97 98Series Dual Foot w4 between feetat wwwbalmarnet to determine if your engine can accommodate an extralarge case alternatorIf you determine that the desired alternator will just not replace the existing alternatorone excellent option may be to leave the existing alternator in place and purchase adual groove crank pulley for the front of the engine in addition to the existing pulleyHave a special mount fabricated or use the Balmar remote Alternator Bracket 5276to accommodate a larger alternatorOnce you have determined that the new alternator is the correct replacement for yourexisting the batteries andor turn the switch to the OFF setting Disconnect the wiring fromthe existing the mounting tensioning bolts and remove the existing alternatorOnce the alternator is disconnected from the engine compare its mounting points to those onyour 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 localmachine shop Balmar offers a universal mounting arm which can replace your existing tensioning arm if needed Others can be obtained through your local auto or marine supplyAttach the mounting foot of the new alternator to its engine mount Some shimming may be necessary to ensure that the alternator is securely mounted within the engine mount The rear bushing is designed to slide to tighten the mountOnce in place inspect to ensure that the alternator pulley is properly aligned with the engine pulley If your belt configuration includes the pulley for the water pump make sure that all three pulleys are properly aligned Connect the output cable see cable sizing belowound field wire statortachther necessary wiring Connect alternator to Balmar regulator wiringharness as indicated in wiring diagram included on Page 12 The alternators positive and groundcables should be sized according to the chart on Page 3 Installation 2If a new regulator is being installed along with the alternator complete its wiring installation according to the instructions included with your regulatorAfter the alternator is installed and the wiring connections are attached inspect the pulley for proper tension Whenchanging pulleys or when using the pulley torquethe shaft nut to 5060 footpounds The shaft nut measures 1516To install the beltLoosen the adjustment arm bolt and alternator pivot assembly boltFit a new highquality belt over the appropriate pulleysTension the alternator until the belt is securely tightened in place Retighten the pivot assembly and tension arm bolts To test tension place a1516 wrench on the alternator shaft nut and apply pressure If the pulley rotates without moving the belt reloosen the bolts apply and retighten Repeat until the belt is properly proper tension by pushing on the outside surface of the belt Thebelt should deflect approximately 14 to 516 under moderate pressure Your local auto parts store may carry a measuring tool designed togauge belt that the Mounting bolts at the alternators pivot point are ease of belt installation you may want to invest in an inexpensive belt tensioning tool like that sold by JCWhitney tensioner provides positive support at the alternator while increasing belttension leaving two free hands to retension mounting and tensioning beltsYour belt will tend to stretch during the first several times you run your engine Make it a part of your normal preflight check to test belt deflection and readjust belt tension when needed If you notice an accumulation of blackbelt on your alternator and surrounding engine area check belt tension If the belt is tensioned and you still experience belt dusting it may be necessary to reduce horsepower load on your belt with the regulators Amp if equippedou may find that a different brand of belt may work more effectively with your See additional information on Page 4Additional Installation Battery CablesThe addition of a highoutput alternator to your charging system may make it necessary to increase the size of yourbattery cables to increase the systems amperage carrying capacity To determine the proper cable size considerBOTH cable length and alternator capacity Both positive andnegative wire runs must be included in your computationIn other words when determining battery cable size weneed to consider the round trip distance Wire size may becalculated with the formula CMK x I x LE whereas CM represents the circular mil area of the conductor K representsthe milfoot resistance of copper I represents current and Lrepresents the length in feet of the roundtrip cable run andE represents voltage drop in voltsWhen using this equation a K constant of 1075 milfoot resistance and voltage drop should be calculated at 3 the standard for critical functions affectingthe safety of vessel passengers In most cases it may bemuch simpler to use the following chart as your guidelinePage 3Belt Drive BeltsYour new highoutput Balmar alternator will increase horsepower load when compared to your standard OEM alternator This additional load may require that you replace the standard drive belt with a heavierduty unit Many aftermarket 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 manyauto parts suppliers such as NAPA carry extra heavyduty belts designed to support larger horsepower loadsAs well as belt quality belt size can have a substantial impact on alternator performance As a ruleofthumb werecommend a minimum 38 belt measured across the back of the beltor our 80amp alternators Minimum beltwidth for 100 to 110amp alternators is 12 Any alternator larger than 110amps will require dual belts for optimal performance as well as acceptable belt life The addition of a larger diameter alternator pulley can often improve beltwear as it will increase belt wrap and surface contact with the belt though the increased pulley diameter will lessen the ratio between thealternator and flywheel pulley and reduce low end amperage output Should you find that your belt is undersized for your alternator the AmpManager mode available in the Max Charge MC612 12volt624 24voltors enables you limit the maximum field potential of the regulator and limit thehorsepower load of the alternator This feature accessible through the Max Charges advanced programming modecan be adjusted in precise 2 increments so output can be adjusted to suit the system without losing morecharging current than necessary For more information see the manual included with your Max Charge MC612 orMC624 regulator Many engine manufacturers can provide replacement pulleys to convert your drive system tosupport dual beltsVoltage RegulationWith the exception of our 6Series alternators which feature patented Smart Ready internal regulation all Balmar highoutput alternators require external regulation in order to operate We recommend our multistage ARS4 and Max Charge regulators to provideoptimal balanced charging for most marine battery ordered with supplied wiring harness the voltage regulatorcan be mounted on a stringer or bulkhead up to four feet from thealternator Excessive heat and exposure to coolant or saltwater candamage the regulator Consider that when determining standard wiring harness measures 54 and features ringterminal connectors at the alternator or plugs as seen at rightdepending on which alternator is being used The flat plug indicated by the letter is used with our the grey rectangular plug indicated by the letter is used with our 6Series and 9Series The black Tshaped plug indicated by the letter is designed for use with our 94Series alternators All7Series 96Series 97Series and 98Series alternators use ring terminal connectorsFan RotationBalmar alternators are designed to turn in a clockwise rotation Face the front of the engine with the engine running to determine direction of rotation Models in the 6Series and 7Series internal fan styles can typically be runin either direction without difficulty Model in the 95Series 96Series 97Series and 98Series feature bidirectional fans so reverse rotation is acceptable If using a 94Series alternator it may be necessary to replace the standard fan with an optional bidirectional fan to ensure proper cooling under loadOlder 90 91 and 912Series alternators may also require a kit for rotation applications Keep in mind alternators with nonkeyed shafts will require pinning to ensure proper performance A longtwist drill bit and a roll pin are included in the reverse rotation kit RotationPage 4Belt Manufacturer WebsitesGates than plugs for stator and field Terminal i5WH3DH6 c 60RI9X5u 0LkQWBKlt5xE Balmar alternators are case grounded ie the alternator establishes its connection to the system groundvia the engine block While the ground is built into its engine mount we recommend that a secondary groundcable be added to the ground terminal if The installed ground cableshould be equal in size to the positive output cable as indicated on Page 3Alternator models designated as Isolated Ground IGeature an independent ground terminal thats isolated fromthe alternator case Typically Isolated Ground alternators are used in applications where the engine is not desiredto be a part of the grounding system This is commonplace in steel or aluminum hull boats or with engines thatdepend on sophisticated electronic ignition systems In Isolated Ground alternator installations the ground cableshould be connected to the central ground small case alternators rated at 110 amps or less come standard with a singlegroove 25 deep vee pulley The deep vee pulley is designed to provide optimalpower transfer for belts measuring 38 10mmo 12 13mmacross the back of the belt Keep in mind 38 and 716 belts may sit low inthe pulley sheave This will not adversely affect the belts performance Higheroutput alternators in small large and extralarge case series are with 12 dual groove pulleys Some models including may be equipped with multigroove serpentine type pulleys Should your application require a different pulley than that provided asstandard Balmar may carry an optional pulley more suited to your needsFor a list of optional pulleys visit call Balmar Customer Service at HeatDuring operation your alternator will become hot as a result of friction and the generation of inductive current Insome instances particularly during extended periods of heavy load alternator case temperature can exceed 200degrees Four system is operating with an ARS4 or Max Charge MC612 voltage regulator with Temperature Sensor MCTSAor will automatically reduce the alternator output by approximately 50 percent if temperatures exceed set safe working limits While this is an extremely effective protectionfor the alternator it should not be depended upon as a part of normal operation Correction of conditions are strongly advisedUse extreme caution when handling the alternator or other engine components during or after use Should youralternator 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 immediately and once it becomes safe to inspect the of the drive belt Under and overtensioned belts are the leading cause of overheating and alternator damage See the section later in the manual for alternator inspection your standard alternator with a highoutput Balmar alternator may dictate that your standard ampmeter be replaced with a high amperage shunttype meter We strongly recommend replacing your amp meterwith a more fully functioning charging system monitor such as the Link Meter from XantrexHeart Interface Inaddition to metering system current these system monitors will indicate battery condition and estimate batterytime remaining before charging is issues Page Balmar alternators provide a source of unrectified AC from the stator output This stator output provides the pulserequired to drive most electric tachometers Most current feature 12pole stator outputs meaning 12 pulses of ACvoltage during each alternator revolutionand older 9Series alternators feature 14pole stator outputsMany standard and aftermarket electrical tachometers feature some level of adjustment to calibrate the tachometer 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 modelFusingThe American Boat and Yacht Council ABYCds for safer boating recommends that cable runs toyour battery banks be fused to protect the boat and owner against damage and injury Circuit protection asdescribed by ABYC standards can be accomplished by installing either a resettable circuit breaker or a fuse Thefuse or breaker you choose will depend on both the amperage rating of the alternator and the size of cable usedBlue Sea Systems a respected manufacturer of highquality fuses and circuit breaker devices recommends the following when sizing the proper circuit protection for your system Fusing should be1The largest available circuit protection device smaller than the amperage capacity of the cable being than the maximum continuous current that will flow in the circuitWe 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 RatiosIn order to achieve optimal performance from your charging system it is essential to determine the capacity yourcharging system is capable of supporting In general the size rating of the alternator should mirror the acceptancerate of the batteries being charged Differing battery technologies will vary in terms of their acceptance rates Forexample a deepcycle flooded battery is typically capable of accepting roughly 25 percent of its available capacityat any given time As a result we want our alternators rated output to equal the acceptance rate of the batterybeing charged when it reaches its full discharge rate In other words a deeply discharged 400 amp hour deep cycleflooded battery would require an alternator rated at 25 percent of 400 amps or 100 amps to support that bankIn simpler terms a deepcycle flooded battery bank will require 25 amps of alternator output for every 100 amphours of battery rating Some newer battery technologies such as AGMs and spiral wound batteries can accept upto 40 percent of their available capacities as such alternator output should be increased to reflect the optimalratio between alternator and battery to meet recommended ratios will commonly result in slower charge times heat and wear and reduced alternator life Multiple Bank Charging OptionsWhen charging a single starting battery the alternator can be connected to the battery directly or via an ONOFFswitch More typically in a marine system the alternator will be supporting a smaller starting battery and largerhouse battery bank or a starting battery along with multiple banks for house loads inverter loads windlass orthruster Many methods of multibank charge control are available ranging from manual switches to products likeBalmars Digital Duo Charge which automatically provides charging current to the starting battery whenever charging voltage is present at the house batteryThe following section outlines many of the most commonly used options for multiplebank battery managementTach Manufacturer Warner 7MultiBank Charge Control Available in two primary types ONOFF or ABBOTH manual switches offer a simple method for charging management Possible installations include separate cables to each battery bank with ONOFF switches in line for eachbank or a common output cable to the common post of the ABBOTH switch with an output cable to each batterybank Field disconnect switches feature terminals where the field output from the regulator to the alternator can beinterrupted when the battery switch is turned to the OFF position This feature ensures that alternator output is discontinued as soon as the battery is disconnected Inexpensive No substantial voltage drop Require user interaction and heightened system understanding Can be accidentally shut downcausing potential alternator damage Does not allow for mixed battery technologies Battery voltage sensed must always be that of battery being charged Sense voltage at common side of battery switch or at alternator positive outputBattery combiners enlist highamperage solenoids to charge multiple battery banks Below a specific voltage setpoint the combiners solenoids remain open isolating the individual battery banks Once the baseline voltage isreached the solenoidseries into one big bankNo user interface required No substantial voltage drop Available in 2 or 3bank models Moderately expensive Does not allow for mixed battery technologies 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 banksthat are comparable in size and degree of discharge Isolators are not necessarily the best choice when charginghouse and start battery banks Only one battery bank can be sensed by the regulator so under or overcharging canbe a substantial issue if batteries are dissimilar in capacity or degree of charge Diodes can drop voltage at thebattery side of the isolator by nearly a full volt which means that the alternator is forced to increase voltage far inexcess of that needed by the batteriesNo 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 secondary battery bank to dangerously high levels May hold high voltage for too long at smaller bank Tendency tounder or overcharge secondary nonsensedery bank Greater chance of early battery failure Voltage must be sensed at most commonly used battery bank typically housesense wire to battery side of isolator or positive post of battery being sensedBalmars Digital Duo Charge connects between the house and start secondaryeries keeping the two banksseparate until the unit senses 13 volts 2624Very Once voltage is reached the Duo Chargesupplies up to 30A to the secondary bank Voltage is regulated at the secondary bank based on a preset programchosen by the user to reflect the secondary battery type Standard and deep cycle flooded gel and AGM batterytypes are supported Optional battery temperature sensing and solenoid drive are included 12 or 24volt settingsNo user interface required Selectable programs ensure proper voltage control even with variedbattery bank capacities and mixed battery constructions Amperage limits require smaller wire gauge Workswith DC or shorepower charge sources Simplifies charging control for alternator and regulator30amp maximum output may not support larger secondary banks bowthruster windlass etcwithout use of manual solenoid control See Digital Duo Charge on Page 8 for higher amperage option Alternator and regulator supply house bank only Sense at house batterys positive post or atthe positive output of the Charge Control Page 8Digital Duo Charge IIAvailable Summer 2004Balmars newest Digital Duo Charge IIconnects between the house and keeping thetwo banks separate until the DuoCharge senses charging Oncevoltage is reached the Duo Charge IIsupplies up to 60 amps to the secondary bank Voltage is regulated at thesecondary bank based on a presetprogram chosen by the user to reflectthe secondary battery type so bothhouse and secondary batteries receiveoptimal charging current Standardand deep cycle flooded gel Optimaand AGM battery types are battery temperature sensingand solenoid drive control are includNo user Selectable programsensure proper voltage control even with varied battery bankcapacities and mixed battery coning based specifically on theneeds of each battery bank Workswith DC or shorepower chargesources Simplifies charging control for alternator and numeric 4 LEDyprovides detailed operational dataForces user tohave fun and concentrate on boating rather than worrying about charging system Alternator and regulator supply house bank only Sense at house batterys positive post or atthe positive output of the alternatorTwo EngineShould more charging power be required than is conveniently available from the engines primary alternator manyboaters choose to install a second alternator In these applications alternators can be used separately as dedicated charge sources for the various battery banks or the outputs from both alternators can be combined to provide asingle source of charging This will require that the field wire from a single regulator be split to supply both alternators This system is commonly used to supply a large house bank with a Duo Charge unit providing charging current to the starting battery Max Charge regulator is recommended for dual alternator substantial increase in available charging amperage Builds in system addition of new bracketry and upgraded crankshaft pulleys Potentially expensive Depends on whether alternators are dedicated to specific banks or if they are combined tosupport a single bank Voltage must be sensed at the Duo ChargeDuo Charge II Wiring Diagram60amp for60amp 9w9PFFD8z 9yP 1V P69SuO05rspzh0 I632ZbK i ybZlG1AW4zAmNY U35m3mX1lzLsa MREpU37EHot 456zYY8 3 KTreqOTDPW LW R 13 elY SFw9Ns PX9de3tIVhCR6 HKK6638oym lQ5a5G4KiJtG 4KfZxyWH4 2VpZx cNEoFNrm WnaQE7uWlX1V0w 7 MI CXsXM 1rdd6 yE7 mlcawa85 jh29oO6UzZxmJ6 2em5 5eZxmJ6 2em4ZA YtU 2em7NL V Ys OY0G 2emS4 a05hw0o ZxmJ62 2em V R2uZxmJ6p 2emu F6v 250P 2emmkAZxfk ehfgliejkonfI4 2emJHmkRZxig 1 tmk Zxdgeahehhebem umk ZxDegffnhhglgb Zx 6zmjE Zx2fg7zcl Zxv4r6zNXki ZxT0gjk Zx koddejre iUD3zlm Zx6 Zxci3njgfnVkEh 7k1E jkrZx GbdjAzQIjB nZx tZ Dejk 0Q39hZx S jkZx R6EjkZx 0AXxtJfJ HjkZx U2jkZx Su1yjkZx 4jkZx XjkZx 3jkZx WjkZx 6jkZx ujkZx eA 3pjkzmbgjkZx Bo3 O6KUNjkZx 8ir1jkZx x0sdd8jkZx5 ryYGjlZxO1 HMA Iwf c eqkZxrE Cf 5h2omnZxy0 r x 54232977I jk w w 39 yjk76v1jkB akiE7 lkrU b 5Ir J Page 9Twin Engine IssuesTwin Engine IssuesTwin engine applications pose some unique challenges in addressing battery needs Some primary charging configurations are as follows 1Dedicate Alternator 1 to charge engine starting batteries May be done with a switch or by connecting the alternator output toone engine battery and a Digital Duo Charge from the primary to the secondary engine batterye Alternator 2 to thehouse battery bank2Combine outputs from Alternator 1 and Alternator 2 to provide increased charging amperage for the main houseerybank and supply the engine and other secondaryeries via Digital Duo Charges or combiners Combining the output fromtwo alternators on two engines will require the use of Balmars Centerfielder described belowiguration will requirthat both alternators are equipped with Max Charge regulators which are designed to provide sufficient field current to drive two alternators For additional information downloadthe Centerfielder instructional manual from the Balmar website Centerfielder enables twin engine systems to balance so available amperage from both alternators can be combined tosupport larger battery banks The Centerfielder monitors field and ignitionwires on port and starboard voltage regulators Max Charge MC612 or MC624 regulators strongly recommended depending on system voltageth regulators are up and runningthe Centerfielder identifies the dominant regulator and splits its field to supply both alternators with the same exitation 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 GPPPPPP PPPUPPPPPPPPP PPPPPP PPPUPPP gO p80 Pp p0 p8 P80 pgpH PhHH 00 PPP O oWo O oW jNNNNNNNNj000 w 0 HxP zNNNDpxNNNN YhxNNNNNHNNNo NNNN0zNNN PZuNNNTP8NNNYH EZ68NNNTNNN b0aNNNNTNNTP 1NNN0g7GONNN x ELNNNdgG 0 8TNNd 0 o1NNNwNNN ppXoh8oNNYNNNH 08P8NNNH0 NN P WNN8 NAhH 8hP0NpOO0 oxoh8 P0Nh8og 07 P 8 51pG PwxxNv8 7NxX w00 ONM Z 1o1MNN0Ph HOPPPPPPPPPPPp 1dNNN X wG 1aNNNpx w00NNNvGx gLZZZPZahuNNj H0 PPPPPPPPPPP0HX fPPPPPPPPNNNSx S8ZNNNP PPPPPPPPPPPp HGu0 0ZNNN xwPPPPPPPPPPP 0PPPPPPPPPPPp PfPPPPPPPPhho8 fPPPPPPPPPh gWONNNPv NNNqHxv Ppv3 v v vG UPPPPPP0 0wPPPPPPPP UPPPPPP wPPPPPPPP UPPPPPPX 0wPPPPPPPP UqPPPW28 GPPPXopw 7pPPPPPPPP UxPoNPPP 8 PPPPPPPP UPNqoPPPp PPPPPPPP UX8PPPx 00PPPPPPPP U2UjPPP PPPPPPPP UXHPPP 7oPPPPPPPP UpPPPhpp PPPPPPPPo 0wPPPPPPPPG U9 U yUNUUNcOwPPPoo ww 0oPPPPPPPPG U g Uc w99j9rO89 PPPPO Wo PPPPPPPP U PPPPPPPP 0o PPPPPPPP PPPPPPPPG xP PPPPPPPP U PPPfPPPPPPPPx 0 x PPPPPPPP U8PPPfPPPPPPPP p wPPPPPPPP UPPPfPPPPPPPPx 7X xPPPPPPPP UPPPfPPPPPPPPo PPPPPPPP pj hPPPPPPPP 8p PPPPPPPP go0 XPPPPPPPP xPPPPPPPP 8PPPPPPPP 0fPPPPPPPPp PPPfPPPPPPPPG UjPPPfPPPPPPPP UPPPfPPPPPPPPx PPPPPPPP PPPPPPPP U9r 0pPPPfPPPPPPPP PPPPPPPP UPPPfPPPPPPPP PPPPPPPP 00 PPPPPPPP 0 UPPPfPPPPPPPP PPPPPPPP UXPPPfPPPPPPPP PPPPPPPP UPPPfPPPPPPPP PPPPPPPP UPPPfPPPPPPPP HPPPPPPPP UPPPfPPPPPPPP PPPPPPPP UPPPfPPPPPPPP 0 8PPPPPPPP UPPPfPPPPPPPP PPPPPPPP UPPPfPPPPPPPP xPPPPPPPP U PPPfPPPPPPPP 00PPPPPPPP PPPPPPPPw PPPfPPPPPPPP8 PPPPPPPPHp HPPPfPPPPPPPP 00 PPPPPPPP PPPPfPPPPPPPP oko0PPPPPPPP owPPPPPPPP ooPPPfPPPPPPPP wPPPPPPPP PPPfPPPPPPPP 0G7 PPPfPPPPPPPP GGPPPPPPPP PPPfPPPPPPPP NBPPPPPPPP HHPPPfPPPPPPPP pPPPPPPPP xPPPfPPPPPPPP TPPPPPPPP PPPfPPPPPPPP PPPPPPPP PPPfPPPPPPPP PB6hPPPPPPPP XPPPfPPPPPPPP q PPPPPPPP wPPPfPPPPPPPP PPPPPPPP PPPfPPPPPPPP PPPPPPPP PPPfPPPPPPPP 0PPPPPPPP 06PPPfPPPPPPPP pHHPPPPPPPP HHPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HkPPPPPPP HPPPfPPPPPPPP HPPPPPP HPPPfPPPPPPPP HqPPPP HPPPfPPPPPPPP HZPP HPPPfPPPPPPPP HS HPPPfPPPPPPPP HP HPPPfPPPPPPPP HPPW HPPPfPPPPPPPP HPPPPd HPPPfPPPPPPPP HPPPPPPd HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP HPPPPPPPP HPPPfPPPPPPPP 5HPPPPPPPP HPPPPPPPP HHPPPPPPPP X 10System the causes of failures in an electrical system is a step by step process Before you begin your searchto determine if the failure can be attributed to the alternator or the volltage regulator we recommend you inspectand clean all system electrical connections Most charging system problems will be corrected by performing the following steps Remove and clean all charging system electrical connections from the alternator the batteries and wire runs this includes theground sideoltage regulators harness for resistance Wires and terminals can and will become corroded andmay need to be cleaned or replaced Check all fusing in the regulator harness and alternator output cablesCharge all batteries to their proper fully charged state and determine if they are serviceable If your batteries are floodedtuse your hydrometer to determine their conditionCheck and tighten alternator belt If the belt shows signs of wear or damage now is an ideal time for replacement Alwaysreplace existing belts with the finest quality replacements available After determining that your batteries and wiring are in suitable condition use the following tests to determine ifcharging 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 malfunctioning Inorder to perform these tests you will need a simple test lamp available at most auto parts or marine hardwarestores West Marine sells Ancor continuity testers for just a few dollarser can also behelpful in checking for voltage drop and resistance in wiring and terminal connections A clamptype DC Amp metermay be useful in diagnosing amperage issues A 10 long 14gauge wire with insulated alligator clips at each endprovides the ability to take measurements with your test lamp or multimeter with a centralized ground pointVoltage Regulator DiagnosisThe failure of the voltage regulator to provide field current to the alternator will cause the charging system to fail Tobegin the voltage regulator tests check to see that the regulator display is lit when the engine is running If the regulator display fails to light after the engine is startedConnect your ground extension wire as described aboveo your second ground terminal at the regulator Connect the otherend of the extension to the ground probe of the test light Turn your ignition switch to the ON position if the regulators to an oil pressure switch connect a jump wire across the oil pressure switch Apply the test lights positive probe to the red powerors black 4wire plug If the test light does not the red powero its source at the battery alternator output or common side of the battery switchest forpower thereIf the red powerwer at that location replace the 10amp fuse in the red poweror power at tregulator wiring plug If the wire has no power at the regulator end inspect for damage along the length of the wire as neededIf the red powerest lamp but the regulator display remains unlit apply the positive probe of the tester tbrown ignitionest lamp remains unlit follow the brown ignitiono its source and test the source with yourtest lamp If the source illuminates the test lamp repair or replace any damaged wire or connectors needed until the test lampindicates current at the regulator end of the brown ignitionIf the regulator is a Max Charge MC612 follow the same testing guidelines for the Positive Battery Sense wire wire connectors or fusing as neededIf the regulator display is illuminated yet charging is not occurring be sure to wait beyond the 45second delaybefore taking test readingsApply the test lamps positive probe to the blue wire in the regulators black 4wire plug with negative probe connected to thregulator groundest lamp does not illuminate the regulator may be damaged If the regulator is within the warrantyperiod see Warranty Info on Page 12omer Service Department at 3604356100If the test lamp is illuminated the regulator is providing field current and the charging problem is likely elswhere in the cing systemFollow the field wire to its connection at the alternator Disconnect from the alternator and apply the test lamp to the wire lamp illuminates the regulator and wiring harness are likely to be goodPage 11System DiagnosisOnce the regulator and harness are tested and proven good disconnect the negative probe of the test lamp fromthe regulator ground and connect the negative probe to the field terminal of the alternator Connect the positiveprobe to the blue fieldom the the test lamp If the lamp does not illuminate the alternator may not be completing the connection to ground Checkthe ground connections at the alternator to system ground If you know how you can use your multimeter to check for the alternator and groundIf the meter indicates substantial amount of resistance between the alternator and the system ground a wiring or terminal connection issue is indicated Recheck system ground cabling and wiringIf an internal fault is indicated as a result of testing remove the alternator and contact Balmar Customer Service or your localternator shop for the test lamp is illuminated when connected inline between the the regulator field wire and the alternator field terminal pa metallic object a screwdriver blade works wellont of the alternator pulley shaft or the rear bearing cover of talternator If the screwdriver blade is magnetically drawn to the alternator the alternators internal components appear to befunctioning correctlyIf the test lamp is lit and magnetism is detected you can remove the test lamp reconnect the blue fieldt theengine Once the engine is started and the regulators initial start delay is complete voltage should climb to levels set by Diagnosis Independent of RegulatorThe alternator can be tested independently of the regulator and wiring harness by connecting the alternators fieldterminal directly to battery voltage Once connected to battery voltage the alternators pulley shaft and rear bearingcover should generate a substantial magnetic pull If no pull is present an internal wire or may be at fault To test the alternator onlyConnect one side of the test lamp to a source of positive battery voltage Connect the other to the alternators field terminalthe test lamp illuminates and the alternator indicates magnetic current start the engine This is known as full fielding the the lamp connected and the engine on voltage at the alternators positive output terminal should steadily climb The Lawill act as an inline resistor so voltage rise should be moderately controlled Once charging voltage is indicated check outvoltage with your multimeterwn A steadily climbing voltage at the alternator output indicates gooalternator alternator and regulator tests indicate proper operation further investigation into battery damage or wiring failureis recommended If charging system performance continues to be compromised we strongly advise that you seekthe assistance of a certified marine electrical diagnostician For additional assistance or contactour Customer Service department at Smart Regulated AlternatorsNew 6Series alternators require slightly different diagnosis to determine if the SmartReady internal regulator is functioning correctly To test the internal the external regulator wiring harness from the alternator wiring plug containing thefield and stator wires Turn the ignition switch to the ON the positive probe of your test lamp on the FIELD terminal of the wiringplug Connect the testers negative probe to ground If the internal regulator isfunctioning properly the test light will illuminate3If testing the operation of the internal regulator with a multimeter adjust themeter to read 12V DC before placing probes at the field terminal and ground Ifthe regulator is working correctly the meter will show approximately 3V DC Balmar 200405 Ballard Commercial Industries Inc Arlington WA 98223 March Kvp5vPBu iPvuyU5U siKPwVujPp w0eUKi By Alternator SeriesPage 12LIMITED PRODUCT WARRANTYBALMAR warrants to the original product is free from any defects in material orworkmanship for a period of one year from the date ofpurchase If any such defect is discovered within thewarranty period BALMAR will replace the regulatorfree of charge subject to verification of the defect ormalfunction upon delivery or shipping prepaid to BALThis warranty DOES NOT apply to defects or physicaldamage resulting from abuse neglect repair alteration modification or unreasonable use of the products resulting in or broken cases nor are parts damaged byfire water freezing collision theft explosion rustcorrosion or items damaged in shipment in route toBALMAR for repair BALMAR assumes no responsibility for consequential damage or loss or expense arising from these products or any labor required for service or repairBALMAR WILL NOT repair or be held responsible forany product sent without proper identification andreturn address or RA number clearly marked on thepackage You must include proof of date and place ofpurchase photocopy of purchase invoicee cannot be responsible for repairs or replacement In orderto expedite warranty claims more efficiently BALMARasks that prior to returning a defective product forrepair you call their customer service department fora warranty return authorization number If factory service is required you can contact our BALMAR Customer Service Department Monday 730 AM to 530 PM PST100ext 3Material required for the repair or replacement for thedefective part or product is to be supplied free ofcharge upon delivery of the defective regulator to BALMAR 19009 61st Ave NE Arlington WA 98223Customer is responsible for all return and any air or rush delivery expense BALMARreserves the right to determine whether to repair orreplace defective componentsTHE ABOVE LIMITATIONS MAY NOT APPLY TO YOUSOME STATES DO NOT ALLOW LIMITATIONS ON HOWLONG AN IMPLIED WARRANTY LASTS NO PERSONAGENT DEALER IS AUTHORIZED TO GIVE ANY WARRANTYBALMAR 19009 61st Ave NE Arlington WAEmail Web Output7Series to be correct attime of may change indesign or output withoutprior notice If actual pinlocations or features differfrom that shown contactBalmar Technical support at3604356100 Balmar isnot liable for damage orinjury derived as a result ofinformation included in thisat wwwbalmarnet for newand updated product uIw6zjakdg HmvpcwY6xAOy 7bYSPGn5h f6aYoPGfr85lq 1IVbnx FSjuzxkSH4 8 DPemu mi vhfecbazvs qokl ptw AAAA IIIIXSOLI G DB qeUOxjVNHC7420 5E0N0Y1e1s1222 2C MYfus sdWME520 2DPjeWKB4 9CPnXKA80 5MZkUH 5 WgQ E2 C nTNIC623AHOW 7zHyOwUvtcskq tp nlkihfedddd10 FECA597D6L4 V3 1 m yiRJD 9854203 scWME8543217HS moSJB741 5JVdtqSH71 7AMZi gWJ70 3IVfyc B BABBB CCDDDDDDHO SWE28FMVllOB61 QzNKq pcVK62GUbp8 DRly5AN ht243 0KXdpz9FSku 4ANZfpyIUjt 3GOVcipx05751 MMMNMLL PPQ7Q 6Ati5V0MD 6320 4 6wmd RKC963104MXet tjaXOG81 JWgy Hb McTp MccD ia bddaXaYEhTXEEh DD Eh DEhDY Eh GD QXGDGzGzYYY EEhDEjBEEdjEja Ej eDDEhEiaEja Ej EaDYCTCTZX I c RX8e8c8YKPXEDY aFFF Fab KKpE PXaFYh EFRXF ha8Y EFPXYCCKRXIIa TX CUXYTX CTXY XY KSKQZX CXEjCFD ia bddaXaYEhTXEEh DD Eh DEhDY Eh GD QXGDGzGzYYY Ej eDDEhEiaEja Ej EaDYCTCTZX I c RX8e8c8YKPXEDY aFFF Fab KKpE PXaFYh EFRXY EFPXYCCddbQXdd 8 CXY CXEjCFD ia bddaXaYEhTXEEh DD Eh DEhDY Eh GD QXGDGzGzYYY Ej eDDEhEiaEja Ej EaDYCTCTZX I c RX8e8c8YKPXEDY aFFF Fab KKpE PXaFYh EFRXF ha8Y EFPXYCCddbQXdd 8 CXY YXRU namexPpost0 CXEjCFD ia bddaXaYEhTXEEh DD Eh DEhDY Eh GD QXGDGzGzYYY EEhDEjBIdEdia bjaFDFEEdjEja Ej eDDEhEiaEja Ej EaDYCTCTZX I c RX8e8c8YKPXEDY aFFF Fab KKpE PXaFYh EFRXY EFPXYCCddbQXdd 8 CXY KSKQZX CXEjCFD ia bddaXaYEhTXEEh DD Eh DEhDY Eh GD QXGDGzGzYYY Ej eDDEhEiaEja Ej EaDYCTCTZX I c RX8e8c8YKPXEDY aFFF Fab KKpE PXaFYh EFRXY EFPXYCCddbQXdd 8 CXY TXCBYQX TXCBYTX Alternator you for choosing a alternator This alternator is and engineered to provide the finest performance and durability for your vesselUnlike most automotivetype alternators found standard on the majority of pleasure craft and marketed as lowerpriced marine alternatives our marine alternators are built specifically to provide exceptional output at lowerengine rpms typical of marine diesel engines so you can enjoy shorter charge cycles greater economy longerbattery life and less noise and fumesWhen used in conjunction with Balmar Max Chargeand ARS4multistage regulatorsyour new Balmar alternator can provide even greater efficiency when charging deepcycle flooded standard flooded gel AGM Optima and other marine battery technologies When preset for your battery type the smart regulatorwill guide your alternator through a charging program thats tailored to provide your batteries with the best carepossible In addition Balmar multistage regulators provide the ability to temperature sense at your an condition occur with an alternator temperature sensor MCTSAtor will reduce field output to 50 percent to allow the alternator to cool under lesser load and the Dash Lamp circuit on the regulator will activate to provide power for a visual or audible alert enabling the user to respond to thesource of the condition Together the Balmar highoutput alternator and multistage regulatorwork to assure the best charge possibleSafety installing your new alternator please take a moment to consider the following guidelines for safe alternator installation and operation Failure to follow could result in injury or damage to your vessels electrical system1Always disconnect your batteries and turn your battery switch to its OFF position prior toinstalling your any loose fitting clothing or jewelry which could become entangled in your motor orother machinery3Wear ANSIapproved safety glasses or eyewear4Ensure that the engine has cooled sufficiently before beginning NOT install your highoutput alternator without ensuring that the system wiring is sufficiently scaled to handle increased amperage loads6Be sure that your work area is sufficiently ventilated and that no fuels or solvents are present in and around your work area7DO NOT operate your charging system without proper fusing Failure to do so could result insevere injury andor damage or loss of your vessel DONT take chances with fusing8DO NOT attempt installation while using alcohol or medications which could impair yourjudgement or reaction time9Use the right tool for the job Use of improper tools could result in damage or injury10Take time to read the manual Equipment damage and possible injury may result from anincomplete understanding of the proper installation and use of the alternatorThe following instructions are intended for use by experienced installers If you are not sufficiently experienced with marine we recommend a qualified electrician be used for installation Safety Mounting2Addl Battery Drive Belts4Vottage Regulation4Fan Duo Charge7Digital Duo Charge II8Twin Engine Charging namerLpost prepUUWJ CXEjCFD ia bddaXaYEhTXEEh DD Eh DEhDY Eh GD QXGDGzGzYYY Ej eDDEhEiaEja Ej EaDYCTCTZX I c RX8e8c8YKPXEDY aFFF Fab KKpE PXaFYh EFRXY EFPXYCCddbQXdd 8 CXY KSKQZX uIw6zjakdg HmvpcwY6xAOy 7bYSPGn5h f6aYoPGfr85lq 1IVbnx FSjuzxkSH4 8 DPemu mi vhfecbazvs qokl ptw AAAA IIIIXSOLI G DB qeUOxjVNHC7420 5E0N0Y1e1s1222 2C MYfus sdWME520 2DPjeWKB4 9CPnXKA80 5MZkUH 5 WgQ E2 C nTNIC623AHOW 7zHyOwUvtcskq tp nlkihfedddd10 FECA597D6L4 V3 1 m yiRJD 9854203 scWME8543217HS moSJB741 5JVdtqSH71 7AMZi gWJ70 3IVfyc B BABBB CCDDDDDDHO SWE28FMVllOB61 QzNKq pcVK62GUbp8 DRly5AN ht243 0KXdpz9FSku 4ANZfpyIUjt 3GOVcipx05751 MMMNMLL PPQ7Q 6Ati5V0MD 6320 4 6wmd RKC963104MXet tjaXOG81 JWgy Hb The Monotype Corporation plc Data The Monotype Corporation plcType Solutions Inc 19901992 All Rights sans serif design Arial contains more humanist than many of its predecessors and as such is more in tune with the mood of the last decades of the twentieth century The overall treatment of curves is softer and fuller than in most industrial style sans serif faces Terminal strokes are cut on the diagonal which helps to give the face a less mechanical appearance Arial is an extremely versatile family of typefaces which can be used with equal success for text setting in reports presentations magazines etc and for display use in newspapers advertising and Regular ItalicVersion 290 The Monotype Corporation plc Data The Monotype Corporation plcType Solutions Inc 19901992 All Rights sans serif design Arial contains more humanist than many of its predecessors and as such is more in tune with the mood of the last decades of the twentieth century The overall treatment of curves is softer and fuller than in most industrial style sans serif faces Terminal strokes are cut on the diagonal which helps to give the face a less mechanical appearance Arial is an extremely versatile family of typefaces which can be used with equal success for text setting in reports presentations magazines etc and for display use in newspapers advertising and RegularVersion 300 MccD

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